b291-000!02!42-Wsp-0002 Specification For Offshore Pipeline Welding

DOCUMENT NO.
SPECIFICATION FOR B291-000-02-42-WSP-0002

OFFSHORE PIPELINE WELDING Rev. 0
Page 1 of 43
SPECIFICATION FOR OFFSHORE PIPELINE WELDING
CLIENT : INDIAN OIL CORPORATION LIMITED

PROJECT:CRUDE HANDLING FACILITIES PROJECT
AT GULF OF KUTCH OFF VADINAR,
GUJARAT
JOB NO. : B291
0 9-06-2020 Issued For Tender S K Mishra P Chowdhary A Roy

Rev.
Date Purpose Prepared by Checked by Approved by
No
Format No. EIL 1641-1924 Rev. 1
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SPECIFICATION FOR DOCUMENT NO.
OFFSHORE PIPELINE B291-000-02-42-WSP-0002
WELDING Rev. 0
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CONTENTS
1.0 SCOPE ....................................................................................................................................... 3
2.0 CODES, STANDARDS AND SPECIFICATIONS .................................................................... 3
3.0 BASE MATERIAL ..................................................................................................................... 4
4.0 WELDING PROCESSES .............................................................................................................. 4
5.0 WELDING CONSUMABLES................................................................................................... 4
6.0 EQUIPMENT AND ACCESSORIES ....................................................................................... 5
8.0 ALIGNMENT AND SPACING................................................................................................ 6
9.0 WEATHER CONDITIONS ...................................................................................................... 6
10.0 GENERAL WELDING REQUIREMENTS ............................................................................. 7
11.0 HEAT TREATMENT ............................................................................................................. 8
12.0 CLEANING OF THE WELD JOINTS ................................................................................. 9
13.0 INSPECTION AND TESTING .......................................................................................... 10
13.1 General ............................................................................................................................ 10
13.2 WELDING PROCEDURE QUALIFICATION................................................................ 10
13.3 Welder's Qualification ..................................................................................................... 10
14.0 VISUAL INSPECTION ...................................................................................................... 11
15.0 NON-DESTRUCTIVE TESTING ...................................................................................... 11
16.0 REPAIR OF WELDS .......................................................................................................... 12
EXHIBIT – A: ELECTRODE QUALIFICATION TEST RECORD ................................................... 14
EXHIBIT – B: STRESS-RELIEF HEAT TREATMENT PROCEDURE ............................................ 18
EXHIBIT – C: WELDING PROCEDURE APPROVAL TEST RECORD ......................................... 19
EXHIBIT – D: WELDER’S APPROVAL TEST RECORD ................................................................ 22
EXHIBIT – E: WELDER'S IDENTIFICATION CARD ...................................................................... 23
EXHIBIT – F: RADIOGRAPHY PROCEDURE FOR PIPE WELDING ........................................... 24
EXHIBIT – G: AUT PROCEDURE FOR PIPE WELDING ............................................................... 25
ANNEXURE – I: DESTRUCTIVE TESTING OF WELDED JOINT- BUTT WELDS ..................... 26
ANNEXURE – II: RADIOGRAPHY ................................................................................................... 30
ANNEXURE – III: ULTRASONIC TESTING .................................................................................... 35
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1.0 SCOPE
The requirements stated herein shall be followed for the fabrication of all types of
welded joint of carbon steel piping system connected with the submarine pipeline and
related facilities.
The welded pipe joints shall include the following:
- All line pipe joints of circumferential butt-welded and socket welded types.
- Attachments of castings, forgings, flanges and supports to pipes.
- Welded manifold headers and other sub-assemblies.
- Welded branch connections with or without reinforcing pads.
- Joints in welded / fabricated piping components.
- The attachments of smaller connections for vent, drain drips and other instrument
tapping.
Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his
responsibilities.
2.0 CODES, STANDARDS AND SPECIFICATIONS
2.1 All welded work, equipment for welding, heat treatment, other auxiliary functions and
the welding personnel shall meet the requirements of the codes, standards and
specifications listed below with the latest edition (published when this tender is floated
in the market):
a) Det Norske Veritas DNV-OS-F101: Submarine Pipeline Systems
b) API SPEC 1104: Welding Pipelines and Related Facilities
c) ANSI B 31.4: Code for Transportation System for Hydrocarbons, Liquid Petroleum
Gas, Anhydrous Ammonia and Alcohols
d) ASME BPV Section II PART C: Specification for welding electrodes and filler
materials
e) ASNT TC-1A: Non-Destructive Testing (ASNT - American Society of Non
Destructive Testing)
f) BS EN ISO 6892-1: Metallic materials — Tensile testing — Part 1: Method of test
at room temperature
g) ISO 6507-1: Metallic materials – Vickers hardness test – Part 1: Test method
h) ISO 148-1: Metallic materials – Charpy pendulam impact test – Pat 1: Test Method
i) B291-000-02-42-WSC-0002: Welding Specification Charts for Offshore Pipeline
In the event of conflict between this Specification and other specifications, applicable
codes and references, written clarification shall be sought from COMPANY before
proceeding with the Work. CONTRACTOR shall obtain COMPANY’s prior written
approval for any deviation from the requirements of this Specification, the standards
referenced herein, or the contract documents. In case of conflict, the requirements of
this Specification and referenced documents, COMPANY’s decision shall be final
regarding interpretation of requirements. This Specification is not intended to be all-
inclusive and the use of the guideline set forth does not relieve CONTRACTOR of
CONTRACTOR’s responsibility to supply a product capable of performing its intended
service.
Welding Specification Charts specified in this document shall mean document no.
B291-000-02-42-WSC-0002 provided in the tender document.
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3.0 BASE MATERIAL

3.1 In general, carbon steel is used in the specifications. The details of material
specifications shall be as per the Welding Specification Charts.
3.2 The CONTRACTOR shall provide the manufacturer’s test certificates for every heat of
the materials, supplied by CONTRACTOR.
3.3 “CONTRACTOR shall develop and utilize a full materials traceability program to track
welding materials from VENDOR source to the ultimate use in the product. Full
traceability program shall record every aspect of welding including welded by
information, date, ambient temperature, NDT repairs, etc.
4.0 WELDING PROCESSES
4.1 The welding processes to be employed are given in the Welding Specification Charts.
4.2 CONTRACTOR shall provide details of the automatic welding processes (machines)
along with past references of similar projects where it has been used, to the
COMPANY for approval. The welding procedure adopted and consumables (including
brand) used shall be specifically approved.
4.3 A combination of different welding processes or a combination of electrodes of different
classes or makes other than given in the Welding Specification Charts, could be
employed for a particular joint only after duly qualifying the welding procedures to be
adopted and after obtaining the approval of the COMPANY.
5.0 WELDING CONSUMABLES
5.1 The CONTRACTOR shall provide all the necessary filler materials, shielding gases etc.
required for the execution of the work.
5.2 The welding electrodes/wires supplied by the CONTRACTOR shall conform to the
classification specified in the Welding Specification Charts. The material shall be of the
make approved by the COMPANY.
5.3 The welding electrodes/wires shall be suitable as proved by weld qualification testing
for the welding process recommended and base metal used. Physical properties and
corrosion resistance of the welds produced by an electrode/wire recommended for the
welding of a particular base metal shall not be lower than the minimum values specified
for the base metal in the finally installed condition and chemical composition shall be
with in the limits specified for base metal unless otherwise specified in welding
specification chart. The choice of electrode/filler wire make shall be made after
conducting the required consumable qualification tests and corrosion testing on the
electrode/filler wire as per relevant ASME specification and bid requirements and shall
be the sole prerogative of the COMPANY. These tests shall be witnessed by the
COMPANY.
5.4 Electrode/filler wire qualification tests records should be submitted as per the Exhibit-A
in respect of the electrodes/filler wire tested by the CONTRACTOR and witnessed by
third party authorized by COMPANY viz Lloyds, DNV, ABS, CEIL, EIL, etc. for
obtaining the approval of COMPANY.
5.5 The CONTRACTOR shall submit batch test certificates from the electrodes/filler wire
manufacturers giving details of physical, chemical and corrosion resistance for each
batch of electrodes/filler wires to be used, tests as required by the Project
Specification, carried out by them. The batch test certificates shall be furnished by
them for COMPANY’s review and approval sufficiently in advance prior to the
commencement of work. Definition of batch shall be as per DNV-OS-F101, Appendix
C, clause no. C 400.
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5.6 All electrodes/wires shall be purchased in sealed containers and stored properly to
prevent deterioration. The electrodes removed from the containers shall be kept in
holding ovens, except cellulose coated electrodes, at a temperature recommended by
the electrodes manufacturer.
Ovens shall be used for low hydrogen electrodes only. Out-of-the oven time of
electrodes before they are consumed shall not exceed the limits recommended by the
electrodes manufacturer. The electrodes shall be handled with care so as to avoid any
damage to the flux covering.
Different grades of electrodes shall be stored separately. Cellulose coated electrodes
shall, however, be stored as per specific recommendations of manufacturer.
5.7 The electrodes used shall be free from rust, oil, grease, earth and other foreign
materials, which affect the quality of welding.
5.8 Shielding Gas
The composition and purity of shielding gas when required by the welding processes
other than shielded metal arc welding and permitted by the COMPANY shall bear the
approval of the COMPANY.
6.0 EQUIPMENT AND ACCESSORIES
6.1 The CONTRACTOR should have the arrangement of sufficient number of welding and
cutting equipment, auxiliaries and accessories of sufficient capacities so as to meet the
target schedules. The welding equipment and specified welding procedure shall be
qualified prior to production welding.
6.2 All the equipment for performing the heat treatment, including transformers,
thermocouples, pyrometers, automatic temperature recorders with suitable calibration
arrangements, etc. shall be provided by the CONTRACTOR, at his own expense and
these should bear the approval of the COMPANY.
6.3 Re-doing of any work necessitated by faculty equipment or operation used by the
CONTRACTOR, shall be done at his own expense.
7.0 BEVEL CLEANING AND INSPECTION
7.1 Before welding, all rust and foreign matter shall be removed from the bevelled ends by
power operated tools. This shall be affected inside and outside and for a minimum
distance of 25 mm from the edge of the weld bevel. The bevel shall be thoroughly
inspected at this stage.
If any of the ends of the pipe joints are damaged to the extent that, in the opinion of
COMPANY, satisfactory weld spacing cannot be obtained and local repair by grinding
can not be successfully done, the damaged ends shall be cut and re-bevelled to the
satisfaction of the COMPANY, with an approved bevelling machine. Manual cutting and
weld repairs of bevels is not allowed. The lamination, split ends or inherent
manufacturing defects in the pipe shall be discovered and the lengths of pipe
containing such defects shall be removed from the line to the satisfaction of
COMPANY.
The pipes that have been cut back, a zone extending 25 mm back from the new field
bevel, shall be ultrasonically tested to the requirement of the line pipe specification to
ensure freedom from lamination, in accordance with the DNV, “Submarine Pipeline
System”. The acceptance limits shall be as per DNV standard and modified by this
specification.
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8.0 ALIGNMENT AND SPACING

8.1 Immediately prior to line-up the CONTRACTOR shall inspect the pipe ends inside and
outside for damage, dents, lamination, etc. Pipe for welding shall be set up correctly by
giving the space and by allowing for temperature changes during welding.
Incorrect alignment shall in no circumstances be sprung into position. Temporary

attachments of any kind are prohibited from being welded to the pipe. Welds joining the
sections of the pipeline valve installation or similar welds classed as tie-in welds shall
be made in-situ. Otherwise, the alignment and welding shall be made at the non-line
work station of the barge with the pipe supported on skids and pack pads or other
suitable means approved by COMPANY at least 500 mm above the work floor level of
the barge, unless approved by the COMPANY otherwise in specific cases.
8.2 Seam orientation of welded pipe shall be selected to ensure that at the circumferential
welds, the longitudinal welds shall be staggered in the top 900 of the pipeline or 250
mm whichever is the less. A longitudinal joint should pass an appurtenance of a
structural element at a minimum distance of 50 mm. Should a section of the line
containing uncompleted welds fall from the skids, the CONTRACTOR shall
immediately inform COMPANY.
8.3 Every effort shall be made to reduce misalignment by the use of the internal clamp and
rotation of the pipes to the best fit. For pipe of same nominal wall thickness the off set
should not exceed 1.6 mm. The off set may be checked from outside using internal
offset checking gauges. Any branch connection sleeve, etc. shall be at least 250 mm
from any other weld. The welds for fittings shall be so located that the toe of the weld
shall not come within 50 mm of any other weld. Cold dressing is permissible only with
prior approval of COMPANY’s representative and only in cases of slight misalignment
and shall only be carried out with a bronze headed hammer. Hot dressing shall not be
permitted. When welding pipes of different wall thickness, the thicker pipe shall be
machined to 1:4 taper.
8.4 The root gap shall be accurately checked and shall conform to the qualified welding
procedure. The use of internal line-up clamps is mandatory. However, in some case
(tie-in welds, flanges, fittings, diameter of pipe below 6" etc.) where it is impossible to
use internal clamps, an external line-up clamp may be used.
8.5 The internal line-up clamps shall not be released before the entire root and first hot
passes have been completed. The pipe/barge also shall not be moved before the first
hot pass is completed.
8.6 When an external line-up clamp is specifically permitted by the COMPANY for risers,
tie-in welds etc., all spaces between bars or at least 600 of the first two passes shall be
welded before the clamp is released. Segments thus welded shall be equally spaced
around the circumference of the pipe. Slag shall be removed and cleaned. The ends of
the segments shall be prepared by grinding to ensure the continuity of the weld bead.
The pipe/barge shall not be moved before the hot pass is 100% completed.
9.0 WEATHER CONDITIONS
9.1 The parts being welded and the welding personnel should be adequately protected
from rain and strong winds. In the absence of such a protection no welding shall be
carried out. The completed welds shall be suitably protected.
9.2 In case of bad weather conditions rendering the sea very rough, welding shall be
suspended till the sea becomes calm.
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10.0 GENERAL WELDING REQUIREMENTS

10.1 Root Pass
10.1.1 Root pass shall be made with the electrodes/filler wires recommended in the
Welding Specification Charts. The size and type of the electrodes used shall be as
per the approved welding procedures.
10.1.2 Separate welding procedures shall be submitted and qualified for vertical up, vertical
down and roll welding. The vertical up method of welding shall be used for the root
pass as well as hot and filler passes of the tie-ins, special crossings, fittings and
special parts, fillet welds, repairs and bad fit-ups and when an external line up clamp
is used.
10.1.3 The root pass of butt joints should be executed properly so as to achieve full
penetration with complete fusion of the root edges. Weld projection inside the pipe
shall not exceed 1.6 mm wherever not specified by the applicable code.
10.1.4 Any deviation desired from the recommended welding technique and electrodes/filler
wires indicated in the Welding Specification Charts should be adopted only after
obtaining express approval of the COMPANY. Any desired deviation may require a
new welding procedure to be qualified.
10.1.5 Welding shall be continuous and uninterrupted during a pass.
10.1.6 On completion of each run, craters, welding irregularities, slag etc. shall be removed
by grinding or by power wire brushing. When simultaneous segmental beads are
made with multiple welding head automatic equipment, care shall be taken to avoid
lack of fusion or lack of penetration at the start-stop points.
10.1.7 When the welding is in progress, care shall be taken to avoid any kind of movement
of the components, shocks, vibrations and stresses, to prevent the occurrence of the
weld cracks.
10.1.8 Fillet welds shall be made by shielded Metal Are Welding (SMAW) process using
low hydrogen electrodes irrespective of the thickness and class of piping. Electrode
size shall not exceed 3.25 mm diameter for socket joints. Al least two passes shall
be made on socket weld joints.
10.1.9 Peening and chiseling shall not be used.
10.2 JOINT COMPLETION
10.2.1 In case of manual welding, the first pass shall be carried out by a minimum of two
welders working simultaneously and so placed as to cause minimum distortion of the
pipe.
10.2.2 The number of welders and the allowable welding sequences shall be as those laid
down in the qualified Welding Procedure Specification (WPS). Once the deposit of
the first pass has been started, it must be completed as rapidly as possible, reducing
interruptions to the minimum. The welding and wire feed speeds shall be within the
parameters of the welding procedure that was established in the Qualified Welding
Procedure Specification.
10.2.3 The pipe shall always be adequately supported and must not be bumped or shaken
during welding. The clamp shall be removed only as indicated in clause 8.5. Before
starting the second pass, the first pass shall be cleaned and flattened with rotating
grinders.
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10.2.4 The interruption between completion for the first pass and starting the second pass
shall be as stated in the WPS and shall not exceed four (4) minutes when not
specified.
10.2.5 The welding speed selected shall enable production of a bead that shall be
sufficiently thick without any undercutting.
10.2.6 The time lapse between second and third pass shall be as stated in the WPS and
shall not exceed five (5) minutes when not specified. The temperature of the weld
must at all times be held within the inter-pass temperature range as established
when the approved welding procedure was performed. If welding is stopped for any
reason, the minimum preheat temperature as established in the qualified welding
procedure must be applied and maintained after a restart of welding takes place and
the inter-pass temperature of the qualified welding procedure must be kept within
the ranges of the temperatures in the qualified welding procedure. Cleaning between
the passes shall be done carefully to reduce the possibility of inclusions of slag or
defects within the weld.
10.2.7 Electrode starting and finishing points will be staggered from pass to pass. Arc-
strike or arc-burn on the pipe surface is not permitted. Arc-strike or arc-burn on the
pipe surface that is caused accidentally by the electrical arc between the electrode
and the electrode holder or the welding cable, the affected portion shall be removed
by grinding in accordance with a Qualified Procedure approved by the COMPANY.
The repair shall be checked by ultrasonic test, radiography and magnetic particle or
dye penetrant tests, whichever the COMPANY feels necessary. The pipe wall
thickness after grinding shall not be less than the minimum thickness limit permitted
for the pipe. Repair of arc strikes by welding is prohibited.
10.2.8 The completed joint shall be carefully brushed and cleaned and shall be free from
spatters, scales etc.
These requirements shall apply not only to the completed weld joints but also to the
bare strip at least so wide as to allow full skip examination at both ends of the pipe
by ultrasonic tests, whenever it is required.
11.0 HEAT TREATMENT
11.1 Pre-heating
11.1.1 Pre-heating requirement for the various materials shall be as per the Welding
Specification Charts and/or as established during the Welding Procedure
Qualification. The preheat temperature must be a minimum 40 °C to offset the
coldest conditions at work site.
11.1.2 Pre-heating shall be performed using electrical resistance or induction heating
methods. Pre-heating by gas burners utilizing acetylene or propane gas and oxy-
propane gas can be used with the permission of the COMPANY under careful
supervision.
11.1.3 Pre-heating shall extend uniformly to at least three times the thickness of the joint,
but not less than 50 mm on both sides of the weld.
11.1.4 Pre-heating temperature shall be maintained over the whole length of the joint during
welding. Crayons or any other temperature indicating devices shall be provided by
the CONTRACTOR to check the temperature.
11.2 Post-Weld Heat Treatment (PWHT)
11.2.1 PWHT whenever required for the joint between the pipes and the fitting, the pipe
body and the supports shall be carried out by the CONTRACTOR at his expense as
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per the relevant specifications and the instructions of the COMPANY to be

applicable for the subject job.
11.2.2 PWHT of the joints shall be carried out as per the requirements laid down in Welding
Specification Charts and/or the requirements of the relevant code.
11.2.3 The CONTRACTOR shall submit the details of the PWHT procedure as per Exhibit
`B' attached for the approval of the COMPANY, before carrying out the actual heat
treatment for the component involved.
11.2.4 PWHT shall be done in a furnace or by using an electric resistance or induction
heating methods.
11.2.5 While carrying out local PWHT, the technique of applying heat shall ensure uniform
temperature attainment at all points of the portion being heated. Care shall be taken
to ensure that the width of the heated band shall attain the specified PWHT
temperature as per the applicable standards/codes.
11.2.6 Through out the cycle of the PWHT, the portion outside the band shall be suitably
wrapped under insulation to avoid any harmful temperature gradient. At the exposed
surface of the pipe, the temperature shall not be allowed to exceed 316°C.
11.2.7 The temperature during PWHT shall be recorded by means of thermocouple.
Adequate numbers of thermocouples shall be attached to the pipe directly at equally
spaced locations along the periphery of the pipe joint. The minimum number of
thermocouples attached per pipe joint shall be two (2) upto 10" diameter and three
(3) for 12" diameter and above. The COMPANY can increase the minimum number
of thermocouples to be attached if found necessary.
11.2.8 Automatic temperature recorders that have been suitably calibrated shall be
employed. The calibration chart of each recorder shall be submitted to the
COMPANY and the necessary approval shall be obtained prior to the starting the
PWHT operation.
11.2.9 Immediately on completion of the PWHT, the temperature records and charts along
with the hardness test results on the weld joints shall be submitted to COMPANY for
its review and clearance.
11.2.10 Each joint shall bear an identification number that shall be maintained in the piping
sketch to be prepared by the CONTRACTOR. The joint identification number shall
appear on the corresponding PWHT charts. The same identification numbers shall
also be followed for the identification of the corresponding radiography films. The
chart containing identification number and piping sketch shall be submitted to the
COMPANY for its review and clearance.
11.2.11The hardness shall be measured in Vickers or Brinell scale by using a portable
hardness tester on the heat affected zone as well as on the weld metal after PWHT
and shall not exceed the maximum hardness specified in the welding Specification
Charts. The weld joint shall be subjected to re-PWHT, when hardness measured
exceeds the specified limit at the CONTRACTOR's own expense.
11.2.12 The CONTRACTOR shall arrange for the hardness testing and shall maintain the
records of all the joints tested. These records shall be checked by the COMPANY's
inspector.
12.0 CLEANING OF THE WELD JOINTS
12.1 All weld joints shall be free from adherent weld spatter, slag, swarf, dirt or foreign
matter.
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13.0 INSPECTION AND TESTING

13.1 GENERAL
13.1.1 The COMPANY's representative shall have a free access to all concerned areas,
where the actual work is being performed. The CONTRACTOR shall also afford the
COMPANY's inspector all means and facilities necessary for carrying out inspection.
13.1.2 The COMPANY is entitled to depute its own representative to the shop or field
where prefabrication may be carried out and to the barge where laying of pipelines
are being done with (but not limited to) the following objectives:
i) To check the conformance to relevant standards and suitability of various
welding equipments and the welding performance.
ii) To supervise the welding procedure qualification
iii) To supervise the welders performance qualification
iv) To check whether shop/barge welding being executed is in conformity with the
relevant specifications and codes of practices followed in pipe construction
13.1.3 CONTRACTOR shall notify COMPANY sufficiently in advance of the

commencement of qualification tests, welding works and acceptance tests to enable
the COMPANY's representative present to supervise them.
13.1.4 The CONTRACTOR shall deploy at least two of their quality control personnel per
shift on the barge to supervise, guide, and enforce their quality control activity.
13.2 WELDING PROCEDURE QUALIFICATION
13.2.1 Welding Procedure Qualification shall be carried out in accordance with the
requirements of DNV Rules for Submarine Pipeline System, latest edition or other
applicable codes, by the CONTRACTOR at his expense at the pipelay barge afloat
or at a simulated condition using identical equipment to be used in pipelay welding.
The CONTRACTOR shall submit the Welding Procedure Specification in format as
per Exhibit-C immediately after the receipt of the order. The base pipe to be used
shall conform to the Project Specification.
13.2.2 COMPANY's representative shall review, check and approve the welding procedure
submitted and shall release the procedure for Procedure Qualification Tests (PQT).
The PQT shall be carried out by the CONTRACTOR under field conditions at his
own expense and in presence of COMPANY representative. A complete set of test
results in format as per Exhibit-C shall be submitted to the COMPANY's inspector for
its review and approval immediately after completing the PQT and at least 2 weeks
before the commencement of actual work. All the tests specified in the DNV
standard shall be carried out. In addition to these tests other tests such as corrosion
tests, metallography etc., as specified for the base metal and other tests as per
Project Specifications shall be carried out. It shall be the responsibility of the
CONTRACTOR to carry out all the tests required to the satisfaction of the
COMPANY's representative.
13.3 WELDER'S QUALIFICATION
13.3.1 Welders shall be qualified prior to or at the pipe lay barge at the offshore site in
accordance with the DNV standard by the CONTRACTOR at his expense. The butt
weld test pieces of the qualification test shall meet the radiography requirements or
Automated Ultrasonic testing requirements (as required for welding procedure
qualification) specified in clause no. 15. The COMPANY's representative shall
witness the test and certify the qualification of each welder separately. Only those
welders who have been approved by the COMPANY's inspector shall be employed
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for actual welding. CONTRACTOR shall submit the welding qualification tests
reports in the standard format as shown in Exhibit C & D and obtain approval before
commencement of the work. It shall be the responsibility of CONTRACTOR to carry
out qualification tests of the Welders.
13.3.2 Pipe material used for Welder's Qualification testing shall conform to Project
specification.
13.3.3 After the Welder’s qualification for each welder, COMPANY can request for a
complete detailed examination of the first weld by each welder to check his ability on
the job. Examination of this test weld shall be carried out in accordance with DNV
standard and as specified in this specification in a laboratory at the expense of the
CONTRACTOR. The CONTRACTOR shall comply with this request.
13.3.4 The welders shall always have in their possession the identification card as shown in
Exhibit-E and shall produce it on demand by the COMPANY's inspector. It shall be
the responsibility of the CONTRACTOR to issue the identity cards after the same is
duly certified by the COMPANY.
13.3.5 No welder shall be permitted to work without the possession of the identify card.
13.3.6 If a welder is found to perform a type of welding or in a position for which he is not
qualified, he shall be stopped from doing any further work. All welds performed by
an unqualified welder shall be cut and re-done by a qualified welder at the expense
of the CONTRACTOR.
14.0 VISUAL INSPECTION
14.1 Inspection of all welds shall be carried out by the COMPANY as per the latest
editions of DNV-OS-F101 before the field coating is applied. All finished welds shall
be visually inspected for parallel and axial alignment of the work, excessive
reinforcement, concavity of welds, shrinkage, cracks, under-cuts, correctness of
dimensions, surface porosity and other surface defects. Undercutting adjacent to the
complete weld shall not exceed the limits specified in the DNV-OS-F101.
15.0 NON-DESTRUCTIVE TESTING
15.1 The non-destructive testing shall mainly consist of examination using AUT inspection
(as per Appendix E of DNV-OS-F101) or X-ray radiography as detailed in Annexure-
II. Contractor to note that narrow bevel weld joints shall be examined by AUT
inspection only.
15.2 100% radiography or AUT for girth welds will be required by the COMPANY. Welds
shall meet the standards of acceptability as set forth in DNV-OS-F101 and as well as
the requirements laid down in subsequent paragraphs of this specification.
15.3 The CONTRACTOR shall make all the arrangements for the NDT (non-destructive
testing) work as required by the specification at his expense.
15.4 The COMPANY shall review all the NDT reports of welds and inform the
CONTRACTOR regarding the unacceptable welds. The decision of the COMPANY
shall be final and binding in this regard.
15.5 All requirements mentioned in the specification shall be arranged and executed by
the CONTRACTOR through his own resources. In addition, the ultrasonic test is
required in the following cases as per Annexure-III of this specification:
15.5.1 When 25 mm or more are cut from the joint as supplied, the ends shall be offered for
ultrasonic testing for an additional length of 25 mm to ensure the absence of
lamination.
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15.5.2 When welds are repaired. Repair attempts will be limited to one attempt per each
defect. After a repair is made, the repaired weld must be inspected visually and with
NDT as per the welding code acceptance criteria as qualified for the pipeline.
15.5.3 When in the opinion of the COMPANY, ultrasonic testing is required to conform or
clarify any defects indicated by radiography, the same shall be carried out.
15.5.4 When automatic procedure is used, at least 10 cm on each side of each weld shall
be subject to ultrasonic testing at the CONTRACTOR's expenses.
15.5.5 In addition, the ultrasonic testing shall be required for certain critical welding of the
pipeline (i.e. tie-ins, welding of valves, flanges) randomly selected at COMPANY's
discretion and at CONTRACTOR's expense. All fillet and groove welds, other than
those radiographed, shall be subject to Dye Penetrant (DP) or Magnetic Particle
(MP) testing as per applicable standards. The non-destructive tests used for
inspecting welds shall be approved by the COMPANY.
15.6 Weld quality shall be judged on the basis of the acceptability criteria mentioned
below:
15.6.1 Any weld which as a result of radiographic and/or ultrasonic examination in the
opinion of COMPANY exhibits imperfections greater than the limits stated in DNV
“Submarine Pipeline Systems” and as superseded in this article, shall be considered
defective and shall so be marked with an identification paint marker.
15.6.2 No crater cracks in the root is acceptable. The defects acceptance criteria for
inadequate penetration and incomplete fusion shall be as per DNV-OS-F101 for root
region. However, the maximum length shall not exceed thickness, t of the pipe for
root defects.
In addition to the acceptance criteria given in DNV standard, no amount of linear
shrinkage at the root revealed in the NDT as used is acceptable.
The acceptance criteria for defects other than root shall be as per DNV “Submarine
Pipeline Systems” with the stipulations mentioned therein for each type of defect
weld.
15.6.3 Un-repaired burn through areas are unacceptable.
15.6.4 Suitable records shall be maintained by the CONTRACTOR as desired by the
COMPANY on the day-to-day work done on welding, radiography, ultrasonic testing.
The CONTRACTOR shall present the records to the COMPANY on day-to-day basis
for review and approval.
16.0 REPAIR OF WELDS
16.1 All welds which do not comply with the standards of acceptability shall be repaired or
the joint cut out and re-welded.
16.2 A separate repair Welding Procedure Specification sheet shall be formulated and
qualified by the CONTRACTOR. All the tests carried out for Procedure Welding
Qualifications shall be conducted for repair Welding Procedure Qualification Testing.
16.3 Defective area shall be excavated by air-arc gouging and/or by grinding. For API 5L
grades above X-60 and thickness over 19 mm, pre-heating shall be carried out prior
to gouging. The groove should extent at least 25 mm on either side beyond the
extremities of the defect to ensure that it is completely removed. Excavated area
shall be examined by DP or MP testing prior to welding in order to ensure the
removal of the defects. Pre-heating for repair welding shall be 500C above the
specified pre-heat for the original welds in the respective WPS.
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Repair of weld cracks will not be accepted. If a weld cracks, a complete cut out of
the subject weld is required prior to re-welding.
16.4 Root sealing or single pass repair deposit shall not be allowed. Internal root defects
shall be ground thoroughly and welded with a minimum of two passes. While
grinding for repair, care shall be taken to ensure that no grinding marks are made on
the pipe surface.
16.5 All repairs shall be subject to minimum requirements such as same testing and
inspection as the original weld. The entire repaired portion, including 50 mm on all
sides of the portion, shall be radiographed. 100% Ultrasonic Testing shall be done at
the repaired area externally including 50 mm all around. Any repaired area that is
wide, irregular or rough shall be rejected and a full cut out shall be done.
16.6 Welds not meeting the specification requirements after one repair may be cut out
depending upon the extent of repair, when decided by COMPANY at
CONTRACTOR’s expense. A report of all repairs shall be maintained by the
CONTRACTOR and submitted every day to the COMPANY for review and approval.
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EXHIBIT – A: ELECTRODE QUALIFICATION TEST RECORD
A) Tested At (Site Name):___________________________ Date:__________________

Manufacturer's Name:___________________________ Test Period:_____________
Brand Name :___________________________
Batch Number and
Size Tested :___________________________
Classification & Code:___________________________

Intended for Welding
in Position :___________________________
In Combination With :___________________________

(if any)
Code of Reference :___________________________

(Used for Testing)
Special Requirements:___________________________
(if any)
B) All-Weld Tensile Test

Base Material Used :___________________________
Pre-Heat Temp. :___________________________
Post-Weld Heat :___________________________
Treatment Details
Visual Examination :___________________________

Radiography :___________________________
Examination
Tensile Test Results
IDENTIFICATION
S.NO. NO. U.T.S. YIELD POINT ELONGATION REMARKS
1
2
3
4
5
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C) Impact Test Results

Test Temperature :__________________ Notch In:_________________
Type of Specimens :__________________ Size of Specimens:_________

(CHARPY)
S.NO. SPECIMEN NO. IMPACT VALUE AVERAGE
1
2
3
4
5
D) Chemical Analysis Report

Electrode Size Used:_________
Batch No.:__________________
Other
%C %S %P %Si %Mn %Cr %Ni %Mo Elements
E) Fillet Weld Test Results

Welding Positions :____________________________________________
Base Materials :____________________________________________
Size of Electrode Used :____________________________________________

Visual Inspection : ____________________________________________
____________________________________________
Macrostructure Test Results:_________________________________________
Fracture Test Results :____________________________________________
Remarks :____________________________________________
F) Other Test Results
Transverse Tensile Test:_____________________________________________
In Combination with Base Material Used:________________________________
Position of Welding:_________________________________________________
Pre-HeatTemperature: _______________________________________________
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Post-Weld HeatTreatment:____________________________________________
Radiography:
IDENTIFICATION NO. U.T.S. FRACTURE IN REMARKS
G) Guided Bend Test

ROOT FACE
POSITION IDENTIFICATION NO. ROOT,
OR SIDEFACE
BEND REMARKS
1.
2.
3.
4.
5.
H) Any other tests

Corrosion Test Remarks
1. ____________________________________
2. ____________________________________
3. ____________________________________
4. ____________________________________
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Metallography Remarks
1. ____________________________________
2. ___________________________________
3. ____________________________________
4. ____________________________________
CONCLUSIONS:
APPROVED BY:
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EXHIBIT – B: STRESS-RELIEF HEAT TREATMENT PROCEDURE
Name of the Heat Treater:_________________________________________________

Name of the Project:______________________________________________________
Specification Reference No.:________________________________________________
1. General Details 2. Furnace Details

Name of the Type of Heating: Gas/Oil/Electrical/
Equipment:______________________ Resistance Induction
Applicable type: (Tick
mark)
Name of the
Assembly/Part:____________________ Capacity (Size):_______________
Assembly/Part Maximum Temp (0C):___________

Drawing No.:______________________
Method of temp.
Material:__________________________ Measurement:__________________
Atmosphere Control:______________
3. Heating Treatment Cycle Details
Charging Temp 0C: _______________________________________________
Rate of cooling, 0C/hr:______________________________________________
Soaking Temp., 0C:_________________________________________________
Soaking Time, hrs.:_________________________________________________
Rate of coding, 0C/hr:________________________________________________
Mode of Cooling: ___________________________________________________
4. Number of Thermocouples and Locations on joint:____________________________
5. Other Details, if any: __________________________________________________
______________________________________________________________________
Notes: The following documents shall be furnished along with the specifications:
i) Material test certificates,
ii) Assembly/Part Drawings.
Signature of the Heat Treater Approved By
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EXHIBIT – C: WELDING PROCEDURE APPROVAL TEST RECORD
Project/Contrac CONTRACTOR
t
Pipe and fitting material
Process
Outside
diameter
Pipe thickness
Joint design (Sketch attached)
Make and type Diameter Current Voltage

of filler metal
Root
Second run
Other runs
Other electrical characteristics ac/dc Electrode negative/positive
Shielding gas
Type of mixture
Flow
Shielding flux
Position
Direction of welding:
Root: Vertical up*/ Vertical down
Second run: Vertical up*/ Vertical down
Other runs: Vertical up*/ Vertical down
Number of welders:
Root:
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Second run:
Other runs:
Time lapse between commencement of second

run and commencement of other runs:
Minimum number of runs before joint allowed

to cool:
Maximum time between commencement and

Completion of weld:
Type of line-up clamp:
Removal of clamp after run:
Lowering off after run:
Cleaning:
Pre-heating:
Minimum temperature:_____0C Ambient temperature:____ 0C
Type of heater to be used:
Interpass temperature:
Minimum temperature:_____0C Maximum temperature:____ 0C
Post weld heat treatment:
Speed of travel:
Test results:
State acceptable:___________ non-acceptable (with reasons):________________ or

give numerical results________________
Non-destructive tests:
Visual:
Radiography:
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Destructive tests: 1 2 3 4
Transverse tensile:
Tensile strength:
Fracture location:
Test temperature:
Macro-examination:
Fillet-weld fracture:
Hardness survey:
Type:_____________ Load:_______
Location of hardness measurements: (Sketch)
Hardness range:_____________
Parent metal________________
Heat affected zone:___________
Weld:______________________
Charpy V-notch impact tests:

Specimen location and size:__________________
Notch location:_____________________________
Test temperature:___________________________
Energy values:______________________________
Additional tests and results

Chemical analysis:______________________________
Microstructural examination:_______________________(attach photographs)
CTOD tests:_____________________________________
Bend tests:_______________________________________
The statements in this record are correct. The test joints were prepared, welded and tested in
accordance with the requirements of this specification.
CONTRACTOR: Inspector:
Position: Witnessed by:
Date: Date:
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EXHIBIT – D: WELDER’S APPROVAL TEST RECORD
Welder test certificate: Test no.:

Project/Contract: Date:
CONTRACTOR: Inspector:
Welder’s name:
Address:
Pipe material:
Pipe thickness:
Pipe outside diameter:
Welding process: Root: Fill and Cap:
Electrode/wire:
Root: Current: Voltage:
Second run: Current: Voltage:
Full and Cap: Current: Voltage:
Direction of travel Root: Vertical up*/ Fill and Cap: Vertical up*/
Vertical down Vertical down
Reason for failure:
Visual:
Non-destructive testing:
Butt joint:
Fillet weld:
Number of attempts:
Comments:
Signature of CONTRACTOR Signed by Inspector

Date: Date:
Time: Time:
* Delete as necessary
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EXHIBIT – E: WELDER'S IDENTIFICATION CARD
Name :__________________________________________
Identification :__________________________________________
Photograph :
Date of Testing :___________________________________________
Valid unit :___________________________________________
Approval of Welding :___________________________________________
Welding Process :___________________________________________
Welding Position :___________________________________________
Material :___________________________________________
Diameter :____________________________________________
Wall thickness :____________________________________________
Type of welding Consumable :_____________________________________________
Code of compliance :_____________________________________________
Welding procedure reference :______________________________________________
Remarks :______________________________________________
Approved by: Employer's Signature with seal
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EXHIBIT – F: RADIOGRAPHY PROCEDURE FOR PIPE WELDING
1. Location:
2. Date of Testing:
3. Name of Supervised CONTRACTOR:
4. Material:
5. Diameter and Thickness:
6. Type of weld joint:
7. Radiation Source (X-ray/Iridium-192):
8. Radiation Intensity:
9. Type of equipment (External/internal):
10. Intensifying screens and material:
11. Filter type and placement mask, Diaphragm lead screen etc. adjacent to radiation
source or specimen):
12. Radiography technique:

13. Geometric relationship (Source Local spot size., Max. and min. source strength, object
to film distance, radiation angle with respect to weld and film):
14. Limit of film coverage:
15. Film type and make:

16. Exposure Time:
17. Processing (Time temperature for development, Stop bath or rinse, fixation, washing,
drying etc.):
18. Density:
19. Sensitivity:
20. Type of Penetrameter:
Approval of the COMPANY Signature of CONTRACTOR with Seal
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EXHIBIT – G: AUT PROCEDURE FOR PIPE WELDING
1. Location:
2. Date of Testing:
3. Name of Supervised CONTRACTOR:
4. Material:
5. Diameter and Thickness:
6. Type of weld joint with sketch:
7. Instrument manufacturer and model:
8. Search unit(s) detail:
9. Surface preparation:
10. Couplant:
11. Focal range(s):
12. Virtual aperture size(s):

13. Scan plan:
14. Calibration blocks:
15. Frequency of calibration:

16. Recording/Evaluation criteria:
17. Data presentation:
18. Acceptance criteria:
Approval of the COMPANY Signature of CONTRACTOR with Seal
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ANNEXURE – I: DESTRUCTIVE TESTING OF WELDED JOINT- BUTT WELDS

1.0 DESTRUCTIVE TESTING OF WELDED JOINT- BUTT WELDS
1.1 Preparation
1.1.1 After the completion of satisfactory visual and non-destructive testing, the test weld
shall be subject to mechanical test.
After satisfactory completion of all visual and non-destructive testing, no further work
on the test weld and no cutting of test specimens from the weld for qualification tests
shall be performed until a period of at least 24 hours has expired since preparation
of test welds.
1.1.2 Weld specimens, shall be taken from the positions indicated in Fig. 1 and 1A of this
specification, from areas as free from defects as possible. For this reason it is
necessary to take the previous non-destructive tests into account. The minimum
number of tests to be carried out is given in Table 1 of this Annexure.
1.1.3 The test shall be carried out at laboratories approved by the COMPANY. The
specimens shall be prepared in accordance with the figures given in the paragraphs
which refer to the individual test.
1.2 Tensile strength
1.2.1 Specimen
1.2.1.1 Specimen shall be taken form the position indicated in Fig.1 and 1A of this
specification.
Table 1
Type and Number of Tests for Procedure Qualification and Production Weld Joints
CHAR CORROSIO
PY N TESTS
TRAN V- MAC
S- NOTC RO+
WALL OUTSI VERS H HARD
THICK DE E ROO SAMP -
- DIA- WELD T NICK LE (3) NESS MICR
NESS METER TENSI BEN FACE SIDE BREA (4) (5) (200X O SSC
(MM) (MM) LE D BEND BEND K (2) & (6) ) (25X) HIC C
12.5  300 2 2 2 0 2 4 2 2 2 2
12.5 300 4 4 0 4 (1) 4 4 2 2 2 2
12.5  300 2 0 0 4 2 4 2 2 2 2
12.5 >300 4 0 0 8 4 4 2 2 2 2
Notes:
1. Root and face bend tests may be used instead of side bends.
2. Nick break test may be omitted for manual metal arc welding to be performed above
water.
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3.
4. Each Charpy `V' notch sample consists of 3 specimens.
5. Impact testing is to be carried out with the `V' notch positioned in the weld metal, on the
fusion line, 2 mm from the fusion line and 5 mm from the fusion line.
6. When more than one welding processes or welding consumables are used, impact
testing shall be carried out in the corresponding welding regions, if the region tested
can not be considered representative for the complete weld.
7. In case the pipe dimensions are such that the use of sub-sized specimens become
necessary, the Charpy V-notch impact values specified in the Welding Specification
Chart shall be modified as below:
Specimen Size (mm) Energy Reduction Factor
10 x 7.5 5/6
10 x 5 2/3
The number of tests indicated herein is for welding procedure qualification only.
Production test shall be carried out as per DNV Rules for Submarine Pipeline System.
1.2.2 Method
1.2.2.1 The test shall be carried out in accordance with BS EN ISO 6892-1.
1.3.0 Nick-break Test
1.3.1 Preparation
1.3.3.1 Specimens for nick-break test with notches thus worked can break in the base
metal, instead of in the fusion zone. Therefore, an alternative test piece must be
used after authorization by the COMPANY with a notch cut in the reinforcement of
cut side weld bead to a maximum depth of 1.5 mm, measured from the surface of
the weld bead. The acceptance criteria shall be as per API 1104.
1.4.0 Macroscopic Inspection
1.4.1 Preparation
1.4.1.1 Specimens shall be taken from the positions indicated in Fig. 1 of this specification
and shall be prepared in accordance with ASTM E3-11.
1.4.1.2 The width of the macro-section has to be at least three times the width of the weld.
The section is to be prepared by grinding and polishing and etched to clearly reveal
the weld metal and heat affected zone.
1.4.2 Method
1.4.2.1 Specimens shall be carefully examined under the microscope, with a magnification
of at least 25x. The COMPANY may ask for microphotographs with 5x
magnification, for documentation purpose.
1.4.3 Requirements
1.4.3.1 Under microscope examination, the welded joints shall show good penetration and
fusion, without any defect exceeding the limits stated in DNV-OS-F101.
1.5.0 Hardness Test
1.5.1 Preparation
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1.5.1.1 The prepared macro-section is to be used for hardness testing using the Vickers
method as per ASTM E92 with 10 kg load. Indentations are to be made along
traverses each approximately 1 mm below the surface at both side of the weld.
In the weld metal a minimum of 6 indentations equally spaced along the traverses
are to be made. The HAZ indentations are to be made along the transverses for
approximately 0.5 mm each into unaffected material and starting as close to the
fusion line as possible.
1.5.1.2 One indentation at each side of the weld along each traverse has to be made on
parent metal. Reference is made to Fig. 3 of this specification. The indentations
are to be made in the adjacent region as well as on the opposite side of the macro-
section along the specified traverses.
1.6.2 Method
1.5.2.1 The test shall be carried out in accordance with ASTM E 92, Vickers hardness,
using a laboratory type machine with a load of 10 kg.
1.5.3 Requirements
1.5.3.1 Hardness value shall not exceed the value given in Welding Specification Chart
(250 HV10) in case of a single reading slightly (+10 HV10) higher than the specified
limit, further indentations should be made to check if the high value is on isolated
case.
1.6.0 Charpy V-Notch Impact Test
1.6.1 Specimen
1.6.1.1 Specimens shall be taken from the position indicated in Fig.1 of this specification.
The test specimens shall be prepared in accordance with BS EN ISO 148-1. Charpy
V-notch specimens shall have dimensions as given in Fig.4 of this specification.
1.6.1.2 Three (3) test specimens shall be taken from each sample and they shall be out and
worked so that their length is transverse and perpendicular to the weld bead with the
notch position as shown perpendicular to the roller direction wherever applicable the
test specimen width shall depend upon the pipe wall nominal thickness as follows:
Wall nominal thickness (mm) Test specimen width (mm)
Over 12 10
Over 9.5 and upto 12 7.5
From 7 upto 9.5 5
Less than 7 2.5
1.6.2 Test Method
1.6.2.1 The test shall be carried out in accordance with BS EN ISO 148-1 or ASTM A 370.
1.6.2.2 Test pieces shall be immersed in a thermostatic bath and maintained at the test
temperature for at least 15 minutes. They shall then be placed in the testing
machine and broken within 5 seconds of their removal from the batch. The test
temperature shall be as specified in the Welding Specification Chart.
1.6.3 Requirements
1.6.3.1 The impact energy shall meet the requirements laid down in APPENDIX C of DNV-
OS-F101, Rules for Submarine Pipeline Systems, unless otherwise specifically
modified by this specification or mentioned in the Welding Specification Chart,
B291-000-02-42-WSC-0002.
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1.7 Bend Test Requirements

1.7.1 The Bend test specimens shall be made and tested as per the requirements of
APPENDIX B of DNV-OS-F101, Rules for submarine pipelines except that the
dimensions of the Jig for guided bend test shall be modified as follows:
Radius of the Plunger `A' : 2t (t = thickness of specimen)
Radius of the dia. `B' : 3t + 1.5 mm
Radius of the dia. `C' : 50.8 mm
1.7.2 The acceptance criterion shall be as per Clause No. F.306 of APPENDIX C of DNV-
OS-F101, Rules for Submarine Pipeline Systems.
1.8 Corrosion Tests
Corrosion tests shall be done on the weld procedure tests when specified regarding
the specification chart as per the following requirements and as specified in the bid
documents to determine the suitability of the weld procedure for the application.
1.8.1 Hydrogen Induced Cracking Test
Method of Testing - The method of testing shall be as per test procedure mentioned
in NACE TM0284.
A) Procedure for Extraction
The specimen shall be as per NACE TM0284.
B) Frequency and number of specimens
Three (3) specimens shall be tested for each weld procedure. Three (3)
specimens shall be taken 1200 apart around the circumference.
C) Acceptance Criteria
The acceptance criteria for Crack Sensitivity Ratio (CSR) shall be 0.00%
(Max.). If one (1) specimen fails to meet the criteria, three (3) more specimens
shall be taken from the same pipe for retests and all the specimens shall meet
the requirements otherwise the weld procedure shall be rejected.
1.8.3 Four Point-bend Test (Sulphide Stress Corrosion Cracking Test)
Bend test shall be carried out on the test made for each weld procedure. One set of
three (3) specimens shall be machined for four point bending tests. The specimen
thickness shall be minimum 5 millimeters and shall be machined from pipe wall
thickness. The location and selection of the specimens shall be decided by the
COMPANY. The test specimen shall be as per NACE TM0177. The specimens shall
be bent to reach a stress level of 72% SMYS, as per ASTM G 39, and then
immersed in NACE solution as per NACE TM0177 for a period of 96 hours with
inner surface in tension. There shall be no Sulphide Stress Corrosion (SSC) Cracks.
If one (1) specimen fails to meet the Criteria, three (3) more specimens shall be
taken from the same pipe for retests and all the specimens shall meet the
requirement otherwise the weld procedure shall be rejected.
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ANNEXURE – II: RADIOGRAPHY
1.0 SCOPE
This annexure covers the radiographic inspection of all types of welded joints of the
main pipeline.
The welded joints shall include the following:
i) DNV Standard “Submarine Pipeline Systems”, OS-F101
ii) ASTM E94 - 04(2010) Standard Guide for Radiographic Examination
iii) The American Society for Nondestructive Testing. Recommended Practice
No. SNT-TC-1A Supplement A.
iv) Project Specification
3.0 PROCEDURE
3.1 The radiography procedure to be adopted shall be submitted by the CONTRACTOR
as per Exhibit F.
3.2 The procedure of radiography shall be qualified to the entire satisfaction of
COMPANY prior to use as per the requirements of DNV. It shall include but not be
limited to the following requirements:
i) Only automatic film processing shall be used.
ii) Lead foil intensifying screens, at both sides of the film shall be used for all
exposures
iii) Only type 2 & 3 films as per ASTM E-94 shall be used.
iv) A densitometer shall be used to determine film density. The transmitted film
density shall be 1.8 - 2.5 throughout the weld. The unexposed base density of
the film shall exceed 0.30.
v) Radiography identification system and documentation for radiography
interpretation reports and their recording system.
3.3 The CONTRACTOR shall qualify each procedure in the presence of the COMPANY
prior to use. The radiography procedures are to be made of a weld joint using pipe
of the same diameter wall thickness and of material same as that used in the
pipeline system.
3.4 The procedure of radiography shall produce radiographs of sufficient density, clarity
and contrast so that defects in the weld or in the pipe adjacent to the weld, and the
outline and wires of the penetrameter are clearly discernible.
3.5 All the girth weld of mainline shall be subjected to 100% radiography testing. The
CONTRACTOR shall furnish all the radiographs to the COMPANY immediately after
processing and drying for review and approval, together with the corresponding
interpretation reports on approved format. The details of the radiographs along with
the joint identification number shall be duly entered in a register and signed by the
CONTRACTOR and submitted to the COMPANY for approval.
3.6 When the radiation source and the film are both on the outside of the weld and
located diametrically opposite each other, the maximum acceptable length of film for
exposure shall not exceed the values given as per the acceptable procedure. The
minimum film overlap, in such cases, shall be 40 mm. The ellipse exposure
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technique may be used on nominal pipe sizes of 2 inch and smaller provided that
the source of film distance used is a minimum of 12 inch.
3.7 Three (3) copies of each acceptable radiography procedure, as per Exhibit-F, and
three (3) copies of radiography qualification records, shall be supplied to the
COMPANY. One (1) set of the qualifying radiographs on the job shall be kept by the
CONTRACTOR's authorized representative to be used as a standard for the quality
of production radiographs during the job. The other two sets shall be retained by the
COMPANY for its permanent record.
3.8 Three (3) copies of the exposure charts relating to material thickness, kilo voltage,
source of film distance and exposure time shall also be made available to the
COMPANY by the CONTRACTOR.
3.9 The CONTRACTOR shall on daily basis record for each radiograph, (1) radiograph's
number, (2) approximate chainage of weld location, (3) whether or not the welds
meet the specified acceptance standards and (4) the nature and approximate
location of unacceptable defects observed. It must be possible to relate back to a
particular butt weld and welder on piping drawing and pipeline alignment drawing.
3.10 Each day's production of processed radiographs shall be properly packaged
separately, identified by at least the (1) date, (2) radiography unit, (3) job locations,
(4) starting and ending progress survey stations and (5) shall include original and
three (3) copies of the daily radiography record. The package shall be submitted to
the COMPANY daily but in no event later than noon of the following day.
3.11 The CONTRACTOR shall provide all the necessary facilities at site, such as a dark
room with controlled temperature, film waiver etc. to enable the COMPANY to
examine the radiographs.
3.12 The CONTRACTOR, if found necessary, may modify the procedure of radiography
testing suiting to the local conditions prevailing. This shall, however, be subject to
the approval of the COMPANY.
3.13 COMPANY shall have free access to all the CONTRACTOR's work facilities in the
field.
3.14 Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his
responsibilities and guarantees.
4.0 RADIATION SOURCE
4.1 Radiography testing shall be carried out using X-radiations. Radiography by Gamma
rays may be allowed, at the discretion of the COMPANY, in case of inaccessible
joint.
4.2 Whenever possible, pipeline welds will be inspected by placing the radiation source
inside the pipe, on the pipeline axis, with a radiation of 6.28 rad (360°).
If it is impossible to place the radiation source inside the pipe, the weld will be
inspected with the source on the outside. An overlap of at least 40 mm at the ends
of each film shall be required to ensure that the first and last location increment
numbers are common to successive films and to establish that no part of a weld has
been omitted.
5.0 LEVEL OF QUALITY
The quality level radiography sensitivity required for radiography testing shall be at
least equivalent to the values in Fig.6. The geometric un-sharpness resulting from
the procedure shall not exceed 0.5 mm.
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6.0 PENETRAMETERS
6.1 The image quality indicator shall be used for the qualification of the welding
procedure and during normal line production. Radiography sensitivity shall be
measured with the Image Quality Indicator (IQI) such as wire type penetrameter.
The penetrameter shall be selected according to DIN EN 462-13 or ISO 19232-1.
For radiographs made with the source on the outside, a pentameter shall be placed
on each side of the film with the smaller wire of the penetrameter turned towards the
end of the film itself. When a complete weld is radiographed in a single exposure
using a source inside the piping, four (4) penetrameters approximately equally
spaced around the circumference shall be used. During the procedure qualification,
IQI shall be placed both on the source side and on the film side. The sensitivity
obtained with IQI on the source side shall not be less than the values shown in Fig.6
of this specification.
6.2 The sensitivity limit may be considered to have been reached when the outline of
the IQI, its identification number and the wire of the required diameter show up
clearly on the radiograph.
The COMPANY may authorize use of types of IQI other than those planned,
provided that they conform to recognized standards and only if the CONTRACTOR
is able to demonstrate that the minimum sensitivity level required is obtained. For
this demonstration, a test shall be carried out comparing the IQI, specified and the
CONTRACTOR's to show up the identification number and other details of the
proposed IQI, which must be visible in the test radiograph. Material of the
pentameter shall be of equivalent radiography density to that of the material under
examination.
7.0 FILM IDENTIFICATION MARKERS
All films shall be clearly identified by lead numbers, letters, and/or markers. The
image of the markers shall appear on the films, without interfering with the
interpretation. These markers positions shall also be marked on the part to be
radiographed and shall be maintained during radiography.
8.0 PROTECTION AND CARE OF FILM
8.1 All unexposed films shall be protected and stored properly as per the requirements
of ASTM E94 and DNV Rules for Submarine Pipeline Systems.
8.2 The exposed and unexposed film shall be protected from heat, light, dust and
moisture. Sufficient shielding shall be supplied to prevent exposure of film to
damaging radiation prior to and following the use of the film for radiography
exposure.
9.0 RE-RADIOGRAPHY
9.1 The weld joints shall be re-radiographed in case of unsatisfactory quality of the
radiographs, at the expense of the CONTRACTOR.
9.2 All the repaired weld joints shall be re-radiographed at no extra cost to the
COMPANY in the same manner as that followed for the original welds. In addition,
the repaired weld areas shall be identified with the original identification number plus
the letter ‘R’ to indicate the repair.
9.3 When evaluating repair film, radiographer shall compare each section (exposure) of
the weld with the original film to assure repair was correctly marked and original
defect removed.
9.4 The COMPANY will review prior to any repair of welds all the radiographs of welds
which contain, according to the CONTRACTOR's interpretation, unacceptable
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defects. The final disposition of all unacceptable welds will be decided by the
COMPANY.
10.0 QUALIFICATION OF RADIOGRAPHER
10.1 As a minimum all personnel conducting radiographic examination shall be certified
to Level-I in accordance with ASNT document SNT-TC-1A.
10.2 All qualification certification should have current validity. Radiography will be
performed under the jurisdiction of and certified ASNT Level-II supervisor.
10.3 Interpretation of radiographs shall be carried out only by the certified ASNT-Level II
personnel.
10.4 All the records of NDT personnel such as background and experience records,
training course records certification records and fitness records shall be submitted to
the COMPANY for review and approval before the NDT personnel are permitted to
perform production radiography and interpret films.
11.0 PRESERVATION OF RADIOGRAPHS
11.1 The radiographs shall be processed to allow storage of films without any
discoloration for at least three years. All the radiographs shall be presented in
suitable folders for preservation along with necessary documentation.
11.2 All radiographs shall become property of the COMPANY.
12.0 EQUIPMENT AND ACCESSORIES
12.1 CONTRACTOR shall make necessary arrangements at his own expense, for
providing the radiography equipment, radiography films and all the accessories for
carrying out the radiography testing for satisfactory and timely complete of the job.
12.2 For carrying out the mainline radiography testing the CONTRACTOR shall be
equipped with suitable mobile/stationary type darkrooms. These shall have all the
required facilities for automatic film processing, film viewer used shall be equipped
with the film illuminator that has a light source of sufficient intensity and suitably
controlled to allow viewing film density up to 4.0 without damaging the film.
13.0 RADIATION PROTECTION
13.1 CONTRACTOR shall be responsible for the protection and personnel monitoring of
every man with or near radiation sources.
13.2 The protection and monitoring shall comply with local regulations.
13.3 In view of visual hazards in the handling of radio-active source of material,
CONTRACTOR shall be solely responsible for complying with all rules and
regulations set forth by Atomic Energy Commission in this regard and COMPANY
shall not be responsible and shall be kept indemnified by the CONTRACTOR for
defaults of whatever nature by the CONTRACTOR. Safety equipment as considered
adequate by the COMPANY for all necessary personnel shall be made available for
use and maintained for immediate and proper use by the CONTRACTOR.
14.0 DISPLAY OF SAFETY INSTRUCTIONS
14.1 The safety provisions should be brought to the notice of all concerned by display on
a notice board at a prominent place at the work spot. The person responsible for the
`SAFETY' be named by the CONTRACTOR.
15.0 ENFORCEMENT OF SAFETY REGULATIONS
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15.1 To ensure effective enforcement of the rules and regulations relating to safety
precautions, the arrangement made by the CONTRACTOR shall be open to
inspection by the COMPANY or their representatives.
16.0 FIRST AID AND INDUSTRIAL INJURIES
16.1 CONTRACTOR shall maintain first aid facilities for its employees and those of sub-
CONTRACTORs.
16.2 CONTRACTOR shall make outside arrangements for ambulance service and for
treatment of industrial injuries. Names of those providing these services shall be
furnished to COMPANY, prior to start of work and their telephone nos. shall be
posted prominently in the CONTRACTOR's field office.
16.3 All critical industrial injuries shall be reported promptly to the COMPANY and a copy
of CONTRACTOR's report covering each personal injury requiring the attention of
physician shall be furnished to the COMPANY.
17.0 NO EXEMPTION
17.1 Notwithstanding the above there is nothing in these to exempt the CONTRACTOR
from the operation of any other act or rules in force.
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ANNEXURE – III: ULTRASONIC TESTING
1.0 General
In addition to the radiographic inspection, only mechanized UT which provides a
permanent registration of the results (hard copy) as per conditions listed in Clause
Nos.17.0 and 18.6 of this specification shall be used. This section concerns manual
ultrasonic testing. The ultrasonic testing by automatic equipment may be used if
approved by the COMPANY.
1.1 Equipment and Operators
1.1.1 The CONTRACTOR who carries out the ultrasonic testing shall have sufficient
qualified personnel, equipment and instruments at his disposal to be able to affect
the tests without hindering or delaying the pipeline assembly operations.
1.1.2 The operators shall be fully qualified as per ASNT procedure, SNT-TC-1A -TC-1A or
equivalent and shall have minimum level II. The operators shall be able to:
- Calibrate the equipment
- Perform an operational test under production conditions
- Interpret the screen picture
- Evaluate the size and location of reflectors
- Interpret the type of defects detected.
1.1.3 The COMPANY has the option of checking the ability of personnel employed for
ultrasonic testing by means of a qualification tests.
1.1.4 The CONTRACTOR appointed to carry out ultrasonic testing shall supply all the
instruments necessary for their execution at site.
1.2 Specification for Ultrasonic Testing Procedure Qualification
1.2.1 Before work begins, the CONTRACTOR shall present a specification describing the
proposed ultrasonic testing procedure qualification.
1.2.2 This specification shall state the following information but not limited to:
- Type of ultrasonic testing equipment used
- Type and dimensions of transducers
- Frequency range
- Details for calibration
- Coupling medium
- Inspection technique
- Record details
- Reference to the welding procedure where it is intended to be adopted the
specification.
- Temperature range of the joints to be under testing.
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1.3 Qualification of Ultrasonic Testing Procedure

1.3.1 The ultrasonic testing procedure shall be approved by the COMPANY. Before
testing begins, the COMPANY may require the qualification test of the ultrasonic
testing procedure. This procedure consists of testing the welds made according to
the same production procedure and under normal operating conditions, where the
typical defects shall be detected by this testing.
1.3.2 This test shall be conducted in the presence of the COMPANY or its representative.
1.4 Test Procedure
1.4.1 Circumferential welds shall be inspected from both sides using angle probes.
1.4.2 The surface on which the probe comes into contact shall be free from metal spatter,
dirt, iron oxide, and scales. At least 50 mm wide on both sides of the welds shall be
cleaned with steel wire brush and the cleaned strip shall be wide enough to allow full
skip examination during ultrasonic testing.
1.4.3 During the testing, if echoes of doubtful origin appear, it shall be necessary to
inspect a convenient area on the pipe surface close to the weld with a straight beam
transducer in order to check the presence of the manufacturing defects that can
interfere the ultrasonic beam.
1.4.4 The testing shall include but not be limited to the following:
- Ultrasonic equipment and coupling medium
- Sample sections for calibration of instruments
- Equipment for cleaning of surface to be examined
- Rules calibrated in centimeters for exact location of the position of defects.
1.4.5 The characteristics of the above listed instruments and equipment shall guarantee:
- The required standards of the inspection procedure previously established and
approved by the COMPANY are satisfied.
- Continuous operation
All the instruments and equipment shall be approved by the COMPANY before
their use. The COMPANY has the authority to reject any item that is
considered unsuitable. The decision of the COMPANY is final. The
CONTRACTOR appointed to carry out ultrasonic testing shall also ensure the
operational efficiency and maintenance of the instruments and equipment and
shall immediately substitute any item rejected by the COMPANY.
All the instruments and equipment necessary for carrying out ultrasonic testing
at site satisfy the requirements laid down by the public boards of institutions
which regulate `safety of work'.
1.5 Ultrasonic Instruments
1.5.1 The ultrasonic instrument
- Shall be pulse-echo type. It shall be able to generate, receive and display the
signals on the screen of a cathode ray tube (CRT). It shall pulse at frequencies
between 1 and 6 MHz. The useful part of the CRT screen shall be at least 70
mm wide and at least 50 mm high.
- Shall have variable amplification with steps of 1dB to 2 dB over a range of at
least 60 dB.
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- The regulation control shall be accurate to within 1dB and this accuracy shall
be certified by the instrument manufacturer.
- It shall be powered by a battery or an electric generator. The autonomy of
operation (endurance) of the instrument shall be sufficient to carry on working
without frequent interruptions. The instrument shall be equipped with an
automatic switch and the switches shall be in off-position when the battery
runs down. The instrument shall be a voltage stabilizing device with a
toleranc
1.6 Probes
1.6.1 The probes used shall have dimensions, frequencies and a refraction angle suited
to the type of steel, the diameter, the thickness and the joint design of the pipeline.
1.7 Reference Sample Pieces
1.7.1 The efficiency of the equipment to be used, the effective refraction angle of the
probe to be employed and the beam output shall be checked using a V1 and V2
sample block, 11W type or the calibration block ASTM E428.
1.7.2 For the calibration of runs and the regulation of detection sensitivity during the test,
a calibration piece shall be used. This piece shall be taken from the production
material and shall be at least 150 mm long (measured in the direction of the axis),
and at least 50 mm wide (measured in the direction of the circumference) as per
Fig. 5 of this specification.
1.7.3 In addition, the calibration piece shall have a hole of 2 mm in diameter passing
through its thickness and positioned so that during calibration the echoes returning
from the two grooves shall not interfere with those returning from the hole.
1.8 Calibration
1.8.1 For a precise check of the sound paths necessary for a full examination of the weld
joint, the probe shall be moved (half skip and full skip distance) until internal and
external notches on the test piece are detected (Fig. 5 of this specification).
1.8.2 The relevant defect limits the path lengths on the time base. The calibration of
reference sensitivity is obtained by utilizing the through-drilled test hole in the
thickness of reference block to draw the Distance Amplitude Correction (DAC)
Curve relevant to the test probe. A reference block shall be used for the reference
curves as per DNV Rules for Submarine Pipeline Systems.
1.8.3 Calibration is carried out according to the following procedure:
Place its internal vertex until the maximum height of echo is displayed on the
screen. This echo is adjusted to 80% or full screen height by means of the
sensitivity adjuster set in dB.
Without varying the amplification, the probe placed a full skip distance from the hole
shall be moved to detect the external vertex of the hole until the maximum height of
echo is obtained. The straight line connecting the peaks of the two echoes obtained
by the above procedure shall represent the 100% reference level while the one
connecting the two points at half height of the same echoes shall represent 50%
reference level.
1.8.4 The two straight lines shall be marked on the screen with a pen. Calibration shall be
repeated for each time tests re-started at intervals not longer than 30 minutes during
normal operations and for each time the conditions fixed in advance altered. This
calibration is applicable provided that the crystal of the probe is 8 x 9 mm size. For
the different sizes of the crystal of the probe, the value of the sensitivity obtained
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from the calibration by a crystal of a different size shall be brought to the value of
sensitivity obtained form the calibration of a 8 x 9 mm crystal. The sensitivities of the
two different size probes shall be compared through the echoes obtained on the
notch of the test piece with the probe position at half skip of the distance.
1.9 Regulation of Amplification during Production Testing
1.9.1 The amplification during production testing shall be obtained by adding 2 to 6 dB,
according to the surface condition of the pipe and its cleanness, to the reference
amplification.
1.10 Evaluation of Indications given by Ultrasonic Testing
1.10.1 Each time that echoes from the weld bead appear during production testing, the
instrument amplification shall be altered to coincide with the reference amplifications
and the probe shall be moved until maximum responses is obtained, paying
attention all the time to the probe-tube coupling.
1.10.2 The acceptance criteria shall be specified in DNV Rules for Submarine Pipeline
Systems and as modified by this specification.
1.10.3 Transfer correction shall be made to the DAC curve before scanning by the job is
under taken.
1.10.4 Scanning for transfer cracks shall also be done.
1.11 Other Equipment
1.11.1 The use of ruler calibrated in centimeters, attached if possible to the probe, for the
precise location of the position of welding defects, is recommended. Defect location
is effected by measuring the projection distance between the probe output and the
reflecting surface.
1.11.2 The operators carrying out the ultrasonic testing shall have tools for cleaning the
pipe surface such as files, brushes etc. besides the probing instrument and shall
have coupling liquid or paste appropriate for the temperature of the section to be
examined.
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DOCUMENT NO.

SPECIFICATION FOR B291-000-02-42-WSP-0002

SPECIFICATION FOR OFFSHORE PIPELINE WELDING

CLIENT : INDIAN OIL CORPORATION LIMITED

JOB NO. : B291

0 9-06-2020 Issued For Tender S K Mishra P Chowdhary A Roy

Format No. EIL 1641-1924 Rev. 1

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Format No. EIL 1641-1924 Rev. 1

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Format No. EIL 1641-1924 Rev. 1

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3.0 BASE MATERIAL

Format No. EIL 1641-1924 Rev. 1

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Format No. EIL 1641-1924 Rev. 1

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8.0 ALIGNMENT AND SPACING

Incorrect alignment shall in no circumstances be sprung into position. Temporary

Format No. EIL 1641-1924 Rev. 1

Page 1606 of 2324

10.0 GENERAL WELDING REQUIREMENTS

Format No. EIL 1641-1924 Rev. 1

Page 1607 of 2324

Format No. EIL 1641-1924 Rev. 1

Page 1608 of 2324

per the relevant specifications and the instructions of the COMPANY to be

Format No. EIL 1641-1924 Rev. 1

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13.0 INSPECTION AND TESTING

13.1.3 CONTRACTOR shall notify COMPANY sufficiently in advance of the

Page 1610 of 2324

Format No. EIL 1641-1924 Rev. 1

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Format No. EIL 1641-1924 Rev. 1

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Format No. EIL 1641-1924 Rev. 1

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EXHIBIT – A: ELECTRODE QUALIFICATION TEST RECORD

A) Tested At (Site Name):___________________________ Date:__________________

Classification & Code:___________________________

In Combination With :___________________________

Code of Reference :___________________________

B) All-Weld Tensile Test

Visual Examination :___________________________

Tensile Test Results

Format No. EIL 1641-1924 Rev. 1

Page 1614 of 2324

C) Impact Test Results

Type of Specimens :__________________ Size of Specimens:_________

S.NO. SPECIMEN NO. IMPACT VALUE AVERAGE

D) Chemical Analysis Report

E) Fillet Weld Test Results

Size of Electrode Used :____________________________________________

Page 1615 of 2324

IDENTIFICATION NO. U.T.S. FRACTURE IN REMARKS

G) Guided Bend Test

A) Tested At (Site Name):_________ Date:

Type of Specimens :__________ Size of Specimens:_

Minimum temperature:_0C Ambient temperature: 0C

Minimum temperature:_0C Maximum temperature: 0C

State acceptable:_ non-acceptable (with reasons):______ or