Document No: QMS-010

Issue: Issue 4 Sep 22

WELDING Change Owner: Head of AI Jaber Alsayegh
Digitally signed by Jaber Alsayegh
DN: cn=Jaber Alsayegh, o, ou,
[email protected],
c=BH
Date: 2022.10.04 07:20:02 +03'00'

SPECIFICATION
Alan Ferguson
Approved by: Field Maint Mngr 2022.10.04 13:13:
54 +03'00'

Page No: 1 of 17

CONTENTS
1. PURPOSE ......................................................................................................... 1
2. SCOPE .............................................................................................................. 1
3. DEFINITIONS AND ABBREVIATIONS ............................................................... 1
4. RELATED DOCUMENTS ..................................................................................... 2
5. DEVIATION AND CONFLICT RESOLUTION ........................................................ 4
6. RESPONSIBILITIES ......................................................................................... 4
7. WELDING PROCEDURES ................................................................................... 4
8. JOINT PREPARATION ...................................................................................... 8
9. WELDING DETAILS .......................................................................................... 9
10. WELDING TECHNIQUES ................................................................................. 12
11. WELD IDENTIFICATION ................................................................................. 13
12. HEAT TREATMENT .......................................................................................... 13
13. FIELD INSPECTION ........................................................................................ 15
14. STANDARDS OF ACCEPTABILITY ................................................................... 17

Revision Control
Issue Date Description
2 Aug 16 Updated following periodic review
3 Aug 19 Updated following periodic review
4 Sep 22 Updated following periodic review

1. PURPOSE
The purpose of this document is to define the standards for welding, thermal treatment,
examination and testing of shop and field fabrication of piping, pipeline, piping components,
structure and equipment for the Bahrain field.
2. SCOPE
This procedure shall be used by engineers, quality personnel and design office personnel
working for appointed contractors, vendors, sub-vendors, and directly for the company, in
new projects, repair and maintenance works.
3. DEFINITIONS AND ABBREVIATIONS
• DEFINITIONS
Company : Tatweer Petroleum
Contractor : Organization contracted by the Company to provide the required Service
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• ABBREVIATIONS
GMAW : Gas Metal Arc Welding
GTAW : Gas Tungsten Arc Welding
HAZ : Heat Affected Zone
HIC : Hydrogen Induced Cracking
ITP : Inspection and Testing Plan
MT : Magnetic Particle Testing
NDT : Non-Destructive Testing
NPS : Nominal Pipe Size
PQR : Procedure Qualification Record
PT : Penetrant Test
PWHT : Post-Weld Heat Treatment
QC : Quality Control
RT : Radiographic Testing
SMAW : Manual Shielded Metal Arc Welding
SAW : Submerged Arc Welding
UT : Ultrasonic Testing
WPQT : Welder Performance Qualification Test
WPS : Welding Procedure Specification
4. RELATED DOCUMENTS
The requirements of the latest edition of the following codes, regulations and standards,
except as superseded herein shall be met or exceeded. In cases where more than one code,
regulation or standard apply to the same condition, the most stringent shall be followed.
American Petroleum Institute (API)
• API 1104, Welding Pipelines and Related Facilities
• API 570, Piping Inspection Code: In-service Inspection, Rating, Repair, and Alteration
of Piping Systems
• API 5L, Line Pipe
• API TR 938-C, Use of Duplex Stainless Steel in the Oil Refinery Industry
• API RP 578, Guidelines for a Material Verification Program (MVP) for New and
Existing Assets
• API 650, Welded Tanks for Oil facilities
American Society of Mechanical Engineers (ASME)
• ASME Boiler and Pressure Vessel Code, all applicable sections.
• ASME BPVC Section II - Part C, Specifications for welding rods, electrodes and filler
metals
• ASME BPVC Section V, Nondestructive Examination
• ASME BPVC Section VIII, Rules for Construction of Pressure Vessels
• ASME BPVC Section IX, Welding, Brazing, and Fusing Qualifications
• ASME B31.1, Power Piping
• ASME B31.3, Process Piping
• ASME B31.4, Pipeline Transportation Systems for Liquids and Slurries
• ASME B31.5, Refrigeration Piping and Heat Transfer Components
• ASME B31.8, Gas Transmission and Distribution Piping Systems
• ASME B16.25, Buttwelding Ends
• ASME B16.9, Factory-Made, Wrought Steel, Butt-welding Induction Bends for
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Transportation and Distribution Systems

American Society of Testing Materials (ASTM)
• ASTM G48, Standard Test Methods for Pitting and Crevice Corrosion Resistance of
Stainless Steels and Related Alloys by Use of Ferric Chloride Solution
• ASTM A370, Standard Test Methods and Definitions for Mechanical Testing of Steel
Products
American Welding Society (AWS)
• AWS D1.1, Structural Welding Code—Steel
• AWS A 2.4, Standard Symbols for Welding, Brazing and Non-Destructive Examination
• AWS A5.1, Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding
• AWS A 5.5, Specification for Low Alloy Steel Electrodes for Shielded Metal Arc Welding
• AWS A 5.12, Specification for Tungsten and Tungsten-Alloy Electrodes for Arc Welding
and Cutting
• AWS A.5.17, Specification for Carbon Steel Electrodes and Fluxes for Submerged Arc
Welding
• AWS Z49.1, Safety in Welding and Cutting and Allied Processes
• AWS A 5.4, Specification for Stainless Steel Electrodes for Shielded Metal Arc Welding
• AWS A 5.9, Welding Consumables—Wire Electrodes, Strip Electrodes, Wires, and
Rods for Arc Welding of Stainless and Heat Resisting Steels— Classification
• AWS A 5.22, Specification for Stainless Steel Flux Cored and Metal Cored Welding
Electrodes and Rods
• AWS A 5.32, Specification for Welding Shielding Gases
National Association of Corrosion Engineers (NACE)
• NACE RP 0472, Methods and Controls to Prevent In-Service Environmental Cracking
of Carbon Steel Weldments in Corrosive Petroleum Refining Environments
• NACE MR0175/ISO 15156, Petroleum, petrochemical, and natural gas industries —
Materials for use in H2S-containing environments in oil and gas production
• NACE TM 0284, Evaluation of Pipeline and Pressure Vessel Steels for Resistance to
Hydrogen-Induced Cracking
British Standards (BS)
• BS-4515-1, Specification for welding of steel pipelines on land and offshore Part 1:
Carbon and carbon manganese steel pipelines
Det Norske Veritas (DNV)
• DNVGL-ST-F101, Submarine pipeline systems
Tatweer Petroleum Procedures & Specifications
• (QMS-009) RADIOGRAPHY EXAMINATION PROCEDURE
• (QMS-015) Inspection and Surveillance of Welding
• (QMS-016) Qualification of Welding Procedures
• (QMS-017) Welder Performance Qualification
• (QMS-003) Procedure for Quality Control of Materials
• (TP-GEN-00032-SPC-A4-0) Piping System Design Criteria
Other Standards
All relevant Regulations, Codes and Statutes of the Authorities having jurisdiction in the
Kingdom of Bahrain.
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5. DEVIATION AND CONFLICT RESOLUTION

In the event of a conflict between this specification and other specifications or
correspondence, a ruling, in writing, shall be obtained from Head of Asset Integrity (HAI)
before any work is started. Some requirements in this specification may be modified by
specific requirements in the purchase specification, in case of conflict, the specific
requirements supersede this specification. Any deviation from this specification must be
approved in writing by the HAI or his delegate, such written approval must be obtained prior
to the commencement of any work which would constitute such a deviation.
6. RESPONSIBILITIES
QC Inspector
Field QC Mechanical Inspector is responsible for ensuring that all welding operations by or on
behalf of the company are carried out in accordance with this procedure and other applicable
procedures, and for witnessing such operations as appropriate.
Head of Asset Integrity (HAI)
The HAI is responsible for compliance and implementation of the Mechanical Integrity
Program, and ensuring that welding activities are carried out in accordance with applicable
code, standard, and procedure.
7. WELDING PROCEDURES
7.1 General
a) Work shall be done by qualified, competent and certified craftsmen in a neat and
workmanlike manner conforming to code requirements, industry standards, Company
specifications and projects approved documentation.
b) Governing codes, specifications, drawings and legal and contractual requirements shall
be adhered to. Non-conformance to any of the requirements shall be immediately
recorded and corrected.
c) All welding materials, consumables, welding equipment, welding procedure qualification
test records, welding procedure specification (WPS) and supporting procedure
qualification records, non-destructive and destructive tests, welder performance
qualification tests (WPQT), documentation and records shall be supplied by the
Contractor.
NOTE: Welding consumables for maintenance works are sometimes supplied by the
Company.
d) Appropriate documentations shall be provided to show capability of performing the
work and hold appropriate licenses and regulatory qualifications.
7.2 Materials
7.2.1 General
a) All pipes and materials shall conform to applicable specifications and standards.
b) All fittings shall conform to applicable specifications and standards as to size, type and
material.
c) Implement material receiving, storage and identification procedures that meet the
requirements of ISO 9001, and that are documented in the quality assurance manual.
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d) Materials to be used shall be only from approved vendors and supported with
Materials Test Certificate which shall be approved by QC Inspector.
7.2.2 Tools and Equipment
a) All tools and equipment used in the welding operations shall be calibrated and in first
class operating condition and shall be of a capacity suited to the work for which they are
employed.
b) Provide suitable wind guards, welder's platforms or bell holes when conditions warrant
their use.
7.2.3 Welding Electrodes and Rods
a) Weld filler metals/ electrodes must conform to applicable AWS/ ASME BPVC Sec II-C
specifications and as specified herein.
b) Electrode and rod diameters shall conform to the requirements of PQR and WPS in
accordance with ASME and API requirements for bevel angle and usage.
c) Electrodes shall deposit weld metal within the limits of chemical composition and
physical properties as specified for the materials to be joined, unless otherwise
approved.
d) Generally, all welding shall be done with low hydrogen type electrodes. Other types of
electrodes shall be considered only if acceptable control can be maintained.
e) Electrodes and rods shall be protected from mechanical damage or deterioration in
accordance with manufacturer's recommendations, and shall be rejected if found to be
defective.
f) Low hydrogen vacuum sealed electrodes shall be used within four hours of packaging
seal being broken. Normally Sealed electrodes shall be kept in an electrodes oven with
a temperature of not less than 212ºF (100ºC) at all times after issuing for site welding
work.
g) Electrodes shall not be returned to ovens once removed. No re-baking is allowed.
h) Welding material receiving, storage and identification procedures shall be elaborated
and implemented.
i) Where welding is used to join two dissimilar strength materials, the electrode of higher
strength shall be used.
j) Welding consumables to be used shall be only from approved vendor and brands, and
supported with Materials Test Certificate and Conformance Certificate which shall be
approved by Company QC Inspector.
7.3 Processes
The following welding processes are permitted, provided satisfactory evidence is submitted that
the procedure is qualified in accordance with the applicable codes and QMS-016 (Qualification
of Welding Procedures):
a) Manual Shielded Metal Arc Welding (SMAW),
b) Gas Metal Arc Welding (GMAW/MIG),
c) Gas Tungsten Arc Welding (GTAW/TIG),
d) Submerged Arc Welding (SAW).
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7.3.1 Specific welding process application requirements are as follows:

a) Generally, carbon steel pipes and equipment shall be welded with SMAW and/or GTAW
processes.
b) Large diameter pipe (greater than or equal to 12" NPS) may be welded with SAW
procedures, except SAW procedures may not be used for repairs.
c) Generally, 3" NPS and smaller pipe butt welds shall be made with GTAW procedures for
at least the root and hot passes.
d) E-6010 root pass in 3" NPS and smaller pipe is acceptable in secondary piping to
instruments, non-code atmospheric drain and vent piping, and where 100% radiography
is used to ensure internal protrusion is less than 1/16" (1.6 mm) regardless of pipe wall
thickness.
e) Root welds and hot pass in pipe that will be subsequently internally coated shall be made
by the GTAW process.
f) All fillet welds, including small weld-o-lets and socket welds, shall be made by the
SMAW process, other welding process can be used after the Company written
approval.
7.3.2 Other processes will be considered, provided:
a) The fabricator's ability to use the process is scrutinized and approved. Information
submitted shall include complete details of the preparation, welding technique, and
welding procedures for specific applications.
b) The quality control program is approved. Information submitted shall include the extent
of non-destructive testing and other inspection techniques employed throughout
production.
c) The maximum individual layer thickness for submerged arc welds shall not exceed the
following:
i. 0.5" (13 mm) for materials 1.25" (32 mm) thick and greater, or
ii. 0.375" (10 mm) for materials less than 1.25" (32 mm) thick.
d) Longitudinal welds made by the submerged arc welding process shall be made only
with removable starting and stopping tabs.
7.3.3 Specific prohibitions are as follows:
a) Permanently installed backing rings shall not be used without the Company prior written
consent.
b) Lap welded joints are not permitted (NOTE: Lap weld is used in tank repair program).
c) Flux core arc welding (FCAW/inner shield) process shall not be used to weld pipes or
equipment.
d) Only one welder shall be used on pipe welds twelve inches in diameter and less,
regardless of wall thickness.
e) All arc strikes on parent metal shall be ground out.
f) No bullet tracks.
g) No dogs or temporary attachments.
h) Longitudinal welding onto the pipe, e.g. for the attachment of lugs or sleeves, shall not
be permitted.
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7.4 Procedures
a) Welding procedure specification (WPS) qualifications shall be in accordance with Tatweer
Petroleum document: Qualification of Welding Procedure (QMS-016).
b) Welding procedures shall include joint preparation sketches showing dimensions for
bevel angle, land size and root gap. In addition, the following information shall be
included in the WPQ:
i. Heat input range,
ii. Preheat and maximum inter-pass temperature,
iii. Welding travel speed.
c) A cross section of the weld metal, HAZ and parent metal shall be examined as part of
the WPS qualifications in accordance with NACE MR0175/ISO 15156-3, para. 6.2.2.2
and A.7.3. Acceptance criteria of the microstructure and hardness of the weldment shall
be in accordance with NACE MR0175/ISO 15156-3, para. A.7.3.
d) The WPS qualification test shall include Hydrogen Induced Stress Cracking (HIC) in
accordance with method of NACE TM 0284 using test solution A.
e) All welding procedures must be qualified for Charpy impact testing for gas service pipes
and equipment or when the code requirements indicate that the parent material requires
impact testing. Test coupons shall be taken from the weld and the HAZ.
f) Impact testing shall be done on all duplex material. The parent metal shall meet
200J. The temperature shall be -50 °C.
g) All duplex and super duplex welding procedure shall have an ASTM G 48 testing done:
i. Temperature for duplex is 22 °C,
ii. Temperature for super duplex is 40 °C.
h) Weld metal chemical analysis shall be required for all welding procedure
qualifications. Chemical analysis of undiluted weld metal shall be required under the
following conditions:
i. Change in electrode, filler metal or welding consumable AWS classification,
ii. Change in electrode, filler metal or welding consumable manufacturer,
iii. Change in electrode, filler metal or welding consumable supplier.
The pad for undiluted weld metal chemical analysis shall comply with the latest edition
of ASME BPVC Section II Part C Fig. 1. The results of the analysis shall meet the
requirements of the applicable ASTM or AWS requirement for the classification of the
electrode under test.
i) Random weld metal analysis of different batch numbers of electrodes, filler metal or
welding consumable shall be carried out, at the discretion of the Company QC
Inspector if there is reason to believe there is a discrepancy in weld metal analysis
between batches.
j) No pre-qualified procedures shall be used for the welding of duplex, super duplex or 6
molly-chrome nickel materials.
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8. JOINT PREPARATION
8.1 Pipe Surface Preparation
a) Surface of pipe at areas to be welded shall be free from dirt, grease, scale, paint, grit or
any other foreign material which may adversely affect the final weld quality.
b) Where welding pipe either to a flange or another pipe, there must be a band at least 1"
(25 mm) wide around the joint that is free of all foreign matter.
c) Each pipe shall be swabbed along its full length, immediately prior to welding alignment.
Swabbing shall remove all dirt and foreign substance from inside the pipe.
8.2 Pipe Cutting
a) Duplex stainless steel shall be cut using plasma arc process, a machine cutter, or
grinding disc dedicated solely for the use on duplex stainless steel. Carbon-arc shall not
be used. Final surface preparation and configuration shall be obtained by machining.
And only compatible cutting fluid with duplex stainless steel shall be used.
b) All pipe ends that are to have flanges attached either in the shop or field must be cut
true and square.
8.3 Bevels
a) Pipe ends shall be adequately protected during transportation, handling and fabrication
and installation. Bevel protectors, where provided, shall remain in place until fabrication
commences.
b) Component ends shall be beveled by machining, grinding, machine thermal cutting or
plasma cutting. Edges shall be left free of slag and the cut surface shall be ground to a
smooth uniform surface, and all machining burrs and trims shall be removed prior
welding
c) For Pipe fittings & Pipe joints in wall thickness above 0.88” (22 mm), J or compound
bevel shall be used as per ASME B31.3 and ASME B16.25.
d) After grinding, the beveled edges shall be visually examined to ensure freedom from
defects. Any beveled edge that has been damaged shall be restored to within the
tolerances required by the welding procedure to be applied. If beyond repair the pipe
shall be cut and the pipe end re-beveled. Contractor shall submit documentation
demonstrating the repair technique and procedure. No repair work is permitted before
written approval of the repair procedure. Restoration involving welding is not permitted.
e) Should laminations or split ends be discovered in any pipe, the full pipe joint shall be
replaced.
f) Un-equal wall thickness shall be beveled as per ASME B16.25 & ASME B31.8.
8.4 Alignment
a) To assure proper spacing and alignment, an approved line-up clamp, Tipton or equal,
shall be used. Internal line-up clamps shall be used wherever possible for butt welds in
pipe NPS 6 and larger. External line-up clamps may be used for butt welding smaller
pipe sizes and for tie-in welds in any size of pipe, or for special welds, such as
connections to valves, flanges and fittings.
b) For pipeline, internal line-up hydraulic clamp should be used except where use of internal
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clamp is not possible, such as for tie-in, repair and pipeline fitting welding.
c) Proper joint spacing shall be done to assure full weld penetration, joint gap (root
spacing) shall match prescriptions specified in the approved WPS.
d) For pipe of the same nominal wall thickness the maximum linear misalignment of the
abutting pipe ends shall not exceed 1/16" (1.6 mm) for up to and including NPS 12, and
3/32" (2.4 mm) for larger diameters. Misalignment in excess of these limits resulting
only from dimensional variations within the specified tolerances, or from abutment of
two pipeline shall be assessed separately by the Company. If the pipe ends are damaged
or dented beyond these acceptable limits, they shall be cut out and re-beveled.
e) When pipes of unequal thickness are joined, the external offset shall not exceed 1/8"
(3.2 mm) and internal offset shall not exceed 3/32" (2.4 mm). If these values are
exceeded, the excess thickness of the heavier end shall be machined or ground back
from the bevel on a one-to-four (1:4) taper. The pipeline thickness change shall be done
utilizing least thickness tolerance pipe piece available in the lot. The internal diameter
change shall be tapered and smooth to ensure smooth pig runs.
f) Maximum angular misalignment permitted between abutting ends is 3 degree.
g) When a pipe with one longitudinal seam is used, this seam shall be within the top 120º
of the circumference and the longitudinal seams of adjacent pipes shall be offset by a
circumferential distance of at least half the pipe outside diameter.
8.5 Tack welding
a) Tack welds shall be avoided wherever possible. Where demonstrated to be unavoidable
and approved by the Company, temporary bar tacks may be employed. Preheat shall
be employed if required by the WPS and welding parameters shall be in accordance with
the appropriate fill pass. Tack welders shall be qualified to weld with the WPS.
b) Temporary tack welds shall not touch the root gap or face.
c) Tack welds incorporated into the final weld shall be ground to a feather edge at each
end to ensure adequate fusion on the root pass.
9. WELDING DETAILS
a) No production welding shall be carried out until all applicable welding procedures and
welders or welding operators are approved and qualified according to the applicable
codes, standards and references, and approved by the Company QC Inspector. Refer
to (QMS-017) Welder Performance Qualification.
b) Welding procedures for each welding process, size and thickness range shall be
approved by the company prior to welder performance qualification.
c) Specify on the construction drawings the identification number(s) of the weld procedures
and inspection requirements applicable to the pipes and equipment to be fabricated.
d) Each weld shall be uniform in width and size throughout its full length.
e) Each layer of welding shall be smooth and free of slag, cracks, pinholes, and shall be
completely fused to the adjacent weld beads and base metal.
f) The cover pass shall be free of coarse ripples, irregular surface, non-uniform bead
pattern, high crown, and deep ridges or valleys between beads.
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g) Butt welds shall be slightly convex, of uniform height, and have full penetration, unless
otherwise approved.
h) For piping, limitations on weld reinforcement by the code shall apply to the internal
surfaces as well as to the external.
i) Fillet welds shall be of a specified size with full throat and the legs of uniform length.
j) Arcs must be struck only in weld area and not on virgin surface, the following shall be
adhered to in case of arc burn:
1. Any arc burns outside of the weld bevel shall be either cut out or repaired.
2. Arc burns may only be repaired by grinding, this is permissible when removal of
the metallurgical notch caused by arc burns, does not reduce the remaining wall
thickness to less than the minimum permitted by the pipe/ equipment wall
thickness calculation.
3. If the resulting wall thickness, after grinding, is less than that permitted by the
pipe wall thickness calculation, the portion of pipe containing the arc burn shall
be removed.
4. Complete removal of the metallurgical notch created by an arc burn shall be
determined as follows:
i. After visible evidence of the arc burn has been removed by grinding, swab
the ground area with a minimum 10% solution of ammonium persulfate
or a 5% solution of Nital.
ii. A darkened spot is evidence of a metallurgical notch and indicates that
additional grinding is necessary.

NOTE: Etchant (10% solution of Ammonium Persulfate or a 5% solution of Nital)

shall be provided by the Contactor from an approved vendor.
k) After each pass, the layer of deposited weld metal must be cleaned to remove all slag
and scale. Use proper wire brushes, grinder, or chipping hammer as needed to prepare
proper surface for succeeding pass.
l) Repair, chipping or grinding of welds shall be done in such a manner as not to gouge,
groove, or reduce the base metal thickness, if base metal is affected, UT gauging is
mandatory to be performed to ensure minimum acceptable thickness.
m) No welding shall be done if the temperature of the base metal is not at least 60°F (15°C),
nor shall there be any welding done if there is moisture, grease or any foreign matter
on the joint to be welded.
n) Peening is not permitted.
o) No welding shall be performed unless the welder and the work area are properly
protected from environmental conditions that may adversely affect the weld (wind, rain
etc.).
p) The maximum and minimum heat input shall not exceed the values qualified for the
WPQ, with no values exceeding 60 Btu/in or being below 12 Btu/in for duplex stainless
steel. For super duplex stainless steel, the corresponding limits shall be based on the
manufacturer’s recommendations.
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q) The maximum inter-pass temperature shall not exceed the value qualified in the WPS,
with no values exceeding 350°F (170°C) for duplex stainless steel and 300°F (150°C)
for super duplex stainless steel. Measurements shall be taken on the parent metal
surface, directly adjacent to the weld groove, using a contact thermometer with an
instant digital display, or other means of measurement approved by the company.
r) Positive material identification (PMI) shall be carried out on the parent metal and all
welding consumables used for welding duplex, super duplex, 6 molly-chrome nickel and
Inconel materials and stainless steel. And PMI with carbon element verification shall be
conducted for low and high carbon stainless steel.
s) Ferrite Testing shall be done on the root, hot pass, final pass and cap using a Ferro
scope or other approved scope by Company. Ferrite for duplex shall be in the range
35 to 65 and for super duplex shall be 40 to 70. Ferrite for stainless steel shall be in
range of 3% to 5%.
t) During night time, or long duration day time breaks, the open ends of the piping and
pipeline welded sections shall be closed with suitable mechanical end caps to prevent
entry of any foreign objects and creatures.
u) In case of interruption of welding is required, the following rules shall apply:
1. For piping systems in parent materials not requiring or having exemption
conditions for PWHT, welding process interruption is permitted only provided
that minimum four (4) layers and not less than 3/8 in. (10 mm) welding has
been completed. During the interruption, the joint shall be protected (covered)
by blankets for cooling speed minimizing and supported both sides by
appropriate temporary means.
2. For piping systems in parent materials not requiring or having exemption rules
for PWHT but with heavy wall thickness (wall THK >/= 18.26 mm) welding
process interruption is permitted only provided that minimum 2/3 of the wall
thickness welding has been completed. During the interruption, the joint shall
be protected (covered) by blankets for cooling speed minimizing and supported
both sides by appropriate temporary means.
3. Additional, for above points 1. & 2., as applicable, before resuming the welding
process for a joint welding interruption, respective joint shall be cleaned by
smooth grinding, visually inspected for cracks and MT/PT shall be used. Preheat
shall be applied accordingly as per the WPS or at the least minimum value for
moisture removal.
h) The weld joint shall be supported to provide adequate working clearance around the
pipe. Pipe shall not be moved or lowered until at least 4 layers or 1/3 (one third) of
parent material thickness, whichever is higher, are completed.
v) Minimum distance between circular joints (pipe piece minimum length) shall be greater
than one and a half (1½) pipe OD or four (4) times the pipe thickness, whichever is
greater, unless otherwise specified/ approved by the Company.
w) Closure welds (Golden joints) number to be as minimum as possible, and shall be
approved by the company.
x) Threaded fittings seal weld is not permitted. If approved by the company, below
guidelines to be followed as a minimum:
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a. Seal welding shall be performed only on clean, free of dirt, debris, grease or
any other sealant traces,
b. MT shall be performed subsequently,
c. A minimum 2 (two) threads but not more than 3 (three) shall be let exposed
prior seal welding,
d. Seal welding of threaded fittings shall consist of minimum 2 (two) welding
layers.
y) The back purge for stainless steel and nickel alloys shall reduce the oxygen level below
0.05%. An oxygen analyzer shall be used to determine the oxygen content inside the
pipe during purging.
10.WELDING TECHNIQUES
10.1 Horizontal Roll Welds
Shall be used only if particularly requested by the Company and only with approved WPS.
10.2 Horizontal Fixed Welds
a) When shielded metal arc welds are made with the pipe in the horizontal fixed position,
the first pass or stringer bead followed by all subsequent passes shall be deposited by
the "uphill" method of welding.
b) The "downhill" method of welding for all passes may be used depending on the
requirements and prior approval of the Company and as per an approved WPS.
10.3 Fillet Welds
a) When slip-on flanges are attached to pipe by welding and the weld is required to be
made in either rolled or fixed positions, the inside weld shall be made first, followed
by the weld at the reverse or back side of the flange. Weld sequence for such cases
shall be clearly mentioned in the WPS.
b) When coupling and socket weld type fittings are attached to piping, the weld size
shall be 1.4 times the nominal pipe wall thickness unless otherwise specified in
approved documents.
c) All fillet welds shall be slightly concave and the length of each leg approximately
equal.
d) Fillet welds attaching supports and other non-pressure attachments shall not exceed
0.375" (9.5 mm) weld size. Other sizes are acceptable only if specified by approved
Company drawing.
10.4 Treatment of Underside of Weld
a) The use of backing rings for butt welds is prohibited.
b) Excessive inside reinforcement of the root pass can be removed by grinding after
approval from the Company.
10.5 Cleaning
a) All slag, knots of filler material and surface defects shall be removed between
passes. Cleaning may be done with either hand or power tools. Flame gouging is
prohibited.
b) Cleanliness shall be maintained during welding. All stubs, rods, flux, slag and other
foreign material must be removed from inside and outside the pipe/ equipment.
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c) All rough irregularities in the cover pass may be removed if prior consent of the
Company is granted or subsequent processes require such cleaning (e.g.: Hardness
Testing, PMI).
d) Weld spatter shall be completely removed when the weld is completed. Grinding may
be used for spatter removal provided that the wall thickness is not reduced below
required minimum value. All grinded areas shall be subject of MT/PT as applicable
and UT THK gauging.
e) Stainless steel and nonferrous materials shall be cleaned with stainless steel grinding
wheels or stainless steel brushes not previously used on other materials.
11.WELD IDENTIFICATION
The weld identification shall be marked or stamped adjacent to the welds. Low stress stamp
in carbon and low alloy steels can be used for wall thickness of 0.25" (6.4 mm) or greater.
For flanged joints where the pipe wall thickness is less than 0.25" (6.4 mm), the weld
identification can be stamped on the edge of the flange. The weld identification shall be
recorded in a permanent written record (e.g. Weld History Sheet), and attached with the
test package.
Each finished weld shall be clearly marked, to identify the portion made by each welder.
The following weld identification data shall be marked adjacent to the completed welded
joint:
• Welder(s) ID
• Joint Number
• Date of welding
• Date of fit-up
• WPS Number
NOTE: For stainless steels, high alloy steels and non-ferrous metals, the weld identification
shall be applied with chlorine-free waterproof paint suitable for stainless steel.
12. HEAT TREATMENT
12.1 Preheat
a) Preheat for welding joints shall be in accordance with approved WPS.
b) In addition to governing code requirements, carbon steel and low alloy steel pipe having
a wall thickness greater than 0.375" (9.5 mm) shall be preheated to 60ºF (15ºC) prior
to welding.
c) Preheating shall be carried out using electrical resistance heaters, induction heaters, or
oxy-propane rosebud torches. Welding or cutting torches shall not be used. Induction
coils shall not be energized during welding.
d) Where induction heating is proposed for the application of either preheat or post-weld
heat treatment, the equipment and the procedure to be used shall be issued for
approval. In particular, demonstrate that heating rates and required temperatures can
be properly controlled and that adequate precautions have been taken against
overheating.
e) The preheating temperature shall cover an area of at least 3 inches width on either/
both side(s) of the weld and shall be maintained over the full length of the weld until
the weld is completed. The weld area shall be protected from draughts, and insulation
 Document No: QMS-010
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WELDING Change Owner: Head of AI

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shall be provided on adjacent areas where this is necessary to maintain the required
temperature of preheating during welding.
f) Measurement of preheat and inter-pass temperatures shall be conducted using
thermocouple, "Tempilstik" thermo-melt crayon, contact pyrometer, or a combination
thereof.
12.2 Post Weld Heat Treatment (PWHT)
a) A written PWHT procedure including description of equipment, method of heating,
location and type of heating elements, temperature measurements and thermocouple
locations, shall be submitted for review and approval.
b) It is recommended that the contractor has non-destructive testing (NDT) inspection
performed on the weld and verifies the weld is satisfactory, before commencing post-
weld heat treatment (PWHT).
c) PWHT of pressure piping and furnace tubes shall be in accordance with the approved
WPS, applicable code and as specified herein.
d) PWHT shall be conducted as per latest edition of the applicable code requirements.
e) PWHT shall be performed as per conditions specified in ASME codes or when the pipe
has been cold bent to a radius of less than 5 times the nominal pipe diameter or when
required by applicable code specifications.
f) Rates of heating and cooling shall be in accordance with the requirements of ASME BPVC
Section VIII, Division 1, paragraph UCS-50, and in any event, the rate of heating above
600°F (316°C) may not be more than 400°F (204°C) per hour, nor the rate of cooling
more than 500°F (260°C) per hour above 600°F (316°C).
g) PWHT of shop produced welds in double jointed line pipe or in pipe spools may be
carried out in an enclosed electric or gas fired furnace. If a gas fired furnace is used
there shall be no direct impingement of flame on the pipework/ equipment. Sufficient
thermocouples shall be employed to ensure a uniform temperature distribution
throughout the pipe assembly/ equipment.
h) After PWHT is completed, the contractor shall again have the weld inspected using NDT
(RT, MT and Hardness Testing).
12.3 Field Stress Relieving
a) Operation shall be carried out electrically by resistance pads or induction coils according
to an approved procedure.
b) Joints to be heat treated shall be adequately insulated on either side of the weld and
open pipe ends blocked throughout the cycle to prevent through draughts. Such
insulation shall be left in place until the weld has cooled to 100°F (40°C) (hand hot).
c) Temperature shall be measured by thermocouples directly attached to the pipe/
equipment by capacitance discharge welding and connected to a chart recorder.
d) The minimum number of thermocouples to be used shall be three at each weld so that
continuous readings can be assured in the event of thermocouple failure. These shall be
equally spaced around the weld circumference, 1 inch from the weld to ensure that the
heated circumferential band will extend at least 1 inch beyond the weld on either side.
On large diameter pipe, extra thermocouples shall be used as necessary to achieve a
 Document No: QMS-010
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WELDING Change Owner: Head of AI

SPECIFICATION Approved by: Field Maint Mngr

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maximum separation of 30 inches around the circumference.

e) Thermocouples and chart recorders shall have valid certificates of calibration.
12.4 General
a) Flange facings and threaded connections must be adequately protected against
oxidation during stress relieving and must be cleaned and freed of defects after stress
relieving.
b) No heat or welding may be applied to any piping or joint after stress relieving is complete
unless permitted by the code to which the piping system is being fabricated. Stress
relieving shall be completed on any piping system before such system is pressure tested.
All NDT shall be performed after PWHT.
c) Detailed post weld heat treatment procedures shall be submitted for approval by the
company QC inspector prior to welding procedure qualification.
d) After completion of the PWHT all thermocouples shall be removed, the attachment
areas shall be grounded smooth to a clean sound metal and shall be examined by MT
or PT after grinding.
e) Capacitor discharge procedure used for attaching thermocouples must be qualified
prior any such operation.
13. FIELD INSPECTION
13.1 General
a) The minimum qualification level for welding inspection personnel shall be in accordance
with of one of the following:
• CSWIP Welding Inspector
• AWS Certified Welding Inspector
b) Non-destructive examination personnel shall hold a valid qualification of one of the
following at the level shown:
• ASNT Level II for the relevant technique
• CSWIP/PCN Tester/Practitioner/Interpreter (Welds) Level 2 for the relevant
technique
c) If the welding inspection or non-destructive testing personnel fail to perform to a
satisfactory standard they shall be disqualified from the works until such time that it can
be demonstrated that they have achieved a satisfactory standard by undertaking a test
by the Company.
d) Prior to welding, examine free-issue materials for damage and compliance with the
relevant materials specification. This examination shall include a review of the materials
certification documentation.
13.2 Inspection Methods
a) The Company may use any method of inspection necessary to establish quality control
and insure adherence to welding procedures. The Company shall have the right to accept
or reject any weld not meeting the requirements of this specification, or if the Company
inspector terms welds unacceptable to the service for which they are intended.
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b) Butt welds shall be fully inspected radiographically as per applicable codes. Ultrasonic
and magnetic particle testing can be used on those welds which cannot be radiographed
(e.g. Cat. D welds). Subject to approval by the Company QC inspector, liquid penetrant
testing may be substituted for magnetic particle testing in exceptional circumstance.
c) The radiographic technique should be X-ray radiography. Subject to company approval,
gamma radiography may be used with an Iridum-192 source.
d) Hardness Testing if required shall be carried out using Portable Hardness Tester such as
Proceq Equotip machine. Hardness Testing procedure shall be elaborated and submitted
for Company approval.
e) Additional inspection of any weld joint at any stage of the fabrication may be requested
by Company, including re-inspection of previously inspected joints. Company also has
the right to request or conduct independent NDT of any joint.
f) Inspection at the mill, shop or fabrication yard shall not release the manufacturer or
fabricator from responsibility for repairing or replacing any defective material or
workmanship that may be subsequently discovered in the field.
g) For welds with a reinforcing pad, the weld between the branch and the header shall be
inspected prior to installing the reinforcing pad and again after installing the reinforcing
pad. All branch connection welds shall be visually examined from the root side to
ensure that proper penetration and fusion have been achieved.
13.3 Non-Destructive Testing
a) All NDT shall be performed only by approved by the Company third party NDT Provider.
b) During production welding, the welding parameters shall be checked against the
approved WPS, the monitoring frequency shall be specified in the contractor's Inspection
and Test Plan (ITP). ITP shall be reviewed and approved by Company QC Inspector prior
to the commencement of the project or welding activity.
c) The completed weld shall present a uniform and workmanlike appearance, symmetrical
to the center line of the weld, and free from pinholes, undercutting or other visible
defects.
d) Discontinuity located by radiography shall not exceed the limits of the "Standards of
Acceptability" as outlined in these specifications.
e) Company may select any number of welds for radiographic inspection.
f) Socket weld gap of 1/16” (1.5 mm) shall be maintained prior welding, and random RT
specified by the Company shall be conducted for verification.
g) The minimum percent coverage of the specified NDT method may be increased (at any
level up to 100%) if, in the opinion of the Company QC inspector, the welds are of
questionable workmanship or if NDT indicates an excessive number of defects.
Additional NDT methods may be used at the discretion of the Company QC inspector
in order to assist in determining the type or extent of defects.
h) Progressive Sampling for Examination as per described in paragraph 341.3.4 of ASME
B31.3 for piping components, and paragraph UW-52 (d) of ASME Sec XIII Div 1 for
Pressure Vessels, must be followed to ensure the quality of the welds and to determine
the quantity of repairs and consequently the repair rate.
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WELDING Change Owner: Head of AI

SPECIFICATION Approved by: Field Maint Mngr

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13.4 Inclement Weather

Welding operations shall be suspended outdoors when in the opinion of the Company’s
representative the weather conditions are unsuitable for welding.
14. STANDARDS OF ACCEPTABILITY
14.1 General
These standards of acceptability apply to pipe, structure and equipment welds based on the
applicable Codes.
Acceptance criteria shall be considered and applied as per governing codes related to the
specific Tatweer Petroleum projects as per the scope of work.
The Company may use any method of inspection necessary to establish quality control, and
insure adherence to welding procedures. Company’s QC inspector shall determine whether
welds and defects will be accepted, and has the full authority to demand repairs and re-welds
on welds if he terms them unacceptable to the service for which such welds are intended.
14.2 Weld Acceptance Criteria
a) Acceptance shall be as per the applicable codes, which will include NACE MR 0175/
ISO15156. The provision of alternative acceptance standard for girth weld mentioned in
Appendix A of API 1104 shall not be used for weld qualification.
b) Welds which contain cracks shall be cut out and replaced.
14.3 Repairs
a) Welding repair procedure addressing the removing and verifying the removal of defects
and containing the applicable approved WPS shall be submitted to Company for approval
before any repairs are commenced.
b) All repairs shall be treated in the same manner as an original weld. Preheat to 300°F
(150°C) is mandatory and weld joint must be insulated after repair if ambient
temperatures are below 50°F (10°C).
c) Not more than one repair shall be allowed in any six (6) inches of weld metal. Welds
exceeding these limitations shall be cut out and pipe shall be re-welded.
d) All repairs shall be radiographed and the film shall accompany the original radiograph
as proof that repair has been made.
e) The contractor shall clearly mark the joint with R suffix for the repaired joint.
14.4 Repair Rate
Unless otherwise specified in the construction contract, the following shall be followed:
a) Individual welder repair rate of less than 3% is acceptable, from 3% up to 4.9% the
repair rate shall be investigated and reported by the contractor, 5% and above the
welder shall be disqualified.
b) Combined repair rate of less than 2% is acceptable, from 2% up to 3.9% the repair rate
shall be investigated and reported by the contractor, 4% and above the welding activities
shall be stopped until further notice from the Company.