DNO IRAQ AS

KU-TWK-00-PI-SPC-0001
PROJECTS SPECIFICATION
Revision: 0 14 May 2015
Next Revision: TBA
GENERAL WELDING SPECIFICATION
Page: 3 of 13

CONTENTS

1.0 PURPOSE AND SCOPE ............................................................................... 4

2.0 POLICY ......................................................................................................... 4
3.0 CODES AND STANDARDS .......................................................................... 4
3.1 American Society of Mechanical Engineers (ASME) ..................................... 4
3.2 American Welding Society (AWS) ................................................................. 4
3.3 American Petroleum Institute (API) ............................................................... 4
3.4 DNO Standards and Procedures ................................................................... 5
4.0 RESPONSIBILITIES ..................................................................................... 5
5.0 SAFETY ........................................................................................................ 5
6.0 WELDING PROCEDURE - GENERAL ......................................................... 6
7.0 WELDING PROCEDURE AND PERFORMANCE QUALIFICATION ........... 6
8.0 MATERIALS .................................................................................................. 7
8.1 Welding Electrodes and Rods ....................................................................... 7
8.2 Shielding Gases ............................................................................................ 9
9.0 JOINT PREPARATION ............................................................................... 10
10.0 WELDING PROCESSES ............................................................................ 10
11.0 THERMAL TREATMENT ............................................................................ 11
12.0 EXAMINATION AND TESTING................................................................... 12
12.1 General ........................................................................................................ 12
12.2 Inspection Methods ..................................................................................... 12
12.3 Non-Destructive Testing .............................................................................. 13
13.0 WELD REPAIRS ......................................................................................... 13

This document is the property of DNO. It must not be reproduced or transmitted to others without authorization
from the Company.
 DNO IRAQ AS
KU-TWK-00-PI-SPC-0001
PROJECTS SPECIFICATION
Revision: 0 14 May 2015
Next Revision: TBA
GENERAL WELDING SPECIFICATION
Page: 4 of 13

1.0 PURPOSE AND SCOPE

The purpose of this specification is to define the minimum standards for the
welding of carbon steel pipe for all process, above ground trunk lines carrying
hydrocarbons and utility piping within all DNO facilities in the Kurdish region of
Northern Iraq.
Wherever a difference exists between this specification and drawings, the
drawings shall govern.
No deviations shall be made from this specification without PRIOR written
authorization from the DNO Project representative.

2.0 POLICY
There shall be open communication. If issues are unclear or there is doubt
over scope of work, drawings, specifications or standards, this shall be
immediately addressed to DNO and resolved.

3.0 CODES AND STANDARDS

The following listed Codes, Standards and Specifications form a part of the
requirements of this specification. Unless otherwise specified, the latest edition
or revision to the codes, standards or specification shall apply.

Codes, industry standards and specifications referenced to shall govern unless

exceptions are noted in this specification.
3.1 American Society of Mechanical Engineers (ASME)
B31.3 Process Piping
B31.4 Liquid Petroleum Transportation Piping System
B16.5 Pipe Flanges and Flanged Fittings
Section II, Part C Welding Rods, Electrodes, and Filler Metals
Section V Non-destructive Examination
Section IX Welding and Brazing Qualifications
3.2 American Welding Society (AWS)
A2.4 Welding Symbols
A3.0 Terms and Definitions
Z49.1 Safety in welding and Cutting and Allied Processes
3.3 American Petroleum Institute (API)
API Std 1104 Welding Pipelines and Related Facilities.

This document is the property of DNO. It must not be reproduced or transmitted to others without authorization
from the Company.
 DNO IRAQ AS
KU-TWK-00-PI-SPC-0001
PROJECTS SPECIFICATION
Revision: 0 14 May 2015
Next Revision: TBA
GENERAL WELDING SPECIFICATION
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3.4 DNO Standards and Procedures

7002-P-001: Piping Material Specification
KU-TWK-00-QA-PRO-0001: Field Pressure Testing Process Facilities,
Process and Utility Piping.
KU-TWK-00-PI-SPC-0002 General Fabrication Specification for Process,
above Ground Trunk Lines & Utility Piping
KU-TWK-00-PI-SPC-0003 General NDT Specification for Process, above
Ground Trunk Lines & Utility Piping

4.0 RESPONSIBILITIES
It shall be the responsibility of DNO to issue Work Instructions that are clear
and unambiguous in defining scope, completion time and special
requirements.
It is the Contractor’s responsibility to execute the work to the appropriate
quality standards and within the timescales set by the Work Order.

5.0 SAFETY
It is a key objective of DNO that all personnel engaged at DNO property, shall
finish his or her work each day safe, well and un-injured. It is expected that any
company or individual contracted to DNO shall adopt the same principal.
It is the responsibility of the Contractor to educate all its employees and sub-
contractors in industry-standard, safe working practices, to be familiar with the
proper operating procedures for all equipment and to provide all personal
protective equipment (PPE), as required by DNO site regulations.
When working on any DNO site all Contractors and their sub-contractors must
at all times adhere to the DNO Permit to Work procedure.
In general, Safety measures for the protection of welders and operators
involved in welding and cutting shall be in accordance with the practices
specified in the American Welding Society Standard Z49.1.
Equipment such as generators, compressors, welding machines, grinders,
vehicles lifting and rigging equipment etc. shall be suitable for the job intended
and shall be mechanically safe and sound. Equipment which is seen to be
unsafe or inappropriate shall be immediately disengaged and removed
completely from DNO premises and property.
Equipment which is used to measure or test shall be calibrated and shall be
accompanied by a valid calibration certificate, to be available at site at all
times.

This document is the property of DNO. It must not be reproduced or transmitted to others without authorization
from the Company.
 DNO IRAQ AS
KU-TWK-00-PI-SPC-0001
PROJECTS SPECIFICATION
Revision: 0 14 May 2015
Next Revision: TBA
GENERAL WELDING SPECIFICATION
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6.0 WELDING PROCEDURE - GENERAL

Work shall be done by qualified and competent craftsmen in a neat and
workmanlike manner conforming to code requirements and industry standards.
The applicable piping code shall be noted on drawings issued by DNO.
Compliance with this specification, the applicable piping code and any
approved Welding Procedure Specifications (WPS), shall in no way relieve
Contractor of the responsibility to provide welds which are sound and suited to
the services for which they are intended.
Non-conformances to any of the requirements above shall be immediately
corrected.
Welding symbols on Isometrics and other drawings or documents shall be in
accordance with American Welding Society A2.4.
Materials supplied shall be as stated on the Isometrics. Any deviations shall
be as noted on the piping isometric. Substitutions, including thicker or thinner
wall materials, are not permitted without prior written authorization
The terms "shop fabricate" and "field fabricate" where noted on the piping
isometrics, shall be defined as follows:
• Shop fabricate-fabrication of pipe performed at a fabricator’s workshop,
remote from the site. Shop fabricated pieces will be supplied to the
Execution Contractor for installation and assembly.
• Field fabrication performed by Execution Contractor at or near the job-
site
No welding shall be performed unless the welder and work area are properly
protected from environmental conditions that may adversely affect the weld
(wind, rain etc.)
Each finished weld shall be clearly marked, to identify the portion made by
each welder, including the welder’s number.

7.0 WELDING PROCEDURE AND PERFORMANCE QUALIFICATION

Prior to commencement on any welding on any pipe, a welding procedure
specific to the pipe material shall be agreed and the procedure shall be
qualified. The Welding Contractor shall be responsible for providing all WPS
and PQR, including all destructive and non-destructive coupon testing for all
pipe welding procedures.
All welders shall be experienced and qualified to the relevant WPS at
Contractors expense.
Welding Procedure Specifications (ASME Form QW-482 or equivalent),
Procedure Qualification Records (ASME Form QW-483 or equivalent), and
Welder's Performance Qualification (ASME Form QW-484 or equivalent) shall

This document is the property of DNO. It must not be reproduced or transmitted to others without authorization
from the Company.
 DNO IRAQ AS
KU-TWK-00-PI-SPC-0001
PROJECTS SPECIFICATION
Revision: 0 14 May 2015
Next Revision: TBA
GENERAL WELDING SPECIFICATION
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conform to the requirements of Section IX of the ASME Code and to the

requirements of this specification.
Welder's Performance Qualification Records shall be currently valid and be
made available to DNO’s review at all times (copies shall always be available
at site).
Welding Procedure Specifications and Procedure Qualification Records shall
be submitted to DNO prior to the start of fabrication. Submittals shall include a
brief summary of the application of individual welding procedures with regard
to types of joints and piping material line classes.
The Contractor shall be responsible for the review of their Sub-contractor’s
welding procedures and procedure qualification records for compliance with
the code and contract requirements. Sub-contractor’s welding procedures and
procedure qualification records shall be submitted to DNO after the fabricator
has been satisfied that all the code and contract requirements have been met
Welding Procedure Specifications shall be clearly identified with the item
number, Contract number and identified by a unique number. Each WPS shall
contain complete data including all welding variables with the maximum and
minimum values qualified, preheat and heat treatment details.
Production welding using the Submerged Arc Welding (SAW) process shall be
performed using the same name brand flux and same name brand or AWS-
ASME classification of wire as used for the procedure qualification. A change
in flux type, i.e. neutral to active and vice versa shall require requalification of
the WPS. A change from one manufacturer’s consumable or flux to that from
another manufacturer shall require approval of DNO QC engineer.
For double welded butt joints (joints welded on both sides), the Welding
Procedure Specification shall specify Vendor's standard inspection procedure
used to assure metal soundness after gouging and cleaning the backside of
the weld.
Welds that are deposited by procedures differing from those authorized may
be subjected to complete removal.
DNO may witness any test pieces and judge the specimens. A welder may be
disqualified at any time if his performance is judged unsatisfactory.

8.0 MATERIALS

8.1 Welding Electrodes and Rods

Weld filler metals / electrodes must conform to applicable AWS specifications
and as specified herein.

Filler metal shall be as specified in ASME Code, Section II, Part C.

Electrode and rod diameters shall conform to the requirements of PQR and

This document is the property of DNO. It must not be reproduced or transmitted to others without authorization
from the Company.
 DNO IRAQ AS
KU-TWK-00-PI-SPC-0001
PROJECTS SPECIFICATION
Revision: 0 14 May 2015
Next Revision: TBA
GENERAL WELDING SPECIFICATION
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WPS in accordance with ASME and API requirements for bevel angle and
usage.
All welding consumables shall be specified in welding procedure specifications
(WPS), including the Manufacturer’s name and brand.
All welding consumables used during production shall be from the same
manufacturer, brand and AWS type as those used and approved during
welding procedure qualifications.
The Contractor should purchase sufficient quantities of each lot of welding
consumables to complete the work.
The Contractor shall maintain a system of traceability whereby the batch
number of the welding consumables is related to the weld numbers with that
particular joint.
All welding consumables shall be stored and handled in accordance with the
Manufacture’s recommendations, as a minimum. Contractor storage, issue
and handling procedures for welding consumables shall be submitted to DNO
QC Engineer for review and approval. Consumables, which become wet,
contaminated or damaged, shall be removed from the Project Site and
destroyed.
Each tin or packet of electrodes or reel of filler wire and bag of flux shall be
clearly marked with the respective lot number. Manufacturer’s Certification
shall be supplied to EN 10204 3.1, for each lot of welding consumables
according to ANSI/AWS A5.01.
Filler material shall be used so that the principal elements in the deposited
weld metal be of the same nominal composition and mechanical properties as
the base metal.
Each tin or packet of electrodes or reel of filler wire and bag of flux shall be
clearly marked.
• For SMAW – Lot classification C4, Schedule J.
• For GMAW/SAW wire – Lot classification S2 from one heat, Schedule J.
• For SAW flux – Lot classification F2, Schedule J.

For dissimilar weld joints, filler metals shall be as follows:

• Carbon steel (P1) and low alloy steel (P3, P4 & P5) combinations within
the Pl to P5 ferritic material group: Filler metal shall be of the low hydrogen
type and similar to the nominal chemistry of the pressure part. For specific
applications or specific fabrications where filler metals other than those
authorized may be desired, the fabricator shall request, prior to the welding
procedure qualification, to use such filler metals. Request shall be made in
writing to DNO's QC Engineer.
• All other filler metals require authorization from DNO's QC Engineer.

This document is the property of DNO. It must not be reproduced or transmitted to others without authorization
from the Company.
 DNO IRAQ AS
KU-TWK-00-PI-SPC-0001
PROJECTS SPECIFICATION
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Next Revision: TBA
GENERAL WELDING SPECIFICATION
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Solid wires for automatic welding processes shall contain the principal
elements required for the deposited weld metal. In Sub- merged arc process,
the addition of alloying elements to the weld pool by means of the flux shall
only be sufficient to offset losses in welding arc but it shall not derive any
principal elements from the flux.
Filler wires in specification AWS-ASME A5.2 shall not be used for welding with
Gas Tungsten-Arc process.
Electrodes of the following classifications are not acceptable for pressure
retaining welds: E6012, E6013, E6020, E7014, and E7024.
Filler wire for Flux-cored Arc welding shall conform to ASME SFA 5.20
The following AWS classifications shall not be permitted;
• EXXT-2, EXXT-3, EXXT-10 and EXXT-GS.
• AWS classification EXXT-G shall be confined to root pass only.
• Filler wire in specification AWS-ASME A5.18,classification ER 7OS-G is
not permitted to be used on carbon steel
• Fluxes that the flux manufacturer recommends for single pass welding
shall not be used for multiple pass welds

The purchaser of Flux-cord Arc welding wire shall specify that the maximum
permissible hydrogen content shall not exceed 10 ml per 100 grams of
deposited weld metal.
Storage of welding materials (covered electrodes, fluxes, bare wires,
consumable inserts, etc.) in designated areas or in designated holding ovens
shall be in accordance with the Manufacturer's recommendations and ASME
Code, Section II, Part C.
Fabricator’s facilities shall include a temperature and humidity controlled
welding consumable and flux store, including holding and drying ovens. Control
and handling of welding materials in fabrication shall be an integral part of the
fabricator's quality assurance plan.

8.2 Shielding Gases

When specified in the WPS, the shielding gas or gas mixture to be used, and
gas quality, shall be qualified in the welding procedure qualification. Shielding
gas shall be suitable for welding and meet the following requirements:

CO2 for Gas Metal Arc Welding (GMAW):

• Carbon dioxide: 99.5% minimum.
• Residuals 0.5% maximum.
• Moisture: 97ppm max at minus 34°C dew point.

This document is the property of DNO. It must not be reproduced or transmitted to others without authorization
from the Company.
 DNO IRAQ AS
KU-TWK-00-PI-SPC-0001
PROJECTS SPECIFICATION
Revision: 0 14 May 2015
Next Revision: TBA
GENERAL WELDING SPECIFICATION
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Gas Shielded Flux Cored Arc Welding (FCAW):

• Argon: 80%.
• Carbon dioxide: 20%.
Gas Tungsten Arc Welding (GTAW):
• Argon: 99.995% minimum
• Moisture: 10.5ppm max at minus 60°C dew point.

Where mixed gases are to be used, the specification, composition and purity
are to be approved by DNO QC Engineer.
Each container of gas shall be identified with the gas type, mixture and purity.
Unmarked containers and/or contaminated gases shall be removed from the
work site. The shielding gas manufacturer shall issue a certificate of
compliance to the qualified purity levels.

9.0 JOINT PREPARATION

Surface of pipe at areas to be welded shall be free from dirt, grease, scale,
paint, grit or any other foreign material which may adversely affect the final
weld quality.
Where welding pipe either to a flange or another pipe, there must be a band at
least 1" (25 mm) wide around the joint that is free of all foreign matter.
Peening is only permitted to the extent necessary to clean the weld.
Cleanliness shall be maintained during welding. All stubs, rods, flux, slag, and
other foreign material shall be removed from inside and outside the pipe.

10.0 WELDING PROCESSES

The following welding processes are permitted, provided satisfactory evidence

is submitted that the procedure is qualified in accordance with the applicable
codes:
Welding Process AWS Letter Designation
Shielded metal Arc Welding (STICK) SMAW
Manual and Automatic Gas Tungsten GTAW Arc Welding (TIG)
Semi or Fully Automated Submerged SAW
Arc Welding
Flux-Cored arc welding FCAW

Welding Procedures for Flux-Cored arc welding (FCAW) shall be re-

established as a new procedure specification. Welding and testing shall be

This document is the property of DNO. It must not be reproduced or transmitted to others without authorization
from the Company.
 DNO IRAQ AS
KU-TWK-00-PI-SPC-0001
PROJECTS SPECIFICATION
Revision: 0 14 May 2015
Next Revision: TBA
GENERAL WELDING SPECIFICATION
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witnessed by the DNO QC Engineer. Flux-cored arc welding (self-shielded)

requires a CTOD test to be conducted for each welding procedure used.
Other welding processes, such as Gas Metal Arc Welding, and Manual
Submerged Arc, require specific written authorization by DNO's QC Engineer.
Generally carbon steel pressure piping shall be welded with SMAW and/or
GMAW processes.
Large diameter pipe (greater than or equal to 12" NPS) may be welded with
SAW procedures; except SAW procedures may not be used for repairs.
SAW should not be used on pipes with a wall thickness of less than 12mm
All butt welds in pipe 2" NPS and larger shall be made by SMAW or GMAW
processes. Root welds may be made by GTAW process and must be made
with the GTAW process in piping 3" NPS and smaller.
Piping requiring special cleaning shall have the root pass deposited with the
gas tungsten arc welding (GTAW) process also known as tungsten inert gas
(TIG) welding. The backside of the root pass shall be purged with inert gas.
All fillet welds, including small weldolets and socket welds, shall be made by
the SMAW process.

11.0 THERMAL TREATMENT

Minimum Mandatory Preheating Temperatures for thermal cutting, tack

welding, and welding shall be as specified in ASME B31.3, Table 330 1.1. The
minimum inter pass temperature shall not be less than the preheat
temperature.
Post-weld Heat Treatment shall be performed in accordance with ASME
B31.3, Table 331.1.1 and Paragraph 331.3, as summarized in Figure 12.1.
Post-weld heat treatment may be required for carbon steel welds when service
conditions are detrimental (e.g. sour service) to welds with high hardness.
Post-weld heat treatment for these services will be indicated on DNO isometric
drawings and shall be performed when required.
Acceptable post weld heat treatment methods are listed as follows in the order
of preference and the Furnace Method shall be used whenever feasible.
• Furnace Method.
• Local Resistance method.
• Local Induction Method.

Threads and gasket surfaces shall be protected from excessive oxidation

during heat treatment.
Post-weld heat treatment procedures and temperatures shall be carefully
controlled and recorded. In case the heat treatment is subcontracted, the

This document is the property of DNO. It must not be reproduced or transmitted to others without authorization
from the Company.
 DNO IRAQ AS
KU-TWK-00-PI-SPC-0001
PROJECTS SPECIFICATION
Revision: 0 14 May 2015
Next Revision: TBA
GENERAL WELDING SPECIFICATION
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fabricator shall witness the heat treatment operation at least during the period
of time when the temperature is above 300 Deg. C and shall sign the heat
treatment charts.

12.0 EXAMINATION AND TESTING

12.1 General
The minimum qualification level for welding inspection personnel shall be in
accordance with of one of the following:
• CSWIP Welding Inspector
• ERS/TWI Welding Inspector
• AWS Certified Welding Inspector
Non-destructive examination personnel shall hold a valid qualification of one of
the following at the level shown:
• ASNT Level II for the relevant technique
• CSWIP/PCN Tester/Practitioner/Interpreter (Welds) Level 2 for the
relevant technique
The inspection organization shall have a written code of practice fully in
compliance with ASTN requirement. The organization shall provide the
required materials certificates. Items supplied without materials certificates
shall not be used without written approval. All damage and discrepancies shall
be reported immediately. After signed acceptance, any discovered damage
shall be the responsibility of the fabricator.
If the welding examination or non-destructive examination personnel fail to
perform to a satisfactory standard they shall be disqualified from the works
until such time that it can be demonstrated that they have achieved a
satisfactory standard by undertaking a test by a third party agency.
Prior to welding, examine free-issue materials for damage and compliance with
the relevant materials specification. This examination shall include a review of
the materials

12.2 Inspection Methods

DNO may use any method of inspection necessary to establish quality control
and insure adherence to welding procedures. DNO shall have the right to
accept or reject any weld not meeting the requirements of this specification, or
if DNO inspector terms welds unacceptable to the service for which they are
intended.
Butt welds shall be inspected by radiographic as per applicable codes
Ultrasonic and magnetic particle testing will be used on those welds which
cannot be radiographed (e.g. Cat. D welds). Subject to approval, liquid

This document is the property of DNO. It must not be reproduced or transmitted to others without authorization
from the Company.
 DNO IRAQ AS
KU-TWK-00-PI-SPC-0001
PROJECTS SPECIFICATION
Revision: 0 14 May 2015
Next Revision: TBA
GENERAL WELDING SPECIFICATION
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penetrant testing may be substituted for magnetic particle testing in

exceptional circumstance.
The radiographic technique should be X-ray radiography. Subject to company
approval, gamma radiography may be used with an Iridum-192 source.

12.3 Non-Destructive Testing

During production welding, the welding parameters shall be checked against
the approved WPS Monitoring frequency shall be specified in the contractor's
inspection and test plan.
The completed weld shall present a uniform and workmanlike appearance,
symmetrical to the centre line of the weld, and free from pinholes, undercutting
or other visible defects.
Weld quality will be checked by radiographic inspection at the expense of
company, unless otherwise specified. Defects located by radiography shall not
exceed the limits of the "Standards of Acceptability" as outlined in these
specifications.
DNO may select any number of welds for radiographic inspection.

13.0 WELD REPAIRS

Unacceptable discontinuities shall be completely removed by chipping,
gouging, grinding or other authorized methods (for the type of material being
repaired) to clean, sound metal, and the excavated area shall be examined by
magnetic particle or liquid penetrant methods to assure complete removal of
defects.
Repairs to correct weld defects shall be made using the same procedure used
for the original weld, or other previously authorized weld procedure.
The repaired areas shall be re-examined using the same inspection
procedures by which the defect was originally detected.
Two repair attempts will be allowed on any one defective area. No further
attempts to repair shall be carried out without the authorization of DNO's QC
Engineer.

This document is the property of DNO. It must not be reproduced or transmitted to others without authorization
from the Company.