GIS 43-331 - API 1104 Pipeline Welding PDF

Guidance on Industry Standard for
API 1104 Pipeline Welding

GIS 43-331

BP GROUP
ENGINEERING TECHNICAL PRACTICES
Document No. GIS 43-331
Applicability Group
Date 21 April 2006
21 April 2006 GIS 43-331
Guidance on Industry Standard for API 1104 Pipeline Welding
Page 2 of 56
Foreword
This is the first issue of Engineering Technical Practice (ETP) BP GIS 43-331. This Guidance on
Industry Standard (GIS) is based on parts of heritage documents from the merged BP companies as
follows:
British Petroleum
GS 118-9 Welding of Transmission Pipelines (Supplementary to API 1104).
GS 118-10 Welding of Transmission Pipelines (Supplementary to BS 4515).
AMOCO
A PN-OFS-WLD-C PipingOffshoreWelding PipelinesConstruction.
Copyright 2006, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipients organization. None of the information
contained in this document shall be disclosed outside the recipients own organization
without the prior written permission of the Director of Engineering, BP Group, unless the
terms of such agreement or contract expressly allow.
21 April 2006 GIS 43-331
Page 3 of 56
Table of Contents
Page
Foreword........................................................................................................................................ 2
Introduction..................................................................................................................................... 6
1 General.................................................................................................................................. 7
1.1 Scope......................................................................................................................... 7
1.2 Welding process restrictions ....................................................................................... 7
1.3 HSSE for pipeline welding operations ......................................................................... 7
1.4 Pre-production consultation........................................................................................ 8
1.5 General duties of the contractor.................................................................................. 8
1.6 Quality assurance....................................................................................................... 8
1.7 Records ...................................................................................................................... 8
1.8 Contractors personnel................................................................................................ 9
1.9 Abbreviations and acronyms..................................................................................... 10
2 Referenced publications ...................................................................................................... 12
3 Definitions of terms.............................................................................................................. 14
3.2 Definitions................................................................................................................. 14
4 Specifications....................................................................................................................... 15
4.1 Equipment................................................................................................................. 15
4.2 Materials................................................................................................................... 15
4.3 Minimum design temperature (MDT)......................................................................... 17
5 Qualification of welding procedures for welds containing filler-metal additives ..................... 17
5.1 Procedure qualification............................................................................................. 17
5.2 Record...................................................................................................................... 18
5.3 Procedure specification............................................................................................. 19
5.4 Essential variables.................................................................................................... 22
5.5 Welding of test jointbutt welds ............................................................................... 25
5.6 Testing of welded jointsbutt welds......................................................................... 26
5.7 Welding of test jointsfillet welds............................................................................. 33
5.8 Testing of welded jointsfillet welds......................................................................... 33
6 Qualification of welders........................................................................................................ 34
6.1 General..................................................................................................................... 34
6.2 Single qualification.................................................................................................... 35
6.3 Multiple qualification.................................................................................................. 35
6.4 Visual examination.................................................................................................... 35
6.6 Radiographybutt welds only................................................................................... 35
7 Design and preparation of a joint for production welding...................................................... 36
7.1 General..................................................................................................................... 36
7.2 Alignment.................................................................................................................. 36
7.3 Use of line-up clamp for butt welds ........................................................................... 37
7.4 Bevel......................................................................................................................... 38
7.5 Weather conditions................................................................................................... 38
21 April 2006 GIS 43-331
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7.6 Clearance................................................................................................................. 38
7.7 Cleaning between beads........................................................................................... 39
7.10 Identification of welds................................................................................................ 39
7.11 Pre-and post-heat treatment..................................................................................... 39
7.12 Weld interruption....................................................................................................... 40
7.13 Branches .................................................................................................................. 40
7.14 Fillet weld attachments.............................................................................................. 41
8 Inspection and testing of production welds........................................................................... 41
8.1 Rights of inspection................................................................................................... 41
8.2 Methods of inspection............................................................................................... 42
8.3 Qualification of inspection personnel......................................................................... 42
8.4 Certification of nondestructive testing personnel ....................................................... 42
9 Acceptance standards for non-destructive testing................................................................ 43
9.1 General..................................................................................................................... 43
9.3 Radiographic testing................................................................................................. 43
9.7 Visual acceptance standards for undercutting........................................................... 44
9.8 Suspect welds........................................................................................................... 44
10 Repair and removal of defects ............................................................................................. 45
10.1 Authorisation for repair.............................................................................................. 45
10.2 Repair procedure...................................................................................................... 46
10.6 Arc burns .................................................................................................................. 47
11 Procedures for nondestructive testing.................................................................................. 47
11.1 Radiographic test methods ....................................................................................... 47
11.2 Magnetic particle test method................................................................................... 50
11.4 Ultrasonic test methods............................................................................................. 50
12 Mechanised welding with filler metal additions..................................................................... 51
12.2 Procedure qualification............................................................................................. 51
12.3 Record...................................................................................................................... 51
12.4 Procedure specification............................................................................................. 52
12.5 Essential variables.................................................................................................... 52
12.6 Qualification of welding equipment and operators..................................................... 52
13 Automatic welding without filler-metal additions ................................................................... 52
Appendix AAlternative acceptance standards for girth welds..................................................... 52
Appendix B In-service welding................................................................................................... 52
B.1 General..................................................................................................................... 52
Appendix C Additional requirements for pipelines subject to high strain levels........................... 53
C.1 Introduction............................................................................................................... 53
C.2 General..................................................................................................................... 53
C.3 Weld procedure qualification testing.......................................................................... 53
C.4 Production welding.................................................................................................... 54
Appendix DCTOD testing.......................................................................................................... 55
Appendix EPin brazing and aluminothermic welding of anode leads ......................................... 55
E.1 J oining technique...................................................................................................... 55
21 April 2006 GIS 43-331
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E.2 Specification and approval of procedure................................................................... 55
Bibliography.................................................................................................................................. 56
List of Tables
Table A - Grade and thickness limits for cellulosic electrodes....................................................... 16
Table B - Diameter and test pipe thickness range of approval ...................................................... 19
Table C - Minimum preheat levels for SMAW (cellulosic) welds.................................................... 21
Table D - Specified minimum delay time before NDT for WPQT welds ......................................... 26
Table 2 - Type and number of test specimens (a) for procedure qualification test......................... 29
Table E - Charpy impact test requirements................................................................................... 31
Table F - Maximum permissible weld and HAZ hardness values (HV10) ...................................... 33
Table G - Type and number of test specimens for repair weld procedure qualification test........... 47
Table H - IQI sensitivity levels....................................................................................................... 49
List of Figures
Figure 3 - Location of test pieces from a butt weld in pipe............................................................. 28
Figure A - Charpy V notch locations.............................................................................................. 30
Figure B - Locations for hardness indents..................................................................................... 32
Figure C - Fillet weld hardness indent locations............................................................................ 34

21 April 2006 GIS 43-331
Page 6 of 56
Introduction
a. Guidance for pipeline welding is based on API STD 1104.
b. Guidance statements of this GIS are modifications to API 1104, Welding of Pipelines and
Related Facilities, Twentieth Edition, November 2005.
c. Modifications to API 1104 are identified as Add, Modify to Read, or Delete.
d. Paragraph numbers in this specification correspond to API 1104.
e. Paragraphs of API 1104 that are not revised remain applicable.
f. If any statement is contradictory to API 1104, the requirements of this GIS shall take
precedence.
g. The technical integrity of all aspects of design, construction, and operation of pipelines is
of the highest importance to BP and compliance with BP HSSE policy shall remain
paramount.
The normative text of API 1104 and this GIS is primarily applicable to the main line, double
joint, and tie-in welding operations for the construction of C-Mn steel and low alloy steel
pipelines.
This GIS has been written primarily for pipelines up to X80 grade. However, it also allows for
construction of pipelines in higher strength steels up to Grade X120 (which are not yet included
in the base API 1104 standard and for which some parameters such as mechanical properties
and defect acceptance criteria will need to be specified individually).
21 April 2006 GIS 43-331
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1 General
1.1 Scope
Add
The scope includes the off-line fabrication of items such as welding nipples to valve bodies or
other fittings and the fabrication welding of branches. The following items are outside the scope
of this GIS:
- Corrosion resistant alloy (CRA) clad linepipe
- Solid CRA linepipe
- The welding of process piping in terminals, pump or compressor stations, or in refineries
- Hyperbaric welding
- Wet welding
- Overlay welding
- Steel catenary risers (SCRs)
Additional requirements for high strain pipelines are given in Appendix C.
Requirements for pin brazing and aluminothermic welding of anode leads are given in
Appendix E
Add
1.2 Welding process restrictions
Mechanised and automatic welding processes are preferred and should be used whenever
possible for pipeline girth welding. Main line welding should be by mechanised or automatic
gas metal arc welding (GMAW) which may include single, multi-torch, or tandem-arc variants
of the process and the use of cored wires. If the use of mechanised or automated GMAW
processes is impracticable, alternative processes may be used. In such instances, welding may
be performed by shielded metal arc welding (SMAW), manual or automated gas tungsten arc
welding (GTAW), semi-automatic GMAW processes using solid or cored wires, or a
combination of these processes.
For double or multiple jointing, girth welds should be made using submerged arc welding
(SAW) whenever possible. If SAW cannot be used, the alternative mainline processes listed
above may be utilised either alone or in combination with SAW.
The welding of pipelines by the oxy-acetylene process or by the flash butt welding process
(FBW) or by any other process not defined above is not permitted.
1.3 HSSE for pipeline welding operations
Welding, cutting, NDT, and associated operations shall be undertaken in a safe manner and with
due regard to individual health and safety and the minimisation of environmental impact.
Welding, cutting, NDT, activities and associated operations shall feature in the operational
safety planning and in the safety audit schedule.
During welding operations, adequate ventilation shall be provided and the quality of breathing
air shall be controlled.
Further information may be provided by government bodies such as the
Occupational Safety and Health Administration (OSHA) in the USA and the Health
and Safety Executive (HSE) in the UK. Detail of good practice related to safety
during welding, cutting, and associated operations can be found in AWS Z49.1 [1].
21 April 2006 GIS 43-331
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Radiography operations shall conform to local regulations regarding the dangers of ionizing
radiation, e.g. in the UK radiography should be undertaken in accordance with the Ionising
Radiation Regulations 1999 (SI 1999 No. 3232) and The Approved Code of Practice and
Guidance Working with Ionising Radiation: Ionising Regulations 1999.
Environmental guidance shall be taken from EN 14717 when undertaking welding and its
associated processes.
1.4 Pre-production consultation
Pre-production meetings shall be held with BP, the Contractor and any third-party inspection
personnel in order to ensure that all parties fully understand the specified requirements. These
meetings shall be held before welding procedure qualification testing and before
commencement of fabrication.
The BP Welding Engineer shall, as a minimum, be consulted at the following stages:
a. During bid evaluation to review the basic welding and NDT methods proposed and to
advise on acceptability.
b. Before weld procedure qualification for approval of the proposed welding procedures.
c. Before production welding for final WPS approval.
1.5 General duties of the contractor
Be responsible for quality assurance.
Be responsible for the compliance of sub-contractors with this GIS.
Unless advised otherwise by BP, supply necessary welding and associated equipment including,
but not limited to: heating equipment, fluxes, gases, filler metals, mechanical handling, and
testing equipment.
If NDT is conducted by the contractor, appropriate NDT equipment including consumables and
handling equipment shall be provided.
If NDT services and equipment are provided by sub-contractors, ensure that the equipment
provided is suitable, well maintained, and, if necessary, is calibrated.
1.6 Quality assurance
The quality assurance system shall comply with either ISO TS 29001 (API Q1) or ISO 9001.
A Quality Plan for the systematic control of construction, inspection, and testing shall be
prepared and implemented. The Quality Plan shall define inspections and tests, the sequence in
which they are to be performed during fabrication, and the level of involvement for the
contractors quality control/inspection personnel, third-party inspection personnel, and BP.
The Quality Plan shall be submitted to BP and approval obtained before commencement of
fabrication.
1.7 Records
Documentation shall be collated, indexed, stored safely, and presented to BP.
A log identifying, by number, each pipe or fitting and identifying the weld numbers joining
them to other items, shall be compiled. Each circumferential weld (whether a field joint or shop-
made weld) shall be allocated a unique number, which shall be used for reference to the weld in
reports, radiographs, and test documents.
21 April 2006 GIS 43-331
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1.8 Contractors personnel
1.8.1 Welding engineer
A competent and suitably qualified Welding Engineer shall be employed. The Welding
Engineer shall be responsible for the technical aspects of welding operations including the
following:
a. Selection of welding processes, equipment, and consumables
b. Preparation and qualification of welding procedures
c. Qualification of welders
d. Providing technical oversight of the production welding
e. Liaison with BP and the NDT sub-contractors
The minimum experience and qualification level for the Welding Engineer should be:
- In USA: Professional Engineer (PE) holding as a minimum a degree in engineering,
metallurgy or materials science and having specialised training in welding technology.
Membership of American Welding Society (AWS) is desirable and a minimum of 5 years
relevant experience in the pipeline welding or fabrication industry is essential.
- In Europe/Rest of the World: Chartered Engineer (CEng/ Dipl Ing) holding, as a minimum,
a degree in engineering, metallurgy or materials science and having specialised training in
welding technology. The requirements of 5.2.2, EN 719 should be met as demonstrated by
the European Welding Engineer (EWE) or International Welding Engineer (IWE)
qualification. Professional Membership of The Welding Institute (UK) is desirable and a
minimum of 5 years relevant experience in the pipeline welding or fabrication industry is
essential.
1.8.2 Welding inspectors
Competent and certificated welding inspection personnel shall be employed in sufficient
numbers to ensure that welding related activities are adequately inspected.
Welding Inspectors shall have a sound knowledge of welding processes and their application to
pipeline welding, and possess the knowledge and skills to carry out the tasks given in the
approved Quality Plan, including those necessary for the following:
- Conduct of routine inspections and checks on site or at suppliers in a systematic manner
- Production of accurate records and reports
Welding Inspectors shall hold current certification to any of the following standards as a
minimum:
- CSWIP (TWI, UK) Welding Inspector
- BGAS-CSWIP (TWI, UK) Welding Inspector
- PCN (BINDT, UK) Weld Inspection Level 2
- AWS QC1 (1996 or later edition) Certified Welding Inspector (CWI)
Alternative Welding Inspector certification is unacceptable unless approved by BP.
A Senior Welding Inspector shall be employed to coordinate and supervise the work of the
welding inspectors. The role of Senior Welding Inspector requires at least 10 years relevant
experience and sound knowledge of welding processes and their application. Formal
engineering training through apprenticeship and technical college education are required.
Senior Welding Inspectors shall hold current certification to any of the following standards as a
minimum:
21 April 2006 GIS 43-331
Page 10 of 56
- CSWIP (TWI, UK) Senior Welding Inspector
- BGAS-CSWIP (TWI, UK) Senior Welding Inspector (SWI) or Senior Pipeline Inspector
(SPI)
- PCN (BINDT, UK) Weld Inspection Level 3
- AWS QC1 (1996 or later edition) Senior Certified Welding Inspector (SCWI)
1.8.3 NDT personnel
NDT personnel shall hold current Level 2 certification (or equivalent), specific to weld testing,
for the appropriate NDT methods to any of the following standards as a minimum:
- CSWIP (TWI, UK)
- BGAS-CSWIP (TWI, UK)
- PCN (BINDT, UK)
- ACCP (ASNT)
- SNT-TC--1A (ASNT)
NDT personnel certificated to the requirements of a Written Practice under the rules of
SNT-TC-1A shall not be used, unless the Written Practice and the personnel certification has
been reviewed and accepted by BP for the specific work.
Personnel engaged in AUT shall be qualified in accordance with GP 43-34.
1.9 Abbreviations and acronyms
The following abbreviations and acronyms are used in this GIS:
ACCP ASNT Central Certification Program
AUT Automatic Ultrasonic Testing
BAM Federal Institute for Materials Research and Testing (Germany)
BGAS-CSWIP British Gas Approval Scheme Certification Scheme for Welding and Inspection
Personnel
BINDT British Institute of Non-Destructive Testing
CE
IIW
Carbon equivalent (IIW formula)
C Eng Chartered Engineer (UK)
CP Cathodic protection
CRA Corrosion resistant alloy
CSWIP Certification Scheme for Welding and Inspection Personnel
CTOD Crack tip opening displacement
CVN Charpy V-notch
Dipl Ing Diploma Ingenieur (Europe)
ECA Engineering Critical Assessment
21 April 2006 GIS 43-331
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FCAW Flux-cored arc welding
GMAW Gas-metal arc welding
GS-FCAW Gas-shielded flux-cored arc welding
GTAW Gas tungsten arc welding
HAZ Heat affected zone
HV Vickers hardness
ID Internal diameter
IIW International Institute of Welding
IQI Image Quality Indicator
MDT Minimum design temperature
MT Magnetic testing
MUT Manual ultrasonic testing
NDT Non-destructive testing
NIST National Institute of Standards and Technology (USA)
OD Outside diameter
P
CM
Cracking parameter (Ito-Bessyo formula)
PCN Personnel certification in non-destructive testing
P-GMAW Pulsed gas metal arc welding
PQR Procedure Qualification Record
PT Penetrant testing
pWPS Preliminary welding procedure specification
RMS Root mean squared
RT Radiographic testing
SAW Submerged arc welding
SCR Steel catenary riser
SMAW Shielded metal arc welding
SMYS Specified minimum yield strength
SS-FCAW Self-shielded flux-cored arc welding
SWE Single wall examination
21 April 2006 GIS 43-331
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SWV Single wall viewing
TWI The Welding Institute (UK)
UT Ultrasonic testing
VT Visual testing
WPQT Welding Procedure Qualification Test
WPS Welding procedure specification
2 Referenced publications
Add
The following standards contain requirements that, through reference in this text, constitute
requirements of this GIS. For references below that are dated, subsequent amendments to, or
revisions of, any of these publications do not apply, although parties to agreements based on this
GIS are encouraged to investigate the possibility of applying the most recent editions of the
standards indicated below. For references below that are undated, the latest edition of the
referenced standards applies.
API
Add
Q1 Specification for Quality Programs for the Petroleum, Petrochemical and
Natural Gas Industry
ASTM
Add
A370 Standard Test Methods and Definitions for Mechanical Testing of Steel
Products
E23 Standard Test Methods for Notched Bar Impact Testing of Metallic
Materials
E92 Standard Test Methods for Vickers Hardness of Metallic Materials
E1815 Standard Test Method for Classification of Film Systems for Industrial
Radiography
AWS
Add
D1.1/D1.1M Steel Structural Welding Code
A4.3 Determination of Hydrogen Content Produced by Arc Welding
C5.3 Recommended Practices for Air Carbon Arc Gouging and Cutting
A5.32 Specification for Welding Shielding Gases
BSI
Add
BS 4515-1 Specification for Welding of Steel Pipelines on Land and Offshore
Part 1: Carbon and Carbon Manganese Steel Pipelines
21 April 2006 GIS 43-331
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BS 7448-1 Fracture mechanics toughness tests. Part 1. Method for the determination
of K
IC
, critical CTOD and critical J values of metallic materials
BS 7910 Guide on methods for assessing the acceptability of flaws in metallic
structures
Add
BP
GIS 43-311 Guidance on Industry Standard for Manufacture of Longitudinal or
Helical Seam Submerged Arc Welded Linepipe in Grades up to X80
GIS 43-312 Guidance on Industry Standard for Manufacture of High Frequency
Induction (HFI) or Electric Resistance Welded (ERW) Linepipe in
Grades up to X70
GIS 43-313 Guidance on Industry Standard for Manufacture of Seamless Linepipe in
Grades up to X80
GIS 43-317 Guidance on Industry Standard for Bends, Fittings, Flanges, and Wyes
GP 18-02 Guidance on Practice for the Storage and Control of Welding
Consumables
GP 43-34 Guidance on Practice for Automatic Ultrasonic Testing of Pipeline Girth
Welds
Canadian Standards Association (CSA)
CSA Z245.1 Steel Line Pipe
CSA Z662 Oil and Gas Pipeline Systems
European Standard (EN)
EN 439 Welding consumables Shielding gases for arc welding and cutting
EN 719 Welding coordination. Tasks and responsibilities
EN 875 Destructive tests on welds in metallic materials - Impact tests - Test
specimen location, notch orientation and examination
EN 1011-2 Welding recommendations for welding of metallic materials Part 2: Arc
welding of ferritic steels
EN 10045-1 Charpy impact test on metallic materials - Part 1: Test method (V- and
U-notches)
EN 10204 Metallic products - Types of inspection documents
EN 10208-1 Steel pipes for pipelines for combustible fluids. Technical delivery
conditions. Pipes of requirement class A
EN 10208-2 Steel pipes for pipelines for combustible fluids. Technical delivery
conditions. Pipes of requirement class B
EN 14717 Welding and allied processes Environmental check list
International Organisation for Standardisation (ISO)
ISO 148 Steel - Charpy impact test (V-notch)
ISO 2504 Radiography of welds and viewing conditions for films - Utilization of
recommended patterns of image quality indicators (I.Q.I.)
ISO 3183 Petroleum and natural gas industries Steel pipe for pipeline
transportation systems
ISO 3690 Welding and allied processes - Determination of hydrogen content in
ferritic steel arc weld metal
21 April 2006 GIS 43-331
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ISO 5580 Non-destructive testing - Industrial radiographic illuminators - Minimum
requirements
ISO 6507-1 Metallic materials Vickers hardness test Part 1: Test method
ISO 9001 Quality management systems - Requirements
ISO 10005 Quality management Guidelines for quality plans
ISO 11699-1 Non-destructive testing - Industrial radiographic films Part 1:
Classification of film systems for industrial radiography
ISO 17636 Non-destructive testing of welds Radiographic testing of fusion-welded
joints
ISO 17638 Non-destructive testing of welds Magnetic particle testing
ISO 17640 Non destructive testing of welds Ultrasonic testing of welded joints
ISO TS 29001 Petroleum, petrochemical and natural gas industries - Sector-specific
quality management systems requirements for product and service supply
organizations
UK regulations
SI 1999 No. 3232 Ionising Radiation Regulations 1999 Statutory Instrument 1999 No. 3232
Work with ionising radiation - Ionising Radiations Regulations 1999
Approved code of practice and guidance (UK HSE)
3 Definitions of terms
3.2 Definitions
3.2.3 Company
Modify to Read
BP plc or its authorised representative
3.2.4 Contractor
Modify to Read
A contractor responsible to BP for construction (including welding) of the pipeline
Add
3.2.21 Arc Energy
The unfactored energy input calculated from the current, voltage and travel speed.
Note: Heat input requires an efficiency factor dependant on the
welding process.
3.2.22 BP
BP plc, an associate or subsidiary of BP, or other organisation as defined in the Conditions of
Contract on a project.
3.2.23 Lot
A single heat of filler wire, a single blend of flux, or for covered electrodes or cored wire, the
combination of a single heat of cored wire with a single dry blend of flux cover or core.
21 April 2006 GIS 43-331
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3.2.24 Quality Plan
Document specifying which procedures and associated resources shall be applied by whom and
when to a specific project, product, process or contract.
Note: Guidance for the production of Quality Plans is given in
ISO 10005.
4 Specifications
4.1 Equipment
Add
Welding power supply voltage and amperage meters shall be calibrated. Independent calibrated
instrumentation shall be provided to measure relevant parameters during production. NDT
equipment shall also be calibrated. Certificates showing that equipment calibration is valid for
the period of use shall be available.
The manufacturer, model and type of equipment shall be identified in the Procedure
Qualification Record (PQR).
SMAW electrode holders shall be fully insulated.
Welding return cables connections shall be of sufficient cross-sectional area to prevent
concentration of current and shall be securely attached to prevent arc burns.
4.2 Materials
4.2.1 Pipe and fittings
Add
c. ISO 3183
d. EN 10208
e. CSA Z245.1
The requirements given apply to materials that comply with any of the standard specifications
listed in a & b (in API 1104) and c to e above. Note that API 5L is supplemented by BP GISs
and that BP supplementary requirements may be applied to any of the above specifications.
Other material specifications may be used if required by statutory regulations of the countries in
which the pipeline will operate.
4.2.2 Filler metal
4.2.2.1 Type and size
Add
In principle, the yield strength of the weld metal should be selected to ensure that the yield
strength of the deposited pipeline girth welds overmatches the actual yield strength of the parent
pipe material. Additional guidance will be provided by the pipeline designer. The deposited
weld metal shall also meet the specified ductility, toughness, and limiting hardness criteria in
accordance with the pipeline design and with this GIS.
Add
4.2.2.1.1 Limitations of use for cellulosic electrodes
Cellulosic coated electrodes shall not be used for:
21 April 2006 GIS 43-331
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- Pipe grades and thicknesses beyond those shown in Table A
- Pipelines subject to high strain (e.g. reeled pipelines)
- Strain based design pipelines
- The welding of fittings, flanges and valves
- Fillet welding (e.g. for anode doubler plate attachment)
In applications in which cellulosic SMAW consumables are being evaluated for use, the
possibility of employing low hydrogen vertical down electrodes shall be considered.
Cellulosic electrodes shall neither be baked nor dried and shall be used straight from the original
packaging.
Table A - Grade and thickness limits for cellulosic electrodes
4.2.2.1.2 Consumable selection for root welding
In some instances it may be necessary to select a root welding consumable having a specific
chemical analysis in order to provide resistance to preferential weld metal corrosion. The
pipeline designer will provide advice on any such requirement. If a weld metal composition is
specified, then one root weld metal chemical analysis shall be conducted for each WPS and each
weld repair procedure to check that the required composition has been achieved.
4.2.2.2 Storage and handling of filler metals and fluxes
Add
The storage and handling of welding consumables shall be in accordance with GP 18-02. A
detailed consumable storage and handling plan shall be submitted for BP review and approval.
Add
4.2.2.3 Consumable lot testing by supplier*
*Note: Some standards, project specifications and/or consumable
suppliers may refer to Consumable Batch Testing.
Each lot of welding consumables shall have a consumable manufacturers certificate
conforming to the relevant ISO, AWS or EN filler metal specification. The testing of each lot
shall include actual deposited weld metal chemical composition, tensile and Charpy impact
tests; refer to BP GP 18-02.
Pipe Grade
(API 5L)
Pipe Grade
(ISO 3183)
(EN 10208)
(CSA Z.245)
Maximum Wall Thickness
(a,b)
<X65 <L450 3/4 (approx 19 mm)
X70 L485 5/8 (approx 16 mm) with E8010 fill passes
3/8 (approx 10 mm) with E9010 fill passes
X80 L555 Root & hot pass only
>X80 >L555 Not permitted
a. E6010 or E6011 electrodes may be used for root pass welding provided sufficient overall weld strength and
toughness is obtained.
b. Preheat shall be applied to cellulosic welds (see 5.3.2.13 and 7.11.1).
21 April 2006 GIS 43-331
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For low hydrogen SMAW consumables, manufacturers certificates shall include average-
diffusible-hydrogen level as determined and reported in accordance with ISO 3690 or
ANSI/AWS A4.3.
Certificates shall comply with BP GP 18-02 and EN 10204 type 3.1.b.
SAW wire shall be tested in combination with the same brand and classification of flux as that
to be used during production welding.
The consumable certificates shall be examined to verify that the same weld properties can be
expected for the production welds as those obtained during weld procedure testing.
4.2.2.4 Additional lot testing
Only the lots of consumables mechanically tested during qualification of the weld procedure
shall be used for production welding of the following pipeline types:
- If the NDT acceptance criterion has been established by an ECA
- For pipe grades of X65 and above
- If consumables with an AWS G designation are used, e.g. E8010-G or ER70S-G
Testing may be conducted to gain approval for additional lots of consumables. Testing shall be
undertaken on a weld made in accordance with the production WPS and shall include:
- 2 all-weld tensile tests
- 2 sets of weld metal Charpy impact tests
- 1 macro-section and hardness survey sampled from the 3 oclock position
- 1 set of weld metal CTOD tests
The testing shall be in accordance with 5.6. The results shall meet the levels required for the
relevant weld procedure(s) and, if applicable, the ECA.
4.2.3 Shielding gases
Add
4.2.3.3 Compliance
Shielding gases shall meet BS EN 439 or AWS A5.32. They shall be pre-mixed and bottled by
the supplier and shall have certificates of compliance. The certificates shall show the
composition and dew point. Subject to BP approval, Ar/CO
2
gases may be mixed at site.
Add
4.3 Minimum design temperature (MDT)
Unless otherwise specified in the contract, the MDT shall be 0C (32F).
5 Qualification of welding procedures for welds containing filler-metal
additives
5.1 Procedure qualification
Add
5.1.1 General
Preliminary Welding Procedure Specifications (pWPSs) shall be submitted for BP agreement
before commencement of the Welding Procedure Qualification Tests (WPQTs).
21 April 2006 GIS 43-331
Page 18 of 56
Welding procedures, including fillet welds and repair procedures, shall be qualified by visual
examination, NDT, and mechanical testing as specified in this GIS.
Welding, NDT and mechanical testing of the WPQT welds shall be witnessed by BP or an
approved third party. The witnessing of mechanical tests shall include the positioning of the
notches for Charpy and CTOD tests.
A WPS written with more than one supporting Procedure Qualification Record (PQR) shall not
permit optional processes, but shall uniquely specify the process for each pass.
5.1.2 Welding procedure parameters
During weld procedure qualification, relevant procedure data, irrespective of whether the item is
a listed essential variable, shall be captured and recorded. Sufficient information shall be
recorded to allow full replication of the procedure qualification welds. A record of the data shall
be kept for the purpose of aiding production and to assist with the diagnosis of problems, but
need not be formally entered on to the PQR, e.g. GMAW machine slope-in settings.
The methods of measuring the welding parameters and the records to be kept shall be agreed
with the BP Welding Engineer.
Following qualification, the pWPS shall be revised to reflect the parameters recorded during
qualification. The revised WPS values for current, voltage, and travel speed for each pass shall
be either:
(i) within the range recorded during WPQT. Transient or anomalous values shall not be used
to establish the range, or
(ii) the mean value +/10%.
The arc energy shall be calculated using the recorded values of current, voltage, and travel
speed without the addition of a percentage.
The final WPS shall state parameters for each pass. However, if fill passes (i.e. passes other than
root, hot pass, and cap) have similar values, the parameters may be combined on the WPS.
If a welding consumable or group of consumables is qualified to weld several different
components or pipe sizes, every effort should be made to ensure that the parameters specified on
the individual WPSs are common across the group of WPSs.
5.2 Record
Modify First Sentence to Read
The details of each procedure shall be recorded
Add
Forms used to record WPS and WPQT details shall contain the relevant information. The format
shall be subject to approval by BP.
The PQR documentation package for each WPS shall comprise:
a. As-run records
b. NDT results
c. Mechanical test results and macrographs
d. Consumable certification
e. Parent material certification
The following data shall also be available if requested by the BP Welding Engineer:
f. Calibration certificates for equipment and measuring devices
21 April 2006 GIS 43-331
Page 19 of 56
g. SNT (ASNT) Written Practice (if applicable)
h. Welding Inspector and NDT personnel certification
i. NDT procedure qualification records
j. Testhouse approval certification
The approved WPSs and PQR packages shall also be available in a good quality electronic
format.
5.3 Procedure specification
5.3.1 General
Add
The relevant BP approved WPSs shall be displayed at each work location and shall be readily
available to each welder.
5.3.2 Specification information
5.3.2.2. Pipe and fitting materials
Modify to Read
Pipe, valves, flanges, and fittings from different manufacturers, or manufactured from materials
supplied from different sources or in different supply conditions, shall require separate
procedure qualification as detailed in 5.4.2.2, unless a material grouping is approved by BP. The
manufacturer(s) shall be noted on the WPS.
5.3.2.3 Diameters and wall thicknesses
Modify to Read
The ranges of pipe diameters and wall thicknesses over which the procedure is approved are
identified in Table B unless alternative ranges are agreed by BP.
Table B - Diameter and test pipe thickness range of approval
5.3.2.4 Joint design
Add
The use of permanent or consumable backing rings is not permitted. An exception is the outer
pipe welds in a pipe-in-pipe system. Non-consumable temporary backing as an integral
permanent feature on an internal clamp will be permitted subject to satisfactory demonstration
of the process.
Test Pipe Diameter Range of Approval
(in) (mm) (in) (mm)
D <2.375 D <60.3 <2.375 <60.3
2.375 <D <12.75 60.3 <D <323.9 2.375 to 12.75 60.3 to 323.9
12.75 <D <24.0 323.9 <D <610 12.75 to 24.0 323.9 to 610
D >24.0 D >610 >24.0 >610
Test pipe thickness =t 0.75t to 1.5t
21 April 2006 GIS 43-331
Page 20 of 56
5.3.2.5 Filler metal and number of beads
Add
The brand name, electrode or wire name, designation and ISO/AWS/EN welding consumable
classification shall be stated in the PQR.
5.3.2.6 Electrical characteristics
Add
The following parameters shall be specified on WPSs:
a. Welding current (including pulse rate, pulse shape or dwell time, and max/min current for
pulsed welding procedures)
b. Diameter of electrodes or welding wires
c. Wire-feed speed (and pulse rate or frequency for pulsed wire procedures)
d. Arc energy for each pass. For multiple (electrically isolated) tandem electrode welding
processes, e.g. SAW or P-GMAW, the effective arc energy per pass shall be calculated as
the sum of the individual arc energies for each electrode. For pulsed procedures, the
effective arc energy shall be calculated on the basis of RMS values. Voltage and current
shall be determined with calibrated meters and recorded for each pass during WPQT
welding using suitable BP approved data monitoring equipment.
If applicable, the following parameters shall be specified in the WPS:
e. Type, diameter and angle of tip for GTAW tungsten electrodes
f. Hot wire diameter, feed speed, current, and voltage
g. Head angle, electrode spacing from top-dead centre and direction of rotation for 1G-rotated
welding
h. Contact tip to workpiece distance
i. Electrode spacing and individual angles relative to pipe surface (for welding with multiple
electrodes)
j. Torch separation and angle for multiple torch welding
k. Torch oscillation frequency for mechanised (automatic) welding
l Shroud (gas-cup) diameter
The welding unit, power supply type, manufacturer, model number, and software version
number shall be stated for automatic, mechanised, or semi-automatic welding procedures.
5.3.2.8 Position
Add
The welding position shall be stated on the WPS and PQR documents.
5.3.2.10 Time between passes
Add
The time between completion of the root bead and commencement of deposition of the hot-pass
shall be not greater than that qualified in the WPQT and should not be greater than 10 minutes.
If cellulosic welding is used, the second run (hot-pass) shall be deposited immediately after
completion of the root bead.
SAW GMAW FCAW
fcaw gmaw SAW
FCAW GMAW saw
21 April 2006 GIS 43-331
Page 21 of 56
5.3.2.11 Type and removal of line-up clamp
Add
For pipe-to-pipe joints over 150 mm (6 in) diameter, an internal line-up clamp should be used. If
it is agreed by BP that this is impracticable, e.g. for tie-ins, an external line-up clamp shall be
used.
If an internal line-up clamp is used, the root run shall be 100% complete before the clamp is
removed. If an external line-up clamp is used, the root run shall be at least 50% complete before
the clamp is removed. In either case, the pipes on both side of the joint shall not be raised,
lowered or otherwise moved until both the root and the second weld pass (hot pass) have been
completed, unless it can be demonstrated to the satisfaction of BP that the root run alone is
adequate to resist the deformation. For SMAW welding using cellulosic coated electrodes, the
hot pass shall always be completed before the pipe is moved.
5.3.2.13 Pre- and post-heat treatment
Add
As a minimum, a preheat temperature shall be selected to ensure that:
a. The pipe is dry before welding
b. The metal temperature is greater than 30C (86F)
c. The metal temperature is greater than 50C (122F) if moisture is present on the pipe
and/or if ambient temperatures are below 5C (41C)
d. The hardness requirements of 5.6.8.3 are met for the weld metal and HAZ
e. The weld metal is not at risk of hydrogen cracking (for cellulosic welds see Table C for
guidance on minimum preheat levels)
f. Sufficient heat is present to prevent cold (hydrogen) cracking in the HAZ
Note: Guidance for the avoidance of HAZ cracking is given in
EN 1011-2, AWS D1.1/D1.1M Annex XI, and BS 4515-1
Annex E.
Table C - Minimum preheat levels for SMAW (cellulosic) welds
The preheat temperature shall not be lower than that recorded during WPQT welding.
The interpass temperature shall not be less than the preheat temperature and shall not exceed the
highest value recorded during WPQT. In no case shall the interpass temperature exceed 300C
(572F).
The preheat and interpass temperatures shall be measured in accordance with 7.11.1.
Filler Grade
(AWS Designation)
Wall Thickness Minimum Preheat
Temperature
(in) (mm) (F) (C)
<0.4 <10 122 50
0.4 <0.6 10 <15 167 75 E6010
>0.6 <0.8 >15 <20 212 100
<0.4 <10 176 80
0.4 <0.6 10 <15 212 100
E7010
&
E8010
>0.6 <0.8 >15 <20 248 120
E9010 <0.4 <10 212 100
21 April 2006 GIS 43-331
Page 22 of 56
If any form of post-weld heat treatment or delayed cooling of the weld is to be used, it shall be
specified in the WPS.
If the weld is to be cooled rapidly to allow immediate AUT, then this shall be simulated during
WPQT. Assisted cooling shall not commence until the weld temperature has cooled without
interference to below 400C (750F).
5.3.2.14 Shielding gases and flow rate
Modify to Read
Shielding gas type, composition, and flow rate (for each torch in multi-torch systems) shall be
specified in the WPS.
Add
5.3.2.17 Bead map
A sketch of the weld cross-section showing the bead sequence shall be made for each WPS.
If bead deposition is by a weaving technique, this shall be designated on the WPS.
Low hydrogen SMAW electrodes shall not be weaved by more than 3 times the nominal
electrode core wire diameter.
5.3.2.18 Period of validity for welding procedures
For new pipeline construction projects, new WPSs shall be prepared and qualified.
For the purposes of undertaking further work to an existing pipeline, a WPS may remain valid
indefinitely. The BP Welding Engineer shall be consulted before re-using the WPS.
5.4 Essential variables
5.4.1 General
Add
An approval of a WPS obtained by a contractor is valid in workshops or sites of that contractor
under identical or equivalent technical and quality control. The validity shall be subject to the
approval of the BP Welding Engineer. Welding procedures shall not be transferred from one
contractor or sub-contractor to another without requalification.
5.4.2 Changes requiring requalification
5.4.2.1 Welding process or method of application
Add
Any change from a single torch per motorised head to multiple torches, or vice-versa, shall
constitute an essential variable.
Any change of wire delivery system for SAW or mechanised (automatic) GMAW/ GTAW,
including from single to double or multiple wires and/or from cold to hot-wire systems, or vice
versa, shall constitute an essential variable.
Add
5.4.2.1.1 Line-up clamp
A change from internal to external line up clamp, or vice-versa; or, from internal clamp without
an internal welder to an internal clamp incorporating an internal welder, shall constitute an
essential variable.
21 April 2006 GIS 43-331
Page 23 of 56
Removal of a line-up clamp at an earlier stage than qualified in the WPQT constitutes an
essential variable.
5.4.2.1.2 Weld or joint backing
Use or removal of copper backing rings or shoes, or combination of these, shall be considered
an essential variable.
5.4.2.1.3 Number of welders or welding operators
The number of welders shall be at least as many as during welding of the test piece and shall be
considered as an essential variable for each pass.
5.4.2.1.4 Interpass cleaning
The method of interpass cleaning shall be considered an essential variable.
5.4.2.2 Base material
Modify to Read
Base material grouping by strength shall only be allowed for materials with an SMYS less than
or equal to 42,000 psi (290 MPa); but, for all grades of material, the following shall constitute
essential variables:
a. Change of manufacturing facility for strip, billet, plate, pipe or forging
b. Change of steel making, plate rolling, forging or pipe manufacturing process
c. For grades up to and including X80, a change of composition resulting in a change of
greater than 0.03CE
IIW
or greater than 0.02P
cm
value. For sour service pipelines, a
change in composition resulting in greater than +0.01 or 0.03CE
IIW
or greater than +0.01
or 0.02P
cm
value.
15 5 6
Cu Ni V Mo Cr Mn
C CE
IIW
+
+
+ +
+ + =
B
V Mo Ni Cr Cu Mn Si
C P
cm
5
10 15 60 20 30
+ + + +
+ +
+ + =
d. For grades above X80, composition limits will be advised on a project by project basis.
5.4.2.3 Joint design
Add
For narrow gap welding, e.g. mechanised (automatic) GMAW, any change in bevel angle
beyond 1, root face beyond 50% or root gap +0.5 mm (0.02 in) constitutes an essential
variable. Any weld preparation with an included angle of less than 20 shall be considered to be
narrow gap welding.
For other welding, any changes in bevel angle by more than 5, or variation in root gap/root
face by more than 50%, constitutes an essential variable.
Note: For pipe grades above X80 (L555), it may be necessary to
impose more stringent limits on the joint design for
mechanised (automatic) welding than those quoted above
as minor changes can result in significant differences in
mechanical properties of the girth welds.
21 April 2006 GIS 43-331
Page 24 of 56
5.4.2.4 Position
Add
A change of welding position shall constitute an essential variable. Welding positions 5G and
2G shall be qualified separately. 6G qualification shall be required if the angle of the pipe is
between 25 and 65 to the horizontal.
5.4.2.5 Wall thickness
Modify to Read
Any change outwith the grouping ranges of pipe by diameter and wall thickness designated in
5.3.2.3, shall constitute an essential variable.
5.4.2.6 Filler metal
Modify to Read
The following changes in filler metal constitute essential variables:
a. Any change in filler metal designation, filler metal manufacturer, manufacturing location
or brand name
b. Any change in welding consumable or size
c. Lot testing as per 4.2.2.3 is required
The compatibility of the base material and the filler metal should be considered from the
standpoint of mechanical properties.
5.4.2.7 Electrical characteristics
Add
Any change in the following shall be considered essential variables:
a. The welding current, arc voltage and travel speed outside that recorded on the WPS
b. For pulsed current welding the pulse rate, pulse shape, and max/min current recorded on
the WPS
c. For GMAW, cored wire welding and hot wire GTAW any change of wire feed speed
outwith the range qualified
d. Arc energy for each pass outside of the range recorded on the WPS
e. Head angle, electrode spacing from top dead centre and direction of rotation for 1G-
Rotated welding
f. Electrode spacing for welding procedures utilising multiple electrodes, e.g. tandem-wire
SAW, or mechanised (automatic) tandem wire or twin torch processes
g. Diameter of electrodes or welding wires
h. For semi-automatic and mechanised (automatic) welding, the welding unit, power supply
type, manufacturer, model number and software version number
5.4.2.8 Time between passes
Add
If using cellulosic electrodes, the time lapse between the start of the root bead and the start of
the second bead shall not exceed the time lapse recorded during welding of the test piece.
21 April 2006 GIS 43-331
Page 25 of 56
5.4.2.10 Shielding gas and flow rate
Add
Any change of shielding gas flow rate greater than 15% of that qualified shall constitute an
essential variable.
5.4.2.11 Shielding flux
Add
For pipeline grades greater than X52, any change of shielding flux manufacturer, manufacturing
location, brand or type constitutes an essential variable. Any change of flux for pipeline grades
X52 and below shall be subject to the agreement of the BP Welding Engineer.
5.4.2.12 Speed of travel
Add
A change in speed of travel beyond the range on the qualified WPS constitutes an essential
variable.
5.4.2.13 Preheat
Add
Any change in the preheat application method shall constitute an essential variable.
Add
5.4.2.15 Arc energy per pass
Any change in arc energy outside of the range in the approved WPS shall constitute an essential
variable.
5.4.2.16 Interpass temperature
An increase in the specified interpass temperature shall constitute an essential variable. The use
of rapid cooling of welds constitutes an essential variable unless simulated in the WPQT.
5.5 Welding of test jointbutt welds
Add
5.5.1 Test pipe for WPQT
The WPQT shall simulate the production welding of the pipelines and shall be undertaken as far
as practicable, under site ambient conditions. For land pipelines, lifting and lowering off shall
be simulated using full pipe lengths.
If an internal line-up clamp will be used in production welding, the length of the nipples used in
the WPQT shall be sufficient to accommodate the full length of the clamp. The minimum length
of any nipple piece used during qualification should be 1 m (3.3 ft) or 1.5 pipe diameters
whichever is the greater.
The minimum length of test rings for the WPQT of fittings and flanges shall be subject to
agreement with BP.
21 April 2006 GIS 43-331
Page 26 of 56
5.6 Testing of welded jointsbutt welds
5.6.1 Preparation
Add
Reference Figure 3 and Table 2, in accordance with this GIS
The blanks from which the mechanical test pieces are machined may be cut from the
qualification weld using oxy-fuel gas cutting, but its dimensions shall be sufficient to allow the
material of the final machined test piece to remain unaffected by the heat from the cutting
operation.
Test specimens shall not be subjected to any elevated temperature degassing treatment.
Add
5.6.1.1 Non-destructive testing of WPQT welds
WPQT welds shall be visually examined (VT) as soon as possible after completion of welding
with 100% coverage of weld surfaces. WPQT welds shall meet the same requirements for weld
profiles and VT as those specified for production welds.
The full circumference of WPQT welds shall be examined by radiographic testing (RT),
ultrasonic testing (AUT or MUT), and magnetic particle testing (MT). For WPQT welds, there
shall be a minimum delay time as specified in Table D between completion of welding and non-
destructive testing of the welds.
Table D - Specified minimum delay time before NDT for WPQT welds
Acceptance by BP shall be required before sectioning of WPQT welds for mechanical testing.
The NDT procedures for WPQT welds shall be qualified and subject to approval by BP.
5.6.1.2 Mechanical testing
Mechanical testing shall be performed by a certified testing laboratory approved by BP.
Test specimens shall be taken from pipeline WPQT butt welds as shown in Figure 3. Repair
weld mechanical testing locations and specimen types/ numbers shall be in accordance with
Table H. Test specimens not shown in Figure 3, e.g. CTOD test pieces, may be taken from any
position around the weld where spare material is available, but the exact locations should be
agreed in each instance with the BP Welding Engineer. More than one weld may be required to
provide sufficient material for testing. Table 2 shows the type and number of test specimens
required.
5.6.1.3 Test temperature
Destructive testing shall be performed at ambient temperature, except for impact testing (see
5.6.6.3) or CTOD testing (see 5.6.10).
For design service temperatures above 100C (212F), elevated temperature transverse and weld
tensile testing shall be undertaken. The test temperature, extent of testing and required strengths
shall be specified on a project specific basis.
WPQT Welds in API/ISO Pipe Grades Welding Process Minimum Delay Before NDT
<API X70 / ISO L485 Any process except cellulosic SMAW 24 hours
<API X70 / ISO L485 Cellulosic SMAW
a
48 hours
>API X70 / ISO L485 Any welding process 72 hours
a
Welds made with cellulosic root/hot pass only may be inspected after 24 hours.
21 April 2006 GIS 43-331
Page 27 of 56
5.6.1.4 Repair of WPQT welds
Weld repairs to WPQT welds are not permitted, except if the purpose is to qualify a repair
procedure.
5.6.2 Tensile-strength test
5.6.2.1 Preparation
Add
Preparation of the tensile test piece shall be as per Figure 4, except that internal and external
weld reinforcement shall be removed before testing.
The position of failure shall be recorded, i.e. weld metal, HAZ or base metal.
21 April 2006 GIS 43-331
Page 28 of 56
Modify Figure 3 to Show
Figure 3 - Location of test pieces from a butt weld in pipe
> 114.2mm (4.500)
but < 323.9mm (12.750)
3
1
3
4
4
2
2
6
1
5
5
6
5
3
1
3
4
4
2
2
6
1
5
5
6
5

1
1
1
1
3
2 2
3
3
3
2
4
4
4
4
2
5
5
5
6
6
1
1
1
1
3
2 2
3
3
3
2
4
4
4
4
2
5
5
5
6
6
Key:
1) Face or side bend
2) Transverse tensile
3) Root or side bend
4) Nick-break
5) Macrosection
6) Charpy V-Notch
Greater than 323.9mm (12.75)

NOTE: Test specimens not shown in Figure-3, e.g. CTOD test pieces, may be taken from any position around the weld where
spare material is available. More than one weld may be required to provide sufficient material for testing.
< 60.3mm (2.375)
4
3
2
2
6
5
5
5
> 60.3mm (2.375) but
< to 114.3mm (4.500)
Also, < 114.3mm (4.500) when
wall thickness > 12.7mm (0.500)
2
3
3
4
4
2
5
6
5
5
2
3
3
4
4
2
5
6
5
5
21 April 2006 GIS 43-331
Page 29 of 56
Modify Table 2 to Read
Table 2 - Type and number of test specimens (a) for procedure qualification test
Number of Specimens for Wall Thickness 12.7 mm (0.500 in)
OD of Pipe
mm (in)
Tensile
Strength
(Cross
Weld
Tensile)
All-Weld
Metal
Tensile
(c)
Nick
Break
(d)
Root
Bend
Face
Bend
Side
Bend
Charpy
Impact
Tests
(set of 3)
(e)
Macro/
HV10
CTOD
(set of 3 )
(f & g)
<60.3 (<2.375) (b) 2 0 2 2 0 0 0 3 3
60.3-114.3 (2.375-
4.500)
2 0 2 2 0 0 2 3 3
>114.3-323.9
(4.500-12.750)
2 1 2 2 2 0 4 3 3
>323.9 (>12.750) 4 1 4 4 4 0 4 3 3

Number of Specimens for Wall Thickness > 12.7 mm (0.500 in)
OD of Pipe
mm (in)
Tensile
Strength
(Cross
Weld
Tensile)
All-Weld
Metal
Tensile
(c)
Nick
Break
(d)
Root
Bend
Face
Bend
Side
Bend
Charpy
Impact
Tests
(set of 3)
(e)
Macro/
HV10
CTOD
(set of 3)
(f & g)
<114.3
(4.500)
2 1 2 0 0 2 2 3 3
>114.3-323.9
(>4.500-12.750)
2 1 2 0 0 4 4 3 3
>323.9 (>12.750) 4 1 4 0 0 8 4 3 3

NOTES:
a Specimen locations shall be in accordance with 5.6 and Figure 3.
b One nick-break and one root-bend specimen shall be taken from each of two test welds, or for pipe less than or equal to 34 mm
(1.315 in) diameter, two full section tensile strength specimens shall be taken.
c If an ECA is to be used for defect acceptance levels, three all-weld metal tensile specimens shall be taken.
d. Nick breaks are not required for mechanised (automatic) welding.
e Charpy impact tests shall comprise weld metal and fusion line specimens machined from the pipe outside diameter. Pipes with
wall thickness > 20 mm shall have additional specimens machined from the ID .Additional sets of Charpy Impact specimens may
be required by the BP welding engineer, e.g. if very thick pipe is to be utilised or the combination of processes or consumables
have not been adequately sampled by the specified locations.
f CTOD tests shall comprise a minimum of one set of weld metal and two sets of HAZ samples (see paragraph D.4 of
Appendix D).
g CTOD tests are only required for pipelines with ECA based acceptance criteria or if required by the pipeline designer.
5.6.2.3 Requirements
Modify to Read
The results of transverse weld tensile tests shall meet or exceed the specified requirements for
the pipe (base metal) with respect to specified tensile strength. Transverse weld tensile
specimens shall fail at a location within the HAZ or base metal.
If base metals of different strength levels are used, then acceptance criteria shall be based on the
lower strength base metal.
21 April 2006 GIS 43-331
Page 30 of 56
Add
5.6.6 Charpy V notch testing
5.6.6.1 Scope
WPQT butt welds shall be subjected to Charpy V notch impact testing.
5.6.6.2 Preparation
The test pieces shall be prepared and tested in accordance with ISO 148, EN 10045-1 and
EN 875 or ASTM A370 and E23.
A set of Charpy impacts shall comprise three specimens. Sets of Charpy specimens shall be
taken from the locations shown in Figure 3.
Specimens shall be notched with the axis of the notch perpendicular to the pipe surface. The
position of the notch for each set shall be as depicted in Figure A.
Full size specimens shall be used if possible.
5.6.6.3 Method
The impact test temperature shall be the minimum design temperature when the following
conditions apply:
- The minimum design temperature is minus 10C (14F) or higher
- The wall thickness is 25 mm (1 in) or lower
- The material SMYS is 555 N/mm
2
(80 ksi) or lower
In addition to the above, for gas pipelines the impact test temperature shall be no higher than
minus 10C (14F).
Test temperatures for welds outside of the above conditions shall be advised by BP.
Figure A - Charpy V notch locations

A(i) Weld Centreline
A(ii) Fusion Line
21 April 2006 GIS 43-331
Page 31 of 56
The Charpy impact values shall meet or exceed the values given in Table E.
Table E - Charpy impact test requirements

For specimens below 10 mm in thickness, the energy requirement shall be reduced pro rata, e.g.
a 7.5 mm specimen shall achieve 75% of the required full size value.
The ductile shear area shall exceed 50%.
Individual samples may be replaced if there is evidence of a weld defect on the fracture surface.
Re-testing may be allowed following discussion with the BP Welding Engineer.
Test results, including percentage ductile shear area, shall be recorded.
5.6.7 Macro-section
5.6.7.1 Method
Macro-sections shall be extracted from procedure qualification test welds at three locations
approximately 90 apart. For welds containing any pass made in the 5G position, macro-
sections shall be extracted as close as practicable to the 12 oclock, 3 oclock and 6 oclock
positions.
When girth welding seam-welded linepipe, an additional macro-section shall be extracted from
the girth-weld at the T-intersection region between the girth weld and seam weld.
Macro-sections shall be polished to a metallographic (1 m) finish and etched in a 2-10% Nital
solution, or other suitable BP approved etchant. The etched specimens shall be thoroughly
examined at 10 times magnification.
Original photo-macrographs of macro-sections at approximately 3 to 5 times magnification shall
be included in the PQR documentation.
5.6.7.2 Acceptance criteria
When examined at 10 times magnification, the macro-section shall reveal:
a. No cracks
b. Complete fusion between adjacent layers of weld metal and between weld metal and base
metal
c. Complete fusion at the root
d. No lack of cross penetration
e. No undercut (unless weld surfaces are to be ground smooth). If weld surfaces are to be
ground smooth, minor undercut may be removed by the surface grinding operation. If the
NOTES:
1 Specimens shall be positioned between 1 2 mm from the pipe outer surface. Additional specimens for thicknesses greater than
20 mm shall be positioned within 1 2 mm from the inner surface.
2 Fusion line Charpy specimens shall sample 50% weld metal and 50% HAZ.
Grade Minimum Average Energy Minimum Individual Energy
ft lbs J ft lbs J
<X80 <L555 37 50 30 40
X80 L555 44 60 33 45
>X80 >L555 To be advised
21 April 2006 GIS 43-331
Page 32 of 56
undercut is of such depth that its removal would result in encroachment of the minimum
specified thickness of the pipe, it shall be deemed unacceptable.
f. No excess cap reinforcement exceeding 1.6 mm (1/16 in) above the base metal surfaces for
weld surfaces not specified to be ground smooth
g. Weld reinforcement shall blend smoothly into the adjacent base metal
h. No penetration of the root bead into the bore exceeding 3 mm (1/8 in). For pipe diameters
less than 60 mm (2-3/8 in) this penetration shall not exceed 1.5 mm (1/16 in).
i. At no point shall the weld surface, ID or OD, lie below the adjacent base metal
Any observed defects shall be within the limits given in Section 9.
5.6.8 Hardness test
5.6.8.1 Preparation
The hardness testing technique shall be the Vickers method with an applied load of 10 kg in
accordance with ISO 6507-1 or ASTM E92.
The hardness surveys shall be undertaken on each of the macro-section specimens specified in
5.6.7. For non-sour pipelines, surveys on the 12 oclock and 6 oclock macro-sections may be
omitted.
5.6.8.2 Method
Each survey shall consist of three rows of indents. One traverse shall be located below the cap,
one above the root (or internal surface) and one at mid-thickness. The positions are shown in
Figure B. The mid-thickness traverse may be waived for single sided welds below 12.7 mm.
The BP Welding Engineer may require additional hardness indent positions, e.g. if a
consumable type has not been sampled by the specified three traverses.
Figure B - Locations for hardness indents
t/2
1 - 2mm
1 - 2mm
t/2
1 - 2mm
1 - 2mm

The macrophotographs shall show the position of each hardness indent and shall be included in
the PQR along with a tabulation or diagram showing the result and location of each indent. The
maximum and minimum values shall be identified.
The individual hardness values shall not exceed the values given in Table F.
NOTES:
1. Parent material indentations shall be at least 20 mm from the fusion line.
2. The first HAZ indentation shall be placed as close to the fusion line as possible. Further indentations into the HAZ shall
be separated by approximately 0.5 mm, however the minimum centre-to-centre separation requirement of 2.5 or 3 times
the mean diagonal of the nearest indentation shall be maintained (ref. ISO 6507-1 and ASTM E92).
3. The same survey pattern shall be applied to double-sided welds.
21 April 2006 GIS 43-331
Page 33 of 56
The parent material hardness values shall not exceed the values permitted in the relevant
material specification.
Table F - Maximum permissible weld and HAZ hardness values (HV10)
5.6.9 Weld metal tensile test (all-weld metal tensile test)
Weld metal tensile test specimens shall be in accordance with ASTM A370. For narrow gap
welds in which the width of the weld bead is insufficient to permit a conventional all-weld metal
tensile test piece to be prepared, the geometry of the test piece shall be agreed with BP. The
longitudinal axis of the tensile test specimen shall coincide with the procedure qualification test-
weld axis. The tensile specimen shall be prepared by machining, and its size and location shall
be such that the gauge length consists only of weld metal.
The weld metal yield strength shall not be less than the SMYS of the pipe. Weld metal
overmatching of the typical pipe yield strength is considered desirable. The weld metal strength,
in relation to the actual pipe yield strengths, shall be considered if an ECA is used or the
pipeline design requires this.
5.6.10 CTOD testing
Requirements concerning CTOD testing can be found in Appendix D.
5.7 Welding of test jointsfillet welds
Add
The tests specified in 5.8 do not provide comprehensive information on the mechanical
properties of the joint. If mechanical properties are relevant to the application, then an additional
qualification shall be made, e.g. a butt weld.
5.8 Testing of welded jointsfillet welds
5.8.1 Preparation
Add
Two macro-sections shall be taken from the test weld at locations agreed with the BP Welding
Engineer. The specimens shall be prepared and examined in accordance with 5.6.7.
5.8.2 Method
Add
One of the macro-sections shall be subject to hardness testing. The test method shall be Vickers
with an applied load of 10 kg in accordance with ISO 6507-1 or ASTM E92. The survey shall
consist of two traverses with indentations as shown in Figure C.
Non-Sour
Grade Location Sour
SMAW Cellulosic
a
Other Processes
Weld 248 275 275 Inside Surface &
Mid-Thickness
HAZ 248 275 275
Weld 275 275 275
b

< X80 <L555
Outside Surface
HAZ 275 325 350
>X80 >L555 To be advised
NOTES:
a Use of cellulosic electrodes is limited to the applications shown in 4.2.2.1.1
b For grade X80 (L555), outside surface weld metal hardness levels up to 300HV10 are permitted
21 April 2006 GIS 43-331
Page 34 of 56
Figure C - Fillet weld hardness indent locations
1 2 mm 1 2 mm

A macrophotograph shall show the position of each hardness indent and shall be included in the
PQR along with a tabulation or diagram showing the result and location of each indent. The
maximum and minimum values shall be identified.
5.8.3 Requirements
Add
If the fillet weld is on the outside of the pipe wall and, therefore, not in contact with the process
fluids, then the criteria given in Table F for outside surface shall apply.
6 Qualification of welders
6.1 General
Add
Welder qualification tests shall be carried out on full diameter project pipe nipples. Test welds
shall be visually sealed at each end until at least the root bead and hot pass have been completed
around the full circumference. Testing shall be witnessed by a BP representative or a BP
approved third party inspector.
Welders shall be qualified for each welding process that they will use in production. Welders
shall complete at least 50% of the circumference for the passes they are being qualified for. For
automatic, mechanised or semi-automatic welding, each welder shall be qualified for each type,
manufacturer, and model number of the welding unit(s) and power supply to be used in
production welding or for weld repair.
Welders shall be qualified before welding on the pipeline.
A welder who has satisfactorily completed a procedure qualification test is automatically
qualified for that procedure.
Previous welder qualification tests may be accepted by BP provided they are fully documented,
supported by production records demonstrating satisfactory welder performance, and are less
than 6 months old. These tests shall have been conducted utilizing a WPS substantially the same
as that for the current work and, for automatic, mechanised or semi-automatic welding
procedures, utilizing the same type, manufacturer, and model number of welding unit and power
supply. Additionally, these tests shall have been conducted by the same fabrication contractor
and witnessed by BP, or have been conducted by a BP approved independent testing laboratory.
In addition to the practical welding test and before the commencement of production welding,
welders shall be required to attend a briefing session arranged jointly with the BP Welding
Engineer. This briefing shall detail the elements of good welding practice and the specification
requirements applicable to production welding. These requirements shall be further emphasized
NOTE: Notes 1 and 2 from Figure B are applicable.
21 April 2006 GIS 43-331
Page 35 of 56
during regular tool-box sessions and each welder shall be issued a card or booklet summarising
these requirements. This card or booklet shall be available for reference at all times when
welding.
Any welder who, in the opinion of BP, is either consistently ignoring good welding practice or
specification requirements or is responsible for a high level of repairs during production shall be
removed from the work, and shall undergo a re-training programme approved by BP before a
retest may be considered.
6.2 Single qualification
6.2.1 General
Add
Qualification welds shall be assessed by VT and shall also be subject to RT. The agreed NDT
regime shall reflect production NDT and shall examine the full weld circumference.
Qualification of welders using GMAW (solid or cored wire) shall be by VT, RT, MUT, and
mechanical testing to include face and root bends or side bends. In the case of manual welds,
nick break tests are also required.
If the application of AUT for the inspection of production girth welds has been agreed by BP, it
may be used for assessment of the welder qualification welds in place of RT. However, the
acceptance criterion used shall be Section 9 rather than an ECA based criterion.
The position of the pipe used in the test shall determine the extent of qualification as follows:
a. Horizontal pipes shall be used to qualify for welds between pipes positioned within 25 of
the horizontal.
b. Vertical pipes shall be used to qualify for welds between pipes positioned within 25 of the
vertical.
c. Pipes at 45 to the horizontal shall be used to qualify for welds between pipes positioned at
intermediate angles between 25 and 65 to the horizontal.
6.2.2 Scope
Modify c. to Read
For SMAW, a change of electrode manufacturer and brand name
6.3 Multiple qualification
Modify to Read
Multiple qualification of the welder shall not be permitted.
6.4 Visual examination
Modify Paragraph 2 to Read
Filler wire protruding into the pipe bore shall not be permitted.
6.6 Radiographybutt welds only
6.6.1 General
Modify to Read
RT (or AUT: see 6.2.1 above) shall be performed on the qualification welds using the same RT
(AUT) procedure as to be used in production.
Testing procedures and acceptance criteria shall be subject to approval by BP.
21 April 2006 GIS 43-331
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7 Design and preparation of a joint for production welding
7.1 General
Add
Any protective coating on the end bevel shall be removed before welding by a BP approved
method.
Before welding, the pipe end shall be cleaned inside and out using power driven wire brushes,
grinders or other method approved by BP, for a minimum distance of 40 mm (1 in) from the
edge of the weld bevel.
If AUT is to be used, a reference line at a specified distance from the root face shall be scribed
onto the pipe surface to allow the AUT equipment to identify the exact location of the root bead.
Arc burns outside of the weld groove shall not be permitted. Remedial action on arc burns shall
be in accordance with 10.6.
Attachment of welding return cables by welding shall not be permitted. Arc burns caused by a
faulty attachment shall be removed in accordance with 10.6.
Repair of the pipe body by welding shall not be permitted.
Add
7.1.1 Weld proximity
The distance between pipeline girth welds shall not be less than twice the outside diameter of
the pipe.
The distance between pipeline girth and branch/attachment welds shall not be less than one pipe
diameter.
The distance between branch/attachment welds on the pipeline shall not be less than one pipe
diameter.
7.2 Alignment
Modify to Read
Pipe ends shall be aligned by rotating pipes, avoiding pipe end bevel damage, thereby achieving
accurate fit up for welding.
The misalignment between the internal surfaces shall not exceed the lesser of 3.0 mm (1/8 in.)
or 1% of the pipe internal diameter at any point.
The longitudinal (or spiral) weld ends shall be separated, at the circumferential weld, by 90 or a
circumferential distance of 250 mm (10 in), whichever is the smaller.
Longitudinal welds shall lie within the top half of the pipe circumference.
If abutting pipes have the same outside diameter with different nominal bores, the smaller bore
shall be machined, ground or filed, to produce an internal taper no steeper than 1 in 4;
alternatively, a transition piece may be inserted. Internal tapering shall be subject to BP
approval if the taper will interfere with ultrasonic inspection. Internal tapering may not be used
with AUT.
Any misalignment in pipe to fitting girth weld set-ups, which exceeds 3.0 mm (1/8 in.) at any
point on the internal surface, shall be subject to corrective action agreed with BP.
Slight misalignment may be corrected using a bronze-headed or other soft-faced hammer of
mass not exceeding 5 kg (11 lb). Hammering must not impinge on the weld area.
Heat shall not be used to correct excessive misalignment.
21 April 2006 GIS 43-331
Page 37 of 56
For some pipeline applications, e.g. pipelines subject to high strain, strain based
design pipelines, or pipelines carrying corrosive fluid streams, a more stringent
maximum limit for internal offset may need to be specified. In such instances, it is
necessary to take this into account when ordering the line pipe as more stringent
tolerances on diameter, wall thickness, and out-of-roundness need to be specified. In
the case of seamless pipes, the ends may require match boring.
7.3 Use of line-up clamp for butt welds
Modify to Read
7.3.1 General
Internal alignment clamps shall be used for pipe-to-pipe butt welds and shall not be released
until 100% of the root pass is completed. If access does not permit the use of an internal clamp
for pipe-to-pipe welds, e.g. on tie-in welds, an external clamp shall be used. For short pipelines
and small diameters (< 150 mm (6 in)), the use of an external clamp may be proposed for BP
approval. A welding sequence that distributes the stress as evenly as possible shall be used, e.g.
two welders working diametrically opposite each other. At least 50% of the root pass shall be
completed before the external clamp is released.
7.3.2 Tacking (tack-welding)
Tack welds (if used) shall be deposited by qualified welders using low hydrogen welding in
accordance with an approved welding specification. If preheat is specified, it shall be applied
before tack welding and be effective over a distance equal to three times the wall thickness or
75 mm (3 in) whichever is the greater and shall be maintained until the joint is complete.
Alignment by tacking for fabrication welds, e.g. for pipe to flange joints, shall be subject to the
approval of BP. The following shall apply when tacking is used:
a. The joints to be tacked shall be adequately supported.
b. The tack welding shall be undertaken by welders qualified in accordance with Section 6.
c. The preheat level required for the main WPS shall be applied for tacking and shall not be
less than 50C (122F.
d. The preferred method is bullet tacking. The bullets shall be made from compatible linepipe
material and shall be removed as the welding progresses.
A bullet tack is made by welding a small piece of material into the weld bevel.
If root tack welds are to be incorporated into the final weld, they shall be at least 25 mm
(1 in) long and shall be thoroughly cleaned of slag and taper ground at each end to ensure
complete root continuity.
e. A minimum of four tacks shall be used for diameters greater than 100 mm (4 in). More
tacks may be required for diameters greater than 300 mm (12 in).
f. Welding shall be confined to the weld preparation.
g. Tacks shall be removed by grinding as root welding progresses around the butt.
h. Tacking shall be incorporated in the WPQT if it is to be used in production.
21 April 2006 GIS 43-331
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7.4 Bevel
7.4.1 Mill bevel
Modify to Read
If pipes are supplied with mill bevelled ends, the API 5L standard bevel will normally be
provided. Alternative bevels may be supplied in order to conform to the joint design specified in
the WPS.
7.4.2 Field bevel
Modify to Read
Weld bevels shall be prepared by machining with a floating head cutter. The bevelling machine
shall follow the ID surface contour in order to ensure a consistent root face dimension.
Mechanised thermal cutting may be accepted for tie-in welds. The cut surface shall be ground
back nominally 2 mm (1/16 in). Manual cutting of field bevels is not permitted.
Add
7.4.3 Bevel condition
Surfaces to be welded shall be free of primers, paints, or coatings. Anti-spatter compounds shall
not be applied to surfaces to be welded.
Fusion faces and adjacent material shall be free from fins, planar defects or cracks, tears,
moisture, scale, rust, grease, or any other foreign matter immediately before welding.
Surfaces contaminated with oil or grease shall be cleaned utilizing a BP approved solvent.
Degreasing of base metal shall extend at least 50 mm (2 in) from the edge of the fusion faces on
both ID and OD surfaces. Solvents used for cleaning shall be used from a suitable container and
approved by BP as HSE compliant with necessary documentation available.
7.4.4 Inspection and treatment of bevels
On pipe which is to be cut back, a zone extending 100 mm (4 in) from the proposed position of
the new field bevel shall be examined by VT and UT to the requirements of the appropriate pipe
material specification.
BP may permit minor imperfections in the pipe ends to be repaired by grinding, before assembly
for welding, provided the remaining wall thickness is acceptable as confirmed by UT.
Weld repairs to pipe ends shall not be permitted.
7.5 Weather conditions
Add
If necessary, measures shall be taken, e.g. by covering the pipe ends, to prevent water or other
extraneous matter being channelled into the weld region.
7.6 Clearance
Add
Full and adequate clearance to the joint shall be provided for the welders so that the full
circumference is readily accessible without hindrance to the welding operation. This may
require staging, pipe lifting, or further excavation.
21 April 2006 GIS 43-331
Page 39 of 56
7.7 Cleaning between beads
Add
Stops and starts should, if necessary, be ground and visible defects and high points shall be
removed by grinding before a further weld run is deposited.
Contact tips shall not be fused into the weld metal. A visual inspection shall be undertaken
between weld passes to confirm no copper has been deposited.
The use of manual slag hammers, chisels, and lightweight vibrating tools for the removal of slag
and spatter is permitted and is not considered peening, except that excessive mechanical
working of the surface that may mask surface defects or otherwise inhibit a proper visual
inspection is prohibited.
7.10 Identification of welds
Add
Accurate records to identify the work of each welder shall be maintained and a weld
identification system providing each weld with a unique identification number shall be
submitted.
Each weld shall be identified with the weld identification number on the adjacent steel surface
using an indelible paint or ink marking system.
The work of each welder shall be identified at each weld or portion of weld with his unique
identification symbol using an indelible paint or ink marking system.
7.11 Pre-and post-heat treatment
Add
7.11.1 Preheat and interpass temperature
Preheat and interpass temperatures shall be in accordance with the BP approved WPS; see
5.3.2.13.
Preheating shall be applied by gas or electrical equipment. Induction heating is preferred for
main pipeline welding and is mandatory for main line welding of pipe diameters greater than
500 mm (20 in). Hand held gas torches shall not be used for main pipeline welding if preheats
greater than 80C (176F) are required. Welding or cutting torches shall not be used for
preheating purposes. The preheating equipment shall maintain a satisfactory temperature
distribution and shall not interfere with the welding operation. Damage to any coatings shall be
avoided.
Preheating shall be applied uniformly on both sides of the joint preparation around the entire
periphery. Local preheating may be used for repair welding. Correct preheat temperatures shall
be maintained throughout the welding of the joint.
The preheat temperature shall be measured at a minimum distance of 75 mm (3 in) from each
edge of the weld bevel at four circumferential locations, each approximately 90 apart. Preheat
temperature measurement shall be made on the heated face of the pipe after a time interval
following the removal of the heat source to allow for temperature equalisation. The time interval
shall be 1 minute per 12.7 mm ( in) of wall thickness, e.g. 2 minutes for 25 mm (1 in) thick
material. The preheat temperature should be confirmed immediately before the commencement
of welding and around the whole joint whilst welding is taking place.
The preheat temperature shall not exceed the minimum preheat temperature given in the
approved WPS by more than 50C (90F).
Interpass temperature shall be measured on the parent material at the edge of the weld bevel
near the weld start location. The temperature shall be measured immediately before the passage
21 April 2006 GIS 43-331
Page 40 of 56
of the arc. The maximum specified interpass temperature shall not be exceeded. Interpass
temperature checks shall be made during welding.
For continuous 1G rotated or 5G welding, interpass temperature shall be measured once per
complete revolution around the weld circumference.
Temperature indicating crayons which melt on attaining the specific temperature may be used to
check preheat and interpass temperature, but shall not be marked on weld bevels, weld beads, or
surfaces to be welded. Temperature indicating crayons or paints, which indicate temperature by
colour change, shall not be used. Alternatively, suitably attached (and calibrated) thermocouples
or calibrated contact or optical pyrometers may be used to check preheat and interpass
temperatures.
If pipe-to-pipe joints are to be left partly completed, the joint shall be wrapped in dry insulating,
heat-resisting material with a waterproof backing and shall be cooled at a slow uniform rate.
Preheat shall be re-applied and the specified temperature attained before recommencement of
welding.
7.11.2 Post heat (including post weld heat treatment)
If post heating or post weld heat treatment is specified, the pipe shall be heated for a minimum
distance on both sides of the joint equal to 2.5(Rt)
(where R is the external radius and t is the

wall thickness of the pipe). The temperature at the edge of this heated band shall be not less than
half the peak temperature.
The method and technique of post weld heat treatment shall be subject to the approval of BP.
Thermocouples shall be used for recording post weld heat treatment temperatures and shall be
positioned to give a true measure of the joint temperature. As a minimum, thermocouples shall
be positioned at the 6 and 12 oclock positions. For pipe sizes above 600 mm (24 in),
thermocouples shall also be placed at the 3 and 9 oclock positions. The thermocouples shall be
in metallic contact with the material being heat treated and shall be securely attached.
Thermocouple wires and junctions shall be protected from direct heat. If electrical resistance
heating is used, thermocouples shall have a protective wrapping to prevent direct radiation on to
the hot junction.
After use, thermocouples shall be removed and any remaining attachment material shall be
removed by grinding. The ground surface shall be examined with MT.
Add
7.12 Weld interruption
Normally, welds shall be completed by continuous welding.
Offshore pipeline welds or welds on fittings, tie-in welds, or repairs shall not be allowed to cool
below the specified minimum preheat temperature before weld completion. No welds shall be
allowed to cool below preheat temperature before the completion of four full circumferential
passes.
For pipe-to-pipe welds for onshore pipelines being constructed on steep gradients (> 10%), the
welds shall not be left partially completed for longer than four hours.
7.13 Branches
7.13.1 General
Procedures for cutting, joint preparation, setting up, welding and NDT shall be subject to
approval by BP.
Forged fittings shall be used for branch and other pressure containing attachments, unless
otherwise approved by BP.
21 April 2006 GIS 43-331
Page 41 of 56
Branch welds shall be sited away from other welds on the pipeline (see 7.1.1).
The pipe area surrounding a branch weld shall be tested for laminations using UT up to a
distance of 100 mm (4 in) surrounding the projected locations of the weld toes. Any laminations
found (individual or cluster) shall not exceed a total area of 500 mm
2
(3/4 in
2
). No lamination,
regardless of size, shall be permitted within 25 mm (1 in) of the projected weld toes.
7.13.2 Set-in type fittings
Set-in type fittings shall be attached to the pipe using a low hydrogen welding process.
If accessible, and following completion of the full weld, the root bead shall be ground flush on
the inside of the pipe, its location clearly marked with indelible pen, and inspected with VT and
MT.
Weld caps shall be subjected to VT and MT.
The full welds shall be examined with RT using the SWE/SWV technique with the film inside
and the radiation source outside, using a minimum source to film distance of 600 mm (24 in). A
minimum of four equidistantly spaced separate exposures shall be used for branches 150 mm
(6 in) nominal bore; a minimum of six equidistantly spaced separate exposures shall be used for
branches > 150 mm (6 in) nominal bore.
The DWE/SWV technique may only be used if approved by BP.
In any event, the centre of the radiation beam shall pass through each weld region being tested
at normal incidence to the weld face.
7.13.3 Set-on type fittings
Set-on type fittings shall be attached to the pipe using a low hydrogen welding process.
The root bead and weld cap shall be examined by VT. VT of the root bead shall be undertaken
through the bore of the fitting from the outside of the pipe. The weld cap shall also be examined
with MT. If access allows, UT shall be undertaken from the inside surface of the fitting.
7.14 Fillet weld attachments
Procedures for welding and NDT shall be subject to approval by BP.
The pipe area surrounding a fillet weld shall be tested for laminations using UT up to a distance
of 100 mm (4 in) surrounding the projected locations of the weld toes. Any laminations found
(individual or cluster) shall not exceed a total area of 500 mm
2
(3/4 in
2
). No lamination,
regardless of size, shall be permitted within 25 mm (1 in) of the projected weld toes.
If any fillet welds are to be made using multiple passes, the first pass shall be deposited mainly
on the pipe and the final weld pass shall not touch the pipe.
Completed fillet welds shall be examined by VT and MT.
8 Inspection and testing of production welds
8.1 Rights of inspection
Add
The right of inspection includes NDT undertaken by BP personnel in addition to any NDT
undertaken by the contractor. For instance, BP may choose to inspect welds by MUT.
21 April 2006 GIS 43-331
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8.2 Methods of inspection
Add
8.2.1 NDT general
Each joint shall be thoroughly cleaned using power driven wire brushes and hand tools
following welding and before inspection. Spatter and extraneous material shall be removed.
Proposed NDT procedures shall be submitted in writing to BP for approval. Qualification of
NDT procedures shall be made on the welding procedure qualification weld(s) or welds made in
accordance with the approved WPS, unless otherwise agreed by BP.
8.2.2 NDT method
The full circumference of pipeline butt welds shall be examined by RT or AUT. For wall
thickness above 25 mm (1 in), AUT is the preferred NDT technique.
The use of automatic ultrasonic testing (AUT) shall be subject to approval by BP on a case by
case basis. If the use of AUT has been approved, testing shall be performed in accordance with
BP GP 43-34. The use of AUT shall not be permitted in place of radiography for the following
weld types:
a. Welds connecting pipes with an internal taper
b. Butt welds to valves, flanges and other fittings
c. Welds in land pipelines to be submerged or buried in river, rail or road crossings. These
welds shall also be subject to MUT or AUT in addition to radiography.
If RT is being used to examine welds produced by GMAW or cored wire systems, MUT shall
be used to supplement RT. The extent of supplementary UT testing will be specified by BP.
MUT and MT equipment and personnel shall be available at site for the full duration of pipeline
construction.
8.2.3 Timing of NDT
Production welds shall be examined by VT immediately upon completion of welding.
On a pipelay vessel, the weld shall not be moved past the weld repair station until the weld NDT
interpretation has been completed.
Coating or wrapping of a welded joint shall not begin until the weld NDT interpretation has
been completed.
8.3 Qualification of inspection personnel
Add
Inspectors shall be qualified in accordance with 1.8.2.
8.4 Certification of nondestructive testing personnel
Add
NDT personnel shall be certificated in accordance with 1.8.3.
21 April 2006 GIS 43-331
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9 Acceptance standards for non-destructive testing
9.1 General
Modify to Read
The acceptance standards defined in Section 9 shall be the minimum requirements for BP
pipelines in which RT is the primary NDT method. If the use of AUT has been approved by BP,
the requirements of Section 9 shall be augmented by an ECA to determine flaw dimensions and
acceptance levels, which shall be subject to BP approval (see Appendix A).
If unacceptable flaws occur in more than five consecutive welds, or if in the opinion of BP a
particular flaw type becomes repetitive in terms of its size and/or location, the cause of the flaws
will be investigated by the BP welding engineer. If necessary, welding shall be terminated until
the cause of unacceptable flaws has been established and satisfactorily resolved.
For off-line fabrication, e.g. risers or welding of nipples to valve bodies, the pipeline
designer may wish to specify acceptance criteria that do not permit defects such as
lack of fusion or lack of penetration, e.g. ASME B31.3 [2] Table 341.3.2 severe
cyclic conditions.
More onerous acceptance criteria than those in Section 9 may be required for
surface breaking root flaws for some pipeline duties. These acceptance criteria are
specified on a project by project basis.
Add
9.1.2 Visual acceptance weld profile
Completed welds shall have a uniform appearance without excessive changes in profile and
shall blend smoothly into the parent material. At no point shall penetration of the root bead into
the bore exceed 3 mm (1/8 in). For pipe diameters less than 60 mm (2 3/8 in), this penetration
shall not exceed 1.5 mm (1/16 in).
9.3 Radiographic testing
9.3.2 Inadequate penetration due to high-low
Modify Paragraph a. to Read
The length of an individual indication of inadequate penetration due to high-low (IPD) exceeds
25 mm (1 in).
9.3.6 Internal concavity
Modify Second Sentence to Read
Internal concavity (IC) up to 25% of the total length of weld is acceptable provided the density
of the radiographic image of the IC does not exceed that of the thinnest adjacent base metal.
9.3.7 Burn-through
Delete 9.3.7.2
Modify First Paragraph of 9.3.7.3 to Read
For all pipe diameters, a burn-through (BT) shall be considered a defect if any of the following
conditions exists:
21 April 2006 GIS 43-331
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9.3.9 Porosity
Add
The total area, when projected radially through the weld, shall not exceed 2% of the projected
weld area in the radiograph. The area shall be the length of the weld affected by the porosity
(with a minimum length of 150 mm (6 in)) times the maximum width of the weld.
9.3.10 Cracks
Modify to Read
Any form of crack or suspected crack shall be unacceptable.
9.3.11 Undercutting
Add
The aggregate length of internal undercut (IU) exceeds 25 mm (1 in) in any continuous 300 mm
(12 in) of weld length.
9.3.12 Accumulation of imperfections
Add
c. The total aggregate length of all indications, including incomplete penetration due to high-
low and undercutting, exceeds 15% of the weld length.
Add
9.3.14 Tungsten inclusions
Tungsten inclusions shall not exceed two per weld and shall be separated by a minimum
distance of 50 mm (2 in).
9.3.15 Copper inclusions
Not permitted
9.7 Visual acceptance standards for undercutting
9.7.2 Acceptance standards
Modify to Read
Weld cap undercutting exceeding 0.4 mm (0.016 in) depth shall be unacceptable and shall be
blended out by light grinding or filing before performing NDT. If blending reduces the pipe wall
thickness below the specified minimum, the entire circumferential weld shall be cut out and the
pipe ends re-bevelled and re-welded.
Add
9.8 Suspect welds
Any weld suspected of not having been produced in accordance with the approved welding
procedure shall be cut out, and may be subject to investigation at the discretion of BP.
21 April 2006 GIS 43-331
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10 Repair and removal of defects
10.1 Authorisation for repair
Add
A full record of repairs shall be maintained. Records shall be made as each flaw is discovered,
and shall include the following:
a. The weld number
b. The type and size of flaw
c. The circumferential location (defined to an approved system)
d. An estimate of the flaw depth (assessed by ultrasonic test, if possible)
e. Name of the welder who produced the flaw
f. Repair welding procedure number
g. Name of repair welder
h. Copy of inspection report for the repair
i. Date of repair
Defects shall not be repaired in any part of the weld without prior approval by BP. Repairs shall
be witnessed by BP; and, the relevant NDT records shall be made available to BP at that time.
10.1.1 Cracks
Modify to Read
Welds with cracks (other than small crater cracks < 4 mm (5/32 in) in length) shall be removed
from the pipeline. The welding procedure shall be suspended until the cause is identified and
remedial measures implemented to prevent further occurrence. Production welding with the
suspended WPS shall only recommence following approval from the BP Welding Engineer.
Small crater cracks shall be removed by local grinding and repaired.
10.1.2 Defects other than cracks
Modify to Read
Weld repairs shall be made in accordance with a BP approved repair welding procedure.
Weld repair lengths shall be limited to 30% of the weld length for repairs that do not open the
root. If a repair opens the root, a maximum of 20% of the weld length shall be repaired. If the
repair cannot be implemented within these limitations, the weld shall be cut out. Further
restrictions on weld excavation may be required if the weld is under load at the time of the
repair, e.g. beyond the tensioners of a laybarge. In such cases, verified calculations justifying
the excavation size shall be submitted for BP approval.
If a root repair weld in a pipeline fails to comply with the requirements of Section 9, the entire
circumferential weld shall be cut out and the pipe ends re-bevelled and re-welded. If necessary,
a second repair may be attempted for regions apart from the root. If this second repair fails to
meet the requirements of Section 9, the entire circumferential weld shall be cut out. For grades
above X70, only a single repair attempt shall be permitted.
For repair of arc burns see 10.6.
Internal weld repairs shall not be permitted except for pipe-to-fitting welds in which the repair
can be undertaken from the open end of the pipe or fitting.
No more than two separate repairs are allowed in any single weld.
21 April 2006 GIS 43-331
Page 46 of 56
10.2 Repair procedure
Add
Repair weld procedure qualification is required. At the discretion of the BP Welding Engineer,
repair welding using the original WPS may be permitted if the material grade is < X52 and the
welding process(es) is manual or semi-automatic and the weld preparation is similar to the
original weld preparation.
The repair weld procedures shall be qualified in accordance with Section 5. However, it is not
necessary to make a full circumferential repair weld. It is only required to make sufficient repair
weld to provide material for mechanical testing. The radial position of the test repair weld shall
be approved by BP.
Single pass repairs are only permitted for cap defects.
Each repair type to be used in production shall be separately qualified, e.g.:
- full penetration repair
- partial penetration repair
- partial penetration re-repair
- cap repair
- internal repair (if permitted)
- intermediate repairs (repairs made with a different process during the course of making the
girth weld, e.g. SMAW repairs to an automatic root)
The repair weld procedure qualification shall be inspected by VT, MT, MUT and RT.
Mechanical testing shall be undertaken in accordance with 5.6 although the number of
mechanical tests may be reduced as shown in Table G.
Individual repair weld procedure qualification excavations shall be limited to a length of
300 mm (12 in).
10.2.2 Add
The portion of weld cut out for repair shall be tapered at the sides and ends to give adequate
access for rewelding. Metal may be removed by thermal gouging followed by grinding.
Grinding shall be used for the last 3 mm (1/8 in) through to the root. Air-arc gouging shall be
controlled by a procedure documenting the allowed variables as required by AWS C5.3.
The minimum allowable repair length shall be 50 mm (2 in) at the bottom of the groove.
10.2.3 Add
Excavations associated with the partial thickness repair of planar flaws shall be tested by MT to
confirm complete removal of the flaw.
21 April 2006 GIS 43-331
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Table G - Type and number of test specimens for repair weld procedure qualification test
Add
10.6 Arc burns
BP shall have the option to require removal of weldments with more than one arc burn from the
pipeline.
Repair of arc burns shall be by careful grinding or filing until visible signs of the arc burn are
removed. Welding shall not be used to repair arc burns. The dressed area shall blend smoothly
into surrounding base metal and shall be examined by VT and MT to ensure freedom from
defects. The remaining wall thickness shall be checked with UT.
If blending to remove the effects of arc burns reduces the wall thickness below the specified
minimum, the defective pipe section shall be cut out and the pipe re-bevelled and re-welded. If a
nipple is used to replace the defective section, its length shall meet the requirements of 7.2.
11 Procedures for nondestructive testing
11.1 Radiographic test methods
11.1.1 General
Add
Radiographic testing shall be conducted using X-ray equipment. If the use of X-ray equipment
is impracticable, Iridium 192, Ytterbium 169 or Selenium 75 may be used subject to approval
by BP; other sources of gamma rays are not permitted.
Radiographic practice shall be in accordance with this GIS and ISO 17636.
Radiographic procedures shall be qualified and approved by BP before use.
As part of the radiographic procedure qualification, test radiographs shall be produced using
each radiographic procedure. These shall be made on the welding procedure qualification welds
Type of Repair
Tensile
Strength
(Cross
Weld
Tensile)
All-Weld
Metal
Tensileb
Bend f
Charpy
Impact
Tests
(set of 3)
c

Macro/
HV10
CTOD
(set of 3)b
Single Pass 0
a
0 0 0 1 0
Multi Pass
Partial
2 1 2 5
d
1 2
Multi Pass
Full Penetration
2 1 2 3
e
1 2
NOTES:
a If the strength of the weld may be significantly affected (e.g. low strength repair electrode on thin wall pipe)
then transverse tensile testing shall be undertaken.
b CTOD and Weld Tensile testing shall be undertaken if the acceptance criterion is based on an ECA. One set of
CTOD specimens shall be notched in the weld metal and one in the HAZ.
c One set of Charpy impacts specimens shall be located in the repair weld metal and associated parent material
HAZ at the fusion line and fusion line +2 mm.
d For partial penetration repair welds, a further two sets of Charpy specimens shall be notched to sample the
repair weld metal and associated original weld metal HAZ at the fusion line and fusion line +2 mm.
e For welds greater than 20 mm, additional sets of weld metal and fusion line Charpys shall be located at the
outer surface for full penetration repair welds.
f The bend specimen type shall be selected in line with 5.6 based upon the thickness and diameter of the weld.
21 April 2006 GIS 43-331
Page 48 of 56
or welds made with the production WPS. The full circumference of each test weld shall be
radiographed.
For radiographic procedure qualification, wire type IQIs, meeting the requirements of ISO 2504,
ASTM E747 or BP approved equivalent, shall be placed across the weld on both the source side
and the film side of the area being examined. The sensitivity level, obtained using the film side
IQI, shall be no worse than that given in Table H. The corresponding sensitivity for the source
side IQI shall be recorded. If any test radiograph shows more than one visible wire of the film
side IQI, compared to the source side IQI image, BP has the option to reject the radiographic
procedure.
The procedure test radiographs shall be submitted to BP for approval before the start of
production. New procedure test radiographs may be requested, at the discretion of BP, whenever
any change is made in operating technique, or whenever production radiographs differ
appreciably from the detail, contrast, definition or density of the qualifying radiographs.
Procedure test radiographs shall be readily available for comparison purposes in each darkroom
used for radiographic viewing.
Film type shall be ISO 11699-1 Class T2 or ASTM E1815 Class I, e.g. Agfa Structurix D5 or
Kodak Industrex T200, or finer grain (slower) film. If it is shown that exposure times would
exceed 2 minutes using X-ray equipment with this film, the use of ISO 11699-1 Class T3 or
ASTM E1815 Class II may be permitted at the discretion of BP.
Lead (Pb) intensifying screens shall be used. BP may approve the use of fluorometallic screens
as an alternative, if it can be demonstrated that test procedures and results are of a standard
acceptable to BP.
11.1.2 Details of procedure
11.1.2.2 Film radiography
Add to a.
Brand name, including specific model name/ number, of X-ray equipment.
Modify e. to Read
Exposure conditions:
For X-ray: Exposure time, mA and kV.
For gamma: Curie-minutes and Gigabecquerel-minutes.
Add to f.
Type and brand name of each processing chemical.
11.1.3 Exposure geometry
11.1.3.1 Film radiography
Modify to Read
Source-weld-film arrangements shall comply with ISO 17636 except that the elliptical
technique shall be used on girth welds on pipe 88.9 mm (3.5 in.) diameter. The perpendicular
technique (straight through) exposures shall not be used unless approved by BP.
The single wall exposure for single wall viewing (SWE/SWV) technique with the radiation
source located inside the pipe/ fitting shall be the preferred technique for RT of girth welds.
11.1.4 Type of image quality indicators (IQI)
Add
Wiretype IQIs corresponding to ISO 2504, ASTM E747, or approved equivalent, shall be used.
21 April 2006 GIS 43-331
Page 49 of 56
11.1.5 Selection of image quality indicators IQI
Add
IQIs sensitivity requirements shall be as given in Table H.
Table H - IQI sensitivity levels
11.1.8 Identification of images
Add
The Radiograph shall contain the following information:
a. Project name, project number and pipeline identification
b. Weld number
c. Whether the radiograph is of a repair weld, of a replacement weld or a re-shoot of
radiograph
d. Marker(s) indicating the position of the radiograph in relation to the weld
e. Pipe diameter and thickness
f. Material grade
g. Date
h. WPS
11.1.9 Storage of film and other imaging media
11.1.9.1 Film
Add
Radiographs shall be stored in an environment that will not detrimentally affect the radiographs.
Boxes shall be used to store radiographs in multiples of 25, 50, or 100 welds. The weld numbers
that apply to the stored radiographs that each box contains shall be clearly visible on each box.
Thickness
a
X-Radiography Gamma Radiography
(in) (mm) SWE/SWV DWE/SWV DWE/DWV SWE/SWV DWE/SWV DWE/DWV
0.18 0.24 4.5 6.0 2.0% 2.5% 3.2% 2.6% 2.7% 3.5%
>0.24 0.35 >6.0 9.0 1.7% 2.0% 3.0% 2.4% 2.5% 3.2%
>0.35 0.55 >9.0 14.0 1.5% 1.8% Note b 2.4% 2.5% Note b
>0.55 0.73 >14.0 18.5 1.4% 1.7% NA 2.0% 2.2% NA
>0.73 1.02 >18.5 26.0 1.3% 1.7% NA 1.7% 2.0% NA
>1.02 1.6 >26.0 40.0 1.1% 1.7% NA 1.5% 1.8% NA
>1.6 >40.0 Note b Note b Note b Note b Note b Note b
a Thickness for SWE/SWV and DWE/SWV is estimated single weld thickness. Thickness for DWE/DWV is one wall thickness plus
one estimated weld thickness.
b

Sensitivity requirement to be agreed with BP following production of test radiographs.
Sensitivity shall be no worse than the values given in this Table. Sensitivity values are based on IQI placed on film side for
SWE/SWV and DWE/SWV exposures and IQI on source side for DWE/DWV exposures. Sensitivity shall be calculated using the
formula:
Sensitivity =
a
Thickness
area weld in visible wire thinnest of Thickness

21 April 2006 GIS 43-331
Page 50 of 56
11.1.10 Film density
11.1.10.1 Film density
Modify to Read
Except for small localized areas caused by weld weave or discontinuities, the radiographic
density shall be between 2.0 and 3.2 in the weld area. If this density range cannot be achieved
within the full weld width in a single exposure, then the above density range shall be achieved
by producing two radiographs of the weld area at different exposures or by using the sandwich
technique, unless otherwise agreed by BP.
Densitometers shall be used for measuring density and shall be calibrated using a density strip
(density reference scale) of known densities. A density strip certified within the last 3 years to a
recognized standard, e.g. NIST or BAM, shall be present on site. To save wear and tear on the
calibrated density strip, a working density strip may be used for checking and calibrating
densitometers; this must be checked against the certified density strip at no more than 3 monthly
intervals.
11.1.10.2 Film viewing equipment
Add
The brightness of the illuminated radiograph shall be such that it can be interpreted
satisfactorily. Illuminators shall meet the requirements of ISO 5580.
11.1.11 Image processing
Add
Radiographic film shall be dried thoroughly before viewing. Films shall be processed to allow
storage without deterioration for a minimum period of five years. One radiograph in every 100
shall be subjected to a residual thiosulphate test.
11.2 Magnetic particle test method
Add
Magnetic particle testing shall comply with ISO 17638 or ASTM E709.
The non-fluorescent wet method of MT using white contrast paint and an AC yoke (110V) shall
be used. Dry powder MT may be used for repair groove inspection. The AC yoke shall be
capable of lifting 4.5 kg at 150 mm (10 lb at 6 in) pole spacing. Poles shall make maximum
contact with the test surface during inspection.
MT procedures, including the method for determining adequate flux levels in the test area, shall
be qualified. MT procedures shall be approved by BP before use.
11.4 Ultrasonic test methods
11.4.1 General
Add
Manual ultrasonic testing shall comply with ISO 17640 or ASTM E164.
UT procedures shall be approved by BP before use.
If the use of AUT is proposed, qualification of the AUT procedures and production testing shall
comply with the requirements of BP document GP 43-34.
21 April 2006 GIS 43-331
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12 Mechanised welding with filler metal additions
Add
If mechanised or automatic processes for main line welding, tie-in welding or for multiple
jointing of pipeline sub-assemblies are proposed, the bid proposal shall include full details of
the processes to be used, the associated welding equipment, and the proposed area of
application.
For mainline welding applications, the proposal shall list the number of welding stations (root
pass to final capping pass) on a spread by spread basis and detail the equipment and number of
welders and other personnel required to operate each station. Full details of the welding shelters
shall also be provided.
A similar level of detail shall be provided for tie in welding and multiple jointing.
Mechanised (automatic) 2G or 5G welding equipment should be operated in-conjunction with
data logging facilities capable of recording the essential variables associated with the arc
including wire feed speeds and travel speeds. The equipment shall record all parameters for
each pass of every weld at a minimum rate of once per 10 degrees of angular rotation and shall
indicate the angular position of each measurement. This data shall be readily retrievable for
monitoring purposes and shall form part of the pipeline construction data package. Data logging
is mandatory if welding with either multi torch or multi wire systems and for girth welds made
in X80 grade linepipe.
Each mechanised (automatic) welding station shall be demonstrated to be fully operational
before it is employed to weld any joints that will be incorporated into the pipeline. For example,
for a spread of welding stations this demonstration may consist of two full girth welds made
consecutively, each weld being required to meet the production acceptance criteria without the
need for any repair. NDT shall utilise the agreed pipeline NDT techniques and equipment.
Internal welding equipment shall also require operational demonstration. Each of these pre-
construction welds shall be uniquely identified and reserved for possible mechanical evaluation
by BP.
This operational demonstration shall be repeated as agreed with BP, but should as a minimum
be repeated after interruptions 7 days in pipeline welding and when a welding spread is
disassembled and transferred from one section of the line to another.
The proposal shall also detail the intended level of technician support for equipment
maintenance and list the principal spares that will be available in order to maintain equipment
serviceability for the duration of the pipelay.
The proposal shall also advise if a manual welding procedure is to be qualified for production or
repair welding.
12.2 Procedure qualification
Modify to Read
The requirements for the qualification and testing of procedures for mechanised (automatic)
welding shall be as per Section 5.
12.3 Record
Add
Additional requirements for mechanised (automatic) welding have been incorporated in
Section 5.
21 April 2006 GIS 43-331
Page 52 of 56
12.4 Procedure specification
Modify to Read
The requirements for the procedure specification of mechanised (automatic) welding have been
incorporated in 5.3.
12.5 Essential variables
Modify to Read
The requirements for mechanised (automatic) welding have been incorporated in 5.4.
12.6 Qualification of welding equipment and operators
Modify to Read
The requirements for mechanised (automatic) welding have been incorporated in Section 6.
13 Automatic welding without filler-metal additions
Delete
Appendix AAlternative acceptance standards for girth welds
Add
The use of alternative acceptance standards for girth welds shall be subject to BP approval
before contract award. The ECA method and testing shall be proposed for BP approval before
the commencement of WPQT. The ECA method may be that described in API 1104 or other
recognised codes (i.e. BS 7910, EPRG Guidelines or CSA Z662). If API 1104 is used then
consideration against plastic collapse shall also form part of the ECA.
The output of the ECA shall be used to develop the weld NDT acceptance standard. The weld
acceptance standard shall include an appropriate NDT sizing allowance (see GP 43-34) which
shall be clearly documented. In addition to the limits derived from the ECA, the following
restrictions on defect size shall apply:
Individual defects with a height greater than 4 mm (5/32 in) (before interaction
assessment) shall not be permitted.
Defects with a height greater than 4 mm (5/32 in) are unusual and their occurrence
indicates abnormal welding. No acceptance of these defects is permitted even
though the ECA may show safe defect heights in excess of 4 mm (5/32 in).
Irrespective of defect height, defects with a length greater than 7 times wall thickness (after
interaction assessment) shall not be permitted.
Appendix B In-service welding
B.1 General
Add
Welding onto in-service live pipelines is usually an individual operation for each application
and may only be undertaken under BP guidance. The in-service welding operation shall be
subject to detailed planning and approval by BP in each instance.
Although Appendix B gives useful guidance on this subject, the techniques employed
for welding on to in-service pipelines and the fundamental technical issues to be
addressed are different from those of new construction pipeline welding.
21 April 2006 GIS 43-331
Page 53 of 56
Add
Appendix C Additional requirements for pipelines subject to high strain levels
C.1 Introduction
This appendix applies to pipelines subject to plastic deformation during installation, e.g.
installation by reeling. High strains may also be generated in operation and the effects on the
welds should be assessed if operational strains are deemed to be significant.
When evaluating the amount of strain at the weld expected during installation, the effects of
misalignment, pipe strength variation, and coating stiffness shall be considered.
C.2 General
C.2.1 Linepipe
The requirements for materials to be used for high strain installation are more onerous than
those for conventional pipe installation. The pipeline is required to have sufficient strain
capacity to withstand multiple strain cycles, and uniform mechanical and dimensional properties
are required to prevent excessive strain localisation. The BP GISs for linepipe give additional
requirements for linepipe subject to high strain. Pipelines welded in accordance with this
appendix shall use linepipe that complies with these additional GIS linepipe requirements.
The linepipe GISs are GIS 43-311 GIS 43-312, GIS 43-313, and GIS 43-317.
C.2.2 Welding process
Welding processes not previously used by the contractor with the proposed installation method
shall require full scale qualification trials. The extent of the trials shall be determined by BP.
Only low hydrogen processes shall be used.
C.2.3 Welding consumables
The consumable selection shall be approved by BP and the consumable should have a track
record with the selected installation method.
The lot testing of weld consumables described in 4.2.2.4 shall be undertaken for each lot of
welding consumables not tested in the welding procedure qualification. Additionally,
- the strain age testing in C.3 shall be performed.
- the minimum Charpy energy shall be 70J at the impact test temperature.
- the yield and UTS of the test weld shall exceed the maximum exhibited yield and tensile
properties of the production pipe.
C.3 Weld procedure qualification testing
C.3.1 Simulation
The weld procedure qualification welds shall be subjected to full scale bending at the maximum
strain predicted during installation. The number of cycles shall be determined from the number
of cycles required for installation plus any contingency operations and agreed with BP. Weld
repair procedures shall be included in the full scale trial and shall be located to undergo
maximum strain.
A procedure shall be provided for BP approval detailing the test string and test method. The
following points shall be addressed:
- The type and number of welds. Each qualified WPS shall be included in the trial testpiece.
21 April 2006 GIS 43-331
Page 54 of 56
- The length of the test string and the spacing of the welds.
- The bending frame dimensions and materials.
- The calculated maximum strain (based on the carousel & pipe diameters).
- A step-by-step description of the test.
- The proposed strain rate.
- Trial report proforma.
If a successful track record can be demonstrated using the same vessel to install pipe of similar
properties with similar welding procedures then, at BPs discretion, the full scale trial may be
omitted. The spool base, the time between cycles, and the temperature shall be considered when
evaluating existing data.
C.3.2 Non-destructive testing
The weld procedure tests shall be subjected to the visual and non-destructive testing specified in
Section 5 before and after straining.
C.3.3 Mechanical testing
The strength of the welds shall be greater than the strength of the production pipes, however
excessive overmatch should be avoided.
C.3.3.1 Evaluation of weld proceduresbending trial welds
The welds shall undergo the mechanical testing specified in Section 5. However, the transverse
tensile locations shall be rotated so that the test pieces are removed from the cardinal points. It is
anticipated that this ensures that the areas undergoing maximum straining are tested.
C.3.3.2 Evaluation of weld procedureswaived bend trial
If the full scale trial is waived, the weld procedures shall be subject to the full testing of
Section 5 plus the following strain aged testing. Weld coupons shall undergo 5% tensile strain
and ageing at 250C (480F) for one hour before the following tests are performed:
- 1 all weld tensile specimen
- 2 transverse weld metal specimens
- 1 macrosection + hardness
- 2 sets of weld metal Charpy impact specimens
- 2 sets of fusion line Charpy impact specimens
- 1 set of fusion line + 2 mm Charpy impact specimens
- Weld and HAZ CTODs
The testing shall be undertaken in accordance with Section 5 and the results shall meet the
requirements of Section 5; however any large deterioration of properties compared with the
unstrained specimens shall be cause for investigation.
C.4 Production welding
The maximum permitted pipe misalignment at the weld shall be 1.5 mm (1/16 in) unless larger
misalignments are demonstrated to be tolerable and are agreed by BP.
21 April 2006 GIS 43-331
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Appendix DCTOD testing
D.1 CTOD testing shall be undertaken in accordance with BS 7448 Parts 1 & 2 by a testing
laboratory specifically approved for CTOD testing by BP.
D.2 Testing shall be based on the use of through thickness notched, single edge notched bend
(SENB) specimens (BS 7448 Part 1 paragraph 5.1) in the NP orientation, unless agreed
otherwise by BP.
D.3 Test specimens shall be notched and fatigue cracked to sample the microstructures at the weld
centre line and in the coarse grained HAZ adjacent to the fusion line.
D.4 The number of valid test results employed to determine the characteristic CTOD of the weld
metal and HAZ microstructures shall comply with BS 7910 paragraphs K.2.3 and 7.1.5.5. This
may require a greater number of CTOD specimens than listed in Table 2.
D.5 The test temperature shall be MDT unless otherwise advised.
D.6 Post test metallography shall be used to identify the initiation point and the associated
microstructure on a minimum of three HAZ specimens selected by BP. The initiation point of
all brittle events shall be identified by metallography.
D.7 Any specific requirement for the achievement of a minimum CTOD will be specified on a
project by project basis.
Appendix EPin brazing and aluminothermic welding of anode leads
E.1 Joining technique
Full details of the joining technique and associated equipment should be submitted to BP for
approval prior to use.
E.2 Specification and approval of procedure
E.2.1 General
A procedure specification shall be submitted for BP approval.
Before qualification, the parameters and information to be recorded and shown on the final
WPS shall be proposed for BP approval. Relevant details of the test, including serial or
catalogue numbers of the components and tools used, shall be recorded. For brazing, this shall
include the electrical settings of the power supply.
The procedure should be qualified by making three consecutive test joints, in the presence of
BP, on material to be used in production. The test material should be selected by BP to represent
the upper quartile of the carbon equivalent range.
The electrical resistance of each weld should be measured and should not exceed 0.1. The
mechanical strength of the weld should be tested by means of a sharp blow from a 1 kg (2.2 lb)
hammer.
The test welds should be sectioned and prepared for metallographic examination. The following
tests should be performed on the sections:
E.2.2 Copper penetration measurement
The depth of copper penetration below the surface of the pipe material should be measured
metallographically. The fusion line of the weld or braze should not be more than 1 mm below
the pipe surface. Intergranular copper penetration of the pipe material shall not exceed 0.5 mm
beyond the fusion line when a specimen is examined at a magnification not exceeding X50.
21 April 2006 GIS 43-331
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E.2.3 Hardness survey
Each test section should be tested using an applied load of 10 kg. A traverse should be made
across the weld zone. The traverse should consist of at least six impressions; two in the HAZ
each side of the weld/braze and one in the parent metal each side of the weld/braze.
The hardness values should not exceed 275 HV10 for sour service and pipe thickness less than
9.5 mm (3/8 in), 300 HV10 for sour service and pipe thickness above 9.5 mm (3/8 in) and
325 HV10 for non-sour service.
Add
Bibliography
American National Standards Institute (ANSI)
[1] AWS Z49.1 Safety in Welding, Cutting, and Allied Processes
American Society of Mechanical Engineers (ASME)
[2] ASME B31.3 Process Piping

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