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    STD.BSI BS 4S35-2-ENGL 2000 mm Ube4bb4 O8L0208 685 me BRITISH STANDARD Specification for welding of steel pipelines on land and offshore — Part 1: Carbon and carbon manganese steel pipelines res sso4nu6 mt001 No COPYING WITHOUT Bal PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW ST Copyright by ti Bish Siandards Instution = ‘Tae ny 13 onan 2008 BS 4515-1:2000 hey gy Wo Sexy seo STD.BST BS 4S1S-3-ENGL 2000 mm 3b24bb9 O8b0205 711 mm BS 4515-1:2000 ‘Te following BS ferences rete tothe work on aie sendard ‘Camis refarence WREI/ SBN 0 800:38177 6 Committees responsible for this British Standard ‘The preparation ofthis British Standard was entrusted by Technical Committee ‘WEEZI, Pipework welding, to Subcommittee WEE2V7, Feld welding of pipelines, ‘upon which the following bodies were represented: Association of Consulting Engineers Baitish Gas ple British Institute of Noo-destructive Testing, Blectiity Association _Enghneering Equipment and Materials Users’ Association rath and Safety Executive International Marine Contractors Association Offshore Contractors Assocation Pipeline Industries Guild ‘The Welding Institute UK Stoel Aasocition Welding Manufacturers’ Association (BEAMA Lid.) Amendments jsoned since publication Kind. No. [Date (Comments ‘opyright by the British Standards ‘ue May 13 08:48:60 2003 nctitution STD.BSI BS 4S3S-3-ENGL 2000 MM Lb24bL9 aLOz10 433 ay | E Page cover a 1 Scope 2 Normative references 3. Terms and definitions 4 Information to be specified and items to be approved 5 Equipment 6 Welding processes 7 Welding consumables 8 Testing, qualification and approval of welding procedures for butt welds 9 Testing, qualification and application of weld procedure for file welds 10 Testing, qualification and approval of welders 11 Production welding. B Inspection and tasting of welds Acceptance and rectification of welds Jone rma) comes Spa ST Annex B (informative) Recommendations for brazing and sluainothermic ‘welding of anodic bonding leads ‘Annex C (Informative) Proposed welding procedure specifiestion ‘Annex D Gnformative) Example of a record form for an MMA welder ‘qualification test Annex E (informative) Guidance for establishing preheating requirements, Annest P (informative) Example of a radiographic specification ‘Bibliography Figare 1 — Preparation of filet weld specinena Figure B.1 — Recommended locations for hardness traverses and impressions. for brazing and sluminothermic welding Figure C.1 — Example of proposed welding procedure specification ‘Figure C.2 — Example of welding procedure specification far production Figure C3 — Asn record of welding procedure qualification teat Figrre D.1 — Example of record form for an MMA welder qualification test Figure E.l —Nomogram for preheating requirements Figure Fl — Example of a radiographic procedure specification Ble Wang posed pecan deta and ares acing ‘Table 2 — Test specimens for procedure approval tests on fillet welds ‘Table 3 — Harness values ‘Table 4 — Diameter and thickness ranges for butt jeints and branch connections ‘Table 6 — Acceptance criteria for welds ‘Table A.1 — Welding procedure specification details and changes affecting approval ‘Table A2 — Qualified ranges of chemical analysis Besoeeeowe ne | SSEse BR oIHBSR BE 8s a or2000 i British Standards Instution 61 2003, Copyright by the 3 i Tus hay BS 4515-1:2000 STD.BSI BS YSRS-2-ENGL 2000 mM u24bb9 OSL02h) 377 Ow Foreword ‘The revision of tis British Standard has been prepared under the direction of the Subcommittee WEE. tis applicable to transmission pipelines for gases, iquids or sluries, both on land and offshore. It supersedes BS 4516:1906 which is withdrawn. I welding in accordance with tis British Standard is agreed with a Statutory Authority ‘as s bass for obtaining approval to operate a pipeline, the employer wil need to (brain the Authority's agreement to any waivers of requirements. Where this standard ‘Provides for the employer to define requirements, the Aufharty’s agreement may be ‘ecessary, Topics carmmonly involved inchude selecting the definition of the pipeline’ ‘starting and termination points, electing to use hardness limits higher than those in ‘Table 5, selecting the methods and frequency of non-destructive examination, electing to use Bagineering Critical Assessment to dertve acceptance criteria, permitting ‘multiple ttempis at repair, or permiting single run oF root repair. The employer ‘should ensure that all relevant points have been agreed with the Statutory Authority before welding begin. ‘This edition tales into account the publication of BS EN 288-0:1900 and gives ‘additional national requirements forthe testing, qualification and approval of butt ‘welding procedures. It should be used in conjunction with BS EN 2860:1990, In reflecting current industry practice, this Brish Standard places duties on, and allocates povrers of approval to, the employer. In this it differs from BS EN 2869 (under which welding procedure approval is independent of the employer) Consequently, the term “qualification” has been retained to describe the series of ‘sections which demonstrate that the technical requirements ofthis British Standard have been met during the process of welding procedure, and welder, approval. It has been assumed, in the drafting ofthis British Standard, thatthe execution of ios ‘provisions will be entrusted to appropriately qualified and experienced personnel “Assessed cxpability. Users of this British Standard are advised to consider the ‘desirability of quality system assesament and registration against the appropriate ‘Standard inthe BS EN 180 6000 sertes by an accredited thirdzpaxty certfiation body. A British Standard does not purport to include all the necessary provisions of ‘contract. Users of Briah Standards are responsible for thelr correct application. ‘Compliance with a British Standard does not of iteelf confer Immunity from legal obligations. ‘Summary of pages ‘This document comprises a front cover, an inside front cover, pages di, pages 1 to31 anda back cover "The BSI copyright notice displayed inthis document indicates when the document was last issued i ‘opyright by the British Stand: ‘ue May 19 09:49:64 2008 ens oran00 STD.BSI BS 4S25-1-ENGL 2000 WH 1624659 0ab0232 205 me BS 4516-1:2000 1 Scope ‘This British Standard spocities requirements for the ‘welding of carbon, carbon manganese and low alloy rent nt exeuting 600 Nand Seine a not accordance with BS 80102 and “3. ‘The sandard applies to pipes of outside diameter 210 mun and larger having a thickness of 5.0mm or ‘Beater, 2 Normative references BS 6072:1081, Method for magnetic particle law detection. BS 80102, Code of practics for pipelines — Port 2: Pipelines on land: design, construction and installation. BS 80103, Code of practice for pipelines — Part: Pipelines subsea: design, construction and installation. BS EN 970:1907, Non-destructive examination of fusion welds — Visual examination. BS EN 1921:1007, Destructive test on wolds én ‘metallic material — Macroscopic and microsoopic BS EN 1435.1007, Non-dastructive examination of welds — Radiographic exemination of welded BS EN 1714:1906, Non-destructive examination of {welded Jott — Draconic ecamination of welded ts ‘BS EN 10160:1900, Utrasonic tasting of stel flat ‘Product of thickness equal or greater than 6mm. (reflection method). BS EN ISO 6507 (all parts), Metallic materials — Vickers hardness test, ED 6101801, Guidance om methods for axsssing acceptability of flasca in fusion welded ‘structures. © Detiton ten fom 85490 8 Terms and definitions For the purposes of this British Standard, the terms ‘and definitions given in BS 490-1:1991 apply together with the following. aL employer ‘owner company or the engineering agency in charge of construction NOTE The ct rh a - [NOTE_The employer may a ough onan an inpcor 32 contractor firm undertaking the contract and any subcontractors engaged In work covered by this standard 3a pipeline ‘continuous line of pipes of any length without frequent branches, used for transporting fluids [NOTE i doe ot inde piping seme ch as proce pant pind witin etoreintalatons [BS.80102 and-3) a4 Joint ‘completed weld joining two sections of pipe, a section of pipe to a fitting, or two fitings 5 welding procedure? specific course of action followed in welding, Including a list of materials and, where necessary, tools to be used a6 welder!) ‘operator who performs the welding a7 ‘approved welder ‘welder who has demonstrated his ability to produce welds meeting the requirements of this standard 38 reotran’) {frst run deposited in the root of a mukt-run weld 39 osttional welding ‘welding wherein the pipe or assembly is held stationary 310 roll welding! ‘method of manipulation by rotating or rolling pipes ‘or pipe assemblies so that all welding is carried out {in or near the flat position. estore by the Brtish Stardards inettution ‘Tue May 13 0sasse1 2003, STD-BST BS 4525-2-ENGL 2000 MB BL2NbL9 O8L0213 142 a BS 4515-1:2000 aa semi-automatic welding!) welding in which some of the welding variables are automatically controlled, but manual guidance is necessary saz mechanized welding? ‘welding in which the welding parameters are controlled mechanically or electronically and may be ‘manually varied daring welding to maintain the required welding condition 3.13 sour service pipeline design conditions in which a risk of sulfide ‘stress cracking exists NOT ‘This is rormaly ame nig NACE MROLTS (1) aad full penetration repair repair from the external surface of the original weld ‘which penetrates to the bore of the pipe 3.5 partial penetration repair rmulthrun repair from the external surface of the original weld which does not penetrate to the bore of the pipe 3.16 cap repalr single run repair to the external surface of the original weld a7 internal (back-weld) repalr repair from the internal surface of the original weld a8 re-repair second attempt at repairing a defect in the same location. For qualification purposes this is a full ‘penetration repair, testing a heataffected zone which ‘hag received three full thermal cycles 319 ‘qualification series of aetions necessary to demonstrate that a ‘proposal meets the technical requirements of this British Standard 3.20 ‘approval formal agreement by the employer that a ‘qualification (or other proposal by the contractor) in ‘accordance with this British Standard is acceptable {or the proposed application Detter ween fam BS 4364 321 preliminary welding jure specification (pWPS) ‘tentative welding procedure specification, which is assumed to be adequate by the manufacturer, but ‘which has not been approved. NOTE. Welding of et pions needed for approval of meting ‘procedure apeication has be arid ou on the bass of Drednary welding procedure speciation GUS) 4 Information to be specified and items to be approved 4.1 Information to be specified by the employer ‘The following information shall be supplied by the ‘employer and folly documented: a) whether batch testing of electrodes and filler materials is required (see 7.1); 'b) whether specific compositional controls are to bbe applied to the deposited weld metal (ee 7.2); {) whether different batches of electrodes and filler materials are to be individually !dentifiable ‘and completely separated (see 7.2); <) whether an alternative location is specified for the excavation location for the repair weld test (Gee BS EN 288-0:1000, Figures Al and A.2); ©) whether specimens should be allowed to cool for a duration other than 24) before testing Gee 8.1); ) whether strain ageing data andlor additional testa are required as the basis for welding procedure epproval for pipe-reeling (see 6.1); ) the type and number of reests required in the event of failure (60° 8.1); 1) whether addtional NDT methods for fillet welds apply (see 9.1); 1) whether a proposed change to a welding procedure will require requalification of the welders (see 10.8); 4) whether prevailing weather conditions are such that quality of the completed weld would be impaired (see 11.9); 1) the method(@) and frequency of visual inspection and nondestructive testing (see 12.1), 1) whether completed welds are to be ground (Gee 12.1); tm) whether alternative techniques are to be used for radiographic testing of welded butt joints Gee 12.4.1); 1) ultrasonic acceptance criteria (see 12.5.4), (0) whether automatic ultrasonic testing i to be used (see 12.6); tedormaton for tin item ay ok be able to be mapped unt the appropiate age of the work erached, 7 © BSI 07-2000 :opyright by the British Standards Institution tue May 13 09:48:62 2003 STD-BST BS WSRS-1-ENGL 2000 MM 2b24669 080224 085 om BS 4615-1:2000 rr ) whether NDT acceptance criteria are to be based on quality control oF critical ssecsament (eee 18.1.1); @ whether the maxirmum planar defect dimension 4s to be less than 25 mm (eee 13.1.2); 1) whether a more stringent limit for root penetration is required (see Table 4c)]- 42 Items sabject to approval by the employer ‘The following iteme shall be subject to approval the employer and filly documented: i 4) ae tena strength of weld meal for ints between diasimilar materials if other than that of the higher strength parent metal (see 7.1); ') consumables to be used (see 7.1); ©) the definition of a batch when batch testing of electrodes and filer materials is required (see 7.1); 4) test weld production on pipes shorter than full length (see 8.1), ©) explanation for NDT failure if a test weld is to be destructively tested ar rewelded to the same procedure (528.1); 1 the type and mumber of retests of a procedure when they are permitted (eee 8.1); 1 welding procedure qualification test details and ‘welding procedure specification for production welding (see 8.1); 1) use of roll welding (see 8.1); {) simulation of a filet weld joint using flat plate fillet welds {see 10.4.1b)}; J) altemative methods of NDT for welder test Dleces [see 10.6c)}; 1 giving a welder a second opportunity to gain ‘approval (see 10.8); 1) all documentation relating to welder ‘qualification tests (see 10.9); 1) use of manual thermal cutting for pipe end beveling and the ality of te operat (ose 1.2); 1) method of obtaining minimum ‘other than rotation of the pipes (see 11.4); 0) method of marking for ultrasonic testing Geeta, nt ) the blending out by grinding of minor ‘imperfections within the joint preparation area [see 11.28)}; @) alternative alignment methods other than {internal line-up clamps (see 11.8.1); +) the stage at which line-up clamps are removed (Gee 115.1); 1) the stage at which the pipe is lowered onto ‘skids, or support ls removed from fittings (eee 11.5.2); £) reduction of preheating requirements for tack ‘welds [see 11.66)} © B51 07200 opyrigit by the British Standards inattution ‘Tue May 13 00:48:62 2003, 1) repair of places where stray arcs have occurred (see 11.8); ¥) means of applying preheat (eee 11.10.25, ‘w) methods of attaching and ‘thermocouples (see 11.10.4); +) the welding procedure for branch connections where the angle between the main and branch is Jess than 60° (see 11.111); ¥) written ultrasonic examination procedure for pipe material around a planned cut-out (gee 11.11.8), 2) all non-destructive testing procedures to be ‘sed (see 12.1); ‘aa) all inspection personnel (see 12.2), ‘ab) the technique in BS EN 1435 to be used for radiographic examination (see 124.1), ac) any method for magnetic particle testing to ‘ied a above ambient temperature (ote 187.1) aad) any proposal to repair a weld (eee 13.2.1); ‘) ary alternative limits on repair weld length (eee 18.2.1), i af) use of root or a0 uae of rot sealing or single run repal deposits ore han one auerpt a rep (ie 18.2.4 ‘ah) technique and equipment for brazing Sttninothennic welding of trode Vond leads (ee annex B); a) proposed brazing of aluminothemale procedure specification (see annex B). ‘4) the position of the longitudinal seam weld (fapplicable) on the subsea pipeline at the 1yperbarie weld location (see annex A), 5 Equipment STD-BST BS 4SMS5-1-ENGL 2000 M@ 2624LL9 080235 TLS a BS 4515-1:2000 6 Welding processes ‘The process used shall be a manual, semi-automatic ‘or mechanized are welding process or combination of processes. 7 Welding consumables 7A General Electrodes, filler wires and shielding gases, and ‘wire/fx combinations shall produce weld metal that Ihas a teste trength atleast equal to the minimum specified for the parent metal. Moisture content of shielding gases shall correspond to a dewpotnt ‘of - 20°C or lower. In the cave of joints between dissintlar materials, the ‘weld metal ahall have a tensile strength at least esmual {0 that specified for the higher strength parent metal ‘unless an alterative value ls approved by the employer. ‘The chemical comporition of the deposited weld ‘metal shall be selected to ensure adequate resistance ‘to degradation from the pipeline contents under the intended operating conditions. The employer shall Indicate whether specific compositional controls are to be applied to meet these requirements. [NOTE Where Nigh uanevere azn are expected ‘ocideraion soul be given fo reqererta for wed metal yd amengh ‘Only consumables which have received the prior approval of be anpoye sal be wed: When required by the employer, batch testing of electrodes ‘and filer materials shal be carried out, in. which case the definition of a batch shall be subject to the spprova ofthe employer. 2 Appvopiate ecroses tnd ler materi. ‘Sth reencnsc he a se gee BS, ‘Bota BS Tn, BS 4100 and BS EN 1038 Carbon ride ted se tldng go sould confor bo 354105 72 Storage and handling Different grades and, when specified by the different batches of electrodes and fer the spproprineaceptance enter specie 9.2 Destructive testing 8.2.1 Teat apectmens ‘The minimum number of test specimens and the teats to which they shal be subjected shall be as given in Table 2 ‘Two ofthe fracture specimens shall be taken from thase locations shown to have the greatest and least root gap. Macro-examanation shall be earied out on ‘one face of each of these two fracture specimens prior to being fractured ‘The specimens shall be prepared as shown in Figure 1 and shall be at leant 25 mm wide and at least 60mm long. ‘They shall be prepared by machine cutting ot ‘thermal cutting followed by ‘bat the sides of the epeciimens shall be emooth and parallel. ‘Table 2 — Test specimens for procedure ‘approval tests on fillet welds ‘Oaiakie Gameter| Minima number of specimens Of pipe Practare|Macro-examiantion] Wardneas| cad tot er sia 2 i 21d jae The farthest sare nade Ona macrrecaminaion 9.2.2 Fracture test 92.2.1 Requirements When tested as described in 9.2.2.2 the exposed ‘surface of each broken spectmen shall be free from cracks, lack of fusion and lack of penetration. Other defects in the weld metal shall be within the following limits. 8) Gas pores. The greatest dimension of any pore shall not exceed 20% of the pipe thickness or 3.mun whichever is the smaller. The combined areas ofall poree shall not exceed 5% of the cross-sectional area; ») Inclusions, Inclusions shall not exceed 1 mm in depth and Sun oF 60% of the pipe thickness in length, whichever is the shorter. There shall be at least 12mm of sound weld metal between adjacent ‘nchusions. 9.2.2.2 Mothod ‘Break the specimens by one of the following ‘methods in such a way that the root of the weld is in tension: 4) supporting both ends and striking the centre of the specimen; ») gxpping one end and striking the other. 9.2.8 Macro-examination 92.9.1 Requirements ‘When tested as described in 9.2.8.2 the profile, dimensions and number of runs of the fillet weld ‘shall be as specified in the welding procedure. The ‘specimens shall be free from cracks, lack of fasion ‘and lack of penetration and the total area of any ‘cavities or inclusions shall not exceed 5% of the {llet weld cross-sectional area. 92.8.2 Method ‘and etch the specimens as described in 'BSEN 1321. Examine the polished and etched ‘urfoces using a hand lens of x6 magnification, Sea ‘Specimens shat May be machine cut or thermally ct. atleast 80mm jong and 25 am wide. Specimens for fracture may be i hacksaw notched in the weld. — Figure 1 — Preparation of fillet weld specimens 6 tue May 13 09:48:63 2003 pst ozo Copyright by the Tue May 13 08:48: STD.BSI BS 4SUS-2-ENGL 2000 mm Ub246b4 O8L0238 724 a BS 4515-1:2000 92.4 Hardness eurcey 924.1 Requirements When tested as described in 9.2.4.2 the hardnese ‘values shall not exceed those given in Table 3 unless otherwise specified by the employer. 92.4.2 Method Carry out the hardness survey on a macro-examination or fracture test specimen a8 ‘appropriate. Test the specimens as deveribed in HS EN 190 6507 using a 10kg load. Make two weld Zone traverses, one across the root and one near the ‘weld cap. The root traverse shall consist of at least five impressions: two in the heataffected zone, one {in the weld metal and one in the parent metal each aide of the weld. The tnverse near the cap shall ‘consist of at least eight impressions: two in the heat-affected zone each side of the weld, two in the ‘weld metal and one in the parent metal side of the weld, 10 Testing, qualification and approval of welders 10.1 General Each welder shall make a test weld or part of 2 weld, ‘aing a qualified procedure to male the welds or See te cae aae es "relding prosedare qualification tot Where more hn ong proceso wees enphined In producing a complete welded Joint, the successful ‘testing of the completed weld shall qualify each welder for his respective portion. Each welder's portion shall be clearly identified. Each welder shall weld that portion af the pipe clrcumference which he will weld in construction in accordance with the qualified welding procedure, ‘A welder shall be given s single qualification for one ‘ot more ofthe following categories, a separate teat Deing required for each category: 8) butt joint; ) branch connections; © fillet welds for sleeves, sockets, slip-on flanges, ‘other attachments and pipe supports, ‘The validty of the welder's qualification begins from the date when all the ‘teste are satisfactorily ‘completed, This date may be different to the date of ‘issue marked on the certificate, ‘A.welder’s qualifteation shall remain valid for a ‘Period of two years providing that the relevant ‘certificate Is signed at six month intervals by the employer/coordinator and that all the following conditions are fulfilled. 1) The welder shall be engaged with reasonable 2) The welder’a work shall be In general ‘accordance with the technical conditions under which the qualifcation test is carried out, [NOTE Thar should be no pectic reason to queion the ‘les Sa ad ode fay of these conditions are not fulfilled, the ‘qualification shall be cancelled. 10.2 Butt joints 10.2.1 Roll welding ‘The test joint shall be made between two pieces of pipe rolled about the horizontal axis, The welder ‘shall deposit metal at or near the position specified in the welding procedure until he has completed, 200mm or slightly less than 25 % of the Joint, ‘whichever is the greater. [NOTE _Aec loving short ditance wowed anther weber ‘ay weld srularperon and oo on smal fe poe {em up to for welders om one one ‘When a welder does not complete the whole joint, the root run shall inchude a stop/start position. ‘Table 8— Hardness vatues ars a aaa aaa oa ia ta SS = we | |e waa rota istic ——_faso ES a ow ES zs ES | ace reer monicinen fa a 0 cap 276 325 350 PS Bekrpern rane © B51 07.2000 British Standards institution ~ 63 2003 STD-BSI BS 4SDS-2-ENGL 201 ‘BS 4515-1:2000 WH 2G24bE9 O8bOZTT LEO a 10.2.2 Posttional welding ‘The pipe containing the test joint shall be fixed as follows: 8) within 20° of horizontal. The pipe containing the test joint shall be fixed hortzontally, b) within 20° of vertical The pipe containing the ‘test joint shall be fixed vertically; ©) betwooen 20° to the vertical and 20° to the horizontal. The pipe containing the test joint shall bbe fixed af 45° to the vertical. 103 Branch connections ‘Unless more than one process is used each welder ‘shall make all the runs on the fall circumference of a Dranch to be qualified for welding branches. ‘A test weld shall be made with the branch and main pipe axes both horizontal or at the actual angle of production welding 104 Fillet welds for sleeves, sockets, slip-on flanges or other attachments 104.1 General ‘A suecesoful single qualification test on either one of the items listed ina) or b) shall qualify a welder for all the attachments given in a) within the limits specified in 10.5: 4) sleeve, socket, slip-on flange or other type of sttachment, 1D) with prior approval of the employer, & simulation of the joint using flat plate materia. [NOTH The mechanical properties ofthe late wad may eat {fon ihe parental fe pie rece ine wen rocdure a the dseredon ofthe employer. 104.2 Filet welds in the flat or horizontal-certical positions ‘The test weld shall be made between a sleeve, socket, flange or other attachment and a piece of pipe rolled about the horizontal axis or on a ‘simulated joint in plate [See 10.4.1b)]. The welder shall deposit metal st or near top centre until he has ‘completed 200 mam or slightly less than 25% of joint, ‘whichever is the greater. LOTR Afsrlening «short cutee unwed acter Weider ‘ay wed 4 mar porn ands on, thus ma pele to {ent wp wo four wees or oe on 10.4.8 Fillet welds tn all positions ‘The test weld shall be made between a sleeve, socket, flange other attachinent and a piece of pipe fixed with the axis horizontal. When a simulated Joint is used, the plates shall be positioned to cover for all the welding postions for which approval is 10.5 Changes affecting qualification and ‘approval (essential variables) ‘A welder who has successfully completed ‘ualication test a detailed in 10.140 104 shall be ‘qualified for the type and postion of weld concemed ‘within the limits ofthe following tems, If any of changes a) to) occur, the welder using the new procedure shall be re-qualified: ‘8) a change from one welding process to another Welding process or combination of welding processes; a change in direction of welding from vvertical-up to vertical-down or vice versa; €) for butt jolnts and branch connections, & change in pipe diameter or thickness outside the ‘anges given in Table 4 (for branches, the diameter ‘of the branch is the applicable dimension), ‘Table 4— Diameter and thickness ranges for batt Joints and branch connections DiametsrD] Diameter | Thlcbnosst | Thickaaw ofteatpipe | range | oftent pipe | range mm” | approves |" ner D=150 [ospwewlrsi2 |=2 D>0 |=pe _|t>i2 |= bam NOTE 1 The value of Dis the nora pipe te, andthe Syprore range should suo be quoted in renal pipe ses, Seren astm qs ton Dts OTE “TR abedous ct pl to pe hone Ie 4) for a branch connection, a change in branch ‘ortentation exceeding 27 from that approved, ‘except that approval on connection with the ‘ranch and main pipe axes both horizontal gives approval forall welding positions; ©) change in Joint design eg, backing ring to no backing ring or single U to sitgleV preparation, 4) for manual metal are welding a change from one electrode covering type to another, 1 for continuous tubular electrodes a change from {metal cored to fux-cored or vie versa; a change from one fux type to another, a change from gas shielded to nonabielded or vice versa, 1) a change from one shielding gus or gas mixture to another gas or gxs mixture; 4) any other change in the welding procedure oF ‘equipment which in the opinion of the employer, ‘will make production of a sound weld more iticlt for the welder. 104 Non-destructive testing ‘The test weld shall present neat workaanie appearance and shall be assessed by visual ‘examraton according to the appropriate acceptance ‘xiteria specified in 19-1 ‘opyright by the Bish Standards Institution te May 13 09:48:64 2008 eps or2I00 STD.BSI BS WS3S~2-ENGL 2000 MM Be2VEG9 O8L0220 382 BS 4515-1:2000 ‘After visual examination (see 12.8) non-destructive testing shall be carried out on each of the test welds using one of the following methods: «) Xradiography as specified in 12.4; ) automatic ultrasonic examination ss specified in 126; ©) with the prior approval of the employer, an alternative method(s). ‘The resultant fm, ultrasonic read-out or other results shall be asseased in accordance with 18.1. 10.7 Destructive testing 10.7.1 Generat Destructive testing shall only be used for examining 10.7.2 Butt joints 10.7.8 Fillet welds ‘The testing of fillet welds for welder ‘shall conform to the requirements for procedure approval tests as given in 9.1.4, except that no hardness survey is required. 10.8 Retests ‘When failure of a welder to pass the test was ‘because of conditions beyond his control, such a ‘welder shall, with the approval of the employer, be «given a second opportunity to gain approval. No further retests shall be given until the contractor has ‘submitted proof of subsequent training of the welder ‘acceptable to the employer, ‘Should one of the destructive test specimens fall to ‘meet the relevant test requirements two additional ‘specimens shall be taken from the positions ‘immediately adjacent to and on elther side of the failed specimen. The welder le not regarded as ‘quakified {f ether additional specimen also fats to ‘Satisfy the test requirements. 10.9 Records ‘The details of each welder’s qualification test and test results shall be recorded. All documentation. relating to welder qualification tests shall be ‘submitted to the employer for approval prior to the ‘welders commencing production work. NOTE. Racor fra sinllar 2 that shown in annex D shouldbe (ed. Te period for whic econ ahold be hep abot be ‘specie ly the enghoyes, 10.10 Mechanized welding For mechanized welding, each welder shall be ‘qualified for a particular part or parts of the ‘operation of making a welded joint. ‘Under no circumstances shall a welder be employed ‘on operations other than those for which he has ‘been tested, qualified and approved. ‘The inspection and testing of welds for. ‘Purposes and records shall be in accordance with ‘the requirements of 10.6, 10.7, 10.8 and 10.9. 11 Production welding 11.1 Proximity of welds “Adjacent welds shall have a toe-totoe distance not. Jeaa than four times the pipe thickness. [NOTE Welds shoul be separated by te maximum poe 112 Pipe end preparation Bevelling shall be done by machining or by machine ‘thermal cutting, manually or mechanically operated. Manual thermal cutting shall not be used for bevelling the ends of pipe for welding unlezs it is dressing shall be by fling, grinding of other ‘Tochacal ume othe dhreettn svn the approved welding procedure. {f bums, small score marks, indentations or other nino imperfections occur within the Joint reparation area, elther: ‘) with the approval of the employer these lamperfections shall be blended out by grinding; or ) the joint shall be re-prepared. en beveling machines shall be tr bacorance wil the pete Secicton ‘On pipe which is cut back, the end zone shall be ‘examined visually and by Ultrasonic examination to ‘the requirements of the appropriate pipe material specification. ‘When a weld is intended to be examined by tltrsonic testing, datum potnts shall be marked on Doth sides of the joint (before welding commences) ‘ata known distance fram the root face on that component. The method of marking shall be subject ‘to approval by the employer. NOTE The datam pont enable the uranic operix to louie Fetecenes in reldon to the weld preperation in the aiwence of ‘Sear dnaun oot pote refloeons ould ve incorrect ened ‘mvohmetic cease © or200 by thé British Standards Institution Sopyright| ‘Tue May 18 00:48:64 2003, STD.BST BS 4S25-2-ENGL 2000 MH UL24LL9 08022) 219 mm BS 4516-1:2000 11.8 Fosion faces ‘The fusion faces and the adjacent material shall be free from fins, planar flaws not conforming to 13.1, ‘tears, moisture, seale, rus, paint, grease or other foreign matter immediately prior to welding. ‘Cleaning to base metal shall extend for at least ‘25mm from the edge of the fusion faces on both, {internal and external faces of the parts to be welded. 1L4 Alignment ‘The alignment of abutting pipe ends shall be such as, to minimize the intemal offset between surfaces. Any ‘offset greater than 1.5 mm, provided itis caused by tolerances, ‘of the pipe or firings. reduced to a minimum by rotation ofthe pipes to ‘obtain the best ft or by other methods approved by the employer. ‘When a pipe with one longitudinal seam io used, this seam shall be within the top half ofthe pipe circumference and the longitudinal seams of adjacent full pipe lengths ahall be offset by an angle of approximately 00° or by a circumferential distance of spprozirately 250 mm, whichever is the smaller. For pipes of different nominal thickness and the same ouside diameter, alignment with a taper not seep than Lin sal be achieved epee ina) or! ') provided that the material grade of the thicker pipe Is equal to or grever than that of the thinner ibe, the smaller bore shall be machined, ground or fle, ') a transition plece shall be inserted. 114 Line-up clamps and pipe supports 11.8.1 Use of Une-up clamps ‘Whenever practicable internal lineup clamps shal ‘be used to hold pipes firaly in position. Other alignraent methods shall be subject to approval ky ‘the employer. Internal line-up clamps shall not be removed before the completion of the root run or ata stage later as, qualified, the pe remaining adequately supported. ‘Onno account shall straps, brackets, cleats or ‘lmilar plate sections be aiached to the pipe by ‘welding forthe purposes of alignment. Riubhionvalooies ‘External lineup clamps shall not be removed until the completed part of the root run covers & minimum of 50% of the circumference of the Joint ‘uuformly spaced, the pipe remaining adequately ‘supported on each side of the joint. ‘The stage at which line-up clamps are removed shall be stated in dhe WPS and qualified subject tothe approval ofthe employer. 11.5.2 Removal of pipe aupports For landlines, the stage at which the pipe is lowered ‘on to ekide, or at which supports are removed in the ‘case of fittings, shall be stated in the WPS and subject to the approval of the employer. ‘On outside diameters up to and including 1143 mm a rminimam of three tack welds each not les than 25 mm long shall be spaced equally around the Joining circumference. On diameters over 1143 mm. atleast four tack welds each not less than 25 mum Jong shall be used. If they are to be incorporated inv the flowl weld, tack welds made in accordance with the welding procedure specified for the root run shall be ground to a suitable taper at each end to ‘ensure adequate fusion with the root run. reheating requirements shall be maintained a specified in 11.10.2 from tack welding to completion of the joint. NOTE Wi he appro ofthe enoloer, ower pebest nay ‘be wed fr tack wei I preheating requirements are reduced, the tack ‘welds shall be removed by careful grinding after at Teast 805% of the root run has been applied, 11.7 Working clearance ‘The working clearance around the pipe at the weld ‘shall be of sufficient size to provide adequate access for welding and inspection of the joint. ‘When the pipe is welded in a trench, the bell hole ‘shall be of sufficient size to provide the welder or welders with ready access to the joint. 11.8 Stray ares ‘Ares shall be struck only on fusion faces und contact ‘of the electrode or of the nonringulated parts of the ‘electrode holder with the outer surface of the pipe shall be avoided, ‘Places where any stray ares have accidentally ‘occurred hall either be repaired or rejected as ‘approved by the employer. ‘Where permission to repate arc strikes has been given by the employer, the procedure shall include, But not be limited to, the mechanical removal of the defective rmateria, blending of the ‘excavation, checking by magnetic particle inspection ted confirmation tat the tenes ofthe pipe or fitting is within permitted tolerances. [NOTE Where the mizimum tines below the wlan, ‘pala to an approved weg procedure may be cared out and ‘sikjoaed to farther nan etic tong 11.9 Weather conditions Welding shall not be undertaken when, in the ‘pinion of the employer, the quality of the completed ‘weld would be impaired by airborne moisture, blowing sands or high winds. NOTE. Where adeqe protection fom the weiter can be Provided welding ny be conned, 10 ‘opyright by the British Standards Institution ‘ue May 13 08:48:64 2008 ‘© 072000 STD.BST BS 4S15-1-ENGL 2000 M® b24bL9 O8L0222 155 Mm BS 4516-1:2000 ——— 11.10 Preheating and post-weld heat treatment 1.10.1 General ‘The prebeating and poot-weld heat treatment. requirements shall be as speciied in the welding procedure. Post-weld heat treatment shall be applied by guefired mufies or electric methods of heating that have been approved by procedure test. Under no circumstances shall manually opersiod gaa torches be ured forthe application of postweld ‘treatment NOTE Po powwel et oazment,refarnce shuld be ad {Swope sonar 04 BS 20. OTE? Gldaee for 11.102 Preheating ‘The area of pipe that is preheated shall extend Gta eeemonue Eee 75 mm on each side of the joint shall be maintained a Preheating shall be applied by gas or electrical ‘meane in the manner used in the procedure qualification such that the equipment used maintains a satisfactory temperature distribution, does not Sao mint nena ‘Care shall be taken to avaid damage to any coating. reat gcoeltes oer the procedure qualification immediately prior to ‘the commencement of welding and around the whole of the joint while welding is taking place. The ono Saher cstmomiyerase {Erie tse pate a th eB as Nos ood Tes ees ba rene ape ra a gee —] saait ‘pve a true reading of the joint temperature. When ‘separate heating sources are used, thermocouples: ‘shall be placed so as to record the temperatures oe 11.104 Thermocouple attachment and junctions _use by methods approved by the ‘Thermocouples shall be in metalic contact with the ‘parts being heated. 11.11 Branches 1.11.1 Angle of branch 11.11.2 Spacing af branches gil of Senge benches sha beset lenge ‘ranches there ib adequate acceas for sedfactory welding and ‘subsequent NDE- 11.11.8 Joint preparation Branch connections and branch openings in the main pipe shal be cut by machining or by Uhermal cutting ‘The cut edges all then be dressed by fling or Grinding to de dlmenslona given in the approved ‘Welding procedure (ave also 11.2) (900 also 18.1.2). 1114 Welding MALAI Gop ‘The gap shall be maintained during the deposition of te fet run. Tock welds shal be toed lpn ‘accordance with the requtrements of 11.6, LLI1A.2 Internal welds Internal welding shell only be carried out as specified in the approved welding procedure. 11,118 Branch reinforcement (compensation) ‘When the reinforcement is thermally cut to shape the ‘cut edges shall be dressed by filing, grinding or machining. ‘The reinforcement shall be securely held in position by tack welds which shall be of sound quality (eee 11.6). Welds connecting reinforcements shall be butt welds oF fillet welds or a combination of these types, made 'm accordance with the appropriate qualified welding procedure. u STD.BSI BS YSLS5-3-ENGL 2000 mw 262469 Oab0223 09] me BS 4515-1:2000 11.12 Inter-ran cleaning Surface slag likely to produce unacceptable weld flaws shall be removed, either by hand or power toole, before a further run is spplied. Visible defects such as cracks, cavities and other deposition faults shall be removed, and particular attention pald to the cleanliness of the junctions Dotween the weld metal and the fusion faces, before deposition of further weld metal (Cluster or surface porosity, stops and starts and high points shall be removed by grinding, 11.18 Partially completed joints Whenever poole, joints shall ot be left paral completed. The welding of fittings ‘completed in one cycle. Where production ‘conditions are such that pipe to pipe joints have to De left partially completed the following conditions shall apply. 4) The minimum number of runs deposited before cooling shall be qualified in the approved welding procedure. 'b) Upon discontinuation of welding the Jolnt shall, ‘be wrapped in dry insulating, heat resisting material with a waterproof backing and shall be cooled in a slow and uniform manner. ©) Pilot to recommencement of welding the joint ‘shall be reheated to within the specified interpass ‘temperature range. 12 Inspection and testing of welds 12. General ‘The method oF combination of methods and frequency of visual inspection and non-destructive ‘tasting shall be as specified by the employer. Prior to the start of welding, all NDT procedures to be used aball be submited fo the employer for approval Ifthe employer requires completed welds to be aground, this shall be stated inthe enquiry and order. ‘When a weld isto be ground, overheating due to the sinding action shal be avoided. 12.2 Personnel qualification ‘All Inspection personnel all have been approved by the employer. 12.8 Visual inspection ‘Al welds shall be visually examined in accordance ‘with BS EN 970 on the outside surface and, where > in the bore. Visually detectable flaws hal be aaseaoed in accordance with 18.1. 124 Radlographle testing 124.1 Generat ‘The radlographic testing of fusion welded ‘freumferential butt joints in steel pipes shall be ‘earied Out in accordance with BS EN 1435:1007, The minimum standard required shall be Class B ‘Gamproved techniques) using one of the following techniques in order of preference, nos. 6.14, 6.1.8, 6.13 oF 6.16 unless otherwise specified by the employer. Class A techniques shall only be used where Clase B ‘cannot be practically achieved and only with the approval ofthe employer. 12.42 Approved radiographte procedures ‘The procedure details shall include the exposure ‘time in addition to the requirements of BS EN 1435, 7 ‘The radiographs used to approve the procedure shall show image quality indicators placed on both the source side and the film side of the area betng ‘examined. The contractaral sensttivty level shall be 1248 Pim atros ‘erp fl tr ea Hareb ama Sad ty seo an 128 Manel ltl ing 1a Geert ‘Where ultrasonic testing is applied, it shall be carried out in accordance with BS EN 1714:1998, using SUSE Sekai a ote pte SSBC UN ceca pee SE OUD eas Sitters aed ccna an SB, clause 13. oe ane sere et = deneerererrse eter SEaa Sees Jescemeedeeeennt ramet Ramen one ssi or2000 copy i the Bria stndard ntti” Stay 13 toute 2008, STD.BST BS 4SUS-3-ENGL 2000 MM 2624469 OabOz24 T2S mm BS 4515-1:2000 12.5.8 Reporting and evaluation All discontinuity indications having an amplirode above the reference level established for scanning in ‘accordance with 12.8.1 shall be recorded. They shall then be sized and characterized, and assessed against ‘the acceptance criteria specified by the employer. 12.6 Automatic ultrasonic testing ‘When specified by the employer, automatic ultrasonic testing shall be used for the initial detection and/or sizing of flaws. format, method of data storage and presentation stall be agreed in order to establish suitable performance for the intended application. Tho ‘Propoved technique shall be demonstrated and ‘validated before being applied to production welds, [NOTE The wwe of rai faw referece spies bse othe ‘cua om geometry and welding procedze may be Fequfe for ‘hi purpose: 12.7 Magnetic particle testing ‘The extent of the testing shall be to cover the weld and weld toe regions. The magnetic particle testing ‘shall be in accordance with BS 6072 with the following variations. 4) Wet methods stall be weed ot ambient temperatures, For higher temperatures the method shall be subject to approval by the employer. ') Reda magnetism tetiques shall not be 18 Acceptance and rectification of welds 18.1 Non-destructive testing acceptance criteria 13.1.1 General ‘The acceptance criteria for non-destructive testing shall be in accordance with either 18.1.8 or, if specified by the employer, 18.1.8, 18.1.2 Acceptance ertterta based on quality controt {In areas of a weld preparation such as pipe ends, fusion faces and branches (see clauses 11.2, 11.8 and 11.11) no planar defects shall exceed in any dimension, either: 2) 25 may or 1b) a smaller value specified by the employer, ‘The acceptance criteria for welds shall be as ‘specified in Table 5. ‘Any accumulation of flaws, except porosity, affecting. 4 total length of weld of 100 mm or more in any ‘continuous weld length of 300 man or a total length ‘of 15% or more of the weld length, whichever isthe ‘greater, shall not be accepted. 18.8 Acceptance criteria based on engineering critical assessment ‘When the employer specifies that engineering critical sssessment (BCA) is to be used for acceptance criteria, it shall be applied in accordance vwith PD 6493, 19.2 Rectification of welds 13.2.1 Removal of flaics ‘When the welds fail to conform wholly or in part to the requirements of 18.1, elther the weld shall be repaired locally or the weld zone shall be entirely Temoved. The excavated partion of the weld shall be sufficiently deep and long to remove the flaw. Weld repairs shall not begin before sufficient nondestructive testing and inspection has been completed. [No weld shall be repaired without the approval of the employer. tre welds shall be removed by thermal cutting or machining When strare gouging or thermal cuting are used, Eire pun state Singh ibe irae run oot ofthe weld shall be removed by mechanical ‘Repairs shall be limited to 30% of the weld length fora partial penetration repair, of 20% ofthe weld length for a full penetration repair. If sltemative Tepai length lt ae proposed they sell be ‘subject to approval by the employer. tet of rings pa pss pee a ay ‘besch arto rove 2 of te wed eagu woud be aa 18.2: Preparation for rewelding At the ends and sides of excavation there shall be & ‘radual taper from the base of the excavation to the surface of the weld metal. The width and profile of ‘excavation shall be such as wil give adequate access for re-welding. onstor200 1B BS 4515-1:2000 STD-BSI BS 4SUS-1-ENGL 2000 MM L24Eb5 O8L0225 9b4 mw 18.2.8 Qualifications Repair welding procedures ahall be qualified when, Fopared by 8 The teat wala vo Gully a peal penetration repair weld procedure shall be made into ‘an excavation to a depth of at least half the pipe thickness centred on the toe of the original weld. 18.2.4 Rewelding Root sealing or single run repair deposits shall only be undertaken if approved by the employer. ‘A repaired weld shall be subject to at Jeast the same testing and inspection requirements as the original ‘weld. Repairs shall not be attempted more than once One fall penctration and one partial penetration” Yrjesg niproved by the employer, Feary a cunt ll roneds procedures OxCEDE Fu penetration repairs aball only be Smplemented ‘under constant supervision. If repairs cannot be Implemented within these limitationa, oF are not ‘effected successfully, the weld shall be cut out Full records of all repairs shall be maintained. ‘Welders shall be re-qualified to use the repair procedure when required by 10.5. ‘Table 5— Acceptance criteria for welds ‘Aeveptance eiteria [Excess weld metal (reinforcement) shall be uniform and shall /merge smoothly with the parent metal and shall extend beyond the original joint preparation by not more than 3 man on each side. In [no area shall the weld face be lower than the adjacent pipe surface. Fillet welds shall be not less than the specified dimensions, regular in form and without undercut as given inh). "The root bead or any concavity shall merge emoothiy into the adjacent surfaces, [Not to exceed S man. If service conditions necessitate a more stringent limit, this shall be specified by the employer. [Length not to exceed 25 % of total length of weld. Depth not to exceed 10% of pipe thickness or 1.5 un whichever is the smaller [but st no point shall the weld, inchuding eap reinforcement, be thinner than the pipe thickness. [Length not to exceed 25 min in any continuous weld length of 300 mum or not to exceed 1/12 of the total length of the weld when this is lese than 900 mm. Depth not to exceed 10% of pipe thickness or 1.5 mun whichever is the smaller. For branch welds this flaw is not permitted. [Length not to exeved 25 mm in any’ continuous weld length of ‘300 min of not to exceed 1/12 of the total length af the weld when this is leas than 900 mm. For branch welds this aw is not permitted. Not permitted. [The toes of welds aball blend smoothly and gradually into the ‘parent metal. Length not to exceed 60 mm in any continuous weld Tength of 300 mm or not to exceed 1/8 of the total length of the ‘weld when this is less than 300mm. Depth not to exceed 10% of pipe thickness or 1.5 mm whichever is the smaller. For branch ‘welds the length shall not exceed 25 mm in any continuous weld Tength of 300 ram or not to excoed 1/12 of the total length of the ‘weld when this is less than 300 ram. Faw oe ') External profile b) intemal profile ©) Root penetration {) Root concavity [¢) Root underest ‘Shrinkage groove “ ops oro00 ‘opyright by the British Standards Institution ibe May 13 08:48:66 2003 STD.BSI BS NS3S~2-ENGL 2000 MM Lb24Eb4 OSLO22b STO am BS 4515-1:2000 ‘Table 5 — Acceptance criteria for welds (continuad) Few or ‘Accopianee evra 1) Elongated linear poreaty in ‘enggih of weld affected not to exceed 60 mam in any confimucus root ran (hollow bead) *-eld length of $00 mum or not to exceed 16 of the total length of the weld when this is les than 900 mun. sheinkage cavity Lack of inter-cun faston Width of elongated inchusons not to exceed 1.5 mm. Lack of side fusion Elongated inctastons Por branch welds the length of weld affected not to exceed 25 mm {any continuous weld length of 300 mm oF not to exceed 1/12 of Paralle! elongated inclusions the total length of the weld when this Tees than 300 mm, (ragan tracks) Toot penetration ‘ouble side welds only”) i) Porosity (other than elongated | Not to exceed a total area when projected radially through the weld] Porosity in root run) of 2% of projected weld area in the radlograph conslting of the length ofthe weld affected by the porosity, with a minimum length ‘of 160mm, multiplied by the maxienun width of the weld. An isolated pore greater than 25 % of the pipe thickness or 3 mm, ‘whichever is the smaller, tn any direction shall be considered unacceptable 1 bolted inclusions [Width of an inclusion not to exceed Swan or half pipe thicknaws, (copper, tungsten or nonrelongated | whichever is the smaller. Total length of inclusions Ht t0 exceed slag) 12mum in any continuous weld length of 300 mim and nat more than four inclusions of maximum wide in this 200mm length, Inclusions hall be separated by a minimum diatance of SO mm. [) Banethrough "Not to exceed Sam in any dimension and only one in any continuous weld length of 00am. i=) Wormhole Not to exeeed 6mm in length or 1.5tam in dlameter for thicknesses ot exceeding 251m, or a length of 25 % ofthe thickness or 12mm, whichever isthe smaller, or Simen in diameter for thicknesses over 25 mum, Fe databor oe BS 051 hin twa Sao crows peta ‘© mst 07.2000 it by the British Standards Insttution ‘Tue May 13 09:48:86 2008 STD.BST BS 4SUS5-2-ENGL 2000 MM BL24bb5 O&L0227 737 BS 4515-12000 Annex A (informative) Recommendations for hyperbaric arc welding A. General A.L.1 Hyperbaric welding may be defined as the ‘process of welding n a dry underwater environment ‘wherein the gaseous atmosphere acting upon the welding are and weldpoo! is at an elevated pressure, the level af which is determined by the depth of water. ALL2 These recommendations relate to the fhyperbarte arc welding of joins in steel pipelines as ‘well as to weld repairs All welding should be perfomned in accordance with the requirements af sections 1 to 12 of this standard, except insofar as they are supplemented by this annex. ‘A.1.8. The recommendations are based on experience of welding in water depths down to 200m and ‘additional precautions and/or more extensive testing ‘may be requlred for greater depths. ‘All welding should be carted out with ‘hydrogen-controled are welding process and within 2 chamber or habitat from which the water has been displaced. Other methods should be subject to special -aialeee mt = A.2 Diving regulations and safety A2.1 All diving operations on the UK continental ‘shelf are subject to The Diving Operations at Work Regulations, 1981 (3). ‘exgoriation with clearly defined individual ‘ensuring effective co-ordination of diving, welding and inspection activites. ‘A283 The contractor should ensure that all personnel ‘exgaged in the work have received suitable training ‘and are familiar with the operstions they sre to ee rae ‘and registration are given in The Diving Speaion of Wor Raplatons, 1913), A.2.4 ‘The diving phase of the work should take due ‘account of interupdons due to team changes st the ‘end of the permitted diver lock-out time, weather Lnitations on diving or other diving restrictions. The {neerruptions in the process of welding do not. influence the integrity of the weld. Details of the ‘course of action to be followed in such an event ‘should be included in the welding procedure ‘specication. Due consideration should be paid to the removal of welding fume and smoke and the control of ‘tempersture caused by welding in confined spaces. AS Equipment 4.8.1. "The contractor should evainate the type and characteristics of the equipment to be used for the tien or real cperation scoring 1 the pale, ‘environmental conditions pipeline configuration and ‘water depth. ‘A.3.2 All plant and equipment should be of proven ‘design and adequately maintained. In particule, all electrical apparanss should risk of electrical shock. NOTE, Guidance on eectical eft provided in Code of ‘Prockc forthe safe eof elcricy nderoater sued by the Deparment OF Beg) 4) ASS The welding habitat should be of sufficient size tw provide adequate access to the joint to be welded ‘and to accommodate all ofthe necessary welding, safety and life support equipment. ‘AS4 The habitat should be adequately iluminated ‘and the work area kept clear of excess fumes to ‘enable remote video surveillance by the supervisory encima Camere bo be provided for Ad Welding processes ‘Ack All welding should be performed using ‘hydrogen controled processes. ‘AA2 When selecting the proceates to be used for a ‘particular application, conelderation to the following ‘should be given due fo the possible influences of b) reduction in weld metal toughness; 6) increased hydrogen partial pressure and risk of cold cracking. A. Electrodes and filler materials ‘A.B.1 A detailed consumables handling and contro! ‘procedure should be established for each type of orsumable md each pian contain m4 ‘minimum the following information: — preparation prior to transfer to the habits — method of packaging — method of transfer to the habitat; — storage prior to use in the habitat; — method of controlling uilization and exposure to the hyperbaric environment; 16 ‘opyright by the British Standards Institution tue May 13 09:48:86 2003 Copyright nj ih brah Standards nettution Si any 13 cen? 2008 STD.BST BS 4SLS-3-ENGL 2000 mm ‘Mb24bb9 O8LO226 673 mw BS 4516-1:2000 SSS A.5.2 The consumables used for ‘qualification and production should be from the same A.8.8. Welding consumables for MMA and FCAW NOTE the cae of connate oly te ‘experience t sould be eeblhed Ut balactary pofarnce ‘an be achieved over the required range of he procadure. AG Shielding gases A.6.1_ All cytinders, supply lines and connections ‘should be clearly marked. 4.6.2 Supply lines should be adequately purged prior ‘to the start of welding. AT Testing, qualification and approval of ‘welding procedures A.T.L A detailed welding procedure specification stould be repered Ths should contin dove ema specified in Table A. wth together: following — water depth (simulated or actual) — gx composition in the habits; — coygen partial pressure; — habitat temperature; — the method of measuring heat input and ‘deposition rate; a — relative humility, A.72 Items already lated in Table ALI for whlch ‘additional information should be provided are as follows. 48) Item o: Time tape between runs. ‘The procedure should provide details ofthe method for closing the weld root and whether here are any restrictions on the tine lapse between nurs. When & ‘time lapee is spectiod, then the defintion of the start and completion of runs should be stated. NOTE order to overcome the fat of prwere ‘cao Set br ee ne i ‘Rete wed panera dopetiod ae ) Jem p: Partially completa weds. ‘The procedure ahould provide details of the course cof action tobe taken de to scheduled and ‘unscheduled interruptions inthe diving operation NOTE? The ding week shoud be planned eo ht a fa ob [rane wings perfomed is consoae operation, ‘Shag ret rape as road elt Sewn aon la be gran ob we iropecioe baer to reamang te wedeg ‘ATS ‘The procedures should be qualified under either ‘molated of actual site condone atthe appropriate ‘water depth. Aza Me peared under smite condos, equipment and operating procedures should ‘equivalent to those to be used in production. A.7.5 The test pleces will normally ‘sections of pipe held in place by external line-up ‘claps amisted by strongbacia. 4.7.6 In addition to those ites specified in Table A, ‘the following items should be regarded aa changes affecting approval ') for TIG and MMA an increase in water depth of 10m 0F20% of the depth of qualifiation, whichever is the greater For all ther processes, the depth of ‘qualification should be by agreement between the ‘contracting parties; ‘b) a change from an argonax or heliox environment to an airarntzox envaermes The comers shold nee repre regain ©) my lnreae above the sbecht hy level for {ur bed weliing proce. Tats should norraly, be canted cat ae man stlpted rove haa, (A.7.7 Items already listed in Table Al for which alternative requirements may have to be specified are Slows. — item o: time lapse between runs (see A.7.2);, — item p: partially completed joints (see A.7.2); — tam welding prntes an increase nthe ‘eience on ee ehage ‘A.7.8 All test bute joints should be subject to non-destructive testing in accordance with 9.1. A.7.9 Destructive testing should be performed in ‘accordance with 9:2. A710 The method and point of the ‘electrical parameters should be established atthe time ‘of procedure qualification and maintained throughout. the work. AS Testing, qualification and approval of ‘welders and welding operators ‘A8.1 Prior to qualification testing, the welders should Ihave received relevant training for welding under pipe {n secordance with the requirements of clause 10 of ‘his standard at the maxnra simulated or actual depth. © Bat 07200) 7 STD.BST BS 4S25-2-ENGL 2000 Ml Db24bL9 0860227 SOT Om BS 4515-1:2000 ‘Table A.1 — Welding procedure specification details and changes affecting approval Tem ‘Welding procedure specification dotalla | Changes affecting opproval "Covent varies) Wid proces Jal [ The peice wena poms [Xchange from one arc welding process (or combination) to another | Whether mancal, seniustomalic or | Any change between manta, mechanized sembantomatic snd mechanized Base material | DI_| Specified standard and euength grade [Any change fspectication To [Heat treatment condition® [Any charge 'bS | Comportion® A cange er an at peed by Diameter ‘=| Nominal outside diameter D of pipe | A change outside the range O78 to 1.60. Trckeeas [a | Nominal wall ickness¢ of pipe [A change outside the range 0-75 to 1.51 oir configuraion |e [Pipe end preperation including the folowing: (witha sketeh, -—[ot_[ype of bevel [any cane including 2 [Angle(s) of beve [Any change outside (arepecified) tolerances) approved tolerances. | Sas frost ae [Any change ouside (anspeciied) approved tolerances: of | Wi of root eae? [Any change outside (arapecified) Molerances [Ray vse of backing Hines rAny addition or deletion, oF change of L roacerial _|Dimenaione? of filer welds Not restricted as an esseiial variable ‘Bocrode or filer [|The following information fs needed for each rum: metal [Nonna danter of sherlede core] Any change Torte cane avr oF he wire fay bores oor ra [Trade nave rany change when Charpy testing required | Chassibeation Any change | Ary diving or pretreatment for [Any relaxation nydroger-controlled electrodes Bo _| Number of wires for esch run Any change ‘Number of rane and gi | Number of runs from each side A change from angle to mulisran oF vice numberof sides vers welded | Sides welded fest and lat Gooble sided | Any change welds ony) iielding gue ot ux] RI Choice of ehieiding ge any change in the ga selected 2 | Componiton of ary gas rabaare TA change exceeding 210% of the nominal sdltion in a wixture S_| Gos ow rae [Any charge exceeding 210% [nd [Trade name end type of fax [Any change Electrical | Ourent (ac. or de) and polaigy rary change characteristics ‘Welding parameters |] | The following information ia needed for each wire size (dtferent values? may be used for diferent rane) ir Beal cei GMM TOUT ar ae a [2 [ae votge 109% 5 | Wi eed sped GA, MAG, FCA Tey lange coe S108 IEW for weceing carrera? celilosic electrodes) [jive peo Any change exconding 30% 5 [Calculated valve of heat input > [No separate restriction op 8 asi e720 ‘pyright by the British Standards Institution ‘ue May 13 09:48:67 2003 SE tala STD-BSI BS 4S3S-2-ENGL 2000 MM LL24bb9 0860230 22) ow BS 4515-12000 ‘Table A.1 — Welding specification details and changes affecting approval (continued) Tom ri ‘Welding procedare opecfcation dctaila sees Maing pyro ‘Welding pasition — [ic axis tothe horizontal [Any change exceeding 225° [Direction of welding] | Vertical up, verieal down or horizontal Welding technique [im | The folowing information is needed for each wire size (diferent valuea® may be used for ditferent rare). al | Maximum amplitade of any mechanized) To be agreed bebween the contracting weave, parties ind | Frequency of any mechanized weave | To be agreed between the contracting iS | Dwell tie atthe side of any mechanized | To be agreed Bebween the contracting weave, ‘Namaber of welders || Number of root ran and of second ran” Any reduction Time lapse betiveen [6 |"Time lapoe between the start ofthe rom [Any increase rans (ceiulosle ‘rn and the start of the secand rin electrodes ooly) Partly completed |p | Number of rans before cooling to ‘Rag veduction int ambient [Lineup carep | @l_| Internal, external, or akemative method A change fram internal to extemal, oF (ecu) trom clamp to alternative [| Number of runs before removal of camp | Ary reduction amen ot fr [Number of runs before this activity | Ary reduetion (on land), | commences ater) [Gleaning of bevels | Whether by power driven or hand tools | No resticion and weid® Preheeting | Prebest temperature ‘Ang reduction, of an increase exceeding 50°C [2 Method of appbing heat ‘Any change [8 _| Method of eemperatire ‘Any change [4 _| Method af temperature Any change 15 [kil tempersture of pipe not requiring | Any reduction [| Maxirours and rani Interpass ‘change temperature foreach ran land Postweld heat [al_| Method of applying best ‘Ary change treatment ud | Soaking temperature Any change hs tne [Any change Repair welds vt] Weld roeedie den fo epi [Ary ofthe cre tocing approval [v2 | Welding procedure datals for the weld to| Ary change affecting the approval of the be procedure for the weld on which the repair welding procedure was qualified Thee ms sal be wetted oad propord WTS, bt ae nok Randy Fo fe rodacton WPS I Ghee eoared agh vest peed anuinh Ue cen Wh a tha debs ae ea et oi rates the qualified range chllbeclcused fom the mean alu meanued in gulfcaton © 5s 072000 ‘by the British Standards Institution — ‘rue ay 13 Soens 2003 STD-BST BS 4525-2-ENGL 2000 MH 2624669 0860233 168 am BS 4516-12000 ‘Table A.2 — Qualified ranges of chemical analysis Value tested Values quate fang Vals tested 20.08% Any Value tested #0.25 % Any Value tested 20.20% [Not over 0.008% | to value tested +001595 Over 0.008% | 0.000 to value tested 40.015 % Any Oto value tested +0015% Any Value teed ~0.08 or +008 [Not over 0.016% | Not less than value tested JOver 0.015% | Value tested #003096 but shall be between 0.016 % and 0.060% ‘Value tested 49.0896 ‘Value vested #0.10% ‘Value tested ~0.20.% or +0.10% ‘Value tested ~0.10% or +0.05% ‘Value tested ~0.10% or +0.05% ‘Value tested 20.0059 ‘Value tested 20.0049 [Not over 004% | Not aver 0.004% JOver 0.004% | Not over value tested Value tested ~0.02 % or 40.01% Por ame fr bow fe dws 18 aes ued we 08 OTA f cmt, eswes¥ Nie Carton squvalent «CME, +MesV, MCE

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