General Secification TWI-thao

TWI WELDING & FABRICATION
TRAINING SPECIFICATION
Document Number: TWI-WIS10-EX-MSR-001 Revision: 3.5 Date: Jan 2017
TWI WELDING & FABRICATION TRAINING SPECIFICATION

Document Number: TWI-WIS10-EX-MSR-001
MAY 30, 2018

TWI
UK
TWI-WIS10-EX-MSR-001 Page 0 of 44
Contents
1. General: ...............................................................................................................................................................6
1.1 Scope............................................................................................................................................................6
1.2 reference code and standards ....................................................................................................................6
2. DEFINITION OF TERMS ........................................................................................................................................7
2.1 General ........................................................................................................................................................7
2.2 Definition .....................................................................................................................................................7
3. QUALITY CONTROL ..............................................................................................................................................9
3.1 Contractor requirements ............................................................................................................................9
3.2 Fabrication requirement .............................................................................................................................9
4. JOINT PREPARATION DETAIL...............................................................................................................................9
4.1 Base metal preparation...............................................................................................................................9
4.2 Bevels .........................................................................................................................................................10
4.3 Alignment. .................................................................................................................................................10
4.4 Assembly for welding ................................................................................................................................10
4.5 Temporary attachment .............................................................................................................................11
4.6 Weather conditions ...................................................................................................................................11
5. WELDING DETAIL ...............................................................................................................................................11
5.1 General requirements ...............................................................................................................................11
5.2 Butt welds ..................................................................................................................................................11
5.3 Fillet welds .................................................................................................................................................12
5.4 Preheating .................................................................................................................................................12
5.4.1 Table 2- Preheat values .....................................................................................................................13
5.4.2 Table 2a- Preheat values ...................................................................................................................13
5.5 Interpass temperature ..............................................................................................................................13
5.6 Arc trikes ....................................................................................................................................................14
5.7 Welding identification...............................................................................................................................14
5.8 Interruption of welding .............................................................................................................................14
5.9 Tack welding ..............................................................................................................................................14
5.10 Inter-run cleaning ......................................................................................................................................15
6. WELDING ACCEPTANCE LEVEL ..........................................................................................................................15
6.1 General ......................................................................................................................................................15
6.2 Excess weld metal .....................................................................................................................................15
6.3 Root profile ................................................................................................................................................15
6.4 Cracks .........................................................................................................................................................15
6.5 Porosity and cavities .................................................................................................................................15
7. WELDING EQUIPMENT ......................................................................................................................................16
7.1 General ......................................................................................................................................................16
7.2 Welding and cutting equipment ...............................................................................................................16
7.3 Equipment for measuring .........................................................................................................................17
8. WELDING CONSUMABLE ...............................................................................................................................17
8.2 Storage and handling ................................................................................................................................17
9. MATERIAL ..........................................................................................................................................................18
9.1 General ......................................................................................................................................................18
9.2 Material requirements ..............................................................................................................................18
9.3 Material marking .......................................................................................................................................18
9.4 Material storage and handling..................................................................................................................18
10. DEFECT REPAIR AND CUT-OUT ......................................................................................................................19
10.1 General ......................................................................................................................................................19
10.2 Remove of defect ......................................................................................................................................19
10.3 Preparation for re-welding .......................................................................................................................19
10.4 Re-welding .................................................................................................................................................19
11. NON-DESTRUCTIVE TESTING .........................................................................................................................20
11.1 General ......................................................................................................................................................20
11.2 Equipment .................................................................................................................................................20
11.3 Health and safety requirements ...............................................................................................................20
11.4 Documentation and records .....................................................................................................................20
11.5 Magnetic particle inspection detail ..........................................................................................................20
11.5.1 General ..............................................................................................................................................20
11.5.2 Equipment and consumables ............................................................................................................20
11.5.3 Material preparation .........................................................................................................................21
11.5.4 Techniques .........................................................................................................................................21
11.6 Dye penetrant inspection detail. ..............................................................................................................21
11.6.1 General ..............................................................................................................................................21
11.6.2 Equipment and consumable .................................................................................................................22
11.6.3 Material preparation .........................................................................................................................22
11.6.4 Techniques .........................................................................................................................................22
11.7 Ultrasonic inspection detail ......................................................................................................................22
11.7.1 General ..............................................................................................................................................22
11.7.2 Equipment and consumable .............................................................................................................23
11.7.3 Material and preparation..................................................................................................................23
11.7.4 Scanning .............................................................................................................................................23
11.8 Radiographic inspection ............................................................................................................................24
11.8.1 General ..............................................................................................................................................24
11.8.2 Equipment and consumable .............................................................................................................24
11.8.3 Radiographic sensitivity ....................................................................................................................25
11.8.4 Techniques .........................................................................................................................................25
12. INSPECTION PERSONNEL ...............................................................................................................................25
12.1 General ......................................................................................................................................................25
12.2 Vision requirements ..................................................................................................................................26
13. RECORDS AND REPORTS ...............................................................................................................................26
13.1 General ......................................................................................................................................................26
13.2 Frequency of reports .................................................................................................................................26
14. SPECIFIC DETAIL FOR WELDING STAINLESS STEEL AND DUPLEX STAINLESS STEEL.....................................26
14.1 General ......................................................................................................................................................26
14.2 Material detail ...........................................................................................................................................26
14.3 Joint preparation .......................................................................................................................................27
14.4 Welding details ..........................................................................................................................................27
14.5 Non- Destructive testing requirement .....................................................................................................28
15. SPECIFIC WELDING DETAIL FOR ALUMINUM AND ALUMINUM ALLOYS .....................................................28
15.1 General ......................................................................................................................................................28
15.2 Material details .........................................................................................................................................28
15.3 Joint preparation details ...........................................................................................................................28
15.4 Table 4- Joint details for aluminum butt welds........................................................................................29
15.5 Welding details ..........................................................................................................................................29
15.6 Process 131 ................................................................................................................................................30
15.7 Process 141 ................................................................................................................................................30
15.8 Non Destructive testing requirements .....................................................................................................30
16. SPECIFIC WELDING DETAILS FOR QUENCHED AND TEMPERED STEEL (QT STEEL) ......................................31
16.1 General ......................................................................................................................................................31
16.2 Welding details ..........................................................................................................................................31
16.3 Non Destructive Testing requirements ....................................................................................................32
17. QUALIFICATION OF WELDING PROCEDURES................................................................................................32
17.1 General ......................................................................................................................................................32
17.3 Essential variable.......................................................................................................................................33
17.4 Welding of test joint..................................................................................................................................34
17.5 Extent of testing ........................................................................................................................................34
17.6 Table 8- Examination and test pieces Non-Destructive requirements....................................................34
17.7 Table 8a- Examination and test pieces Destructive Test Requirements. ................................................35
17.8 Welding position .......................................................................................................................................36
17.9 Joint configuration ....................................................................................................................................36
17.10 Location and cutting of test specimens ................................................................................................36
17.11 Impact testing ( Chapy V-notch) ...........................................................................................................36
17.12 Tensile testing........................................................................................................................................37
17.13 Macro-examination ...............................................................................................................................37
17.14 Hardness testing ....................................................................................................................................37
17.15 Fillet Fracture Test .................................................................................................................................38
17.16 Bend test ................................................................................................................................................38
18. QUALIFICATION OF WELDERS .......................................................................................................................38
18.1 General ......................................................................................................................................................38
18.3 Examination and testing ...........................................................................................................................39
18.4 Essential Variables and range of approval ...............................................................................................39
18.5 Table 10- Essential variable.......................................................................................................................39
18.6 Re Test .......................................................................................................................................................41
18.7 Period of validity .......................................................................................................................................41
18.8 Welding position qualification range .......................................................................................................41
18.9 Table 11- welding position qualification range ........................................................................................41
18.10 Test to be conducted. ............................................................................................................................42
18.11 Table 12-welding qualification tests.....................................................................................................42
19. POST WELD HEAT TREATMENT (PWHT) ...................................................................................................42
19.1 General ......................................................................................................................................................42
19.2 Temperature measurement ......................................................................................................................43
19.3 Temperature and heating/cooling rates ..................................................................................................43
19.4 Reports and records ..................................................................................................................................44
1. General:
1.1 Scope
This document define the technical requirements for the welding and fabrication of both onshore and
offshore structures.
This specification outlines the minimum quality and technical standard for material, fabrication and
welding, testing, inspection and all personal involved in the fabrication of structures used for both the
offshore and onshore environments. This document covers the arc welding of fillet, butt and socket welds
in carbon steel, low alloy steel, austenitic stainless steel. Austenitic-ferrite stainless steel and Aluminum.
All the requirements of this document shall be strictly adhered too; no deviation shall be permitted without
a written approval from company.
All fabrication and welding actives shall be carried out in a safe manner in accordance with the applicable
code and standards, to comply with the local government regulation
1.2 reference code and standards
The following list of codes and standards are to be used in conjunction with this document, if any conflicts
exist between this document and the codes and standards listed; the requirements of this document shall
apply. The last revision of all applicable codes and standards shall be adopted.
. BS 499-1 Welding terms-glossary for welding, brazing and thermal cutting
. BS EN ISO 17637 Non-destructive examination of fusion welds-visual examination
. BS EN ISO 6520-1 Classification off geometric imperfections in metallic material-fusion welding
BS EN 10204 Metallic products-types of inspection documents
BS EN ISO 2553 Welded Brazing and soldered joints-symbolic representation on drawings
BS EN ISO 4063 Welding and allied processes- Nomenclature of process and reference number.
BS EN ISO 2560 Welding consumable –covered electrodes for manual metal arc welding of non-
alloy and fine grain steel-classification
AWS A5.1 Specification for carbon steel electrodes
AWS A5.4 Specification for stainless steel electrodes for shielding metal arc welding
AWS A5.5 Specification for alloy steel electrodes for shielding metal arc welding
BS EN ISO 14341 Welding consumable–wire electrodes and deposits for gas shielded metal arc
welding of non-alloy and fine grain steels - classification
BS EN 1011 Welding-Recommendation for welding of metallic material
2. DEFINITION OF TERMS
2.1 General
For the purpose of this document the following definition shall apply. The terms used in this
documentation are in accordance with BS 499-1 and BS EN ISO 6520-1, other terms may be encountered
from other codes and standards not listed. Where terms encountered in this document that are not
clearly defined, common sense shall prevail.
2.2 Definition
Company: TWI Ltd
Contractor: An entity performing specific work under contract of the company
Defect: An imperfection of sufficient magnitude to warrant rejection
Imperfection: A discontinues or regularity
Indication: Evidence obtained by Non-Destructives testing
Welding: An operation in which two or more parts are to be unite, by mean of heat
or pressure or both.
Weld: A union of pieces of metal made by welding
Welder: The operation who performs welding
Shop weld: A weld made within the premises of the manufacture of the welded
assembly
Site weld: A weld made at the location where the assembly is to be installed
Parent metal: Metal to be joined or surfaced during
Filler metal: Metal added during welding
Heat effected zone: The part of the parent metal that is metallurgical affected by the heat of
welding
Joint: A connection where the individual components, suitably prepared and

assembled, are joined by welding
Manual welding: Welding in which the operator control by parameters and the mean
marking the weld are control by hand
Continuous welding: A weld extending along the entire length of the joint
Intermittent welding: A series of welds of the same type and dimension at interval along the
joint
Arc welding current: Current passing through the electrode
Arc voltage: Electrical potential between contact tip or electrode holder and work
piece
Interpass temperature: Temperature in a multi-run and adjacent parent metal immediately prior
to the applicable of the next run
Heat input: Energy introduced into the weld region during welding per unit run length
Preheat temperature: Temperature of the work piece immediately prior to any welding
operation
Shall: Denotes a mandatory action
Should: Denotes a strongly recommended action
Table 1-Abbreviation and symbols

Abbreviation and symbols Term
I Arc welding current
V Arc welding voltage
W Welding speed
K Thermal efficiency factor
Q Heat input
a Nominal Throat thickness of fillet weld
d Diameter of pore
h Height or with imperfection
l Length of imperfection in longitudinal direction of the weld
s Nominal butt weld thickness
t Parent material thickness
z Leg length of a fillet weld
CE Carbon Equivalent
MTC Material test certification
< Less than
> Greater than
≤ Less than or equal to
≥ Greater than or equal to
≈ approximately
3. QUALITY CONTROL
3.1 Contractor requirements
All the contracting parties involved with the fabrication and welding of structural in accordance with this
document shall have in place a quality management system and quality control manual. This document
shall cover all construction actives.
3.2 Fabrication requirement
All fabrication and welding activities shall be conducted in accordance with detail procedures for the
control of quality. The following procedures shall be available and approved prior to the commencement
of fabrication and welding works, all welding and fabrication works shall be 100% visual inspected.
 Welding and repairs
 Storage, control, and identification of welding consumables
 Welder qualification records
 Inspection/NDT
 Post weld heat treatment (where applicable)
 Parameter checks and progress of welding
 Material traceability
 NDT traceability
 Inspection test plans (ITPs)
4. JOINT PREPARATION DETAIL
4.1 Base metal preparation

All surface to be welded shall be visual examined and shall be cleaned to bright metal for a distance of not
less 30 mm for edge of the weld bevel. All surface contaminants including paints, oils, grease, or other
foreign substances shall be removed from the weld bevel.
Surface cleaning should be carried out using power cleaning tools, any cleaning on flame cut bevels shall
be carried using a disc grinder to a smooth finish sufficiently as to remove the first 3 mm from the flame
cut edge. Surface rusting shall be removed with a rotary wire brush where the area shows visible pitting,
grinding and ultrasonic thickness checking shall be carried out to ensure reduction of the wall thickness
has not exceeded 2%.
Note: for specific detail on stainless, duplex, QT steel and aluminum, refer to the relevant sections of this
documents.
4.2 Bevels
The welded bevels shall be beveled to the dimension specific in the approved procedure. In the case of
manual welding in the PA, PB, PE, PF. PG, PH, PJ, H-Lo 45, J-Lo 45 position, the bevel angle should be 300 +
5, -00. In the PC position the bottom bevel 150 +50, -00 , top bevel 450+50, -00. For alternative welding
processes such as automatic welding alternative bevel angles may be considered providing they are in
accordance with the approved procedures.
All welded bevels shall be carried out by machining or machine thermal cutting, manually or mechanically
operated. Manual thermal cutting shall not be used. The only time that manual thermal cutting shall be
considered is the cutting of pipe/plate for attachment fittings weldolets, sweepolet, etc., where machining
or machine thermal cutting is not practicable and only if company give approved.
Prior to fit-up all bevels shall be subjected to visual and magnetic particle (in the case of ferrite materials)
or penetration (in the case of non-ferrite material inspection.
Any indication found on the bevel faces, score marks, surface breaking lamination, machine damage,
lapping or any other imperfection shall be removed by grinding.
This shall be acceptable providing the thickness/depth of the repair area doesn’t exceed 3% the material
thickness. This is be qualified the use of UT or a suitable depth-measure gauge.
Where pipe/plate are to be cut back for purpose of attachment fittings, a zone extend 90 mm back from
the proposed position shall be fully examination visual and ultrasonic inspection for material imperfection,
lamination, laps. Folds, segregations etc. Visual acceptance is give in section 9 of this document.
4.3 Alignment.
The alignment of abutting ends shall minimize the offset between surface, for pipe and plate ends, linear
misalignment is permissible if maximum dimension does not exceed 1.5 mm. where parent material of
different thickness exist, the thinner of two material shall take as the material thickness, in the case of
plate welds angular distortion shall not exceed 5mm.
In the case of longitudinal seamed pipes/vessels, the longitudinal seams shall be offset by 900. Miters of
weld pipe joint shall not permitted. Angular misalignment at the weld toes of less than 30 is not to be
classed as a miter, and is acceptable providing that the angular misalignment is equally distributed on the
both sites of the joint to maximum of 1.50 per site.
In the case of fillet welds, unless otherwise specified, the fusion face to be joined by fillet weld shall be is
as close contact as possible, maximum gap permitted shall not exceed 3mm.
A fillet weld as deposited shall not be of less than the specified dimensions, see section 5 for detail.
4.4 Assembly for welding
Parts to be welded shall be assembled in such a way that adequate access is available to a personnel
involved with welding, inspection and the related actives for producing the weld joint. Jigs and fixtures may
be used where applicable providing no undue stress applied to the joint during welding operation. To
minimize stress and distortion it may be necessary to pre-set joints prior to welding and/ or to specify the
welding sequence to assist the control of stress and distortion, e.g. Back step/back kid welding.
4.5 Temporary attachment

The use of temporary attachments may be used for purpose of assembly where the applicable procedures
require them. They shall be used in such a way that the can be easies removed without any damage
occurring to the structure, all materials used for the temporary attachments shall be compatible with
parent material. All temporary attachment shall be carefully removed after used, where removal is carried
out by air-arc gouging, arc gouging or flame cutting; the cut shall be made clear of any parent material
such as that 3.0 mm of the temporary attachment id left or final removal by grinding smooth. After such
as an operation. 100% inspection on the affected area of the parent material shall be carried out. If any
imperfections are found e.g. undercut or under flushing these area shall be blended smooth they shall be
considered acceptable proving the depth doesn’t exceed 2% of base material thickness. This shall be
verified by the used of ultrasonic inspection or suitable depth gauge.
Note: Removal of temporary attachments by hammering or bending is not permitted.

4.6 Weather conditions
All areas of welding shall be adequately protected from wind, moisture, now, blizzards ect. Maximum air
velocity for welding processes shall be limited as follows:
 111 (SMAW) .: 20 mph (32km/hr).
 136 (GMAW).: 15mph (24km/hr)
 141 (GTAW).: 5.0 mph (8km/hr)
Note: the engineering shall state whether welding shall not be carried out because prevailing weather
condition could impair the quality of the complete weld.
5. WELDING DETAIL
5.1 General requirements
Only qualified welders shall carried out the welding in accordance with the applicable qualified welding
procedures. The surface to be welded shall be free from any contaminants, grease, paints, scale, rust and
any other foreign material that may adversely affect the quality of the weld joint. The joint design, root
gap, root face, bevel angles, alignment etc. shall be in accordance with this document and the approved
welding procedure specification applicable.
5.2 Butt welds

All butt weld shall be welded in such a way that the entire groove is completely filled (at no point shall the
weld face be lower than the parent material). The ends of the butt weld shall be welded in such a way as
to allow the full length and thickness of the groove to fill; this may be achieved by the use of run-off/run
on plate. If required a suitable backing material may be used to support the root during welding, this
material shall be metallurgical compatible with both the filler and parent plate/pipe material. No
permanent backing to be used.
In all butt welds, no joints shall be completed with single pass welding technique, I,e a minimum of two
weld passes shall be applied. Excessive weaving techniques shall be avoided with a maximum weave of 2
times that of electrode diameter permitted.
In the case of full penetration butt welds, which are to be welded from both sides, the back of the first run
shall be cleaned out prior to the welding of the second side. This shall be achieved by suitable mean to
clean to sound metal, this shall be inspected before commencement of welding on the second side by both
visual and magnetic particle inspection, the case of non- ferrous material both visual and liquid penetration
inspection
5.3 Fillet welds
Welding shall not have start/stop near Conner; the welding shall be continuous around the canners. All
fillet welds shall be made with minimum of two passes, in the case of a two weld pass fillet welds, the
second pass to be applied as close to the extremity of the first pass without impinging onto the pipe. Slip
on flange ≤ 100 mm shall have one weld run deposited on inside providing and tack weld are positioned
on back side prior welding.
The deposited fillet weld dimension shall be as below:

Leg length.
Leg length. Throat thickness
 Minimum=t Minimum = t x 0.7
 Maximum = t+3 mm Maximum = t + 0.5 mm
Note: in the case of different thicknesses, welding is to be based on the material minimum t
5.4 Preheating
For the welding of ferrite steel, the area of joint that is subjected to preheat shall extend around the entire
periphery of the pipe or the part to be welded. In each case the area extending not less than 100mm on
each side of the joint shall be maintained at the required temperature. Where practicable, the temperature
shall be measured on the surface opposite to that on which the heat applied. If this not practicable, the
temperature shall be confirmed on the heat faces at a time after the removal of the heat source, this shall
be relate to parent material thickness, this is allow for temperature equalization. The time shall be 2
minutes for a thickness not greater than 25 mm, with an additional 1 minute for each 12 mm above than
thickness. Preheating shall be applied by other gas flame cutter, case should away by taken to avoid
damage to the parent material and any applicable coating. 01 Cau
The minimum shall be determined by temperature indicating crayons, the type with melt or by suitably
attached calibrated thermal couples or pyrometers.
Note: Crayons or paints, which indicate temperature by colour change, are not permitted
The above only refers to the welding of ferrite steel, when welding stainless steel preheat should be
avoided. See section 14 for specific detail on the welding of stainless.
The pre-heats are based on weld ability trial and the following factors:

 Heat input:
 Hydrogen scale: A, B, C, D, E
 Combined material thickness
 Carbon equivalent CE%= C + + +
Note: Thermal efficiency values to be applied
5.4.1 Table 2- Preheat values
Hydrogen scale A & B
Heat input value kj/mm Temperature 0C Combine Carbon equivalent

thickness (CE)
< 0.5 1750C Any thickness < 0.45 %
≥ 0.5 < 2.0 1500C Any thickness < 0.45 %
≥ 2.0 < 4.0 1000C ≤ 80 mm < 0.45 %
≥ 4.0 < 5.0 1250C >80mm < 0.45 %
≥ 5.0 No preheat required
5.4.2 Table 2a- Preheat values

Hydrogen scale C,D & D, E
Heat input value kj/mm Temperature 0C Combine Carbon equivalent

thickness (CE)
< 0.5 1500C Any thickness < 0.45 %
≥ 0.5 < 2.0 1250C Any thickness < 0.45 %
≥ 2.0 < 4.0 750C ≤ 80 mm < 0.45 %
≥ 3.0 < 4.2 500C >80mm < 0.45 %
≥ 5.0 No preheat required
Note: for CE value of 0.45% and above and additional 500C preheat temperature required
from the values shown in the above table.
5.5 Interpass temperature

The maximum interpass temperature or preheat temperature for ferrite steel shall not exceed 2500C. The
minimum interpass temperature shall not drop below the minimum calculated preheat temperature.
Temperature shall be monitored by the same as for preheat temperature.
Note: the above only refers to the welding of ferrite steels, when welding stainless steel. See section 14
for specific detail on the welding of stainless steels.
5.6 Arc trikes

Arc trikes outside the weld groove area shall be removed by grinding. All arc strikes outside the groove
area shall be subjected to magnetic particle inspection. (in the case of non- ferrite steel penetration
inspection shall be used ). All indications of cracking shall be again subjected to grinding and re-inspection
to ensure completed removal.
Where the arc strikes have been repaired by grinding confirmation that the thickness of the parent material
is within the permitted tolerance, this shall be thickness reduction of no more than 2% of the original
material thickness, confirmation shall either be by ultrasonic inspection or a suitable depth gauge
5.7 Welding identification

A weld number shall identify all welds; if the weld has been repaired the letter “R” indicating a “repair
weld” shall follow the weld number. If weld has to remove the letter “RW”, indication are-weld, shall follow
the weld number. If the re-weld has to repaired, the letters “RWR”, indication re-weld repair, shall follow
the weld number.
Note: either a permanence paint stick marker or low stress metal stamp only used for weld identification
5.8 Interruption of welding

Whenever possible, welding of joint shall be complete in one continuous operation. Where interruption
is unavoidable the following shall apply:
 For material thicknesses ≤ 25 mm, a minimum of two weld passes shall be completed over the
full weld thickness and length (root and hot pass).
 For material > 25 mm weld thickness, a minimum of three weld passes shall be completes over
the full weld thickness and length.
In the case of all joints, when welding is interruption the joint shall protected from contamination,
moisture, ect. And shall be cooled in slow uninform manner.
Prior to the recommencement of the welding, the joint shall be subjected to the same preheat
temperature as specific.
Note: in all cases the company shall approve all interruption of welding.
5.9 Tack welding
In all case the use of clamps is preferred over tack welding. If the tack welds are to used, tack welding
shall only be carried out by qualified welders, these tack welds shall be subjected to the same preheat
and interpass temperature as groove/fillet welding and the following shall apply:
 All tack welds performed to hold member in alignment which will not be incorporated into the
completed weld (bridge tacking) shall be removed by grinding prior to the welding approaching
the tack area.
 All tack welds that will be incorporated in to completed weld, prior to the continuation of
welding, the tack weld shall be have a minimum length of 45 mm or 20% of the total weld length
wherever is the less
5.10 Inter-run cleaning
Each weld pass shall be thoroughly cleaned before the commencement of the next weld pass the
cleaning may be performed by hand or power tools. All scale and slag shall be removed. The stop/start
shall be blended smooth.
6. WELDING ACCEPTANCE LEVEL

6.1 General
All weld metal shall be subjected too visual inspection. Inspection pf welds during welding shall carried
out on the root pass where practical. All weld caps shall be examined, all inspection welds shall comply
with the acceptance levels in this document shall cause for rejection
6.2 Excess weld metal
Excess weld metal reinforcement shall be uniform and not greater than 2.0 mm in height. The toe of weld
shall blend smoothly with parent material with no sharp indication visible. The weld toes shall not extend
into the parent material by more than 2.5 mm on either side of the weld. At no point shall the weld face
be lower than the plate/pipe surface
Note: acceptance for fillet weld sizes shall comply with section 5 of this document.
6.3 Root profile
The root pass shall blend smoothly with parent material with o sharp indication visible. The penetration
bead shall not exceed 3 mm
6.4 Cracks
Not permitted
If cracks are found in a weld the entire weld shall be cut out, under no circumstances shall weld with
positively identified crack be repaired.
Note: With the approval of the company, crater cracks of no less than 5 mm may be repaired.
6.5 Porosity and cavities
Maximum permitted individual pore dimension

 Butt weld: 1.5 mm max
 Fillet weld: 1.5 mm max
In the case of elongated cavities (wormholes), the maximum length permitted shall not exceed 15 mm in
any continuous or intermittent length.
In the case of clustered porosity the area shall not exceed 50 mm2.
Table 3- acceptance criteria for welds
No Defect type Acceptance criteria
1 Slag/silica inclusion The length of the slag/silica inclusion shall not exceed 50
mm in any continues or intermittent length. Accumulative
total length shall not exceed 50 mm
01 cau
2 Undercut No sharp undercut shall be permitted. The maximum length
not exceed 50 mm in any continuous or intermittent length.
Accumulation total length shall not exceed 50 mm. the
depth shall not be great than 1.0 mm.
3 Lack of fusion Surface breaking lack of sidewall fusion shall not exceed 15
mm in any continuous or intermittent length. Accumulative
total shall not exceed 15 mm in any weld length.
4 Lack of root penetration Not permitted
5 Lack of root fusion Accumulation 50 mm max, continuous or intermittent
6 Burn through Not permitted
7 Root concavity 50 mm maximum length. 3 mm maximum depth
8 Cold lap/overlap Not permitted
9 Oxidized root Not permitted
10 Mechanical damaged No stray tack welds permitted. All grinding/chipping/hard

stamping/hammer mark shall be blended smoothly.
7. WELDING EQUIPMENT
7.1 General
The contracting parties carrying out the fabrication works shall be responsible ensuring that all the
equipment required is in a good safe working order.
7.2 Welding and cutting equipment
All welding plant and cutting equipment shall be capacity necessary to produce a sound weld in accordance
with the relation procedures being adopted. All welding plant and equipment shall be calibrated every 3
months with maintain record available. Cabling must be sufficiently insulated and of a sufficient cross
section to carry out the required value without overheating. Equipment not meeting these requirement
shall be replace.
Note: All Welding plant shall have an OCV not exceeding 90 volts.
7.3 Equipment for measuring
All equipment required for measuring shall have a valid certificates of calibration, calibration shall carried
out every 12 mouths, the date shall be clearly visible either on the measuring device itself or available in
the form documentation , with clear traceability to the measuring device in question
Adequate mean of measuring welding parameter such as welding current, welding voltage and travel
speeds shall be available.
8. WELDING CONSUMABLE
8.1 General
The electrode, filler wire, wire/flux combination and flux types shall be such that they product sound weld
meeting the requirements of the applicable procedures being adopted. The completed weld metal shall
have tensile strength value at least equal to minimum specification for parent material. In the case of
dissimilar joints, the weld metal shall have a tensile strength at least equal to that of higher strength
material.
The chemical composition of the deposited weld metal shall be compatible to that of parent material. All
welding consumable shall be free from damage. Chips, contamination and used within the
recommendation of the manufacture.
8.2 Storage and handling
All SAW flux shall be stored in accordance with the manufacture’s recommendations. SAW Flux maybe
recycle provide the reused is free from all contaminates, slag, mill scale and other foreign matter. All recycle
fluxes shall be mixed with an equal amount of new flux before being used (50:50 ratio).
All MMA welding consumable shall be treated in accordance with the manufacture’s detail
recommendation. When it is necessary to dry and bake the consumable, the consumable shall be remove
from its original container prior to any applicable heat treatments, after the heat treatment the
consumable shall store in such a way as to keep them free from moisture intake, i.e. drying ovens. In the
case of consumable that have been vacuum packed, these shall be used in accordance with manufacturer’s
recommendation. In the case of hydrogen controlled consumables it is recommended that the welders be
issued with electrodes in heat quiver.
Note: All drying and backing overs for welding consumbles shall be provided with the means of
measuring the oven temperature.
Shielding gases shall be stored and kept in the original supplied container and these shall be stored in such
a way as to avoided extreme temperatures. Gases shall only be used in the containers supply by
manufacture with no mixing of gases to be conducted on site. All gases containers shall clearly marked
without any signs of damage; containers, which don’t comply shall not be used.
9. MATERIAL
9.1 General
All materials to be used in fabrication shall be in a clean, corrosion free condition; no evidence on the
surface pitting shall be visible. Materials with lamination shall not be sued on any fabrication, C-Mn steel >
25mm thickness must have a lamination check and this must reference on the mill certificates. Material
not having a valid mill certificates shall not use under any circumstances. Both contractor and client
inspectors shall inspect all material arrived on site, material not complying with requirements shall be
quarantined until the material shall comply with the requirements of this document. All materials arriving
on site shall only purchase from company approved manufactures list.
9.2 Material requirements
 All structural steel shall be new stock.
 Spiral welded pipe shall not be used.
 Electric-resistance welded (ERW) pipes shall not be used.
 No material with a CE% above 0.48 shall be used for fabrication purposes.
 Constructor shall maintain all material traceability, showing the material heat numbers of major
load bearing structural members
 Contractor shall mark each mill certificate with the contractor’s job number, item number to be
used, quantity to be used, e, g. number of maters and area of structural material.
Contractor shall maintain traceability map showing the material heat number of all major load-bearing
structural member.
Note: for specific detail on stainless, duplex, QT steel and aluminum, refer to relation section of this
document.
9.3 Material marking

All steel shall be suitably marked on upon delivery to the contractor’s fabrication yard. The steel shall
marked in such a way that the type of steel, heat number and any applicable special test can be easily
recognized.
All heat numbers or other identification marking shall be transferred from piece to piece prior to cutting,
cut pieces shall be remarked in the same way as the original markings.
All markings shall be stenciled with a suitable marker or a low stress concentration die on both ends of
each item.
9.4 Material storage and handling
All structural material shall be store above ground on flat surface or platform type skids. Material shall be
storage in such in a way that they are kept free from dirt, grease, paint spray or any other foreign matter
ad kept free form corrosion. In the case of stainless steel grades these shall be stored in a separate area
from ferrite steel, covered over at all times, and no contact to be made with ferrite material at any time,
e.g. fork lift trucks shall be suitably protected against steel to steel contact, all lifting equipment shall be
used in such a way to avoid ferrite contact with the stainless steel material.
10. DEFECT REPAIR AND CUT-OUT

10.1 General
All weld repairs shall be conducted in accordance with the weld repair procedures and only conducted by
qualified welders. No weld repair or cut out shall be conducted without the authorization of the company.
All repaired shall be witness 100% by a qualified welding inspector. A weld may only be repaired once, of
the weld still contains unacceptable defects in accordance with this document the entire weld shall be
removed. Crack, see general acceptance level section 6.
10.2 Remove of defect
All weld that fail to comply the requirements of this document shall either be repaired or the entire weld
removed. Repairs shall not be carried out until full inspection has been conducted.
Defect shall be removed by grinding or air arc gouging. When arc- air gouging is employer resultant removal
cavity shall be ground to clean base metal before any welding can commence . Entire weld removal may be
carried out by thermal cutting
When thermal gouging or thermal cutting is being used, the last 10% through the root of weld shall be
removed by mechanical grinding.
10.3 Preparation for re-welding
In the case of partial weld removal, the cut out portion shall be sufficiently deep and enough to remove
the entire defect, at the ends and sides of excavation area there shall a gradual taper from the base of the
cut to surface of the weld metal. The width and depth of the excavation shall give adequate access for re-
welding. The repair groove shall be inspection by the penetrant or magnetic particle inspection to ensure
that the defect has been entire removed.
In the case of cut-out, involving the entire defective weld to remove, the preparation shall be re-made in
accordance with requirements of this document
10.4 Re-welding
A repaired welding is subjected to the same testing and inspection as the original weld, with preheat
temperature 750 C above that of the original weld preheat temperature. Repair weld shall limited to 25%
of the original weld length, defect that exceed this value required entire weld to be removed. All re-welding
shall only be carried out under full supervisor from qualified welding inspector, no vertical down welding
is permitted for weld repairs. Full record and reports of all repairs shall be maintained.
11. NON-DESTRUCTIVE TESTING

11.1 General
Contractor shall propose specific for procedures for all NDT methods to be used e.g. MPI, DPI, UT and RT.
Contractor shall only use NDT personnel qualified to EN ISO 9712 level II as a minimum in the applicable
description, this also includes any third party inspection services. All third party inspection services
companies can only be used with approval from the company
Whenever radiography is employed as the main NDT method, a percentage of welds shall inspected by
ultrasonic testing. As a minimum 100% of the first 10 welds, after with 100% of weld after every 25 welds
completed.
Note: 100% of the weld shall be tested by the inspection method being used.
11.2 Equipment
All contractor and third parties conducting NDT shall provide a full list of all inspection equipment to be
used including all relevant calibration certificates, this shall also include comprehensive spare parts list.
11.3 Health and safety requirements
Contractor shall be solely responsible for all safety concerns associated with the NDT method being
employed. When suing radioactive material these shall comply with the government regulation and
possesses a permit from the relevant national atomic energy agency.
11.4 Documentation and records
All completed NDT reports shall be submitted to the company for approval and signature. The NDT
technician performing the inspection shall sign all reports
All NDT reports shall have an original copy issued to the company and a soft and hard copy retained in the
job file.
All discontinuities detected shall have both the length and position from datum reported. UT reports shall
also include the discontinuities depth.
11.5 Magnetic particle inspection detail
11.5.1 General
MPI for the purpose of detecting surface discontinuities in ferrous butt welds, fillet welds and
ferromagnetic components. Wet method MPI shall be used in all case except for inspection of hot
materials and components (> 600C)
11.5.2 Equipment and consumables
Magnetization shall only be carried out used an AC Yoke (DC yoke shall not be used). Pole spacing’s shall
be a minimum of 150 mm and maximum of 300 mm. AC yolk lift test with a weight of 4.5 kg, permanent
magnets lift test with a weight of 18 kg.
Magnetization method to be used shall show three indicates on a Castrol Buma Strip (brass type). If this
cannot be achieve then the magnetizing method must be change or adjusted.
Indicating medium shall be a water or solvent suspension of black ferromagnetic particles. Only
company approved trade names may be used. Indicating medium shall be periodically agitator to assure
correct concentration of particle, only aerosol magnetic inks supplied by the manufacture shall be used.
Where black ink particles are being used a white contrast paint shall be applied prior to inspection, this
shall be supplied by the same manufacture as black ink particles i.e. no mixing of manufacture shall be
permitted.
Note: The used permanent magnets shall only be used on live plant as a safety precaution and then
only by prior company approval
Fluorescent methods shall not considered.
11.5.3 Material preparation
All surface at least 30 mm either side of the area to be tested shall be free from welding slag scale,
grease, oil, excessive weld spatter and any other foreign material which may be interface with
inspection.
11.5.4 Techniques
 Apply white contrast paint where black particles are to be used.

 Magnetize the weld area or area to inspect. Large weld areas may be required multiple
inspection to cover the entire surface or test area to inspected.
 While the component is magnetized, apply ink and inspect for indication. Black particles inks
shall be inspected in a well-lit area of no less than 500 Lux.
Evaluation of imperfections shall be assessed in accordance with section 6 of this document.
11.6 Dye penetrant inspection detail.

11.6.1 General
The DPI shall only be used the detection of surface breaking defects on non-ferrous materials, e.g.
austenitic grade stainless steel, duplex grade stainless steels and copper, aluminum based material.
Colour contrast solvent based penetrants shall be used at all items, the use of any other penetrants
method e.g. water based or fluorescent may only be used with company approval. DPI shall only be
used at temperature between 100 C and 500 C.
11.6.2 Equipment and consumable
The colour of contrast inspection the test area shall be illuminated by daylight or artificial light no less
than 500 Lux.
When the company permitted fluorescent inspections the UV-A irradiance at the surface under
inspection shall not less than 10W/m2 (1000 mW/Cm2) with maximum background light is 20 Lux.
Only the company approved trade name shall be sued. All consumable used shall from the same
manufactures i.e no mixing of manufacture shall be permitted.
11.6.3 Material preparation
All surface at least 30 mm either side of the area to be test shall be free from welding slag, scale, grease,
oil, excessive welding spatter and any other foreign material which may be interface with inspection.
All surface shall be inspection by DPI shall be cleaned thoroughly using a solvent based cleaner.
11.6.4 Techniques
 Cleaning, all cleaning shall be carried out as above

 Application, entire area to be tested shall have a uniform coating of penetrants applied by
spraying or brushing. Penetrant shall be left in contact with component under test for a
minimum of 5 minutes and maximum 15 minutes; at no time shall the penetrant be allowed to
dry. If this does occur the penetrant process must be start again.
 Penetrant removal, all excess penetrant shall remove initially by wiping with a free cloth. If
further traces off penetrant are still present, this may be removed by the solvent dampened
cloth; under no circumstance shall solvent remover be applied directly to the component.
Before the application of the developer it is essential that a surface complete dry.
 Apply of developer, a non-aqueous developer shall be applied uniformly in a layer across the
entire test surface.
 Inspection, inspection of the test surface shall be start immediately the developer is applied,
any signs of penetrant bleed-out may indicate the presence of discontinuities
Evaluation of imperfections shall be assessed in accordance with section 6 this document
11.7 Ultrasonic inspection detail
11.7.1 General
Ultrasonic shall be used detection of sub-surface discontinuities; UT shall not be carried out inspection
on austenitic grade steel, duplex stainless steel and aluminum may be considerate providing sufficient
attenuation checks have been conducted and then only by company approval. All UT technicians
supplied by either contractor or third party NDT companies shall subjected to company UT cross
checking, UT shall only be considered as a primary NDT method for the following:
 Material thickness > 80 mm
 Tee butt welds
 Cucumiform butt weld
 Set –through butt weld (including nozzles)
 Set on butt weld (including nozzles)
Couplant used shall be a gel or grease (water bases couplants shall not be considered) suitable for
transmission of sound weave into the material under test. Counplant used for calibration shall be
identical to that used for testing
Reference blocks shall be V1 (A2) and V2 (A4), IOW black (used for beam profiles) and RC block (used
for resolution checks)
Probes to be used for weld body scanning (cap ad welded) are 450, 600, and 700 refraction angles 4 MHz
to 5 MHz frequency with a single crystal area approximately 80 mm2. Parent material scanning and weld
cap dressed flush, o0 4MHz to 5MHz with a twin crystal area approximately 80 mm2.
The detection unit used shall be calibrated and shall be capable of operating with a frequency range of
1.5 MHz to 6 MHz
Note: for the material < 15 mm, the omission of 450 probe shall apply
11.7.3 Material and preparation
Before ultrasonic inspection is carried out a zone of sufficient size (no less than 90 mm) shall be
thoroughly cleaned with all spatter, scales, slag, removed, either side of the weld. Any paint or other
surface shall coatings, which interface with the weld scanning, shall be removed. The surface profile
shall be sufficiently regular as to permit a uniform contact between probe and parent material
throughout the test. When echoes from reinforcement are likely to interface with the test. The
reinforcement shall be dressed to smooth profile. Prior to inspection the area adjacent to be welding
inspected by a 00 compresses ion probe to confirm the material thickness under test and to detect the
presence of any lamination, which may interface with the ultrasonic inspection.
11.7.4 Scanning
Test sensitivity for angle probes shall be set so that the echo from a 1.5 mm side drilled hole (V1 (A2),
or V2 (A4) block) is 80% full screen height. Test sensitivity for compression probes shall be set so the
2nd back wall echo from test depth is 80% full screen height. In both cases, when scanning an addition
6 dB shall be added. The weld shall be scanned in a zig, zag manner, the probe being moved between
the weld reinforcement and skid distance / full skid distance, the beam shall directed at the weld length
normally. The weld shall be scanner form both side.
Evaluation of imperfections shall be conducted in accordance with section 6 of this document.
The methods with shall be used for the sizing of any imperfection found.
 20dB drop method: For imperfections with dimensions smaller than the probe beam
spread at discontinuity beam path
 6 dB drop method: For imperfection with dimensions large than the probe beam spread
at the discontinuity beam bath
Note: automatic ultrasonic inspection may be considered but only with the approval of the company
11.8 Radiographic inspection
11.8.1 General
RT shall be used for the detection of sub-surface discontinuities (surface discontinuities may be also be
detected with RT which may have beam missed by a surface detection NDT method) RT shall be
considerate as the primary NDT method unless the condition of 11.7.1 exist. RT (X and /or gamma) shall
be conducted on butt welded joints (including the HAZ area) for pipes, plate vessel and structural of
both ferrous and non-ferrous material. Radiographic shall only be conducted by personnel holding a
current national radiation safety certificates
Radiation source Ir192 shall have a maximum source dimension of 2 x 2 mm; no sources shall be used
for the purpose of weld inspection that have an intensity less than 444GBq. For the purposes of safety
a maximum of 60 Ci isotopes are permitted for used on site. The used of Se &5 is preferable for the
inspection of weds with penetrated thickness up to 40 mm.
X-ray units shall be capable of an output no less than 250 KV, with a focal spot size no greater than 4 x
2 mm; this shall be checked every six months.
Radiographic film shall be of the fine grain type, high contrast direction type and for all gamma
radiography and X radiography above 120 KV’s, lead screens shall be used. All unexposed film shall be
store in a clean dry area where surrounding conditions will not deteriorate the condition of the film
All chemicals used for the processing of films shall be in accordance with the manufacturer’s
recommendations.
The following equipment shall be available in the viewing area:
 Densitometer with a certified density strip
 Film viewer capable of viewer films of exposed densities over 3.5 H & D
 Magnifying glass (10 x magnification)
 All applicable codes and standards
Films identification, films shall be identified as to the company requirements with 6 mm lead letters. A
number belt with numbers at 1 cm interval shall be used to ensure complete coverage. The minimum
identification to be provided on the radiograph shall be:
 Date
 Job number
 Datum
 Penetrometer (IQI)
11.8.3 Radiographic sensitivity
Exposed radiographs shall have an average H & D density at the sound weld metal image of a minimum
of 2.0 and maximum of 3.5, the density shall be assessed by calibrated densitometer.
ISO EN wire type penetrometer shall be used with a minimum sensitivity calculation of 2% in the weld
image area.
hoi anh dung
Maximum Ug levels shall not exceed 0.25 mm unless approved by company; this shall only be
considered when it is proven that the radiographic technique being used can’t achieve this value.
11.8.4 Techniques
The following radiographic techniques (where possible and practicable) shall be used as required to
ensure full radiographic coverage.
 Double wall double image (DWDI) for pipe diameter up to 100 mm, minimum of three exposures
 Double wall single image (DWSI) for pipe diameter above 100 mm. Pipe diameters up to 660
mm, a minimum of four exposures are required. Pipe diameter above 660 mm to 1100 mm, a
minimum of 5 exposure are required. Pipe over 1100 mm required minimum 6 exposures, more
may be required as to the company requirement
 Single wall single image (SWSI) minimum 150 mm SFD
 Single wall single image (SWSI) (panoramic) source inside, films outside, this technique is
preferable for all pipe diameter over 330 mm.
Note: minimum SFD/FFD shall be calculate using the material thickness and the maximum Ug value
(0.25 mm) permitted.
Evaluation of imperfection shall be conducted in accordance with section 6 of this document.
Note: only as BS EN SO 9712 radiographic level II qualified person shall be permitted to sign off viewer
radiographs.
12. INSPECTION PERSONNEL
12.1 General
All personnel involved with the inspection of welds and related actives shall be qualified to a minimum of
level II certified by an approved certification body, with meet the current requirements of BS EN ISO 9712.
12.2 Vision requirements
All inspection personnel shall have satisfactory vision as determined by an oculist, optometrist or medically
recognized person in accordance with the following requirements
1. Near vision acuity shall permit reading a minimum of jaeger number 1 or time roman N 4 at not less
than 30 cm with one or both eye, either corrected or uncorrected.
2. Colour vision shall be sufficient that they can distinguish and differentiate contrast between colours
used in the NDT method concerned as specified by the company.
Note: A documented vision test shall be carried out at less one year.
13. RECORDS AND REPORTS

13.1 General
Contractor shall provide company’s welding inspector with a daily reports of all welding and related
activities. The reports shall show as a minimum, weld number, radiograph number ( if applicable), all UT,
MPI, DPI report numbers ( if applicable), status of each welded joint (accepted, repaired and accepted,
rejected or cut-out, welders ID number, heat treatment reports and any other applicable detail. The reports
shall be presented on format approved by the company; no other report format shall be permitted
13.2 Frequency of reports
The time between inspection date and reports shall be not exceed 48 hours for all inspection method.
14. SPECIFIC DETAIL FOR WELDING STAINLESS STEEL AND DUPLEX STAINLESS STEEL.
14.1 General
Phan chia
All fabrication of stainless steel and duplex grade steel shall be segregated from all other works and kept
free from and possible any possible contaminating materials such as copper, carbon steels, zinc, etc.
All tools used in the fabrication of stainless steels shall be kept separate from other tools and clear marked
with a colour code. This includes grinding wheel; wire brushes (stainless wire only) etc. and should be kept
in thorough clean condition. All workbenches shall be entire stainless steel or suitably covered with a
covering material of sufficient thickness as to achieve carbon to stainless contact.
All stainless steels shall be store under cover and on wooded block of sufficient thicken the material to be
stored a minimum of 320 mm off the ground.
14.2 Material detail
All austenitic stainless steels for fabrication welding shall be of the grade 316L, with a maximum carbon
content of 0.03 %. All austenitic stainless steels shall be supplied in a solution- annealed condition, de-scale
pickled and passivized. Any cold working should be carried out before final heat treatment. All austenitic
stainless steel shall be subjected to positive material identification (PMI) before being issued for site use
for alloy content verify.
All duplex stainless steel for fabrication and welding shall have a nitrogen content not less than 0.14% and
a ferrite content between 40% and 60% for base material and 30% to 55% for weld metal. All duplex
stainless steel shall be supplied in a solution annealed condition, de-scale, pickled as passivized, after
welding shall undergo the same treatment. Any cold working should be carried out before final heat
treatment. All duplex stainless steel shall be subjected to a ferrite check after welding and positive material
identification (PMI) before being issued to site use for alloy content verification.
14.3 Joint preparation
Generally no special joint preparations are required for the welding of austenitic stainless steels and duplex
steels. Any thermally cut bevels for welding shall be mechanically ground or machined back from the cut
edge by at least 5 mm to elimination any contamination from the thermal cutting process. Hard stamping
should be avoided; when this is unavoidable the hard stamping shall be of the rounded type and not applied
in any high stress concentration area.
14.4 Welding details
The use of preheat should be avoided and may only be considered when approved by the company. All
welding of stainless steel and duplex grades shall be monitored 100% by an approved welding inspector
with amps, voltage, travel speed and heat input being recorded at all time, these records shall be made
available to the company upon requires. Only welding process 141 shall be used for the root pass and
second pass on all austenitic & duplex steel, other welding process may be considered for filler and capping
passes with company approval. In all cases stringer beads only shall be applied. Shielding gases for both
austenitic and duplex stainless steel shall be of a purity of 99, 99 % argon with oxygen content for backing
gases prior to welding 500 ppm maximum.
01 Cau
The following variables shall be strictly adhered to at all time.
 Heat input 18 to 22 Cr 0.5 to 1.75 KJ/mm
 Heat input 23 to 25 Cr 0.5 to 1.5 KJ/mm
 Interpass temperature 18 to 22 Cr 1750 C Maximum
 Interpass temperature 23 to 25 Cr 1500 C Maximum
After welding it is essential that all surface slag, scale and any other contamination are removed this is may
be conducted by mechanical means or by wire brushing (stainless steel only).
Post weld heat treatments are generally not necessary for both austenitic and duplex stainless steels. Heat
treatment however may be required for purpose of stress reliving after extensive cold working, cold
deformation etc. these heat treatment may only be carried out if approved by company at a minimum
temperature 4500C.
14.5 Non- Destructive testing requirement
For both austenitic and duplex stainless steel the following shall be applied:
 100% visual inspection on all welds
 100% dye penetrant on all welds
 100% radiography on all butt welds.
Evaluation of imperfection shall be conducted in accordance with section 6 of this document
Note: ultrasonic inspection may be considered as a backup only on duplex stainless steel and only with
prior company approval.
15. SPECIFIC WELDING DETAIL FOR ALUMINUM AND ALUMINUM ALLOYS
15.1 General
All fabrication of aluminum and aluminum alloys shall be segregated from all other works and kept free
from any possible contaminating materials such as copper, carbon steel, zinc, etc.
All tools used in the fabrication of aluminum and aluminum alloys shall be kept separate from other stool
and clearly marked with colour code. This includes grinding wheels; wire brushes (stainless wire only) etc.
and should be kept in thorough cleaned condition. All workbenches shall be free from any ferrite base
material or suitably covered with a covering material of sufficient thickness as to be avoid ferrite to
aluminum contact.
All aluminum and aluminum alloy shall store under cover, plates are to be stored in the vertical position as
to minimize moisture condensation and long term moisture collection between layers. All aluminum and
aluminum alloys shall be stores on wooded blocks of sufficient thickness for the material to be stores a
minimum of 320 mm of the ground.
Note: all filler material and base materials shall be brought into the welding are no less than 24 hours
before the commencement of all welding operations, to ensure they are at room temperature.
15.2 Material details
Series 1XXX, 3XXX and 7XXX aluminum and aluminum alloys shall not use for the purpose of fabrication
and welding. All aluminum and aluminum alloys shall be free from all cutting oils and other contaminations.
15.3 Joint preparation details
All cutting of aluminum and aluminum alloys shall conducted using either; plasma arc, laser, or by suitable
mechanical means (the use of cutting lubricants shall be avoided). The use of oxy fuel gas cutting, carbon
arc cutting or gouging shall not use. When plasma and laser cutting is used on series 2XXX and 6XXX, a
minimum of 3 mm shall be removed by mechanical mean from the cut edge, after removal the cut edge
shall be inspected by DPI to ensure no cracking present on the cut edge.
Note: all filler materials and base material on series 2XXX, and 6XXX the cut edge my contain solicitation
cracking and detrimental parent material condition.
Before the commencement of welding all fusion faces shall be cleaned and degreased by solvents and the
oxide layer removed by mechanical means. The prior between cleaning and welding shall not exceed 30
minutes to avoid recontamination.
Note: degreasing by chemical etching will remove the surface oxide; this method can be considered but
only by company approved. If chemical etching is to be used stainless steel wire brushing shall be carried
out on all etched surfaces to remove the by-product residuals with may be have a detrimental effect on
the weld quality.
In all cases after cleaning the fusion faces shall be free from moisture, compressed blowing should be
avoided as compressed air my contain moisture and contaminations.
15.4 Table 4- Joint details for aluminum butt welds
01 cau
Welding position Material thickness Root gap Root face Included bevel
angle
PA < 12.5 mm 0 to 0.5 mm 0 to 0.5 mm 0 to 700
12.5 to 25 mm 0.5 to 1.25mm 1.6 to 3.2 mm 700
>25 mm 0.5 to 1.5 mm 2.0 to 4.5 mm 700
PC, PE < 12.5 mm 0.5 to 1.25 mm 0 to 1.6 mm 0 to 700
≥ 12.5 mm 1.0 to 1.5 mm 1.6 to 3.2 mm 700
PF,PH < 12.5 mm 0 to 1 mm 0 to 1.6 mm 0 to 700
H-JO 45 ≥ 12.5 mm 1 to 1.5 mm 1.6 to 3.2 mm 700
Fillet weld dimension shall be in accordance with section 5.3 of this document.
Note: PG, PJ and J-LO45 welding position shall not be considered for the welding of aluminum and
aluminum alloys.
Only welding processes 141 & 131 shall be considered for the welding of aluminum and aluminum alloys.
In both argon (99,997 % pure) shall be used as shield gas. All pipe butt joints to be welded using process
141.
Note: Aron/Helium mixes may be considered buy only by company approval and only by using fully
approved WPS’s.
During the welding duration for both 141 and 141 welding process, interpass temperatures shall not exceed
1100 C; series 6XXX aluminum shall not exceed 900.
Preheating shall not be applicable to treatable base material and series 5XXX base materials containing Mg
contents above 3%, all other base materials shall be subjected to a preheat temperature as to the approved
WPS, but no greater than 1200C.
15.6 Process 131
 Leading are (push) technique to be used for increased cleaning action

 Spray transfer mode (pulse transfer mode may be considered for position welding and on thinner
material < 3.5 mm)
 Filler wire to match the melting point as closed as possible to the base material meting point.
 Constant voltage characteristic welding plant.
 Travel speeds shall not be less than 6.5 mm/s
 Welding current DC EP
 Heat inputs
Table 5 Process 131 Heat Input Values
Material thickness Minimum heat input (KJ/mm) Maximum Heat input
<3.5 mm 0.24 0.32
≥3.5 mm< 6.5 mm 0.35 0.41
≥6.5 mm 0.57 0.85
15.7 Process 141
 Filler material to match the melting point as close as possible to bas materials melting point.
 Constant current characteristic welding plant
 Zirconlate or lanthanated tungsten electrode (smooth hemisphere electrode tip).
 Electrode diameter as to the approved WPS, min diameter 1.6 mm, max diameter 4.5 mm
 Welding current AC
 Heat input.
Table 5A-Process 141 heat input values. 01 cau

Material thickness Minimum heat input (KJ/mm) Maximum heat input (KJ/mm)
<3.5mm 0.42 0.57
≥3.5mm < 6.5 mm 0.89 1.2
≥6.5mm 1.98 3.2
15.8 Non Destructive testing requirements
For aluminum and aluminum alloys, the following shall be applied

 100% visual inspection for all welds
 100% dye penetrant on all welds
 100 % radiography on all welds
 Evaluation of imperfections shall be conducted in accordance with section 6 of this document
Note: ultrasonic inspection may be considered as back up only duplex stainless steel and only with prior
company approval.
16. SPECIFIC WELDING DETAILS FOR QUENCHED AND TEMPERED STEEL (QT STEEL)
16.1 General
No special joint requirements are required for QT steels, material preparations, joint configurations, bevel
angles etc., shall be carried out in accordance with section 4 of this document. Only grade A514/QT-100
steel shall be considered. Specified minimum yield 100,000 psi (698 N/mm2), maximum > 110,000 psi (758
N/mm2) UTS, for thickness up to 63mm. QT steel plate thickness > 63mm shall not be considered for
fabrication and welding unless specifically approved by company.
All welding operations shall be conducted using a welding process/welding consumable capable of
depositing hydrogen < 10 ml of hydrogen per 100g of welding metal deposited (Scale B). If the MMA
welding process is being use for welding operation the use of the basic (low hydrogen) electrode only may
be considered. The electrode shall be baked/dried in accordance with manufactures recommendations and
the approval consumable procedure (refer to section 8 of this document).
Note: all basic electrodes shall be issued in quivers (hot boxes) at temperature between 700C to 900C; all
returned electrodes shall not be re-baked.
If the SAW welding process is being used only agglomerated-high basic fluxes shall considered. All flux
treatments shall be carried out in accordance with the manufacture’s recommendations and approved
consumable procedure (refer to section8 of this document)
Note: When using SAW on QT steel the flux recycling shall only permitted to ratio of 50% new to 50% old.
When welding QT steel with MMA welding process the electrode must match the material UTS value as
close as possible, only electrodes depositing between 110,000 psi UTS (AWS E11018M) to 120,000 psi UTS
(AWS A5.5 E 120 18M) value considered.
Note: Welding processes 131, 135 and 136 shall not be considered for weld QT steel.
Minimum preheat value and interpass temperature shall be as below
Table 6- Minimum preheat and interpass temperature for QT steel
Plate thickness Minimum preheat temperature Minimum interpass temperature
< 12.5 mm 250C 200C
≥12.5 to 25 mm 500C 500C
≥25 to 50 mm 750C 800C
> 50 mm 1000C 1000C
Note preheat temperature shall not exceed 1100C.
Table 6a- Minimum heat input value for QT steels. 01 cau

Preheat temperature Plate thickness
< 12.5 mm ≥12.5 to 25 mm ≥25 to 50 mm > 50 mm
250C 0.9 KJ/mm 2.24 KJ/mm 4.7 KJ/mm 6.06 KJ/mm
16.3 Non Destructive Testing requirements
No special inspection requirement are required for QT steels. All NDT requirements shall comply with
section 11 of this document. Evaluation of imperfections shall be conducted in accordance with section 6
of this document.
17. QUALIFICATION OF WELDING PROCEDURES
17.1 General
For all new welding procedure qualification tests. Contractor shall submit to company approval preliminary
welding procedure specification (pWPS) for approval before the commencement of the qualification test.
Contractor shall also submit to company a repair pWPS for all main welding procedure. In the case of
stainless steel and duplex stainless steels pre-qualified WPS’s shall under no circumstance be used. In the
case of carbon steels generally, unless approved by company pre-qualified WPS, shall not be permitted for
used. WPS’s previously used by a contractor and meeting all the requirement of this document may be
submitted to company approval. Only WPS’s approval by company shall be used
Approval and testing of welding procedure specification shall consist of the following stages.
I. The contractor shall submit to the company a detailed pWPS for all welding and repair welding
procedure specification.
II. The company shall provide approval before test commence
III. Before any production welding can commence, test weld shall be made using these procedures
under simulated site condition.
IV. The quality of the test welds shall be determined by Non-destructive and destructive testing after
the specimen have been allowed to cool to ambient temperature shall meet the less than 48
hours.
V. For the WPSs approved for use in production the test results shall meet the requirements of this
document
Note: if the test piece fail to comply with the requirements of this document, one further test piece may
be welded and subjected to the same test condition. If the second test piece fails the WPS it is to be
considered as rejected and new pWPS shall be submitted to company for approval.
01 cau
All welding procedures shall be submitted and approved by company prior to their use. This shall include
a welding procedure specification (WPS), Welding procedure approval records (WPAR), with all supporting
documents for materials, NDT and destructive testing. All company approved WPS’s using for production
welding shall be clearly displayed at all work location.
17.3 Essential variable
When any of the changes give in table 7 are made to the WPS, the WPS shall be re-qualified and fully
approved under the same conditions as the original.
Table – Change Affecting Approval- Essential Variable.

Welding process 1. From one process to another process.
2. From manual to semi-automatic or mechanized welding process or
vice - versa
Material specification Any signification change in grade and condition
Material thickness Any change in thickness of ± 20% of the minimum thickness

01 cau
Joint configuration Any change in joint configuration outside the tolerances of this
document
Filler metal type Any change from trade name and classification type
Filler metal diameter Any change in diameter used for the root pass and second pass
Any change for other runs to a large diameter.
Shielding gas and flow rate Any change
Shielding flux Any change in flux type and trade name
Electrical characteristics Any change in current type to polarity
Welding position See 17.9
Direction of welding Any change in direction
Time lapse between Any increase in time between completion of welding pass and
commencement of next pass
Partially completed joint Any changes from requirements of this document
Preheating Any change from requirements of this document
Interpass temperature Any change in temperature
Post weld heat treatment Any change from approved procedure
Welding parameter Any change by 15% in the specified of value of current, voltage, wire
feed speed, rut out length or travel speed 01 cau
17.4 Welding of test joint
Preparation and welding shall be carried out in accordance with pWPS, and under simulated production
conditions. If tack welds are to be fused in to the final joint they shall be included in the test piece. All weld
passes shall be cleaned until free from slag, and visible defects prior to the deposition of the next run. All
welding shall be inspected/monitored 100% throughout the test piece welding by both contractor and
company inspectors.
Note: all completed procedure shall be left in the as welded condition; surface dressing on the cap may
be permitted but only after visual inspection has beam carried out by company inspector.
17.5 Extent of testing
The testing to be carried out on the test pieces are both no-destructive and destructive test methods.
The test required shall be in accordance with table 8 and table 8a.
17.6 Table 8- Examination and test pieces Non-Destructive requirements.
Test Piece Extent of test Note
Butt weld Visual 100% Please refer to

Radiographic or Ultrasonic 100% figures 4 for joint
Magnetic Partial or Dye penetrant 100% configuration for
UT
T Butt joints Visual 100% Please refer to

Ultrasonic 100% figures 4 for joint
Magnetic Particle or Dye Penetrant 100% configuration for
UT
Fillet welds Visual 100%

Magnetic Particle or Dye Penetrant 100%
Other welds Visual 100% Please refer to
Radiographic or Ultrasonic 100% figures 4 for joint
Magnetic Partial or Dye penetrant 100% configuration for
UT
17.7 Table 8a- Examination and test pieces Destructive Test Requirements. 01 cau
Butt weld Transverse Tensile Test 02 specimens Impacts test are only
Transverse Bend Test 1 Root and 01 face required in the root
specimens area for all material
Impact test (Chatpy) 1 set of 3 thicknesses more than
Hardness test (Vickers) 1 specimens 12 mm and side bends
Macro examination 1 specimen to be performed.
T Butt joints Hardness test(Vickers) 1 specimen

Macro examination 1specimen
Fillet welds Hardness test (Vickers) 1 specimen
Macro examination 2 specimen
Fracture fillet test 1 specimen
Other welds Hardness test (Vickers) specimen Other tests may be

Macro examination 1specimen required by company
Note: All destructive testing shall only be carried in a company approved testing laboratory. A company
representative shall witness all destructive testing at all times.
Both plate and pipe require separate weld qualification, except for plate to pipe fillet welds which are
covered by a fillet qualification as per table 10.
17.8 Welding position
In all cases when impact tests are not required the position of the test welding qualified for a welding
positions (both pipe and plate). When impact test are required, a test piece carried out in the vertical up
position will only be qualified for vertical up welding. All other position can be qualified in one welding
position (both pipe and plate).
17.9 Joint configuration
For test pieces welded from one side only, this also qualifies joints to be welded from both side. Test pieces
welded from both sides does not qualifies joints to be welded from one side one (both plate and pipe).
For test pieces welded without backing, this also qualifies joints to be welded with backing. Test pieces
welded with backing doses not qualify joints to be made without backing.
Butt, T-Butt, fillet and other joint configurations require separate qualifications.
T butt also qualify fillet welds within the range.
17.10 Location and cutting of test specimens
All test specimens shall be either thermally or mechanically cut; if thermal is to be used at least 3 mm from
the cut edge must be removed by mechanical means. The location of test specimens shall be in accordance
with the company requirements. The dimensions of test specimens shall be in accordance with this
document.
Test specimens shall only be taken after NDT has been conducted and accepted, it is permitted to take a
test specimen in an area free from any know acceptable imperfections, detected by NDT, but these areas
must be kept as close as possible to the company requirements.
17.11 Impact testing ( Chapy V-notch)

When the impact test are required, the minimum average value of impact energy and minimum individual
values of impact energy for each group of three impact tests shall not be less than the values gives in table
9 ; this is applicable for both welding procedure and repair welding procedure approval. The test
temperature shall be the minimum design temperature. This is normally 00 C for any structure to be
installed underground, and -100C for all structures operating in an outdoor environment. High strength
materials and materials and materials with a greater thickness than 50 mm may be require lower
temperature, if required these temperatures will be specified by company . The number of sets impact
tests shall be in accordance with table 4 as of this document, the impact specimens shall machine
transverse to the weld and positioned within 2 mm of the root and 2 mm of the cap surface with the notch
located in the vertical center of weld.
The dimension of the test specimens shall be as in accordance with table.
Note: V-Notch 2 mm in depth, notch radius 0.25 mm 450 included angle.
Table 9-Impact Energy Values. 01 cau
Material thickness mm Charpy V-notch Charpy energy (Joules)
specimen size mm
Min. average value Min. individual value
>6.5 to < 10 10 x 5 29 17
≥10 to < 12.5 10 x 8 33 20
≥ 12.5 10 x 10 40 30
17.12 Tensile testing

When tensile testing is required, the tensile strength of the weld zone of each specimen shall be equal to
or not greater than 20% of that specified for the minimum tensile strength of the parent material. If the
specimens breaks in the weld metal it shall be considered acceptable providing it meets the requirements
as stated above.
If the specimen break in the parent material (outside the weld zone) it shall be considered acceptable
providing the tensile strength is not less than 90 % of specimen tensile strength of the parent material. If
none of above can be achieved the specimen shall be considered a failure.
 For parent material thickness < 12 mm the tensile test specimen shall be ground smooth (excess
weld metal removed).
 For material thickness ≥ 25 mm, excess weld metal may be left undressed.
 Test specimen dimension: length 240 mm width 25 mm, full thickness.
17.13 Macro-examination
When required, macro specimens shall be cut out transvers to the weld and shall be free from crack and
lack of fusion; all other defects shall be in accordance with section 6 of this document. Macro specimens
shall be full thickness and cut in such a way as to include weld metal, HAZ shall include unaffected parent
material. The macro specimen shall be cut, polished to P 400 paper, etched and viewed under X 5
magnification.
Note: micro specimens shall be required on certain Aluminum grade.
17.14 Hardness testing
Macro specimens shall be used for the hardness testing, the hardness specimens shall be test under a 10Kg
load, unless a load less is required for test welds with a narrow HAZ, a change load will require company
approval. The hardness impressions in the hardness test specimens shall be made in accordance with figure
1. The hardness test shall be acceptable providing meets the requirements of table 6.
Figure 1-Location for hardness testing.
3mm
3mm
3mm
3mm
17.15 Fillet Fracture Test
When required fillet fracture tests shall be made with a minimum fillet weld size to be use on construction
(minimum of two passes), fill weld size to be in accordance with this document see section 5 for more
detail. Acceptance of the fracture fillet test shall be in accordance with section 6 of this document.
Test specimen dimension: two plates in a Tee configuration 150 mm x 70 mm
17.16 Bend test
When required a face bend and root bend shall be carried out, for material over 10 mm thickness, a side
bend test shall be carried out. Both the cap & root pass shall be as welded. Any indication/rupture on the
surface under tension exceeding 2 mm shall be considered unacceptable
Test specimens shall be a minimum of 300 mm in length, 25 mm width.
Note: the bending machine former diameter shall be 4 x material thickness.
18. QUALIFICATION OF WELDERS

18.1 General
All welders shall qualified by conducting a company approved welders qualification test.
Welder qualification test shall be conducted in accordance with the applicable approved WPS and
witnessed by company inspector, contractor’s inspector and third party inspector is applicable. The
welder qualification test shall met the requirements of this document.
Contractor may submit evidence of a welder’s previous qualification for company approval; no
previously qualified welders are permitted to conduct any production welding without company
approval.
Contractor shall have qualification certificates for each qualified welder on file available for company
review. An up to date register shall be maintained of all qualified piping and structural welders
The register shall include the following:
 Welders name and identifying number
 Welding process and position for with each welder is qualified.
 Date of qualification (test date)
 WPS for which each welder is qualified.
18.3 Examination and testing
Each test piece shall be marked with a permanent marker (paint stick), the welder’s identification
number and test date; if the testing is to be done independently the examination body shall be included
All qualification test shall undergo visual and none destructives testing in accordance with this
document. Destructive test shall only be carried out on fillet welds in accordance with this document.
Note: A welder who conducted the WPQR shall automatically qualify in the process, position and
material qualified in the WPQR (assuming all the requirements are met).
18.4 Essential Variables and range of approval
The qualification range of approval for each welder shall be in accordance with this document, and any
changes in the WPS, with is considered harder to weld than the welder is qualified for, shall undergo a
new qualification test, the welder shall only be qualified on the product type of the test piece (plate or
pipe)
The qualification range of each welder shall as follows:

18.5 Table 10- Essential variable
Variable –essential Change affecting approval
Welding process 1. Welder is qualified only in the process, which was used in the
qualification tests. However 136 qualifies 135 also within the
same range of approval
2. Separate qualification in various processes, qualifies for their
combinations also.
Material specification 1. Any change in material group except that

a) Qualification in group 3 qualifies group 1
b) Qualification in group 5 (Q&T steel) qualifies group 1
Material thickness 1. T≤ 5 mm qualifies T to 2T in mm
2. T> 5 mm but ≤ 15 mm qualifies 5 mm to 2T in mm
3. T> 15 mm qualifies for all thickness
1 cau
Plate-Pipe-other 1. Plate qualification for plate only
2. Pipe qualifies plate, pipe and also plate to pipe joints
3. For all other components, joints separate qualification in
necessary
Joint configuration 1. Change from fillet to butt weld

2. Deletion of a backing strip
Filler metal type 1. Change from rutile to LH type electrode

01 cau
2. Change from cellulosic to other types or vice versa
3. Change from fused flux to agglomerated flux or vice versa
4. Cellulose electrode qualifies only that type
5. Low hydrogen electrode qualifies for rutile electrodes also
6. Solid wire qualifies metal cored but not flux cored
7. Flux cored qualifies only flux cored
Filler metal diameter 1. Any change in diameter of the electrode, filler wire by more than
50% for the root run
01 Cau
Shielding gas and flow rate 1. Change from active gas to insert gas or vice versa
2. Any increase or decrease in gas flow rate by more than 50%
Shielding gas 1. Change from fusion flux to agglomerated flux or vice versa
Electrical Characteristics 1. Any change in any type of current of polarity
Welding position 1. Any change in position beyond that permitted by table 11
Direction of welding 1. Change from PF to PG

2. Change from HLO45 to JLO45
01 cau
3. Qualifies in PF, PG, HLO45, JL045 qualifies to that position only
Time lapse between 1. Beyond that is permitted by the WPS
Preheating 1. Changes byond that is permitted by WPS

2. Changes in the method of preheating
Interpass temperature 1. Any change beyond that is permitted by the WPS
PWHT 1. Any change beyond that is permitted by WPS
Welding parameter 1. Any change beyond that is permitted by the WPS
Pipe diameter 1. Test pipe diameter (d) less than 10 mm qualifies only (d)
2. Test pipe diameter (d) more than 10mm but less than 75 mm
qualified from (d) to (2d). 01 Cau
3. Test pipe diameter (d) more than 75 mm qualifies all pipe
diameter above 75 mm 01 cau
Techniques 1. Change from one of the following modes to other

Manual
Semi-automatic
Automatic
Mechanizes
Robotic
Each mode qualifies to that mode only
2. Addition or deletion of any sequencing technique like back-step,

skid etc.
3. Change in the metal transfer mode in MIG/MAG process
4. Single wire to multi wire and vice versa in SAW process
5. Change to autogenously welding or vice versa TIG
6. Change to pushing and vice versa in MIG/MAG/FCAW/TIG
process
7. Change from single layer to multi-layer welding; multi-layer
qualifies single layer but not vice versa
18.6 Re Test
If the qualification test piece fails in accordance with the requirements of this document, the welder
shall conduct a new test piece, if the welder fails a second time the welder shall be regarded as
incapable of welding in accordance with the approved WPS. In both cases if the failure is due to faulty
welding equipment or any other reason other than welder skill a retest shall permitted.
18.7 Period of validity
A qualified welder shall remain qualified within the range of approval for the duration of the
project/contract providing, the welder has been working in accordance with the qualification WPS for
within every 6 months 01 cau
If the welder hasn’t been working in accordance with the qualification WPS for over six months, the
welder is required to conduct a new qualification test weld.
18.8 Welding position qualification range
All welding qualification ranges shall be in accordance with table 11 of this document. All fillet welds
require a separate qualification test.
18.9 Table 11- welding position qualification range
Welding position of test piece Position qualified for butt Position qualified for fillet
welds only welds only
PA PA only PA only
PB N/A PA, PB
PC PA, PB, PC PA, PB, PC
PD N/A PA, PB, PC, PD
PE PA, PC, PE N/A
PF PA, PC, PE, PF PA, PB, PC, PD, PF
PG PG only PG only
H-LO45 (Pipe only) PA, PC, PE, PF, H-LO45 N/A

tai day Khoang co
J-LO45 ((Pipe only) PG, H-LO45 N/A vi tri 5G do do khi
han chu vi bon

18.10 Test to be conducted.
phai Qualified o vi
The following tests shall conducted for welder qualification. tro 6G
18.11 Table 12-welding qualification tests.
Type of test Butt welds pipe and plate Fillet welds Other welds
Bend test –BS EN 2 side bends for T>12 mm Not required As per required
ISO 5173 1 face and 1 root for T, 12mm
Radiographic-BS EN Yes. But not required if bend Not required --do--
ISO 17636-1 test are done
Macro examination Not required except in case of One sample to be --do--
under 10X weld made with combination of taken from start
processes stop position and
examination
Fillet fracture test Not applicable One sample to be --do--
BS EN ISO 9017 taken from start
stop position
19. POST WELD HEAT TREATMENT (PWHT)
19.1 General
PWHT shall be carried out for the purpose of stress relieving and hydrogen release. PWHT shall only be
carried in accordance with the approved procedures and only when approved by the company. All
PWHT treatments shall be carried out in a controlled manner either by used of furnace or as an
alternative by the use of heating blankets. When PWHT is to be carried out by the used of furnace, the
components shall be place centrally in the furnace as to ensure uniform heating throughout the
component thickness (at the time the component is place into furnace, the furnace temperature shall
be no less than 500 C and no greater than 2800 C.
When the heat blackest are to be used, the heating blankets shall be placed in such a way as to ensure
a uniform heating of the component and the temperature variation throughout the component is no
greater than 750C.
Note: Localized PWHT shall be carried out under any circumstance. In all cases the PWHT temperature
shall be maintained throughout the components thickness.
19.2 Temperature measurement
All temperature measurements shall be monitor by the use of thermocouples and multipoint
temperature recorders. A minimum of three thermocouples shall be used and place in such a way as to
ensure uniforms heating throughout the component. No thermocouple reading shall be more than 300C
apart throughout the PWHT heating cycle. All measuring devices being used shall have a valid certificate
of calibration (all calibration certificates shall be checked by the company inspector before the PWHT
process is carried out). All temperature recorders shall be checked by the company’s inspector to ensure
the speed of the chart being used matched that of the temperature recorder.
Note: The method of thermocouple attachments shall be approved by the company prior to the
commencement of PWHT.
19.3 Temperature and heating/cooling rates
Where dissimilar thickness existing, the thicker member shall be taken as the material thickness.
C/Mn Steels
 Maximum PWHT temperature 6500C, minimum PWHT temperature 5800C
 Material thickness > 25 m, soaking time 1 hour per 25 mm of material thickness.≤ 25 mm,
soaking time 45 minutes per 25 mm material thickness
 Heating rates; above 3200 ( controlled heating) the heating rate shall be 50000 C divided by
maximum material thickness, but no greater than 2200C per hour
 Cooling rates shall be the same as the heating rate to a temperature of 3200C (controlled cooling
rate).
Quenching and tempered steel
 When required the PWHT temperature shall be the same as for C/Mn steel except the maximum
PWHT temperature shall not exceed 6000C, heating rates shall be controlled from 3000 C,
cooling rates shall be controlled to 3000C.
 Insulation and thermocouples shall not be removes until the component’s temperature has
dropped to below 1100C.
Austenitic and duplex stainless steels
 When require the PWHT temperatures shall be the same as QT steel except the maximum PWHT
temperature shall not exceed 450oC
Note: In all case thermocouples and insulation shall not be removed until the component’s
temperature has dropped below 1100C
19.4 Reports and records

All PWHT charts shall be reviewed by all parties, Company, Contractor and where applicable third party
QC. The PWHT charts shall be filed in the contractor QA/QC department and shall be make available
for review at any time if requires
Note: no stress reliving shall be carried until all welding has been completed (including and any
repairs.)
Note: full inspection to be carried out after all PWHT has been conducted in accordance with the initial
inspection requirements of this document.

General Secification TWI-thao

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TWI WELDING & FABRICATION

TWI WELDING & FABRICATION TRAINING SPECIFICATION

MAY 30, 2018

. BS 499-1 Welding terms-glossary for welding, brazing and thermal cutting

. BS EN ISO 17637 Non-destructive examination of fusion welds-visual examination

. BS EN ISO 6520-1 Classification off geometric imperfections in metallic material-fusion welding

BS EN 10204 Metallic products-types of inspection documents

BS EN ISO 2553 Welded Brazing and soldered joints-symbolic representation on drawings

AWS A5.1 Specification for carbon steel electrodes

BS EN 1011 Welding-Recommendation for welding of metallic material

Contractor: An entity performing specific work under contract of the company

Defect: An imperfection of sufficient magnitude to warrant rejection

Imperfection: A discontinues or regularity

Indication: Evidence obtained by Non-Destructives testing

Weld: A union of pieces of metal made by welding

Welder: The operation who performs welding

Parent metal: Metal to be joined or surfaced during

Filler metal: Metal added during welding

Joint: A connection where the individual components, suitably prepared and

Arc welding current: Current passing through the electrode

Shall: Denotes a mandatory action

Should: Denotes a strongly recommended action

Table 1-Abbreviation and symbols

I Arc welding current

V Arc welding voltage

K Thermal efficiency factor

a Nominal Throat thickness of fillet weld

h Height or with imperfection

l Length of imperfection in longitudinal direction of the weld

s Nominal butt weld thickness

t Parent material thickness

z Leg length of a fillet weld

MTC Material test certification

< Less than

> Greater than

≥ Greater than or equal to

3.1 Contractor requirements

4. JOINT PREPARATION DETAIL

4.1 Base metal preparation

4.4 Assembly for welding

4.5 Temporary attachment

Note: Removal of temporary attachments by hammering or bending is not permitted.

5.2 Butt welds

The deposited fillet weld dimension shall be as below:

 Minimum=t Minimum = t x 0.7

 Maximum = t+3 mm Maximum = t + 0.5 mm

Heat input value kj/mm Temperature 0C Combine Carbon equivalent

< 0.5 1750C Any thickness < 0.45 %

≥ 0.5 < 2.0 1500C Any thickness < 0.45 %

≥ 2.0 < 4.0 1000C ≤ 80 mm < 0.45 %

≥ 4.0 < 5.0 1250C >80mm < 0.45 %

≥ 5.0 No preheat required

5.4.2 Table 2a- Preheat values

Heat input value kj/mm Temperature 0C Combine Carbon equivalent

< 0.5 1500C Any thickness < 0.45 %

≥ 0.5 < 2.0 1250C Any thickness < 0.45 %

≥ 2.0 < 4.0 750C ≤ 80 mm < 0.45 %

≥ 3.0 < 4.2 500C >80mm < 0.45 %

≥ 5.0 No preheat required

5.5 Interpass temperature

5.6 Arc trikes

5.7 Welding identification

5.8 Interruption of welding