Dev-Aad-mp-sp-jpk-1058 Rev b2 Welding and NDT of Cs Linepipe To Bs 4515-1 (2004)

CLIENT
PROJECT
ANDREW DEVELOPMENT PROJECT

&
DEVENICK DEVELOPMENT PROJECT
DOCUMENT TYPE
SPECIFICATION
TITLE
PROJECT NO.
06-3022.01 / 06-2999.01
REF.
ANDREW: 06-3022-01-K-1-013
DEVENICK: 06-2999-01-K-1-015
WELDING AND NDT OF CARBON STEEL

LINEPIPE TO BS 4515-1(2004)
NO. OF SHEETS
77
ANDREW
DOCUMENT NO.
DEV-AAD-MP-SP-JPK-1058
DEVENICK
DOCUMENT NO.
DEV-DEV-MP-SP-JPK-1072
STAMP
B2
09/09/2009
RE-ISSUED FOR RFP
DC
SE
ACH
CBN
B1
28/08/2009
ISSUED FOR RFP
DC
CF
ACH
RR
A2
28/07/2009
RE-ISSUED FOR COMMENT
DC
AL
AH
CBN
A1
30/03/2009
ISSUED FOR COMMENT
SE
GAS
AWL
CBN
REV
DATE
REVISION
BY
CHK
LE
QA
PM
COMMENTS SHEET
REVISION
A1
DATE
30/03/2009
COMMENTS
A2
28/07/2009
RE-ISSUED FOR COMMENT.

Format amended to incorporate ADD and Devenick projects.
Specification revised to incorporate client comments and a
statement added relating to ETP compliance.
B1
28/08/2009
ISSUED FOR RFP

Revised as per client comments.
B2
09/09/2009
RE-ISSUED FOR RFP

Section 2.0 Revised technical deviation number.
Section 4.2s Revised paragraph to include welding of spools.
Section 8.3.6 Revised paragraph pertaining to post test
metallography.
Section 12.1 Revised technical content.
Section 13.1 Revised technical content.
ISSUED FOR COMMENT
DEV-AAD-MP-SP-JPK-1058 Rev B2
DEV-DEV-MP-SP-JPK-1072 Rev B2
BP Exploration Operating Company Ltd

Andrew & Devenick Development Projects
Welding and NDT of Carbon Steel Linepipe to BS 4515-1
(2004)
WELDING AND NDT OF CARBON STEEL LINEPIPE TO BS 4515-1(2004)

Table of Contents
U
1.0
INTRODUCTION ........................................................................................................4
1.1
Purpose of Document .....................................................................................................4
1.2
Safety..............................................................................................................................4
1.3
Definitions .......................................................................................................................4
1.4
Abbreviations ..................................................................................................................5
1.5
HSEQ for Pipeline Welding Operations..........................................................................7
1.6
Pre-Production Consultation...........................................................................................8
1.7
Duties of the Contractor..................................................................................................8
1.8
Quality Conformance ......................................................................................................8
1.9
Records...........................................................................................................................9
1.10
Contractors Personnel ...................................................................................................9
2.0
NORMATIVE REFERENCES...................................................................................12
2.1
Specification Compliance .............................................................................................12
2.2
Conflict of Information...................................................................................................12
2.3
Revisions ......................................................................................................................13
2.4
Referenced Documents................................................................................................13
2.5
Codes and Standards ...................................................................................................13
3.0
TERMS AND DEFINITIONS.....................................................................................16
3.1
General .........................................................................................................................16
4.0
INFORMATION AND REQUIREMENTS TO BE APPROVED AND DOCUMENTED17
4.1
Information to be Supplied by the Company ................................................................17
4.2
Items subject to approval by the Company ..................................................................20
5.0
EQUIPMENT ............................................................................................................26
6.0
WELDING PROCESSES .........................................................................................27
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6.1
General .........................................................................................................................27
6.2
Automatic (Mechanised) Welding.................................................................................27
7.0
WELDING CONSUMABLES....................................................................................29
7.1
General .........................................................................................................................29
7.2
Storage and Handling ...................................................................................................29
8.0
TESTING, QUALIFICATION AND ACCEPTANCE OF WELDING PROCEDURES

FOR BUTT WELDS .................................................................................................31
8.1
General .........................................................................................................................31
8.2
Changes Affecting Qualification and Approval (Essential Variables) of butt welds .....35
8.3
Destructive Testing .......................................................................................................39
9.0
TESTING, QUALIFICATION AND APPLICATION OF WELDING PROCEDURE

FOR FILLET WELDING ...........................................................................................46
9.1
Non-Destructive Testing of Fillet Welds .......................................................................46
9.2
Destructive Testing of Fillet Welds ...............................................................................46
10.0
TESTING, QUALIFICATION AND APPROVAL OF WELDERS..............................47
10.1
General .........................................................................................................................47
10.2
Butt Joints .....................................................................................................................47
10.4
Fillet Welds for Sleeves, Sockets, Slip-on Flanges or Other Attachments ..................48
10.5
Changes Affecting Qualification and Acceptance (Essential Variables) of Welders....48
10.6
Non-Destructive Testing ...............................................................................................48
10.7
Destructive Testing .......................................................................................................48
11.0
PRODUCTION WELDING .......................................................................................50
11.1
Proximity of Welds ........................................................................................................50
11.2
Pipe End Preparation....................................................................................................50
11.3
Fusion Faces ................................................................................................................51
11.4
Alignment ......................................................................................................................51
11.5
Line-Up Clamps and Pipe Supports .............................................................................51

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11.6
Tack Welds ...................................................................................................................52
11.8
Stray Arcs .....................................................................................................................53
11.9
Weather Conditions ......................................................................................................54
11.10 Preheating and Post Weld Heat Treatment..................................................................54

11.11 Branches.......................................................................................................................56
11.12 Inter-run Cleaning .........................................................................................................57
11.13 Partially Completed Joints ............................................................................................57
11.14 Fillet Weld Attachments ................................................................................................57
11.15 Records.........................................................................................................................57
12.0
INSPECTION AND TESTING OF WELDS ..............................................................59
12.1
General .........................................................................................................................59
12.2
Personnel Qualification.................................................................................................61
12.4
Radiographic Testing....................................................................................................61
12.5
Manual Ultrasonic Testing ............................................................................................66
12.6
Automatic Ultrasonic Testing ........................................................................................67
12.7
Magnetic Particle Testing .............................................................................................67
13.0
ACCEPTANCE AND RECTIFICATION OF WELDS ...............................................69
13.1
Non-Destructive Testing Acceptance Criteria ..............................................................69
13.2
Rectification of Welds ...................................................................................................71
ANNEX H ADDITIONAL REQUIREMENTS FOR PIPELINES SUBJECT TO HIGH

STRAIN LEVELS .....................................................................................................73
H1
Introduction ...................................................................................................................73
H.2
General .........................................................................................................................73
H.3
Weld Procedure Qualification Testing ..........................................................................73
H.4
Production Welding.......................................................................................................75
Page 3 of 75

(2004)
1.0
INTRODUCTION
0B
1.1
Purpose of Document
14B
This specification when read in conjunction with the referenced standards, specifications,
other listed documents and relevant data sheets, defines the minimum technical
requirements for the field welding and NDT of carbon steel linepipe in accordance with BS
4515-1: 2004 for sour-service conditions (applicable to steel grades up to X65).
Paragraph numbers in this specification correspond to BS 4515-1: 2004.
Modifications to BS4515-1: 2004 are identified as Add or Modified to Read in this
U
specification.
1.2
Safety
15B
All risks to personnel and the environment resulting from the Andrew and Devenick
Projects should be As Low As Reasonably Practicable (ALARP). Safety is the primary
consideration during design and all risks associated with the design shall be minimized by
adhering to the relevant governing design codes, and COMPANY International procedural
requirements.
1.3
Definitions
16B
Approval
Consent given in writing, on behalf of the COMPANY

in advance of an event, by a person with appropriate
authority.
Approval by the COMPANY does not
relieve the CONTRACTOR from any of its contractual

obligations nor from having to make good any part of
the item to be delivered found to be defective
subsequent to COMPANYs approval.
COMPANY
BP Exploration Operating Company Ltd or any of its

subsidiaries or representative agents.
CONTRACTOR
The Party contracted by the COMPANY to be

responsible for the welding and NDT.
Linepipe
Generic statement covering spools, flanges and

fittings.
Shall
Indicates mandatory requirements.
Should
Indicates preferred course of action.
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SUPPLIER/MANUFACTURER
A party which supplies materials, equipment or

services to the CONTRACTOR.
1.4
Abbreviations
17B
AC
Alternating Current
ACCP
ASNT Central Certification Programme
ALARP
As Low as Reasonably Practicable
Ar
Argon
ANSI
American National Standards Institute
ASNT
American Society for Non-Destructive Testing
ASTM
American Society for Testing and Materials
AWS
American Welding Society
BAM
Federal Institute for Materials Research and Testing (Germany)
BGAS-CSWIP -
British Gas Approval Scheme Certification Scheme for Welding and

Inspection Personnel
BGAS Transco-
A qualified and certification system, formerly known as ERS, for

Pipeline Inspection Personnel, Originally Instituted and Run by the
Former British Gas Engineering Research Station, Killingworth, UK.
BINDT
British Institute of Non-Destructive Testing
BS
British Standard
C Eng
Chartered Engineer
CEIIW
Carbon Equivalent (International Institute of Welding Formula)
CO2
Carbon Dioxide
CSWIP
Certification Scheme for Welding and Inspection Personnel
CVN
Charpy V Notch
DC
Direct Current
Dipl Ing
Diploma Ingenieur (Europe)
DWDI
Double Wall Double Image
DWSI
Double Wall Single Image
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ECA
Engineering Critical Assessment
EN
European Norm
EWE
European Welding Engineer
FDIS
Document Under Review
FL
Fusion Line
GMAW
Gas Metal Arc Welding
GSFCAW
Gas Shielded Flux Cored Arc Welding
GTAW
Gas Tungsten Arc Welding
HAZ
Heat Affected Zone
HSE
Heath and Safety Executive
HSEQ
Health, Safety, Environmental and Quality
HV
Vickers Hardness
ID
Inside Diameter
IIW
International Institute of Welding
IQI
Image Quality Indicator
ISO
International Standards Organisation
IWE
International Welding Engineer
MDT
Minimum Design Temperature
mm
Millimetres
MPE
Magnetic Particle Examination
MUT
Manual Ultrasonic Testing
NDT
Non-Destructive Testing
NIST
National Institute of Standards and Technology (USA)
O2
Oxygen
OD
Outside Diameter
Pb
Lead
Pcm
Ito-Bessyo Formula Carbon Equivalent
Page 6 of 75

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PCN
Personnel Certification in Non-Destructive Testing
PE
Professional Engineer
PGMAW
Pulsed Gas Metal Arc Welding
PQR
Procedure Qualification Record
pWPS
Preliminary Welding Procedure Specification
RE
Radiographic Examination
RMS
Root Mean Square
SAW
Submerged Arc Welding
SI
1.5
Statutory Instrument
SMAW
Shielded Metal Arc Welding
SMYS
Specified Minimum Yield Strength
SWE
Single Wall Examination
SWV
Single Wall Viewing
SWSI
Single Wall Single Image
TWI
The Welding Institute (UK)
UT
Ultrasonic Testing
VE
Visual Examination
WPS
Welding Procedure Specification
WPQ
Welding Procedure Qualification
WPQR
Welding Procedure Qualification Record
WPQT
Welding Procedure Qualification Test
HSEQ for Pipeline Welding Operations

18B
Welding, cutting, NDT, and associated operations shall be undertaken in a safe manner
and with due regard to individual health and safety, and the minimisation of environmental
impact consistent with COMPANY requirements. Welding, cutting, NDT activities, and
associated operations shall feature in CONTRACTORS operational safety planning and in
the safety audit schedule. ANSI Z49.1 or similar codes should be followed.
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(2004)
Measures shall be taken to ensure adequate ventilation and control the quality of breathing
air during welding operations.
As a minimum, radiography operations shall conform to the Ionising Radiation Regulations
1999 (SI 1999 No. 3232) and the Approved Code of Practice and Guidance Working with
Ionising Radiation: Ionising Regulations 1999.
Environmental guidance shall be taken from EN 14717 when undertaking welding and its
associated processes.
1.6
Pre-Production Consultation
19B
Pre-production meetings shall be held with the COMPANY and any appropriate third-party
inspection personnel in order to ensure that all parties fully understand the requirements.
These meetings shall be held before welding procedure qualification testing and before
commencement of fabrication.
The COMPANY Welding Engineer shall be consulted at the following stages:
1. During bid evaluation to agree the basic welding and NDT methods proposed and to
advise on acceptability.
2. Before weld procedure qualification for approval of the proposed welding procedures
(pWPS).
3. Before production welding for approval of the final WPS.
Duties of the Contractor
1.7
20B
Construction, welding and pipe-lay shall be carried out by a well trained and qualified
workforce employing reliable, modern, and well maintained equipment and shall also be fully
compliant with safe and environmentally sound working practices at all times.
Unless advised otherwise by COMPANY welding and associated equipment including, but
not limited to: heating equipment, fluxes, gases, filler metals, welding units, mechanical
handling, testing equipment, and NDT equipment shall be supplied and appropriately
calibrated.
Be responsible for the compliance of sub-contractors with this specification.
1.8
Quality Conformance
21B
The CONTRACTOR shall demonstrate to the satisfaction of the COMPANY that his activities
within the scope of this document comply with ISO 3834 Parts 1 & 2 and the relevant
sections of BS EN ISO 9001.
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(2004)
Prior to the commencement of work, the CONTRACTOR shall submit to the COMPANY for
review and approval, a Quality Plan and procedural specifications, which shall include
procedures for storage and control of materials and welding consumables, welding and
non-destructive testing and supporting qualification records. The Quality Plan shall define
all sub-contractors involvement within the work.
Names of individuals Welding Engineers / Welding Inspectors responsible for implementation
of quality assurance and quality control functions shall be included.
Records
1.9
2B
Documents required by this specification shall be gathered, collated, indexed, stored, and
finally presented to COMPANY for secure long term storage.
A log identifying, by number, each pipe or fitting and identifying the weld numbers joining
them to other items shall be compiled.
Each circumferential weld (whether a field joint or shop-made weld) shall be allocated a
unique number, which shall be used for reference to the weld in reports and test documents.
All documentation shall be available in an agreed, good quality, electronic format.
Contractors Personnel
1.10
23B
1.10.1 General
73B
Personnel associated with welding including engineers, welders, welding operators,

welding inspectors and non-destructive testing technicians shall be properly trained and
qualified to recognised industry standards by examination and/or by individual test.
1.10.2 Welding Engineers
74B
A competent and suitably qualified Welding Engineer shall be employed. The Welding
Engineer shall be responsible for the technical aspects of all welding operations including
the following:
Selection of welding processes, equipment and consumables;
Preparation and qualification of welding procedures;
Qualification of welders;
Providing technical oversight of the production welding;
Liaison with the COMPANY and the NDT SUB-CONTRACTORS.
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The minimum experience and qualification level for the Welding Engineer should be:
Chartered Engineer (C.Eng / Dipl Ing) holding as a minimum a degree in engineering,
metallurgy or materials science and having specialised training in welding technology. The
requirements of ISO 14731(FDIS) / EN 719 should be met as demonstrated by the
European Welding Engineer (EWE) or International Welding Engineer (IWE) qualification.
Professional Membership of The Welding Institute (UK) is desirable and a minimum of 5
years relevant experience in the pipeline welding or fabrication industry is deemed
essential.
1.10.3 Welding Inspectors
75B
Competent and certificated welding inspection personnel shall be employed in sufficient

numbers to ensure that all welding related activities are adequately inspected.
Welding Inspectors shall have a sound knowledge of welding processes and their
application to pipeline welding, and possess the knowledge and skills to carry out the tasks
given in the accepted Quality Plan, including those necessary for the following:
Conduct of routine inspections and checks on site or at suppliers in a systematic

manner;
Production of accurate records and reports.
Welding Inspectors shall, as a minimum, hold current certification to any of the following
standards:
CSWIP (TWI, UK) Welding Inspector;
BGAS-CSWIP (TWI, UK) Welding Inspector;
PCN (BINDT, UK) Weld Inspection Level 2;
AWS QC1 (1996 or later edition) Certified Welding Inspector (CWI).
Alternative Welding Inspector certification is unacceptable unless accepted by the

COMPANY.
A Senior Welding Inspector shall be employed to supervise the work of the welding
inspectors. The role of senior welding inspector requires at least 10 years relevant
experience and sound knowledge of welding processes and their application. Formal
engineering training through apprenticeship and technical college education are required.
Senior Welding Inspectors shall, as a minimum, hold current certification to any of the
following standards:
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CSWIP (TWI, UK) Senior Welding Inspector;
BGAS-CSWIP (TWI, UK) Senior Welding Inspector (SWI) or Senior Pipeline

Inspector (SPI);
PCN (BINDT, UK) Weld Inspection Level 3;
AWS QC1 (1996 or later edition) Senior Certified Welding Inspector (SCWI).
Page 11 of 75

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2.0
NORMATIVE REFERENCES
1B
2.1
Specification Compliance
24B
This specification has been written to be in full compliance with BP GIS 43-333 Guidance on
Industry Standard BS 4515-1 2004 for Pipeline Welding. Non-applicable paragraphs and
clauses of this GIS to this specification are detailed within technical deviation (JPK-DR-002).
CONTRACTOR shall be in complete compliance with the requirements of the following GIS
documents unless instructed otherwise by this specification:
GIS 43-311
Longitudinal or Helical Seam Submerged Arc Welded Linepipe in

Grades up to X80 Supplement to API 5L, 43rd Edition 30th May
2007.
GIS 43-312
High Frequency Induction (HFI) or Electric Resistance Welded

(ERW) Linepipe in Grades up to X70 - Supplement to API 5L, 43rd
Edition 30th May 2007.
GIS 43-313
Seamless Linepipe in Grades up to X80 Supplement to API 5L,

43rd Edition 30th May 2007.
GIS 43-339
Automated Ultrasonic Testing of Pipeline Girth Welds 30th October

2007.
GIS 18-012
Guidance on Industry Standard for Storage and Control of Welding

Consumables 31st October 2007.
Note: Within the GIS documents CONTRACTOR shall replace the words must and
should with shall to read as mandatory requirements. Any shall or must in commentary
(text in blue italics) does not specify an ETP requirement.
The CONTRACTOR is responsible for the quality of materials and workmanship in
performance of the work.
2.2
Conflict of Information
25B
In the event of any conflict, inconsistency or ambiguity between the contract documents, this
Specification or any other specification and associated data sheets, or with any of the
applicable codes, standards and regulations the CONTRACTOR shall immediately inform the
COMPANY in writing and receive written clarification from the COMPANY before preceding
with the work.
Page 12 of 75

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2.2.1
Project Documents
76B
The following documents pertaining to the Andrew and Devenick Projects are related or
applicable to this Specification:
DEV-AAD-MP-DS-JPK-1055 /
DEV-DEV-MP-DS-JPK-1070
Carbon Steel Induction Bends Specification
DEV-AAD-MP-SP-JPK-1056 /
Specification for Carbon Steel Flanges, Fittings and

Bulkheads
Methanol Injection Linepipe Data Sheet
Gas Lift Linepipe Data Sheet
DEV-AAD-ME-SP-JPK-1096 /
Specification for Subsea Valves
Revisions
2.3
26B
The latest issues for the relevant standards, codes, statutory regulations and specifications
referenced herein shall be applied to the work.
Referenced Documents
2.4
27B
It is the responsibility of the CONTRACTOR to ensure that he has received from the
COMPANY all specifications, etc which are referenced within applicable specifications to
enable him to understand and comply with all aspects of the work to be performed for the
COMPANY.
Codes and Standards
2.5
28B
The CONTRACTOR is responsible for the quality of the work and compliance with the
requirements
of
the
Specifications as listed.
applicable
International
Codes,
Statutory
Regulations
and
The following Codes, Standards and Specifications with their
latest published amendments shall apply.

Statement does not apply to BS4515-1: 2004.
2.5.1
American National Standards Institute (ANSI) / American Welding Society (AWS)

7B
ANSI/AWS A4.3
Standard Methods for Determination of the Diffusible

Hydrogen Content of Martensitic, Bainitic, and Ferritic Steel
Weld Metal Produced by Arc Welding
ANSI/AWS A5.32
Specification for Welding Shielding Gases
ANSI/AWS C5.3
Recommended Practices for Air Carbon Arc Gouging and

Cutting
Page 13 of 75

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Standard for AWS Certification of Welding Inspectors
ANSI/AWS Z49.1
Safety in Welding Cutting, and Allied Processes
2.5.2
ANSI/AWS QC1
British Standards and Regulations

78B
BS 4515-1 (2004)
Specification for welding of steel pipelines on land and

offshore. Carbon and carbon manganese steel pipelines
BS EN 288:9
Specification and Approval of Welding Procedures for Metallic

Materials
BS EN 1043
Destructive Testing on Welds in Metallic Materials- Hardness

Testing Part 1 Hardness Tests on Welded Joints
BS EN 10045
Charpy Impact Testing of Metallic Materials
BS EN 10204
Metallic Products Types of Inspection Document
BS EN 12074
Welding consumables. Quality requirements for manufacture,

supply and distribution of consumables for welding and allied
processes
BS EN 1435
Non-Destructive
Examination
of
Welds.
Radiographic
Examination of Welded Joints

BS EN ISO 14175
Welding consumables. Gases and gas mixtures for fusion

welding and allied processes
BS EN 14717
Welding and allied processes. Environmental check list
BS EN ISO 15609-1
Specification and qualification of welding procedures for

metallic materials. Welding procedure specification. Arc
welding
2.5.3
BS EN ISO 9001
Quality Management Systems Requirements
SI 1999 No. 3232
The Ionising Radiations Regulations 1999
International Standards Organisation

79B
ISO 2504
Radiography of Welds and Viewing Conditions for Films

Utilisation of Recommended Patterns of Image Quality
Indicators (IQIs)
ISO 3690
Welding and Allied Processes Determination of Hydrogen

Content in Ferritic Steel Arc Welds
Page 14 of 75

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ISO 3834
Quality Requirements for Welding. Fusion Welding of Metallic

Materials, Parts 1-6.
ISO 5173
Destructive Tests on Welds in Metallic Materials Bend Tests
ISO 5580
Non-Destructive Testing Industrial Radiographic Illuminators

Minimum Requirements
ISO 6507-1
Metallic Materials. Vickers Hardness Test. Test Method
ISO 11699-1
Non-Destructive Testing Industrial Radiographic Films

Part 1:
Classification
of
Film
Systems
for
Industrial
Radiography
ISO 14731/FDIS
Welding Co-Ordination Tasks and Responsibilities (Under

Revision)
ISO 17636
Non-Destructive Testing of Welds- Radiographic Testing of

Fusion Welded Joints
ISO 17638
2.5.4
Non-Destructive Testing of Welds- Magnetic Particle Testing
Others
80B
ASTM E1815-96
Standard Test Method for Classification of Film Systems for

Industrial Radiography
Page 15 of 75

(2004)
3.0
TERMS AND DEFINITIONS

2B
3.1
General
29B
This document shall be read hereafter in conjunction with BS 4515-1; 2004 as clarified,
amended or supplemented below.
The clause numbers used reflect correspondingly
numbered sections within.

The following terms shall be Modified to Read:
U
3.5 Contractor
See 1.3
3.6 Employer
For Employer read COMPANY
Add:
U
3.26. Batch (lot)

A single heat of filler wire, a single blend of flux, or for covered electrodes or cored wire, the
combination of a single heat of cored wire with a single dry blend of flux cover or core.
3.27. COMPANY
See 1.3
3.28. Quality plan
Document specifying which procedures and associated resources shall be applied by
whom and when to a specific project, product, process or contract
Page 16 of 75

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4.0
4.1
INFORMATION AND REQUIREMENTS TO BE APPROVED AND DOCUMENTED

3B
Information to be Supplied by the Company

30B
Information to be supplied by the COMPANY is given as additions or clarifications to the

appropriate Sections of BS 4515-1: 2004.
Clause
BS 4515-1: 2004
Supplement
Whether batch testing of

electrodes and filler materials is
required.
Batch testing of electrodes and filler material is

required. See sections 7.2.1 & 7.2.2 of this
specification.
Production welding shall utilise the same
batches of consumables as those used for
welding procedure qualification.
Whether specific compositional

controls are to be applied to the
deposited weld metal
All consumables will be proposed by

CONTRACTOR and subject to COMPANY
approval. See Section 4.2a and 7.1 of this
specification.
The degree of yield strength

overmatching for welds in pipe
materials where installation
methods
involve
plastic
deformation of the pipe or for
welds in pipe of specified
minimum
yield
strength
(SMYS) 500-550N/mm2.
The yield strength of welding consumables shall

overmatch SMYS of the respective base
material by 80MPa-200MPa. See Section 8.3.2
of this specification.
Whether different batches of

electrodes and filler materials
are
to
be
individually
identifiable and completely
separated.
Different batches of electrodes and filler

materials shall be individually identified and
completely separated.
The type and number of retests required in the event of

failure during testing and
qualification
of
welding
procedures.
Re-testing is permitted subject to COMPANY

approval, provided the CONTRACTOR can
demonstrate that the test failure was due to error
in test procedure, specimen preparation or
defect in the mechanical test specimen.
Whether an alternative location

is specified for the excavation
location for the repair weld test.
No alternative locations are required for repair

test weld.
Whether strain ageing data

and/or additional tests are
required as the basis for
welding procedure approval for
pipe-reeling.
See Annex H of this specification. The use of

historical data may be permitted subject to
meeting the requirements of this specification
and if agreed by the COMPANY.
Page 17 of 75

(2004)
Clause
BS 4515-1: 2004
Supplement
Whether specimens should be

allowed to cool for a duration
other than 24 hours before
testing.
Specimens shall be allowed to cool for 24 hours

before testing.
The method of weld tensile

testing when a minimum weld
metal
yield
strength
requirement is specified.
Tensile testing shall be in accordance with BS

EN 288-9 and sections 8.2, 8.3 and 8.4 of BS
4515-1. No flattening of test pieces shall be
permitted. See section 8.3.2 of this specification.
Charpy toughness and test

temperature for conditions
other than pipe and wall
thicknesses up to and including
25mm,
minimum
design
temperatures not lower than 10C and pipe material with a
specified
minimum
yield
strength not greater than
550N/mm2.
Impact requirements as per Section 8.3.5 of BS

4515-1 and as modified by this specification.
Whether
additional
NDT
methods for fillet welds apply.
There are no additional NDT requirements to

visual and MPE for fillet welds.
Whether the hardness values

of test specimens exceed those
given in Table 4.
The hardness shall not exceed the sour-service

criteria of Table 3 of BS EN 288-9.
Whether a proposed change to

a welding procedure will
require re-qualification of the
welders.
All
changes
from
approved
weld
procedures/specifications shall be subject to
prior written COMPANY approval and, where
necessary and appropriate, to the successful requalification of WPS and/or welders.
Whether prevailing weather

conditions are such that quality
of the completed weld would be
impaired.
All welding shall be performed under conditions

where protection from adverse weather
conditions is assured.
The method(s) and frequency

of visual inspection and nondestructive testing.
See section 12.1 of this specification.
Whether completed welds are

to be ground.
Completed welds may be ground when agreed

with the COMPANY to facilitate NDT provided
the wall thickness complies with the minimum
specified limit. Grinding shall ensure no stress
raisers and a smooth transition exists.
Page 18 of 75

(2004)
Clause
BS 4515-1: 2004
Supplement
Whether alternative techniques

are to be used for radiographic
testing of welded butt joints.
See section 12.4.1 of this specification.
Ultrasonic testing acceptance

criteria
Whether NDT acceptance

criteria are to be based on
quality control or engineering
critical assessment.
The use of alternative acceptance standards for

girth welds shall be subject to COMPANY
approval before contract award. See section
13.1.3 of this specification.
Whether the maximum planar

defect dimension is to be less
than 25mm.
No planar defects shall be permitted in the weld

preparation area.
Whether a more stringent limit

for root penetration is required.
A more stringent limit for root penetration is not

required except for pipe less than 6 inch NB for
which this shall be limited to 1.5mm maximum.
Whether different hardness

limits for anode bonding joints
are required for anode bonding
joints.
Hardness shall be in accordance with the limits

outlined within this specification.
The composition and thickness

of the pipe corrosion resistant
alloy (CRA) layer.
Not applicable.
The
method
of
linepipe
manufacture, including seal
weld and longitudinal weld
details where these items are
present in CRA clad and lined
pipelines.
Not applicable.
The maximum oxygen content

of backing gas during welding
or the corrosion tests that the
weld is required to pass.
Not applicable.
Whether
the
strength
contribution of the CRA layer
has been used in the design.
Not applicable.
aa
Whether additional hardness

traverses are required in CRA
clad and lined pipelines.
Not applicable.
ab
Hardness limits for CRA

portions of the weldment.
Not applicable
Page 19 of 75

(2004)
Clause
BS 4515-1: 2004
Supplement
ac
The composition limits for

chemical analysis of the weld in
CRA clad and lined pipelines.
Not applicable.
ad
Whether a chemical analysis is

required
for
seal
weld
qualification CRA clad and
lined pipelines.
Not applicable.
ae
Whether internal weld or

cutting spatter in CRA clad and
lined
pipelines
requires
removal and the method to be
used.
Not applicable.
af
Whether weld root acceptance

criteria more onerous than
those in Table 5 are required in
Not applicable.
ag
Whether full penetration repairs

are permitted in CRA clad and
lined pipelines.
Not applicable.
Whether pre-qualification trials

of welding processes are
required
See section 6 of this specification
ai
Whether additional hardness

surveys on macro-sections are
required
See section 8.3.4 of this specification
aj
Whether additional Charpy test

locations are required
See section 8.3.5 of this specification
Add:
ah
U
4.2
Items subject to approval by the Company

31B
The items to be approved by the COMPANY are included in this Specification as additions or
clarifications or amendments to the appropriate Sections of BS 4515-1: 2004.
Clause
BS 4515-1: 2004
Supplement
Welding consumables to be
used.
The maximum Ni content of the as-deposited

weld metal (root) shall be in the range of 0.6%
to 1.0%.
Page 20 of 75

(2004)
Clause
BS 4515-1: 2004
Supplement
The definition of a batch when

batch testing of electrodes and
filler materials is required.
Batch: a single heat of filler wire, a single blend

of flux, or for covered electrodes or cored wire,
the combination of a single heat of cored wire
with a single dry blend of flux cover or core.
The tensile strength of weld

metal for joints between
dissimilar materials, if other
than that of the higher strength
parent metal.
In the case of dissimilar metal welds, the weld

metal shall have strength at least equal to that
of the lower strength parent material.
The type and number of retests of a welding procedure

when they are permitted.
Re-tests of a welding procedure shall only be

permitted for minor deviations to specification
requirements at the discretion of the
COMPANY.
Test weld production on pipes

shorter than full length.
Any proposal to carry out the test welds on

pipes less than 12m long shall be subject to
COMPANY approval.
Use of roll welding.
The use of roll welding shall not be permitted,

unless agreed by COMPANY.
Use of a test weld for

destructive testing or rewelding to the same procedure
following NDT failure.
An explanation shall be given to the satisfaction

of the COMPANY for the presence of any flaws
in the test weld outside the specified
acceptance criteria before approval is given for
the test piece to be subject to destructive
testing.
Welding procedure qualification

test details and welding
procedure specification for
production welding.
Applicable.
Simulation of a fillet weld joint

using flat plate fillet welds.
The simulation of a fillet weld joint using flat

plate welds shall not be permitted.
Alternative methods of NDT for

welder test piece.
Giving a welder a second

opportunity to gain approval.
All documentation relating to
welder qualification tests.
Page 21 of 75
All documentation relating to welder qualification

tests shall be approved by the COMPANY; prior
to the welder being allowed to commence
production work.
Welder records shall be
included within the as-built documentation and
issued to COMPANY in electronic format.
Welder records shall be kept for a period of ten
years.

(2004)
Clause
BS 4515-1: 2004
Supplement
Use of manual thermal cutting

for pipe end bevelling and the
ability of the operator.
Manual thermal cutting shall not be used for

bevelling the pipe ends for welding.
The blending out by grinding of

minor imperfections within the
joint preparation area.
The joint shall be re-prepared in the event of

small score marks, indentations, etc being
present within the joint preparation area.
Method of marking datum

points on a joint for ultrasonic
testing.
The method of marking ultrasonic datum points

shall be included in the ultrasonic procedure for
weld examination and shall be subject to
APPROVAL by the COMPANY.
Method of obtaining minimum

misalignment,
other
than
rotation of the pipes.
Only rotation of the pipes shall be used for

obtaining minimum misalignment.
Method of alignment of pipes

other than internal line-up
clamps.
Alignment methods other than the use of

internal line-up clamp shall be subject to
approval by the COMPANY. See section 11.5.1
of this specification.
The stage at which line-up

clamps are removed.
Internal line-up clamps shall not be removed

until after completion of the root run and hot
pass. External line-up clamps shall not be
removed until at least 50% of the circumference
of the joint uniformly spaced have been filled, as
described in Section 11.5.1 of this specification.
The stage at which the pipe is

lowered onto skids or support
is removed from fittings.
For subsea spools, pipes shall not be moved or

lifted until at least a 1/3rd of the weld has been
deposited, unless it can be demonstrated as
acceptable through calculation.
Repair of places where stray

arcs have occurred.
Areas showing stray arcs may only be repaired

by mechanical removal of the defective
material, blending of the excavation, checking
by MPE followed by confirmation that pipe or
fitting wall thickness is within specified
tolerances. Repair by welding shall not be
permitted. Pipes not maintaining minimum wall
thickness shall be rejected.
Means of applying pre-heat.
Approval of the proposed method of pre-heating

shall be included with review of the weld
procedure specification. See section 11.10.2 of
this specification.
Page 22 of 75

(2004)
Clause
BS 4515-1: 2004
Supplement
Methods of attaching
removing thermocouples.
and
Thermocouples shall be attached to the pipe by

the capacitance discharge method. After use,
the thermocouples junctions shall be removed
by grinding and the area of attachment shall be
examined by MPE. Methods of thermocouple
attachment and removal shall be subject to
review by the COMPANY.
The welding procedure for

branch connections where the
angle between the main and
branch is less than 60.
A branch simulation test weld is required for

branch welds where the angle between the
main line and branch is less than 60C.
Written ultrasonic examination

procedure for pipe material
around a planned cut-out.
Procedure to be APPROVED by COMPANY, if

applicable.
All
non-destructive
testing
procedures to be used.
All NDT procedures used for examination of

procedure qualification and production welds
shall be qualified and then subject to approval of
the COMPANY.
All inspection personnel.
The qualification certificates of all NDT

personnel shall be subject to review and
approval by COMPANY.
aa
The technique in BS EN 1435

to be used for radiographic
examination.
Only class B techniques of ISO 17636 shall be

used, unless geometric constraints oblige
relaxation to class A.
The welding
CONTRACTOR shall provide explanation for
any non-use of class B. techniques and
demonstrate
their acceptability to the
COMPANY.
ab
Any method for magnetic

particle testing to be used at
above ambient temperature.
Wet methods of magnetic particle testing shall

always be used for weld assessment and
acceptance purposes. Dry powder may be used
for repair inspection. See Section 12.7.
ac
Any proposal to repair a weld.
The COMPANY shall approve all weld repairs.
ad
Any alternative limits on repair

weld length.
The limits to the length of weld repairs shall be

as specified in Section 13.2.1 of BS 4515-1, i.e.
30% of the weld length maximum for a partial
penetration repair and 20% of the weld length
for a full penetration repair.
ae
Use of root sealing or single

run repair deposits.
Root sealing or single run repairs are not

acceptable.
Page 23 of 75

(2004)
Clause
BS 4515-1: 2004
Supplement
af
More than one attempt at a

repair.
Only one attempt may be made at a full

penetration repair of carbon manganese steel
welds, provided it is qualified. Two attempts
may be made at a partial penetration repair of
carbon manganese steel welds provided that
the repair procedure is qualified by two
simulated repairs.
ag
The position of the longitudinal

seam weld (if applicable) on
the subsea pipeline at the
hyperbaric weld location.
Not applicable. Relates to hyperbaric welding.
ah
Joining
technique
and
equipment for brazing or
aluminothermic welding of
anode bonding leads.
Applicable. Pin brazing shall be used unless

otherwise directed by COMPANY. Procedures
for attachment of anode bonding leads shall be
approved by COMPANY.
ai
Proposed brazing or aluminothermic welding procedure

specification.
Refer to ah.
aj
Method of chemical analysis of

butt welds in CRA clad and
lined pipelines.
As ah above.
ak
The location, elements to be

analysed,
method
and
acceptance criteria for seal
weld chemical analysis in CRA
clad and lined pipelines.
Not applicable.
al
Whether
grinding,
wire
brushing or filing of the internal
surface of CRA clad and lined
pipelines is permitted.
Not applicable.
am
Cessation of oxygen monitoring

immediately prior to completion
of the root pass in CRA clad
and lined pipelines.
The method of flaw removal in
Not applicable.
A reduction in the number of

mechanical test samples for
qualification of repair weld
procedures in CRA clad and
lined pipelines.
Use of automatic and semiautomatic welding systems
Not applicable.
an
ao
ap
Page 24 of 75
Not applicable.
See section 6 of this specification.

(2004)
Clause
BS 4515-1: 2004
Supplement
aq
Approval
of
welding
consumable
handling
and
storage procedure
ar
The mixing of Ar/CO2 shielding

gas at site
as
The type of weld monitoring

equipment for use during WPQ
testing
at
The forms used for recording

for WPQ information
See specification 8.1.6 of this specification.
au
The re-use of existing WPSs
av
Alternative etchants to Nital
aw
Acceptance of existing welder

qualifications
ax
Method of
coatings
end
ay
The solvent for grease removal
az
Use of internal tapering
ba
Re-start of welding following

suspension due to cracking
bb
Full scale
(H.3.1)
See section H.3.1 of this specification.
removing
bend
procedure
Page 25 of 75

(2004)
5.0
EQUIPMENT
4B
Add
U
Independent calibrated instrumentation shall be provided to measure all relevant

parameters during WPQT and production.
The use of permanent or consumable backing rings is not permitted. An exception is the
outer pipe welds in a pipe-in-pipe system. Non-consumable temporary backing as an
integral permanent feature on an internal clamp is permitted subject to satisfactory
demonstration of the process.
SMAW electrode holders shall be fully insulated.
Welding return cables connections shall be of sufficient cross-sectional area to prevent
concentration of current and shall be securely attached to prevent arc burns.
Page 26 of 75

(2004)
6.0
WELDING PROCESSES
5B
Add:
U
General
6.1
32B
Mechanised and automatic welding processes are preferred and should be used whenever
possible for pipeline girth welding.
Main line welding should be by mechanised or
automatic gas metal arc welding (GMAW) which may include single, multi-torch, or tandemarc variants of the process and the use of cored wires.
If the use of mechanised or
automated GMAW processes are impracticable, alternative processes may be used. In

such instances, welding may be performed by shielded metal arc welding (SMAW), manual
or automated gas tungsten arc welding (GTAW), semi-automatic GMAW processes using
solid or cored wires, or a combination of these processes.
For double or multiple jointing, girth welds should be made using submerged arc welding
(SAW) whenever possible. If SAW cannot be used, the alternative mainline processes
listed above may be utilised either alone or in combination with SAW.
The welding of pipelines by the oxy-acetylene process or by the flash-butt welding process
(FBW) or by any other process not defined above is not permitted.
When applicable the welding process or combination of processes proposed for the pipelay
welding operation shall be specified in the bid. Manual processes, semi-automatic or
automatic welding systems may be offered. If a process or system is proposed of which
COMPANY has no previous experience, COMPANY will specify welding and NDT trials
which shall be undertaken and completed successfully before the proposed technique can
be approved for qualification testing. Separate qualification of a SMAW procedure may also
be required, for possible use in the event of failure of semiautomatic or automatic
equipment in production welding.
6.2
Automatic (Mechanised) Welding

3B
If mechanised or automatic processes are proposed for main line welding, tie-in welding, or
multiple jointing of pipeline sub-assemblies, the bid shall include full details of the
processes to be used, the associated welding equipment, and the proposed area of
application.
For mainline welding applications, the proposal shall list the number of welding stations
(root pass to final capping pass) either on the firing line (offshore lay barge) or spool base
and detail the equipment and number of welders and other personnel required to operate
each station. Full details of the welding shelters shall also be provided.
Page 27 of 75

(2004)
A similar level of detail shall be provided for tie in welding and multiple jointing.
Mechanised 2G or 5G welding equipment should be operated in conjunction with data
logging facilities capable of recording the essential variables associated with the arc,
including wire feed speeds and travel speeds. The equipment shall record all parameters
for each pass of every weld at a minimum rate of once per 10 degrees of angular rotation
and shall indicate the angular position of each measurement. This data shall be readily
retrievable for monitoring purposes and shall form part of the pipeline construction data
package. Data logging is mandatory if welding with either multi torch or multi wire systems
and for girth welds made in X80 grade linepipe.
Each mechanised (automatic) welding station shall be demonstrated to be fully operational
before it is employed to weld any joints that will be incorporated into the pipeline. For
example, for a spread of welding stations this demonstration may consist of two full girth
welds made consecutively, each weld being required to meet the production acceptance
criteria without the need for any repair. NDT shall utilise the agreed pipeline NDT
techniques and equipment.
Internal welding equipment shall also require operational demonstration. Each of these
pre-construction welds shall be uniquely identified and reserved for possible mechanical
evaluation by COMPANY.
This operational demonstration shall be repeated as agreed with COMPANY but should, as
a minimum, be repeated after interruptions 7 days in pipeline welding and when a
welding spread is disassembled and transferred from one section of the line to another.
The proposal shall also detail the intended level of technician support for equipment
maintenance and list the principal spares that will be available in order to maintain
equipment serviceability for the duration of the pipelay.
The proposal shall also advise if a manual welding procedure is to be qualified for
production or repair welding.
Page 28 of 75

(2004)
7.0
WELDING CONSUMABLES
7.1
6B
General
34B
Add:
U
The selection of electrodes, filler materials and wire/flux combinations shall be approved by
the COMPANY.
In principle, the yield strength of the weld metal should be selected to ensure that the yield
strength of the deposited pipeline girth welds overmatches the actual yield strength of the
parent pipe material. The deposited weld metal shall also meet the specified ductility,
toughness, and limiting hardness criteria in accordance with this specification.
The definition of a batch (lot) of consumables shall be that stated in 3.26.
7.1.1
Weld Metal Composition

81B
A weld root chemical analysis shall be carried out on each welding procedure.
The
following elements shall be reported: Carbon, Silicon, Manganese, Sulphur, Phosphorus,

Chromium, Nickel, Molybdenum, Copper, Aluminum, Titanium, Vanadium, Boron, Nitrogen
and any other elements deliberately added.
7.2
Storage and Handling

35B
Add:
U
The storage and handling of welding consumables shall be in accordance with BP GIS 18012. A detailed consumable storage and handling plan shall be submitted for COMPANY
review and acceptance.
Shielding gases shall meet the requirements of BS EN ISO 14175 or AWS A5.32. Gases
shall be pre-mixed and bottled by the supplier and shall have certificates of compliance.
The certificates shall show the composition and dew point.
Subject to COMPANY approval, standard Ar/CO2 gases may be mixed at site.
7.2.1
Consumable Batch Testing by Contractor

82B
Add:
U
Each batch/lot of welding consumables shall have a consumable manufacturers certificate

conforming to the relevant EN, ISO or AWS filler metal specification. The testing of each
batch shall include actual deposited weld metal chemical composition, tensile and Charpy
impact tests; refer to BP GIS 18-012 and Section 7.2.2.
Page 29 of 75

(2004)
For low hydrogen SMAW consumables (<5ml/100g), manufacturers certificates shall
include average-diffusible-hydrogen level as determined and reported in accordance with
ISO 3690 or ANSI/AWS A4.3.
All certificates shall comply with BP GIS 18-012 and EN 10204 type 3.1.
SAW wire shall be tested in combination with the same brand and classification of flux as
that to be used during production welding.
The consumable certificates shall be examined to verify that the same weld properties can
be expected for the production welds as those obtained during weld procedure testing.
Additional Batch Testing by Contractor
7.2.2
83B
Add:
U
Only the batches of consumables mechanically tested during qualification of the weld
procedure shall be used for production welding of the following pipeline types:
If the NDT acceptance criterion has been established by an ECA.
For pipe grades of X65 and above.
If consumables with an AWS G designation are used, e.g. E8010-G or ER70S-G.
Add:
U
Each cast and batch of consumables for production welding shall be subjected to the
following tests during qualification of weld procedures:
2 x tensile tests to determine yield strength, ultimate tensile strength and

elongation.
2 x charpy impact tests conducted in accordance with Section 8.3.5.
1 x macro-hardness survey sampled from the 3 oclock position.
1 set of weld metal CTOD (tests required only for pipelines with ECA based
acceptance criteria or if required by designer).
Weld metal chemical analysis (see section 7.1.1)
The testing shall be in accordance with Section 8.3. The results shall meet the levels
required for the relevant weld procedure(s) and if applicable the ECA.
Page 30 of 75

(2004)
8.0
TESTING, QUALIFICATION AND ACCEPTANCE OF WELDING PROCEDURES FOR

7B
BUTT WELDS
8.1
General
36B
Add following second paragraph:

U
Welding procedure qualification test shall be carried out specifically for pipe, valve, flange
and fitting materials using contract materials or COMPANY approved equivalent materials.
The WPQT shall simulate the production welding and shall be undertaken as far as
practicable under site ambient conditions.
Add following third paragraph:
U
Repair weld procedure shall be required for each type of repair expected during production.
It is not necessary to make a full circumferential repair weld. It is only required to make
sufficient repair weld to provide material for mechanical testing.
Repairs shall comply with Figure 1 of BS 4515-1.
Single pass repairs are only permitted for cap defects.
Each repair type to be used in production shall be separately qualified e.g.
Full penetration repair.
Partial penetration repair/re-repair.
Cap repair.
Internal repair (When permitted).
Intermediate repairs (Repairs made with a different process during the course of
making the girth weld, e.g. SMAW repairs to an automatic root).
Individual repair weld procedure qualification excavations shall be limited to 300 mm.
Excavations shall be made to simulate those expected during production using the
appropriate profile and depth. Note: The excavation shall be mimicked and a drawing
included within the WPQT documentation package.
Add:
U
Repair welds and welding to forgings shall be made using low hydrogen welding
consumables/filler metals i.e. < 5ml/100g. Electrodes for SMAW shall be vacuum packed
and used in accordance with the manufacturers recommendations.
Page 31 of 75

(2004)
Add:
U
8.1.1
Protocol for Testing

84B
Preliminary Welding Procedure Specifications (pWPSs) shall be submitted to the

COMPANY before commencement of the Welding Procedure Qualification Tests (WPQTs).
Prior to WPQT and production welding, meetings shall be held between the COMPANY,
the CONTRACTOR and any third party inspection personnel in order to ensure that all
parties fully understand the specified project requirements.
All welding procedures, including repair procedures, shall be qualified by visual
examination, MPE, RE, MUT/AUT and mechanical testing as specified in this specification.
Welding, NDT and mechanical testing of the WPQT welds shall be witnessed by the
COMPANY or an accepted third party. The witnessing of mechanical tests should include
the positioning of the notches for charpy and CTOD tests.
8.1.2
Welding Procedure Specification Information

85B
The WPS shall incorporate the information required by BS EN ISO 15609-1, BS EN 288-9,
and the following:
Material manufacturer.
Arc energy.
Welding machine manufacturer, type, and model (for semi-automatic, mechanised

and automatic processes).
Software version (if applicable).
Hot wire diameter, feed speed, current, and voltage (if applicable).
For multi-wire processes the following parameters shall also be specified on the WPS when
applicable:
Number and size of wires.
Electrode spacing.
Individual wire angle relative to pipe surface.
Head spacing for multi-head welding.
Offset from top dead centre for 1G rotated welding.
Direction of rotation for 1G rotated welding.
Page 32 of 75

(2004)
Shroud diameter for tandem GMAW/PGMAW.
For welding processes involving multiple heads, the COMPANY Welding Engineer may
require further parameters to be shown on the WPS.
8.1.3
Pipe and Fitting Materials

86B
Pipe, valves, flanges, and fittings from different manufacturers, or manufactured from
materials supplied from different sources or in different supply conditions, require separate
procedure qualification as detailed in 8.2.2 & 8.2.3, unless a material grouping is approved by
the COMPANY.
8.1.4
Welding Procedure Parameters

87B
During weld procedure qualification, all relevant procedure data, irrespective of whether the
item is a listed essential variable, shall be captured and recorded. Sufficient information
shall be recorded to allow full replication of the procedure qualification welds. A record of
the data shall be kept for the purpose of aiding production and to assist with the diagnosis
of problems, but need not be formally entered on to the PQR, e.g. GMAW/PGMAW
machine slope-in settings.
The methods of measuring the welding parameters and the records to be kept shall be
agreed with the COMPANY Welding Engineer.
Following WPQT, the pWPS shall be revised to reflect the parameters recorded during
qualification. For each welding pass the values for current, voltage and travels speed shall
be recorded on the WPS by either:
Within the range recorded during WPQT, noting that transient and anomalous
values should not be used to establish the parameter range;
The mean value 10%.
The final WPS shall state parameters for each pass. However, if fill passes (i.e. passes
other than root, hot pass and cap) have similar values, the parameters may be combined
on the WPS.
When a welding consumable or group of consumables is qualified to weld several different
components or pipe sizes, every effort should be made to ensure that the parameters
specified on the individual WPSs are common across the group of WPSs.
A WPS written with more than one supporting Procedure Qualification Record (PQR) shall
not permit optional processes, but shall specify the process for each pass.
Page 33 of 75

(2004)
All welding procedures, including repair procedures, shall be qualified by visual
examination, NDT and mechanical testing as detailed in BS 4515-1 and this specification.
The final WPS shall be accepted by the COMPANY before being used for production
welding.
8.1.5
Arc Energy
8B
The arc energy for each pass shall be calculated using the recorded values of current,
voltage and travels speed from the PQR without the addition of a percentage.
Arc energy shall be recorded for each pass on the PQR.
For multiple (electrically isolated) tandem electrode welding processes e.g. SAW or
PGMAW, the effective arc energy per pass shall be calculated as the sum of individual arc
energies for each electrode. For pulsed procedures, the effective arc energy shall be
calculated on the basis of RMS values.
Voltage and current shall be determined with calibrated meters and recorded for each pass
during WPQT welding using a suitable COMPANY approved monitoring equipment.
Note: Calculation of arc energy assumes each welding process has an efficiency of 1.
U
8.1.6
Records
89B
The details of each weld procedure shall be recorded. Forms used to record WPS and
WPQT details shall contain the relevant information. The format shall be subject to
The PQR documentation package for each WPS shall comprise:
As-run records.
NDT results.
Mechanical test results and macrographs.
Consumable certification.
Parent material certification.
The following data shall also be available if requested by the COMPANY Welding
Engineer:
Calibration certificates for equipment and measuring devices.
SNT (ASNT) Written Practice (if applicable).
Page 34 of 75

(2004)
Welding Inspector and NDT personnel certification.
NDT procedure qualification records.
Testhouse approval certification.
The approved WPSs and PQR packages shall also be available in a good quality electronic
format.
Period of Validity
8.1.7
90B
For new pipeline construction projects, new WPSs shall be prepared and qualified.
For the purposes of undertaking further work to an existing pipeline, a WPS may remain
valid indefinitely. The COMPANY Welding Engineer shall be consulted before re-using the
WPS.
Changes Affecting Qualification and Approval (Essential Variables) of butt welds
8.2
37B
Modified to Read:
U
The following restrictions apply to all welding procedure specifications in addition to those
given in BS EN 288-9 and BS 4515-1.
Page 35 of 75

(2004)
Table 1
U
WELDING PROCEDURE SPECIFICATION DETAILS AND CHANGES AFFECTING APPROVAL

U
ELECTRODE a
OR
FILLER
MATERIALS
Welding
b1
parameters
b2
b3i
b3ii
b4
b5
Preheat and p4
Interpass
Temperature
Add:
TRADE NAME
ANY CHANGE
Electrical stick-out
Any change exceeding 5mm
(SAW, GMAW/PGMAW,
GSFCAW)
Arc voltage
Any change outside the range
of the approved production
WPS
Wire feed speed
qualified
Welding current
of the approved
production
WPS
Travel speed
of the approved
production
WPS
Calculated value of arc Any change outside the range
energy
of the approved
production
WPS
Application of preheat
Any change.
8.2.1
Transfer of WPSs
91B
Welding procedures shall not be transferred from one CONTRACTOR or SUBCONTRACTOR to another without re-qualification.
Material Supply Condition
8.2.2
92B
Changes in the following material condition shall require re-qualification of the WPS:
8.2.3
Steel making, plate rolling, forging, or pipe manufacturing process.
Manufacturing facility for strip, billet, plate, pipe, or forging.
Chemical Composition
93B
The following shall constitute essential variables:
For sour service pipelines, a change of composition resulting in a change of greater

than +0.00 or -0.03 CEIIW or greater than +0.01 or -0.02 Pcm.
Page 36 of 75

(2004)
CEIIW and Pcm are defined as follows:
CE IIW C
Pcm C
Mn Cr Mo V Ni Cu
6
5
15
Si Mn Cu Cr Ni Mo V
5B
30
20
60 15 10
Diameter
8.2.4
94B
The pipe diameter shall be within the limits shown in Table 8.1.
Table 8.1
U
DIAMETER RANGE OF APPROVAL FOR WPQT

U
TEST PIPE DIAMETER (mm)
RANGE OF APPROVAL (mm)
<60.3
<60.3
60.3 < D < 323.9
60.3 to 323.9
323.9 < D < 610
323.9 to 610
D >610
>610
Weld Preparation
8.2.5
95B
For narrow gap welding, any change in bevel angle beyond 1, root face beyond 50%, or
root gap +0.5 mm, constitutes an essential variable. Any weld preparation with an included
angle of less than 20 shall be considered to be narrow gap welding.
For all other welding, any changes in bevel angle by more than 5, or variation in root
gap/root face by more than 50%, constitutes an essential variable.
8.2.6
Type of Joint
96B
Use or deletion of temporary, e.g. copper, backing rings or shoes shall be considered an
essential variable.
Change from a girth weld to a fillet weld shall constitute an essential variable. Fillet welds
shall be qualified separately.
The configuration, shape, and size of branch weld test pieces shall be the same as the
branch welds to be made in production.
The qualification of branch welds shall include an additional butt weld qualification to prove
the mechanical properties of the joint.
Page 37 of 75

(2004)
8.2.7
Filler Metal
97B
The following changes shall require re-approval of the WPS:
Any change in filler metal designation, filler metal manufacturer, manufacturing

location, or brand name.
Any change in consumable diameter per pass.
A change in batch number if consumable batch control has been specified (see
7.2.2).
Welding Machines
8.2.8
98B
The welding unit, power supply type, manufacturer, model number and software version
number shall constitute essential variables for semi-automatic, mechanised and automatic
welding.
8.2.9
Type of Current
9B
For pulsed welding, the type of current includes the pulse rate, pulse shape and maximum
and minimum current.
8.2.10 Preheat Temperature
10B
The method of preheat application shall be an essential variable.

8.2.11 Interpass Temperature
10B
The use of rapid cooling of welds constitutes an essential variable unless simulated in
WPQT.
8.2.12 Time Interval
102B
For hydrogen controlled processes, an increase in the maximum time between completion
of the root pass and the start of the second pass shall not exceed the time lapse recorded
during the welding of the test piece.
8.2.13 Other Parameters
103B
Changes to the following require re-qualification of the WPS:
Head angle, electrode spacing from top dead centre and direction of rotation for 1G
rotated welding.
Electrode spacing for welding procedures utilizing multiple electrodes e.g. tandem
wire SAW, or mechanized tandem wire or twin torch processes.
Page 38 of 75

(2004)
8.3
Destructive Testing
38B
Add:
U
The blanks from which the mechanical test pieces are machined may be cut from the
qualification weld using oxy-fuel gas cutting; but its dimensions shall be sufficient to allow
the material of the final machined test piece to remain unaffected by the heat from the
cutting operation.
Test specimens shall not be subjected to any elevated temperature degassing treatment.
The type and extent of mechanical testing shall be in accordance with Table 8.2. The test
piece locations shall be as shown in Figures 8.1 and 8.2.
Page 39 of 75

(2004)
Table 8.2
U
INSPECTION AND TESTING OF THE TEST PIECES FOR GIRTH WELDING

U
TYPE OF INSPECTION/TEST
Transverse Tensile Test
FULL PENETRATION
REPAIR
BUTT WELD
2 (diameters 323.9mm)
4 (diameters > 323.9mm)

1a
1h
Impact Test
4b,c,d
2b,c,d
Side Bends
2e
2e
Macro-examination and
hardness test
3f,g,h
1h
CTOD
3h,i
3h,i
All Weld Tensile Test
NOTES:
a.
When an ECA is used to determine defect acceptance levels, a minimum of three all weld metal
specimens shall be taken.
b.
Additional sets of Charpy Impacts may be required by the COMPANY Welding Engineer. For example, if
very thick pipe is to be utilised or the combination of processes or consumables has not been adequately
sampled by the specified locations.
c.
For thicknesses greater than 20 mm, a total of 6 sets shall be required. The additional 2 sets shall be
taken from the outer surface (see Figure 3 BS 288-9).
d.
Impact testing is not required for pipe sizes below 60.3 mm diameter with thicknesses less than 12.7
mm.
e.
Side bends are only required for GMAW/PGMAW and GSFCAW (Vertically down) welding processes.
For Wt >25mm four side bends shall be conducted. For full and partial penetration repairs two side
bends are required.
f.
Additional macro-examinations and hardness tests are required for long seam T-intersections (see 8.3.3).
g.
For non-sour pipelines, the number of hardness surveys may be reduced (see 8.3.4).
h.
CTOD tests shall comprise a minimum of one set of weld metal and two sets of fusion line samples.
i.
Tests are only required for pipelines with ECA based acceptance criteria or if required by the pipeline
designer.
j.
See 7.1.1 for weld chemical analysis test requirements.
Page 40 of 75

(2004)
Figure 8.1
U
LOCATION OF TEST SPECIMENS FOR A FIXED POSITION GIRTH WELD PIPE FOR
U
UPWARDS WELDING
Key:
1 Area 1 for:
7
1
3
4
- 1 tensile specimen
2 Area 2 for:
- Impact test specimens (WCL, FL & FL+2mm)
- 1 macro test specimen
- Additional test specimens if required.
3 Area 3 for:
4 Area 4 for:
- 1 hardness test specimen
5 Area 5 for:
- AWT Specimens
6 Top for fixed pipe
7 Area 7 for:
- 1 transverse tensile (>323.9mm)
- Impact test specimens (WCL, FL & FL +2mm)
8 Area 8 for:
Figure 8.2
U
LOCATION OF TEST SPECIMENS FOR A FIXED POSITION GIRTH WELD PIPE FOR
U
DOWNWARDS WELDING
6
7
1
3
4
Page 41 of 75
Key:
1 Area 1 for:
2 Area 2 for:
- 1 hardness test specimen
- Side bends
3 Area 3 for:
4 Area 4 for:
- Additional test specimens if required.
5 Area 5 for:
- AWT Specimens
6 Top for fixed pipe
7 Area 7 for:

(2004)
CTOD and additional all weld tensile specimens may be taken from available material
around the weld. The locations shall be agreed with COMPANY. More than one weld may
be required to provide sufficient material for testing.
Transverse Weld Tensile Test
8.3.1
104B
Add:
U
The results of all transverse weld tensile tests shall meet or exceed the specified
requirements for the pipe (base metal) with respect to specified tensile strength.
Transverse weld tensile specimens shall fail at a location within the HAZ or base metal.
Failure in the weld metal is unacceptable.
If base metals of different strength levels are used, then acceptance criteria shall be based
on the lower strength base metal.
8.3.2
Weld Metal Tensile Testing

105B
Add:
U
The weld metal shall exceed the parent pipe SMYS by between 80 to 200MPa. Weld
metals exhibiting overmatching shall ensure this is not to the detriment of other mechanical
properties and shall be demonstrated through WPQT. Any large deterioration of properties
compared shall be cause for investigation by the CONTRACTOR and COMPANY Welding
Engineers. Weld metal overmatching shall be achieved at both room temperature and
maximum design temperature. The weld metal strength shall be considered in relation to
the actual pipe yield strengths when an ECA is used.
Macro-Examination
8.3.3
106B
Add:
U
Three macro-examination test pieces shall be taken from each WPQ. The locations shall
be at 12, 3 and 6 oclock (see Figures 8.1 and 8.2).
When girth welding SAW-welded linepipe, an additional macro-examination specimen shall
be extracted from the girth-weld at the T-intersection region between the girth weld and
seam weld.
All macro-examination specimens shall be polished to a metallographic (1m) finish and
etched in a 2-10% Nital solution, or other suitable COMPANY accepted etchant. The
etched specimens shall be thoroughly examined at 10 times magnification.
Page 42 of 75

(2004)
The prepared surface shall exhibit no cracks or lack of fusion defects. Volumetric defects
shall be investigated and shall not exceed the acceptance criteria of Section 13.0.
Original photo-macrographs of macro-examination specimens at approximately 3 to 5 times
magnification shall be included in the PQR documentation.
8.3.4
Hardness Testing
107B
Clarification:
U
All hardness testing shall meet the sour-service criteria as laid down in BS EN 288:9, Table
3. The parent material hardness shall not exceed the values permitted in the relevant
linepipe material specification.
Add:
U
Hardness testing shall be in accordance with EN 1043-1 or ISO 6507-1.

The hardness surveys shall be undertaken on each of the macro-examination specimens
specified in 8.3.3.
Each survey shall consist of three rows of indents. One traverse shall be located below the
cap, one above the root (or internal surface) and one at mid-thickness. The positions are
shown in Figure 8.3. The mid-thickness traverse may be waived for single sided welds
below 12.7 mm. The COMPANY Welding Engineer may require additional hardness indent
positions, e.g. when a consumable type has not been sampled by the three specified
traverses.
Figure 8.3
U
GIRTH WELD HARDNESS INDENTATIONS

U
1 - 2mm
t/2
1 - 2mm
NOTES:
1. Parent material indentations shall be at least 20 mm from the fusion line.
2. The first HAZ indentation shall be placed as close to the fusion line as possible. Further
indentations into the HAZ shall be separated by approximately 0.5 mm, however the minimum
Page 43 of 75

(2004)
centre-to-centre separation requirement of 3 times the mean diagonal of the nearest indentation
shall be maintained (ref. ISO 6507-1).
3. The same survey pattern shall be applied to double-sided welds.
The macrophotographs shall show the position of each hardness indent and shall be
included in the PQR along with tabulation or diagram showing the result and location of
each indent. The maximum and minimum values shall be identified.
Impact Testing
8.3.5
108B
Clarification:
U
For gas pipelines the impact test temperature shall be no higher than minus 10C.
Clarification:
U
Sample preparation shall be conducted in accordance with BS EN 10045 Part 1.

Add:
U
Impact tests shall be carried out in the fusion line + 2mm locations. The impact test
requirement for all pipe/bend/fitting/forging is 50J minimum average and 40J minimum
individual, for 3 specimens at the minimum design temperature.
Add:
U
8.3.6
Crack Tip Opening Displacement (CTOD) Testing

109B
Fracture toughness tests are only required for pipeline subject to an ECA, and shall be
conducted at minimum design temperature. The required minimum CTOD value shall be
0.15 mm unless otherwise justified through an ECA.
CTOD testing shall be undertaken in accordance with BS 7448 Parts 1 & 2 by a testing
laboratory specifically approved for CTOD testing by COMPANY.
Testing shall be based on the use of through thickness notched, single edge notched bend
(SENB) specimens (BS 7448 Part 1 paragraph 5.1) in the NP orientation, unless agreed
otherwise by COMPANY.
Test specimens shall be notched and fatigue cracked to sample the microstructures at the
weld centre line and in the coarse grained HAZ adjacent to the fusion line.
The number of valid test results employed to determine the characteristic CTOD of the
weld metal and HAZ microstructures shall comply with BS 7910 paragraphs K.2.3 and
7.1.5.5. This may require a greater number of CTOD specimens than listed in Table 8.2.
Page 44 of 75

(2004)
Post test metallography shall be used to identify the initiation point and the associated
microstructure on a minimum of three HAZ specimens selected by COMPANY.
The
initiation point of brittle events shall be identified by metallography. The specimen is

considered qualified if:
The pre-crack tip is not more than 0.5mm from the fusion line.
Grain coarsened HAZ microstructure is present within a region confined by a plane

perpendicular to the crack plane through the crack tip and a parallel plane 0.5mm
ahead of the crack tip.
8.3.7
Bend Testing
10B
Transverse root bend and side bend specimens shall be prepared and tested in
accordance with ISO 5173:
Specimens shall be of full material thickness and the root samples shall be nominally
25mm in width while the side bend specimens shall be nominally 10mm in thickness.
Bending shall employ a former having a minimum diameter of 4x and a maximum

diameter of 6x the full pipe wall thickness.
Testing shall not reveal any open weld defects greater than 3mm in length.
Defects shall not be acceptable in the root or hot pass location.
Tearing from the specimen edges up to a maximum length of 3mm shall be acceptable
provided that it is not associated with any weld defects.
Page 45 of 75

(2004)
9.0
TESTING, QUALIFICATION AND APPLICATION OF WELDING PROCEDURE FOR

8B
FILLET WELDING
9.1
Non-Destructive Testing of Fillet Welds

39B
Clarification: There are no additional NDT requirements to visual and MPE for fillet welds.
U
Destructive Testing of Fillet Welds
9.2
40B
Add:
U
If mechanical properties are relevant to the application, an additional qualification shall be

made, e.g. a butt weld.
Page 46 of 75

(2004)
10.0
TESTING, QUALIFICATION AND APPROVAL OF WELDERS
10.1
9B
General
41B
Add:
U
Welders shall be qualified prior to welding on the pipeline.

Previous welder qualification tests may be accepted by the COMPANY provided they are
fully documented, supported by production records demonstrating satisfactory welder
performance, and are less than 6 months old. These tests shall have been conducted
utilizing a WPS substantially the same as that for the current work and for automatic,
mechanised or semi-automatic welding procedures, utilizing the same type, manufacturer
and model number of welding unit and power supply. Additionally, these tests shall have
been conducted by the same fabrication CONTRACTOR and witnessed by the COMPANY,
or have been conducted by a COMPANY accepted independent testing laboratory.
In addition to the practical welding test and prior to the commencement of production
welding, all welders shall be required to attend a briefing session arranged jointly by the
CONTRACTORS and the COMPANY welding engineer. This briefing will detail the
elements of good welding practice and the specification requirements applicable to
production welding. These requirements shall be further emphasized during regular toolbox sessions and each welder shall also be issued with a card or booklet summarizing
these requirements, the contents of which shall be agreed between the CONTRACTOR
and the COMPANY.
Any welder who, in the opinion of the COMPANY is either consistently ignoring good
welding practice or specification requirements or is responsible for a high level of repairs
during production shall be removed from the work, and shall undergo a re-training
programme accepted by the COMPANY before a retest may be considered.
Butt Joints
10.2
42B
Add:
U
Welder qualification tests shall be carried out on full diameter project pipe nipples. Test
welds shall be visually sealed at each end until at least the root bead and hot pass have
been completed around the full circumference.
All qualification welding shall be carried out in the presence of a COMPANY representative.
The COMPANYs decision on acceptance is final.
Welders shall weld at least 50% of the circumference of the test pipe.
Page 47 of 75

(2004)
10.4
Fillet Welds for Sleeves, Sockets, Slip-on Flanges or Other Attachments

43B
Clarification:
U
The simulation of a fillet weld joint using flat plate welds shall not be permitted.
Add:
U
Procedures for welding and NDT of fillet welded attachments to pipelines shall be subject
to acceptance by the COMPANY.
The pipe area surrounding a fillet weld shall be tested for laminations using MUT up to a
distance of 100 mm surrounding the projected locations of the weld toes. Any laminations
found shall comply with the applicable project line pipe specification.
Where any fillet welds are to be made using multiple passes, the first pass shall be
deposited mainly on the pipe and the final weld pass shall not touch the pipe.
Completed fillet welds shall be examined by visual examination and MPE.
10.5
Changes Affecting Qualification and Acceptance (Essential Variables) of Welders

4B
Modified to Read:
U
For manual metal-arc welding, a change in electrode trade name.

10.6
Non-Destructive Testing
45B
Add:
U
NDT of welder test-pieces for butt welds shall include visual examination, MPE. RE and
MUT/AUT if GMAW/PGMAW and GSFCAW (Vertical down) is used.
Where SMAW,
GTAW or SAW or GSFCAW (Vertical Up) is used visual examination, MPE, and RE shall
be used.
If the application of AUT for the inspection of pipeline girth welds has been agreed by
COMPANY, it may be used for the assessment of the welder qualification welds in place of
radiography. However, the acceptance criterion used shall be BS 4515-1 Table 6 and
section 13.1.2 of this specification, rather than an ECA based criterion.
Destructive Testing
10.7
46B
10.7.2 Butt joints

1B
Add:
U
Page 48 of 75

(2004)
For butt welds, macro-examination shall be undertaken. Additionally, for welding using
GMAW/PGMAW and GSFCAW (Vertical Down) welding processes, bend testing in
accordance with ISO 5173 shall also be performed.
Page 49 of 75

(2004)
11.0
PRODUCTION WELDING
10B
Add:
U
Any weld suspected of not having been produced in accordance with the accepted welding
procedure shall be cut out, and may be subject to investigation at the discretion of the
COMPANY.
11.1
Proximity of Welds
47B
Add:
U
The distance between pipeline girth welds shall not be less than twice the outside diameter
of the pipe.
The distance between pipeline girth and branch/attachment welds shall not be less than
one pipe diameter.
The distance between branch/attachment welds on the pipeline shall not be less than one
pipe diameter.
11.2
Pipe End Preparation

48B
Add:
U
Pipe ends shall be bevelled to the dimensions specified in the WPS.

Weld bevels shall be prepared by machining with a floating head cutter. The bevelling
machine shall follow the ID surface contour in order to ensure a consistent root face
dimension. Mechanised thermal cutting may be accepted for tie-in welds. The cut surface
shall be ground back nominally 2mm. Manual cutting of field bevels is not permitted.
Any protective coating on the end bevel shall be removed prior to welding by a COMPANY
accepted method.
Weld repairs to pipe ends shall not be permitted.
The COMPANY may permit minor
imperfections in the pipe ends to be repaired by grinding, prior to assembly for welding,
provided the remaining wall thickness is acceptable as confirmed by MUT.
If AUT is to be used, a reference line at a specified distance from the root face shall be
scribed onto the pipe surface to allow the exact location of the root bead to be identified.
Clarification:
U
On pipe which is to be cut back, a zone extending 100 mm from the proposed position of
the new field bevel shall be examined by VE, and MUT to check for laminations to the
requirements of the appropriate linepipe material specification.
Page 50 of 75

(2004)
11.3
Fusion Faces
49B
Add:
U
Surfaces contaminated with oil or grease shall be cleaned utilizing solvent. Degreasing of
base metal shall extend at least 50 mm from the edge of the fusion faces on both ID and
OD surfaces. All cleaning solvents shall be used from a suitable container, shall have all
necessary documentation available and be accepted by the COMPANY as HSE compliant.
Alignment
11.4
50B
Modified to Read:
U
Pipes shall be aligned with care. The alignment of abutting pipe ends shall minimize the
internal offset between surfaces. Any offset greater than 1.5 mm, provided it is caused by
dimensional variations within specified tolerances, shall be equally distributed around the
circumference of the pipe or fittings. Misalignment shall be reduced to a minimum by
rotation of the pipes to obtain the best fit.
Maximum misalignment shall be:
< 1.0 mm for pipe diameter < 6.
1.5 mm for pipe diameter 6.
Add:
U
Heat shall not be used to correct excessive misalignment.

Internal tapering shall not be permitted if the tapering interferes with ultrasonic inspection.
11.5
Line-Up Clamps and Pipe Supports

51B
11.5.1 Use of Line-Up Clamps

12B
Modified to Read:
U
Powered internal alignment clamps shall be used for pipe-to-pipe butt welds. Where access
does not permit the use of an internal clamp for pipe-to-pipe welds, an external clamp shall
be used. For small diameters (<150 mm), the use of an external clamp may be proposed
for COMPANY acceptance. A welding sequence that distributes the stresses as evenly as
possible shall be used, e.g. two welders working diametrically opposite each other.
If an internal line-up clamp is used, the root run shall be 100% complete before the clamp
is removed. When an external line-up clamp is used, the root run shall be at least 50%
complete before the clamp is removed.
Page 51 of 75

(2004)
Line-up clamps or other devices for maintaining line-up shall be of the same type as used
during the welding of test pieces for WPS approval. The stage at which line-up clamps are
removed shall be stated in the WPS and qualified subject to the approval of the
COMPANY. The line-up clamp shall be designed to prevent damage to the pipe and
coatings.
Straps, brackets, cleats, or similar plate sections shall not be attached to the pipe by
welding for the purposes of alignment.
Modified to Read:
U
Internal line-up clamps shall not be removed until the completion of the root and hot pass.
Alternatively the CONTRACTOR shall present a case, supported by stress analysis, which
proves that a weld with only the root pass in place will not be adversely affected by
movement.
If an internal clamp incorporates a copper back-up bar, the backing bar shall be subject to
a full circumferential visual examination at least once every ten welds to ensure no fusion
of copper is taking place.
Add:
U
The COMPANY shall accept line-up methods for fittings and flanges.
Tack Welds
11.6
52B
Add:
U
All tack welds (if used) shall be deposited by qualified welders using low hydrogen welding
in accordance with an accepted welding specification. Where preheat is specified, it shall
be applied prior to tack welding and be effective over a distance equal to three times the
wall thickness or 75 mm whichever is the greatest and shall be maintained until the joint is
complete.
Alignment by tacking for fabrication welds, e.g. for pipe to flange joints, shall be subject to
the acceptance of the COMPANY. The following shall apply when tacking is used:
The joints to be tacked will be adequately supported.
Tack welding to be undertaken by qualified welders in accordance with Section

10.0.
The preheat level required for the main WPS shall be applied for tacking and shall
be not less than 50C.
Page 52 of 75

(2004)
The preferred method is bullet tacking. The bullets shall be made from compatible
linepipe material.
A minimum of four tacks shall be used for diameters >100mm. More tacks may be
required for diameters > 300mm.
All welding shall be confined to the weld preparation and not impinge on the root
area.
Tacks shall be removed by grinding as root welding progresses around the butt.
If tack welds are to be incorporated in to the final weld, they shall be at least 25mm
long and shall be thoroughly cleaned of slag and taper ground at each end to
ensure complete root continuity.
The intended method of tacking to be used in production shall be incorporated in

the WPQT.
COMPANY may agree to waive MPE of the ground area following tack removal.
Stray Arcs
11.8
53B
Add:
U
The COMPANY shall have the option to require removal of weldments with more than one
arc burn from the pipeline.
Repair of parent material by welding is not permitted.
If blending to remove the effects of arc burns reduces the wall thickness below the
specified minimum, the defective pipe section shall be cut out and the pipe re-bevelled and
re-welded. Welding shall not be used to repair arc burns. For non-reeled applications, if a
nipple is used to replace the defective section, its length shall be at least two pipe
diameters.
Welding return cables shall be of sufficient cross-sectional area to prevent concentration of
current and shall be securely attached to prevent stray arcing. Attachment by welding shall
not be performed.
Clarification:
U
Areas showing stray arcs may only be repaired by mechanical removal of the defective
material and blending of the excavation. MPE together with confirmation that pipe or fitting
wall thickness is within specified tolerances shall be confirmed.
Page 53 of 75

(2004)
11.9
Weather Conditions
54B
Add:
U
When necessary, measures shall be taken, e.g. by covering the pipe ends, to prevent
water or other extraneous matter being channelled into the weld region.
The COMPANY shall decide if the protection given from the weather is adequate and that it
will not affect the quality of the completed weld.
11.10 Preheating and Post Weld Heat Treatment
5B
General
11.10.1
13B
Modified to Read:
U
Preheat and interpass temperatures shall be in accordance with the COMPANY approved
WPS.
As a minimum the preheat temperature shall be selected to ensure that:
The pipe is dry prior to welding
The metal temperature is greater than 30C, or greater than 50C when moisture is
present on the pipe, or when the ambient temperature is below 5C.
The hardness requirement of Section 8.3.4 is met for the weld and HAZ.
If the weld is to be cooled rapidly to allow immediate AUT, this shall be simulated during
WPQT.
Assisted cooling shall not commence until the weld temperature has cooled
without interference to below 300C.

11.10.2
Preheating
14B
Add:
U
Preheating shall be applied by gas or electrical equipment. Induction heating is preferred

for pipeline welding and is mandatory for welding of pipe diameters greater than 500mm.
Hand held gas torches shall not be used for welding when preheats greater than 80C are
required. Welding or cutting torches shall not be used for preheating purposes. The
preheating equipment shall maintain a satisfactory temperature distribution and shall not
interfere with the welding operation. Care shall be taken to avoid damage to any coatings
and interference with the welding.
Page 54 of 75

(2004)
Preheating shall be applied uniformly on both sides of the joint preparation around the
entire periphery. Local preheating may be used for repair welding. Correct preheat
temperatures shall be maintained throughout the welding of the joint.
The preheat temperature shall be measured at a minimum distance of 75 mm from each
edge of the weld bevel at a minimum of four circumferential locations, each approximately
90 apart. Preheat temperature measurement shall be made on the heated face of the pipe
after a time interval following the removal of the heat source to allow for temperature
equalisation. The time interval shall be 1 minute per 12.7 mm of wall thickness, e.g. 2
minutes for 25 mm thick material. The preheat temperature shall be confirmed immediately
prior to the commencement of welding and around the whole joint whilst welding is taking
place.
Interpass temperature shall be measured on the parent material at the edge of the weld
bevel near the weld start location. The temperature shall be measured immediately before
the passage of the arc and the maximum specified interpass temperature shall not be
exceeded.
For continuous rotated welding, interpass temperature shall be measured at least once per
complete revolution.
Temperature indicating crayons which melt on attaining the specific temperature may be
used to check preheat and interpass temperature, but shall not be marked on weld bevels,
weld beads or surfaces to be welded. Temperature indicating crayons or paints which
indicate temperature by colour change shall not be used. Alternatively, suitably attached
(and calibrated) thermocouples, or calibrated contact or optical pyrometers, may be used to
check preheat and interpass temperatures.
When pipe-to-pipe joints are to be left partly completed, the joint shall be wrapped in dry
insulating, heat-resisting material with a waterproof backing and shall be cooled at a slow
uniform rate. Preheat shall be re-applied and the specified temperature attained before
recommencement of welding.
11.10.4
Thermocouple Attachment and Junctions

15B
Add:
U
Thermocouples shall be attached to the pipe by the capacitance discharge method. After
use, the thermocouples junctions shall be removed by grinding and the area of attachment
shall be examined by MPE.
Page 55 of 75

(2004)
11.11 Branches
56B
Add:
U
Procedures for cutting, joint preparation, setting-up, welding and NDT shall be subject to
COMPANY acceptance.
Forged fittings shall be used for branches and other pressure containing attachments
unless otherwise accepted by the COMPANY.
11.11.2
Spacing of Branches
16B
Add:
U
Refer to 11.1
11.11.4
Welding
17B
Add:
U
11.11.4.3 Set-in Fitting Welds

Set-in fitting welds shall be inspected as follows:
Where accessible and following completion of the full weld, the root bead shall be
ground flush on the inside of the pipe, its location clearly marked with indelible pen
and inspected by visual and MPE.
Weld caps to be subjected to visual and MPE;
The full welds shall be examined with radiography using the SWE/SWV technique
with the film inside and radiation source outside, using a minimum source to film
distance of 600mm. A minimum of four equidistantly spaced separate exposures
shall be used for branches 150mm nominal bore. The DWE/SWV technique may
only be used if accepted by the COMPANY. In each event the centre radiation beam
shall pass through each weld region being tested at normal incidence to the weld
face.
Set on fitting welds shall be inspected as follows:
The root bead and weld cap shall be examined by visual examination. Visual
examination of the root bore shall be undertaken through the bore of the fitting from
the outside of the pipe;
Weld caps shall be examined by MPE. Where access allows MUT shall be
undertaken from the inside surface of the fitting.
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(2004)
11.12 Inter-run Cleaning
57B
Add:
U
Contact tips shall not be fused into the weld metal. A visual inspection shall be undertaken
between weld passes to confirm no copper has been deposited.
11.13 Partially Completed Joints
58B
Add:
U
Offshore pipeline welds or welds on fittings, tie-in welds, or repairs shall not be allowed to
cool below the specified minimum preheat temperature before weld completion. No welds
shall be allowed to cool below preheat temperature before the completion four full
circumferential passes.
All welds shall be completed by continuous welding.
11.14 Fillet Weld Attachments
59B
Procedures for welding and NDT of fillet welded attachments to pipelines shall be subject to
The pipe area surrounding a fillet weld shall be tested for laminations using UT up to a
distance of 100 mm surrounding the projected locations of the weld toes. Any laminations
found (individual or cluster) shall not exceed a total area of 500 mm2. No lamination
regardless of size shall be permitted within 25 mm of the projected weld toes.
If any fillet welds are to be made using multiple passes, the first pass shall be deposited
mainly on the pipe and the final weld pass shall not touch the pipe.
Completed fillet welds shall be examined by VE and MPE.
11.15 Records
60B
Add:
U
All documentation required by this specification and BS 4515-1 shall be collated, indexed,
stored safely and presented to the COMPANY.
A log identifying, by number, each pipe or fitting and identifying the weld numbers joining
them to other items shall be compiled. Each circumferential weld (whether a field joint or
shop-made weld) shall be allocated a unique number, which shall be used for reference to
the weld in all reports, radiographs and test documents.
Quality records shall include the following:
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(2004)
Record of contract/design review.
Material certificates.
Consumable certificates.
Welder name and / or number.
WPSs.
Welding procedure acceptance test records.
Welder or welder operator acceptance certificates.
Non-destructive testing personnel certificates.
Heat treatment records.
Non-destructive testing and destructive testing procedures and reports.
Dimensional reports.
Records of repair and other non-conformity reports.
Site or technical queries pertaining to welding and NDT.
The above documentation shall be traceable back to individual weld numbers, where
applicable. The accepted WPS and PQR packages shall also be available in a good quality
electronic format.
Page 58 of 75

(2004)
12.0
INSPECTION AND TESTING OF WELDS

1B
12.1
General
61B
Clarification:
U
Every pipeline weld shall be subject to individual examination and non-destructive test
using reliable, modern, and proven techniques, and shall be shown to meet the design
code acceptance criteria in all respects before the pipeline is put into service.
An ECA and CTOD tests are mandatory when pipeline installation is by reeling or S-Lay. For
the fabrication of spools CTODS and ECA is only required where the minimum design
temperature is lower than -46C and or thicknesses > 40mm. The use of an ECA shall not
be required on pipe diameters 6 and/or wt <10mm.
The use of narrow gap welding techniques (with an inclusive bevel angle 20) dictates
that AUT shall be required.
Each production butt weld shall be subjected to a visual (external), RT and supplementary
UT or AUT examination or a combination of both, unless otherwise agreed with the
COMPANY.
For wall thickness above 25 mm, AUT is the preferred NDT technique.
For manual or semi-automatic welding processes using a conventional bevel configuration,
one of the following NDT methodologies may be adopted subject to COMPANY review and
approval:
Where RT is the primary NDE method, MUT shall be used to supplement RT when
planar defects are detected during production welding. MUT shall be used to
establish defect size, height and position. An ECA (when required) shall be used to
develop the weld NDE acceptance standard taking cognizance of the NDE sizing
accuracy.
Alternatively, visual and RT may be considered, provided the CONTRACTOR can

demonstrate its ability detect the defects defined within the workmanship
acceptance criteria as detailed in this specification and Table 5 (BS 4515-2) and
Section 13.1.2 of this specification. The acceptance criteria shall be no cracks or
planar defects within the weld i.e surface breaking or within the body of the weld.
RT and single wall techniques shall only be used for NDE of girth welds. To avoid
repairs or cut-outs it is recommended that a MUT be qualified to assist RT.
Page 59 of 75

(2004)
Add:
U
Radiographic procedures shall be qualified on test welds containing representative defects

which are subjected to sectioning to confirm defect sizes and NDT by additional methods.
The CONTRACTOR shall demonstrate that his NDT production methods and procedures
can detect the defects defined within the acceptance criteria.
Proposed NDT procedures shall be submitted in writing to the COMPANY for approval. All
procedures shall be qualified and approved by the COMPANY before use.
The full length of pipeline branch and fillet welds shall be examined in accordance with
11.11.4 and 11.14.
The use of automatic ultrasonic testing (AUT) shall be subject to approval by the
COMPANY.
If the use of AUT has been approved, testing shall be performed in
accordance with GIS 43-339. The use of AUT is not permitted in place of radiography for
the following weld types:
Welds connecting pipes with an internal taper.
Butt welds to valves, flanges and other fittings.
MUT and MPE equipment and personnel shall be available at site for the full duration of
pipeline construction.
The COMPANY shall have the right to inspect or test any weld by non-destructive or
destructive means. This inspection may be made during the welding or after the weld has
been completed.
The right of inspection may include NDT undertaken by COMPANY
personnel in addition to any NDT undertaken by the CONTRACTOR. For example, the
COMPANY may choose to inspect welds by MUT.
On a pipe-laying barge, the weld shall not be moved past the weld repair station until the
interpretation of the radiograph and all other NDT is complete and the weld has been
judged satisfactory. Coating/ wrapping of a welded joint shall not begin until the weld has
been judged satisfactory, unless otherwise approved by COMPANY.
Clarification:
U
Completed welds may be ground when agreed with the COMPANY to facilitate NDT
provided the wall thickness complies with the minimum specified limit. Grinding shall
ensure no stress raisers and a smooth transition exists.
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(2004)
12.2
Personnel Qualification
62B
Modified to Read:
U
NDT personnel shall hold current Level 2 certification (or equivalent), specific to weld
testing, for the appropriate NDT methods to any of the following standards as a minimum:
CSWIP (TWI, UK);
BGAS-CSWIP (TWI, UK);
PCN (BINDT, UK);
ACCP (ASNT);
SNT-TC-1A (ASNT).
NDT personnel certificated to the requirements of a Written Practice under the rules of
SNT-TC-1A shall not be used, unless the Written Practice and the personnel certification
has been reviewed and accepted by COMPANY for the specific work.
Personnel engaged in AUT shall be qualified in accordance with GIS 43-339.
Radiographic Testing
12.4
63B
12.4.1 General
18B
Add:
U
Radiographic testing shall be conducted using X-ray equipment. Where the use of X-ray
equipment is impracticable, Iridium 192, Ytterbium 169 or Selenium 75 may be used
subject to acceptance by COMPANY. Other sources of gamma rays are not permitted.
Radiographic practice shall be in accordance with this specification and ISO 17636.
12.4.2 Approved Radiographic Procedures
19B
Add:
U
12.4.2.1 General
As part of the radiographic procedure qualification, test radiographs shall be produced
using each radiographic procedure planned for use; these shall be made on the welding
procedure qualification welds or welds made with the production WPS. The full
circumference of each test weld shall be radiographed.
Film type shall be ISO 11699-1 Class T2 or ASTM E1815-96 Class I, e.g., Agfa Structurix
D5 or Kodak Industrex T200, or finer grain (slower) film. Where it is shown that exposure
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(2004)
times would exceed 2 minutes using X-ray equipment with this film, the use of ISO 11699-1
Class T3 or ASTM E1815-96 Class II may be permitted at the discretion of COMPANY.
Lead (Pb) intensifying screens shall be used.
COMPANY may accept the use of
fluorometallic screens, as an alternative, where the CONTRACTOR is able to demonstrate

that test procedures and results are of a standard acceptable to COMPANY.
12.4.2.2 Procedure Specification (Addition)
Specifications of radiographic procedures shall, where relevant, define the following:
Pipe diameter and wall thickness;
Radiation and source;
X-ray equipment manufacturer, model name and number;
Technique (equipment rating, in voltage, external or internal equipment);
Geometric relationships (source focal-size, film focus distance, object-film distance,

radiation angle with respect to weld and film);
Penumbra or geometric unsharpness;
Film type (trade name, designation and dimensions);
Intensifying screens (front and/or back, material thickness, filters);
Exposure
conditions
(voltage,
current
and
duration,
Curie-minutes
and
Gigabecquerel-minutes);
Processing (developing time/temperature, stop-bath, fixation, washing, drying,

manual or automatic processing, manufacturer and type of equipment);
IQI type and sensitivities, in percent of wall thickness, based on source-and film-side
indicators, respectively);
Film density;
Film overlap;
Reference to actual WPS;
Temperature of welds during inspection;
Archival life;
Initial source strength.
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(2004)
12.4.2.3 Exposure Geometry
Source-weld-film arrangements shall comply with ISO 17636 except that the elliptical
technique shall be used on all girth welds on pipe 88.9mm diameter. The perpendicular
technique (straight through) exposures shall not be used unless accepted by the
COMPANY.
The single wall exposure for single wall viewing (SWE/SWV) technique with the radiation
source located inside the pipe/ fitting shall be the preferred technique for radiography of
girth welds.
12.4.2.4 Type of Image Quality Indicators
Only wire type IQIs (ISO 2504 or COMPANY accepted equivalent) shall be used.
12.4.2.5 Selection of Image Quality Indicators
For radiographic procedure qualification, wire type IQIs shall be placed across the weld on
both the source side and the film side of the area being examined. The sensitivity level,
obtained using the film side IQI, shall be no worse than that given in Table 12.1. The
corresponding sensitivity for the source side IQI shall be recorded. If any test radiograph
shows one visible wire more on the film side IQI, compared to the source side IQI, the
COMPANY has the option to reject the radiographic procedure.
Table 12.1
U
SENSITIVITY REQUIREMENTS
U
THICKNESS
X RADIOGRAPHY
(1)
GAMMA RADIOGRAPHY
(mm)
SWSI
DWSI
DWDI
SWSI
DWSI
DWDI
4.5-6.0
2.0%
2.5%
3.2%
2.6%
2.7%
3.5%
>6.0-9.0
1.7%
2.0%
3.0%
2.4%
2.5%
3.2%
>9.0-14.0
1.5%
1.8%
Note 3
2.4%
2.5%
Note 3
>14.0-18.5
1.4%
1.7%
N/A
2.0%
2.2%
N/A
>18.5-26.0
1.3%
1.7%
N/A
1.7%
2.0%
N/A
>26.0-40.0
1.1%
1.7%
N/A
1.5%
1.8%
N/A
>40.0
Note 3
Note 3
Note 3
Note 3
Note 3
Note 3
Note 1 - Thickness for SWSI and DWSI is estimated for a single weld thickness
Note 2 - Sensitivity shall be no worse than the values given in this table. Sensitivity shall be
calculated using the formula:
Page 63 of 75

(2004)
Thickness of thinnest wire visible in weld area

Thickness1
Sensitivity =
Note 3 - Sensitivity requirement to be agreed with COMPANY following production of test
radiographs.
The procedure test radiographs shall be submitted to COMPANY for acceptance prior to
the start of production. New procedure test radiographs may be requested at the discretion
of the COMPANY whenever any change is made in operating technique or whenever
production radiographs differ appreciably from the detail, contrast, definition or density of
the qualifying radiographs.
Procedure test radiographs shall be readily available for comparison purposes in each
darkroom used for radiographic viewing.
Page 64 of 75

(2004)
12.4.2.6 Film Density
Except for small localized areas caused by weld weave or discontinuities, the radiographic
density shall be between 2.0 and 3.2 in the weld area. If this density range cannot be
achieved within the full weld width in a single exposure, then the above density range shall
be achieved by producing two radiographs of the weld area at different exposures or by
using the sandwich technique, unless otherwise agreed by COMPANY.
Densitometers shall be used for measuring density and shall be calibrated using a density
strip (density reference scale) of known densities. A density strip certified within the last 3
years to a recognized standard, e.g., NIST or BAM, shall be present on site. To save wear
and tear on the calibrated density strip, a working density strip may be used for checking
and calibrating densitometers; this shall be checked against the certified density strip at no
more than 3 monthly intervals.
12.4.2.7. Information on radiograph
The radiographs shall contain the following information:
Project name, project number, and pipeline identification.
Weld number.
Whether the radiograph is of a repair weld, of a replacement weld or a re-shoot.
Marker(s) indicating the position of the radiograph in relation to the weld.
Pipe diameter and thickness.
Material grade.
Date.
WPS number.
12.4.2.8 Film Viewing Equipment

The viewing facilities shall provide subdued lighting of an intensity that will not cause
troublesome reflections, shadows or glare on the radiograph. The viewing equipment shall
produce sufficient brightness for the illuminated radiograph to be satisfactorily interpreted
and shall meet the requirements of ISO 5580. The image shall be free from fog and
processing irregularities that could mask the image of actual imperfections. All radiographic
film shall be dried thoroughly prior to viewing.
Page 65 of 75

(2004)
12.4.3 Film Storage
120B
Add:
U
For the main production pipeline and when agreed with the COMPANY, radiographic film
shall be digitized using methods that give adequate resolution and stored in electronic
media in an agreed manner with the COMPANY.
All radiographic film shall be dried thoroughly prior to viewing and shall be processed to
allow storage of the film without deterioration for a minimum period of 5 years
At the discretion of COMPANY, the radiographic CONTRACTOR shall satisfactorily
demonstrate that the film can be processed, using the site facilities, to have a fog level not
greater than 0.3.
One radiograph in every 100 shall be subjected to a residual thiosulphate test, to ensure
that the film has been suitably processed for 5 years storage.
The procedure for this test
shall form part of the radiographic procedure package for COMPANY approval.
Radiographs shall be stored in an environment that will not detrimentally affect the
radiographs. Boxes shall be used to store radiographs in multiples of 25, 50 or 100 welds.
The weld numbers that apply to the stored radiographs that each box contains shall be
clearly visible on each box.
12.5
Manual Ultrasonic Testing

64B
12.5.1 General
12B
Add:
U
MUT shall comply with the requirements of ISO 17640. Specifications for MUT procedures
shall define the following:
Type of UT equipment;
Type and dimensions of transducers;
Range of frequencies;
Method of calibration;
Reference block drawing;
Surface requirements;
Coupling medium;
Examination techniques;
Page 66 of 75

(2004)
Weld identification method;
Reporting requirements;
Reference to the applicable WPS;
Temperature range of weld during examination.
12.5.3 Reporting and Evaluation

12B
Add:
U
Discontinuity indications having a amplitude above the reference level shall be assessed
against the requirements of Table 6 of BS 4515-1 and the following:
All cracks are unacceptable, regardless of size, location in the weld;
Linear indications (other than cracks) interpreted to be open to the surface are
unacceptable if they exceed a length equal to the wall thickness but not exceeding
25mm in total length in continuous 300mm length of weld or 8% of the weld length;
Linear indications interpreted to be buried within the weld are unacceptable if they
exceed a length equal to but not exceeding 50mm in total length in a continuous
300mm of weld or 15%of the weld;
Individual defects with a height greater than one pass height (determined after
reviewing a macro-section from the main line WPQT) but not greater than 4mm and
before interaction assessment shall not be permitted.
Automatic Ultrasonic Testing
12.6
65B
Add:
U
The use of automatic ultrasonic testing shall be subject to COMPANY approval in each
instance. The qualification of the AUT procedures and production testing shall comply with
GIS 43-339.
12.7
Magnetic Particle Testing

6B
Add:
U
Magnetic particle testing shall comply with the requirements of ISO 17638.
The non-fluorescent wet method of MPE using white contrast paint and an AC yoke (110V)
shall be used. Dry powder MPE may be used for repair groove inspection. The AC yoke
shall be capable of lifting 4.5 kg at 150 mm pole spacing. Poles shall make maximum
contact with the test surface during inspection. DC prods shall not be used.
Page 67 of 75

(2004)
All MPE procedures, including the method for determining adequate flux levels in the test
area, shall be qualified.
Page 68 of 75

(2004)
13.0
ACCEPTANCE AND RECTIFICATION OF WELDS

12B
13.1
Non-Destructive Testing Acceptance Criteria

67B
13.1.1 General
123B
Add:
U
The acceptance standards defined in Section 13.1.2 below shall be the minimum
requirement in which radiography is the primary NDT method. Where manual or semiautomatic welding processes are adopted with a conventional bevel configuration and RT is
the primary NDE method, MUT shall be used to supplement RT when cracks or planar
defects are detected during production welding. MUT shall be used to establish defect size,
height and position.
If the use of AUT has been approved by COMPANY, Section 13.1.2 below shall be
augmented by an ECA in accordance with BS 7910 (Level 3) to determine flaw dimensions
and acceptance levels which shall be subject to COMPANY approval (refer to Section
13.1.3 of this specification).
When unacceptable flaws occur in more than five consecutive welds or when, in the
opinion of the COMPANY, a particular flaw type becomes repetitive in terms of its size
and/or location, the cause of the flaws will be investigated by the Welding Engineers
working on behalf of the CONTRACTOR and the COMPANY. If necessary, welding will be
terminated until the cause of unacceptable flaws has been established and satisfactorily
resolved.
13.1.2 Acceptance Criteria Based on Quality Control
124B
Add:
U
In areas of weld preparation such as pipe ends, fusion faces and branches, planar defects
are not acceptable.
Add:
U
(BS 4515-1 Table 6f): The maximum length of incomplete penetration, lack of cross
penetration or lack of root fusion in any continuous 300mm weld length is limited to but not
exceeding 25mm.
Add:
U
(BS 4515-1 Table 6I) The maximum length of inter run fusion and lack of side fusion in any
continuous 300mm weld length is limited to but not exceeding 50mm.
Page 69 of 75

(2004)
Add:
U
(BS 4515-1 Table 6g) Cracks or crack like defects are unacceptable. In the event that such
defects are detected the complete weld shall be cut from the pipeline and the cause of the
cracking shall be established to the satisfaction of the COMPANY.
Add:
U
(BS 4515-1 Table 6k) Tungsten inclusions Tungsten inclusions shall not exceed two per
weld and shall be separated by a minimum of 50 mm. The maximum dimension of a
tungsten inclusion not to exceed 3mm or 50% of the wall thickness, whichever is smaller.
(BS 4515-1 Table 6k) Copper inclusions are not permitted.
13.1.3 Acceptance Criteria Based on Engineering Critical Assessment (ECA)
125B
Add:
U
The use of alternative acceptance standards for girth welds shall be subject to COMPANY
approval before contract award. The ECA method and testing shall be proposed for
COMPANY approval before the commencement of WPQT.
The output of the ECA shall be used to develop the weld NDT acceptance standard. The
weld acceptance standard shall include an appropriate NDT sizing allowance (see GIS 43339) which shall be clearly documented. In addition to the limits derived from the ECA, the
following restrictions on defect size shall apply:
Individual defects with a height greater than 4 mm (before interaction assessment)

shall not be permitted;
No acceptance of any defect >4mm shall be permitted, even if demonstrated

through the ECA;
Irrespective of defect height, defects with a length greater than 7 times wall
thickness (after interaction assessment) shall not be permitted.
The COMPANY reserves the right to modify the ECA acceptance criteria.
Add:
U
13.1.4 Suspected Welds

126B
Any weld suspected of not having been produced in accordance with the approved welding
procedure shall be cut out, and may be subject to investigation at the discretion of the
COMPANY.
Page 70 of 75

(2004)
13.2
Rectification of Welds
68B
13.2.1 Removal of Flaws

127B
Add:
U
A WPS for repair welding shall be in accordance with Section 8 of this specification.
Defects shall not be repaired in any part of the weld without prior acceptance by the
COMPANY. All repairs shall be witnessed by the COMPANY, and the relevant NDT
records shall be made available to COMPANY at that time.
Internal weld repairs shall not be permitted except for pipe-to-fitting welds where the repair
can be undertaken from the open end of the pipe or fitting, subject to successful welding
procedure qualification.
No more than two separate repairs are allowed in any single weld.
Welds with cracks (other than small crater cracks 4 mm in length) shall be removed from
the pipeline. The welding procedure shall be suspended until the cause is identified and
remedial measures implemented to prevent further occurrence. Production welding with the
suspended WPS shall only recommence following acceptance from COMPANY Welding
Engineer.
Small crater cracks shall be removed by local grinding and repaired.
For repair of arc burns, see 11.8.
13.2.2 Preparation for Re-Welding
128B
Add:
U
The minimum allowable repair length shall not to be less than 50 mm at the bottom of the
groove. Metal may be removed by thermal gouging followed by grinding. Grinding shall be
used for the last 3 mm through to the root. Air-arc gouging shall be controlled by a
procedure documenting the allowed variables as required by AWS C5.3.
If there are significant loads or deformation at the weld repair station, verified calculations
justifying the excavation size shall be submitted for COMPANY approval.
13.2.4 Re-Welding
129B
Add:
U
Internal weld repairs shall not be permitted except for pipe-to-fitting welds where the repair
can be undertaken from the open end of the pipe or fitting, subject to successful welding
procedure qualification.
Page 71 of 75

(2004)
When a root repair weld in a pipeline fails to comply with Section 13, the entire
circumferential weld shall be cut out and the pipe ends shall be re-bevelled and re-welded.
If necessary, a second repair may be attempted for all regions apart from the root. If this
second repair fails to meet Section 13, the entire circumferential weld shall be cut out.
One full penetration repair is permitted subject to successful welding procedure
qualification. Two partial penetration repairs are permitted subject to successful welding
procedure qualification. Partial penetration repairs are not permitted within 3mm of the pipe
internal surface.
The COMPANY may require the full circumference of repaired welds to be re-examined by
the same examination method which located the defect.
A full record of all repairs shall be maintained by the CONTRACTOR. The record shall be
made as each defect is discovered, and shall include the following:
The weld number;
The type and size of defect;
The circumferential location (defined to an accepted system);
An estimate of the depth (assessed by ultrasonic test where possible);
Mimic taken of repair profile and sketch included detailing (depth, position relative to
original weld, width and length of excavation);
Name and/or number of the welder who produced the defect;
Repair welding procedure number;
Name and/or number of repair welder;
Copy of the inspection report for the repair;
Date of repair.
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(2004)
ANNEX H ADDITIONAL REQUIREMENTS FOR PIPELINES SUBJECT TO HIGH STRAIN LEVELS
13B
H1
69B
Introduction
This section applies to pipelines subject to plastic deformation during installation, e.g.
installation by reeling.
When evaluating the amount of strain at the weld expected during installation, the effects of
misalignment, pipe strength variation, and coating stiffness shall be considered.
H.2
70B
General
H.2.1 Linepipe
130B
Pipelines welded in accordance with this appendix shall use linepipe that complies with the
additional high strain requirements of GIS 43-311, GIS 43-312, or GIS 43-313.
H.2.2 Welding Processes
13B
Welding processes not previously used by the CONTRACTOR with the proposed
installation method shall require full scale qualification trials. The extent of the trials shall be
determined by COMPANY.
Only low hydrogen processes shall be used.
H.2.3 Welding Consumables
132B
The consumable selection shall be approved by COMPANY and the consumable should
have a track record with the selected installation method.
The batch testing of weld consumables described in 7.2.2 shall be undertaken for each
batch of welding consumables not tested in the welding procedure qualification.
Additionally:
-
The strain age testing in accordance with Section H3 shall be performed.
The minimum Charpy energy shall be 70J at the impact test temperature.
The yield and UTS of the test weld shall exceed the maximum exhibited yield and
tensile properties of the production pipe.
H.3
71B
Weld Procedure Qualification Testing
H.3.1 Simulation
13B
The weld procedure qualification welds shall be subjected to full scale bending at the
maximum strain predicted during installation. The number of cycles shall be determined
from the number of cycles required for installation, plus any contingency operations and
Page 73 of 75

(2004)
agreed with COMPANY. Weld repair procedures shall be included in the full scale trial and
shall be located to undergo maximum strain.
A procedure shall be provided for COMPANY approval detailing the test string and test
method. The following points shall be addressed:
-
The type and number of welds. Each qualified WPS shall be included in the trial
test piece;
The length of the test string and the spacing of the welds;
The bending frame dimensions and materials;
The calculated maximum strain (based on the carousel & pipe diameters);
A step-by-step description of the test;
The proposed strain rate;
Trial report format.
If a successful track record using the same vessel to install pipe of similar properties with
similar welding procedures can be demonstrated; then, at COMPANYs discretion, the full
scale trial may be omitted. The spool base, the time between cycles, and the temperature
shall be considered when evaluating existing data.
H.3.2 Non-Destructive Testing
134B
The weld procedure tests shall be subjected to the visual and non-destructive testing
specified in Section 8 of this specification before and after straining.
H.3.3 Mechanical Testing
135B
The strength of the welds shall be greater than the strength of the production pipes;
however, excessive overmatch should be avoided.
H.3.3.1 Evaluation of Weld Procedure Bending Trial Welds
136B
The welds shall undergo the mechanical testing specified in Section 8 of this specification.
However, the transverse tensile locations shall be rotated so that the test pieces are
removed from the cardinal points. It is anticipated that this will ensure that the areas
undergoing maximum straining will be tested.
H.3.3.2 Evaluation of Weld Procedures Waived Bend Trial
137B
When the full scale trial is waived, the weld procedures shall be subject to the full testing of
Section 8 of this specification plus the following strain aged testing. Weld coupons shall
Page 74 of 75

(2004)
undergo 3% tensile strain and ageing at 250C for one hour before the following tests are
performed:
-
1 all weld tensile specimen;
2 transverse weld metal specimens;
1 macro-examination + hardness;
2 sets of weld metal Charpy impact specimens;
2 sets of fusion line Charpy impact specimens;
1 set of fusion line +2 mm Charpy impact specimens;
Weld and HAZ CTODs.
The testing shall be undertaken in accordance with Section 8 and the results shall meet the
requirements of Section 8 of this specification; however, any large deterioration of
properties compared with the unstrained specimens shall be cause for investigation.
H.4
72B
Production Welding
The maximum permitted pipe misalignment at the weld shall be 1.5 mm unless larger
misalignments are demonstrated to be tolerable and are agreed by COMPANY.
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Dev-Aad-mp-sp-jpk-1058 Rev b2 Welding and NDT of Cs Linepipe To Bs 4515-1 (2004)

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Dev-Aad-mp-sp-jpk-1058 Rev b2 Welding and NDT of Cs Linepipe To Bs 4515-1 (2004)

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CLIENT

ANDREW DEVELOPMENT PROJECT

WELDING AND NDT OF CARBON STEEL

RE-ISSUED FOR RFP

ISSUED FOR RFP

RE-ISSUED FOR COMMENT

ISSUED FOR COMMENT

RE-ISSUED FOR COMMENT.

ISSUED FOR RFP

RE-ISSUED FOR RFP

ISSUED FOR COMMENT

BP Exploration Operating Company Ltd

WELDING AND NDT OF CARBON STEEL LINEPIPE TO BS 4515-1(2004)

Purpose of Document .....................................................................................................4

HSEQ for Pipeline Welding Operations..........................................................................7

Duties of the Contractor..................................................................................................8

Quality Conformance ......................................................................................................8

Contractors Personnel ...................................................................................................9

Specification Compliance .............................................................................................12

Codes and Standards ...................................................................................................13

TERMS AND DEFINITIONS.....................................................................................16

INFORMATION AND REQUIREMENTS TO BE APPROVED AND DOCUMENTED17

Information to be Supplied by the Company ................................................................17

Items subject to approval by the Company ..................................................................20

WELDING PROCESSES .........................................................................................27

BP Exploration Operating Company Ltd

Automatic (Mechanised) Welding.................................................................................27

Storage and Handling ...................................................................................................29

TESTING, QUALIFICATION AND ACCEPTANCE OF WELDING PROCEDURES

Destructive Testing .......................................................................................................39

TESTING, QUALIFICATION AND APPLICATION OF WELDING PROCEDURE

Non-Destructive Testing of Fillet Welds .......................................................................46

Destructive Testing of Fillet Welds ...............................................................................46

TESTING, QUALIFICATION AND APPROVAL OF WELDERS..............................47

Butt Joints .....................................................................................................................47

Changes Affecting Qualification and Acceptance (Essential Variables) of Welders....48

Non-Destructive Testing ...............................................................................................48

Destructive Testing .......................................................................................................48

PRODUCTION WELDING .......................................................................................50

Proximity of Welds ........................................................................................................50

Pipe End Preparation....................................................................................................50

Fusion Faces ................................................................................................................51

Line-Up Clamps and Pipe Supports .............................................................................51

BP Exploration Operating Company Ltd

Tack Welds ...................................................................................................................52

Stray Arcs .....................................................................................................................53

Weather Conditions ......................................................................................................54

11.10 Preheating and Post Weld Heat Treatment..................................................................54

INSPECTION AND TESTING OF WELDS ..............................................................59

Manual Ultrasonic Testing ............................................................................................66

Automatic Ultrasonic Testing ........................................................................................67

Magnetic Particle Testing .............................................................................................67

ACCEPTANCE AND RECTIFICATION OF WELDS ...............................................69

Non-Destructive Testing Acceptance Criteria ..............................................................69