Petroleum Development Oman L.L.C.

UNRESTRICTEDDocument ID : SP-1167 (ERD 43-03)

April 2000

Filing key :

Specification for Welding

on Pressurised Pipes

(Amendments/Supplements to DEP 30.10.60.30-Gen)

Keywords:API RP 1107

Hot Tapping

Inspection

Procedure Qualification Record

Pipelines

Piping

Repair

Testing

Welder Qualification

Welding Procedure Qualification

Welding Procedure Specification

This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part of this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written consent of the owner.

Authorised For Issue

Signed :

UER (OTT/1)

CFDH Materials and Corrosion

The following table lists the four most recent revisions to this document. Details of all revisions prior to these are held on file by the issuing department.

Version No.DateAuthorScope / Remarks

Version 1.005/04/00OTT/15Original issue.

Contents

11.Introduction

1.1Purpose11.2Changes to the Specification12.Specification for Welding on Pressurised Pipes22.1Specification Requirements22.2Process Deliverables22.3Process Owner's Responsibility22.4Performance Levels / Indicators22.5Performance Monitoring22.6Effective period22.7Review and Improvement2Appendix A Glossary of Definitions, Terms and Abbreviations3Appendix BAmendments/Supplements to Part II of DEP 30.10.60.30-Gen4Contents of Appendix B

1General41.4Materials41.4.2Filler Metal41.6Quality Assurance System42.Qualification of Welding Procedures42.1Procedure Qualification42.4Essential Variables42.6Procedure Qualification Tests52.6.1Preparation52.6.6Macro-section tests fillet welds53.Welder Qualification53.1Purpose54.Maintenance Welding54.1General54.8Preheating and Interpass Temperature55Inspection and Testing of Maintenance Welds65.2Right of Inspection65.3Non-Destructive Testing65.4Certification of Non-Destructive Testing Personnel68.Documentation68.2Pre-Welding Documentation68.2.1Content of the Quality Plan6Appendix C References7User Comment Form8

1.Introduction

1.1Purpose

This specification gives the minimum technical requirements for the welding of fittings on to pressurised pipelines, using the SMAW process.

This specification replaces ERD 43-03, Specification for Welding on Pressurised Pipes, issued in January 1996. The basis of ERD 43-03 was API Recommended Practice RP1107, Pipeline Maintenance Welding Practices. Part II of the ERD consisted of amendments and supplements to RP1107. In December 1998, most of the requirements of ERD 43-03 were incorporated into DEP 30.10.60.30-Gen, Welding on Pressurised Pipes, Part II of which includes similar changes to the API document. The DEP has been adopted by PDO as the basis for hot tap welding and related work. Therefore, the technical content of this specification is confined to those aspects of the DEP where the particular requirements of PDO are not adequately covered. These are presented in Part II as amendments and supplements to DEP 30.10.60.30-Gen.

1.2Changes to the Specification

This specification shall not be changed without approval from the Custodian, the Welding Functional Discipline Head (CFDH), UER (OTT/1), who owns this specification. If you think any part of this specification is not correct, write your comments on a copy of the User Comments Form. The form is included as the last page of this specification. Send the copy with your comments and personal details to DCS.

2.Specification for Welding on Pressurised Pipes

This Specification gives the minimum technical requirements for any work, which requires welds to be made on to pressurised pipelines and piping, i.e. hot tap welding and similar operations. It is applicable to both off-plot pipelines or flowlines and to on-plot piping and associated equipment. This specification is not applicable to tanks, vessels, emergency repairs, water pipelines or any piping operating below 10 barg.

2.1Specification Requirements

Welding, and inspection shall be in accordance with the requirements of Part II of DEP 30.10.60.30-Gen, December 1998, (and API RP1107, Third Edition, April 1991), as further amended and supplemented by Appendix B of this specification. The amendments and supplements of the text in Appendix B have been necessary to incorporate special PDO requirements.

The Clause numbering in Appendix B follows that of API RP1107. Where clauses of API RP1107 are amended or supplemented neither by this specification nor by DEP 30.10.60.30 they shall apply in their entirety.

2.2 Process Deliverables

Process deliverables comprise field welds to pressurised pipelines, flowlines and on-plot piping, normally to attach pre-formed split tees, reinforced set-on branches and reduced branch fittings for hot tap connections.

2.3Process Owner's Responsibility

The owner of this specification, OTT/1, as CFDH Welding, is responsible for authorising all proposed deviations or amendments to the specification and for the instigation of periodic reviews and updates in accordance with Clauses 1.2 and 2.7.

2.4Performance Levels / Indicators

See relevant weld inspection and testing acceptance criteria in API RP1107, DEP 30.60.10.30-Gen and the amendments/supplements given in Appendix B of this specification.

2.5Performance Monitoring

Requirements for monitoring welding process variables, welder performance and weld quality are detailed in relevant sections of API RP1107 as amended/supplemented by Part II of DEP 30.10.60.30-Gen and Appendix B of this specification.

2.6Effective period

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

2.7Review and Improvement

This specification will be reviewed and updated once every three years. The review authority will be UER (OTT/1, CFDH Materials and Corrosion).

Appendix A Glossary of Definitions, Terms and Abbreviations

The definitions, terms and abbreviations of DEP30.10.60.30-Gen Part I,( Section 1.3) apply, with the following changes:

General Definitions

Add the following:

CompanyPetroleum Development Oman LLC. (To be taken as synonymous with the term Principal used in the DEP).

Corporate Functional Discipline HeadThe person responsible for the discipline to which the standard belongs.

UserThe Company, Consultant or Contractor designate who uses this document.

mayIndicates a possible course of action

Specific Definitions

Delete the definition for Company.

Abbreviations

Add the following:

CFDHCorporate Functional Discipline Head

DCSDocument Control Section (OTB/2)

TATechnical Authority, as defined in ERD-00-02 and GU-272.

Appendix BAmendments/Supplements to Part II of DEP 30.10.60.30-Gen

1General

1.4Materials

1.4.2 Filler Metal

1.4.2.2 Storage and handling of filler metal

Add the following:

Prior to the commencement of qualification or production welding, whichever is sooner, the Contractor shall submit a consumable handling procedure to the Company for review and approval. Test welding or production welding shall not commence until the consumable handling procedure has been approved by Company TA Level 2 or higher.

1.6 Quality Assurance System

Add the following to the end of the first sentence:

and with PDO specification SP-1171

2. Qualification of Welding Procedures

2.1 Procedure Qualification

Delete the second paragraph and replace as follows:

Qualification welding, NDT and destructive testing shall be witnessed by the Company unless otherwise stated in the Contract Document.

Previously qualified standard welding procedures listed in Company Procedure PR-1276 may be used, subject to the approval of the Company, and the provisions given below:

The essential variables of Section 2.4 of DEP 30.10.60.30 are fully satisfied. Particular attention is directed to item 2.4p.

Any additional test requirements included in PR-1276 or otherwise specified by the Company Welding TA-2 are met. (This may be completed during any welder qualification and/or training required.)

Issue and control of standard PQRs is strictly in accordance with PR-1276. These include preparation by the Contractor of a project-specific WPS for each application.

The Contractors own PQRs may also be submitted to the Company CFDH for consideration provided all the above requirements are met. Essential Variables

2.4Essential Variables

Replace item o. as follows:

Any changes in welding parameters which result in a variation of heat input greater than 10% of that qualified, with the following exception. For root and buttering runs deposited directly on to run pipe of thickness 6.4mm and below, the permitted variation in qualified heat input shall be limited to +0%, -15%.

2.6 Procedure Qualification Tests

2.6.1 Preparation

Add the following:

All testing shall be witnessed by a Company Representative or a Company approved third party inspection agency. The Contractor shall confirm the availability of the Company Representative. In the event of the Company Representative not witnessing the testing, the Contractor shall be responsible for the engagement and hiring of the inspection agency. All test reports shall be endorsed and signed by the testing organisation, the Contractor, and the inspector who witnessed the testing. Where an inspection agency has witnessed the testing, the agency shall also issue a Certificate of Conformance, which states that the testing practices and procedures were in compliance with API RP1107, DEP 30.10.60.30-Gen and this specification. The test reports and certification shall be included in the PQR.

2.6.6Macro-section tests fillet welds

2.6.6.3 Acceptance criteria

Replace the first paragraph as follows:

For material designated to meet the requirements of either sour service, NACE MR0175 or DEP 31.40.31-Gen., the maximum root and mid-thickness hardness shall be 248 HV10. The maximum cap hardness shall be 275 HV10.

3.Welder Qualification

3.1Purpose

Replace the first sentence of the second paragraph as follows:

Test welding shall be witnessed by the Company. Welding parameters shall be monitored by the Contractor to demonstrate that consistent control of the heat input ranges specified in the applicable WPS is achieved.

4.Maintenance Welding

4.1General

(e)Replace third sentence with the following:The magnetic particle inspection procedure shall be in accordance with ERD-07-02.

4.8Preheating and Interpass Temperature

(c)Circumferential fillet welds

Insert the following before the first sentence:

The provisions for circumferential fillet welds shall also apply to the welding of reduced branch fittings to pressurised run pipe. Where preheating is by induction or resistance-heating methods, the procedure for preheat maintenance during welding shall be agreed by the Company, based on previously established data.

Add the following:

NOTE:On thin wall run pipe (4.8 - 6 mm), a minimum preheat temperature lower than 150C may be necessary during deposition of the initial buttering and/or branch root runs. Any such change would be established from the feasibility study (DEP 31.38.60.10-Gen) and procedure qualification tests. In all cases, the deviation shall be authorised by the Company welding CFDH and detailed in the approved WPS.

5Inspection and Testing of Maintenance Welds

5.1Right of Inspection

Add the following:

All field welding shall be witnessed by the Company at a minimum level of TA-3.

5.3Non-Destructive Testing

Replace the last sentence with the following:

All magnetic particle inspection shall be performed in accordance with a Company approved procedure meeting the requirements of ERD-07-02. The procedure shall be submitted to the Company prior to test welding or production welding, whichever is the sooner.

5.4Certification of Non-Destructive Testing Personnel

Delete existing section and replace as follows:

All non-destructive examination personnel shall be qualified and certificated for the method of NDT to be carried out in accordance with ISO 9712 to NDT Level 2 or higher. The roles and responsibilities of NDT personnel shall be as defined in the levels of competence in ISO 9712. Personnel certified to ASNT Level II are acceptable provided that the certifying Level III NDT Engineer has been approved by the Company.

Equivalent inspection and NDT qualifications e.g. CSWIP/PCN Tester/Practitioner/ Interpreter (Welds), Level 2, may be accepted at the sole discretion of the Company.

If, in the opinion of the Company, welding examination or non-destructive examination personnel fail to perform to a satisfactory standard, they shall be disqualified from the works until such time that it can be demonstrated by the Contractor that they have achieved a satisfactory standard by undertaking, at the Contractor's expense, a test by a third party agency approved by the Company.

8. Documentation

8.2 Pre-Welding Documentation

8.2.1Content of the Quality Plan

In the second paragraph, replace reference to ISO 10005 with: SP-1171.

Replace the text of item 2 as follows:

2.Reference to ANSI/API RP1107, DEP 30.10.60.30-Gen and this specification.

Appendix C References

The following changes are applicable to Appendix C of DEP 30.10.60.30-Gen:

PDO Standards

Add the following references:

Technical Authorities System

Non-Destructive Examination (Amendments/Supplements to ASME Section V)

Guideline for Granting Technical Authority System

Standard Procedure Qualification Records for Welding on Pressurised Pipes

Quality Assurance Specification for Engineering Works

ERD-00-02

ERD-07-02

GU-272

PR-1276

SP-1171

Shell Group Standards

Add the following references:

Welding on Pressurised Pipes (Amendments/Supplements to ANSI/API RP 1107)DEP 30.10.60.30-Gen

American Standards

Delete reference to ASTM E 1444.

International Standards

Delete reference to ISO 10005

User Comment Form

User Comment Form

If you find something that is incorrect, ambiguous or could be better in this document, write your comments and suggestions on this form. Send the form to the Document Control Section (DCS). They make a record of your comment and send the form to the correct CFDH. The form has spaces for your personal details. This lets DCS or the CFDH ask you about your comments and tell you about the decision.

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