Petroleum Development Oman L.L.C.

UNRESTRICTED Document ID: SP-1167

October 2006

Specification for Welding

on Pressurised Pipes

(Amendments/Supplements to DEP 30.10.60.30-Gen)

Keywords:

API RP 1107
Hot Tapping
Inspection
Procedure Qualification Record
Pipelines
Piping
Repair
Testing
Welder Qualification
Welding Procedure Qualification
Welding Procedure Specification

This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part
of this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted
in any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior
written consent of the owner.
Specification for Welding on Pressurised Pipes Version 2.0

The following table lists the most recent revisions to this document. Details of all revisions prior to
these are held on file by the issuing department.

Version No. Date Author Scope / Remarks

Version 2.0 10-10-2006 UEC / 11 Change the document to reflect revised cross
referenced Specifications .
Version 1.0 05/04/00 OTT/15 Original issue.

October 2006 Page I SP-

1167
Specification for Welding on Pressurised Pipes Version 2.0

Contents

1. Introduction.................................................................................................................... 1
1.1 Purpose....................................................................................................................... 1
1.2 Changes to the Specification.......................................................................................1

2. Specification for Welding on Pressurised Pipes.............................................................2

2.1 Specification Requirements.........................................................................................2
2.2 Process Deliverables................................................................................................... 2
2.3 Process Owner's Responsibility...................................................................................2
2.4 Performance Levels / Indicators..................................................................................2
2.5 Performance Monitoring............................................................................................. 2
2.6 Effective period.......................................................................................................... 2
2.7 Review and Improvement...........................................................................................2

Appendix A Glossary of Definitions, Terms and Abbreviations.........................................3

Appendix B Amendments/Supplements to Part II of DEP 30.10.60.30-Gen................4

1 General........................................................................................................................... 4
1.4 Materials..................................................................................................................... 4
1.4.2 Filler Metal................................................................................................. 4
1.6 Quality Assurance System...........................................................................................4

2. Qualification of Welding Procedures.............................................................................4

2.1 Procedure Qualification............................................................................................... 4
2.4 Essential Variables...................................................................................................... 4
2.6 Procedure Qualification Tests......................................................................................5
2.6.1 Preparation.................................................................................................. 5
2.6.6 Macro-section tests – fillet welds................................................................5

3. Welder Qualification...................................................................................................... 5
3.1 Purpose....................................................................................................................... 5

4. Maintenance Welding..................................................................................................... 5
4.1 General....................................................................................................................... 5
4.8 Preheating and Interpass Temperature.........................................................................5

5 Inspection and Testing of Maintenance Welds..............................................................6

5.2 Visual Inspection........................................................................................................ 6
5.3 Non-Destructive Testing............................................................................................. 6
5.4 Certification of Non-Destructive Testing Personnel.....................................................6

8. Documentation................................................................................................................ 6
8.2 Pre-Welding Documentation.......................................................................................6
8.2.1 Content of the Quality Plan.........................................................................6

Appendix C References........................................................................................................ 7

User Comment Form........................................................................................................... 8

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Specification for Welding on Pressurised Pipes Version 2.0

1. Introduction
1.1 Purpose

This specification gives the minimum technical requirements for the welding of fittings on to
pressurised pipelines, using the SMAW process.

The DEP has been adopted by PDO as the basis for hot tap welding and related work.
Therefore, the technical content of this specification is confined to those aspects of the DEP
where the particular requirements of PDO are not adequately covered. These are presented in
Part II as amendments and supplements to DEP 30.10.60.30-Gen.

1.2 Changes to the Specification

This specification shall not be changed without approval from the Custodian, the Material
and Corrosion Functional Discipline Head (CFDH), UER (UEC /1), who owns this
specification. If you think any part of this specification is not correct, write your comments
on a copy of the User Comments Form. The form is included as the last page of this
specification. Send the copy with your comments and personal details to DCS.

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Specification for Welding on Pressurised Pipes Version 2.0

2. Specification for Welding on Pressurised Pipes

This Specification gives the minimum technical requirements for any work, which requires
welds to be made on to pressurised pipelines and piping, i.e. hot tap welding and similar
operations. It is applicable to both off-plot pipelines and flowlines and to on-plot piping and
associated equipment. This specification is not applicable to tanks, vessels, emergency
repairs, water pipelines or any piping operating below 10 barg.

2.1 Specification Requirements

Welding, and inspection shall be in accordance with the requirements of Part II of DEP
30.10.60.30-Gen, December 1998, (and API RP1107, Third Edition, April 1991), as further
amended and supplemented by Appendix B of this specification. The amendments and
supplements of the text in Appendix B have been necessary to incorporate special PDO
requirements.

The Clause numbering in Appendix B follows that of API RP1107. Where clauses of API
RP1107 are amended or supplemented neither by this specification nor by DEP 30.10.60.30
they shall apply in their entirety.

2.2 Process Deliverables

Process deliverables comprise field welds to pressurised pipelines, flowlines and on-plot
piping, normally to attach pre-formed split tees, reinforced set-on branches and reduced
branch fittings for hot tap connections.

2.3 Process Owner's Responsibility

The owner of this specification, UEC/1, as CFDH of Material and Corrosion, is responsible
for authorising all proposed deviations or amendments to the specification and for the
instigation of periodic reviews and updates in accordance with Clauses 1.2 and 2.7.

2.4 Performance Levels / Indicators

See relevant weld inspection and testing acceptance criteria in API RP1107, DEP
30.60.10.30-Gen and the amendments/supplements given in Appendix B of this specification.

2.5 Performance Monitoring

Requirements for monitoring welding process variables, welder performance and weld
quality are detailed in relevant sections of API RP1107 as amended/supplemented by Part II
of DEP 30.10.60.30-Gen and Appendix B of this specification.

2.6 Effective period

The requirements of this specification shall remain in force indefinitely unless superseded by
an authorised revision.

2.7 Review and Improvement

This specification will be reviewed and updated once every three years. The review
authority will be UER (UEC/1, CFDH Materials and Corrosion).

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Specification for Welding on Pressurised Pipes Version 2.0

Appendix A Glossary of Definitions, Terms and Abbreviations

The definitions, terms and abbreviations of DEP30.10.60.30-Gen Part I, (Section 1.3) apply,
with the following changes:

General Definitions

Add the following:

Company Petroleum Development Oman LLC. (To be taken as

synonymous with the term ‘Principal’ used in the DEP).
Corporate Functional The person responsible for the discipline to which the standard
Discipline Head belongs.
User The Company, Consultant or Contractor designate who uses
this document.
may Indicates a possible course of action

Specific Definitions

Delete the definition for ‘Company’.

Abbreviations

Add the following:

CFDH Corporate Functional Discipline Head

DCS Document Control Section
TA Technical Authority, as defined in ERD-00-02 and GU-272.

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Specification for Welding on Pressurised Pipes Version 2.0

Appendix B Amendments/Supplements to Part II of DEP 30.10.60.30-Gen

1 General
1.4 Materials

1.4.2 Filler Metal

1.4.2.2 Storage and handling of filler metal

Add the following:

Prior to the commencement of qualification or production welding, whichever is sooner, the

Contractor shall submit a consumable handling procedure to the Company for review and
approval. Test welding or production welding shall not commence until the consumable
handling procedure has been approved by Company TA Level 2 or higher.

1.6 Quality Assurance System

Add the following to the end of the first sentence:

and with PDO specification SP-1171

2. Qualification of Welding Procedures

2.1 Procedure Qualification

Delete the second paragraph and replace as follows:

Qualification welding, NDT and destructive testing shall be witnessed by the Company
unless otherwise stated in the Contract Document.

Previously qualified standard welding procedures listed in Company Procedure PR-1276 may
be used, subject to the approval of the Company, and the provisions given below:

 The essential variables of Section 2.4 of DEP 30.10.60.30 are fully satisfied. Particular
attention is directed to item 2.4p.
 Any additional test requirements included in PR-1276 or otherwise specified by the
Company Welding TA-2 are met. (This may be completed during any welder
qualification and/or training required.)
 Issue and control of standard PQRs is strictly in accordance with PR-1276. These
include preparation by the Contractor of a project-specific WPS for each application.

The Contractor’s own PQRs may also be submitted to the Company CFDH for consideration
provided all the above requirements are met.

2.4 Essential Variables

Replace item o. as follows:

Any changes in welding parameters which result in a variation of heat input greater than ±
10% of that qualified, with the following exception. For root and buttering runs deposited
directly on to run pipe of thickness 6.4mm and below, the permitted variation in qualified
heat input shall be limited to +0%, -15%.

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Specification for Welding on Pressurised Pipes Version 2.0

2.6 Procedure Qualification Tests

2.6.1 Preparation

Add the following:

All testing shall be witnessed by a Company Representative or a Company approved third

party inspection agency. The Contractor shall confirm the availability of the Company
Representative. In the event of the Company Representative not witnessing the testing, the
Contractor shall be responsible for the engagement and hiring of the inspection agency. All
test reports shall be endorsed and signed by the testing organisation, the Contractor, and the
inspector who witnessed the testing. Where an inspection agency has witnessed the testing,
the agency shall also issue a Certificate of Conformance, which states that the testing
practices and procedures were in compliance with API RP1107, DEP 30.10.60.30-Gen and
this specification. The test reports and certification shall be included in the PQR.

2.6.6 Macro-section tests – fillet welds

2.6.6.3 Acceptance criteria

Replace the first paragraph as follows:

For material designated to meet the requirements of either ‘sour service’, NACE MR0175 or
DEP 31.40.20.37-Gen. (sour services application), the maximum root and mid-thickness
hardness shall be 248 HV10. The maximum cap hardness shall be 275 HV10.

Replace the second paragraph as follows:

For material not designated to meet the requirements of either ‘sour service’, NACE MR0175
or DEP 31.40.20.37-Gen. (non sour services application), the maximum root and mid-
thickness hardness shall be 325 HV10.

3. Welder Qualification
3.1 Purpose

Replace the first sentence of the second paragraph as follows:

Test welding shall be witnessed by the Company. Welding parameters shall be monitored by
the Contractor to demonstrate that consistent control of the heat input ranges specified in the
applicable WPS is achieved.

4. Maintenance Welding
4.1 General

(e) Replace third sentence with the following:

The magnetic particle inspection procedure shall be in accordance with SP-1176.

4.8 Preheating and Interpass Temperature

(c) Circumferential fillet welds

Insert the following before the first sentence:

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Specification for Welding on Pressurised Pipes Version 2.0

The provisions for circumferential fillet welds shall also apply to the welding of reduced
branch fittings to pressurised run pipe. Where preheating is by induction or resistance-
heating methods, the procedure for preheat maintenance during welding shall be agreed by
the Company, based on previously established data.

Add the following:

NOTE: On thin wall run pipe (4.8 - 6 mm), a minimum preheat temperature lower than 150°C may be necessary
during deposition of the initial buttering and/or branch root runs. Any such change would be established
from the feasibility study (DEP 31.38.60.10-Gen) and procedure qualification tests. In all cases, the
deviation shall be authorised by the Company welding CFDH and detailed in the approved WPS.

5 Inspection and Testing of Maintenance Welds

5.2 Visual Inspection

Add the following:

All field welding shall be witnessed by the Company at a minimum level of TA-3.

5.3 Non-Destructive Testing

Replace the last sentence with the following:

All magnetic particle inspection shall be performed in accordance with a Company approved
procedure meeting the requirements of SP-1176. The procedure shall be submitted to the
Company prior to test welding or production welding, whichever is the sooner.

5.4 Certification of Non-Destructive Testing Personnel

Delete existing section and replace as follows:

All non-destructive examination personnel shall be qualified and certificated for the method
of NDT to be carried out in accordance with ISO 9712 to NDT Level 2 or higher. The roles
and responsibilities of NDT personnel shall be as defined in the levels of competence in ISO
9712. Personnel certified to ASNT Level II are acceptable provided that the certifying Level
III NDT Engineer has been approved by the Company.

Equivalent inspection and NDT qualifications e.g. CSWIP/PCN Tester/Practitioner/

Interpreter (Welds), Level 2, may be accepted at the sole discretion of the Company.

If, in the opinion of the Company, welding examination or non-destructive examination

personnel fail to perform to a satisfactory standard, they shall be disqualified from the works
until such time that it can be demonstrated by the Contractor that they have achieved a
satisfactory standard by undertaking, at the Contractor's expense, a test by a third party
agency approved by the Company.

8. Documentation
8.2 Pre-Welding Documentation

8.2.1 Content of the Quality Plan

In the second paragraph, replace reference to ‘ISO 10005’ with: ‘SP-1171’.

Replace the text of item 2 as follows:

2. Reference to ANSI/API RP1107, DEP 30.10.60.30-Gen and this specification.

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Specification for Welding on Pressurised Pipes Version 2.0

Appendix C References
The following changes are applicable to Appendix C of DEP 30.10.60.30-Gen:

PDO Standards
Add the following references:
Technical Authorities System ERD-00-02
Non-Destructive Examination (Amendments/Supplements to ASME Section V) SP-1176
Guideline for Granting Technical Authority System GU-272
Standard Procedure Qualification Records for Welding on Pressurised Pipes PR-1276
Quality Assurance Specification for Engineering Works SP-1171

Shell Group Standards

Add the following references:
Welding on Pressurised Pipes (Amendments/Supplements to ANSI/API RP 1107) DEP 30.10.60.30-
Gen
American Standards
Delete reference to ASTM E 1444.
International Standards
Delete reference to ISO 10005

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Specification for Welding on Pressurised Pipes Version 2.0

User Comment Form

User Comment Form
If you find something that is incorrect, ambiguous or could be better in this document, write your comments
and suggestions on this form. Send the form to the Document Control Section (DCS). They make a record
of your comment and send the form to the correct CFDH. The form has spaces for your personal details.
This lets DCS or the CFDH ask you about your comments and tell you about the decision.
Procedure Details Title: Issue Date:
Number:

Page Number: Heading Number: Figure Number:

Comments:

Suggestions:

User’s personal details

Name: Ref. Signature: Date:
Ind.:
Phone:
Document Control Section Actions
Comment Date: CFDH
Number: Ref. Ind.:

Recd.: To CFDH:
CFDH Actions
Recd. Decision: Inits.: Ref. Date:
Date: Ind.:
Reject: 
Accept, revise at next issue: 
Accept, issue temporary amendment 
Comments:

Originator Date: Inits.: Document Date: Inits.:

Advised: Control
Section
Advised:

October 2006 Page 8 SP-1167