Specification 001 - Welding and Fabrication of Structural Steel

Revision 0 Specification 001 2 of 19
1.0 INTRODUCTION

1.1 Scope
This specification together with AWS D1.1 or other recognised standard defines the
minimum requirements for welding, fabrication and inspection of steel structures.

1.2 Definitions
For the purpose of this specification the term "Company" shall mean Heerema Marine
Contractors Nederland B.V. (hereafter called HMC) or their nominated representative. The
Contractor shall mean the nominated Fabricator and/or his Subcontractor for the supply
and/or fabrication of structural steelwork described in the contract requirements.

The "Client" is the organisation contracted by the Company to execute projects according the
contract requirements.

1.3 Performance
The Contractor shall have in charge of the work, at all times, a thoroughly competent
supervisor who is experienced in this category of structural work. The Contractor shall
designate a competent representative familiar with all phases of fabrication and
administration with which HMC may communicate at all times.

The Contractor shall employ only qualified craftsmen to perform all aspects of the work
including testing.

The Contractor shall inform HMC two (2) working days prior to the commencement of any
work.
The Contractor shall report progress on a weekly basis.

1.4 Conflicting requirements
Deviations from or additions to this specification and pertaining documents are not allowed
unless instructed or agreed in writing by HMC. In case of contradicting requirements or
omissions the Contractor shall obtain a written ruling from HMC before proceeding with the
work affected.

As a general rule, the requirements of relevant codes, standards, specifications, laws and
governmental regulations and the regulations of the appointed Certifying Authority, if
applicable shall be adhered to.

However, if these are less stringent than the requirements of this specification, this
specification shall be adhered to. Where the requirements of either the codes, standards,
specifications, governmental laws or the Certifying Authorities are more stringent than the
requirements of this specification, the Contractor shall adhere to these and inform HMC
accordingly.

1.5 Quality Assurance
The Contractor shall maintain an effective program for quality assurance and quality control,
planned with all manufacturing functions necessary to meet the requirements of the contract.
The requirements shall be met by the establishment and implementation of procedures which
shall ensure that acceptable product is delivered to HMC. The program shall ensure that
quality requirements are determined prior to commencement of manufacture and
subsequently satisfied throughout the phase of production and delivery.

Contractor quality systems and quality control procedures shall be in accordance with the
applicable part of ISO 9000 or an approved equivalent and shall be submitted for the review
and approval of HMC.

1.6 Quality System procedures
Contractor and/or his subcontractors shall have available for HMC review the control
procedures that comprise the quality system. Should HMC consider that insufficient
procedures are available to control the work, or that the available procedures are inadequate,
Contractor shall produce the additional procedures required or revise existing procedures to
HMC satisfaction. Contractors procedures, as a minimum, shall address the following
activities:
Contract review and clarification
Fabrication facilities
Design control
Testing
Purchasing control
Welding (procedures, qualifications)
Dimensional Control
Control of HMC provided materials and supplied documents
Process control for fabrication
Control and calibration of inspection, measuring and test equipment
Control of non-conforming materials and disposition of same
Compilation of as-built documentation
Quality assurance internal audits and follow up activity
Mechanical completion
Load out and seafastening

The above requirements also applies to all Subcontractors quality systems.

1.7 Reference Specifications, Codes and Standards
The latest editions at time of Contract including addenda, supplements etc. of the following
Codes and Standards shall govern the execution of work. The Contractor shall provide
himself with copies of all the referenced documents, and shall make them readily available to
all personnel involved in the work.

American Institute of Steel Construction (AISC)
AISC Code of Standard Practices for Steel Buildings and Bridges
AISC Specification for the Design, Fabrication and Erection of
Structural Steel for Buildings

American Welding Society (AWS)
ANSI/AWS A2-4 Standard symbols for welding, brazing and non-destructive
examination.
AWS A5.1 Specification for Covered Carbon Steel Arc Welding Electrodes
AWS A5.5 Specification for Low Alloy Steel Covered Arc welding Electrodes
AWS A5.17 Specification for Carbon Steel Electrodes and Fluxes for Submerged
Arc Welding
AWS A5.18 Specification for Carbon Steel Filler Metals for Gas Shielded Arc
Welding
AWS A5.20 Carbon Steel Electrodes for Flux-Cored Arc Welding
AWS A5.23 Specification for Low Alloy Steel Electrodes and Fluxes for
Submerged Arc Welding
AWS A5.28 Specification for Low Alloy Steel Electrodes for Gas Shielded Metal
Arc Welding
AWS A5.29 Specification for Low Alloy Steel Electrodes for Flux Cored Arc
Welding
AWS D1.1 Structural Welding Code Steel

American Petroleum Institute (API)
API RP 2A Recommended practice for planning, designing and constructing fixed
offshore platforms.
API 2H Specification for Carbon Manganese Steel Plate (Normalized) for
Offshore Structures
API 2W Specification for Carbon Manganese Steel Plate (TMCP) for
Offshore Structures
API 2Y Specification for Carbon Manganese Steel Plate (QT) for
Offshore Structures
API 5L Specification for Line Pipe

American Society of Mechanical Engineers (ASME)
ASME BPV-V Non-destructive examination
ASME BPV-VIII Pressure vessels - division 1
ASME BPV-IX Welding and brazing qualifications

The American Society for Non-destructive Testing, Inc. (ASNT)
SNT-TC-1A Recommended Practise for the Training and Certification for NDT
Personnel

European standards
BS 7191 Weldable Structural Steels for Fixed Offshore Structures
EN 287-1 Approval Testing of Welders for Fusion Welding-Steels
EN 288-3 Specification and Approval of Welding Procedures for Metallic
materials
EN 439 Welding Consumables, Shielding Gases for Arc Welding and Cutting
EN 473 Qualification and Certification of NDT Personnel
EN 1011 Recommendations for Arc Welding of Ferritic Steels
EN 10025 Hot Rolled Products of Non-alloy Structural Steels
EN 10160 Ultrasonic Testing of Steel Flat Product of Thickness Equal or Greater
than 6 mm
EN 10204 Metallic Products Types of Inspection Documents
EN 10225 Weldable Structural Steels for Fixed Offshore Structures

International Standards Organisation
ISO 3690 Determination of Hydrogen in deposited Weld Metal Arising from the
use of Covered Electrodes for Welding Mild and Low Alloy Steels
ISO 9000-2000 Model for Quality Assurance in Design, Development, Production,
Installation and Servicing.

2.0 MATERIALS

2.1 Definitions of steel types, Plate, Rolled Sections and Tubulars.
HMC recognises the following types of structural steel:

Type I - High Strength Steel with TTP
Type II - High Strength Steel
Type III - Primary Steel with TTP
Type IV - Primary Steel with Charpy V impact test at -40 C
Type V - Primary Steel with Charpy V impact test at 20 C
Type VI - Secondary Steel

Table I
Type Nominal
Yield
(N/mm
2
)
Impact (C)
Charpy-V
Minimum
Average (J)
Minimum
Single (J)
TTP Internal
Soundness
I 450 -40 60 J 42 J Z35 UT a)
II 450 -40 60 J 42 J - UT b)
III 355 -40 50 J 35 J Z35 UT a)
IV 355 -40 50 J 35 J - UT b)
V 355 -20 27 J 19 J - -
VI 235 - - - - -

The relevant types of steel shall be indicated on the approved construction drawings.

a) Ultrasonic testing shall meet the requirements of EN 10160 class S
3
/ E
2
b) Ultrasonic testing shall meet the requirements of EN 10160 class S
1
/ E
2

Structural steel shall meet the requirements of API 5L, API 2H/2W/2Y, BS 7191, EN 10025,
EN 10225 and table 1 with the restrictions that the Carbon (C) content is limited to a
maximum of 0.18 percent and the Carbon Equivalent (Ceq) is restricted to a maximum of
0.43 for all types.

Long formula Ceq = C +
6
Mn
+
5
V Mo Cr + +
+
15
Cu Ni+

Contractor may propose equivalent alternatives; its acceptance is to the sole discretion of
HMC.

2.1.1 Condition of Supplied Steel
All steel supplied shall be reasonably free from scale and rust. Any deformation of material
shall be kept separate and reported.

Each piece of steel shall be traceable to its relevant certificate.
Subject to HMC approval non-traceable steel may be used upon satisfactory verification.
Verification shall include all testing as required by paragraph 2.1.

2.1.2 Certification of Steel
Material received without certification shall not be used in fabrication and kept separate until
material certificates are received and controlled against the requirements described in chapter
2.1 of this specification.

Steel types I, II, III and IV shall as a minimum be supplied with 3.1.C certificates according
EN 10204. Steel types V and VI shall be supplied with EN 10204 3.1.B certification unless
specified otherwise. Squares, round and flat bars, angle-lines shall at least be supplied with
EN 10204 2.2 certification.

Copies of original certification or verified true copies shall be supplied for all materials. All
pieces of steel shall be traceable to its certification by cast number or piece mark.

2.2 Transfer of Identification
The Contractor shall ensure that the documentation and transfer of marking is strictly
controlled so that any material can be easily identified by its heat, cast, or stock-number.

2.3 Welding Consumables
The welding consumables used in fabrication shall be approved by classification societies
and selected to produce welds with mechanical properties equivalent to those required for the
base metal and shall be subject to approval by HMC prior to use.

Welding consumables for the work shall be / have been supplied with a certificate of
compliance as a minimum.

Except for solid wires all consumables shall be classified as low hydrogen type.
Low hydrogen consumables are defined as those that produce deposit weld metal with no
more than 5ml/100g diffusible hydrogen. For self-shielded flux cored wire, hydrogen content
of no more than 8ml/100g weld metal may be accepted.

All consumables shall comply with one of the following codes, or an approved alternative:
GMAW AWS A5.18
GTAW AWS A5.18
FCAW AWS A5.20, A5.29
SAW AWS A5.17, A5.23
SMAW AWS A5.1, A5.5
Shielding Gases EN 439

Hydrogen testing shall be according to ISO 3690

2.3.1 Storage and handling
All welding consumables shall be stored and/or baked as recommended by the appropriate
manufacturer.

Vacuum packed electrodes may be used in accordance with manufacturer recommendations.
All unidentifiable, damaged, wet, rusty or otherwise contaminated consumables are to be
removed from the work site.
3.0 WELDING PROCEDURE AND WELDER QUALIFICATION

3.1 Welding Procedure Specifications (WPS)
Welding procedure specifications shall be prepared in accordance with AWS D1.1 and/or
EN 288 part 2. Welding procedures specifications shall be submitted for approval prior to
use.

3.2 Qualification of welding procedures
Welding procedures shall be qualified in accordance with AWS D1.1 structural welding code
or EN 288 part 3 and the additional requirements in this specification. Qualifications shall be
made and tested for the actual combination of steel grade, welding process and welding
consumable used.

3.2.1 Previously qualified procedures
The Contractor may submit previously qualified welding procedures, which meet all the
requirements of this specification for approval. A recognised Certifying Authority must
authenticate all submissions. Acceptance of a previously qualified weld procedure is at the
sole discretion of HMC. Any additional tests required to qualify procedures shall be
witnessed by HMC and the Certifying Authority.

Pre-qualification under section 3 of AWS D1.1 is not permitted.

3.3 Essential Variables
Essential variables shall be those required by the applicable industry code and the additional
variables as listed below. Any deviation from these variables shall require that a new weld
procedure be qualified.

The maximum thickness range qualified shall be 2 times the test piece thickness with a
maximum of 63.5 mm.

3.3.1 Base metal fabrication
The chemistry of the base material used to qualify project weld procedures should reflect a
carbon equivalent of that of the upper range to be welded in production. In general, the
carbon equivalent of the material used to qualify a procedure should not be less than that of
production plate minus 0.05.

3.4 Examination of the test weld

3.4.1 General
The type and number of tests shall be in accordance with AWS D1.1 or EN 288 part 3 and
the additional requirements given below.

3.4.2 Non-destructive Testing
The test weld shall be non-destructively tested in accordance with Section 6 of this
specification. Extent and type of NDT shall be in accordance with table 2 Inspection
category A.

3.4.3 Impact Testing (Charpy V-notch)
Impact testing shall be carried out on butt weld tests at the following locations on the cap
side.
Weld centre line -
Fusion line - (bevel side)
Fusion line + 2mm - (bevel side)
Fusion line + 5mm - (bevel side)

When actual qualification or production weld thickness exceeds 50mm (2 inch) also impact
testing in the root region at the same locations as cap side is required.

Three test specimens will be required for each set. Specimens shall be sampled a maximum
of 2 mm below the surface of the parent metal and transverse to the weld.
For double sided welds the specimens shall be sampled in the root area.

The minimum Charpy energy values to be obtained at the relevant test temperature for the
types of steel listed in table 1 are as follows:

Type Average of three Individual
I & II 45 joules 32 joules
III & IV 36 joules 26 joules
V 27 joules 19 joules

3.4.4 Hardness Testing
Vickers hardness test shall be performed on the macro-etched specimen using 10kg load.
Hardness tests to be taken within 2mm of the plate surface at the cap and within 2mm at the
root. These tests shall establish the hardness of the weld metal and the maximum hardness in
the HAZ. Exact hardness indent locations shall be reported. The maximum permissible
hardness shall not exceed 325 HV 10.

3.4.5 Macro Examination
A macro section shall be prepared and examined in accordance with AWS D1.1 or EN 288
part 3.

3.5 Welder and welding operators qualifications
Welders, welding operators and tack welders shall be qualified in accordance with AWS
D1.1 or EN 287.

The qualifications shall be certified by a recognised Certifying Authority/or Classification
Society. Certification based upon X-ray inspection only shall not be acceptable.

Existing valid welder qualification certificates may be accepted providing it can be
demonstrated that the welders are adequately qualified and are currently engaged on work,
which has been/is subject to third party inspection. Any such qualification records will be
presented to HMC for approval prior to the planned start of fabrication.
4.0 PRODUCTION AND ASSEMBLY

4.1 General
All construction work shall be undertaken in accordance with this specification, the
drawings, and relevant procedures approved by HMC.

The Contractor shall apply a weld numbering system for identification on all shop drawings
and as reference in all documentation.

4.2 Welding
All welding shall be carried out to recommendations given in AWS D1.1 and/or EN 1011-1.

4.2.1 Welding Sequences
Contractor shall develop welding and assembly sequences to minimise distortion and
residual stresses in the structure.

No remedial treatment shall be carried out to rectify distortion without the prior approval of
HMC.

4.2.2 Straightening of structural members
Members distorted by welding shall be straightened by appropriate mechanical means or by
carefully localised heat according to a detailed work instruction. If hot straightening is
proposed, the maximum temperature shall not exceed the temperature limit recommended by
the steel manufacturer, but it shall in no case be higher than 500 C.

4.3 Surface and Edge Preparation
Edges to be welded shall be prepared by machining, or by thermal cutting followed by
grinding to bright metal.

All weld preparations prepared for welding shall be subject to visual inspection.
The surfaces and edges shall be smooth uniform and free from fins, tears, cracks and other
material that will prevent proper welding. Any defects found shall be dressed out by
grinding. If the depth of excavation exceeds 5 mm, a weld repair shall be made according to
an approved weld procedure.

4.4 Assembly
The parts to be joined by butt welds shall be carefully aligned. Weld preparation tolerances
shall comply with the qualified welding procedure and the tolerances given in AWS D1.1 or
EN 288-3 unless otherwise indicated on the contract drawings.

Where butt welds are to be made between different thicknesses, a transition using a taper of
1:4 shall be provided.

The parts to be joined by fillet welds shall be brought into as close contact as practical. Any
root gaps in multi-pass fillet welds shall be compensated for by a corresponding increase in
fillet leg length up to a maximum of 6mm. For single-pass fillet welds, the root gap shall be
limited to 3 mm and the weld leg length shall be compensated for by the same amount.
No welding shall be started until the structure, which will be stiffened thereby, has been
properly aligned. The structural members shall be held in position by clamps, bridges,
bullets, tack welds or other suitable means.

Permanent backing strips are not accepted, unless shown in design drawings.

4.4.1 Repair of poor fit-up
Root gaps, which are out of tolerance, shall be corrected by grinding or buttering followed
by grinding, back to the required profile. Buttering passes shall be applied according to an
approved buttering procedure. The depth of buttering on any member shall not exceed 2 T of
the thinner part or 19 mm whichever is less.

4.5 Tack Welds
Tack welds shall be of a minimum length of four times the base metal thickness or 100 mm,
whichever is less, and shall be carried out in accordance with an approved welding
procedure.

Tack welds that form part of the completed weld shall be ground to a featheredge, crack
detected and fused with the root run.

4.6 Attachments
Temporary attachments as lifting lugs, lugs for scaffolding and assembly and other
fabrication and erection aids shall subsequently be removed. Removal shall be by arc-air
gouging or cutting minimum 3 mm above the surface of the base metal and the remainder
ground flush. The ground area shall be visually examined and magnetic particle inspected.

All welding of attachments shall comply with the requirements for the structure to which
they are attached.

Removal of temporary attachments by hammering will not be permitted.

4.7 Preheat and Interpass Temperature
The minimum preheat temperature for each joint shall be determined by the use of AWS
D1.1 or EN 1011, except that it shall not be lower than the qualified welding procedure. The
maximum interpass temperature shall not exceed 250C.

The Contractor shall provide temperature recorders and/or temple-sticks to ensure
conformity to the specified heat treatment.

4.8 Post Weld Heat Treatment
PWHT of welds will be required when the design throat of the thinnest member of the
material being welded exceeds 63.5 mm.
PWHT may be waved if adequate fracture toughness can be documented in the as welded
conditions.

The Contractor shall prepare detailed procedures for PWHT which shall include:
Heating rate
Cooling rate
Soaking temperature and time
Heating facilities
Insulation
Control devices
Recording equipment
Sketch illustrating the method of support
Number and location of thermocouples

The procedures employed shall be in accordance with the relevant sections of
established international standards.

4.9 Weld Dimensions
All structural welds shall conform to the types, sizes and extent detailed on the drawings. In
the absence of specific instructions all welds shall conform to AWS D1.1. All structural
welds shall be continuous and shall have complete penetration and fusion of weld and base
metal.

4.10 Compatibility of Welds
All welds shall develop the strength, ductility and notch toughness specified for the steel
being welded.
Welds forming connections between steel of different grades shall develop the same unit
strength as that specified for the higher strength steel and shall develop values of ductility
and notch toughness equal to the lower value of those specified for the grade of steel being
joined.

4.11 Weld Profile and Surface Finish
Welds shall be in the as welded state unless noted on construction drawings. All welds shall
be of the specified size and shape, and shall be blend smoothly into the parent material
without overlap or unacceptable undercut. The weld surface and the adjacent area of the
weld shall be clean and free of all dirt, grease, paint, weld spatter etc.

4.12 Weld Repairs
The Contractor shall repair or replace all welds that do not meet the requirements of the
appropriate codes and standards and this specification.

Removal of defects and deposition of repair welds shall be in accordance with the qualified
repair welding procedure.

When a weld procedure qualified for the original weld is used to cover repairs, pre-heat shall
be increased 50C above that qualified.

Removal of defective weld metal or portions of the base metal shall be done by machining,
grinding, chipping, arc-air gouging and any other method, which produces a clean,
uncontaminated surface. Oxygen-acetylene gouging will not be acceptable.

All arc-air gouges shall be power disk ground to bright metal to remove residual carbon.
The defect and 25mm of sound metal beyond each end of the defect shall be removed
Extent of defects in weld or base metal shall be ascertained by use of non-destructive
inspection.

All repair welds shall be re-examined in accordance with par. 6.4.1 of this specification.

5.0 FABRICATION OF STRUCTURAL MEMBERS AND MATERIALS

5.1 General
All fabrication and tolerances shall conform to the approved design drawings and comply
with API RP2A WSD section 11 and this specification.

5.1.1 Tubular connections
When two or more tubulars join in a x-joint, the larger diameter member shall continue
through the joint, and the other shall frame onto the through member and be considered the
minor member. Unless specified otherwise on the drawings, when two or more minor
members intersect or overlap at a joint, the order in which each member frames into the joint
will be determined by wall thickness and/or diameter. The member with the thickest wall
will be the continuous or through member, and the sequence for framing the remaining
members shall be based on the order of decreasing wall thickness. Should two or more
members have the same wall thickness, the larger diameter member shall always be the
continuous or through member.

5.2 Splices
Structural members may be spliced for economic use of material.
Any splices shall develop the full strength and cross section of the member joined.

Welded joints of axially aligned structural members of different material size; thickness,
diameters or widths shall be made in such a manner that the slope through the transition zone
does not exceed 1:4. The transition shall be accomplished by chamfering the thicker part,
tapering the wider part, sloping weld metal, or by any combination of these. The locations of
all splices shall be in accordance with the following requirements:

5.2.1 Structural tubulars
Butt splices in tubulars shall have the longitudinal seam radially offset by not less than 45.

Splices shall not be located closer together than 1000 mm, or one (1) diameter of the pipe,
whichever is less. There shall not be more than two (2) splices in any 3000mm interval of
pipe.

5.2.2 Beams - Structural Shapes
Butt splices in fabricated girders shall minimize the use of cope holes for welding access, by
splicing webs prior to mating with the flange. The use of the beam shall determine the
location and frequency of splicing.

Splices shall not be located closer together than twice the depth of the beam, or 1000 mm
whichever is smaller. Other splice locations may be used subject to approval by HMC.

There shall not be more than two splices in any 3000 mm interval of structural shape.

In cantilever beams, there shall be no splice located closer to the point of support than one-
half of the cantilevered length. For beams in any span between supports, there shall be no
splice in the middle one-fourth of any span, nor in the eighth of the span nearest any support,
nor over any support. The location of all splices in critical members is subject to the approval
of HMC.

Splicing in beams and shapes shall not be allowed underneath bearing-pads.

5.3 Fabrication Tolerances

5.3.1 General Requirements
The Contractor shall provide all personnel, equipment and instruments required to monitor
and control dimensions and tolerances.

Instruments used shall be in accurate adjustment and shall have current valid calibration
certificates.

Reference temperature for survey activities should be 20 deg. C. The allowable tolerances
given for individual members shall not cumulate to give unacceptable deviation for the
finished section or complete structure.

If tolerances given for individual sections and components are conflicting, those tolerances
representing the stricter values shall be governing. If no appropriate tolerance is specified,
the tolerance requirements shall be agreed.

5.3.2 Tolerances
Dimensional tolerances of built-up members, including deviation from straightness and
deviation from specified camber, shall conform to the requirements of AWS D1.1 Structural
Welding Code.

5.3.3 Cruciform Joints
Eccentricity of non-continuous plating in cruciform joints shall not exceed 0.5t where t is the
thickness of the thinnest non-continuous member or 8 mm, whichever is smaller.

5.4 FABRICATION AND INSTALLATION OF GRILLAGES

5.4.1 General
All barge dimensions, web frame locations and levels to be confirmed by Contractor prior to
commencing fabrication.
Barge data shown on drawings is considered nominal only.

Contractor shall ensure that full bearing is achieved at the grillage/barge pack locations and
shall shim, if necessary.

Grillage beams shall be set out relative to each other and relative to the centre line of barge.

5.4.2 Tolerances
Load out grillage and seafastening shall be fabricated and installed in accordance with
acceptable tolerances for relevant structures defined in this document. (Ref. Section 5.1
through 5.3)

Specific tolerance requirements shall be shown on respective drawings and shall be
mandatory.

Location of wing plates to barge frames to be within +/- 5mm of frame C.L., bulkhead C.L
or bulb flat C.L.

Contractor to ensure that the relative level at bearing and skid surfaces are coplanar within
5mm with the barge at simulated tow ballast condition to be advised by HMC.

6.0 INSPECTION AND NON DESTRUCTIVE TESTING

6.1 General
The Contractor and/or his subcontractors shall be responsible for undertaking all of
the inspection and NDT required by this Specification. Any inspection by HMC or
Certifying Authority shall not absolve the Contractor of this responsibility.

HMC shall have the right to inspect the material, fabrication and erection of all items
covered by this Specification.

Contractor shall ascertain that all welding is performed in accordance with this specification
and any written addenda approved by HMC.

Final inspection and NDT of structural steel welds shall not been carried out before 24 hours
after completion. Final inspection on welds subject to PWHT may be performed when all
heat treatment have been completed.

6.2 Qualification of inspectors and NDT Operators
All NDT operators shall be qualified to meet the recommendations of SNT-TC-1A,
EN 473 Level II or approved equivalent. NDT operator qualification test certificates to be
approved by the Company prior to commencing inspection activities.

6.3 Table 2 Extent of non-destructive testing for structural welds

Extent of testing

Inspection
Category
Type of
Connection
Visual
Examination
RT UT MT
A Butt weld
T-connection
Fillet weld
Partial Pen
100%
100%
100%
100%
1)
-
-
-
100%
100%
-
-
100%
100%
100%
100%
B Butt weld
T-connection
Fillet weld
Partial Pen
100%
100%
100%
100%
1)
-
-
-
50%
50%
-
-
100%
100%
100%
100%
C Butt weld
T-connection
Fillet weld
Partial Pen
100%
100%
100%
100%
1)
-
-
-
20%
20%
-
-
20%
20%
20%
20%
D All
connections
100% - - 10%

1) For thicknesses where the use of ultrasonic examination is impractical, radiography
shall be used

6.4 Inspection Levels
The percentage of weld inspections shall be interpreted as follows:
For welds over 1 meter in length, the percentage of welds to be inspected shall mean the
thorough inspection of the stated percentage length of each weld.
For welds not exceeding 1 meter, the percentage of welds to be inspected shall mean a
percentage of the connections of the given type.

If defects are detected during percentage examinations, this percentage may be increased at
the instruction of Company.

6.4.1 Repairs and removals
Weld repairs shall be subject to 100% inspection by the methods required for the original
weld. For surfaces ground after the removal of welded attachments and where repair of
defects is by removal by grinding, the area shall be subject to 100% visual inspection and
100% MPI.

6.5 Visual examination and finish of welds
The visual examination shall be carried out in accordance with AWS D1.1

6.6 Radiographic Inspection
Radiographic testing shall be carried out in accordance with ASME V, Article 2.
The soundness of the welded joint shall comply with the requirements of ASME VIII
Division 1 appendix 4.

6.7 Ultrasonic Inspection
Ultrasonic testing of welds in plate and butt welds shall be performed in accordance with
ASME V, Article 5. The acceptance criteria for welds shall comply with ASME VIII
Division 1, appendix 12.

6.8 Magnetic Particle Inspection
Magnetic particle testing shall be carried out in accordance with ASME V, Article 7.
The acceptance criteria shall comply with ASME VIII Division 1, appendix 6.

6.9 Liquid Penetrant Inspection
Liquid Penetrant testing shall be carried out in accordance with ASME V, Article 6.
The acceptance criteria shall comply with ASME VIII Division 1, appendix 8.
7.0 DOCUMENTATION

7.1 Pre-Fabrication Documentation
Prior to commencement of any part of the fabrication, the Contractor shall submit for HMC
approval the following documentation and procedures as a minimum requirement for the
contract.
Welding Procedure Specifications
Welding Procedure Qualification Records
Welder Qualifications
Material Control Procedure
Consumables Storage and Handling Procedures
NDE Procedures
NDE Operator Qualifications
Weld Location and Material Identification Plan
Quality/Inspection Plan
Dimensional Control Procedures

7.2 Quality Records
The Contractor shall maintain quality records as documentary evidence of conformance to
quality requirements. Quality records shall be made available to HMC for analysis and
review on a daily/weekly basis.

7.3 Final Documentation Packages
The Contractor shall provide HMC with final as-built documentation package covering each
fabricated section or sub assembly within 7 working days of completion.

The documentation packages will contain objective evidence that the related items of
fabrication conform to the specified requirements. The actual content and scope of all
packages is to be mutually agreed and approved by HMC prior to commencement of work.

All data, with the possible exception of drawings or charts, should be suitable for
photocopying (i.e. A4/A3 size) and to be a reproducible quality that would facilitate
microfilm or computer processing. Typical example of structural element data package
would be as follows.
Weld Notation and Material Location Plan
Material Certification (including welding consumables)
NDE Index (Reference Sheet)
NDE Reports
Dimensional Survey Reports
As-built Drawings
Engineering Concessions
Outstanding Work Punch List
Approved Procedures Index (Weld and NDE)
Approved Welders Qualification Record
NDE Operator Qualification Record
Inspection Release Document

Specification 001 - Welding and Fabrication of Structural Steel

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Specification 001 - Welding and Fabrication of Structural Steel

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