SP-1097 DSS Welding Specs PDF

Specification for Welding of Duplex and Super Duplex Stainless Steel Pipelines
Version3.0
Petroleum Development Oman L.L.C.
Document title: Specification for Welding of Duplex and
Super Duplex Stainless Steel Pipelines

(Amendments/Supplements to API Std 1104)
Document ID SP- 1097
Document Type Specification
Security Unrestricted
Discipline Material & Corrosion
Owner UEC-Materials and Integrity Manager
Issue Date September 2018
Version 3.0
Keywords: This document is the property of Petroleum Development Oman, LLC. Neither
the whole nor any part of this document may be disclosed to others or reproduced, stored
in a retrieval system, or transmitted in any form by any means (electronic, mechanical,
reprographic recording or otherwise) without prior written consent of the owner.
July 2018 i SP-1097

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July 2018 ii SP-1097

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i Document Authorisation
Authorised For Issue
Document Authorisation
Document Owner Document Custodian Document Author
(CFDH)
Behlani, Nasser NABHANI,TALAL Ghafri, Mohamed

UEC UEC1 UEC11
Date : 05-09-2018 Date : 05-09-2018 8:53 Date : 05-09-2018

12:00 AM AM 8:48 AM
July 2018 iii SP-1097

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ii Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details of
all revisions prior to these are held on file by the issuing department.
Version No. Date Author Scope / Remarks

Version 1.0 3/8/99 OTT/112 Extensive revision of original issue of SP
1189.
Version 2.0 25/05/05 UEC/11 Updated based on past experience
Version 3.0 24/06/18 UEC/11 Updated based on latest standards and
Lessons Learned.
iii Related Business Processes

Code Business Process (EPBM 4.0)
iv Related Corporate Management System (CMS) Documents

The related CMS Documents can be retrieved from the Corporate Management Portal
(CMS).
Keywords:
API 1104
Duplex Stainless Steel
Inspection
Off-plot
Pipelines
Procedure Qualification Record
Production Welding
Testing
Welding Procedure Specification
Welder Qualification
July 2018 iv SP-1097

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PETROLEUM DEVELOPMENT OMAN L.L.C. I
DOCUMENT TITLE: SPECIFICATION FOR WELDING OF DUPLEX AND I
I DOCUMENT AUTHORISATION III
II REVISION HISTORY IV
III RELATED BUSINESS PROCESSES IV
IV RELATED CORPORATE MANAGEMENT SYSTEM (CMS) DOCUMENTS IV
1. INTRODUCTION 1
1.1 Purpose 1
1.2 Changes to the Specification 1
2. SPECIFICATION FOR WELDING DUPLEX STAINLESS STEEL 2
2.1 Specification Requirements 2
2.2 Process Deliverables 2
2.3 Process Owner's Responsibility 2
2.4 Performance Levels / Indicators 2
2.5 Performance Monitoring 2
2.6 Effective period 3
2.7 Review and Improvement 3
3 GLOSSARY OF DEFINITIONS, TERMS AND ABBREVIATIONS 4
AMENDMENTS/SUPPLEMENTS TO API SPEC 1104 7
1 Scope 7
2 NORMATIVE REFERENCES 7
3 TERMS, DEFINITIONS, ACRONYMS AND ABBREVIATIONS 7
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4 SPECIFICATIONS 7
4.1 Equipment 7
4.2 Materials 8
5 QUALIFICATION OF WELDING PROCEDURES WITH FILLER METAL

ADDITIONS 10
5.1 Procedure Qualification 10
5.2 Record 10
5.3 Welding Procedure Specification 10
5.4 Essential Variables 13
5.5 Welding of Test Joints - Butt Welds 15
5.6 Testing Of Welded Joints - Butt Welds 16
5.7 Welding of Test Joints - Fillet Welds 20
5.8 Testing Of Welded Joints - Fillet Welds 20
5.8.1 Preparation 20
5.9 Welding of Test Repair Welds 21
5.10 Testing of Repair Welds 21
5.11 Records 21
6 QUALIFICATION OF WELDERS 22
6.1 General 22
6.2 Single Qualification 22
6.3 Multiple Qualification 23
6.4 Visual Examination 23
6.5 Destructive Testing 23
6.6 Non-destructive Testing (Radiography) - Butt Welds Only 24
6.7 Retesting 24
6.8 Records 24
7 DESIGN AND PREPARATION OF A JOINT FOR PRODUCTION WELDING 25
7.1 General 25
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7.2 Alignment 26
7.3 Use of Line-Up Clamp for Butt Welds 26
7.4 Bevel 26
7.7 Cleaning Between Beads 27
7.8 Position Welding 27
7.10 Identification of Welds 27
7.11 Pre- and Post-Heat Treatment 27
7.13 Weld Interruption 28
7.14 Weld Finishing 28
7.15 Shielding and Backing Gas 28
8 Inspection and Testing of Production Welds 28
8.2 Methods of Inspection 28
8.3 Qualification of Inspection Personnel 28
8.4 Certification of Non-Destructive Testing Personnel 29
8.5 Extent of Inspection and Testing 29
8.6 Records 29
9 ACCEPTANCE STANDARDS FOR NON-DESTRUCTIVE TESTING 29
9.1 General 29
9.3 Radiographic Testing 30
9.4 Magnetic Particle Testing 31
9.5 Liquid Penetrant Testing 31
10 REPAIR AND REMOVAL OF WELD DEFECTS 31
10.2.6 Welded Double repairs 31
10.2.7 Repair Area length 31
10.2.7.1 Large Diameter Pipe 31
11 PROCEDURES FOR NON-DESTRUCTIVE TESTING (NDT) 32
11.1 Radiographic Test Methods 32
11.2 Magnetic Particle Test Method 33
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12 MECHANIZED WELDING WITH FILLER WIRE ADDITIONS 33
13 AUTOMATIC WELDING WITHOUT FILLER-METAL ADDITIONS 33
14 DOCUMENTATION 33
14.1 General 33
ANNEXURE TO API 1104 34
A ALTERNATIVE ACCEPTANCE STANDARDS FOR GIRTH WELDS 34
A.1 General 34
B IN-SERVICE WELDING 34
FIGURE A - LOCATION OF MACRO SECTION AND IMPACT TEST SPECIMENS

35
FIGURE B - ORIENTATION AND LOCATION OF CHARPY IMPACT SPECIMENS

36
FIGURE C - HARDNESS INDENT LOCATIONS 37
APPENDIX C REFERENCES 38
USER COMMENT FORM 40
July 2018 viii SP-1097

Specification for Welding of Duplex and Super Duplex Stainless Steel Pipelines Version 3.0
1. Introduction
1.1 Purpose
This specification is a revision of SP-1097 version 2.0, Specification for Welding of Duplex
Stainless Steel Pipelines, issued in May 2005. The purpose of this specification is to define
the minimum technical requirements for the welding of duplex stainless steel pipelines and
flow lines.
The basis of this specification is API Std 1104 Twenty first edition, September 2013
including addendum 2 May 2016.
1.2 Changes to the Specification

This specification shall not be changed without approval from the Custodian, the Material &
Corrosion Functional Discipline Head UEC (CFDH), who owns this specification. If you
think the specification is not correct, write your comments on a copy of the User Comments
form. The form is included as the last page of this specification. Send the copy with your
comments and personal details to DCS.
September 2018 Page 1 SP-1097

2. Specification for Welding Duplex Stainless Steel

This Specification gives the minimum technical requirements for the welding of duplex
stainless steel pipelines and ancillary equipment where the applicable Code has been defined
by the Company as ASME B31.4 or ASME B31.8.
This Specification is applicable to all classes of pipelines as defined in SP-1211 and is based
on API Std 1104, 21edition, including addendum 2 May 2016. Appendix B gives
amendments and supplements to the base standard. Tables or figures supplementary to those
of API Std 1104 have been designated with capital letters.
This document is not applicable to:
 Welding of on-plot pipe work and fabricated equipment, (covered by PDO specification
SP-1173)
 Manufacture of longitudinally welded pipe,
 Welding on to pipelines under operating conditions, (hot tap operations)
 Welding of pipelines on use in sour service, as defined under NACE

MR0175/ISO15156
2.1 Specification Requirements

Welding, fabrication and inspection shall be in accordance with the requirements of API Std
1104, 21edition, including addendum 2 May 2016, as amended and supplemented by
Appendix B of this specification.
The scope of API Std 1104 is confined to carbon and low alloy steels and the extensive
amendments and supplements of the text in Appendix B have been necessary to incorporate
the special requirements for welding duplex stainless steels. Other general amendments and
supplements are included in Appendix B where considered necessary to ensure pipeline
integrity in accordance with PDO and Shell Group requirements
The Clause numbering in Appendix B follows that of API Std 1104. Where clauses of API
1104 are not amended or supplemented they shall apply in their entirety.
2.2 Process Deliverables

Process deliverables comprise field welded duplex stainless steel pipelines, flow lines and
related welded fabrications designed to ASME B31.4 or ASME B31.8 and intended for off-
plot oil and gas service.
2.3 Process Owner's Responsibility

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

See relevant API Std 1104 weld inspection and testing acceptance criteria and the
amendments/supplements given in Appendix B of this specification.
2.5 Performance Monitoring

Requirements for monitoring welding process variables, welder performance and weld
quality are detailed in relevant sections of API Std 1104 as amended by Appendix B of this
specification.

2.6 Effective period

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

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

3 Glossary of Definitions, Terms and Abbreviations

Certain terms and abbreviations used in this document are defined below. The listed
definitions shall be considered to supplement those given in API Std 1104.
General Definitions
Contractor The party which carries out all or part of the design,
engineering, procurement, construction, commissioning or
management of a project, or operation or maintenance of a
facility. The Company may undertake all or part of the duties of
the Contractor.
Manufacturer/ The party which manufactures or supplies equipment and

Supplier services to perform the duties specified by the Contractor.
Company Petroleum Development Oman LLC. The Company will

generally specify the technical requirements. The Company may
also include an agent or consultant authorised to act for, and on
behalf of, the Company.
User The Company, Consultant or Contractor who uses this

document.
Corporate Functional The person within the Company responsible for the discipline to
Discipline Head which the standard belongs
shall Indicates a requirement. Any deviation to a requirement shall be

approved by the CFDH.
should Indicates a recommendation. A deviation to a recommendation

shall be approved by the Company welding-TA 2.
may Indicates a possible course of action.
Specific Definitions
Batch or Lot As defined in AWS A5.01, Clause 5 (Classification) and Clause
(see App. B, 6 (Testing)
4.2.2.1)
Duplex A chromium-nickel-molybdenum stainless steel containing a
stainless steel balance of austenite and ferrite stabilising alloying elements
such that the microstructure at room temperature consists of
approximately equal proportions of austenite and ferrite.
Nominal Nominal thickness t shall have the following meanings:

thickness
- butt joint; parent metal thickness, which for joints between
a dissimilar thickness is that of the thinner material.
- fillet weld; parent metal thickness, which for joints between
dissimilar thicknesses is that of the thicker material.
- set-on branch connection; thickness of branch pipe
- set-through branch connection; thickness of main pipe.

Verified Copy A photocopy of an original document which has been re-

endorsed and signed by the organisation producing the
photocopy to verify that none of the information has been
adulterated.
Welding Co- The Contractor nominated authority on the quality aspects of

ordinator welding. The Welding Co-ordinator shall be a Welding
Engineer meeting the recommendations for European Welding
Engineer (refer ISO 14731). However, other
national/international qualifications may be considered at the
discretion of the Company. The Welding Co-ordinator shall be
approved by the Company TA-2 (Welding).
Abbreviations
a Throat Thickness of Fillet Weld
AWS American Welding Society
CSWIP Certification Scheme for Welding Inspection Personnel
D Nominal Outside Diameter
FCAW Flux Cored Arc Welding
GMAW Gas Metal Arc Welding
GTAW Gas Tungsten Arc Welding
HAZ Heat Affected Zone
HV Vickers Hardness
NDE Non-destructive Examination
PAMS Portable arc monitoring system
PCN Personnel Certification in NDE
PQR Procedure Qualification Record
PRE Pitting Resistance Equivalent
PT Penetrant Testing
PWHT Post Weld Heat Treatment
RT Radiographic Testing
SAW Submerged Arc Welding
SMAW Shielded Metal Arc Welding
t Nominal Thickness
TA Technical Authority,

UNS Unified Numbering System
WPS Welding Procedure Specification

Amendments/Supplements to API Spec 1104

1 Scope
Delete the 1st paragraph and replace with the following;
This specification covers the arc welding of butt, branch and fillet welds in duplex and super
duplex stainless steel pipelines used in field constructions.
Welding may be carried out by a SMAW, GTAW, GMAW, SAW, PAW or gas shielded
FCAW process, or a combination of these processes. A manual, automatic welding
technique, or combination of these techniques, may be used. The first and second passes of
single sided butt welds SHALL be made using GTAW process. Filler metal shall be used
for all passes. Roll welding shall be accepted when an automatic welding process is used.
GMAW, GTAW, and gas shielded FCAW shall be restricted to construction areas protected
against wind and draught.
The following shall not be used:
1. Socket welds
2. Semi-automatic processes.
3. Oxy-fuel gas welding processes
4. Gas welding, self- shielded gas FCAW welding and flash butt welding processes
5. Permanent backing bars
2 Normative References
See also Appendix C of this specification.
3 Terms, definitions, Acronyms and Abbreviations

See also above Appendix A of this specification.
4 Specifications
4.1 Equipment
Add the following:
Welding parameter measuring equipments shall be calibrated.
GTAW power units shall incorporate a high frequency starting unit, slope-out control and
gas delay facility as a minimum. Direct contact shall be prevented between duplex stainless
steel and carbon steel equipment.
Grinding wheels dedicated to duplex and super duplex stainless steel work shall be used.
Wire brushes shall be of stainless steel. All such dedicated equipment and consumables
shall be identified by colour coding or other suitable means.

4.2 Materials
4.2.1 Pipe and Piping Components
Replace existing section as follows:
Pipe shall be in accordance with one of the following:
DEP 31.40.20.34
Fittings shall be in accordance with one of the following:
 DEP
 Shell MESC codes
The Contractor shall obtain verified copies of the materials certificates for all free-issue
items to be welded. Contractor supplied items shall have original or verified copies of
materials certificates and certification. Items without materials certificates shall not be used
unless they are re-certified by re-testing by company authorised representative.
4.2.2 Filler metals and Fluxes
4.2.2.1 Types
Add as follows:
Only Company-approved Manufacturers shall be used. Other manufacturers may be

accepted if a 3 years track record is presented and agreed with Material Corrosion Integrity
(M CI) TA 1
The welding consumable certificate shall be in accordance with ISO 10474 type 3.1.
Alternatively each batch of welding consumables may be tested in accordance with
applicable consumable classification specification.
The chromium content shall be at least match with the parent material and nickel content
shall be over match with the parent material analysis.
All filler metals shall have classification society, e.g. Lloyd's, DNV type approval
4.2.2.2 Storage and handling of filler metals and fluxes
Add the following:
Contractor shall develop consumable handing procedure in line with consumable

manufacturer recommendations and approved by Company welding TA 2.
4.2.3 Shielding gases
4.2.3.1 Types
Add the following:
The shielding and purge gas shall be certified as complying with ISO 14175, or equivalent.
The purity or component concentrations of the gas shall be as specified on the WPS and
shall be the same for procedure qualification and production welding

The dew point of shielding and purge gas shall be -30 degree C or below
4.2.3.2 Storage and handling
Add the following:
Gases in containers that are unidentifiable shall not be used.

5 Qualification of Welding Procedures with Filler Metal

Additions
5.1 Procedure Qualification
Add the following:
The WPS and PQR SHALL [PS] be approved by the Company welding TA-2 for each
project.
All welding procedure qualification shall be done in Oman only and shall be witnessed by the
Company welding Inspector under simulated site conditions.
Previously qualified welding procedures by the same contractor may be used subject to the
following:
 The PQR is fully in accordance with this specification.

 The WPS is amended to reflect the project specific details.
WPS proposals for qualification shall be submitted to the Company a minimum of two
weeks prior to the proposed date of test welding. The WPS proposals shall be endorsed and
signed by the Contractors authorised representative prior to submission. The Authorised
Company welding Engineer shall endorse “APPROVED FOR QUALIFICATION", the
contract number, the date and signature. Only WPSs endorsed shall be used for test welding.
5.2 Record
Add the following:
The PQR shall include the following Documents:
 The WPS Approved for Qualification with all the details specified in clause 5.3.
 The actual welding details with all the details specified in clause 2.3
 Material certificates.
 Consumables certificates.
 PAMS printout of the welding parameters*.
 Summary of welding parameters including heat input calculation
 Visual inspection report.
 NDT reports.
 Laboratory test report.
* Welding parameters shall be recorded by means of a calibrated portable arc monitoring system with printout
facility.
5.3 Welding Procedure Specification

5.3.1 General
Add the following:
The WPS shall show the following non-technical information:
 Date
 Contractor’s logo
 Revision number
 Contract number
 Project title
 Contractors signature and endorsement

 MDMT
 Service (Sour/non-sour)
 Client: PDO
5.3.2 Specification Information
5.3.2.2 Materials
UNS number of material specification and grade of pipe or fittings or flanges shall be stated.
5.3.2.3 Diameters and wall thicknesses
The following limits shall apply for all diameters and thicknesses:
 Qualified diameter range; when D <323mm, 0.5D to 2 D; when D > 323mm; 0.5D to
maximum to be welded.
 Qualified wall thickness range, 0.75t to 1.5t. but not < 5mm. For t < 5mm, a change
outside the range t to 1.5t
 Qualified throat thickness, (fillet weld), 0.75a to 1.5a.
Nominal thickness, t, is dependent on weld configuration and is defined in Appendix A of

this specification.
Welds made using fully automatic equipment shall be separately qualified for each
combination of pipe diameter and wall thickness.
5.3.2.4 Joint design
Add the following:
The WPS shall indicate the allowable tolerances on each of the joint design details.
Where automatic welding is specified, a U-groove preparation without root gap shall be
used.
5.3.2.5 Filler metal, Flux and number of beads
Add the following:
Details of the filler metal manufacturer and brand name shall be stated on the WPS for each
pass.
For SMAW, maximum bead width shall be restricted to 2.5 times the electrode diameter.
Based on the minimum line pipe thickness of 4.8 mm normally specified for pipelines, joints
shall be completed with a minimum of three passes.
5.3.2.6 Electrical characteristics
Add the following:
Where applicable, electrode stick-out, contact tube-to-work distance, and wire feed speed
shall be specified for each bead. If pulse welding is used, background current and pulse
parameters shall also be specified or a unique program reference included.

5.3.2.7 Flame characteristics
Delete this section: Replace existing section as follows:
Oxyfuel gas welding shall not be used.
5.3.2.8 Position
Add the following:
WPSs for manually welded line pipe butt joints shall be qualified in the 5G position to cover
production welding 5 G positions. Automatic welds shall be qualified for each position to be
used in production. Branches, attachment welds and ancillary piping may be qualified in the
production welding position or, to cover all positions, in the 6G position, at the option of the
Contractor.
5.3.2.9 Direction of welding
Add the following:
Except where an automatic process is specified, all positional welds shall be deposited by
uphill progression only.
5.3.2.11 Type and removal of line-up clamp
Replace last sentence as follows:
An internal or external line-up clamp shall be used for all girth welds except where it is
demonstrated that to do so would be impractical, in which case tack welding may be
permitted by Company authorised welding engineer
An internal line-up clamp shall not be removed until deposition is completed of the first two
passes. An external line-up clamp shall not be removed until the root bead is at least 50%
complete, equally distributed around the joint.
The minimum number of passes to be deposited before the pipe is lowered off shall be
stated.
See also clause 7.3 of this specification.
5.3.2.13 Pre- and post-Weld heat treatment (PWHT)
Add the following:
The maximum interpass temperatures shall also be specified.
5.3.2.14 Shielding gas and flow rate
Change title to:
Shielding/backing gas and flow rate
Add the following:
For root welding of single-sided joints, gas back purge shall be specified. The WPS shall
include requirements for flushing prior to commencement of welding and for monitoring of
exit gas oxygen content, (see section 7.17 of this specification).

5.3.2.15 Shielding flux
Add the following:
AWS flux classification, the manufacturer, brand name and the type of flux shall also be
specified.
5.3.2.16 Speed of travel
Speed of travel shall be shown in millimetres per minute or millimetres per second.
5.3.2.17 Method of cooling after welding
Delete this title and add the following new sections, 5.3.2.17 – 5.3.2.21:
5.3.2.18 Heat input range
Heat Input (kJ/mm) = (Volts x Amps x 60) / (1000 x Welding Speed (mm/min.))
The allowable range of heat input rates to be applied by each welding process for each bead
shall be specified.
5.3.2.19 Number of welders
The WPS shall designate the number of root pass welders and hot pass (second pass)
welders.
5.3.2.20 Partially completed joint
The minimum number of passes before the joint is allowed to cool to ambient temperature
shall be specified. The minimum shall be three passes or one third of the joint whichever is
greater.
See also clause 7.14 of this specification.
5.3.2.21 Tungsten electrode for GTAW welding
The AWS electrode class shall be specified in the WPS.
5.3.2.22 Welding technique
For automatic welding, the following shall be specified:
- amplitude of weave;
- frequency of weave; and
- dwell time.
5.4 Essential Variables

5.4.2 Changes requiring requalification
5.4.2.1 Welding process or Method of application
Replace as follows,
Any change in process or combination of processes. Any change in equipment type and
model for mechanised or automatic welding.

5.4.2.2 Base material
Replace as follows:
Any change in UNS number. A change in the PREN exceeding –1.5 or +2.5.
For super-duplex grades the following shall be considered an essential variable:
 Any change in manufacturer
 Any change in product form (casting, forging) for pipes and fittings. A procedure
qualified by welding together products from different manufacturers or different
product forms shall qualify both the combination and welds between each product.
5.4.2.3 Joint Design
Delete existing section and replace by:
Any change in bevel dimension outside the tolerance stated in the approved WPS, Branch
welds shall require separate qualification in accordance with Section 5.7.
5.4.2.4 Position
Add the following:
Any change in the angle of the axis of the pipe greater than 25 from that used for
qualification shall constitute an essential variable.
5.4.2.6 Filler metal
Replace existing section, including Table 1, as follows:
The following changes in the qualified WPS shall be considered as essential variables:
 A change in the diameter of electrode or filler wire.

 A change in filler metal classification.
 For super duplex material: a change of filler metal trade name
5.4.2.10 Shielding gas and flow rate
Change title to:
Shielding/backing gas and flow rate
Add the following:
A change of shielding or backing gas flow rate to one outside the range ± 20% of the
average value qualified and specified shall also constitute an essential variable.
Any increase in the oxygen content of the effluent backing gas beyond that qualified shall
necessitate re-qualification.
Any decrease in the number of passes before cessation of backing gas flow shall constitute
an essential variable.
5.4.2.11 Shielding flux

Any change in classification or trade name constitutes an essential variable.
5.4.2.12 Speed of travel
Add the following:
Any change in the range of qualified speed of travel, or electrode run out length, outside the
range ± 15% of that qualified shall constitute an essential variable. See also 5.4.2.13,
following.
5.4.2.14 PWHT
Delete this section and replace with the following new sections, 5.4.2.14 – 5.4.2.19:
5.4.2.15 Welding current or heat input
Any change in average welding heat input per pass outside the range ± 10% of that qualified
and the addition or deletion of pulsating current shall be considered essential variables.
5.4.2.16 Interpass temperature
Any increase in maximum interpass temperature shall constitute an essential variable.
5.4.2.17 Number and sequence of weld beads
Any change in the sequence of deposition shall constitute an essential variable.
5.4.2.18 Removal of line-up clamp
Removal of the line-up clamp at a stage earlier than stated in the approved for construction
WPS shall constitute an essential variable.
5.4.2.19 Partially completed joint
Any change in the minimum number of runs before the joint is allowed to cool shall
constitute an essential variable.
5.4.2.20 Diameter
See clause 5.3.2.3 of this specification.
5.5 Welding of Test Joints - Butt Welds

Test welding shall be performed under simulated site conditions using full pipe lengths as
appropriate In order that root oxidation can be assessed under ‘worst case’ conditions,
welding should commence as soon as the maximum specified back purge oxygen level is
reached.
Test welding shall be witnessed by a authorised Company representative. The Contractor

shall give the Company a minimum of 48 hours' notice of the intention to proceed with test
welding.
Immediately prior to test welding, the Contractor shall have available at the test site for
Company inspection, the following documents:
 WPS endorsed "Approved for Qualification".

 Materials certificates, or verified copies, traceable to the items to be welded.

 Batch certificates, or verified copies, traceable to the welding consumables.

 The approved consumable handling procedure.
No test welding is permissible without recording the welding parameters using a calibrated
portable arc monitor.
5.6 Testing Of Welded Joints - Butt Welds
5.6.1 Preparation
Delete the existing section and replace as follows:
Test welds shall be subjected to NDT as detailed in 5.6.1.1, before sectioning for destructive
testing in accordance with 5.6.1.2.
5.6.1.1 Non-destructive testing of test welds
NDT shall be witnessed by a authorised Company inspector.
The NDT shall consist of the following:
 Visual examination
 Liquid penetrant testing
 Radiographic testing
The acceptance criteria shall be as stated in Section 6 of this specification. Any weld that
fails to meet the acceptance criteria shall not be offered for destructive testing. Visual
examination of all butt welds shall include the pipe bore surfaces. The degree of oxidation
present on these surfaces following welding shall be within the visual acceptance criteria of
DEP 30.10.60.31-GEN.
5.6.1.2 Destructive testing of test welds
Following Company approval of the NDT, all test welds shall be sectioned at the locations
shown in Figure 3 of API Std 1104 and Figure A of this specification. Sectioning and
testing shall be performed at a Company-approved test laboratory.
All test reports shall be endorsed and signed by the testing organisation, the Contractor, and
the Company Inspector who witnessed the testing.
5.6.3 Nick-break test
Delete this section.
Add the following new sections, 5.6.6 – 5.6.11:
5.6.6 Macroscopic examination and hardness test
5.6.6.1 Preparation
Specimens shall be prepared for macroscopic examination by grinding or other suitable

method to a 600 grit paper finish. The prepared surfaces shall be etched using a suitable
etchant to reveal the pass sequence, HAZ, defects etc. Metallographic examination of
representative sections shall also be carried out and observations included with the
macroscopic examination report to confirm the microstructure of the weld/HAZ and the
absence of deleterious phases.

The sections of the weld taken for macroscopic examination and hardness testing shall also
be used for ferrite measurement as required in clause 5.6.7 of this specification.
5.6.6.2 Method
The macro sections shall be examined at a minimum magnification of x5. Macro-

photographs showing the hardness indentations shall be included in the PQR.
The hardness shall be measured in accordance with ASTM E92, using HV10. For pipe butt
welds, the hardness indentations shall be as shown in Figure C of this specification. For pipe
of t less than 10 millimetres, the mid-thickness traverse may be omitted.
5.6.6.3 Requirements
The macro sections shall not show defects exceeding the acceptance standards given in
Section 6 of this specification. Each specimen shall exhibit a smooth and regular profile and
the reinforcement shall blend smoothly with the parent metal. Slight intermittent undercut
with a maximum depth of 10% of the pipe wall thickness or 0.4 millimetres, whichever is
the smaller, shall be deemed acceptable. Excess penetration shall not exceed the
requirements of clause 9.3.6.4 of this specification. Joint misalignment shall not exceed 1.6
millimetres.
The maximum hardness values from each traverse shall not exceed 325 HV10.
5.6.7 Ferrite measurement
5.6.7.1 Preparation
Measurements of ferrite level shall be made on the prepared sections used for macro-
examination and hardness measurements.
5.6.7.2 Method
The ferrite content shall be determined by microscopic point counting in accordance with
ASTM E562 and magnetic measurement technique using an instrument calibrated to AWS
4.2 (for DSS only). Ferrite determinations shall be made in the weld metal and both HAZ
areas at a depth of 1mm from the inside and from the outside surfaces, or for magnetic
techniques, as close to the surface as is practicable. Additional checks shall be made in the
centre of the unaffected base material on each side of the weld.
Ferrite content determined by microscopic point counting shall be in the range 40 - 60% for
the parent material and 35 - 65% in the weld/HAZ regions. The ferrite range for magnetic
measurements shall be between 30 – 70 FN. In the event that borderline unacceptable or
otherwise doubtful results are obtained using magnetic measurement, a check point-counting
determination may be made. If the results of these repeat tests are satisfactory, the ferrite
content shall be considered to be acceptable.
5.6.8 Charpy V-Notch Impact Testing
5.6.8.1 Preparation
Each procedure qualification shall include impact testing unless the nominal pipe wall
thickness is less than 4.8 mm.
One set of three specimens shall be taken at each of the following positions:
 root weld centre line

 root fusion line (50% intersection of notch)

 root fusion line + 2 millimetres
When the wall thickness exceeds 20 millimetres, an additional set of three specimens shall
be taken at each of the following positions:
 cap weld centre line

 cap fusion line (50% intersection of notch)
 cap fusion line + 2 millimetres
These requirements are summarised in Figure B of this specification.
Specimens shall be 10 x 10 millimetres full size wherever possible. Where these dimensions
are not possible, the largest obtainable standard sub-size specimens shall be extracted.
5.6.8.2 Test temperatures and acceptance criteria
Testing in accordance with ASTM A370 and this specification shall be conducted at -46
Deg.C.
For each set of three specimens, only one of the individual values may be below the
minimum average energy requirement with an absolute minimum as defined by the
minimum individual acceptance criterion.
The acceptance criteria are detailed in the Table below. For other standard specimen
dimensions, the acceptance criteria shall be applied pro rata.
Specimen Size, mm Charpy Energy, Joules
Minimum Average Minimum Single
10 x 10 50 40
10 x 7.5 40 32
10 x 5 33 26
5.6.9 Corrosion Testing
5.6.9.1 Preparation
A coupon specimen of dimensions 5 cm x 5 cm x full wall thickness shall be prepared in

accordance with ASTM G48. No flattening of the coupon material shall be carried out. The
weld seam shall be located centrally and parallel to one axis. The edges of the specimen
shall be rounded to minimise edge effects and the sides ground to 600 grit finish or better.
Other surfaces shall be in the "as-finished" condition.
5.6.9.2 Method
A pitting corrosion resistance test shall be conducted in accordance with ASTM G48,
Method A using the total immersion ferric chloride test. The specimen shall be degreased,
dried and weighed to three decimal places and the weight recorded.
The specimen shall be held in the solution at an angle of 45, with inside surface uppermost.
Unless otherwise directed, the test shall be conducted for a period of 24 hours at a
temperature of 22C ± 2C. For 'super duplex' grades the test temperature shall be 35C -
37C.

On completion of the test period the specimen shall be rinsed, cleaned, dried and weighed
using the procedures specified in ASTM G48A.
The specimen shall be examined at a magnification of x20. No pitting shall be visible.

Weight loss shall be presented as total weight loss and weight loss per unit area. The latter
shall not exceed 4gm/m2
All samples shall be made available for inspection by the Company.
5.6.9.4 Other corrosion testing
Further testing may be required by the Company where duplex stainless steels are specified
for service in environments containing H2S.
5.6.10 Chemical analysis
Chemical analysis shall be conducted of the root run weld metal. The weld metal sample
shall be taken from an adjacent or equivalent location to that shown for the impact test
specimens in Figure A. The elements required for calculation of the PRE (see Section
4.2.2.1) shall be determined. The PRE value shall exceed the minimum specified for the
base material to be welded.
5.6.11 Retests
5.6.11.1 General
If the results of destructive testing are unsatisfactory owing to defective specimen

preparation or a localised weld defect, the Contractor shall inform the Company and obtain
approval to proceed with retests as detailed below.
5.6.11.2 Tensile tests and bend tests
If only one tensile or bend specimen does not meet the acceptance criteria, two additional
specimens shall be tested. Both of the additional specimens shall meet the acceptance
criteria.
5.6.11.3 Hardness tests
If only one hardness result exceeds the specified maximum then three further impressions
shall be made in close proximity to that which failed such that they do not mutually
interfere. If all of the further tests are below the specified maximum then the test shall be
accepted.
5.6.11.4 Charpy v-notch impact tests
If the specified minimum average value has been achieved and more than one specimen is
below the specified average value, or one specimen is below the specified minimum
individual value, a retest of three further specimens shall be made. All three individual
retest values shall equal or exceed the specified minimum average value.
5.6.11.5 Corrosion tests
Re-testing shall not be allowed.

5.6.11.6 New procedure requirement
If the test joint fails to meet the minimum requirements, a new WPS proposal shall be
established and re-qualified.
5.7 Welding of Test Joints - Fillet Welds

Change title as follows:
Welding of Test Joints - Fillet Welds and Branch Welds

Delete existing section and replace as follows:
The configuration of fillet weld and branch weld test joints shall be in accordance with the
weld details to be used in production and the limitations of section 5.3 of this specification.
See also the note under section 5.1.
Test welding shall be witnessed by the Company and shall only commence after the WPS
proposal has been approved by the Company and endorsed "APPROVED FOR
QUALIFICATION".
5.8 Testing Of Welded Joints - Fillet Welds

Testing of Welded Joints - Fillet Welds and Branch Welds
5.8.1 Preparation
Prior to cutting, test welds shall be visually inspected and liquid-penetrant tested. If the
weld is deemed acceptable in accordance with the acceptance criteria detailed in Section 6 of
this specification it may be offered for destructive testing
Test specimens for macroscopic examination and hardness testing shall be cut from the joint
at the locations shown in Figure 10 of API Std 1104. The specimens should be machine cut
and one face shall be prepared for macroscopic examination by grinding or other suitable
method to a 600 grit paper finish. The prepared surfaces shall be etched using a suitable
etchant to reveal the pass sequence, HAZ, defects etc.
5.8.2 Method
Macroscopic examination and hardness measurement shall be carried out in accordance with
section 5.6.6.2 of this specification. On full penetration branch welds, ferrite checks shall
also be conducted in accordance with section 5.6.7.2 of this specification.
5.8.3 Requirements
Macroscopic examination, hardness and ferrite requirements shall be in accordance with

clauses 5.6.6.3 and 5.6.7.3 of this specification.

Add the following new sections5.9 – 5.11:
5.9 Welding of Test Repair Welds

Repair welding procedures shall be prepared and qualified for each type of repair to be
performed in accordance with sections 5 and 10 of this specification. The initial girth weld
shall be welded to the appropriate qualified WPS. The maximum depth of partial
penetration repair welds shall the lesser of 0.5t or t-6 mm, (see also section 10.16). Where
the execution of single run repairs has been agreed (see section 10.1.1) separate qualification
shall be made. Back-welded repairs or root weld repair are not permitted. Test repair weld
excavations shall be located as shown by the appropriate diagram in Figure 1 of BS 4515 Pt.
2.
5.10 Testing of Repair Welds
5.10.2 Preparation
Non-destructive and destructive testing of the repair weld shall be performed as required in
(5.6) and (10.1.3) except where modified below.
5.10.3 Method
Provided the repair weld procedure is representative of the original weld qualification,
destructive tests shall be as listed below. Otherwise full procedure qualification tests shall
apply as specified in section 5.6 of this specification’.
- 1 transverse tensile, (5.6.2);

- bend test, (5.6.4 or 5.6.5);
- 1 macro-hardness test, (5.6.6) at the locations shown in Figure 8 of BS 4515 Part 2;
- Ferrite measurement (5.6.7), which for partial penetration repairs shall include
measurements made in the new HAZ formed in the original weld;
- Charpy testing (5.6.8) at the locations shown in Figure 4
- Corrosion testing (5.6.9), to include the junction of new and original weld metal.
5.10.4 Requirements
The acceptance criteria shall be as for the original welding procedure qualification.
5.11 Records
The procedure qualification record shall include the following:
Approved for qualification WPS
 Print-outs from the portable arc monitoring system for each pass
 Visual inspection and NDT reports
 Heat treatment reports
 Original laboratory test certificates, including macrophotographs
 Original or verified copies of materials certificates for the test coupon materials
 Original or verified copies of batch certificates for the filler materials and
shielding/backing gases employed for test welding.
The PQR shall be submitted to the Company for review and approval with the revised WPS
for production welding.

6 Qualification of Welders
6.1 General
Add the following:
Welders who weld the procedure qualification test coupons, which are satisfactory, shall be
deemed as being qualified.
Welders shall have a valid Company qualification within the validity defined in this
specification or they shall be qualified using the Approved For Construction WPS.
Qualification shall be valid for a period of six months. This period may be extended by a
further six months when it can be shown by NDT from production welding that the welder
has produced satisfactory welds using the approved for construction WPS. After 12 months
the welder shall be re-qualified, unless otherwise agreed by the Company’.
Welders shall be re-qualified when the Company has reason to question the welder's ability
to make welds that meet this specification.
For butt welds, welders shall be qualified by visual examination, radiographic testing, bend
testing and macro-examination.
For branch welds and fillet welds, welders shall be qualified by visual examination, liquid
penetrate testing, and macro-examination.
6.2 Single Qualification

6.2.1 General
Delete first sentence and replace as follows:
The use of segments of pipe nipples shall not be permitted. Each of the two pipe nipples
used to make the test weld shall be a minimum length of D or they shall be of sufficient
length to accommodate the alignment device being used, whichever is greater.
6.2.2 Scope
Delete items a., b., c., d., e., f., and g. and replace with the following:
For sour service/critical applications, as determined by the Company in the Contract

document, the limits of welder qualification are the essential variables of the WPS. In such
cases, any change that necessitates re-qualification of the WPS shall cause for re-
qualification of welders to the new, approved WPS. The following essential variables shall
be applied for welder qualification:
(a) A change from one welding process to another or a change from manual to automatic or
vice versa.
(b) A change in joint thickness to more than twice the thickness of the test joint.
(c) A change in pipe or branch diameter outside the range 0.5D to 2 D, where D is the test
pipe diameter.
(d) A major change in joint configuration, e.g. ‘U’ to ‘V’ preparation
(e) Any change in welding position, except that qualification in the 6G position shall
qualify all positions.
(f) A change in welding progression from uphill to downhill or vice versa.
(g) For manual welding electrodes, a change from one coating type to another
(h) Any change in the nominal composition of the shielding gas.

6.3 Multiple Qualification

6.3.1 General
This clause of API Std 1104 shall not be applicable.
6.3.2 Scope
This clause of API Std 1104 shall not be applicable.
6.4 Visual Examination

Delete existing section and replace with the following:
Performance of visual examination and the acceptance criteria shall be as defined in section
9 of this specification.
6.5 Destructive Testing

6.5.1 Sampling of test butt welds
Delete existing section, including Table 3, and replace with the following:
After satisfactory radiographic testing, the test weld shall be sectioned for macro-
examination in accordance with Section 5.6.6. Hardness testing may be omitted. The
number of macro-sections shall be two per welder's portion. The acceptance criteria shall be
as defined in Section 9.
6.5.2 Tensile strength, nick-break and bend test procedures for butt welds
: Add the following:
The specified tensile strength and nick-break tests may be omitted.
6.5.6 Sampling of test fillet welds
Sampling of Test Fillet Welds and Branch Welds
Add the following:
See also the note in section 5.1 of this specification.
Prior to cutting, in addition to the visual examination specified in clause 6.4, the test welds
shall be liquid penetrant tested and shall meet the requirements of section 9 of this
specification.
6.5.7 Test methods and requirements for fillet welds
Test Methods and Requirements for Fillet Welds and Branch Welds
The fillet weld samples shall be prepared and subjected to macro-examination in accordance
with section 5.8 of this specification.

6.6 Non-destructive Testing (Radiography) - Butt Welds Only

6.6.1 General
The qualification butt weld shall be examined by radiography in addition to the destructive
testing specified in API Std 1104 section 6.5 and this specification.
6.6.2 Inspection requirements
Add the following:
The test weld shall meet the requirements of API Std 1104 as modified by this specification.
6.7 Retesting
If the test weld does not meet the specified acceptance criteria, the welder may carry out two
repeat tests. Both of the repeat welds shall meet the specified acceptance criteria. Failure of
one or both repeat welds shall result in disqualification of the welder until such time as the
Contractor can demonstrate to the Company by records that satisfactory training has been
received. The welder may then be presented for further qualification testing.
6.8 Records
Add the following:
The Contractor shall maintain the records of the tests and test results of each welder. The
Contractor shall assign each welder a unique identification number, letter, or symbol to
ensure traceability to specific welds. If a welder ceases to work for the Contractor, the
unique identification shall not be re-assigned to another welder.

7 Design and Preparation of a Joint for Production

Welding
Production Welding
7.1 General
No production welding shall be carried out before the WPSs have been endorsed as
'Approved for Construction' by the Company and the welders qualified to weld using the
approved WPSs.
The approved WPSs shall be available at the construction site.
The preparation and welding of pipeline shall be in accordance with the qualified and
approved WPS.
Fusion faces and the surrounding surfaces within a minimum of 25 millimetres of the joint
shall be free from heavy scale, moisture, oil, paint, or any other substance which may have a
deleterious effect on the weld quality or progress.
Stray arc strikes shall be removed by grinding. The ground area shall be liquid penetrant
tested and thickness checked. Where the thickness is below the specified minimum, the
section of pipe shall be removed. Any arcing from a poor connection shall be treated as an
arc strike. Connections shall be made to the work by clamps having stainless steel contact
surfaces. Earth cables shall not be welded to pipeline components.
7.1.1 Handling and storage
7.1.1.1 General
All precautions shall be taken throughout fabrication to minimise contamination of duplex

stainless steel materials resulting from direct contact with carbon steels, exposure to ferrous
dust, swarf or other debris and from residual deposits on or near fusion faces. Equipment
used for grinding and cleaning of edge preparations shall be dedicated for stainless steel
work. Wire brushes shall be of stainless steel. Precautions required for handling equipment
and line-up clamps are included in Clause 4.1 of this specification. General precautions to
be applied during the storage of duplex stainless steels and in handling line pipe are outlined
in Clauses 7.1.1.2 and 7.1.2.3, following.
Surface oxidation or metallic contamination which will not respond to washing or

degreasing treatments shall be removed using power tools or by a pickling treatment.
Pickling procedures shall be subject to prior approved by the Company. Washing shall be
performed with potable water.
7.1.1.2 Storage
a) Components stored in an open site or within a fabrication workshop shall be protected from
environmental contamination.
b) Duplex stainless steels shall be clearly identified and segregated from other stored materials.
7.1.1.3 Pipe handling
c) Supports, rollers and other pipe handling equipment shall be of compatible material or shall be
suitably lined to prevent damage or contamination of the pipe work.

d) Slings and supports for lifting duplex stainless steel pipe and assemblies shall be of Nylon or
similar compatible material.
e) Pipe handling by means of hooks in pipe ends shall not be permitted.
7.1.2 Weather protection
f) Work shall not be performed when the weather and/or degree of protection does not permit
satisfactory workmanship.
g) Enclosures giving adequate protection to the weld area at all times from wind, rain and
moisture shall be provided. In windy conditions the pipe ends shall be sealed to prevent
through draughts.
h) Weld surfaces shall be thoroughly cleaned and dried before welding. Moisture shall be
removed by means of blowers, or in exceptional cases a heating torch may be used provided no
signs of surface oxidation are allowed to develop.
7.2 Alignment
No welding shall be carried out until the alignment specified in the approved WPS has been
achieved.
Hammering or heating of the pipe shall not be permitted.
Joint design shall be in accordance with ASME B31.4 or B31.8. Any taper shall not be
steeper than 1 in 4.
When a pipe with one longitudinal seam is used, this seam shall be within the top 120 of the
circumference. The longitudinal seams of consecutive pipes shall be offset by at least 45.
7.3 Use of Line-Up Clamp for Butt Welds

Internal line-up clamps shall be used wherever possible and their design shall be such as to
allow the introduction and containment of root purging gases, as required in clause 7.17.
External line-up clamps may be used for line pipe less than 150 NB, for tie-in welds and for
special welds, such as connections to valves, flanges and fittings.
Pipe shall not be moved or lowered off until the second pass has been completed. An internal
line-up clamp shall not be removed until deposition is completed of the first two passes. An
external line-up clamp shall not be removed until the root bead is at least 50% complete,
equally distributed around the joint.
Where an internal or external line-up clamp cannot be used, alignment may be achieved
using tack welds. Tack welds shall be temporary bridge or bullet tacks using suitable duplex
stainless steel material. Welding parameters shall be in accordance with the appropriate fill
pass. Tack welding shall be performed only by welders qualified to weld with the WPS. The
tack welds shall be removed by grinding as welding progresses around the joint.
Fully penetrating root tacks shall not be allowed.
7.4 Bevel
7.4.2 Field bevel

Component ends shall normally be bevelled by machining or grinding. Preparation of weld

edges by plasma cutting is permissible provided a machine guided torch is used. Edges shall
be ground to a smooth bright uniform finish with the removal of a minimum of 0.5
millimetres of metal.
The new bevel shall be visually examined Burns, small score marks, indentations, other
imperfections, and linear indications shall be unacceptable and the bevel shall be re-
prepared. Repair by welding shall not be permitted. Edges shall be free from slag, spatter,
dirt, grease or other foreign matter which may affect weld quality. Acetone may be used for
surface cleaning.
Where pipes are cut, pipe markings shall be transferred to the off-cut in order to maintain
identification.
7.7 Cleaning Between Beads

Delete, ‘When automatic or semi-automatic welding is used’ and replace with the following:
‘For all types of welding’
7.8 Position Welding
7.8.2 Filler and finish beads
Replace last sentence of first paragraph as follows:
The weld metal reinforcement at the cap shall not exceed the requirements of clause 9.3.13
of this specification.
7.10 Identification of Welds

Prior to commencing the root pass, the welder shall clearly mark the pipe adjacent to the
weld with the symbol or identification assigned to him. Where tack welding has been
approved by the Company, no marks shall be made for the tack welding.
Marking shall be made with weather-proof chalk, paint, chloride-free crayon, or pen. Die
stamps shall not be used. The root pass welder shall make a mark at the top of the pipe.
Where two welders make the root pass, they shall each make a mark at the top of the pipe on
the side where they are about to weld. Subsequent welders shall mark the pipe below the
first code in the sequence which they work. The identification marks shall not be removed
until the welds have been inspected both visually and non-destructively.
7.11 Pre- and Post-Heat Treatment

7.11.1 Preheat and interpass temperature control and measurement
If welding is likely to be performed below 15C or condensation of moisture on the weld

area is possible a minimum preheat of 50C shall be applied to a minimum bandwidth of
75mm either side of the joint. Welding or cutting torches shall not be used.
The maximum preheats and interpass temperature shall be 150C. Temperature

measurement shall be by thermocouple, thermo melt crayon, contact pyrometer or a
combination of these. Thermo melt crayons shall not be applied within the bevel area.

Add the following new sections, 7.13– 7.16:
7.13 Weld Interruption

Where interruption is unavoidable, a minimum of three passes or one third of the joint
thickness, whichever is greater, shall have been deposited. On resumption of welding any
preheat requirements specified in the approved WPS shall be applied.
7.14 Weld Finishing

Welds shall be left in as welded condition and shall not be peened.
When fabrication is completed, all surfaces adjacent to the welds shall be cleaned of spatter,
burrs, and other imperfections which could interfere with radiographic or ultrasonic
inspection.
7.15 Shielding and Backing Gas

Argon, Helium or Argon/Helium mixtures of at least 99.995% purity shall be used as
shielding and backing gas. Gas mixtures containing nitrogen additions may be used subject
to the approval of the Company. Hydrogen additions are not permitted.
Gas back purge shall be maintained during the welding of all full penetration butt joints until
a minimum of 6 mm thickness of weld metal has been deposited. The same criteria shall be
applied to confirm the acceptable maximum depth of partial penetration repair welds.
Flushing with backing gas shall be carried out before welding. The oxygen content of the
exit gas shall be monitored using suitable oxygen measuring equipment and welding shall
not commence until a level that is qualified in the PQR but shall not be more than 0.2%.
Monitoring shall be continued during welding to ensure that this limit is not exceeded.
8 Inspection and Testing of Production Welds
8.2 Methods of Inspection

Add the following:
Welds shall be evaluated to the requirements of Section 9 of API Std 1104 and this
specification. Manual Ultrasonic testing of welds is not acceptable and specialized UT
techniques require company NDT TA2 approval. A Written NDT procedure in accordance
with Section 11 of API Std 1104 shall be approved by the Company prior to production
welding as applicable. The procedures shall be in accordance with Section 11 of API Std
1104 and this specification.
The primary NDT method shall be X-ray radiography using film types classified C1, C2 or
C3 according to EN 584-1.
The use of a crawler camera or other remote system shall be used for diameters greater than
8 inch.
8.3 Qualification of Inspection Personnel

Replace existing section as follows: Add the following:
Welding inspection personnel shall hold a valid qualification of one of the following:

 CSWIP 3.2 with minimum of 2 years in DSS welding inspection after

certification (or)
 AWS SCWI with minimum of 2 years in DSS welding inspection after

certification
Other qualifications shall be agreed by the company as equivalent to above.
8.4 Certification of Non-Destructive Testing Personnel

Add the following new sections, 8.5 and 8.6:
8.5 Extent of Inspection and Testing

During production welding the welding parameters shall be monitored and recorded as per
ITP.
Radiographic frequency for all pressure rating butt welds shall be 100%. The frequency for
class less than 600 rating can be optimised if the contractor can produce statistical analysis
to demonstrate performance over 3 years period.
All fillet welds shall be examined by liquid penetrant examination.
The Company authorised inspector shall inspect all the welds and verify compliance to the
specification.
8.6 Records
The Contractor shall generate a weld history sheet for every weld which shall contain the
following information:
 Weld number
 Isometric and line number
 Materials specification and identification
 The WPS employed
 The welder(s)' identity symbols
 Date welded
 Visual inspection disposition
 NDT reports where applicable (to be attached to the weld history sheet)
 Type of repair, if applicable, and WPS
 NDT reports for repairs (to be attached to the weld history sheet)
 PWHT if applicable (chart to be attached to the weld history sheet)
 Batch number of consumables employed
9 Acceptance Standards for Non-Destructive Testing

9.1 General
Add the following:
Wherever accessible, the extent of oxidation on the root and HAZ surfaces of single-sided
welds shall be assessed for comparison with the visual acceptance criteria of DEP
30.10.60.31-Gen.

9.3 Radiographic Testing

9.3.1 Inadequate Penetration without High-Low (IP)
This type of defect shall not be acceptable regardless of the length.
9.3.2 Inadequate penetration due to high-low (IPD)
Replace existing section, including Figure 14, as follows:
9.3.3 Inadequate cross penetration ( ICP)
9.3.7 Burn-Through (BT)
Delete sub-sections 9.3.7.2 and 9.3.7.3. Replace with new sub-section 9.3.7.2.
9.3.7.2 Acceptance Criteria
Any amount of burn-through shall be unacceptable, irrespective of pipe diameter.
9.3.8 Slag Inclusions
9.3.8.1 General
Add the following
Tungsten and copper inclusions shall be treated as slag inclusions for the
purposes of assessment.
9.3.10 Cracks
Cracks of any type shall not be accepted and repair of weldment crack approval shall be
obtained approval from company welding TA2.
Add the following new section:
9.3.14 Excess Reinforcement and Penetration
Weld reinforcement, when measured from the adjacent parent material surface, shall not
exceed the following values:
Wall thickness External weld reinforcement

(mm) (mm)
6.4 and under 1.6
6.4 - 12.7 2.5
Over 12.7 3.0

Internal protrusion of the weld root shall not exceed 1.5mm. When measuring internal
protusion, the line of the pipe bore outside the HAZ should be taken as the reference. Local
profile changes adjacent to the fusion line should be discounted.
9.4 Magnetic Particle Testing

9.5 Liquid Penetrant Testing
9.5.2 Acceptance standards
Delete existing section and replace with the following:
Any relevant linear indications shall be unacceptable.
10 Repair and Removal of Weld Defects

10.2.1 Company Authorisation
Cracked weld joints shall be cut out and not to be repaired. A weld with other unacceptable
defects may be repaired only once. If the repair is unacceptable then the complete weld and
HAZ shall be removed.
10.2.3 Repair of Defects other than Cracks
Delete this section, including items a., b., c., d., e and replace with the following:
All repairs shall be performed in accordance with a separately qualified repair welding WPS.
The repair welding procedure shall be qualified in accordance with sections 5.9 and 5.10 of
this specification on a full-thickness girth weld. For qualification of repair welding
procedure, original welding procedure impact and hardness test requirements shall be met.
10.2.5 Back Weld Repairs
Delete this section and replace with the following:
Back weld repairs are not acceptable.
10.2.6 Welded Double repairs

Weld double repairs are not acceptable.
10.2.7 Repair Area length
10.2.7.1 Large Diameter Pipe

The total repair length shall not exceed 40% of the total weld length. For partial penetration
repairs, the maximum length of a single repair portion shall be 30% of the total weld length.

For full penetration repairs, the maximum length of a single repair portion shall be 20% of
the total weld length. Groove taper shall be included in the measurements.
11 Procedures for Non-Destructive Testing (NDT)

11.1 Radiographic Test Methods
11.1.1 General
Add the following:
The radiation shall be X-ray for penetrated thickness up to 25mm. The technique shall be
film outside, source of radiation inside. Where the source of radiation cannot be located
inside the pipe, the Company may agree to use of the film and source of radiation outside:
double wall single image technique.
The Contractor shall qualify a radiographic testing procedure prior to testing production
welds by producing radiographs that comply with this specification. These shall be retained
for reference during production and should be suitable both for confirmation of radiographic
quality and for assessment of questionable root profile features (weld protrusion, concavity
etc.) from density measurements. Note: Radiographic testing procedure qualification may be
undertaken on test welds produced for welding procedure qualification.
11.1.2.3 Other imaging media
11.1.5 Selection of IQIs
Replace the note with the following,
NOTE: For the purpose of IQI selection, the thickness of the weld means specified wall
thickness plus weld reinforcement (internal plus external combined) and shall be applicable
for all type of exposures
Add the following,
For radiographic procedure qualification, IQIs shall also be placed on the surface facing the
source of radiation. The specified sensitivity requirement shall be achieved on the source
side IQIs. The sensitivity achieved on the film side IQIs shall be recorded for comparison
and used for evaluating production radiographs.
11.1.10 Film density
11.1.10.1 General
The minimum density shall be 2.0. The maximum density shall be 3.5 where adequate
interpretation can be achieved with the viewing screen.

11.2 Magnetic Particle Test Method

12 Mechanized welding with filler wire additions

Requirements for Mechanized welding with filler wire additions are included in the
preceding sections of this specification.
13 Automatic Welding Without Filler-Metal Additions

Welding without filler metal addition is not permitted.
Add the following new section:
14 Documentation
14.1 General
The Contractor shall maintain a record system which ensures weld traceability. The
Contractor shall be responsible for compiling the following document packages which shall
be submitted to the Company upon completion of the works:
(a)
 Copy of approved Welding Procedure Register
 Copies of approved WPSs
 Copies of approved repair WPSs
 Copies of all supporting PQRs
 List of approved welders and their identification
 List of Company welders' cards
 Copies of the Company welders' cards
 List of approved NDT operators
 Copies of NDT operator qualification certificates
 List of Company-approved deviations to the Code and this specification
 Copies of Company-approved deviations to the Code or this specification
 List of consumable batch certificates
 Copies of consumable batch certificates
 List of materials certificates
 Copies of materials certificates
 List of test equipment
 Copies of calibration certificates
(b)
 Certificate of Compliance
 List of as-built drawings
 As built drawings showing unique weld numbers
 List of weld history sheets
 Copies of weld history sheets which shall show for each weld
 weld number
 isometric and line number
 material specifications and identification
 the WPS employed

 the welders' identity symbols

 date welded
 visual inspection disposition
 NDE reports where applicable (to be attached to weld history sheet)
 type of repair, if applicable, and WPS
 NDE reports for repairs (to be attached to weld history sheet)
 PWHT if applicable (chart to be attached to weld history sheet)
 batch number of consumables employed
 Radiographs - indexed and stored in a fireproof container
 List of site test records
 Copies of site test records
 List of non-conformances/corrective actions issued during external or internal audits
 Copies of non-conformances/corrective actions issued during external or internal audits
Annexure to API 1104
A Alternative Acceptance Standards for Girth Welds

A.1 General
Add the following:
This Appendix shall be applied only when specified by the Company.
B In-Service Welding
Delete this Appendix in its entirety.

Figure A - Location of Macro section and Impact Test Specimens

Top of pipe
Mac rosection/hardness
Weld metal
Impact
Fusi on line
A spec imens
Fusi on line + 2mm
( a ) . Pip e d ia me te r s u p to
a n d in c lu d in g 4 in c h e s ( 1 1 4 .3 mm)
Top of pipe
Weld metal
Impact
Fusi on line
spec imens
Fusi on line + 2mm
( b ) . Pip e d ia me te r s g r e a te r
th a n 4 in c h e s ( 1 1 4 .3 mm)
N o te : If a d d itio n a l imp a c t s p e c ime n s a r e r e q u ir e d d u e to th e w a ll

th ic k n e s s e x c e e d in g 2 0 mm th e s e s h a ll b e ta k e n fr o m lo c a tio n A

Figure B - Orientation and Location of Charpy Impact Specimens

C/L
_ 20mm
t< Notch
t 2mm
Weld metal specimen
C/L
Specimen axis
_ 20mm
t<
Notch
2mm
FL + 2
FL
Heat affected zone specimens
C/L
2mm
t > 20mm
2mm
Weld metal specimens
C/L
FL 2mm
FL + 2
t > 20mm
FL + 2 2mm
FL
Heat affected zone specimens

Figure C - Hardness Indent Locations
1
.5+
-0.5mm
X XX
XXX X XX
XXX X
0
.5
t
X X X
XXX X XX
XX X X
X X X
XXX X XX
XX X X
1
.5+
-0.5mm
H
ard
nes
sin
den
ta
tio
nsinth
eHA
Zsp
ace
dat0
.5
m m
On
eind
entatio
no fe
v eryseto
f3 s
hallb
easc
los
e toth
efu
sio
nlin
eas
p
oss
ib
lebuts ha
llnotinte
rs
e c
tit
1
.5+
-0.5mm
0
.5XL
EGL
ENG
TH

Appendix C References
In this specification, reference is made to the following publications:
Notes:
(1) See also additional references listed in API 1104 Section 1.3.
(2) Unless specifically designated by date, the latest edition of each publication shall be used together with any amendments.
PDO Standards
Technical Authorities System GU-225
Quality Assurance Specification for Engineering Works SP-1171
Offshore Pipeline Engineering. SP-1211
Shell Group Standards

Oxidation of Stainless Steel Weldments DEP 30.10.60.31-Gen
Welded and Seamless Duplex and Super Duplex Stainless Steel Line Pipe DEP 31.40.20.34-Gen
(Amendments/supplements to API Spec. 5LC)
American Standards
Pipeline Transportation Systems for Liquid Hydrocarbons and Other ASME B31.4
Liquids
ASME B31.8
Gas Transmission and Distribution Piping Systems
ASME IX
Boiler and Pressure Vessel Code, Section IX, Welding and Brazing
Qualifications
Specification for CRA Linepipe API Std 5LC
Welding of Pipelines and Related Facilities, Eighteenth Edition, May 1994 API Std 1104
Standard Test Methods and Definitions for Mechanical Testing of Steel ASTM A370
Products
Methods of Preparation of Metallographic Specimens ASTM E3
Standard Test Method for Vickers Hardness of Metallic Materials ASTM E92
Standard Test Method for Determining Volume Fraction by Systematic ASTM E562
Manual Point Count
Standard Test Methods for Pitting and Crevice Corrosion Resistance of ASTM G48
Stainless Steels and Related Alloys by the Use of Ferric Chloride Solution
Sulphide Stress Cracking Resistant Metallic Materials for Oilfield NACE MR0175
Equipment
British Standards
Welding of Steel Pipelines on Land and Offshore, Parts 2 BS 4515
Implementation EN 729 on quality requirements for fusion welding of PD CR 13576

metallic materials
International Standards

Radiographic Image Quality Indicators for Non-Destructive Testing - ISO 1027

Principles and Identification
Recommended Practice for Radiographic Examination of Fusion Welded ISO 1106-3

Joints - Part 3: Fusion Welded Circumferential Joints in Steel Pipes of up to
50 mm Wall Thickness
Quality requirements for welding - Fusion welding of metallic materials - 3834-2 (Note 1)
Part 2: Comprehensive quality requirements
Non-Destructive Testing - Industrial Radiographic Illuminators – Minimum ISO 5580

Requirements
Quality Systems - Model for Quality Assurance in Design, Development, ISO 9001
Production, Installation and Servicing.
Non-Destructive Testing - Qualification and Certification of Personnel ISO 9712
Welding Consumables - Shielding Gases for Arc Welding and Cutting ISO 14175
Welding Co-ordination - Tasks and Responsibilities 14731 (Note 2)
Note 1 Also published as EN 719

Note 2 Also published as EN 729

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Specification for Welding of Duplex and Super Duplex Stainless Steel Pipelines

Petroleum Development Oman L.L.C.

Document title: Specification for Welding of Duplex and

Super Duplex Stainless Steel Pipelines

Document ID SP- 1097

Document Type Specification

Discipline Material & Corrosion

Owner UEC-Materials and Integrity Manager

Issue Date September 2018

July 2018 i SP-1097

This page was intentionally left blank

July 2018 ii SP-1097

Document Owner Document Custodian Document Author

Behlani, Nasser NABHANI,TALAL Ghafri, Mohamed

Date : 05-09-2018 Date : 05-09-2018 8:53 Date : 05-09-2018

July 2018 iii SP-1097

Version No. Date Author Scope / Remarks

iii Related Business Processes

iv Related Corporate Management System (CMS) Documents

July 2018 iv SP-1097

PETROLEUM DEVELOPMENT OMAN L.L.C. I

DOCUMENT TITLE: SPECIFICATION FOR WELDING OF DUPLEX AND I

I DOCUMENT AUTHORISATION III

III RELATED BUSINESS PROCESSES IV

IV RELATED CORPORATE MANAGEMENT SYSTEM (CMS) DOCUMENTS IV

1.2 Changes to the Specification 1

2. SPECIFICATION FOR WELDING DUPLEX STAINLESS STEEL 2

2.1 Specification Requirements 2

2.2 Process Deliverables 2

2.3 Process Owner's Responsibility 2

2.4 Performance Levels / Indicators 2

2.5 Performance Monitoring 2

2.6 Effective period 3

2.7 Review and Improvement 3

3 GLOSSARY OF DEFINITIONS, TERMS AND ABBREVIATIONS 4

AMENDMENTS/SUPPLEMENTS TO API SPEC 1104 7

3 TERMS, DEFINITIONS, ACRONYMS AND ABBREVIATIONS 7

July 2018 v SP-1097

5 QUALIFICATION OF WELDING PROCEDURES WITH FILLER METAL

5.1 Procedure Qualification 10

5.3 Welding Procedure Specification 10

5.4 Essential Variables 13

5.5 Welding of Test Joints - Butt Welds 15

5.6 Testing Of Welded Joints - Butt Welds 16

5.7 Welding of Test Joints - Fillet Welds 20

5.8 Testing Of Welded Joints - Fillet Welds 20

5.9 Welding of Test Repair Welds 21

5.10 Testing of Repair Welds 21

6.2 Single Qualification 22

6.3 Multiple Qualification 23

6.4 Visual Examination 23

6.5 Destructive Testing 23

6.6 Non-destructive Testing (Radiography) - Butt Welds Only 24

7 DESIGN AND PREPARATION OF A JOINT FOR PRODUCTION WELDING 25

July 2018 vi SP-1097

7.3 Use of Line-Up Clamp for Butt Welds 26

7.7 Cleaning Between Beads 27

7.8 Position Welding 27