Vous êtes sur la page 1sur 14

w i '

p &) c=.~)sJl
(4. Jd& ZA
KUWAIT OIL COMPANY (K.S.C.)

Engineering Group

Specification Number
0 75-WH- 7002
Field Welding Requirements
Including: Welding, Heat Treatment and ND T of
Piping (Form 167A)

1 5 AUG 94 ISSUED AS KOC ENG GROUP SPEC


0 7 MAR 93 ISSUED FOR INVITATION TO BID SS

Rev Date Revision BY Chkd Section PE Client


Specification Number Rev Date Sheet

0 KOC Engi&ng
spwmam
Gmp
01 5-WH-1002 0 05-8-94 2 0 f 14

CONTENTS

1.0 SCOPE ............................................... 3

2.0 STANDARD SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3.0 WELDING PROCESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.0 MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 . 1 Base Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 . 2 Backing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.3 Weld Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5.0 WELDING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6.0 WELDER AND WELDING OPERATORS ......................... 5

7.0 WELDING .SPECIFIC NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

8.0 WELDING .GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

9.0 REPAIRS ............................................. 5


10.0 HEATTREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10.1 Preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10.2 Post-Weld Heat Treatment (PWHT) . . . . . . . . . . . . . . . . . . . . . . . 6

1 1.0 NON-DESTRUCTIVE EXAMINATION (NDE) . . . . . . . . . . . . . . . . . . . . . . 6


1 1.4 Requirements for particle inspection . . . . . . . . . . . . . . . . . . . . . . 11
1 1.5 Requirements for Liquid Penetrant Inspection . . . . . . . . . . . . . . . . 12

12.0 RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

13.0 PACKING. MARKING AND DOCUMENTATION . . . . . . . . . . . . . . . . . . . . 13


E n g W n g Grwp
SpdtkWbn
Specification Number

015-WH-1C--
I R~ I I Sheet
-... I
1.0 SCOPE

1.1 This specification covers the welded fabrication of pipework and equipment
for installation at the Facility in Kuwait.

1.2 Field welding shall fully comply with all relevant contractual requirements
specified in the Scope of Work and the Technical Specification of the
Contract.

1.3 This general field welding specification shall be used in conjunction with the
applicable approved Welding Procedure Specifications (WPS). It is intended
as a control document for pipe and pipe spool fabrication.

2.0 STANDARD SPECIFICATIONS

2.1 All field welding shall conform, except where otherwise specified, to the
current issue and amendments of the following standards prevailing on the
effective date of the Contract:

2.1.1 International Standards

ASME 831.3 Chemical Plant and Petroleum Refinery Piping

ASME 831.4 Liquid Transmission Systems for Hydrocarbons,


Liquid Petroleum Gas, Anhydrous Ammonia, and
Alcohols

ASME B31.8 Gas Transmission and Distribution Piping


Systems

ASME V Non-Destructive Examination

ASME IX Welding and Brazing Qualifications

2.1.2 Engineering Group Specifications

0 15-AH-1001 Basic Design Criteria

0 15-AH- 1002 International Codes and Standards

015-KH-1902 Spare Parts and Maintenance Requirements

01 5-UH-1001 Packing, Marking and Documentation

01 5-WH-1001 Welding ProcedureApproval and Welding Quality


Requirements

015-XH-1005 Shop and Field Painting


2.2 Compliance with this specification shall not relieve the Contractor of its
responsibility to supply equipment suited to meet the specified service
conditions and applicable regulations.

2.3 Where conflicts exist between this specification and other Drawings
standards, codes and specifications, the most stringent shall be applied.

3.0 WELDING PROCESSES

The welding process, or combination of welding processes, and process variables,


shall be specified in the applicable WPS.

4.0 MATERIALS

Base Metal

4.1.1 Only the P group of materials referenced in a WPS may be welded


with that WPS.

4.1.2 Impact tested materials require additional qualification within a P


group.

Backing Materials

Use of backing materials is not allowed.

Weld Consumables

4.3.1 Weld consumables shall conform to the type specified in the WPS.

4.3.2 All weld consumables shall be purchased with batch certification.

4.3.3 Low-hydrogen and alloy consumables shall be purchased in


hermetically sealed containers.

4.3.4 As a minimum, all weld consumables shall be stored in accordance


with the Approved Manufacturer's recommendations.

4.3.5 Bakinglstorage ovens and portable heated quivers shall be used as


and when required by the Approved consumable Manufacturers.

4.3.6 Electrodes and flux that are damaged or wet shall be scrapped.

4.3.7 A system for recording the issue of consumables shall be maintained.

5.0 WELDING EQUIPMENT

All welding plant and equipment shall be maintained in good working order, with
a regular service schedule.
--

6.0 WELDER AND WELDING OPERATORS

All welders and welding operators shall be tested onsite in accordance with
ASME Section IX and under supervision of the Company's inspection staff.

Each welder and welding operator shall be issued with a qualification


certificate for each test passed. The certificate shall be issued by the
Company.

A full register of welder and welding operator qualifications and certificates


shall be maintained onsite.

A weld register shall be maintained detailing the repair rates for each
qualified welderlwelding operator.

Welderslwelding operators with an unacceptable repair rate shall be


retested andlor given an additional training period, followed by retest.

7.0 WELDING - SPECIFIC NOTES


For specific notes on welding, refer to individual piping classes and notes in the
attached form 167A.

8.0 WELDING - GENERAL


Only submitted and approved WPS as listed on the form 167A shall be
used.

Galvanized, coated, primed or painted surfaces shall be removed back to


clean metal for a minimum distance of 75 mm from the intended weld
bevel1 end.

Prior to welding, the bevellend face and adjacent surfaces shall be cleaned
by filing, brushing, grinding or by the use of approved solvents.

All welding surfaces shall be free of oil, grease and other contaminants.

Tack welds, if forming part of the root pass, shall have the start and stop
ends ground smooth to blend into the root. All defective tack welds shall
be removed.

Vertical down welding is not permitted.

Peening is prohibited on all weld passes.

9.0 REPAIRS

Repairs shall be carried out using the welding parameters detailed on the original
approved WPS.
10.0 HEAT TREATMENT

10.1 Preheat

10.1.1 Minimum preheat temperatures shall be as stated on approved


WPS and the applicable standards and codes.

10.1.2 Under no circumstances shall preheats be less than those


stated on the form 167A.

10.1.3 Contact pyrometers and/or temperature indicating crayons


shall be used to monitor preheats.

10.1.4 Preheat shall be maintained over a distance of 3 in. on either


side of the weld.

10.2 Post-Weld Heat Treatment (PWHT)

10.2.1 PWHT shall be performed when specified on the form 167A


and/or applicable WPS and standards.

10.2.2 PWHT range shall be 580°C to 620° C (1080°F to 1150°F)


. The cooling rate from 600°C to 400°C shall not exceed
200°C/hr.

10.2.3 Where PWHT is subcontracted, the Subcontractor shall submit


PWHT procedures for reviewlapproval by the Company.

10.2.4 PWHT shall be recorded on charts via thermocouples, full


records of each PWHT must be maintained.

11.0 NON-DESTRUCTIVE EXAMINATION (NDE)

1 1.1 The minimum required percentage of NDT for piping shall be as specified on
the form 167A and shall be in accordance with the relevant code
requirements.

11.2 All NDTs shall be carried out in accordance with the design code, standard,
specification and the requirements detailed hereinafter. The capabilities of
the Contractor should include as a minimum any or all the following
methods of testing: radiography (X and gamma rays), magnestic particle,
dye penetrant, vacuum box testing, ultrasonics and eddy current).

11.3 The responsibility of the Contractor should ensure the following:

11.3.1 To perform only examinations for which he is adequately


equipped and staffed.
Specification Number
EngillOOIJng Grwp
01 5-WH-1002
Spd&wbn

11.3.2 His employees perform only examinations for which they are
qualified.

11.3.3 His equipment is calibrated and personnel certified.

11.3.4 Maintain a complete record of his equipment and update all


licenses from authorities for using radiation sources, personnel
and location of storing such radiation sources.

11.3.5 To submit to the Company final reports of all examinations


that indicate compliance or non-compliance of the job
required.

The Company shall have the right to inspect the procedures


and equipment and to review personnel qualifications.

A written procedure for each NDT to be used shall be


submitted to the Company for review and approval.

All NDT employees should have qualifications in NDT in the


fields to which they are engaged. ASNT Level Ill, 11, I or
CSWlP and PCN are the qualifications required in evaluating
the Contractor's staff.

11.4 The following section defines the minimum requirements for radiography
work to be carried out by the Contractor or his approved Subcontractor.

11 .4.1 Procedure

A detailed procedure and production of images shall be


prepared by the Contractor for Company approval which shall
include the following:

Radiation source machine identification.

Approved Film Manufacturer and relevant ASTM Class.

Intensifying scree.

Exposure geometry (double wall double imageldouble


wall single imagelor single wall single image).

Source film distance or focal film distance.

Number of exposures required for radiography of a


complete weld.

Exposure conditions and exposure time.


Specification Number Rev Date Sheet

- ---
w----
015-WH-1002 0 05-8-94 8 o f 14

h. Processing (manual or automatic).

i. Material thickness range.

j. Penetrameters (IQI):type, material and related standard.

k. Density and sensitivity.

I. Collimator or field limitation device.

m. Safety precautions and aids.

11-4.2 Minimum Requirements for Radiographic Examination

X-radiography shall be used for Site inspection unless


prior approval is obtained for the use of the isotape
lridium 192.

The density through the weld metal shall not be less


than 1.8 and not more than 3. The Company has the
right to check the Contractor's unexposed films at any
time and from any lot of films intended to be used by
the Contractor.

The following types of industrial radiographic films shall


be used for X-Ray and lridium 192:

1. For lridium 192 Radiography:

I Class 1 I Low-Speed Film For Material


Thickness < 0.50"
Class 2 Med.-Speed Film For material Thickness
> 0.50" but not

s2.
Class 3 High-speed Film

For X-Ray Radiography:


exceeding 1"
For material
Thickness < 1",

Mat'l Thickness (inch) K.V. Range Film Class


Specification Number Rev Date Sheet

QKOC-
E ~ i t m d n Grwp
'n
g
015-WH-1002 0 05-8-94 9 of 14

Upto 114 inclusive


Upto 114 inclusive
> 114 - 112 inclusive
> 114 - 112 inclusive
> 112 - 1 inclusive
> 1 inclusive

d. Penetrameters (IQI)

Quality indicator (penetrameter) shall conform to


ASTM-E747 for wire penetrameter or any
alternative standard for wire penetrameter
subject t o Company approval.

At least one penetrameter per radiograph


exposed simultaneously with the specimen shall
be used.

The penetrameter shall be based on weld


thickness.

e. Sensitivity:

2% or better sensitivity is required.

f. Exposure Geometry:

Double wall double image technique shall be used


for piping of less than 3 112-in. inclusive. At
least two exposures separated by 90 degrees
shall be made for the radiographic inspection of
a complete weld. One penetrameter on the
source side with its length perpendicular to the
weld shall be used.

For single wall single image, at least four


penetrameters spaced approximately equally
around the circumference of the pipe shall be
used at source side.

Double wall single image shall be used for pipe


diameter > 3 112 in. The penetrameter shall be
placed on source side if applicable; otherwise it
shall be placed on film side at the mid length of
the film: an overlap of at least 2 in. is required
between shots.

-
g. Identification of Locations Markers on Radiographs

Each radiograph shall be identified so that there


is a permanent correlation between the part
radiographed and the film.

The types of identification and method of


identification shall be as per the Contractor's
procedure unless otherwise specified by the
Company.

The letter "R" should be used t o designate a


radiography of repaired area.

The exact location of location markers should be


clearly marked on the surface being radiographed
so that the area of interest can be identified
accurately.

When more than one image is used t o inspect a


weld, identification markers shall overlap at a
minimum of 2 in. The last reference marker on
each end of the image shall appear on the
appropriate adjacent images in a way that no
part of the weld could be omitted.

h. Radiographic Report

The format of radiography results shall be based on this


specification and shall be agreed upon with KOC prior
t o implementation of the work.

i. Interpretation

1. Prior t o any weld repairs, the radiographs,


attached with the radiography report and any
relevant Drawings, shall be submitted t o the
Company Inspector.

2. The designated length for interpretation shall not


contain any discontinuities whose severity
exceeds that allowed in the related code,
standard, specification or Company limitations.

3. When t w o or more types of weld defects are


present in the same radiograph whose extent
equals the maximum acceptable limit for both,
the weld shall be judged unacceptable.
Specification Number Rev Date Sheet
Eng/&ng Grwp
01 5-WH-1002 0 05-8-94 11 of 14

4. Radiographs showing processing defects,


improper density or sensitivity, or any image that
masks the weld or adjacent base metal shall not
be submitted for interpretation.

j w Record of Radiographic Examination

1. The Contractor shall produce a record for all films


with their identification marks on a developed
shall plate diagram (for tanks), on isometrics or
plans (for piping) and on the welding key plan
(for other equipment).

2. Upon completion and acceptance of the relevant


equipment or piping and all other related works
by the Company, all radiographic films shall be
handed over to the Company in good condition
when they will become the sole property of the
Company and shall be retained for a minimum
period of 5 years.

k. Radiography work shall be at the expenses of the


Contractor. Should the Company request for additional
radiography, it will be at the Company's expense
unless such radiographs reveal conditions which do not
meet the Contract specification. The cost of the
rework of these non-conforming conditions including
that of radiography shall be to the Contractor's
account.

11.4 Requirements for particle inspection shall be as follows:

11.4.1 Equipment for magnetization of parts shall be capable of


inducing flux density of sufficient intensity and direction to
perform the required job.

1 1.4.2 Either AC or DC (full wave or half wave rectified) equipment


or permanent magnets shall be used as specified in the
Contractor's procedureto produce the required magnetization.
Flexible movable legs of the yoke should be available for work
requirements.

11.4.3 Magnetic particle may be applied wet or dry. Dry particles


should be applied uniformly with a dusting or light blowing
action. Wet particles should be applied by aerosol cans or by
hosing. Provisions should be made available to ensure that
Specification Number Rev Date Sheet
Eng/I)OOY/ngGmup
01 ~-WH-IOO~ o 05-8-94 12 of 14
SpiWfmbn

the required amount of particles are in the suspension when


the spray is applied and to periodically check the concentration
of the solution. When fluorescent dyed particles are use,
ultraviolet (UV) light (3200- 3800 A") must be available.

1 1.4.4 Equipment for demagnetization should be available for


demagnetizing parts to the minimum residual field.

11.5 Requirements for Liquid Penetrant Inspection shall be as follows:

11.5.1 The Contractor should prepare the necessary apparatus to


apply the penetrant, wash the surface of the part, dry the part
and apply a developer and a properly lighted area in which the
part can be inspected by the Company. The inspection
materials should not aversely affect the parts to be tested.
When fluorescent dyed particles are used, UV light. (3200-
3800 A) must be available.

11.5.2 Only aerosol cans for cleaner, penetrant and developers shall
be used in order to allow for smooth flow of parts.

11.6 When specifying vacuum box test method, the equipment should be
capable of producing vacuum pressure of 350 m bar with good viewing
appearance without any noticeable air leakage through the rubber sealing.

11.7 NDT shall be carried out after completion of any PWHT where PWHT is
specified.

11.8 The use of ultrasonic (UT) examination of welds, in place of radiography,


is subject to Company approval.

1 1.9 Each weld subject to NDT shall be given a unique identification traceable to
an isometricldrawing.

1 1 .I0 All other NDT requirements shall be in accordance with the relevant
codes and standards.

12.0 RECORDS

12.1 Weld records shall be maintained at the Site of the Facility and as a
minimum shall consist of the following:

12.1.I Marked isometrics detailing all shop and field erection welds
made.

12.1.2 Marked drawings of field run pipework detailing all field welds
made.

-
Specification Number Rev Date Sheet
EwiMng Grwp
01 6-WH-1002 0 05-8-94 13 of 14
-n

12.1.3 Approved weldinglNDT1PWHT procedures.

12.1.4 Welderlwelding operator qualification records.

12.1.5 NDT personnel qualifications.

12.1.6 NDT records (including radiographs).

12.1.7 PWHT charts and records.

13.0 PACKING, MARKING AND DOCUMENTATION

For all relevant requirements, refer to the Engineering Group Specification entitled
"Packing, Marking and Documentation" (Number 01 5-UH-1001).