PROCEDURES

General Index:
a) Fabrication & Installation Procedure
1.0
2.0
3.0
4.0

Pag.

20

Pag.

36

Welding process check

Welders & welding operator qualification check
Ultrasonic testing specification
Radiographic examination specification
Visual inspection requirement
Marking & Reports
Hydrostatic testing

d) Painting Procedure
1.0
2.0
3.0
4.0

Pag.

Cutting, Fitting and Alignment

Cleaning of surface to be welded
Preheating treatment
Welding process specification
Post weld heat treatment
Repair of weld defects

c) Non-destructive testing procedure

1.0
2.0
3.0
4.0
5.0
6.0
7.0

General arrangements on site

Site plan & equipment
Manufacturing / fabrication process specification
Erection / installation process specification

b) Welding Procedure
1.0
2.0
3.0
4.0
5.0
6.0

Pag.

Field blasting & painting procedure

Field touch up requirements
Inspection requirements
General painting requirements

Pag. 1

FABRICATION & INSTALLATION PROCEDURE

Index:
1.0 General Arrangements on Site................................................................................................Pag. 3
2.0 Site plan & equipment............................................................................................................Pag. 3
3.0 Manufacturing / Fabrication process specifications...............................................................Pag. 3
3.1 Construction characteristics.........................................................................................Pag. 5
3.2 Welding........................................................................................................................Pag. 6
4.0 Test, inspection, assembly and installation.............................................................................Pag. 6
4.1 Generality....................................................................................................................Pag. 6
5.0 Erection / installation process specifications..........................................................................Pag. 6

Pag. 2

1.0 General Arrangements on site

Astaldi-CBI prepared an area for the penstock fabrication, quality control, sand blasting and painting
shops. These facilities are located in the Unduavi Valley, in a suitable area in Sacahuaya close to the
Yanacachi Penstock and Powerhouse. Nearby a camp facilities are also constructed for personnel
working in the Penstock Manufacture and Erection activities.
A factory supervisor with a staff of 40 to 50 workers (according to work progress) are employed for
pipe fabrication activities and a erection supervisor with a staff of 20 to 40 workers pipeline (according
to work progress) are employed for the erection and testing of the Penstock. Welders and other
personnel which have already worked with Astaldi-CBI in other similar jobs (Zongo and San Jacinto)
are employed as far as possible, there will be 2 qualified Inspectors, 1 for the manufacturing process
and 1 for the erection process. Welders and inspectors will be trained and certified by approved welding
experts, and according to the attached "Qualification Procedures for Welders.
Nondestructive tests will be carried out by Astaldi-CBI's inspectors under the supervision of a welding
expert who will issue Quality Control Reports and Certificates of Tests that have been carried out during
fabrication.

2.0 Site plan & equipment

Site plan attached.
TAQUESI PROJECT PENSTOCK MANUFACTURING SHOP FACILITIES.
No. 1 1000 Square Meters of the main body structure in steel with steel roof, steel side walls and
gates, for Penstock Manufacturing Shop;
No. 1 200 square Meters of the main body structure in steel with steel roof, steel side walls and gates,
for sand Blast and Painting activities;
No. 2 5 Tons Overhead Traveling Bridge Crane - lifting capacity six (6) meters from bottom.
No. 1 12 Tons Caterpillar V300B Fork Lift with Diesel Motor;
No. 1 Diesel Generating Set, 150KW;
No. 1 Steel Plates Guillotine Shear - Capacity 25 x 3000 Millimeters;
No. 4 Oxyacetylene Single or Multi Torch with motorized Cutting Machine for cutting and beveling
of Steel Plates.
No. 1 Three Roller Bending Machine with 16 x 2550 millimeters Capacity - minimum radius of 200
millimeters
No. 1 Three Roller Bending Machine with 45 x 3000 millimeters Capacity - minimum radius of 500
millimeters
No. 4 Motorized adjustable Pipe Rollers Capacity of six (6) Ton load with twelve (12) Tons Rotation.
No. 15 Free adjustable Pipe Rollers. Capacity of six (6) Tons Load
No. 1 Automatic Submerged Arc welding Machine ESAB Type, mounted over motorized manipulator
with DC Generator of 800 Amps. The Manipulator has arm four (4) meters long and three (3)
meters supporting column plus the standing platform. The motorized system moves over rails
and have the possibility to weld longitudinal and circumferential joints inside and outside of the
pipes.
No. 3 Submerged ESAB and Lincoln Tractor type with 800 and 600 Amps DC Generators. The
Tractors over special guides has the possibility to weld longitudinal and circumferential outside
Pag. 3

No.14
No.2
No. 1
No. 3
No. 8
No. 1
No. 1
No. 1
No. 2
No. 2
No. 2
No. 1
No. 2

and inside joints in a fixed position, with pipe over Motorized Tube Rollers. (Normally the
circumferential inside joints would be welded with a manipulator)
ESAB DC 400 Amps Welding Machine for manual welding.
ESAB DC 600 Amps Welding Machine for manual welding and for Arc Air Torch.
ESAB DC 400 Amps Gas Semi-Automatic Welding Machine
High Frequency Generator with four (4) Inlet each for Grinding Machines
High Frequency Angular Grinding Machine
Directional x-ray Apparatus - 200 kW for Quality Control
Ultrasonic Apparatus for Quality Control
Alternative Motorized Saw
Heating and Treatment Ovens for Submerged Arc Welding Flux Electrical Type
Vertical Heating and Treatment Ovens for Welding electrodes Electrical Type - Around 1200
Electrodes capacity
Electrical Motorized Air Compressors for Arc Air Torches
Diesel Motor Welding Machine - 600 Amps
Pick-up or Shop service.

The shop is complete with all the electrical and distribution panels, lighting system, air distribution
system and all necessary hand tools such as hydraulic and mechanical jacks, tir-4, lift pulleys, lifting
cables, individual tools and all the protective clothing required. Also incorporated in the shop will be
tools spare parts and consumable materials store. Store for welding materials, first aid infirmary,
workshop office, x-ray laboratory and permanent material store.
For the Taquesi project the shop will also be provided with the following:
No. 1
No. 2
No. 1
No. 2

Air Compressor of High Capacity - 7 Bars,

Sand Blasting Machines,
Infrastructure to meet environment basic requirements.
Cable way (Blondins) load capacity 5 Tons.

3.0 Manufacturing / Fabrication Process Specifications

ASTALDI-CBI, due to inaccessibility of the job-site shall manufacture the Penstock, Bends, Manifolds,
Manholes and Expansion joints in Bolivia.
Fabrication shall comply with ASTM, AWWS, AWS standards and specifications. Nondestructive testing
will be 100% ultrasonic testing, and 15% for pipe factory and 60% pipeline radiographic examinations of
circumferential and longitudinal joints. Depending on the performance of the welders and radiographic
examination records, the percentage requirement of radiographic examination can be reduced.
The manufacturing process will be as follows:

Check drawings, QA handbook and welder certificates;

Receiving material and Certificates test Result from Mill;

Marking plates;

Squaring, cutting plates with guillotine shear or oxyacetylene;

Beveling and special cuttings with oxyacetylene;

Roll bending with machine for plates 830 mm thick. Use jig to control radius;

Longitudinal tack welding;

Longitudinal internal/external submerged arc welding;

Assembling of pipes;
Pag. 4

3.1

Circumferential internal submerged arc welding;

Circumferential external submerged arc welding;
Check dimensions and roundness (Sample sheet is attached);
Visual dimensions check and perform NDE;
Repairs of faulty elements;
Perform NDE of repaired elements;
Pipe welding sheet will be prepared (Sample sheet is attached);
Sandblasting;
Painting;
Painting inspection;
Each pipe will be marked with an ID and Position number.

Construction characteristics
Materials:
The steel utilized for manufacturing the Penstock is ASTM A537 CL. 1 - produced in Italy and all
other welding materials according to WPS (Welding Procedure Specifications).
Material characteristics
a)
b)

c)
d)
e)
f)

1.

2.
e)
f)
g)
h)
i)
j)

The metal plates for the manufacturing the Penstock shall be ASTM A537 CL. 1 produced in Italy shall be produced in compliance with applicable specifications;
All welding materials shall be in compliance with WPS and applicable specifications;
The steel used in the construction of the other parts such as Bends, Manifolds, Flanges and
Expansion Joints shall also be ASTM A537 CL. 1;
Anchor rings for pipes AP11AP17 will be manufactured and welded to the pipes in the
shop;
Manholes will be placed according to shop drawings and will be manufactured in the shop;
Expansion joints will be manufactured in the shop. Assembling of expansion joints will be
made accordance with specifications, pipes will be cut according to a thermal expansion
charts, depending on the temperature and length in which the expansion joint is installed;
Saddle supports steel plate, 8 mm thick, shall have a half moon of 120 form, and shall be
welded to anchor hooks for second stage concrete;
Pipes shall be completely painted in the shop, except for 20 cm. at both ends that shall be
painted on the job site, after erection and inspections.
The flange and coupling tie rod, bolt and nut dimension after machining shall not be
inferior to nominal values.
The average internal diameter of every pipe or element, established by the measure of the
external development at the two ends and of the thickness, shall not be different from the
theoretic diameter more than 0.3% plus or minus with a maximum of 5 mm.
The ovalization of every pipe or segment, determined by the maximum length difference of
almost two diameters perpendicular between them, can not be greater than 0.01D, D been
the theoretic internal diameter.
Anchor rings shall be fabricated and welded to the pipes in the workshop according to
approved shop drawings.
Mechanical expansion joints shall be manufactured in the workshop according to approved
shop drawings.
The theoretic mass of every pipe or element appear on the single mass list an the shop
drawings on the basis of the final project for the piping, a variation less than 5% is
Pag. 5

accepted. The theoretic mass shall be calculated on the basis of the nominal dimensions
and mass volume of 7.85 kg/dm3.
3.2 Welding
Materials used in the construction of welded parts shall comply with the requirements for materials
given an shall be proven of weldable quality.
a)
b)
c)
d)
e)

f)

Records of the names of the welders who make each weld shall be maintained. Welders and
welding operators shall be qualified and qualification records shall be available for audit.
Two sample test will made, for tensile test and for bend test as per attached sheet. These
tests will be certified by a qualified firm.
Welding of the pipes in the workshop will be by automatic welding machines. Welds will
be butt welds from inside and outside. In tunnel sections welding will be from inside only
against external counter bars.
The edge to be butt welded shall be completely free from exfoliation, cracks or incision,
rust, calamine, humidity and shall be, therefore, submitted to the checks and adequately
protected.
When the temperature of the elements to be welded is lower than +5C, and anyhow when
the room temperature is lower than 5C or there is excessive ventilation (with influence
on the protection of the arc), the welding operations shall be made with appropriate
methods so that the cooling, after the welding, is sufficiently slow to guarantee from
cracking risk.
The removal of alignment jacks, tack welds and/or other possible appendixes shall be done
by grinding and subsequent visual examination of the grinded areas .

4.0 Tests, inspection, assembling and installation

4.1 Generality
For planning and checking of the construction phases (manufacturing), for assembling (erection) and put in
service (starting), the formulation related to the tests and control and for certified documentation, are valid
with the following specification.
a)
b)

For site activity, welding sheets shall be used;

Certified documentation relating to tests and checks will be related with the single check
and test carried out and will state the checked values and their evaluation, the used method,
the referring standards or the procedure used.

5.0 Erection and installation process specification

The erection of Yanacachi Penstock will be carried out in two phases. In the first phase, the cable way
(Blondins) will be installed for erecting the pipe sections going from AP17 to AP15. In the second phase the
Blondins will be moved for erecting the line going from AP15 to AP11.

Pag. 6

The pipe sections located in anchor points AP17 to AP11 will be positioned first, leveled according to plan.
The pipe will be welded to the anchor stay rods prepared during 1 phase concrete. After 2 phase concrete
of the block, the erection of pipe sections will follow from one AP point to the other AP point and so forth
up to Yanacachi tunnel Portal.
The procedure for Penstock installation on job site is as follows:
-

The pipes will be transported from the pipe factory to the erection site on a truck with special
supporting saddles;
Set up equipment, tools, temporary support shall be ready on the erection site including ventilation
for the steel lined sections;
Pipes will be unloaded with a cable way (Blondins) Lifting Capacity 5 Tons;
When working on slope and elevation areas, internal and external scaffold will be prepared and
erected.
The pipes will be lifted brought to position with the Blondins, a 60 cm alignment slide will be
welded and the joint spaced with a 2-3 mm spacer;
If necessary an aux. support will be welded on the front part to maintain the pipe in position;
The pipe will be aligned and edges tack welded;
The inside welding shall be carried out first;
The exterior will be cleaned with arc-air and welded from the exterior;
Ultrasonic and radiographic tests will be made and eventual repairs will be carried-out;
The welded part will be painted and the painting will be checked;
Anchor rings for pipes AP11AP17 will be manufactured and welded to the pipes in the shop.
Manholes will be placed according to approved shop drawings and will be manufactured in the shop.
Expansion joints will be manufactured in the shop. Assembling of expansion joints will be made in
accordance with specifications. Slip pipes will be cut according to a thermal expansion charts,
depending on the temperature and length in which the expansion joint is installed;
Saddle supports steel plate, 8 mm thick, shall have a half moon of 120 form, and shall be welded to
anchor stay hooks.
Welding will proceed in accordance with WPS here after specified. For security reasons during night
shifts, the interior of pipe will be welded and during day shifts the exterior will be welded;
Painting and controls will follow;
For erection of steel lined tunnel sections, a trolley mounted on rails will be used to transport the
pipes, auxiliary foot supports welded to the pipe ends will be left to concrete. Welding will be from
inside only against external counter bars ;
Visual inspection will be carried-out in the interior of the piping;
Covers of the manholes will be placed, o-rings checked;
Expansion joints will be tightened to torque;
Finally the piping will be filled with water and leak tested ;
Infiltration and leak inspections and controls will be carried-out;
A hydropressure test will be carried out to underground piping prior to covering. Hollow blind
flanges with adequate safety valves and manometers will be welded at the 2 ends of the piping. The
piping will be filled with water; pressure will be gradually brought to 1-1/2 times the design
pressure of the piping and maintained for 30 minutes; after a visual control of the piping the
pressure will be lowered to the design pressure and maintained at this pressure for the time required
to permit inspection of the piping. If during test defects appear, the defectous element will be
repaired in accordance to specifications and the hydrostatic test will be repeated. The blind flanges
will be removed, and the erection will proceed.

Pag. 7

Erection of Chojlla Penstock:

The same procedure of Yanacachi Penstock will be followed, except for stretch between AP25 and AP26
where the cable crane can not be installed due to the presence of a high voltage Lines. On this stretch, a
construction access road will be constructed to carry out the penstock civil and erection works.
Annex C erection plans Yanacachi and Chojlla

Pag. 8

WELDING PROCEDURE
Index:
1.0 Cutting, Fitting and alignment...............................................................................................Pag. 10
2.0 Cleaning of surface to be welded...........................................................................................Pag. 10
2.1 Preparation of base metal.............................................................................................Pag. 10
3.0 Preheating treatment..............................................................................................................Pag. 11
3.1 Weather condition for welding.....................................................................................Pag. 11
3.2 Preheat and interpass temperature................................................................................Pag. 11
4.0 Welding process specifications..............................................................................................Pag. 11
4.1 General welding procedure specifications for shielded metal arc process....................Pag.
4.2 Control of parameters..................................................................................................Pag.
4.3 Technique.....................................................................................................................Pag.
4.4 General welding procedure specifications for submerged arc welding process............Pag.
4.5 Filler metal...................................................................................................................Pag.
4.6 Control of parameters..................................................................................................Pag.
4.7 Technique.....................................................................................................................Pag.

11
13
13
14
15
15
16

5.0 Post weld heat treatment (Removed. Not applicable)............................................................. Pag. 17

6.0 Repair of weld defects............................................................................................................Pag. 17
6.1 Repair of weld defects.................................................................................................Pag.
6.2 Appearance of welding................................................................................................Pag.
6.3 Repairs.........................................................................................................................Pag.
6.4 Re-examination of repaired areas.................................................................................Pag.

17
17
17
17

Pag. 9

1.0 Cutting, Fitting and Alignment

(a) When plates are shaped by oxyacetylene or arc cutting, the edges to be welded shall be uniform
and smooth and shall be freed of all loose scale and slag accumulations before welding .
(b) Plates that are being welded shall be fitted, aligned, and retained in position during the welding
operation.
(c) Bars, jacks, clamps, tack welds, or other appropriate means may be used to hold the edges of parts
in alignment. Tack welds used to secure alignment shall either be removed completely when they
have served their purpose, or their stopping and starting ends shall be properly prepared by
grinding or outer suitable means so that they may be satisfactorily incorporated into the final weld.
Tack welds, whether removed or left its place, shall be made using a fillet weld or butt weld
procedure qualified in accordance with Section IX. Tack welds to be left in place shall be made by
welders qualified in accordance wills Section IX, and shall be examined visually for defects, and if
found to be defective shall be removed.
(d) The edges of butt joints shall be held during welding so that the tolerances are not exceeded in the
completed joint. When fitted girth joints have deviations exceeding the permitted tolerances, the
head or shell ring, whichever is out-of-true, shall be reformed until the errors are within the limits
specified. Where fillet welds are used, the lapped plates shall fit closely and be kept in contact
during welding.
(e) (Removed. Not applicable)

2.0 Cleaning of surfaces

Cleaning of surfaces to be welded
(a) The surfaces to be welded shall be clean and free of scale, rust, oil, grease, slag, detrimental oxides,
and other deleterious foreign material. The method and extent of cleaning should be determined based
on the material to be welded and the contaminants to be removed. When weld metal is to be deposited
over a previously welded surface, all slag shall be removed by a roughing tool, chisel, chipping hammer
or other suitable means, as to prevent inclusion of impurities in the weld metal.
(b) Cast surfaces to be welded shall be machined chipped, or ground to remove foundry scale and to
expose sound metal.
(c) The requirements in (a) and (b) above are not intended to apply to any process of welding by which
proper fusion and penetration are otherwise obtained and by which the weld remains free from defects.
2.1 Preparation of base metal
The edges or surfaces of the pieces to be joined by welding shall be prepared by flame cutting, plasma arc
cutting, arc gouging, machining, shearing, grinding, or chipping and shall be cleaned of detrimental oil,
grease, scale and rust. The edges of the pieces may have a protective coating applied to them which need not
be removed before they are welded unless specifically prohibited by the specific WPS.

Pag. 10

3.0 Preheating treatment

No preheating is required except as an aid for removing surface moisture prior to the start of
welding, except as indicated in the WPS.
3.1 Weather conditions for welding
Welding shall not be performed when the surfaces in the welding area (within 6" (15.2cm) of the arc) are
wet; nor in periods of high winds unless the welder and the pieces to be welded are properly protected.
3.2 Preheat and interpass temperature (When required by the specific WPS)
3.2.1 Method
If required, preheat and/or interpass temperature shall be achieved by any suitable means which will
keep the temperature of the joint within the specified limits shown on the specific WPS. The method
of pre-heating and the heat source to be used may be changed or supplemented as deemed necessary
or desirable.
3.2.2 Continuous Preheat:
When continuous preheat is required, it shall be a uniform preheat during the time of welding,
obtained by pipe burners or strip heaters. On vertical joints or radial joints the required preheat is
necessary along the entire length.
On circumferential joints of large diameter vessels, the required reheat is necessary along the area or
areas being welded. When welders are spaced around the entire circumferential joint on small
diameter vessels, the entire joint shall be preheated.
3.2.3 Monitoring:
Joints requiring preheat and/or interpass temperature control will be checked before and/or during
welding of the joints to ensure that the minimum temperature is being maintained and that the
maximum interpass temperature is not exceeded.
For temperance greater than or equal to 150 F (66 C), temperature indicating crayons will normally
be used to determine that the joint is at the required minimum temperature or above, but not
exceeding the maximum interpass temperature.

4.0 Welding process specification

4.1 General welding procedure specifications for shielded metal arc process
Scope
This is a general Welding Procedure Specification to be used with a specific Welding Procedure
Specification (WPS) when referred on the WPS. In case of conflict between this documents and the specific
WPS, the specific WPS shall govern.
Pag. 11

Reference
ASME Boiler and Pressure Vessel Code, Section IX. Welding Qualifications, Edition and Addenda as shown
on the specific WPS.
Procedure qualifications
WPS for the project have been supplied by the welding materials supplier ESAB.
Preparation on base metal
The edges or surfaces of the pieces to be joined by welding shall be prepared by flame cutting, plasma arc
cutting, arc gouging, machining, shearing, grinding, or chipping and shall be cleaned of detrimental oil,
grease, scale and rust. The edges of the pieces may have a protective coating applied to them which need not
be removed before they are welded unless specifically prohibited by the specific WPS.
4.1.1 Weather conditions for welding
Welding shall not be performed when the surfaces in the welding area (within 6" (15.2cm) of the arc)
are wet; nor in periods of high winds unless the welder and the pieces to be welded are properly
protected.
4.1.2 Joints (QW-402)
4.1.2.1

Root Opening
Normal root opening shall be 0-1 1/4" (0 m-m - 6.4 mm). See contract drawings for the
specific joint detail. Spacer bar joints are considered 0" gap.

4.1.2.2

Wide Gaps
The following technique shall be used for welding joints with wide gaps which exceed
twice that specified on the applicable contract drawing. When zero gap is specified on the
contract drawings, gaps exceeding 3/16 (4.8 mm) shall be reduced as outlined below to a
3/16" (4.8 mm) or smaller gap. Maximum weld build-up shall be T (where T is the
thickness of the plate) for each plate edge or 1/2" (12.7 mm) whichever is smaller.
Method:
Plate edge build-up shall be done with a welding, procedure approved for contract use.
Weld passes shall be deposited utilizing a stringer bead technique to restore the plate edges
to the gap and approximate joint configuration as shown on the contract drawing.
On single or square butt joints a temporary back-up bar of compatible material may be
used. The edges should be built-up using stringer beads to restore the joint to the gap and
approximate joint configuration as shown on contract drawings, before tying the edges
together.
The temporary back-up bar shall be removed by gouging, chipping or grinding to clean,
sound-metal the second side.

4.1.2.3

Narrow Gaps
The following technique shall be used for correcting joints with gaps less than specified on
the applicable contract drawing which are not sufficiently wide to allow free manipulation
of the electrode in the joint.
Pag. 12

Method:
The plate edges of the joint shall be prepared by flame cutting, plasma arc cutting, grinding
arc gouging or chopping to restore the joint to the gap and approximate joint configuration
shown on the contract drawings. Gouging dross, burning dross, or reside shall be removed
by brushing or grinding before welding commences.
4.1.2.4

Retainers
Nonmetallic retainers or non-fusing metal retainers may only be used when they are
specified on the specific WPS.

4.1.2.5

Backing
Double welded groove welds are considered welding with backing.
For single welded groove welds, the backing shall be as specified in the specific WPS.

4.2 Control of parameters (QW-409)

Control of amperes and volts will be by the burn-off-rate (BOR) method. Control of the heat input/volume of
weld metal will be by bead size where applicable.
4.3 Technique (QW-410)
4.3.1 Tack Welds
Tack welds used to secure alignment shall either be removed completely, when they have served
their purpose, or their stopping and starting ends shall be properly made and prepared so that they
may be satisfactorily incorporated into the final weld. Defective tack welds shall be removed.
4.3.2 Cleaning
Pneumatic or other mechanical tools may be used as an aid to cleaning slag or flux from the weld.
Such mechanical cleaning is not considered peening. Slag or flux remaining on any weld bead shall
be removed before laying down the next successive weld bead to the extent required to assure
complete fusion. Cleaning of stainless steel or Nickel-Chromium-Iron alloy weld metal or base
metal shall be with uncontaminated stainless steel brushes, grinding discs or wheels or by other
suitable means. All completed welds shall have the weld spatter removed and welds not ground shall
be wire brushed.
4.3.3 Appearance of Welding
Any defects that appear on the surface of any weld bead shall be removed by chipping, or arc
gouging before depositing the next successive weld bead. The welding current and manner of
depositing the weld metal shall be such that there shall be practically no undercutting of the finished
joint except as permitted by the applicable Code. The surface of welds shall be free from coarse
ripples or groove, overlaps, and abrupt ridges or valleys. Reinforcement shall be according to the
applicable Code.
Pag. 13

4.3.4 Treatment of Backside of Welding Joint

The back side of double welded groove welds shall be prepared by chipping, grinding, or arc
gouging to clean sound metal. The root of the groove shall be sufficiently wide to permit fusion and
allowed free manipulation of the electrode. Gouging, dross or residue shall be removed by brushing
or grinding before welding commences.
4.3.5 Peening
No peening shall be allowed unless specified on the specific WPS or unless specified in special
instruction issued by the Welding and Q.C. Manager
4.4 General welding procedure specifications for submerged arc welding process (SAW)
Scope
This is a general Welding Procedure Specification to be used with a specific Welding Procedure
Specification (WPS) when referenced on the WPS. In cases of conflict between this document and the
specific WPS, the specific WPS shall govern.
Reference
ASME Boiler and Pressure Vessel Code, Section IX, Welding Qualifications, Edition and Addenda as shown
on the specific WPS.
Procedure qualifications
WPS for the project have been supplied by the welding materials supplier ESAB.
Preparation of base metal
The edges or surfaces of the pieces to be joined by welding shall be prepared by flame cutting, plasma arc
cutting, arc gouging, machining, shearing, grinding or chipping and shall be cleaned of detrimental oil,
grease, scale ad rust. The edges of the pieces may have a protective coating applied to them which need not
be removed before they are welded unless specifically prohibited by the specific WPS.
4.4.1 Weather condition for welding
Welding shall not be performed when the surfaces in the welding area (within 6" (15.2 cm) of the
arc) are wet; nor in periods of high winds unless the welder and the pieces to be welded are properly
protected.
4.4.2 Joints (QW-402)
4.4.2.1
4.4.2.2

Root Opening
Normal root opening shall be 0- 1/4" (0 mm-6.4 mm). Spacer bar joints are considered 0"
gap.
Wide Gaps
The following technique shall be used for welding joints with wide gaps which exceed
twice that specified on the applicable contract drawing. When zero gap is specified on the
contract drawing, gaps exceeding 3/16" (4.8 mm) shall be reduced as outlined below to a
3/16" (4.8 mm) or smaller gap. Maximum weld build-up shall be T (where T is the
thickness of the plate) for each plate edge or (12.7 mm) whichever is smaller.
Pag. 14

Method:
Plate edge build-up shall be done with a welding procedure approved for contract use.
Weld passes shall be deposited utilizing a stringer bead technique to restore the plate edges
to the gap and approximate joint configuration as shown on the contract drawings.
On single or square butt joints, a temporary back-up bar of compatible material may be
used. The edges should be built-up using stringer beads to restore the joint to the gap and
approximate joint configuration as shown on contract drawings, before tying the edges
together.
The temporary back-up bar shall be removed by gouging, chipping or grinding to clean,
sound-metal before welding the second side.
4.4.2.3

Narrow Gaps
The following technique shall be used for correcting joints with gaps less than specified on
the applicable contract drawing which are not sufficiently wide to allow free manipulation
of the electrode in the joint.
Method:
The plate edges of the joint shall be prepared by flame cutting, plasma arc cutting, arc
gouging, or chipping to restore the joint to the gap and approximate joint configuration
shown on the contract drawings. Gouging dross, burning dross, or residue shall be removed
by brushing or grinding before welding commences.

4.4.2.4

Retainers
Nonmetallic retainers or non-fusing metal retainers may only be used when they are
specified on the specific WPS.

4.4.2.5

Backing
Double welded groove welds are considered welding, with backing,
For single welded groove welds, the backing shall be as specified in the specific WPS.

4.5 Filler metal (QW-404)

Supplemental filler metals or supplementary powdered filler metals may only be used when specified on the
specific WPS.
Flux from re-crushed slag shall not be used, unless specified on the specific WPS.
4.6 Control of parameters (QW-409)
Control of amperes and volts will be by amp and volt meters. Control of heat input/volume of weld metal
will be by amperage, voltage, and travel speed control where applicable.

Pag. 15

4.7 Technique (QW-410)

4.7.1 Tack Welds
Tack welds used to secure alignment shall either be removed completely, when they have served
their purpose, or their stopping and starting ends shall be properly made and prepared so that they
may be satisfactorily incorporated into the final weld. Defective tack welds shall be removed.
4.7.2 Cleaning
Pneumatic or other mechanical tools may be used as an aid to cleaning slag or flux from the weld.
Such mechanical cleaning is not considered peening. Slag or flux remaining on any weld bead shall
be removed before laying down the next successive weld bead to the extent required to assure
complete fusion. Cleaning of stainless steel or Nickel-Chromium-Iron alloy weld metal or base metal
shall be with uncontaminated stainless steel brushes, grinding discs or wheels or by other suitable
means. All completed welds shall have the weld spatter removed and welds not ground shall be wire
brushed.
4.7.3 Appearance of Welding
Any defects that appear on the surface of any weld bead shall be removed by chipping, or arc
gouging before depositing the next successive weld bead. The welding current and manner of
depositing the weld metal shall be such that there shall be practically no undercutting of the finished
joint except as permitted by the applicable Code. The surface of welds shall be free from coarse
ripples or groove, overlaps, and abrupt ridges or valleys. Reinforcement shall be according to the
applicable Code.
4.7.4 Treatment of Backside of Welding Joint
Downflat:
The back side of double welded groove welds shall be prepared by chipping, grinding, or arc
gouging to clean sound metal. If gouging is performed, dross or residue shall be removed by
brushing or grinding before welding commences.
Horizontal:
When automatic submerged-arc process is used to weld horizontal groove welds, both sides may be
welded simultaneously and no treatment of the back site of the joint is necessary to ensure complete
penetration and fusion.
4.7.5 Peening
No peening shall be allowed unless specified on the specific WPS or unless specified in special
instruction issued by the Welding and Q.C. Manager
4.7.6 Electrode Spacing (Multiple Electrodes)
Tandem Arc:
The centerline spacing between electrodes shall be a nominal 3/4" (19.1 mm).
Twin Arc:
The centerline spacing between electrodes shall be a nominal 5/6" (7.9 mm).
Pag. 16

5.0 Postweld heat treatment

Postweld heat treatment is not required as per WPS.
5.1 Removed. Not applicable.

6.0 Repair of weld defects

6.1 Repair of weld defects
Defects, such as cracks, pinholes. and incomplete fusion, detected visually or by the hydrostatic or pneumatic
test or by ultrasonic or x-ray examinations - shall be removed by mechanical means or by thermal gouging
processes, after which the joint shall be rewelded.
6.2 Appearance of Welding:
Any defects that appear on the surface of any weld bead shall be removed by chipping, or arc gouging before
depositing the next successive weld bead. The welding current and manner of depositing the weld metal shall
be such that there shall be practically no undercutting of the finished joint except as permitted by the
applicable Code. The surface of welds shall be free from coarse ripples or groove, overlaps, and abrupt
ridges or valleys. Reinforcement shall be according to the applicable Code.
6.3 Repairs
6.3.1
6.3.2

When an imperfection is repaired by chipping or grinding and subsequent repair by welding is non
required, the excavated area shall be blended into the surrounding surface so as to avoid sharp
notches, crevices or corners.
When an imperfection is to be repaired by welding, after the imperfection is thought to have been
removed and prior to making weld repairs, the area shall be examined by the applicable steps in the
Procedure section of the Technique Procedure to ensure it has been removed or reduced to an
acceptably sized imperfection.

6.4 Re-examination of repaired areas

Repaired areas shall be re-examined by examination methods that were originally required for the affected
area, except that, when the depth of repair is less than the radiographic sensitivity required, re-radiography
may be omitted.

Pag. 17

NON-DESTRUCTIVE TESTING PROCEDURE

Index:
1.0 Welding process check...........................................................................................................Pag. 19
1.1 Check of welding procedure........................................................................................Pag. 19
2.0 Welders & welding operators qualification check .................................................................Pag. 20
2.1 Check of welders & welding operator qualification.....................................................Pag. 20
3.0 Ultrasonic testing specifications.............................................................................................Pag. 20
3.1 Technique for ultrasonic examination of welded joints................................................Pag. 20
4.0 Radiographic examination specifications...............................................................................Pag.
4.1 Radiographic examination 60 % of welded joints........................................................Pag.
4.2 Radiation energy..........................................................................................................Pag.
4.3 Geometrical unsharpened limitation guidelines...........................................................Pag.
4.4 Evaluation of radiographic quality...............................................................................Pag.
4.5 Documentation.............................................................................................................Pag.
4.6 Radiographic requirements for ASME Section VIII Code
Division 1 e 2 pressure vessels..........................................................................................Pag.
4.7 Acceptance criteria for spot radiography of Division 1 vessels only............................Pag.
4.8 Evaluation and re-examination....................................................................................Pag.

20
20
24
25
25
26
27
28
29

5.0 Visual inspection requirement................................................................................................Pag. 29

5.1 Visual inspection technique procedure standard technique..........................................Pag. 29
5.2 Visual inspection requirements for ASME Section VIII Code
Division 1 & 2 pressure vessels.......................................................................................Pag. 29
6.0 Marking & Reports................................................................................................................Pag. 31
6.1 General marking and reports........................................................................................Pag. 31
6.2 Placement of location markers (film interval numbers or
identification numbers) and film identification...............................................................Pag. 32
7.0 Hydropressure testing............................................................................................................Pag. 33
7.1 Hydrostatic test for underground piping ......................................................................Pag. 33
7.2 Final hydraulic test.......................................................................................................Pag. 33

Pag. 18

1.0 Welding process check

The Inspector shall review the welding procedures specifications (WPS) to be used in addition to the
contract specified codes and specifications.

2.0 Welders & welding operators qualification check

2.1 Check of welder and welding operator qualifications
a)
b)

The Manufacturer shall certify that the welding on a vessel has been done only by welders and
welding operators who have been qualified under the requirements of Section IX and the Inspector
shall assure himself that only qualified welders and welding operators have been used.
The Manufacturer shall make available to the Inspector a certified copy of the record of the
qualification tests of each welder and welding operator. The Inspector shall have the right at any time
to call for a witness tests of the welding procedure or of' the ability of any welder and welding
operator.

3.0 Ultrasonic testing specifications

3.1 Technique for ultrasonic examination of welded joints
Ultrasonic 100% examination of welded joints, shall be performed in accordance with attached Appendix
and shall be evaluated to the acceptance standards specified. The written examination procedure shall be
available to the Inspector and shall he proven by actual demonstration to the satisfaction of the Inspector to
be capable of detecting and locating imperfections described in this Division.
3.1.1 Ultrasonic examination of welds
Scope
This Appendix describes methods which shall be employed when ultrasonic examination of welds specified
in this Division.
Ultrasonic examination shall be performed in accordance with a written procedure, certified by the
Manufacturer to he in accordance with the requirements of T-150 of Section V.
Certification of competence of nondestructive examiner
The Manufacturer shall certify that personnel performing and evaluating ultrasonic examinations required by
this Division are qualified. SNTTC-1A shall be used as a guideline for employers to establish their written
practice for qualification of their personnel. Provisions for training, experience, and qualification of NDE
personnel shall be described in the Manufacturers Quality Control System.
Acceptance rejection standards
These Standards shall apply unless other standards are specified for specific applications within this
Division.

Pag. 19

Imperfections which produce a response greater than 20% of the reference level shall be investigated to the
extent that the operator can determine the shape, identity, and location of all such imperfections and evaluate
them in terms of the acceptance standards given in (a) and (b) below.
a)
b)

Indications characterized as cracks, lack of fusion, or incomplete penetration are unacceptable

regardless of length.
Other imperfections are unacceptable if the indications exceed the reference level amplitude.

Report of examination
The Manufacturer shall prepare a report of the ultrasonic examination and a copy of this report shall he
retained by the Manufacturer until the Manufacturer's Data Report has been signed by the inspector. The
report shall contain the information required by Section V. In addition, a record of repaired areas shall he
noted as well as the results of the reexamination of the repaired areas. The Manufacturer shall also maintain a
record of all reflections from uncorrected areas having responses that exceed 50% of the reference level. This
record shall locate each area, the response level, the dimensions, the depth below the surface, and the
classification.

4.0 Radiographic examination specification

4.1 Radiographic examination of welded joints (15% pipe factory and 60% pipeline)
a)

All welded joints to be radiographed shall be examined in accordance as per attached specifications
1)
2)

A complete set of radiographs and records, maintained.

The personnel performing and evaluating radiographic examinations required by this Division are
qualified and certified in accordance with procedures.
3) Final acceptance of radiographs shall be based on the ability to see the prescribed penetrameter
image and the specified hole or the designated wire of a wire penetrameter.
4) Recommended Practice No. SNT-TC-IA, Personnel Qualification and Certification in
Nondestructive Testing, is published by the American Society for Nondestructive Testing Inc.
1711 Arlingate Plaza, Caller #28518, Columbus, Ohio 43.

b)

Indications shown on the radiographs of welds and characterized as imperfections are unacceptable
under the following conditions and shall be repaired, and the repair radiographed, ultrasonically
examined in accordance with the method and the standards specified, provided the defect has been
confirmed by the ultrasonic examination to the satisfaction of the Authorized Inspector prior to
making the repair. For material thickness in excess of 1 in., the concurrence of the user shall be
obtained. This ultrasonic examination shall be noted under remarks on the Manufacturer's Data
Report Form:
1)
2)

any indication characterized as a crack or zone of incomplete fusion or penetration;

any other elongated indication on the radiograph which has length greater than:

(a) 1/4 in. for t up to 3/4 in.

(b) 1/3 in. for t from 3/4 in. to 2 1/4 in.
(c) 3/4 in. for t over 2 1/4 in.
where t= the thickness of the weld excluding any allowable reinforcement. For a butt weld joining
two members having different thickness at the weld, t is the thinner of these two thickness. If a
Pag. 20

full penetration weld includes a fillet weld, the thickness of the throat of the fillet shall be
included in t.

c)

3)

any group of aligned indications that have an aggregate length greater than t in a length of 12t,
except when the distance between the successive imperfections exceeds 6L where L is the length
of the longest imperfection in the group;

4)

rounded indications in excess of that specified by the acceptance standards.

All welded joints to be examined by Real Time Radioscopic Examination shall be examined in
accordance with Specifications.
1)

2)
3)

A complete set of records shall be evaluated by the Manufacturer prior to being presented to the
Inspector. Imperfections shall be repaired and the repair reexamined by either film or Real Time
Radioscopic Examination. Records shall be retained until the Data Report has been signed by the
Inspector.
Provisions for training, experience, qualification and certification of personnel responsible for
equipment setup, calibration, operation, and evaluation of examination data shall be described in
the Manufacturer's Quality Control System.
The use of Real Time Radioscopic Examination shall be noted under remarks on the
Manufacturer's Data Report.

4.1.2 ASME section v code article 2

Scope
This General Radiographic Examination technique procedure contains the requirements of Article 2 of the
ASME Section V Code and is to be used with the procedure for the applicable referencing Code or Standard.
This examination method shall be used to inspect steel, nickel and aluminum welds in the thickness range
from 1/6 inch (3.2 mm) to 14 inches (356 mm).
Reference
1995 ASME Section V Code, Article 2, with the following Addenda: 96.
Equipment and materials
As per attached RX Procedures (English version will be submitted as soon as possible)
4.1.3 Technique for radiographic examination
Prepare weld surfaces by removing weld surface irregularities on both sides (where accessible) by
any suitable process to such a degree that the resulting radiographic image due to any irregularities
can not mask or be confused with the image of any discontinuity. The finished surface of all butt
welded joints may be flush with the base material or may have reasonably uniform crowns.
IQI Selection (See table at the end of section)
For weld without reinforcement, the thickness on which the penetrameter is based is the
nominal single wall thickness. This is the weld thickness. Back-up bars, backing rings or
backing strips are not to be considered as part of the weld thickness
For we1ds with reinforcement, the thickness on which the penetrameter is based is the
nominal single wall thickness plus the estimated weld reinforcement. 'This is the weld
thickness and includes the estimated weld reinforcement on both sides. Back-up bars,
backing rings or backing strips are not to be considered as part of the weld or
reinforcement thickness.
Pag. 21

When the weld metal is of an alloy group or grade which has a radiation attenuation that
differs from the base material, the penetrameter material selection shall be based on the
weld metal or shall be from an alloy material group or grade with less radiation absorption
than the material being radiographed. As an example, for Inconel weld metal use of a
carbon steel or stainless steel IQI is acceptable
When density limits can not be met with one penetrameter and the exceptional density
area(s) is at the interface of the weld meta1 and the base material, the materia1 se1ection
for the additional penetrameter(s) shall be based on the base material.

IQI Placement
-

For single or double wall exposures for single wall viewing, place a source side
penetrameter on the side nearest the radiation source. Where inaccessibility prevents this,
place a film side penetrameter in contact with the object being examined. Place a lead letter
F" adjacent to or on the penetrameter (s) , but it sha11 not mask the essential hole or
designated wire.

For double wall exposures for double wall viewing, place a source side penetrameter on the
side nearest the radiation source.

When using hole type penetrameters, place then adjacent to or on the weld. If the filler
metal is not radiographically similar to the base material (as categories in SE1025), place
the hole type penetrameter on the weld. When using wire type penetrameters, place them
on the weld with the wires perpendicular to the length of the weld. The lead identification
numbers for either type penetrameter shall not appear in the area of interest

Lead identification numbers and lead letter F when used, may appear in the area of
interest; if geometric configuration makes it impractical to place the penetrameter.

4.1.4 Number of IQIs

Use at least one penetrameter for each exposure
An additional penetrameter may be used to meet the required density variation limits.
When one or more than one film holder or cassette is used for a single exposure, a penetrameter
image shall appear on each radiograph, except for the following conditions:
1

For cylindrical components where the source is placed on the axis of the component for a single
exposure, at least three penetrameters, spaced approximately 120 deg. Apart, are required under
the following conditions:
a) when the complete circumference is radiographed using one or more film holders, or;
b) when a section or sections of the circumference, where the length between the ends of the
outermost sections span 240 or more deg., is radiographed using one or more film holders.
Additional film locations may be required to obtain necessary penetrameter spacing.

For cylindrical components where the source is placed on the axis of the component for a single
exposure, at least three penetrameters, with one placed at each end of the span of the
circumference radiographed and one in the approximate center of the span, are required under
the following conditions:
a) when a section of the circumference, the length of which is greater than 120 deg. And less
than 240 deg., is radiographed using just one film holder, or;

Pag. 22

b)

when a section or sections of the circumference, where the length between the ends of the
outermost sections span less than 240 deg., is radiographed using more than one film
holder.

In (1) and (2) above, where sections of longitudinal welds adjoining the circumferential weld are
radiographed simultaneously with the cricumferential weld, an additional penetrameter shall be
placed on each longitudinal weld at the end of the section most remote from the junction with the
circumferential weld being radiographed.

For spherical components where the source is placed at the center of the component for a single
exposure, at least three penetrameters, spaced approximately 120 dec. Apart, are required under
the following conditions:
a) when a complete circumference is radiographed using one or more film holders, or;
b) when a section or sections of a circumference, where the length between the ends of the
outermost sections span 240 or more deg., is radiographed using one or more film holders.
Additional film locations may be required to obtain necessary penetrameter spacing.

For spherical components where the source is placed at the center of the component for a single
exposure, at least three penetrameter, with one placed at each end of the radiographed span of the
circumference radiographed and one in the approximate center of the span, are required under
the following conditions:
a) when a section of a circumference, the length of which is greater than 120 deg. And less than
240 deg., is radiographed using just one film holder, or;
b) when a section or sections of a circumference, where the length between the ends of the
outermost sections span less than 240 deg., is radiographed using more than one film
holder.

In (4) and (5) above, where other welds are radiographed simultaneously with the
circumferential weld, one additional penetrameter shall be placed on each other weld.

When an array of components in a circle is radiographed, at least one penetrameter shall show on
each component image

In order to maintain the continu8iti of records involving subsequent exposure, all radiographs
exhibiting penetrameters which qualify the techniques permitted in accordance with (1) through
(6) above shall be retained.

4.1.5 Shimming Hole Type Penetrameters

If the weld reinforcement and/or backing strip are not removed, if needed, place a shim of radiographically similar material to the weld metal under the hole type penetrameter so that the density
throughout the area of interest meets the density limits.
Shim size, if needed, shall exceed the hole type penetrameter dimension such that the outline of at
least three sides of the penetrameter image through the shim are visible in the radiograph.
4.1.6 Blocking and Masking Technique
Use filters, if necessary, to improve the quality of the radiograph
A lead symbol 3, with minimum dimensions of inch (12.7 mm) in height and 1/16 inch (1.6
mm) in thickness, shall be attached to the back of each film holder during exposure. If a light image
of the B appears on a darker background of the radiograph, protection form backscatter is
Pag. 23

insufficient and the radiograph shall be considered unacceptable. A dark image of the B on a
lighter background is not cause for rejection.
4.1.7 Length of Film
For 100% radiographic examination, the length of film used will be determined by the job
conditions. However, film length shall be at least 1 inch (25 mm) greater than the interval spacing to
ensure adequate overlap at each end.
For spot radiographic examination, the minimum length of film shall be 7 inches (178 mm).
4.1.8 Shape of film
Shape of the film to the contour of the object and place it as close as possible to the surface of the
weld during exposure.
4.1.9 Number of Exposures
4.1.9.1

The number of spot radiographs and their locations shall be in accordance with drawings
and instructions.

4.1.9.2

For the Single Wall Technique, when the source is located on the inside or outside of the
vessel or pipe, an adequate number of exposures shall be made to demonstrate coverage.

4.1.9.3

For the Double Wall Technique for Single Wall Viewing, a minimum of three (3) exposures
separated by 120 is required.

4.1.9.4 For the Double Wall Technique for Double Wall Viewing, (3 inch (89 mm) O.D. pipe or
less), the following applies:
1)

A minimum of two (2) exposures are required, taken at 90 to each other, when the
radiation beam is offset from the plane of the weld centerline at an angle sufficient to
separate the images of the weld so there is no overlap of areas to be interpreted. See
Figure C.

2)

A minimum of three (3) exposures are required, taken at 60 to 120 to each other,
when the radiation beam is positioned so the images of both walls are superimposed.

4.2 Radiation energy

4.2.1 X-radiation
The radiographic technique shall demonstrate that the required radiographic sensitivity has been
obtained.
4.2.2 Gamma Radiation
42.2.1

The minimum thickness of steel or nickel for which radioactive Iridium 192 may be used
shall be 0.75 inches (19 mm) and for Cobalt 60 shall be 1.50 inches (38 mm) except al
provided in 6.3

4.2.2.2. Radioactive isotopes shall not be used on aluminum with a minimum thickness less than
2.50 inches (63.5 mm)
Pag. 24

4.2.3
The maximum thickness for the use of radioactive isotopes is primarily dictated by exposure time;
therefore, upper limits are not shown. The minimum recommended thickness limitation may be
reduced when the radiographic techniques used demonstrate that the required radiographic sensitivity
has been obtained.
4.3 Geometrical unsharpened limitation guidelines
The following geometrical unsharpened values shall be used as a guide for determining minimum source to
weld or object distant (D). Final acceptance of radiographs shall be based on the ability to see the prescribed
penetrameter image and specified hole or the designated wire of a wire penetramenter.
Material
Thickness, inches (mm)

Ug
Maximum inches (mm)

Under 2 (51)
2 (51) through 3 (75)
Over 3 (76) through 3 (102)
Greater than 4 (102)

0.020
0.030
0.040
0.070

(0..5)
(0.76)
(1.0)
(1.8)

Geometrical unsharpened (Ug), equals effective source size (F): the maximum projected dimension of the
radiating source in the plane perpendicular to the distance D from the weld or object being radiographed,
times the distance (d) from source side of weld or object being radiographed to the film, over distance (D)
form source of radiation to weld or object being radiographed.
UG = Fd/D

4.4 Evaluation of radiographic quality

Evaluate the radiographic quality by the image of a properly located IQI and the following film quality
requirements:
4.4.1

The images of the identifying numbers and the following as applicable.

1 Hole Type Penetrameters
a) Penetrameter Outline
b) Specified Essential Hole
2 Wire Type Penetrameters
a) Designated Wire

4.4.2

The film density through the image of the body of a hole type penetrameter or adjacent to the
designated wire of a wire type penetrameter and the area of interest for single film viewing
shall be 1.8 minimum for radiographs made with an X-ray source and 2.0 minimum for
radiographs made with a gamma ray source. For composite viewing of multiple film
exposures, each film of the composite set shall have a minimum density of 1.3. The
Pag. 25

maximum density shall be 4.0 for viewing. A tolerance of 0.05 in density is allowed for
variations between densitometer readings.
4.4.3

Each penetrameter shall represent an area of essentially uniform radiographic density as

judged by a calibrated density comparison strip or densitometer. If the film density through
the area of interest, varies by more than minus 15 or plus 30 percent from the density
through the body of the hole type penetrameter or adjacent to the designated wire of a wire
type penetramenter, then an additional penetramenter is required for the exceptional area or
areas.
When shims are used, the thirty (30) percent density restriction may be exceeded, provided
the hole type penetrameter required sensitivity is displayed and the density limitations are
not exceeded.

4.4.4

If the requirements are met by using two Penetrameters, one shall be representative of the
lightest area of interest and the other the darkest are of interest, and the intervening densities
on the radiograph shall be considered as having acceptable density.

4.4.5

All radiographs shall be free from mechanical, chemical or other processing defects that
could interfere with proper interpretation of the radiograph.

4.5 Documentation
Record radiographs, with their grading, on a Report of Radiography Examination
4.5.1.1 Record spot radiography and 100% radiography on separate report forms.
4.5.1.2 Acceptable radiographs may be combined on one line of the report, provided the interval
numbers are consecutive.
4.5.1.3 List tracers separately in sequence and mark them T1, T2, etc.
4.5.1.4 List repairs separately in sequence and mark them R1, R2, etc.
4.5.1.5 List reshots, taken for reason other than either of the above, separately from the original film
and mark them RS.
4.5.1.6 When inaccessibility or other limitations prevent the location of markers, a dimensioned
sketch of the geometric arrangement including marker locations shall be documented on
the back of the Report of Radiography Examination form.
4.5.2

The following radiographs need not be retained or recorded.

4.5.2.1 In-Process Radiographs taken for information only on an area of a joint not fully welded
regardless of whether or not they are used for making repairs.
4.5.2.2 Technique radiographs showing no rejectable indications taken to establish parameters that
produce radiographs that meet the film quality requirements of this procedure.
4.5.2.3 Radiographs showing no rejectable indications, but unacceptable from standpoint of film
quality requirements due to defective film, improper processing, physical damage, or
improper technique.
4.5.2.4 Radiographs that can not be identified as to location (i.e. vessel, joint number, film number)
4.5.2.5 Record on the Record Drawing or Checklist the film interval or identification numbers and
the sequential direction of the numbers for each weld joint as follows:
4.5.2.6 For 100% or Random Radiography, record the first and last interval number
4.5.2.7 For Spot Radiography, record all the film identification numbers.
4.5.2.8 Record joint identification number
4.5.2.9 Record welders or operators identification for all butt welded joints.
Pag. 26

4.6 Radiographic requirements for ASME Section VIII Code Division 1 e 2 pressure vessels
Scope
This procedure contains the ASME Section VIII Code radiographic acceptance criteria requirements and is to
be used with the applicable standard or contract X or N general Radiographic Examination Technique
Procedure RT5 or RTDF.
Reference
1992 ASME Section VIII Code or with any of the following Addenda: 92, 93, 94
1995 ASME Section VIII Code or with any of the following Addenda: 95, 96
Personnel
Personnel performing this examination shall be qualified in accordance with a Nondestructive Examination
Personnel Training, Qualification and certification Program which is in accordance with the guidelines of the
Code referenced edition of SNT-TC-1A. Level I, II or III personnel may perform radiography and level II or
III personnel shall evaluate.
Reinforcement
Reinforcement on each side of all butt welded joints shall not exceed the following thickness:
Nominal Wall
Thickness (T), In. (mm)

Less than 3/32

3/32 to 3/16
Over 3/16 to
Over to 1
Over 1 to 2
Over 2 to 3
Over 3 to 4
Over 4 to 5
Over 5

(2.4)
(2.4 to 4.8) incl.
(4.8 to 12.7), incl.
(12.7 to 25.4) incl.
(25.4 to 51) incl.
(51 to 75) incl.
(76 to 102) incl.
(102 to 127) incl.
(127)

Maximum Reinforcement, I (mm)

Circumferential Joints
In pipe and tubing
Division 1
Division 2
3/32
1/8
5/32
1/8
1/8
1/4
1/4
1/4
5/16

(2.4)
(3.2)
(4.0)
(3.0)
(3.0)
(6.4)
(6.4)
(6.4)
(7.9)

3/32
3/32
1/8
5/32
5/32
5/32
5/32
1/4
5/16

(2.4)
(2.4)
(3.2)
(4.0)
(4.0)
(4.0)
(4.0)
(6.4)
(7.9)

Other
Welds
Div. 1 & 2
1/32
1/16
3/32
3/32
1/8
5/32
7/32
1/4
5/15

(0.8)
(1.6)
(2.4)
(2.4)
(3.2)
(4.0)
(5.6)
(6.4)
(7.9)

Weld length shown in spot radiographs

- Each radiograph shall clearly show a minimum of 6 inches (152 mm) of weld length.
- In addition all four-way junction radiographs shall clearly show not less than four (4) inches (102 mm) of
longitudinal weld length on each side of the circumferential weld. A junction is considered a four-way when
the course stagger is 5T or less. T equals the thickness of the thicker plate.
Evaluation of indication
- All relevant indication shall be evaluated in terms of the Acceptance Criteria in this procedure.
- Relevant indications not characterized as being a crack or zone of incomplete fusion or penetration shall
be evaluated as being:
Elongated indications if their length is more than three (3) times the width
Rounded indications if their length is equal to or less than three (3) times the width

Pag. 27

Acceptance criteria for 100% radiography of division 1 vessels and all radiography (100% and spot) of
division 2 vessels
Sections of welds that are shown by radiography to have any of the following types of discontinuities are
unacceptable. The weld shall be repaired and re-radiographed in accordance with this procedure.
- Any indication characterized as a crack or zone of incomplete fusion or penetration.
- Any other elongated indication which has a length greater then:
1/4 in. (6.3 mm) for T up to 3/4 in. (19 mm)
1/3 T for T from 3/4 in. (19 mm) to 2-1/4 in. (57 mm)
3/4 in. (19 mm) for T over 2-1/4 in. (57 mm)
T = the thickness of the weld excluding any allowable reinforcement. For a butt weld
joining two members having different thickness at the weld, T is the thinner of these two
thickness. If a full penetration weld includes a fillet weld, the thickness of the throat of the
fillet shall be included in T.
- Any group of aligned indications that have an aggregate length greater than T in a length of 12 T,
except where the distance between successive imperfections exceeds 6L, where L is the length of
the longest imperfections in the group.
- Rounded indications in excess of that shown as acceptable in Appendix 4 of Division 1 or in
Appendix 8 of Division 2 of the ASME Section VIII Code.
4.7 Acceptance criteria for spot radiography of Division 1 vessels only
4.7.1

4.7.2

4.7.3

Welds in which the radiography shows any of the following types of discontinuities are unacceptable
until repaired and re-radiographed per this procedure:
4.7.1.1 Any indication characterized as a crack or zone of incomplete fusion or penetration.
4.7.1.2 Indications characterized as slag inclusions or cavities which have a length greater than 2/3T
where T is the thickness of the weld excluding any allowable reinforcement. For a butt weld
joining two members having different thickness at the weld, T is the thinner of these two
thickness. If a full penetration weld includes a fillet weld, the thickness of the throat of the
fillet shall be included in T. Maximum length of any such indication shall be inch (19
mm). Any such indication shorter than inch (6 mm) shall be acceptable for any plate
thickness.
If several indications within the above limitations exist in line, the weld shall be acceptable if the
sum of the longest dimensions of all such indications is no more than T in a length of 6T (or
proportionately for radiographs shorter than 6T) and if the longest indications considered are
separated by at least 3L of acceptable weld metal, where L is the length of the longest indication.
Rounded indications are not a factor in the acceptability of welds required to be spot radiographed.

4.8 Evaluation and re-examination

4.8.1

When a spot radiograph is graded acceptable the entire length of weld represented by this radiograph
is acceptable.

4.8.2

When a spot radiograph discloses welding which does not comply with the minimum requirements
two additional radiographs (tracers) shall be taken in the same weld unit at locations away from the
original spot.
Pag. 28

4.8.2.1

If the two additional radiographs (tracers) show welding which meets the minimum quality
requirements the entire weld unit represented by the three radiographs is acceptable. The
unacceptable welding disclosed by the first of the three radiographs shall be removed and
the area repaired and re-radiographed.
4.8.2.2 If either of the two additional radiographs (tracers) shows unacceptable welding, the entire
unit of weld represented shall be rejected. At the option of the Manufacturer:
EITHER
The entire unit of rejected weld shall be removed, the joint rewelded and spot radiographed
in accordance with this procedure.
OR
The entire unit of rejected weld shall be 100% radiographed and only unacceptable welding
need be repaired and spot radiographed in accordance with this procedure.

5.0 Visual inspection requirement

The rules in the following paragraphs apply specifically to the inspection and testing of pressure vessels and
vessel parts that are fabricated by welding and shall be used in conjunction with the general requirements for
Inspection and Tests and with the specific requirements for Inspection and Tests that pertain to the class of
material used.
5.1 Visual inspection technique procedure standard technique
Scope
This general visual inspection technique procedure is to be used with the procedure for the applicable
referencing Code or Standard.
Personnel
Experienced personnel shall perform the inspections outlined in this procedure.
Equipment
Fillet weld gauges, weld reinforcement gauges and measuring tapes
Two cell (C or D) flashlight or brighter light source
Wire brushes and /or Grinding Wheels for stainless steel and nickel base alloy material, use wheels
and 300 Series stainless brushes that have not been previously used on carbon or low alloys steels.
If necessary, cleaning agents such as isopropyl alcohol, Tri-sodium phosphate, double-check DR-60
or equal.
NOTE: When examining nickel base alloys or austenitic stainless steels, all materials, including
penetrants, solvents or cleaning agents, developers, etc. shall be analyzed individually for
residual total sulfur, chlorine and fluorine content in accordance with Section V, Article 6,
Paragraph T-641. For nickel base alloys, the residual total sulfur content shall not exceed
one (1) percent by weight. For austenitic stainless steels, the residual total chlorine and
fluorine content shall not exceed one (1) percent by weight or by D808 the residue total
shall not exceed 1% by weight. Certification of test results for each material, including
batch number, if applicable shall obtain. Cleaning solvents and agents purchased with
known chemical composition do not require analysis.
If necessary, visual aids, such as mirrors, magnifying lenses etc.
Procedure
Prepare and clean the weld surface to be inspected.
Remove weld spatter, slag and flux with descaling tools, wire brushes, grinding wheels or other
suitable means. Use stainless wire brushes when brushing austenitic or nickel base alloy material.
Pag. 29

As necessary, clean welds of dirt, oil, grease or other substances that might interfere with the
examination using a cleaning agent.
While performing the inspection, natural or artificial lighting shall be adequate to illuminate the
surface being examined to a minimum of fifty (50) foot cans. Illumination form any one of the
following light sources or a brighter light source is adequate:
Light Source
Maximum Source to Object
Distance in inches (mm)

2D Cell
Flashlight

60 Watt
Bulb

75 Watt
Bulb

100 Watt
Bulb

10 (254)

10 (254)

13 (381)

18 (457)

If possible, the surface being inspected shall be viewed without visual aids. However, visual aids
such as mirrors, magnifying lenses, etc. may be used if access to the surface being examined is not
easily achieved.
Personnel performing direct visual inspections shall have access sufficient to place the eye within 24
inches (610 mm) of the surface to be inspected and at an angle not less than 30 degrees to the surface
to be inspected. If the use of visual aids is required, the resolution capability shall be at least
equivalent to that obtainable by direct visual observation.
This may be demonstrated by the inspector being able to see a fine line, 1/32 inch (.8 mm) wide or
less, or other artificial flaw on the surface (or a surface similar to that being examined) in the least
discernible (viewable) location of the area being examined).
If required by the applicable Code or Standard, inspect joints after fit-up, but before welding, for
correct weld edge prep, gap and alignment.
After welding, inspect welds for surface indications and appearance and measure at representative
locations for adequacy of size, concavity, convexity (if applicable), reinforcement and length using
gauges and measuring tapes.
Where readily accessible for viewing without visual aids, inspect the root surface of single sided
welds to determine the amount of penetration (protusion) or concavity (suck up).

5.2 Visual inspection requirements for ASME Section VIII Code division 1 & 2 pressure vessels
Scope
This procedure contains the ASME Section VIII Code visual inspection acceptance criteria requirements for
complete welds and is to be used with the applicable standard or contract X or N general Visual
Inspection Technique Procedure VI5.
Reference
1992 ASME Section VIII Code or with any of the following Addenda: 92, 93, 94
1995 ASME Section VIII Code or with any of the following Addenda: 95, 96
Acceptance Criteria
As welded surfaces are permitted, provided the surface of welds are sufficiently free from coarse
ripples, grooves, overlaps, and abrupt ridges and valleys.
The surface condition of the finished weld shall be suitable for proper interpretation of radiographic
and other required nondestructive examinations when these examinations are required by contract
drawings.
Undercut shall not exceed 1/32 inch (0.8 mm) or 10% of the nominal thickness of the adjoining
surface, whichever is less.
The surface of butt welded joints may be flush with the base material or may have uniform crowns.
The height of reinforcement for each weld surface shall not exceed the following:
Pag. 30

Nominal Wall
Thickness (T), In. (mm)

Less than 3/32

3/32 to 3/16
Over 3/16 to
Over to 1
Over 1 to 2
Over 2 to 3
Over 3 to 4
Over 4 to 5
Over 5

Maximum Reinforcement, I (mm)

Circumferential Joints
In pipe and tubing
Division 1
Division 2

(2.4)
(2.4 to 4.8) incl.
(4.8 to 12.7), incl.
(12.7 to 25.4) incl.
(25.4 to 51) incl.
(51 to 75) incl.
(76 to 102) incl.
(102 to 127) incl.
(127)

3/32
1/8
5/32
1/8
1/8
1/4
1/4
1/4
5/16

(2.4)
(3.2)
(4.0)
(3.0)
(3.0)
(6.4)
(6.4)
(6.4)
(7.9)

3/32
3/32
1/8
5/32
5/32
5/32
5/32
1/4
5/16

(2.4)
(2.4)
(3.2)
(4.0)
(4.0)
(4.0)
(4.0)
(6.4)
(7.9)

Other
Welds
Div. 1 & 2
1/32
1/16
3/32
3/32
1/8
5/32
7/32
1/4
5/15

(0.8)
(1.6)
(2.4)
(2.4)
(3.2)
(4.0)
(5.6)
(6.4)
(7.9)

Concavity on the root side of a single side welded circumferential butt weld is permitted when the
resulting thickness of the weld is at least equal to the thickness of the thinner member of the two (2)
sections being joined and the contour of the concavity is smooth.

Offset of final butt welded joints shall not be greater than that shown in the following Table
NOTE: t is the nominal thickness of the thinner section of the joint.
Section Thickness, in. (mm)
A
Up to 1/2 (12.7), incl.
Over to (12.7 to 19), incl.
Over to 1-1/2 (19 to 38), incl.
Over 1-1/2 to 2 (38 to 51)
Over 2 (51)

Joint Categories
B,C, & D

1/4 t
1/8 in. (3.2)
1/8 in. (3.2)
1/8 in. (3.2)
Lesser of
1/16t or 3/8 in. (9.5)

1/4 t
t
3/16 in. (4.8)
1/8 t
Lesser of
1/8t or in. (19)

Any offset within the allowable tolerance of the Table shall be faired at a three to one taper over the
width of the finished weld, or if necessary, by adding additional weld metal beyond what would
otherwise be the edge of the weld.
Fillet Welds
Fillet welds may vary from convex to concave
The size of the fillet weld shall be determined as follows:
Cracks or other linear indications in welds are unacceptable.

6.0 Marking & Reports

6.1 General marking and reports
The provisions for marking and reports, UG-115 through UG-120, shall apply without supplement to welded
pressure vessels.

Pag. 31

6.2 Placement of location markers (film interval numbers or identification numbers) and film
identification
Place location markers, which are to appear as images on the film, on the surface near the weld ate the film
intervals for multiple exposures or the approximate center point of the film location for single exposures. The
location of the markers shall be marked permanently on the surface of the part when permitted (shall be with
a low stress centerpunch) or on a record drawing. In this manner, the area of interest on a radiograph may be
accurately traceable to its location on the surface of the part. It also provides evidence on the radiograph that
the area being examined has been obtained, When permanent marking is not allowed, use temporary marking
such as a paint stick or equal.
6.2.1

Lead number location markers (film interval numbers or identification numbers), which are
to appear as images on the film, shall be placed on the material adjacent to the weld at the
marks located in 5.1 and as follows:

6.2.2

Location markers shall be placed on the source side when radiographing joints in:
- Flat components or longitudinal joints in cylindrical or conical components;
- Curved or spherical components whose concave side is toward the source and when the
source to material distance is less than the inside radius of the component;
- Curved or spherical components whose convex side is toward the source.

6.2.3

Location markers shall be placed on the film side when radiographing joints in curved or
spherical components whose concave side is toward the source and when the source to
material distance is greater than the inside radius.

6.2.4

Location markers may be placed on either the source side or film side when radiographing
joints in curved or spherical components whose concave side is toward the source and the
source to material distance equal the inside radius of the component.

6.2.5

As an alternative to source side placement, location markers may be placed on the film side
when the radiograph shows coverage beyond the location markers to the extent
demonstrated as follows:

6.2.6

Markers for pipe welds shall be lead numbers as follows:

6.2.7

For single wall viewing, circumferential number tapes shall be used. The 0 numbers shall be
placed on the 0 point on the pipe and the remaining numbers located clockwise (or counterclockwise) around the outside of the pipe. A minimum number of markers shall be used to
provide evidence that the required coverage has been obtained.

6.2.8

For double wall viewing, at least one location marker shall be placed on the source side
surface adjacent to the weld for each exposure.

6.2.9

Permanently mark each film with the following information:

Contract Number
Pipe Line Identification
Joint identification number
Film interval numbers or identification numbers
Re-shot, repair shot or tracer shot identification (RS, R1, T1, Etc,)
Manufacturers name or symbol
Welder or operators identification (if not on check list or record drawing)
Date of the Radiograph
Pag. 32

7.0 Hydropressure testing

7.1 Hydrostatic test for underground piping
As indicated in Erection procedure (page 7):
7.1.1

7.1.2
7.1.3

For the pipes, the pressure shall first be gradually brought to the testing value, later shall be
lowered to the calculated value and maintained for the time needed to allow, where possible,
visual control of the welding; shall then be brought to test value and maintained with this
value for at least 10 minutes, and anyhow for the time needed in order to make a careful
exam of all the welded joints and expansion joints that may need tightened.
If the hydraulic test reveals unacceptable local deformation or transuding for lack of
penetration, scoring, cracks, porosity or other, the faulty element shall be repaired and reexamined.
The pressure, during the hydraulic test shall be recorded continually with a manometer.

7.2 Final hydraulic test

7.2.1 Test methods
7.2.1.1
7.2.1.2

7.2.1.3
7.2.1.4
7.2.1.5

7.2.1.6

After the completion of erection, and an accurate internal control of the piping in order to
ensure that no extraneous materials remained inside, the pipes shall be submitted, before
starting, to the static tests of hydraulic pressure.
For the tests execution, the downstream cut-off may be carried out with the machine valves
when the seal is already checked and the relative base foundations verified also for the
loads resulting from the tests; when these conditions are not respected, flanged bottoms
shall be used, the piping shall be filled with water through the bottoms with pump
connections, the air discharge and the manometer. Safety valves shall be gagged,
provisions shall be made to limit maximum pressure applied during test.
The piping shall be filled with water and maintained for the required length of time to permit
in services leak testing. All bolts of the expansion joints shall be adjusted.
If during tests appear seal defects, the defectous elements, if possible, shall be repaired in
accordance to the specifications or a replace may be requested. The hydraulic test of the
piping section where the defectous element was found shall be repeated.
The pressure shall be gradually brought to test value and so maintained for 30 minutes; then
lowered to the value corresponding to maximum static level in the load chamber or in the
piezometer well; at this pressure through visual control the junctions carried out during the
site assembly shall be checked; at last the pressure shall be brought back to test value and
maintained for the required time to carry out the piping inspection.
If during test appear resistance or seal defects, the defectous element, if possible, shall be
repaired in accordance to the specification of paragraph 7.4 or a replacement may be
requested.
The hydraulic test of the piping section where the defectous element was found shall be
repeated.

Pag. 33

PAINTING PROCEDURE

Index:
1.0 Field blasting & painting procedure.......................................................................................Pag. 35
1.1 Scope...........................................................................................................................Pag. 35
1.2 Surface preparation......................................................................................................Pag 35
1.3 Painting........................................................................................................................Pag. 35
Technical Data: Navitar AS...............................................................................................Pag. 36
Technical Data: Jotabar ZEP..............................................................................................Pag. 39
Technical Data: Primastic Universal..................................................................................Pag. 42
2.0 Field Touch-Up Requirements...............................................................................................Pag. 45
3.0 Inspection Requirements........................................................................................................Pag. 45
4.0 General Painting requirements...............................................................................................Pag. 45
4.1 Paint buckets...................................................................................................................Pag. 46

Pag. 34

1.0 Field blasting & painting procedure

1.1 Scope
This procedure covers the material, surface preparation, coating system and general standard requirement for
the Field cleaning, blasting and painting of the Penstocks. In areas, where Penstock will be buried (at power
houses) the external coating shall be the same as internal coating.
1.2 Surface preparation
Internal and external will be sand blasted in accordance with the S.S. Grade 2-1/2, white metal.
1.3 Painting
Internal surface:

two (2) coats of Epoxy coal-tar NAVITAR AS for a total thickness of dry film of 400
micros.

External surface: one (1) coat of Zinc-rich epoxy primer JOTABAR ZEP for a total thickness of dry film of
50 microns;
two (2) coats of high solids modified epoxy PRIMASTIC UNIVERSAL for a total
thickness of dry film of 90 microns.
The total external surface will have a total dry film thickness of 140 microns.

Pag. 35

NAVITAR AS
PRODUCT:

Navitar AS

DESCRIPTION:

Navitar AS is 3 solventless, two-pack epoxy coal-tar coating which may be

applied by ordinary airless spray in a high film thickness.

RECOMMENDED USE:

Submerged steel structures, buried concrete or steel structures. Excellent

protection against corrosion, Excellent in combination with cathodic
protection.

TECHNICAL INFORMATION:
Colour
Solids (% by volume):
Flash point
Flexibility
Gloss
Water resistance
Chemical resistance
Solvent resistance
Abrasion resistance

:
:
:
:
:
:
:
:
:

Application range typical

Dark Brown/Black
90 2
75 C 2 (Setaflash)
Good
Semi-flat
Excellent
Good
Good (discoloration)
Good
Film thickness per coat
in microns
Dry
Wet
200 400
300

Theoretical spreading rate

m2/l

225 445
330

4.5 2.3
3.0

APPLICATION DATA:
Application methods
Miring ratio
(by volume)
Pot life (23 C)
Thinner/Cleaner
Guiding data airless spray
Pressure at nozzle
Nozzle tip
Spray angle
Filter

:
:
:
:
:

Airless spray, Brush may be used for smaller areas

2 parts Comp. A (base) to be mixed thoroughly with
1 part Comp. B (curing agent)
1 hour (Reduced at higher temp.)
Jotun Thinner No. 17

:
:
:
:

20 MPa (20150 kp/cm2 2800 psi)

0.53 0.79 mm (0.021-0.031")
40-80
Check to ensure that filters are clean

Pag. 36

NAVITAR AS (cont.)

SURFACE
PREPARATION:

Clean dry and undamaged shopprimer or blast cleaning to Sa 2. (ISO

8501-1:1988/SS 05 5900). Power tool cleaning to min. St 2 (SIS 05 5900) may
be acceptable for minor touch-up work subject to exposure conditions.

CONDITION DURING
APPLICATION:

DRYING/
CURING TIME:

Substrate
temperature
10 C
23C
35 C
1.
2.
3.
4.

Surface
Dry
24 h
12 h
4h

The temperature of the substrate should be minimum 15 C and at least 3 C

above the dew point of the air. The temperature and the relative humidity should
be measured in the vicinity of the substrate. The temperature of the paint should
be approx. 20 C at the time of application. If no heating unit is installed on the
spray equipment, preheating in a water-bath to 20 C is recommended.

The drying times are measured according to BS 3900 Part C2 and BS 3900
Part C3.
Drying times are generally related to air circulation, temperature, film thickness
and number of coats, and will be affected correspondingly. The figures given in
the table are typical with:
* Good ventilation
* Recommended film thickness
* One coat on top of inert substrate
1

Hard
Dry

Cured

48 h
24 h
6h

14 d
7d
3d

Dry to recoat3
Minimum
48 h
24 h
6h

Maximum 4
Interior

Exterior

7d
7d
4d

Measured according to BS 3900 Part C2

Measured according to BS 3900 Part C3
Recommended data given far recoating with the same genetic type of paint.
The surface should be free from chalking and contamination prior to application. At interior exposure
note that best intercoat adhesion occurs when the subsequent coat is applied before the preceding coat is
cured. At exterior exposure the chalking effect especially from the sunlight limits the maximum dry to
recoat time.

The given data must be considered as guidelines only. The actual drying time/times before recoating
may be shorter or longer, depending on existing coating, generic type, film thickness, system chosen,
no. of coats, ventilation, temperature, requirement for early handling and mechanical strength etc. A
complete system can be described on a system sheet, where all parameters and special conditions could
be included.
TYPICAL RECOMMENDED
PAINT SYSTEM:
Navitar AS (diluted 25%)

Stripe coat
Navitar AS

1 x 300 m (Dry Film

Thickness)

Pag. 37

NAVITAR AS (cont.)

STORAGE AND PACKING:

STORAGE:

PACKING CONTENT:
HEALTH AND SAFETY:

The product most be stored in accordance with national regulations.

Preferred storage conditions are to keep the containers in a dry space
provided with adequate ventilation. The containers should be sealed
tightly.
13 1 Comp. A (base) and 6.51 Comp. B (curing agent)
Please observe the precautionary notices displayed on the container.
Spray under well ventilated conditions. Do not breathe or inhale mist.
Avoid skin contact. Spillage on the skin should immediately be removed
with suitable cleanser, soap, and water, Eyes should be well flushed with
water and medical attention sought immediately.
For detailed information on the health and safety hazards and
precautions for use of this product, we refer to the Material Safety
Data Sheet

DISCLAIMER:

The information in this data sheet is given to the best of our knowledge based on laboratory
testing and practical experience. However, as the product is often used under conditions beyond
our control, we can not guarantee anything but the quality of the product itself. We reserve the
right to change the given data without notice.
VERSION 1/97. ISSUED SEPTEMBER 1997, JOTUN FAINTS NORWAY
THIS DATA SUPERSEDES THOSE PREVIOUSLY ISSUES

Pag. 38

JOTABAR ZEP
PRODUCT:

JOTABAR ZEP

DESCRIPTION:

Jotabar ZEP is a two-pack zinc-rich epoxy primer.

RECOMMENDED USE:

As primer on blast cleaned steel. Jotabar ZEP is used in combination with

most sophisticate coating systems to increase the durability

TECHNICAL INFORMATION:
Colour
Solids (% by volume):
Flash point
Flexibility
Gloss
Water resistance
Chemical resistance
Solvent resistance
Abrasion resistance

:
:
:
:
:
:
:
:
:

Application range typical

Grey
43 2
25 C 2 (Setaflash)
Good
Flat
Excellent
Fair
Fair
Good
Film thickness per coat
in microns
Dry
Wet
25 75
50

Theoretical spreading rate

m2/l

60 175
115

17.2 5.7
8.6

APPLICATION DATA:
Application methods
Miring ratio
(by volume)
Pot life (23 C)
Thinner/Cleaner
Guiding data airless spray
Pressure at nozzle
Nozzle tip
Spray angle
Filter

SURFACE
PREPARATION:

:
:
:
:
:

Airless spray, Brush may be used for smaller areas

2 parts Comp. A (base) to be mixed thoroughly with
1 part Comp. B (curing agent)
24 hours
Jotun Thinner No. 17

:
:
:
:

15 MPa (150 kp/cm2 2100 psi)

0.38 0.53 mm (0.015-0.021")
40-80
Check to ensure that filters are clean

Blast cleaning to Sa 2. (ISO 8501-1:1988/SS 05 5900).

Pag. 39

JOTABAR ZEP

CONDITION DURING
APPLICATION:

DRYING/
CURING TIME:

The drying times are measured according to BS 3900 Part C2 and BS 3900
Part C3.
Drying times are generally related to air circulation, temperature, film thickness
and number of coats, and will be affected correspondingly. The figures given in
the table are typical with:
* Good ventilation (outdoor exposure or free circulation air)
* Recommended film thickness
* One coat on top of inert substrate
1

Substrate
temperature

Surface
Dry

5 C
10 C
23C
35 C

50 min
20 min
10 min
5 min

1.
2.
3.
4.

The temperature of the substrate should be minimum 5 C and at least 3 C

above the dew point of the air in the vicinity of the substrate. Continuous
stirring during application will prevent the heavy zinc pigment from settling.

Hard
Dry

Cured

Dry to recoat3
Minimum

3h
2h
1.5 h
1h

10 d
7d
5d
3d

3h
2h
1.5 h
1h

Maximum 4
-

Measured according to BS 3900 Part C2

Measured according to BS 3900 Part C3
Recommended data given far recoating with coatings normally specified on top of zinc epoxy coatings.
The surface should be free from zinc salts and other contamination prior to application of the subsequent
coat.

The given data must be considered as guidelines only. The actual drying time/times before recoating
may be shorter or longer, depending on existing coating, generic type, film thickness, system chosen,
no. of coats, ventilation, temperature, requirement for early handling and mechanical strength etc. A
complete system can be described on a system sheet, where all parameters and special conditions could
be included.
TYPICAL RECOMMENDED
PAINT SYSTEM:

STORAGE AND PACKING:

STORAGE:

HANDLING:
PACKING CONTENT:

Jotabar ZEP
Topcoat:

1 x 40 m (Dry Film Thickness)

Vinyproof, Penguard, Pioner or Conseal as Specified

The product most be stored in accordance with national regulations.

Preferred storage conditions are to keep the containers in a dry space
provided with adequate ventilation. The containers should be sealed
tightly.
Handle with care, Stir well before use.
6.75 1 Comp. A (base) and 2.25 1 Comp. B (curing agent)

Pag. 40

JOTABAR ZEP

HEALTH AND SAFETY:

Please observe the precautionary notices displayed on the container.

Spray under well ventilated conditions. Do not breathe or inhale mist.
Avoid skin contact. Spillage on the skin should immediately be removed
with suitable cleanser, soap, and water, Eyes should be well flushed with
water and medical attention sought immediately.
For detailed information on the health and safety hazards and
precautions for use of this product, we refer to the Material Safety
Data Sheet

DISCLAIMER:

The information in this data sheet is given to the best of our knowledge based on laboratory
testing and practical experience. However, as the product is often used under conditions beyond
our control, we can not guarantee anything but the quality of the product itself. We reserve the
right to change the given data without notice.
VERSION 1/97. ISSUED JUNE 1997, JOTUN FAINTS NORWAY
THIS DATA SUPERSEDES

Pag. 41

PRIMASTIC UNIVERSAL
PRODUCT:
DESCRIPTION:

PRIMASTC UNIVERSAL
Primastic Universal is a two-pack, high solids modified epoxy coating.

RECOMMENDED USE:

Anticorrosive primer for steel structures above and below water, also on
steel where blast cleaning may not be possible.

TECHNICAL INFORMATION:
Colour
Solids (% by volume):
Flash point
Flexibility
Gloss
Gloss retention
Water resistance
Chemical resistance
Solvent resistance
Abrasion resistance

:
:
:
:
:
:
:
:
:
:

Application range typical

Aluminium/Aluminium red toner

75 2
35 C 2 (Setaflash)
Good
Semi-gloss
Fair
Very good
Good
Good
Very good
Film thickness per coat
in microns
Dry
Wet
100 250
125

Theoretical spreading rate

m2/l

135 335
170

7.5 3.0
6.0

APPLICATION DATA:
Application methods
Miring ratio
(by volume)
Pot life (23 C)
Thinner/Cleaner
Guiding data airless spray
Pressure at nozzle
Nozzle tip
Spray angle
Filter

:
:
:
:
:

Airless spray,
5 parts Comp. A (base) to be mixed thoroughly with
1 part Comp. B (curing agent)
10 minutes
Jotun Thinner No. 17

:
:
:
:

15 MPa (150 kp/cm2 2100 psi)

0.58 0.79 mm (0.023-0.031")
40-80
Check to ensure that filters are clean

Pag. 42

PRIMASTC UNIVERSAL

APPLICATION DATA (Cont.)

NOTE:

* The temperature of the mixture of base and curing agent is recommended to be at

least 15C, otherwise extra solvent may be required to obtain correct viscosity.
* Too much solvent results in lower sag resistance and slower cure.
* If extra solvent is necessary, this should be added after mixing of the two
components.

SURFACE
PREPARATION:

Power tool cleaning to St. 2, mill scale free (ISO 8501-1:1988/SS 05 59 00).
Improved surface pretreatment will improve the performance. When used over
old coating systems, the surface must be clean and dry.

CONDITION DURING
APPLICATION:

DRYING/
CURING TIME:
Part C3.

The temperature of the substrate should be minimum 10 C and at least 3 C

above the dew point of the air in the vicinity of the substrate. When used in
confined spaces, good ventilation is necessary. Do not use heated air until the
solvents have evaporated from the coating film to avoid surface drying and
solvent entrapment. Primastic Universal should not be exposed to oil, chemicals
or strong mechanical stress until fully cured.

The drying times are measured according to BS 3900 Part C2 and BS 3900
Drying times are generally related to air circulation, temperature, film thickness
and number of coats, and will be affected correspondingly. The figures given in
the table are typical with:
* Good ventilation (outdoor exposure or free circulation of

air)
* Recommended film thickness
* One coat on top of inert substrate
Substrate
temperature
10 C
23 C
35 C
1.
2.
3.
4.

Surface
Dry
8h
4h
2h

Hard
Dry

Cured

Dry to recoat3
Minimum

24 h
10 h
5h

14 d
7d
3d

24 h
10 h
5h

Maximum 4
Interior
-

Measured according to BS 3900 Part C2

Measured according to BS 3900 Part C3
Recommended data given far recoating with the same genetic type of paint.
Provided the surface is free from chalking and contamination prior to application. There is normally no
overcoating time limit. Best intercoat adhesion occurs, however, when the subsequent coat is applied
before the preceding coat has cured. If the coating has been exposed to direct sunlight for some time,
special attention must be paid to surface cleaning and mattening/removal of the surface layer in order to
obtain good adhesion.
Pag. 43

PRIMASTC UNIVERSAL

DRYING /
CURING TIME: (cont.)
The given data must be considered as guidelines only. The actual drying time/times befog recoating
may be shorter or longer, depending on existing coating, generic type, film thickness, system chosen,
no. of coats, ventilation, temperature, requirement for early handling and mechanical strength etc. A
complete system can be described on a system sheet, where all parameters and special conditions could
be included.
TYPICAL RECOMMENDED
PAINT SYSTEM
ABOVE WATER:
Thickness)

Primastic Universal

TYPICAL RECOMMENDED
PAINT SYSTEM
Primastic Universal
UNDER WATER:
STORAGE AND PACKING:
STORAGE:

PACKING CONTENT:
HEALTH AND SAFETY:

2 x 125 m (Dry Film Thickness)

Hardtop AS
1 x 40 m (Dry Film

2 x 200 m (Dry Film Thickness)

Antifouling system as specified

The product most be stored in accordance with national regulations.

Preferred storage conditions are to keep the containers in a dry space
provided with adequate ventilation. The containers should be sealed
tightly.
16.7 1 Comp. A, 3.3 1 Comp. B
Please observe the precautionary notices displayed on the container.
Spray under well ventilated conditions. Do not breathe or inhale mist.
Avoid skin contact. Spillage on the skin should immediately be removed
with suitable cleanser, soap, and water, Eyes should be well flushed with
water and medical attention sought immediately.
For detailed information on the health and safety hazards and
precautions for use of this product, we refer to the Material Safety
Data Sheet

DISCLAIMER:

The information in this data sheet is given to the best of our knowledge based on laboratory
testing and practical experience. However, as the product is often used under conditions beyond
our control, we can not guarantee anything but the quality of the product itself. We reserve the
right to change the given data without notice.

VERSION 1/98. ISSUED APRIL 1998, JOTUN FAINTS NORWAY

THIS DATA SUPERSEDES THOSE PREVIOUSLY ISSUED

Pag. 44

2.0 Field Touch-Up Requirements

Surfaces previously primed, that show signs of rusting, shall be re-cleaned and/or re-blast cleaned and
primed, per sections above of this procedure.
Abnormal or excessive runs and sags shall be abrasive paper cleaned until smooth and touch-up coated per
sections above of this procedure.
Any coating that is under the nominal thickness shall be coated again to bring that coat of paint to the
thickness specified in sections above of this procedure.
Any coat of paint that has moisture, water, or other contamination evident on the surface, shall not be topcoated until that surface has been properly cleaned of the contamination. Contamination such as dirt, dust,
dry spray, over-spray, etc., that is embedded in the previous coat of paint, shall be abrasive paper cleaned
until smooth, before over-coating.

3.0 Inspection Requirements

Surface preparation shall be checked visually using comparable pictorial standards
An Elcometer or Microtest DFT Gage shall be used to check the Dry Film Thickness of the applied coatings,
to insure the nominal DFT is achieved. If an area is found to be under millage, additional readings shall be
taken, as needed, to determine the area of primer that is under the specified nominal thickness.
The field painting supervisor shall be responsible for the daily painting inspection and completing the Daily
Field Blasting/Painting Inspection Report.

4.0 Painting general Requirements

Painting of any surfaces shall not proceed when any of the following environmental conditions exist:
a)

When the surface temperature is above 40C or below 10C, or per the paint manufacturer's
requirements for specific paints.

b)

When the relative humidity in the work area is greater than 85% or per the paint manufacturer's
recommendation for specific paints.

c)

The surface temperature is less than 3C (5F) above the dew point of the air in the work area.

d)

Moisture or other detrimental surface contamination is evident on the surfaces to be blasted or

primed. Detrimental surface contamination does not include ingrain stains.

Pag. 45

4.1 Paint buckets

Paint buckets shall be stored per the manufacturer's instructions.
Application of each coat of paint shall be per the manufacturer's instructions.
Thinning of the paints shall be per the manufacturer's instructions.
Drying times between coats shall be per the manufacturer's instructions.
Mixing of the paints shall be per the manufacturer's instructions.
Ventilation and safety of the paints shall be per the manufacturer's instructions.

Pag. 46