T/SP/P/2: Specification For The

T/SP/P/2
SPECIFICATION FOR THE
WELDING OF STEEL LAND PIPELINES DESIGNED TO

OPERATE AT PRESSURES GREATER THAN 7 BAR
(SUPPLEMENTARY TO BS 4515-1: 2009)
June 2009
© National Grid Gas plc 2009 – All rights reserved

)
i T/SP/P/2
CONTENTS
Page
FOREWORD iii
BRIEF HISTORY iv
KEY CHANGES iv
1. SCOPE 1
2. REFERENCES 1
3. TERMS, DEFINITIONS AND ABBREVIATIONS 1
4. INFORMATION AND REQUIREMENTS TO BE APPROVED AND DOCUMENTED 2
5. EQUIPMENT 2
6. WELDING PROCESS 2
7. WELDING CONSUMABLES 3
8. TESTING, QUALIFICATION AND APPROVAL OF WELDING PROCEDURES 4
9. TESTING, QUALIFICATION AND APPROVAL OF WELDERS 11
10. PRODUCTION WELDING 11
11. INSPECTION AND TESTING OF WELDS 16
12. ACCEPTANCE AND RECTIFICATION OF WELDS 17
TABLES
1 NATIONAL GRID GAS MATERIALS SPECIFICATIONS 19
2 INFORMATION TO BE SUPPLIED BY THE EMPLOYER 20
3 ITEMS SUBJECT TO APPROVAL BY THE EMPLOYER 22
4 ADDITIONAL TEST SPECIMENS FOR PROCEDURE APPROVAL OF

MECHANISED BUTT WELDS 25
5 TEST SPECIMENS FOR PROCEDURE APPROVAL OF REPAIR WELDS NOT

IDENTICAL TO THE ORIGINAL MECHANISED WELDING PROCEDURE 25
6 DESTRUCTIVE TESTING - PERMITTED RE-TESTS 26
7 CHARPY IMPACT SPECIMEN TEST REQUIREMENTS 27
8 WELD JOINT ALIGNMENT TOLERANCES 27
FIGURES
1 LOCATION OF ADDITIONAL TEST SPECIMEN FOR BUTT WELDS MADE WITH A

MECHANISED WELDING PROCESS 28
2 LOCATION OF TEST SPECIMENS FOR FORGED SET-IN BRANCH

CONNECTIONS 29

ii T/SP/P/2
Page
3 LOCATION AND NUMBER OF ADDITIONAL TEST SPECIMENS FOR FULL

PENETRATION REPAIRS TO BUTT WELDS MADE WITH A MECHANISED
WELDING PROCESS 30
4 LOCATION AND NUMBER OF ADDITIONAL TEST SPECIMENS FOR PARTIAL

PENETRATION REPAIRS TO BUTT WELDS MADE WITH A MECHANISED WELDING
PROCESS 30
5 POSITION OF CTOD SPECIMEN NOTCH FOR ASSESSING AN ORIGINAL

WELD OR A FULL PENETRATION REPAIR WELD 31
6 POSITION OF CTOD SPECIMEN NOTCH FOR ASSESSING A PARTIAL

PENETRATION REPAIR WELD 31
7 CONFIGURATION REQUIRED FOR SOCKET JOINTS PRIOR TO WELDING 32
APPENDICES
A REFERENCES 33
B GUIDANCE ON POST WELD HEAT TREATMENT 35
C PIPE END MAGNETISM 36
D BELL-HOLE EXCAVATION DETAILS 38

iii T/SP/P/2
FOREWORD
This Specification was approved by Gas Engineering Policy Manager on 26/06/09 for use by
Managers, Engineers and Supervisors throughout National Grid Gas.
National Grid Gas documents are revised, when necessary, by the issue of new editions.
Users should ensure that they are in possession of the latest edition by referring to the
Document Library of safety and engineering documents available on the company intranet.
Compliance with this safety and engineering document does not confer immunity from
prosecution for breach of statutory or other legal obligations.
BRIEF HISTORY
Edition Date Approval

First published as GC/PS/P2 February 1971 -
BGC/PS/P2
January 1974
(Various amendments made -
1974, 1975, 1976 & 1980).
BGC/PS/P2 + A1, A2 & April 1981 to February 1994
-
Erratum.
BGES/P2 +A1
(Incorporating BGC/PS/P2, November 1994 to April 2000
-
BGC/PS/P8 + A1, A2 & A3 and
BGC/PS/P17 + A1 & A2).
T/SP/P2 (editorial update to
reflect company de-merger EPSG/T03/733
June 2001 to August 2004
2000, National Grid merger EPSG/L01/328
2002 and to comply with GRM).
Revised and re-issued as
May 2006 EPSG/A05/10271
T/SP/P/2.
Revised and re-issued as
June 2009
T/SP/P/2
KEY CHANGES (Identifies the key changes from the previous document)
Section Amendments
Amended to align with revised BS 4515-1:2009 and further technical

Whole document
clarifications

iv T/SP/P/2
DISCLAIMER
This safety and engineering document is provided for use by National Grid Gas and such of
its contractors as are obliged by the terms and conditions of their contracts to comply with this
document. Where this document is used by any other party it is the responsibility of that party
to ensure that this document is correctly applied.
MANDATORY AND NON-MANDATORY REQUIREMENTS
In this document:
Shall: indicates a mandatory requirement.
Should: indicates best practice and is the preferred option. If an alternative method is used
then a suitable and sufficient risk assessment shall be completed to show that the alternative
method delivers the same, or better, level of protection.

1 T/SP/P/2
SPECIFICATION FOR
WELDING OF STEEL LAND PIPELINES DESIGNED TO OPERATE AT
PRESSURES GREATER THAN 7 BAR (SUPPLEMENTARY TO BS 4515-1:2009)
1. SCOPE
This specification provides requirements for the welding of steel land pipelines, designed to
operate at pressures greater than 7 bar up to and including 100 bar and in accordance with
IGE/TD/1.
This specification details the requirements for the welding of carbon, carbon manganese and
low alloy steel pipelines with specified minimum yield strengths (SMYS) not exceeding 555
2
N/mm (i.e. grade L555 or X80) designed in accordance with relevant IGEM documents.
This specification applies to the welding of pipe, fittings and attachments that comply with the
relevant National Grid Gas specifications given in Table 1 of this specification. It also applies
to the welding of pipe or fittings, not manufactured in accordance with the specifications in
Table 1, providing that the design and the mechanical and chemical properties of the pipe or
fitting comply with one of the specifications listed.
Welding shall be in accordance with BS 4515-1, except where amended by the additional or
alternative requirements contained within this specification. All modifications herein shall take
precedence over BS 4515-1. The clause references used within this specification relate
directly to those in the parent standard BS 4515-1.
2. REFERENCES
In addition to those documents referenced in Section 2 of BS 4515-1: 2009; reference is also

made to the documents listed in Appendix A of this specification, unless specified by dated
reference, the latest edition of the document, including all addenda and revisions, shall apply.
3. TERMS AND DEFINITIONS AND ABBREVIATIONS
3.1 Terms and definitions
The following additional definitions to those described in BS 4515-1 shall apply:
Bell-hole: An excavation that permits access to below ground pipe work

to facilitate the welding, inspection, coating or any other activity
required to conduct the works.
Consistency trials: A series of consecutive welds of repeatable quality made to the

satisfaction of the employer, to demonstrate that the proposed
welding process or welding system has the technical capability
to consistently produce sound welds with the desired
metallurgical properties using the approved welding procedure.
Dressing: Light grinding in the weld area where the parent pipe or fitting
is not reduced in wall thickness below the minimum allowed by
the relevant specification.
Employer: National Grid Gas plc, or its nominated representative.
Internal repair: A repair from the internal surface of the original weld consisting
of two weld runs only, one on top of the other.
Inspector: The body, association or employee which monitors that the

materials and construction are in accordance with this
specification.

2 T/SP/P/2
Pipeline: The extent of all fabrication up to and including block valve

assemblies, terminating at the attachment weld to a pig trap as
defined by the Pipeline Safety Regulations 1996 or as modified
by the Employer.
Remedial welding: Welding carried out to correct visual defects while the weld is
still above the original minimum inter-pass temperature stated
in the approved welding procedure.
Statutory Authority: The body or organisation that, through the power vested in it by
Government Statute regulates the requirements with which
particular pipelines have to comply.
Supply condition: This term is taken to mean the heat-treated condition of the materials to
be welded.
Tie-in weld: A welded joint that connects two sections of pipe work together in such
a manner that direct access to the internal surface of the joint is
precluded.
3.2 Abbreviations
For the purpose of this specification the following abbreviations apply:
• CTOD Crack tip opening displacement

• DN Nominal diameter
• NWT Nominal wall thickness
• OD Outside diameter
• MPA Manual Phased Array ultrasonic testing
• NDT Non-destructive testing
• SMYS Specified minimum yield strength.
4. INFORMATION AND REQUIREMENTS TO BE APPROVED AND DOCUMENTED
4.1 Information to be supplied by the Employer
See Table 2 of this specification.

4.2 Items subject to approval by the Employer
See Table 3 of this specification.
5. EQUIPMENT
In addition to the requirements of BS 4515-1:

The Contractor shall provide calibrated arc monitoring equipment that is independent of the
welding plant. It shall be used to record welding process or procedure qualification
parameters and for the surveillance of production welding. The equipment shall be made
available to the Employers Inspector for monitoring purposes when requested.
6. WELDING PROCESS
In addition to BS 4515-1 the following requirements shall apply:
6.1. Welding process and welding system approval

When required by the Employer, the contractor shall demonstrate that any proposed welding
process, combined welding process, or welding system has the technical capability to
consistently produce sound welds with the desired metallurgical properties using the
approved welding procedure. Welding procedure qualification and additional test welds shall
be made to prove consistency.

3 T/SP/P/2
The extent of any welding process or welding system consistency trials shall be agreed
between the contractor and the Employer. This should be agreed at tender or contract award
and in all cases shall be prior to the welding of procedure qualification welds.
As a minimum, the consistency trials shall include sufficient test welds to qualify the proposed
welding procedure, followed by five consistency test welds made using the approved welding
procedure.
6.2 Non-destructive testing and destructive testing requirements for welding

process and welding system consistency trials
All test welds shall be subject to full non-destructive testing in accordance with T/SP/NDT/2,
and shall meet the requirements of BS 4515-1, Table 9 (as amended by clause 12 of this
specification).
All welding procedure qualification test welds shall be subject to the destructive tests specified
in BS 4515–1 and any additional tests required by the employer. The number of CTOD test
specimens (if required), will be specified by the Employer or be agreed between the Employer
and the contractor prior to welding commencing.
One of the five consistency welds (chosen at random by the Employer) shall be subject to full
destructive testing. The extent of CTOD testing for this weld may be varied by agreement between
the Employer and the contractor prior to welding commencing. The test welds shall fully meet the
specified acceptance criteria.
Where a gas or self shielded flux cored wire process is proposed (either individually or as part of a
combined process procedure), all five consistency test welds shall be subject to full destructive
testing. The extent of mechanical testing shall be agreed between the Employer and the contractor
prior to welding commencing.
7. WELDING CONSUMABLES
7.1 General
• When tested in accordance with clause 8.3.2 the weld metal yield strength of welds in
pipe material of L555 (or X80) grade shall overmatch the specified minimum yield
strength by at least 5%.
• In addition to the requirements of clause 7.1, Note 2 of BS 4515-1, add to the end of
the first sentence “and BS EN ISO 18276”.
7.2 Storage and Handling
• There shall be no mixing of gases in the field.
• Compressed gases shall only be stored and handled in accordance with industry
guidelines and best practice.
• The contractor shall produce a welding consumable storage and handling procedure
for approval by the Employer. In addition to the requirements of BS 4515-1, 7.2 and
the recommendations of the consumable manufacturers, any special measures
identified by the contractor for the storage, handling and the use of welding
consumables in the field (e.g. vacuum packaging of electrodes at a location other
than the manufacturers factory) shall be fully described in this procedure.
• At the discretion of the Employer, the contractor shall be required to perform such
additional tests that demonstrate that the storage and handling of welding
consumables has not lead to any deterioration of the required consumable
specification or properties.

4 T/SP/P/2
8. TESTING, QUALIFICATION AND APPROVAL OF WELDING PROCEDURES

In addition to 8.1 of BS 4515-1 the following requirements shall apply:
8.1 General
Separate procedures shall be provided for any proposed remedial welding. Remedial
procedures are those that will be used to correct defects while the production joint is still
above the original joint minimum inter-pass temperature. The qualification of remedial welding
procedures shall simulate the intended production application. For production welding a
record of all remedial welding shall be made.
8.1 k)
Replace existing BS 4515-1 clause 8.1 k with:
In the event of the failure of a specified mechanical test specimen the Employer shall be
informed. Subject to meeting the criteria given in Table 6 of this specification and the following
requirements, a re-test will be allowed:
• Insufficient original weld material for re-test
Where there is insufficient material available for a re-test, a new test piece shall be
produced using the same welding procedure and a replacement specimen or set of
specimens for the failed specimen, as appropriate, shall be tested.
• Reason for failure of a test specimen
The reason for the original failure shall be established and reported to the employer.
All re-test results shall be reported to the Employer who will determine if the welding
procedure can be approved, or whether complete re-qualification of the welding
procedure is required.
• Failure of a re-test specimen
If any of the additional test specimens do not comply with the relevant requirements,
the proposed welding procedure shall be rejected.
8.1 l)

A calibrated welding arc monitor that provides a printed record shall be used to record the
welding parameters of all welding procedure qualification test welds (see 5.0).
8.1.1 Welding procedure test welds (all welding processes)

a) Welding procedure qualification tests shall be carried out on pipe or fittings made
from the same material and of the same outside diameter and thickness as that to be
used in production. When approved by the Employer, the range of approval specified
in clause 8.2 of BS 4515-1 may be applied to qualified welding procedures.
b) A minimum of two welders shall be used to weld pipe ≥ 457 mm OD.
c) Minimum preheat and weld inter-pass temperatures used in the qualification of a

welding procedure test weld shall be in accordance with 10.10.2 of this specification.
d) Welding electrodes or consumables achieving the low hydrogen requirements of

Scale D (as defined by BS EN 1011:Part 2, with ≤ 5 ml of diffusible hydrogen content
per 100g of deposited weld metal) shall be used to weld all un-pupped fittings ≥
914mm OD (see 10.1 of this specification).

5 T/SP/P/2
e) The sequence of joint completion shall be agreed between the Employer and the
contractor prior to welding procedure qualification tests commencing.
f) Where production conditions are such that pipe-to-pipe joints cannot be completed in
one welding heat cycle, the welding of the test welds shall simulate the number of
heat cycles where the joint has been allowed to cool to ambient temperature before
completion.
g) All fittings shall be welded with a root welded in the vertical-up direction and the weld
completed in a single heat cycle. At the discretion of the Employer, for material
grades up to and including L450, Induction bends with tangent lengths either side of
the bend may be welded in two heat cycles. Induction bends of L555 or X80 grade
material shall be welded in one heat cycle.
h) When the qualified welding procedure is intended to cover a range of thicknesses, it

may be necessary to complete the cap with a split or multi run cap rather than a
single weave cap, the welding procedure qualification test shall cover both capping
options.
Where both capping options can be accommodated on one test piece, then this shall
be permitted, providing that sufficient test material is available to remove all primary
mechanical test specimens from the required locations and the additional macro
specimens from each welding position covered by the alternative capping option. If
insufficient test material is available from the original test joint then a further test weld
shall be produced using the alternative capping option.
The additional macro specimens shall be subject to a hardness survey and macro
photograph (see 8.3.2.4 and 8.3.2.5).
i) Single stringer bead cap repair deposits and single pass internal repair procedures
will not be permitted (see j) below).
j) Qualification of a single pass root bead remedial procedure is permitted for

mechanised welding systems using internal welding heads only.
k) Remedial welding procedures shall be subject to the same qualification and testing
requirements as repair procedures.
l) Repair welds comprising two weld passes only, that are carried out to the internal
surface of the original weld joint and that use the same welding process as the
original welding procedure, shall be qualified by macro and hardness testing only
(see 8.4.3.3 and 8.4.3.4). The test specimens shall be removed from the applicable
location shown in Figure 4 b.
m) Re-repairs, i.e. multiple attempts to repair the same area of a weld shall not be
permitted.
n) When required by the Employer, a retrospective welding procedure qualification test

shall be performed between the new and the existing pipe materials that establish a
direct connection to an existing pipeline. This test shall be undertaken as soon as the
existing pipe material becomes available. The test weld shall be fully tested in
accordance with, and meet the requirements of this specification.
o) All fillet welds shall be welded using a low hydrogen process. The procedure shall
provide for a minimum of two passes. The major portion of the first pass shall be
deposited preferentially on the pipe or major component body.
p) Pin brazing of attachment lugs shall not be permitted for new construction projects.
q) Welding of socket joints shall be completed in a single heat cycle, with care being
taken to prevent overheating of the pipe and fitting during welding.

6 T/SP/P/2
r) For horizontal socket joints welding is only permitted using the vertical-up technique
(position PF).
s) Socket fillet weld leg lengths must be equal. The weld profile shall not be concave,
i.e. the fillet weld throat thickness must be greater than 0.7 times the leg length.
t) When ultrasonic testing is applied to manual welds as the primary method of weld
inspection before they have cooled to ambient temperature (i.e. below 60ºC) and
where water is the nominated ultrasonic couplant, the welding procedure qualification
test shall include simulation of the water cooling effect.
u) It may be necessary to produce more than one test weld to accommodate the
required mechanical testing. The contractor shall produce sufficient test welds to fully
qualify the proposed welding process or procedure in accordance with this
specification.
8.1.2 Welding procedure test welds (semi-automatic or mechanised welding

systems)
The optimum welding parameters used to qualify a semi-automatic or mechanised welding
system shall be recorded on the WPQR. Should the proposed limits of the welding parameter
range need to be more tightly controlled than the tolerances given in BS 4515-1 Table 1 this
shall be specified on the WPS sheet.
If the proposed limits of the welding parameter range will exceed the tolerances given in BS
4515-1 Table 1, further qualification will be required. The limits of the ranges used for
production welding shall be agreed between the Employer and the contractor prior to welding
commencing.
A test weld shall also be produced that demonstrates that the welding system is capable of
producing a sound weld at the extremes of joint fit-up tolerances.
8.1.3 Previously qualified welding procedures

Where a contractor proposes the use of a *previously qualified welding procedure, it shall be
offered for the Employer’s consideration at contract award stage. The approval or use of a
previously qualified welding procedure will be at the sole discretion of the Employer.
Previously qualified welding procedures will not be considered where either of the pipe
materials joined is L555 or X80 grade.
* That remains valid within the changes affecting approval given in clause 8.2 of BS 4515-1
and as amended by this specification.
8.2 Changes affecting qualification and approval (essential variables)

Add the following clauses:
8.2.1 When a welding procedure will be used on existing pipe material, confirmation of the
pipe chemical analysis and estimated material grade is required. This may be
confirmed through the production of the original mill certificate or by material sampling
in accordance with T/PM/Q/10.
8.2.2 L555 (or X80) grade pipe material is supplied to specific manufacturers target
chemistry. Where the Employer identifies a significant change in the target chemistry
of individual pipe production runs, then additional welding procedure qualification
shall be required.
8.2.3 The range of approval for set-on fittings shall be as follows:
a) Diameter of set-on fitting

7 T/SP/P/2
0.5D to 2D where the set-on fitting is 33.4mm OD.
0.5D to 1.5D where the set-on fitting is 60.3mm OD.
0.5D to D where the set-on fitting is 88.9mm OD.
b) Diameter of carrier pipe.
0.5D to 2D where the OD of the carrier pipe is ≤ 323.9 mm (no restriction above 323.9mm
OD).
c) Nominal wall thickness of test pipe:
Thickness range of approval
Dimensions in millimetres
*Thickness t of line
pipe tested
*Steel *Steel *Steel
2 2 2
Re ≤ 290N/mm Re >290 to ≤ 360N/mm Re >360N/mm
4.8 > t ≤ 12.7 t 4.8 to 12.7 Not applicable

6.4 to 14.3
12.7 > t ≤ 19.1 t Not applicable 12.7 to 19.1
19.1 > t ≤ 28.7 t Not applicable Not applicable 14.3 to 28.7
• Standardised line pipe supplied in accordance with T/SP/DAT/6
• Qualification of a higher yield strength material will cover a lower yield strength
material in the same range but not vice-versa.
• Where more than one thickness of pipe will be used within the yield strength ranges
given above, the thicker pipe shall be used to qualify the welding procedure.
d) Welding position
The range of approval for the welding position is ± 25° of the position tested except for
position PB according to BS 499-1:2009 which is qualified by position PE, PF or PG.
8.3 Testing of butt welds for procedure qualification

8.3.1 Non-destructive testing
The test pieces shall be examined as stated in BS 4515-1, 8.3.1 however, the examination
techniques used shall be in accordance with T/SP/NDT/2.
8.3.2 Destructive testing
8.3.2.1 Test specimens
• The macro specimens detailed in Figure 1a and 1b shall be hardness tested in
accordance with 8.3.2.5.
• The number of hardness surveys required for non-sour service by Table 3 shall be
amended to 2 for ≤ 114.3 mm OD and 3 for > 114.3 mm OD.
• The number of test specimens for destructive testing of repair test welds, where the
welding process or procedure is not identical to the mechanised or semi mechanised
welding procedure used to make the original joint, shall be as specified in Table 5 of
this specification.

8 T/SP/P/2
8.3.2.2 Transverse tensile test specimens

Transverse tensile testing is not required for butt welds in pipe ≤ 114.3 mm OD.
8.3.2.3 Weld metal tensile testing

Where L555 (or X80) pipe material grade is used or where CTOD tests are specified by the
Employer, two all-weld tensile specimens shall be prepared and tested in accordance with BS
EN 876 and BS EN 10002 Pt 1.The yield strength obtained for the weld metal shall overmatch
the specified minimum yield strength of the L555 (or X80) pipe by at least 5%.
8.3.2.4 Macro-examination requirements

In addition to the requirements of BS4515-1:
Photographs of each macro specimen showing the location of the hardness impressions shall
be provided with the mechanical test records for all welding procedures tested.
BS4515-1 requires that macro test specimens shall be examined at a magnification of x 5. In

addition, the degree of photographic magnification used shall be recorded accurately on the
test report.
Where L555 (or X80) grade material is examined, a macro specimen shall be removed at the
intersection of the pipe seam weld and girth weld location for hardness testing in accordance
with 8.3.2.5 of BS 4515-1 and this specification. Where there are two seam welds junctions,
the specimen shall be removed from the side of the joint with the highest carbon equivalent
percentage.
8.3.2.5 Hardness
In addition to the requirements of BS 4515:1
Hardness surveys shall be carried out on all macro specimens.
8.3.2.6 Impact testing

a) Charpy impact testing is required for all butt welds in pipe of outside diameter
greater than 114.3 mm.
b) Unless otherwise indicated, the test temperature shall be 0°C for buried
pipelines, minus 10°C for pipe-work for use in outdoor ambient conditions, or
the actual gas temperature, whichever is the lesser.
c) Absorbed energy requirements for Charpy impact tests are given in Table 7 of
this specification.
d) For joints greater than 15.9mm NWT, where the welding procedure includes a
*combination of welding directions and/or combined welding processes, an
additional set of VWT0 and VHT0 Charpy impact specimens shall be taken
from within 1mm to 2mm of the outer surface of the pipe and tested.
When the majority of welding is in the vertical up direction the specimens shall
be taken from the 3 o’clock position. When the majority of welding is in the
vertical down direction the specimens shall be taken from the 6 o’clock position.
When the volume of weld deposited in different directions is approximately
equal, the location of testing shall be agreed between the Employer and the
contractor prior to welding commencing.
*other than the composite procedure where the root pass is welded vertical–up
and the remainder of the passes are welded in the vertical-down direction
e) When the Employer specifies that batch testing of welding consumables is

required (e.g. for the welding of L555 (or X80) grade material), one set of weld

9 T/SP/P/2
metal, and one set of HAZ, cap Charpy impact specimens (positioned in
accordance with BS 4515-1 Figure 3b) shall be taken from the approximate
location shown in Figure 1 of this specification and tested at –20°C. These
tests are for information purposes only and the need for these tests shall be
agreed with the Employer prior to commencing procedure qualification welding.

Add the following clauses:
8.3.2.7 Material toughness testing for fracture mechanics calculations
The Employer may require additional destructive tests (i.e. CTOD and All-weld tensile tests).
They may be specified for particular projects, welding processes or welding systems, where
one or both of the pipe materials joined are a L555 (or X80) grade, or where the use of an
ECA to determine defect acceptance criteria is proposed.
8.3.2.8 Method of Testing for Main Procedure

Where CTOD testing is specified, the extent of testing shall be a minimum of one set of three
weld metal centre line specimens and one set of three fusion line specimens cut from the
area of highest heat input (usually 180°). For mechanised welding procedures, the minimum
additional specimens required for materials toughness testing shall be as given in Table 4 of
this specification or shall be as agreed with the Employer prior to welding of the test joint.
CTOD testing of the weld metal and heat affected zone shall be carried out at the minimum
design temperature in accordance with BS 7448 under displacement control. The fracture
toughness shall be reported in terms of the crack tip opening displacement (CTOD) and the J-
integral values. The test specimens shall be cut from the test joint at the locations shown in
Figure 1 of this specification. The specimens shall be notched as shown in Figure 3. All-weld
tensile specimens shall be cut from the test joint at the location shown in Figure 1 of this
specification and shall be prepared and tested in accordance with BS EN 876 and BS EN
10002 Pt 1. The primary purpose of the all-weld tensile test is to enable calculation of
fracture toughness to be made.
The Employer will specify any weld procedure acceptance and re-testing criteria.
8.3.2.9 Forged set-on branch attachments
National Grid specification T/SP/PW/11: Part 1 limits the maximum size of a set-on fitting to
88.9 mm OD. The destructive tests required when qualifying a small diameter branch
attachment welding procedure e.g. a weld-o-let (within the range 21.3 mm to 88.9 mm OD),
shall consist of two macro sections taken 90º apart from each other (one aligned with the pipe
axis and one transverse to the skirt of the weld). A hardness survey on both macro sections
is required in accordance with BS 4515-1, Figure 8.
8.3.2.10 Forged set-in branch attachments
The destructive tests required for the qualification of the skirt and branch welds of forged set-
in branch attachments (i.e. sweep-o-let fittings) shall be agreed with the Employer prior to
producing the test welds. As a minimum, testing shall be in accordance with and from the
locations shown in Figure 2 of this specification.
8.4 Testing of repair welds for procedure testing

8.4.3 Destructive testing
8.4.3.1 General

10 T/SP/P/2

Where the repair welding process or procedure is not identical to the mechanised or semi-
mechanised welding procedure used to make the original joint, the number of test specimens
for testing of the repair test weld shall be as specified in Table 5 of this specification.
Test specimens from a two pass internal repair test weld (see 8.1.1 k and l) of this
specification) shall be cut from the repair test weld from the applicable location shown in BS
4515-1, Figure 4 b.
Add the following clause to BS 4515-1:
8.4.3.6 Method of CTOD Testing for Repair Procedures
When material toughness testing has been used to obtain the approval of the main
procedure, the following specimens shall be removed from each repair procedure test weld
and tested at the minimum design temperature:
• Group A – Three preferred geometry fracture mechanics specimens with the notch
positioned along the centreline of the repair weld as shown in Figure 5 of this
specification.
• Group B – Three preferred geometry fracture mechanics specimens with the notch
positioned such that the fusion boundary between the repair weld and the original
weld intersects the notch tip at the mid-depth position of the repair weld as shown in
Figure 6 of this specification.
• Group C – Three preferred geometry fracture mechanics specimens with the notch
positioned such that the fusion boundary between the repair weld and the pipe
material intersects the notch tip at the mid-depth position of the repair weld as shown
in Figure 6 of this specification.
• For repair weld qualification of mechanised welds, the minimum number of CTOD
specimens and other tests required shall be as listed in Table 5 of this specification.
Any variation to the number of specimens tested shall be agreed with the Employer
prior to welding of the test joint.
• The acceptance and re-testing criteria for all repair weld procedures are identical to
the requirements of the original welding procedure.
• When material fracture toughness testing of the main procedure is required by the
employer for information purposes only, the extent of repair weld CTOD testing may
be reduced by agreement.
8.5 Testing of fillet welds for procedure qualification

8.5.2 Destructive testing of fillet welds
8.5.2.3 Macro-examination
Photographs of each macro specimen showing the location of the hardness impressions shall
be provided with the mechanical test records.

11 T/SP/P/2
BS 4515-1 requires that Macro test specimens shall be examined at a magnification of x 5. In

addition to this, the degree of photographic magnification used shall be recorded accurately
on the test report.
9. TESTING, QUALIFICATION AND APPROVAL OF WELDERS

9.1 General
For the purpose of welder qualification, set-on branch attachment welding shall be classed as
a butt weld.
9.2.2 Positional Welding
The welder’s test shall include the 6 o’clock and 12 o’clock pipe positions or the equivalent
positions for the specified categories b and c. Alternatively at the discretion of the Employer,
a welder may be qualified on the first production weld, not to include fittings. This shall
include not less than 100% of one side of a complete weld from 12 o’clock through to 6
o’clock position or the equivalent positions for the specified categories b and c subject to the
limitations of 9.1.
Add the following clause to BS 4515-1:
9.2.3 Mechanised welding

For single process mechanised welding, each welder shall be qualified for all parts of the
operation of making the joint (except where they are not required to make an internally
deposited root pass).
9.6 Non-destructive testing

The test pieces shall be examined as stated in BS 4515-1, 9.6 however, the examination
10. PRODUCTION WELDING
10.1 Proximity of welds

Replace the existing text in BS4515-1 with:
• Adjacent circumferential welds shall be separated by the lesser of one pipe diameter
or 750 mm (except where fittings with shorter pipe-pups are used). The Employer
shall be informed of any proposed deviation to this requirement and will decide
whether the joint may be welded or whether further modification to the pipeline or
pipe-work is required to ensure compliance.
• Any fittings (except induction bends with tangent lengths) equal to or greater than 457
mm OD to be used in a pipeline shall have pipe-pups welded to them under
fabrication shop conditions before being incorporated into the pipeline. The pup
length shall be not less than 250 mm. When space restrictions prohibit fittings with
pipe-pups being installed or results in a fitting being welded to a fitting, special care
shall be taken with the joint set-up and the application of pre-heat.
• Set-on welded attachments and fillet welds shall have a weld toe-to-toe distance from
any other weld of not less than four times the pipe thickness or 25 mm whichever is
the greater.
• Full penetration welds (e.g. forged set-in branches adjacent to circumferential or

longitudinal welds) shall normally be not less than 100 mm apart. Should special
circumstances require closer proximity, it shall be subject to the approval of the
Employer.
Note Welds should be separated by the maximum possible distance.

12 T/SP/P/2
The production route shall be planned to ensure that, where necessary, back grinding of root
beads and inspection of the weld root is maintained, this is particularly important for fittings
(see Table 2 s of this specification). To facilitate welding, repair and inspection, the use of
pipe-pups interposed between fittings and branches is desirable.
10.2 Pipe end preparation
The NDT requirements for the ultrasonic testing of cut pipe ends and areas of pipe prepared
for welded attachments is specified in clause 10.8 of T/SP/NDT/2.
10.3 Fusion Faces

Replace the first sentence in BS 4515-1 with:
The contractor shall ensure that the fusion faces on pipes and the adjacent material are free
from fins, planar flaws not conforming to clause 12.1, tears, moisture, scale, rust, paint,
grease, contamination or foreign matter immediately prior to welding.
Add to the existing text in BS 4515-1:
• Fusion faces not complying with the requirements of clauses 10.2 and 10.3 shall be
re-prepared before welding.
• All coatings other than fusion-bonded epoxy (FBE) shall be cut back not less than
150 mm.
• Except for FBE, all coatings and their adhesive mastics shall be prevented from
attaining temperatures sufficient to cause the emission of toxic fumes. Where a non-
FBE coating has been cut back, all traces of adhesive mastic shall be removed.
Scraping, blast cleaning or a suitable stripping agent may be acceptable. Heating
methods shall not be used.
• Consideration shall be given to providing personnel protection and effective collection

and disposal of fumes in all cases where a polyethylene or urethane coating may be
heated to temperatures that cause the emission of toxic fumes. Fumes from coating
removal and welding can be particularly hazardous in confined spaces.
10.4 Alignment
• No force shall be used to spring or superimpose additional stresses on any

component during construction.
• Mitres at welded joints are not permitted. Angular misalignment at the weld of less
than 3° is not classed as a mitre, and is acceptable provided that the misalignment is
equally distributed on both sides of the joint to a maximum of 1.5° per side.
• Prior to welding commencing the contractor shall submit a method statement for the
correction of excessive joint misalignment for approval by the Employer.
• To prevent unacceptable stress concentrations in the weld joint, line up clamps shall
be used to support and align the weld joint wherever possible. When the internal root
offset, after rotation of the abutting ends to achieve best alignment, is greater than the
tolerance range given in Table 8 of this specification, excessive misalignment shall be
corrected in accordance with the approved method statement before welding.

13 T/SP/P/2
• For pipes of different nominal thickness and the same outside diameter, alignment
shall be achieved in accordance with T/SP/P/16.
• For socket joints, the pipe end must be inserted fully into the socket and then
withdrawn 2.0 (+ 0.5, - 0) mm as shown in Figure 7 of this specification. This gap is
vital to the integrity of the finished joint. The assembly shall be checked to be
squarely aligned and any necessary adjustment made prior to tack welding (see 10.6
of this specification).
• When required by the Employer the contractor shall demonstrate that the correct
alignment and expansion spacing has been achieved for socket welded joints by
destructively testing a production weld chosen at random by the Employer or their
representative. Alternatively, the joint can be examined by radiography and the
original fit-up confirmed.
• For submerged arc welded helical (SAWH) i.e. spiral line pipe, and when joining line
pipe to a pre-fabricated fitting short pipe pup piece, the position of the weld seams at
the mating faces of adjacent pipes shall be offset by a distance of not less than
100mm.
10.5 Line up clamps and pipe supports
10.5.1 Use of line up clamps

In addition to the requirements of BS4515-1:
Precautions shall be taken to minimise pipe coating damage when external line-up clamps
are used. All external line-up clamps and earth return clamps shall be lifted into place and
shall not be dragged along the pipe surface. To eliminate coating damage when using
mechanised welding machines, the support frames shall be adequately padded and the
buttons on externally fitted bands shall be profiled to protect the coating surface from
damage.
10.5.2 Removal of pipe supports

The pipeline shall remain fully supported throughout the welding, inspection and coating
operations.
10.6 Tack welds

• Tack welding (excluding bridge tacks) shall be carried out in accordance with that part
of the approved welding procedure that is to be used for the root run. In all cases only
qualified welders may carry out tack welding. On diameters equal to or greater than
457 mm OD, at least four equally spaced tack welds, each not less than 50 mm
length, shall be used.
• Bridge tack welding may only be carried out when agreed by the Employer. The
contractor shall submit a written procedure for the Employers approval, which as a
minimum, shall describe the following items:
• The welding procedure to be used.
• The method of bridge tack welding.
• The type and size of material to be used as bridging pieces
• The pre-heating temperature to be applied before tack-welding.
• The sequence and method of bridge tack removal.

14 T/SP/P/2
• The maximum diameter of pipe that may be bridge tack welded and then moved to
another position or location to complete the weld.
• When the approved welding procedure uses low hydrogen consumables for the fill
and cap passes, bridge tacking shall take place using the same type of consumable.
• When socket joints have reached the minimum pre-heat temperature, the assembly
may be tack welded in order to maintain alignment during the welding cycle. A
minimum of two tack welds must be used, each not less than 12 mm in length. The
tack welds must be equally spaced. When welding pipes in the horizontal position,
the tack welds must be placed at the 3 o'clock and 9 o'clock positions. The tacks
shall be ground smooth and the ends tapered to ensure fusion of the remainder of the
weld run.
• Should excessive pipe end magnetism prevent satisfactory weld deposition, the
affected pipe or component shall be de-magnetised immediately prior to welding of
the joint (see Appendix C of this specification).
10.7 Working clearance

• Excavations shall meet the current statutory and National Grid Gas requirements. For
recommended dimensions of bell-holes see Appendix D of this specification.
Background lighting should be to Table 2 of T/PM/EL/1, for exterior illumination levels
for working areas. Refer to T/SP/NDT/2 for the required viewing conditions for visual
and magnetic particle inspection.
• Weather protection canopies or habitats must be of a clear flame retardant material or

have clear windows that allow an unobstructed view of the operation. The canopies
or habitats must be of adequate size to provide unhindered access for all heating,
welding and inspection activities. Provision shall be made for adequate welding fume
extraction.
10.8 Stray arcs

• In order to reduce the risk of unwanted arc strikes, electrode holders shall be of the
fully insulated type.
• Not more than one arc strike per weld may be repaired. Two or more arc strikes will
be cause for the complete removal of the weld and damaged pipe material.
• With the prior agreement of the employer in each case, weld deposition repairs to
restore pipe wall thickness shall only be carried out using an approved welding
procedure. The repaired area shall be examined using complementary NDT methods
capable of detecting surface and sub-surface weld defects in any orientation.
• The application of weld deposition repairs is limited to pipe material grade ≤ L450 and
2
shall not be carried out on pipe material with a SMYS ≥ 485 N/mm . Weld deposition
shall not be applied to pipelines that are designed to accommodate pressure cycling
or where it could affect the pipeline fatigue life.
10.9 Weather conditions

The Employer will decide, in consultation with the contractor, whether weather conditions are
such that work has to cease or whether with adequate weather protection, welding can
proceed or continue.
10.10 Preheating and post weld heat treatment

15 T/SP/P/2
10.10.1 General
Guidance is given in Appendix B of this specification for the post weld heat treatment of
welded joints when this is required, the PWHT welding procedure shall be to an appropriate
standard e.g. BS 2633.
10.10.2 Preheating
The minimum pre-heating temperature shall be determined by temperature-indicating crayons

(which melt when the required temperature is reached) or by suitably attached
thermocouples. Crayons or paints that indicate temperature by colour change and infra-red
pyrometers are not permitted.
For all pipe-to-pipe joints, fittings and socket assemblies, the following minimum preheat
temperatures shall apply (unless a higher pre-heat temperature is required based on the
results of weldability trials or if specified in the contractor’s proposed welding procedure):
a) Pipe to pipe joints
• Pipe material ≥ L450 ( or X65) grade and having a wall thickness greater than
or equal to 19.1mm;
(i) A minimum preheat temperature of 100°C shall be applied when

cellulosic welding procedures are used.
(ii) When approved by the Employer, a minimum preheat temperature of

80°C may be applied where the fill and cap passes are deposited using
low hydrogen consumables.
• A minimum preheat temperature of 100°C shall be used for pipe material of

L555 (or X80) grade regardless of wall thickness.
• For all other pipe grades (< L450 or X65) and wall thickness combinations, a
minimum preheat temperature of 50 °C shall be used.
b) Pipe to fitting or fitting to fitting joints
The weld procedure for fittings (other than socket assemblies), shall include a minimum
preheat and weld inter-pass temperature requirement of 150°C.
c) Socket joint assemblies
• Socket joint assemblies shall not be heated above 150°C care shall be
exercised to prevent overheating of the pipe and fitting.
• When welding socket assemblies adjacent to isolation joints or ball valves, the
body of the component shall not be allowed to exceed a temperature of 50°C
for an isolation joint or 100°C for a ball valve respectively. These components
shall only be welded under constant supervision.
d) Air-arc gouging
Where air-arc gouging is undertaken, both components shall be pre-heated to the minimum
temperature specified in the repair welding procedure prior to air-arc gouging

16 T/SP/P/2
e) Weld inter-pass temperature
The weld inter-pass temperature shall not fall below the minimum pre-heat temperature
specified on the approved welding procedure specification. Any variation proposed to this
requirement for pipe welding shall be approved by the Employer and be qualified at the lower
temperature during the welding procedure test.
10.10.3 Post weld heat treatment temperatures

Any proposal to use alternative methods for measuring the post-weld heat treatment
temperature shall be agreed by the Employer.
10.11 Branches
All branches shall be made with specialised fittings (e.g. forged or pressed tees, forged set-in
or set-on components) and these shall be specified in the design of the fabrication.
10.11.2 Spacing of branches

See clauses 10.1 of BS 4515-1, and 10.1 of this specification.
10.11.3 Joint preparation
The NDT requirements for the ultrasonic testing of cut pipe ends and area’s of pipe prepared
for welded attachments is specified in clause 10.8 of T/SP/NDT/2.
10.12 Inter-run cleaning

Delete the word “cracks” from the second paragraph and insert the following text at the end of
the final paragraph:
The cause of any visible cracks or crack-like indications found during welding shall
immediately be investigated and reported to the Employer or their Representative. Should a
crack be confirmed then the complete joint shall be cut-out and removed. Where a crack-like
indication is proved not to be a crack, it may be removed by grinding and the joint completed.
Note: Any delay to the normal welding cycle shall be within the maximum welding time-lapse
requirements if specified.
10.13 Partially completed joints

Add the following requirements to item a):
• Unless otherwise agreed by the Employer, the joint shall be completed in the
specified heat cycle (see 8.1.1 items e, f, g and q of this specification).
• Any welded joint carried out in a trench or excavation shall have at least 50% of the
weld joint thickness completed before being allowed to cool to ambient temperature.
• In excavations, where pipe fabrications are to be joined to a fixed end and the pipe
support can only be maintained throughout by mechanical lifting equipment, this joint
shall be completed in one welding cycle before being lowering off.

17 T/SP/P/2
Add the following requirements to item c):
• Any welded joint that will be left partially completed shall be fully supported
throughout each production stage i.e. before being allowed to cool to ambient
temperature, during re-heating and until the weld is completed. The method of
support shall be clearly defined by a method statement and submitted to the
Employer for approval.
• Prior to re-heating partially completed welded joints, the joint supports shall be
checked to ensure that the support has been maintained. This is required to
prevent potential failure and separation of a partially completed weld joint during
work as a result of unacceptable stress levels.
11. INSPECTION AND TESTING OF WELDS
11.1 General
Additional or alternative requirements to clause 11.1 of BS 4515-1 are specified in National
Grid specification T/SP/NDT/2 and 10.1, Table 2, 4.1 r, 4.1s and Table 3, 4.2z of this
specification.
Any additional NDT requirements for tie-in welds that will be hydrostatically tested shall be
agreed between the employer and the contractor before production welding commences.
The supplementary NDT methods to be used to examine welds that will not be hydrostatically
tested (i.e. golden welds) are specified in T/SP/NDT/2.
12. ACCEPTANCE AND RECTIFICATION OF WELDS

12.1.2 Acceptance criteria based on quality control
The following additional requirements to Table 9 of BS 4515-1 shall apply:
Flaw type Acceptance criteria

External profile a External weld reinforcement shall not exceed 3mm in
height
Cracks g Welds having defects identified positively as cracks
shall be cut out.
Crater cracks greater than 5mm in any direction shall
be cut out.
Crater cracks less than or equal to 5mm in any
direction shall be removed and repaired or cut out.
Isolated copper inclusions k Not permitted.
If present, all traces of copper shall be removed and
the weld repaired.
12.1.3 Acceptance criteria

When the Employer specifies that an engineering critical assessment (ECA) is to be used to
establish acceptance criteria, it shall be applied in accordance with the European Pipeline
Research Group (EPRG) tier 2 requirement (contained in BS EN 12732) or in accordance
with BS 7910:2005 + A1 as agreed with the Employer.
12.2 Rectification of welds

12.2.3 Qualifications

18 T/SP/P/2
• Where it is proposed to carry out a shallow repair to the internal surface of the original
weld, the test weld to qualify this type of repair shall be made into an excavation
sufficiently deep to accommodate two weld runs one on top of the other (see 8.1.1,
l)). Internal repairs consisting of three or more weld runs shall be treated as a multi-
pass back-weld repair and shall be qualified in accordance with BS 4515-1, 8.4.3.1
and Figure 4 e).
12.2.4 Re-welding
• Root sealing repair deposits are not permitted (see 8.1 i and 8.4.3 of this
specification).For mechanised welding systems that deposit the root bead internally,
remedial work may be carried out while the weld inter pass temperature is still above
the minimum stated in the approved welding procedure.
• Remedial welding procedures shall be approved by the Employer and qualified on

test welds that simulate the type of alternative repair (see 8.1 j and k of this
specification). For production welding a record of all remedial welding shall be made.
• During production welding, single woven and multiple pass external weld cap repairs
shall match the original weld profile and width (see 8.1.1 h of this specification).
• Internal repairs shall only be carried out when approved by the employer and subject
to a site specific risk assessment.

19 T/SP/P/2
Table 1. National Grid Gas material specifications
Items to be welded Relevant specification(s)
Bends, Tees, Reducers and End- B11

caps
B12
Forgings & Forged components F1
B12
Pipe TS-C4Gas-PIP0

20 T/SP/P/2
Table 2 Information to be supplied by the Employer (BS 4515-1; 4.1)

The following items are to be supplied by the Employer and shall be fully
documented:
Information (BS 4515-1) Requirement (T/SP/P/2)
a) Whether batch testing of electrodes and Batch testing is required when welding steels of
filler materials is required (see 7.1). minimum specified yield strengths greater than 485
2
N/mm (L485 or X70 grade).
b) Whether specific compositional controls are Specific compositional control requirements will be
to be applied to the deposited weld metal contract specific.
(see 7.1).
c) The degree of yield strength overmatching For L555 (or X80) pipe material grade the deposited
for welds in pipe materials where weld metal yield strength shall overmatch the SMYS
installation methods involve plastic of the parent material by at least 5%. Any other
deformation of the pipe or for welds in additional requirements will be contract specific.
grade L555 pipe (see 7.1).
d) Whether different batches of electrodes and For L555 (or X80) pipe material grade the individual
filler materials are to be individually batches shall be identifiable and completely
identifiable and completely separated separated.
(see 7.2).
e) The type and number of re-tests required in In the event of failure of any of the mechanical
the event of failure (see 8.1 k). tests, retests may be permitted at the Employers
discretion. (see 8.1 k of this specification).
f) Whether an alternative location is specified Alternative locations are not required.
for the excavation location for the repair
weld test (see 8.4.1).
g) Whether strain ageing data and/or Not applicable to land pipelines.
additional tests are required as the basis for
welding procedure approval for pipe reeling
(see 8.1i).
h) Whether specimens should be allowed to Any alternative duration will be contract specific.
cool for durations other than 24 hours
before testing (see 8.1g).
i) The method of weld tensile testing when a All-weld tensile specimens shall be prepared and
minimum weld metal yield strength tested in accordance with BS EN 876 and EN
requirement is specified (see 8.3.2.3). 10002 Pt 1.
j) The number and location of transverse Transverse tensile testing is not required for butt
tensile test specimens required for welding welds in pipe of outside diameter ≤ 114.3 mm (see
procedure testing on pipes up to and 8.3.2.2 of this specification).
including of 114.3mm diameter (see
8.3.2.1).
k) Whether Charpy impact tests are required Charpy impact testing is required for all butt welds
for welding procedure approval of butt joints in pipe of outside diameter greater than 114.3 mm
(see 8.3.2.1) (see 8.3.2.6 a of this specification).
l) The number and location of test specimens Charpy impact testing is not required for butt welds
required for Charpy impact tests on pipes of in pipe of outside diameter 114.3 mm or less (see
diameter 114.3mm or less (see 8.3.2.1). 8.3.2.6 a of this specification).

21 T/SP/P/2
Table 2 (continued) Information to be supplied by the Employer (BS 4515-1; 4.1)

The following items are to be supplied by the Employer and shall be fully
documented:
Information (BS 4515-1) Requirement (T/SP/P/2)
m) Charpy toughness and test temperature for The Employer will specify any requirements different to
conditions other than pipe and wall those specified in 8.3.2.6 on a contract specific basis.
thicknesses up to and including 25 mm,
minimum design temperatures not lower
°
than –10 C and pipe grades up to L555 (see
8.3.2.6).
n) Whether additional NDT methods for fillet No additional methods are required
welds apply (see 8.5.1 b).
o Whether alternative hardness values to The hardness limits shall be as specified in
those given in Table 7 are required (see BS 4515-1: Table 7.
8.5.2.4).
p) Whether a proposed change to a welding Any change in the welding procedure or equipment
procedure or equipment requires re- which, in the opinion of the Employer, makes
qualification of the welders (see 9.5 i). production of a sound weld more difficult will be cause
for re-qualification of the welder.
q) Whether prevailing weather conditions are The Employer will decide, in consultation with the
such that quality of the completed weld contractor, whether weather conditions are such that
.
would be impaired (see 10.9) work has to cease or whether with adequate weather
protection welding can proceed or continue.
r) The method(s) and frequency of visual Each weld shall be examined visually during
inspection and NDT (see 11.1). production and upon completion to ensure compliance
with the approved welding procedure and to detect
unacceptable defects. See 10.12 and 11.1 of this
specification and also T/SP/NDT/2: clause 8.1.
s) Whether completed welds are to be ground Welds may be dressed internally or externally to assist
(see 11.1). inspection and interpretation. Set-in fittings e.g.
sweep-o-lets shall have the weld cap and root dressed
(internally only where access permits, see 10.1of this
specification).
t) Whether alternative techniques are to be An alternative technique to BS EN 1435: 1997 Class B
used for radiographic testing of welded butt shall not be used without the approval of the
joints (see 11.4.1). Employer.
u) Ultrasonic testing acceptance criteria BS 4515-1: Table 9 as amended by clause 12.1.2 of
(see 11.5.3) this specification
v) Whether NDT acceptance criteria are to be An ECA will only be required when specified by the
based on quality control or engineering Employer.
critical assessment (see 12.1.1).
w) Whether the maximum planar defect When specified by the Employer.
dimension is to be less than 25 mm
(see 12.1.2).
x) Whether a more stringent limit for root When specified by the Employer.
penetration is required (see Table 9 flaw
type c).
y) Whether different hardness limits for anode The hardness limits shall be as specified in BS4515-1:
bonding joints are required (see B.2). clause B.2, b.
Note: BS 4515-1 Items z) to jj) refer to clad steels which are outside the scope of T/SP/P/2

22 T/SP/P/2
Table 3 Items subject to approval by the Employer (BS 4515-1; 4.2)

The following items are subject to approval by the Employer and shall be fully documented:
Item (BS 4515-1) Requirement (T/SP/P/2)
a) Welding consumables to be used (see 7.1). Only welding consumables approved by the
Employer may be used.
All fillet welds shall be welded with low hydrogen
electrodes.
Cellulosic electrodes shall not be used for the
welding of fittings of 914 mm pipe outside diameter
and above.
For L555 (or X80) grade pipe materials cellulosic
electrodes shall only be used for the root and hot
pass runs. All subsequent runs shall be completed
using low hydrogen welding consumables.
b) The definition of a batch when batch testing For consumables designed to match or exceed the
of electrodes and filler materials is required strength of L555 (or X80) grade pipe material, each
(see 7.1) material cast shall be tested. A BS EN 10204 Type
3.1 certificate, giving the chemical analysis, tensile
and Charpy impact properties shall be supplied
(see Table 2 a of this specification).
c) The tensile strength of weld metals for joints The tensile strength of the higher strength parent
between dissimilar materials if other than material will apply.
that of the higher strength parent metal (see For L555 (or X80) grade pipe material, the weld
7.1) metal yield strength shall exceed the parent
material minimum yield strength by at least 5%.
d) Test weld production on pipes shorter than The Employer will decide whether any deviation can
full length (see 8.1 b). be permitted (e.g. PC welding position).
e) Use of roll welding (see 8.1 d). To be approved by the Employer.
Roll welding shall be limited to pipe of maximum
219 mm outside diameter.
f) Use of a test weld for destructive testing or The Employer will decide whether a defective test
re-welding to the same procedure following weld may be used for destructive testing.
NDT failure (see 8.1 h). If the failure is due to cracking, the reason for
cracking shall be established by the contactor.
The results of this investigation shall be submitted
to the Employer before attempting to produce
another test weld using the original welding
procedure.
g) The type and number of re-tests of a In the event of failure of any of the mechanical
welding procedure when they are permitted tests, retests may be permitted at the Employers
(see 8.1 k) discretion. (see 8.1 k of this specification).
h) Welding procedure qualification test details To be approved by the Employer prior to production
and welding procedure specification for welding commencing.
production welding (see 8.1 l).
i) Any deviations from the ranges given in The Employer shall review any proposed deviation.
Table 2 (see Table 1). Consideration shall be given to the potential for any
deviation to produce an adverse effect on the
integrity of the welded joint.
i) Simulation of a fillet weld joint using flat Simulation plate fillet welds are permitted.
plate fillet welds (see 9.4.1b).

23 T/SP/P/2
Table 3 (continued) Items subject to approval by the Employer (BS 4515-1; 4.2)
The following items are subject to approval by the Employer and shall be fully documented:
k) Alternative methods of NDT for welder test With the prior approval of the Employer, butt weld
pieces (see 9.6c). tests may be examined using MPA ultrasonic
testing.
Fillet weld tests shall be examined visually and by
magnetic particle inspection.
l) Giving a welder a second opportunity to The Employer may agree to a second test attempt,
gain approval (see 9.8). where it can be demonstrated that the reason for
failure was beyond the welders' control.
m) All documentation relating to welder Records shall be kept for the period of validity. A
qualification tests (see 9.9) welder’s qualification will remain valid for the period
stated in BS 4515-1:9.1 subject to satisfactory
performance.
n) Use of manual thermal cutting for pipe end Not permitted.
bevelling and the ability of the operator
(see 10.2).
o) The blending out by grinding of minor The blending out of minor imperfections will be at
imperfections within the joint preparation the Employers discretion in each case.
area (see 10.2 a).
p) Method of marking datum points on a joint See T/SP/NDT/2: D7.1.
for ultrasonic testing (see 10.2).
q) Method of obtaining minimum mis- The contactor shall submit a method statement for
alignment other than rotation of the pipes approval by the Employer that details how
(see 10.4). excessive pipe misalignment will be corrected. (see
10.4 of this specification).
r) Method of alignment of pipes other than Wherever practicable, approved external or internal
internal line-up clamps (see 10.5.1). pipe clamps shall be used (subject to pipe
diameter).
s) The stage at which line clamps are See BS 4515-1: clause 10.5.1.
removed (see 10.5.1).
t) The stage at which the pipe is lowered onto The root bead shall be completed and any
skids or support is removed for fittings (see additional reinforcement deposited (if required by
10.5.2). the qualified welding procedure) before the pipe is
lowered off.
All pipe and fittings must be fully supported
throughout the welding cycle (see 10.5.2 of this
specification).
u) Repair of places where stray arcs have See clause 10.8 of this specification.
occurred (see 10.8).
v) Means of applying preheat (see 10.10.2). To be approved by the Employer prior to use (see
10.10.2 of this specification).
w) Methods of attaching and removing The methods to be used shall be submitted to the
thermocouples (see 10.10.4). Employer for approval prior to use.
x) The welding procedure for branch All branches shall be made with specialised fittings
connections where the angle between the e.g. forged or pressed tees, forged set-in or set-on
main and branch is less than 60° fittings which preclude the need for a branch / main
(see 10.11.1). angle of less than 60°.

24 T/SP/P/2
Table 3 (continued) Items subject to approval by the Employer (BS 4515-1; 4.2)
The following items are subject to approval by the Employer and shall be documented:
y) Written ultrasonic examination procedure See T/SP/NDT/2, 10.8.

for pipe material around planned cut out A written procedure shall be submitted to the
(see 10.11.3). Employer for approval prior to commencing.
z) All NDT procedures to be used for See T/SP/NDT/2, 7.1.
inspection and testing (see 11.1).
aa) All inspection personnel (See 11.2). See T/SP/NDT/2, 6.1.
All inspection personnel shall be qualified in the
appropriate grade of the BGAS approval scheme
for the duties they are to perform.
bb) The technique in BS EN 1435:1997 +A2 to See T/SP/NDT/2, 9.1.2.
be used for radiographic examination (see Alternative techniques shall not be used without the
11.4.1). Employers approval.
cc) Any method for magnetic particle testing to See T/SP/NDT/2, 12.3.
be used at above ambient temperature Magnetic particle testing shall be carried out at
[see 11.7 a)]. ambient temperature, unless otherwise agreed by
the Employer.
dd) Any alternative standard to be used for To be specified by the Employer on a project
engineering critical assessment (see specific basis (see 12.1.3 of this specification).
12.1.3).
ee Any proposal to repair a weld (see 12.2.1). See clauses 8.4 and 12.2 of BS 4515-1 and 8.4 and
12.2 of this specification.
ff) Any alternative limits on repair weld length Not permitted without the Employers approval.
(see 12.2.1).
gg) Use of root sealing or single run repair Root sealing and single stringer bead cap repair
deposits (see 12.2.4). deposits are not permitted (see 8.1 i and j of this
specification).
hh) More than one attempt at repair Not permitted.
(see 12.2.4).
ii) The position of the longitudinal seam weld Not applicable, should National Grid Gas build a
(if applicable) on the sub sea pipeline at the sub-sea pipeline a specific T/SP/P/2 Annex A
hyperbaric weld location (see annex A). supplement will be issued.
jj) Joining technique and equipment for To be approved by the Employer prior to production
brazing or aluminothermic welding of anode welding commencing (see 8.1 p of this
bonding leads (see B.1). specification).
kk) Proposed brazing or aluminothermic To be approved by the Employer prior to production
welding procedure specification (see B.2). welding commencing (see 8.1 p of this
specification).
Note: BS 4515-1 items ll) to qq) refer to clad steels which are outside the scope of T/SP/P/2.

25 T/SP/P/2
Table 4 Additional test specimens for procedure approval of mechanised or semi-

automatic butt welds
Number of specimens
1 2, 4
All weld tensile CTOD weld centre CTOD weld HAZ Macro/
2, 4 3
line Hardness
2 *6 *6 1
1) All weld tensile specimens required for yield strength confirmation and CTOD calculation.
2) CTOD (Bx2B, SENB) tested at the minimum design temperature under displacement control.
3) Macro specimen (and hardness survey) at butt weld and pipe seam weld junction.
4) *The number of CTOD specimens required shall be agreed with the Employer prior to the
welding of any test welds.
Table 5 Test specimens for procedure approval of repair welds not identical to the
original mechanised or semi automatic welding procedure
Number of specimens
Number of specimens 3
Charpy CTOD
Type of Weld Repair All weld Tensile Weld HAZ Weld HAZ Macro &
tensile centre Hardness
2
line
1
Full Penetration Repair 1 1 3 3 3 3 1
Partial Penetration 1 1 3 6 3 6 1
1
Repair
Internal Root Repair 0 0 0 0 0 0 1
1) For typical locations see Figure 3 and 4.
2) Hardness survey made on macro-examination specimen.
3) The number of CTOD specimens required shall be agreed with the Employer prior to the welding
of any test welds.

26 T/SP/P/2
Table 6 Destructive testing of welding procedures – permitted re-tests
Re-test Re-testing requirements

Type of test Failure type
allowed
Any specimen type Invalid due to a geometric

2
or volumetric weld Yes Two additional specimens
imperfection
Transverse tensile test
Failure to meet test 3
All weld tensile test Yes Two additional specimens
requirements
One set of Charpy Failure to meet test One additional set of

Yes ,4
impact test specimens requirements specimens
Failure to meet test
Fracture test No Welding procedure rejected
requirements
Failure to meet test
Macro specimen No Welding procedure rejected
requirements
Failure to meet test 5
Hardness survey Yes Additional hardness survey
requirements
Note 1: General - A retest will be allowed providing that not more than one of the original valid
specimens tested fails to meet the requirements.
Note 2: For each invalid specimen, a further two specimens shall be tested. Where three individual
specimens comprise a set of specimens and failure is due to an invalid specimen, one additional
set of three individual specimens shall be tested.
Note 3: Providing that not more than one of the original valid specimens tested failed to meet test
requirements, two additional test specimens shall be taken from a location either side of the failed
specimen.
Note 4: Where three individual specimens comprise a set of specimens and a single specimen
has failed, one additional set of three individual specimens shall be tested. Each additional
specimen shall meet the individual minimum value required and the combined average value of all
six specimens tested (the additional set and the original set) shall meet the required minimum
average value for a set.
Note 5: If a single hardness impression fails to meet test requirements, two additional hardness
impressions, one either side of the original failed impression may be tested. The additional
hardness impressions shall not be influenced by deformation caused by the failed impression.
Should it be impractical to re-test adjacent to the original failed hardness impression, the original
macro specimen surface shall be reground (or with the approval of the Employer the specimen
reversed), re-prepared in accordance with 8.3.2.4 and re-tested.

27 T/SP/P/2
Table 7 Charpy impact specimen test requirements
Charpy vee-notch Minimum Impact energy requirement (J)

Pipe thickness
specimen size Individual value Average value
≥ 12.5 to < 25mm 10mm x 10mm 30 40
1 1
≥ 12.5 to < 28mm 10mm x 10mm 45 56
2
≥ 10mm to < 12.5mm 10mm x 7.5mm 24 32
≥ 6.3mm to < 10mm 10mm x 5.0mm 21 28
≥ 6.3mm to < 10mm 10mm x 2.5mm 11 15
1. Requirement for L555 ( or X80 )grade materials.
2. For pipe thickness ≥12.5 mm full size specimens shall be used
3. The sub-sized specimen impact requirements apply only to materials with a SMYS ≤ 448
2
N/mm .
Table 8 Weld joint alignment tolerances
*Permitted misalignment of abutting surfaces
Wall thickness External misalignment Internal misalignment
1.5 mm around entire

T ≤ 10 mm 0.3 x T
circumference
10 mm < T ≤ 24 mm 3.0 mm 2 mm over length DN
T > 24 mm 0.125 x T 2.5 mm over length 1/3 DN
* Unless a lower tolerance is specified by the pipe work designer.
Note: T = Pipe or component thickness. DN = Nominal diameter.

28 T/SP/P/2
8 1
2
5
4 3
Specimen Position Mechanical Test

Location
1 45° All weld tensile
2 Typically 140° Set of weld metal Charpy impact tests at –20° C
3 180° Set of CTOD weld centre line tests
4 180° Set of CTOD weld heat affected zone tests
5 225° All weld tensile
6 270° Set of CTOD weld centre line tests
7 270° Set of CTOD weld heat affected zone tests
8 Pipe weld seam Macro and hardness
Notes:
a) The above specimens represent the minimum requirements and may increase
depending on wall thickness and the use of any mixed welding processes.
b) The Employer will specify the number of CTOD specimens required. As a
minimum one set of weld metal and one set of HAZ specimens shall be tested
from the area of highest heat input.
c) The all weld tensile specimens shall be taken from as high up in the weld body
as practicably possible without compromising specimen size.
d) The hardness survey is made on the macro-specimen.
e) Specimens from location 2 will only be required when batch testing of welding
consumables is specified by the Employer.
Figure 1 Location of additional test specimens for butt welds made with a mechanised
welding process

29 T/SP/P/2
Top
Fitting Pipe
Side
Side Top
Location Specimens
1 Macro and hardness
a,b
2 Set of Charpy impact tests, weld metal centre line
a,b
3 Top Set of Charpy impact tests fusion line pipe side
a,b
4 Set of Charpy impact tests fusion line fitting side
5 Transverse Tensile (reduced section, if necessary)
6 Macro and hardness
a,b
7 Set of Charpy impact tests, weld metal centre line
a,b
8 Set of Charpy impact tests fusion line pipe side
Side a,b
9 Set of Charpy impact tests fusion line fitting side
10 Transverse Tensile (reduced section, if necessary)
c
11 All weld metal tensile specimen
a .
Specimens shall be located within 2mm of the root surface of the weld
b
When the pipe wall thickness exceeds 20mm, 2 additional sets, one weld metal, one fitting
HAZ are required at both locations, but taken within 1mm to 2mm of the outside surface of
the pipe.
c 2
When required by the employer (i.e. for fitting material of 555N/mm SMYS), an all weld
metal tensile specimen taken from the side of the sweepolet weld shall be tested in
accordance with 8.3.2.3
Figure 2 Location of test specimens for forged set-in branch connections

30 T/SP/P/2
Specimen Location
Set of Charpy Tests Weld Metal Centre Line 1
1
Set of Charpy Tests Weld Fusion Line 2
2 All Weld Tensile 3

Macro and Hardness 4
3 Set of CTOD, Weld Centre Line Tests (Fig 1) 5
Set of CTOD, Weld Fusion Line Tests (Fig 1) 6
4
Tensile 7
5 Note 1: The minimum requirement may increase depending
on wall thickness and the use of any mixed welding
6 process
Note 2: The hardness survey is made on the macro
7 specimen.
Note 3: The number of CTOD specimens required may be
varied by National Grid agreement
Figure 3 Location and number of additional test specimens for full penetration repairs to
butt welds made with a mechanized welding process
Specimen Location
Macro Hardness 1
1
Set of Charpy Tests Weld Centre Line 2
2
Set of Charpy Tests Weld Fusion Line 3
3 Set of Charpy Tests Weld/Weld Fusion Line 4
4 All Weld Tensile 5
5 Set of CTOD Weld Centre Line (Fig 2) 6

Set of CTOD, Weld Fusion Line (Fig 2) 7
6
Set of CTOD Weld/Weld Fusion Line (Fig 2) 8
7 Tensile 9
Note 1: The minimum requirement may increase depending
8
on wall thickness and the use of any mixed welding
9
process
Note 2: The hardness survey is made on the macro
specimen.
Note 3: The number of CTOD specimens required may be
varied by National Grid agreement
Figure 4 Location and number of additional test specimens for partial penetration repairs
to butt welds made with a mechanized welding process

31 T/SP/P/2
Positions of CTOD notches
Original weld or full

penetration repair weld
Figure 5 Position of crack tip opening displacement specimen notch for assessing
original weld or full penetration repair weld
Figure 6 Position of crack tip opening displacement specimen notch for assessing partial-
penetration repair weld

32 T/SP/P/2
Figure 7 Configuration required for socket joints prior to welding

33 T/SP/P/2
APPENDIX A
REFERENCES
In addition to those documents referenced in BS 4515-1: 2009 section 2; reference is made to

the following documents required for the application of this specification:
External documents
BS 499-1:2009 Welding terms and symbols Part 1- Glossary for welding, brazing and
thermal cutting
BS 499-1 Supplement: 1992 Welding terms and symbols Part 1- Glossary for
welding, brazing and thermal cutting – Definitions for electric welding
equipment
BS 2633 Class 1 arc welding of ferritic steel pipe work for carrying fluids.
BS 4515-1:2009 Specification for welding of steel pipelines on land and offshore:

Part 1: Carbon and carbon manganese steel pipelines.
BS 7448-2 Fracture Mechanics toughness tests Part 2. Method for determination of

KI c, critical CTOD and J integral values of welds in metallic materials.
BS EN 876 Destructive tests on welds in metallic materials – Longitudinal tensile test

on weld metal in fusion welded joints.
BS EN 895 Destructive tests on welds in metallic materials – Transverse tensile test.
BS EN 1011: Part 2 Welding – Recommendations for welding metallic materials Part 2: Arc
welding ferritic steels
BS EN 10002-1 Tensile testing of metallic materials –Part 1: Method of test at ambient

temperature
BS EN 10204 Metallic products – Types of inspection documents
BS EN 12732 Gas supply systems – Welded steel pipe work – Functional requirements
BS EN ISO 18276 Welding consumables – Tubular cored electrodes for gas-shielded and
non-gas shielded metal arc welding of high strength steels - Classification
IGEM Documents
IGE/TD/1 The Institute of Gas Engineers Recommendations on Transmission and

Distribution Practice – Steel Pipelines for High Pressure Gas
Transmission.
National Grid Gas documents
T/SP/B/11 Carbon and carbon manganese steel bends 200mm nominal size and
above produced from pipe by induction bending for operating pressures
greater than 7 bar
T/SP/B/12 Steel bends, tees, reducers and end caps operating at pressures greater
than 7 bar
T/SP/F/1 Carbon and carbon manganese steel forgings and forged components
operating at pressures greater than 7 bar

34 T/SP/P/2
T/PM/EL/1 Procedures for the selection, maintenance and installation of luminaires and
lamps
T/PM/Q/10 The sampling of steel pipe and fittings for material testing for pipelines and
pipe work designed to operate above 2 bar.
T/SP/P/16 The dimensions and applications of standard weld end preparations for
steel pipe, fittings and valves
T/SP/PW/11: Part 1 Pipework systems operating at pressures exceeding 7 bar Part 1 –

Design and materials
T/SP/NDT/2 Non-destructive testing of welds on construction and fabrication projects
TS-C4 Gas – PIPO Specification for steel pipes for pipelines
Statutory Instruments
1996 No 825 Pipeline Safety Regulations 1996

35 T/SP/P/2
APPENDIX B
GUIDANCE ON POST WELD HEAT TREATMENT
B.1 Post-weld heat treatment of circumferential butt welds may be required in the
following circumstances:
a) When the carbon equivalent of the material based on ladle analysis is greater
than 0.53.
b) When the pipe thickness is greater than 32 mm.
c) When hardness limitations cannot be met in the as-welded condition.
When materials of differing thickness or carbon equivalents are to be welded, the greater
thickness or carbon equivalent should be used in determining the post-weld heat treatment
requirements.
B.2 Where residual stresses are to be controlled, it is normally necessary to carry out a
stress relieving heat treatment which will involve heating the pipe or component to a
temperature within the range 580 °C to 620 °C, maintaining this for a period of time followed
by controlled cooling. This heat treatment procedure can take some hours to complete.
Reference should be made to an appropriate standard (e.g. BS 2633) for the details of
carrying out such heat treatment.
Where hardness reduction is required, normally a short term tempering procedure is used.
This involves rapid heating of the pipe to a temperature higher than 450 °C followed by air-
cooling. The extent of this heat treatment should be ascertained by experimental work to
ensure that the required properties are achieved for a specific application.
B.3 The methods of applying heat treatment are:
a) furnace, slow heating and cooling times.

b) induction coils, rapid through-thickness heating, large power supply needed,
narrow band of heating possible.
c) resistance coils, slower heating than induction, very controllable but slower.

36 T/SP/P/2
APPENDIX C
PIPE END MAGNETISM
C.1 Introduction
Excessive magnetism at the pipe ends can prevent satisfactory weld deposition; this is
particularly so when a magnetic pig has been passed through the line but also may be
present in new components.
To overcome this magnetic effect, a number of alternative actions may be carried out,
depending upon the strength of the effect.
C.2 Low levels of magnetism

At low levels of magnetism (less than 50 gauss), which probably are sufficient to hold a paper
clip to the pipe end, no precautions are usually needed.
C.3 Medium levels of magnetism

At medium levels of magnetism (50 gauss to 120 gauss), there is sufficient magnetism to hold
a large diameter welding rod to the pipe end. Under these circumstances, the easiest method
of overcoming the effect is to use ac welding for the root, using an electrode that is suitable
for the purpose. The use of AC for the root in these circumstances does not justify re-
qualification of the weld procedure.
Sometimes AC is not effective at these levels and it must then be treated as a high level
effect.
C.4 High levels of magnetism

High level of magnetism (over 120 gauss) is the usual level of magnetism that is found after a
pig run with a magnetic cleaning pig or the on line inspection vehicle. AC welding is usually
not a satisfactory solution and de-magnetization or de-gaussing must be carried out. One
such method, which is field proven, is as follows:
a) Step 1
Separate all components and de-magnetize them all, if necessary, before
setting up the joint. The pipe and component ends need to be not less than
300 mm apart during de-magnetization.
b) Step 2
Measure the magnetic field at a number of points round the pipe, taking the
readings on the root face. Keep the gaussmeter in line with the pipe and the
end of the probe holder should be in gentle contact with the pipe. Identify the
area where the field is at its maximum, mark the position and note the
reading.
c) Step 3
Wrap welding cable of 300 A minimum capacity round the pipe to give 18 to
20 turns. The edge of the coil must be 50 mm to 80 mm from the end of the
pipe. Aluminium cored cable is not recommended but can be used if
necessary on larger diameters. Short lengths of pipe (pups) may not require
a full number of turns. The amount of cable needed is as given in Table C.1.
d) Step 4
Connect the coil to a welding generator and, setting a low current (less than
80 A), switch on using the polarity change switch. Observe the change in
reading shown on the gauss-meter. If the reading reduces or reverses, note
the position of the polarity switch. If the reading increases, reverse the
polarity and check the decrease. Note the polarity. Switch off.
e) Step 5
Turn the generator controls to maximum and, using the polarity switch, turn
on the current to the same polarity as noted in operation d) above. After 10 s

37 T/SP/P/2
switch off. The current level must drop immediately. Do not reduce current
gradually.
f) Step 6
Take gaussmeter reading at the point noted in operation b) above and
compare with original reading. If everything has been done correctly, the field
should have reduced or reversed. If not, return to operation b) above and
repeat operations b), d) and e) above.
g) Step 7
Check the reading and:
1) If reading after de-magnetization is less than 50 gauss, welding is
possible with dc durrent - no further action necessary.
2) If reading is less than 120 gauss, welding should be possible with ac
current. At this stage, there is the choice of either welding with ac or
carrying out the procedure in operation h) below.
4) If reading is greater than 120 gauss, further de-magnetization is
necessary as in operation h) below. If polarity has reversed, return to
operation d) above.
h) Step 8
If reading is greater than 400 gauss, repeat operations e), f) and g) above.
If reading is between 120 gauss and 400 gauss, reduce current to 60% and
repeat operation e) above.
NOTE - If there has been a field reversal, the procedure should be modified
so as to use opposite polarity as used in operation e) above.
i) Step 9
Degauss other components where necessary prior to fitting up.
C.5 Non-destructive testing

Where the magnetic field still affects the welding arc, radiographic
examination shall be supplemented with ultrasonic testing.
TABLE C.1 - Minimum length of cable required for de-magnetization (de-gaussing)
Minimum length of Minimum length of

Pipe OD (mm) Pipe OD (mm)
cable (m)* cable (m)*
114.3 5 610 40
168.3 10 762 50
219.1 15 914 60
273.1 20 1067 70
323.9 25 1219 80
457 30 1422 90
*The above cable lengths refer only to the coils. Additional cable is necessary to connect the
coil to the welding generators.

38 T/SP/P/2
APPENDIX D
BELL- HOLE EXCAVATION DETAILS
Plan view
Trench Girth weld
2.0m 2.0m Pipeline
Section view
Minimum of 2.0m
for rain cover
2.0m 2.0m
0.6m
Minimum

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T/SP/P/2

SPECIFICATION FOR THE

WELDING OF STEEL LAND PIPELINES DESIGNED TO

© National Grid Gas plc 2009 – All rights reserved

3. TERMS, DEFINITIONS AND ABBREVIATIONS 1

4. INFORMATION AND REQUIREMENTS TO BE APPROVED AND DOCUMENTED 2

8. TESTING, QUALIFICATION AND APPROVAL OF WELDING PROCEDURES 4

9. TESTING, QUALIFICATION AND APPROVAL OF WELDERS 11

10. PRODUCTION WELDING 11

11. INSPECTION AND TESTING OF WELDS 16

12. ACCEPTANCE AND RECTIFICATION OF WELDS 17

1 NATIONAL GRID GAS MATERIALS SPECIFICATIONS 19

2 INFORMATION TO BE SUPPLIED BY THE EMPLOYER 20

3 ITEMS SUBJECT TO APPROVAL BY THE EMPLOYER 22

4 ADDITIONAL TEST SPECIMENS FOR PROCEDURE APPROVAL OF

5 TEST SPECIMENS FOR PROCEDURE APPROVAL OF REPAIR WELDS NOT

6 DESTRUCTIVE TESTING - PERMITTED RE-TESTS 26

7 CHARPY IMPACT SPECIMEN TEST REQUIREMENTS 27

8 WELD JOINT ALIGNMENT TOLERANCES 27

1 LOCATION OF ADDITIONAL TEST SPECIMEN FOR BUTT WELDS MADE WITH A

2 LOCATION OF TEST SPECIMENS FOR FORGED SET-IN BRANCH

© National Grid Gas plc 2009 – All rights reserved

3 LOCATION AND NUMBER OF ADDITIONAL TEST SPECIMENS FOR FULL

4 LOCATION AND NUMBER OF ADDITIONAL TEST SPECIMENS FOR PARTIAL

5 POSITION OF CTOD SPECIMEN NOTCH FOR ASSESSING AN ORIGINAL

6 POSITION OF CTOD SPECIMEN NOTCH FOR ASSESSING A PARTIAL

7 CONFIGURATION REQUIRED FOR SOCKET JOINTS PRIOR TO WELDING 32

B GUIDANCE ON POST WELD HEAT TREATMENT 35

C PIPE END MAGNETISM 36

D BELL-HOLE EXCAVATION DETAILS 38

© National Grid Gas plc 2009 – All rights reserved

Edition Date Approval

Amended to align with revised BS 4515-1:2009 and further technical

© National Grid Gas plc 2009 – All rights reserved

MANDATORY AND NON-MANDATORY REQUIREMENTS

Shall: indicates a mandatory requirement.

© National Grid Gas plc 2009 – All rights reserved

In addition to those documents referenced in Section 2 of BS 4515-1: 2009; reference is also

3. TERMS AND DEFINITIONS AND ABBREVIATIONS

3.1 Terms and definitions

The following additional definitions to those described in BS 4515-1 shall apply:

Bell-hole: An excavation that permits access to below ground pipe work

Consistency trials: A series of consecutive welds of repeatable quality made to the

Employer: National Grid Gas plc, or its nominated representative.

Inspector: The body, association or employee which monitors that the

© National Grid Gas plc 2009 – All rights reserved

Pipeline: The extent of all fabrication up to and including block valve

For the purpose of this specification the following abbreviations apply:

• CTOD Crack tip opening displacement

4. INFORMATION AND REQUIREMENTS TO BE APPROVED AND DOCUMENTED

4.1 Information to be supplied by the Employer

See Table 2 of this specification.

In addition to the requirements of BS 4515-1:

6.1. Welding process and welding system approval

© National Grid Gas plc 2009 – All rights reserved