Specification 580 Rev. 0 - Pipelines Welding and NDT Testing

TABLE OF CONTENTS
1.
INTRODUCTION .........................................................................................................................................5
1.1 General ............................................................................................................................................5
1.2 Scope ..............................................................................................................................................5
1.3 Quality Assurance.............................................................................................................................5
1.4 Quality Plan......................................................................................................................................5
1.5 Inspection Notice .............................................................................................................................5
1.6 Terms and Definitions ......................................................................................................................6
1.7 Abbreviations ...................................................................................................................................6
2.
REFERENCED CODES, STANDARDS AND SPECIFICATIONS .........................................................................7

2.1 Codes and Standards .......................................................................................................................7
3.
GENERAL ..................................................................................................................................................9
3.1 Scope ..............................................................................................................................................9
3.2 Welding Processes ...........................................................................................................................9
Table 1:
Welding Processes and Consumables:............................................................................................. 9
3.3 Welding Consumables ......................................................................................................................9
3.4 Storage and Handling of Welding Consumables ..............................................................................10
3.5 Equipment .....................................................................................................................................10
3.6 Personnel.......................................................................................................................................11
4.
QUALIFICATION OF WELDING PROCEDURES ............................................................................................12

4.1 Welding Procedure Specifications...................................................................................................12
4.2 Welding Procedures - Essential Variables........................................................................................13
4.3 Procedure Qualification Test Welds.................................................................................................13
Table 2:
Extent of testing complete butt weld: ............................................................................................. 14
Table 3:
Extent of testing for full penetration repair: ................................................................................... 15
Table 4:
Extent of testing for partial penetration repair: .............................................................................. 15
Table 5:
Extent of testing for single pass cap repair .................................................................................... 16
4.4 Mechanical Testing of Welding Procedure Qualification test welds ..................................................16
Table 6:
Charpy requirements weld testing: ................................................................................................. 17
Table 7:
Hardness value requirements: ........................................................................................................ 17
4.5 Permitted Welding Procedure Qualification retests..........................................................................18
4.6 Failure Of Welding Procedure Qualification Tests ............................................................................18
4.7 Brazing and aluminothermic welding of anodic bonding leads .........................................................18
Figure 1: Requirements for hardness traverse and impressions ................................................................. 19
4.8 Weld Procedure Qualification Record(s) ..........................................................................................20
Table 8:
Checklist WPQ Records.................................................................................................................... 20
5.
QUALIFICATION OF WELDERS ..................................................................................................................21

5.1 General ..........................................................................................................................................21
5.2 Welder Certificate...........................................................................................................................21
5.3 Re-qualification of welders .............................................................................................................22
5.4 Anode cable pin brazers .................................................................................................................22
5.5 Welder qualification: weld inspection and testing ............................................................................22
Table 9:
Welder Qualification Tests Requirements per Welder ................................................................... 22
6.
PRODUCTION WELDING...........................................................................................................................23
6.1 General ..........................................................................................................................................23
6.2 (Line) Pipe Preparation ...................................................................................................................23
6.3 Alignment.......................................................................................................................................23
Table 10: Permitted misalignment of surfaces (EN 12732:2000 Table G1) ................................................... 24
6.4 Weather Protection ........................................................................................................................24
6.5 Tack Welds ....................................................................................................................................24
6.6 Stray Arcs.......................................................................................................................................24
6.7 Inter-Run Cleaning..........................................................................................................................24
6.8 Preheat and Interpass Temperature ...............................................................................................24
6.9 Partially completed welds ...............................................................................................................25
6.10 Post-Weld Heat Treatment ..............................................................................................................25
6.11 Material Traceability and Weld Identification...................................................................................25
6.12 Production Weld Tests ....................................................................................................................26
GDF SUEZ E&P Nederland B.V.

Specification 580, Rev. 0
Page 2 of 54
7.
REPAIR WELDING....................................................................................................................................27
7.1 General ..........................................................................................................................................27
7.2 Defect Removal..............................................................................................................................27
7.3 Inspection of Weld Repairs .............................................................................................................27
7.4 Record of Weld Repair....................................................................................................................28
7.5 Weld Repair Rate ...........................................................................................................................28
8.
INSPECTION AND TESTING OF PRODUCTION WELDS................................................................................29

8.1 Visual Inspection ............................................................................................................................29
8.2 Non-destructive Testing ..................................................................................................................29
8.3 Acceptance Criteria NDT.................................................................................................................29
9.
RADIOGRAPHY ........................................................................................................................................30
9.1 Radiographic Procedures................................................................................................................30
9.2 Procedure Radiographs ..................................................................................................................30
9.3 Production Radiography .................................................................................................................30
9.4 Radiation Protection.......................................................................................................................31
9.5 Qualification of Radiographers........................................................................................................31
9.6 Film Identification...........................................................................................................................31
9.7 Film Processing ..............................................................................................................................31
9.8 Storage of Unexposed films ............................................................................................................31
9.9 Storage of Radiographs ..................................................................................................................32
10.
MANUAL ULTRASONIC TESTING................................................................................................................33
11.
AUTOMATED ULTRASONIC TESTING (AUT) ................................................................................................34

11.1 Approval of Contractor, Operators and System ................................................................................34
11.2 AUT System ....................................................................................................................................34
11.3 Calibration Block for pulse-echo and through-transmission technique .............................................35
Table 11: Tolerances of reflectors: .................................................................................................................. 35
11.4 Calibration time of flight diffraction technique: ................................................................................36
Table 12: Tolerances of notches:..................................................................................................................... 36
11.5 Procedure ......................................................................................................................................36
11.6 Inspection ......................................................................................................................................37
11.7 Pulseecho and through transmission technique............................................................................37
11.8 Time of flight diffraction..................................................................................................................37
11.9 Repeat inspection ..........................................................................................................................37
11.10 Surface condition and Temperature ...............................................................................................37
11.11 Couplant .......................................................................................................................................38
11.12 Ultrasonic equipment pulse-echo and through transmission...........................................................38
11.13 Ultrasonic equipment TOFD ........................................................................................................38
11.14 Probes ..........................................................................................................................................38
11.15 Monitor/display .............................................................................................................................38
11.16 Storage .........................................................................................................................................38
11.17 Qualification of AUT system ...........................................................................................................39
11.18 Inspection of Weld Repairs ............................................................................................................39
12.
SURFACE EXAMINATION ..........................................................................................................................40

12.1 Magnetic Particle Inspection (MPI).................................................................................................40
12.2 Dye Penetrant Inspection (DPI) ......................................................................................................40

Page 3 of 54
13.
INTERPRETATION AND ACCEPTANCE CRITERIA FOR N.D.T. .......................................................................41

13.1 Acceptance Criteria Visual .............................................................................................................41
Figure 2: Angle of incidence between parent metal and weld ...................................................................... 41
13.2 Acceptance Criteria Radiography ...................................................................................................41
13.3 Acceptance Criteria Manual Ultrasonic Testing...............................................................................41
13.4 Mechanised Pulse Echo + TOFD: Interpretation and sizing of weld defects .....................................41
13.5 Acceptance Criteria Mechanised Pulse Echo + TOFD ......................................................................42
13.6 Acceptance Criteria Magnetic Particle Inspection ...........................................................................42
13.7 Acceptance Criteria Dye Penetrant Inspection ................................................................................42
14.
REPORTING OF N.D.T. .............................................................................................................................43

14.1 General .........................................................................................................................................43
14.2 Specific MPI
43
14.3 Specific Dye Penetrant............................................................................................................................. 43
14.4 Specific Ultrasonic.................................................................................................................................... 43
14.5 Specific AUT
43
14.6 Specific Radiographic: ............................................................................................................................. 44
15.
DOCUMENTATION ...................................................................................................................................45
15.1 General .........................................................................................................................................45
15.2 Initial Submissions ........................................................................................................................45
15.3 Final Documentation .....................................................................................................................45
15.4 Storage by CONTRACTOR ...............................................................................................................46
15.5 Delivery Documentation ................................................................................................................46
APPENDIX 1: MECHANICAL TEST REQUIREMENTS PIPE WELDS.................................................................47
Appendix 1A
Sample locations mainline weld .................................................................................. 47
Appendix 1B
Sample locations Full Penetration Repair................................................................... 47
Appendix 1C
Sample locations Partial Penetration Repair .............................................................. 48
Appendix 1D
Sample locations Cap Repair....................................................................................... 48
APPENDIX 2: IMPACT TESTING DETAILS ....................................................................................................49
Appendix 2A
Charpy details mainline weld and full penetration repair .......................................... 49
Appendix 2B
Charpy details partial penetration repair .................................................................... 49
APPENDIX 3: HARDNESS TESTING DETAILS ..............................................................................................50
APPENDIX 4: RADIOGRAPHIC ACCEPTANCE CRITERIA:...............................................................................51
APPENDIX 5:MANUAL ULTRASONICS ACCEPTANCE CRITERIA ....................................................................52
APPENDIX 6:Mechanised Pulse Echo + TOFD Acceptance Criteria .............................................................53
Acceptance criteria based on good workmanship ............................................................................................. 53

Page 4 of 54
1.
INTRODUCTION
1.1
GENERAL
GDF SUEZ E&P Nederland B.V. (GDF SUEZ) is a company producing hydrocarbons in the Dutch sector
of the North Sea. For this purpose several production and treatment facilities have been installed
along with connecting pipelines.
1.2
SCOPE
1.2.1
The purpose of this document is to define the minimum requirements for the approval of welding
consumables, welding processes, welding operators as well as production welding and weld
inspection of carbon steel pipelines in compliance with and in addition to the requirements of EN
12732:2000, NEN 3650-2:2003, and EN 288-9:1999.
1.2.2
A Scope of Work will be issued giving project specific requirements which shall include design details
and the requirement (or not) for Nickel content and CTOD testing.
1.3
QUALITY ASSURANCE
1.3.1
CONTRACTOR shall have in operation an approved Quality System based on the requirements of ENISO 3834 Parts 1, 2 and 4: 2006 (see also table 2 in EN 12732:2000).
1.3.2
CONTRACTORs Quality Manual(s) shall be submitted for review, by GDF SUEZ, as part of his bid
documents.
1.4
QUALITY PLAN
1.4.1
CONTRACTOR shall submit a Quality Plan, based on his Quality Manual (s), covering all operations to
GDF SUEZ for approval. CONTRACTOR's subsequent Quality Control of the work shall strictly adhere
to the agreed Quality Plan.
1.4.2
Quality Plan shall show hold, witness, review, monitor and approve points for GDF SUEZ and
CERTIFYING AUTHORITY. Regarding inspection, the Quality Control Plan shall include:
A flowchart illustrating each inspection point and its relative location in the procedure cycle,
where conformance of characteristics is verified.
The characteristics to be inspected at each inspection point, the procedures and acceptance
criteria to be used. The procedures shall be provided to GDF SUEZ, as requested.
Copies of specific forms used by CONTRACTOR to record the results of each inspection.
1.4.3
CONTRACTOR shall maintain quality records as documentary evidence of compliance with quality
requirements. Quality records shall be available to GDF SUEZ for analysis and review.
1.4.4
All CONTRACTOR inspection systems shall be subject to evaluation and checks by GDF SUEZ to
ensure that the system is effectively applied and meets the requirements of this specification.
1.4.5
CONTRACTOR shall employ experienced and competent supervisors to ensure that both the standard
of workmanship and the quality of materials used comply with the requirements of this specification.
1.5
INSPECTION NOTICE
1.5.1
CONTRACTOR shall give GDF SUEZ and CERTIFYING AUTHORITY inspectors at least five working days
notice of the time and location of fabrication, inspection and testing work. All production shall be
subject to inspection by GDF SUEZ and/or the CERTIFYING AUTHORITY.
1.5.2
Intermediate inspections and/or examinations carried out or stage approvals given by GDF SUEZ or
the CERTIFYING AUTHORITY do not absolve the CONTRACTOR from his responsibility that the
material(s), welding and testing have to comply fully with all rules, regulations and specifications.

Page 5 of 54
1.6
TERMS AND DEFINITIONS

The following terms and definitions apply in this Specification:
1.7
GDF SUEZ
GDF SUEZ E&P

representative
Nederland
B.V.
or
its
CONTRACTOR
Engineering and Installation Contractor appointed by GDF

SUEZ
CERTIFYING AUTHORITY
Any authority required by law and/or as nominated by GDF

SUEZ in accordance with the Contract for which certificates
shall be obtained before the work shall be accepted by GDF
SUEZ as well as those persons acting as its representatives.
shall
indicates a mandatory requirement.
should
indicates a preferred method.
ABBREVIATIONS
The following abbreviations have been used and apply in this Specification:
AUT
CSWIP
CW
CTOD
DN
DPI
FCAW
FL
GMAW
GTAW
HAZ
IQI
LR
MAG
MIG
MMAYS
MMATS
MPI
MRB
NDT
PAM
PO
PWT
SAW
SMAW
SMTS
SMYS
SVGA
TOFD
UT
WPQ(R)
WPS
WPT

Automatic Ultrasonic Testing

Certification Scheme for Welding & Inspection Personnel
Centre (line) of Weld
Crack Tip Opening Displacement
Diameter Nominal
Dye Penetrant Inspection
Fluxed Core Arc Welding
Fusion Line
Gas Metal Arc Welding
Gas Tungsten Arc Welding
Heat Affected Zone of Weld.
Image Quality Indicators
Latest Revision
Metal Active Gas (welding)
Metal Inert Gas (welding)
Materials Maximum Allowable Yield Strength
Materials Maximum Allowable Tensile Strength
Magnetic Particle Inspection
Manufacturing Record Book
Non Destructive Testing.
Portable Arc Monitoring
Purchase Order
Production Weld Test
Submerged Arc Welding
Shielded Metal-Arc Welding
Specified Minimum Tensile Strength
Specified Minimum Yield Strength
Super Video Graphics Array
Time of Flight Diffraction
Ultrasonic Testing
Welding Procedure Qualification (Records)
Welding Procedure Specification
Welding Production Test
Page 6 of 54
nominated
2.
REFERENCED CODES, STANDARDS AND SPECIFICATIONS
2.1
CODES AND STANDARDS
2.1.1
All Work covered by this Specification shall be performed by CONTRACTOR, as a minimum, in

accordance with the requirements of the following referenced codes and standards;
NEN 3650-2:2003
Requirements for Steel Pipeline Transportation Systems.
NEN 3653:2009
Methods for the determination of NDE acceptance criteria for defects in pipeline girth
welds.
EN 12732:2000
Gas supply systems-Welding Steel pipe work - Functional requirements.
API 1104: 2005 Errata

1 2007
Welding of Pipelines and Related Facilities

Alternative Acceptance Standards for Girth Welds
Boiler and pressure vessel code, section 5: article 4, mandatory appendices numbers I
and II and article 5 mandatory appendices numbers I and II (July 2001)
ASME BPV 5
BS 7448:pt 2.:1997
Fracture mechanics toughness tests: CTOD.
EN 10045-1:1990
Metallic materials Charpy impact test Part 1: Test method.
EN 10204:2004
Metallic Products Types of inspection documents.
EN 10208-2:2009
EN 10246-17:2000
EN 10246-18:2000
EN 1043-1:1995
Steel Pipes for pipelines in combustible fluids Technical delivery conditions Part 2:
Pipes of requirement class B.
Non-destructive testing of steel tubes Part 17: Ultrasonic testing of tube ends of
seamless and welded steel tubes for the detection of laminar imperfections.
Non-destructive testing of steel tubes Part 18: Magnetic particle testing of tube ends
of seamless and welded steel tubes for the detection of laminar imperfections.
Destructive test on weld in metallic materials-Hardness testing-Part 1: Hardness test
on arc welded joints.
EN 12668-2:2001
Characterization and verification of ultrasonic examination equipment. Part 2: Probes .
EN 12668-3:2000
Characterization and verification of ultrasonic examination equipment. Part 3:

Combined equipment.
EN 1290:1998
A2:2003
EN 1291:1998
A2:2003
EN 1321:1997
EN 1418:1998
EN 1435:1997
A2:2003
EN 15609-1:2004
EN 1668:1997
EN 1714:1998
EN 24063:1992
EN 25580:1992
EN 287-1:2004
A2:2006
EN 288-9:1999
EN 462-1:1995
Non-destructive examination of welds Magnetic particle examination of welds.

Non-destructive examination of welds- Magnetic particle testing Acceptance levels.
Destructive tests on welds in metallic materials Macroscopic and microscopic
examination of welds.
Welding personnel. Approval testing of welding operators for fusion welding and
resistance weld setters for fully mechanized and automatic welding of metallic
materials
Non-destructive examination of welds Radiographic examination of welded joints.
Specification and qualification of welding procedures for metallic materials Welding
procedure specification Part 1: Arc welding.
Welding consumables Rods, wires and deposits for tungsten inert gas welding of nonalloy and fine grain steels Classification.
Non-destructive examination of welds Ultrasonic examination of welded joints.
Welding, brazing, soldering and braze welding of metals Nomenclature of processes
and reference numbers for symbolic representation on drawings.
Specification for minimum requirements for industrial radiographic illuminators for nondestructive testing
Approval testing of welders Fusion welding Part 1: Steels.
Specification and approval of welding procedures for metallic materials Part 9:
Welding procedure test for pipeline welding on land and offshore site butt welding of
transmission pipelines.
Non-destructive testing Image quality of radiographs Part 1: Image quality
indicators (wire type) Determination of image quality value
Page 7 of 54
EN 473:2008
Qualification and certification of NDT personnel. General principals.
EN 499:1995
Welding consumables Covered electrodes for manual metal arc welding of non-alloy
and fine grain steels Classification.
EN 571-1:199
Non-destructive testing-Penetrant testing-Part 1: General principals.
EN 583-1:1999
Non-destructive testing-Ultrasonic examination -Part 1: General principals.
EN 583-6:2009
TOFD technique as a method for detection and sizing of discontinuities.
EN 756:2004
EN 757:1997
Welding consumables. Solid wires, solid wire-flux and tubular cored electrode-flux
combinations for submerged arc welding of non alloy and fine grain steels.
Classification
Welding consumables Covered electrodes for manual metal arc welding of high
strength steels Classification.
EN 760:1996
Welding consumables Fluxes for submerged arc welding Classification.
EN 875:1995
Destructive tests on welds in metallic materials-Impact tests-Test specimen location,

notch orientation and examination.
EN 895:1995
Destructive tests on welds in metallic materials Transverse tensile test.
EN 910:1996
Destructive tests on welds in metallic materials Bend tests.
EN 970:1997
Non destructive examination of fusion welds visual examination.
EN-ISO 6892-1:2009
Metallic materials. Tensile testing Part 1:. Method of test at room temperature
EN-ISO 14175:2008
Welding consumables Shielding gases for arc welding and cutting.
EN-ISO 14341:2008
EN-ISO 17632:2004
EN-ISO 3834-1:2006
EN-ISO 3834-2:2006
EN-ISO 3834-4:2006
Welding consumables Wire electrodes and deposits for gas-shielded metal arc
welding of non-alloy and fine grain steels Classification.
Welding consumables Tubular cored electrodes for gas shielded and non-gas
shielded metal arc welding of non-alloy and fine grain steels Classification.
Quality requirements for welding Fusion welding of metallic materials Part 1:
Criteria for the selection of the appropriate level of quality requirements.
Comprehensive quality requirements.
Elementary quality requirements.
ISO 17025:2005
General requirements for the competence of testing and calibration laboratories.
ISO 3690:2000
Welding and allied processes -- Determination of hydrogen content in ferritic steel arc
weld metal
ISO 9001
Quality Management Systems : Requirements
2.1.2
The edition of each code and standard stated in this section shall apply; together with all published
amendments. Where conflict occurs between the requirements of this Specification and referenced
codes and standards, the most stringent requirements shall apply. Where any of the documents are
revised and the revision affects the scope of supply, CONTRACTOR shall notify GDF SUEZ in writing
immediately.

Page 8 of 54
3.
GENERAL
3.1
SCOPE
3.1.1
All welding shall, be carried out in accordance with the requirements of EN 12732:2000 NEN 36502:2003, and EN 288-9:1999, augmented with the additional requirements detailed in this
specification.
3.2
WELDING PROCESSES
3.2.1
All welding shall be by Manual, Semi-Automatic or Automatic Shielded Metal-Arc Welding (SMAW),
Fluxed Core Arc Welding (FCAW), Gas Metal Arc Welding (GMAW), Gas Tungsten Arc Welding (GTAW)
or Submerged Arc Welding (SAW). Other processes may be agreed by GDF SUEZ; however in such
cases the inspection and testing requirements may be varied as deemed necessary by GDF SUEZ
and/or CERTIFYING AUTHORITY.
Table 1:
Welding Processes and Consumables:
Type of Process
Procedure
no.
according to:
EN 24063
Shielded Metal Arc Welding
111
Gas Metal Arc Welding
135, 141
Flux-Cored Arc Welding
114, 136, 138
Shielding gases
Submerged Arc Welding
12
Fluxes for submerged arc 12
welding
Consumables shall be in accordance

with:
EN 499 & EN 757
EN-ISO 14341 & EN 1668
EN-ISO 17632
EN-ISO 14175:
EN 756
EN 760
3.2.2
FCAW process shall be thoroughly controlled at all times by CONTRACTOR to avoid any excessive
scatters in the mechanical properties (and specially impact properties) of weld deposits. In that view,
mechanical test results of qualification test welds shall show sufficient safety margins against the
requirements of this specification. The GDF SUEZ reserves the right to reject such a process when its
reliability is not satisfactory.
3.3
WELDING CONSUMABLES
3.3.1
Welding consumables shall be selected to ensure that they overmatch the maximum allowable yield
and tensile values of the projects line pipe. The Materials Maximum Allowable Yield Strength
(MMAYS) shall be overmatched by at least 50 Mpa and the Materials Maximum Allowable Tensile
Strength (MMATS) shall be overmatched by at least 30 Mpa. As such the minimum weld metals;
1) Yield Strength shall be the line pipes SMYS + 120 Mpa + 50 Mpa = 170 Mpa
2) Tensile Strength shall be the line pipes SMTS + 120 Mpa + 30 Mpa.= 150 Mpa.
3.3.2
The deposited weld metal, shall exhibit mechanical properties greater than, and chemical analysis
similar to (taking into account any specific property requirements), those of the actual base material.
For the welding of the carbon steel line pipe and parts, the nickel content of deposited weld metal
shall not exceed 1%.
3.3.3
When specified in the Scope of Work the root pas shall be welded with a consumable which contains
less than 0.25% Nickel.
3.3.4
All batch test certificates (according to EN 10204:2004, type 3.1) for welding filler materials showing
all test results, including impact testing, all weld tensile testing and chemical analyses, shall be
provided by CONTRACTOR for each production batch of consumables in use.
3.3.5
Low hydrogen consumables shall give a maximum diffusible hydrogen content of 5 ml per 100 grams
of Weld Metal determined with the method specified by ISO 3690:2000. The electrodes shall be
supplied in vacuum packing. Moreover, they shall be guaranteed against moisture absorption for 8
hours after pack opening.

Page 9 of 54
3.3.6
Cellulosic coated electrodes may be used provided that special weld procedures preventing hydrogen
induced cracking are established.
3.3.7
Special considerations are to be made when welding steels with a SMYS above 420MPa to ensure
safety against cold cracking in the HAZ and/or weld metal. Attention must also be paid to the
requirements for overmatching yield and tensile strength.
3.3.8
Welding consumables for other processes than manual or mechanised arc welding may require
special consideration with respect to certification, handling and storage (see also 3.4 of this
Specification).
3.4
STORAGE AND HANDLING OF WELDING CONSUMABLES
3.4.1
The minimum requirements for the care, storage, control and handling of consumables and flux (for
SAW) shall be those of the relevant consumable manufacturer. CONTRACTOR shall provide a detailed
storage, control and handling procedure to GDF SUEZ. Any proposed re-cycling of flux is subject to
GDF SUEZ approval.
3.4.2
Different grades and batches shall be individually identified and completely separated from each
other.
3.4.3
Low hydrogen welding consumables shall be supplied in sealed, dirt and moisture-resistant
packages. Damaged packages and any consumables showing signs of damage, deterioration,
corrosion or any other contamination shall not be used.
3.4.4
Cellulosic consumables shall always be kept in their original container.
3.4.5
Consumables shall be stored and handled at all times in such a way as to avoid damage and
contamination to them and their containers. Consumables in open containers shall be protected
from environmental moisture changes.
3.5
EQUIPMENT
3.5.1
All welding shall be performed using equipment of a type that has proved to be reliable and suitable
for the work being performed. Equipment used for production welding shall be of the same
specification to that used to qualify the welding procedure. Cable lengths shall also reflect those
used in production.
3.5.2
CONTRACTOR shall ensure and demonstrate that all welding machines are properly earthed to avoid
the occurrence of stray arcing. CONTRACTOR shall provide earth clamps of an approved design and
shall ensure only insulated electrode holders are used.
3.5.3
Current certification/calibration certificates for all testing equipment shall be provided to GDF SUEZ
for review prior to use. CONTRACTOR shall maintain a system for calibration control for all equipment.
3.5.4
Independent means shall be provided by CONTRACTOR for the accurate monitoring of all welding
parameters including current, voltage, welding speed, thermal input, preheat, interpass temperature
and, for fine wire and gas shielded welding, process-wire feed speed, gas flow rate and gas
composition (especially oxygen level) etc. These parameters shall be measured and recorded on a
sampling basis (to be agreed) during each shift.
3.5.5
Where (semi-) automatic welding systems are utilised the equipment shall be designed to provide
current cut-off linked to wire feed speed in order to minimise the risk of copper contamination at stop
points. This shall be proven during procedure qualification and also on production welding equipment
at start of production (using a sacrificial pipe sample).
3.5.6
Where copper tips are used, CONTRACTOR shall have a control procedure in place to ensure that no
welding shall be allowed to continue once a copper touch has been discovered. Further actions on
this subject shall be agreed by CONTRACTOR and GDF SUEZ prior to commencement of production.

Page 10 of 54
3.6
PERSONNEL
3.6.1
CONTRACTOR's welding supervisors shall have full knowledge of all specification requirements and
the applicable standards and codes and shall be qualified according to EN 12732:2000 Section
11.3
3.6.2
Current copies of all pertinent documentation, such as this Specification and approved Welding
Procedure Specifications, shall be in the English language and shall be at the disposal of the welding
crews and inspection personnel during all operations.
3.6.3
All welders shall be qualified as set out in Section 5 of this Specification.
3.6.4
All CONTRACTORs welding inspection personnel shall be qualified according to a minimum of CSWIP
3.1 Welding Inspector or a GDF SUEZ approved equivalent and be in possession of a current eyesight
certificate in accordance with EN 970 and EN 473:2008.
3.6.5
Non Destructive Examination personnel shall be qualified in accordance with EN 473:2008 and as
detailed in the NDT sections of this specification.

Page 11 of 54
4.
QUALIFICATION OF WELDING PROCEDURES
4.1
WELDING PROCEDURE SPECIFICATIONS
4.1.1
CONTRACTOR shall propose detailed Welding Procedure Specifications (WPS) for all production and
proposed/anticipated repair welding. Proposed WPSs along with a matrix detailing all procedures and
the amount of tests to be carried out shall be submitted to GDF SUEZ and the CERTIFYING
AUTHORITY for review prior to welding of the test welds.
4.1.2
The weld procedure shall be proven, if required, to be suitable for reeling and, if deemed necessary
by GDF SUEZ and/or CERTIFYING AUTHORITY, extra tests may be required to prove such suitability.
4.1.3
Any change(s) to any of the proposed WPS's shall be proposed/discussed with GDF SUEZ and the
CERTIFYING AUTHORITY before being implemented.
4.1.4
Welding Procedure Specifications (WPS) shall be prepared on forms in accordance with EN 156091:2004 and shall contain, as a minimum, the following information:
a)
Material specification of base materials.
b)
Welding process and whether manual or automatic.
c)
Qualified Wall thickness and diameter range (see Section 4.2).
d)
Geometry of weld groove including dimensional tolerances.
e)
Root gap (if any) showing allowable tolerances.
f)
Welding position and direction.
g)
Filler metal name/type/classification/diameter per pass/layer.
h)
Name/type/specification/classification/composition of flux and/or flows.
i)
Gas shielding flow and gas backing (purging) flow (if any).
j)
Backing strips (permanent backing strips are not allowed).
k)
Number and sequence of all passes (indicate stringer or weave beads and maximum weave
width).
l)
Welding current* and voltage range* and polarity. If pulse welding is used, the pulse range.
m)
Travel speed and electrode run-out length for each pass and permitted range.
n)
Heat input range*.
o)
Minimum preheat and maximum inter-pass temperatures and where measured.
p)
Post-weld heat treatment (if any).
q)
Method of cleaning and cutting.
r)
Method of joint set-up including clamp type.
s)
(Repairs) method of defect removal and preparation of weld area.
t)
(Repairs) pre-heat prior to gouging.
u)
(Repairs) minimum and maximum opening sizes.
* Note:
Recorded ranges shall be included in the WPS, these shall not include % allowances,
these must be noted separately in the WPS.
4.1.5
All WPS's, including all procedures for repair welding, shall be welded/qualified in accordance with
the requirements of EN 288-9:1999 and this specification.
4.1.6
All welding and testing required to qualify a procedure shall be performed in the presence of GDF
SUEZ, who shall receive ten (10) days minimum advance notice of the date qualification welding is to
start.
4.1.7
GDF SUEZ shall witness all non-destructive examinations and destructive testing and shall review
and approve all related results. All mechanical testing shall be carried out by a certified (see ISO/IEC
17025:1999) testing facility subject to prior approval of GDF SUEZ.
4.1.8
Production welding shall not commence until all Welding Procedure Qualifications (WPQ) have been
accepted/approved by GDF SUEZ and the CERTIFYING AUTHORITY.

Page 12 of 54
4.2
WELDING PROCEDURES - ESSENTIAL VARIABLES
4.2.1
An approval of a WPS obtained by a manufacturer is valid in workshops or sites under the same
technical and quality control of that manufacturer (EN 288-9:1999 8.2).
Essential variables shall be as defined in EN 288-9:1999 with the addition of those detailed in this
specification. Any changes outside the permissible limits of the essential variables shall necessitate
re-qualification of the welding procedure.
4.2.2
Additional requirements for essential variables:

1.
Filler metal: clause 3.3.3 of this specification replaces clauses 8.4.4 and 8.4.5 of EN 2889:1999.
2.
Heat input: clause 4.3.5 of this specification replaces clause 8.4.7 of EN 288-9:1999.
3.
Any change in size/diameter of welding consumable: replaces clause 8.5.1 of EN 288-9:1999.
4.
The use of water quenching/cooling (for a rapid reduction of the material temperature for NDT
or any other reason).
5.
The use of hot-starts.
4.3
PROCEDURE QUALIFICATION TEST WELDS
4.3.1
CONTRACTOR shall perform all procedure qualification test welds in accordance with EN 288-9:1999
and the relevant sections of this specification
4.3.2
Test welds shall be identified with a unique number, which shall be hard-stamped in the pipe. All test
samples shall be hard-stamped with the GDF SUEZ inspectors mark prior to removal from the test
pipe. All marking shall be recorded by CONTRACTOR and witnessed by GDF SUEZ and the
CERTIFYING AUTHORITY.
4.3.3
All pipe for qualification test welds shall be line pipe selected from production pipe manufactured for
this project and from each steel manufacturer or source of supply. Contractor shall check this pipe
for identification and conformity to the line pipe specifications and relevant certificates (EN 10208-2
and EN 10204). The pipe selected for procedure welding should be supplied from the heat or lot
exhibiting one of the highest carbon equivalents as proven by the product analysis during line pipe
production.
4.3.4
At least one complete weld shall be made and tested to qualify each pipe to pipe welding procedure
and one weld for pipe to fitting welding procedure. For small diameter pipe, additional welds shall be
made where necessary to provide sufficient material for testing. When manual welding is to be used,
a minimum of one complete test joint is to be made for each Welding Procedure. For semi-automatic
or automatic welding equipment, a minimum of three consecutive complete test joints shall to be
made (all of which must be acceptable for NDT).
4.3.5
Procedure qualification test welds, and all repair test welds, shall be carried out between two pieces
of pipe (each with a minimum length of 500mm), which shall be restrained. Weld Procedure
Qualifications shall be completely monitored and recorded by CONTRACTORs QC department using
calibrated Portable Arc Monitoring (PAMs or ALX unit) equipment. All as-runs recording, for
example, voltage, amperage, pre-heat and inter-pass temperature (refer to 6.8 for the requirements),
travel speed, electrodes, position, welder, polarity, gas composition etc. shall be included in the
documentation package submitted along with the NDT and Mechanical Test Results, prior to
approval of the WPQ and final WPS.
4.3.6
For qualification of delays between runs refer to 6.9 of this specification.
4.3.7
Where the use of water quenching/cooling is proposed (for a rapid reduction of the material
temperature to allow Automated Ultrasonic Testing), this shall be qualified during procedure
qualifications and noted on the ultimate WPS.
4.3.8
The test welds shall be non-destructively inspected in accordance with the relevant NDT sections of
this Specification. Should the test weld not meet the stated acceptance criteria it shall not be
submitted for mechanical testing.
4.3.9
NDT of procedures shall take place a minimum of 24 hours after completion of welding.

Page 13 of 54
4.3.10
Welds, which pass non-destructive testing shall be tested in full accordance with EN 288-9:1999 and
this specification. Samples shall be removed from the locations described in Appendix 1.
4.3.11
The following tables show the minimum amount of procedures to be qualified as well as the
inspection and testing requirements that are in compliance with or in addition to EN 288-9:1999.
Consideration should be taken with EN 288-9:1999 Section 8 with regards to qualification ranges.
Typical examples are given for repair excavation requirements.
Table 2:
Extent of testing complete butt weld:
Test Piece
Butt-weld
At least 1 complete
weld per process
(see 4.3.4)
Note: For Double
sided SAW side
bends may be used
to replace root and
face bends.
Type of inspection
Visual examination
Radiographic examination
Ultrasonic examination
MPI examination
Type of test
Transverse tensile test
All weld tensile test
Impact test
Macro examination
Hardness test
Bend test
CTOD (if required in the Scope of
Work)
Extent of inspection
100%
100%
100%
100%
Extent of testing
2 specimens
4 specimens
4 sets cap &
4sets root (>20mm)
2 test specimens
2 test specimens
2 root & 2 face
9 (3x CW + 6x FL)
Note
Section 8
Section 9
Section 10/11
Section 12
Note
See 4.4.1
See 4.4.2
See 4.4.3
See 4.4.4
See 4.4.5
See 4.4.6
See 4.4.7
CW
Cap
Fill(s)
Th
Hot Pass
Root Pass
CW
External Cap
Th
Root Area
Internal Cap
Typical examples of mainline and double joint welds are shown here.

Page 14 of 54
Table 3:
Extent of testing for full penetration repair:
Test Piece
Full Penetration
Repair weld
1 off
Type of inspection
Visual examination
MPI examination
Type of test
Impact test
100%
100%
100%
100%
Extent of testing
1 specimens
4 sets cap &
4 sets root(>20mm)
1 test specimens
1 test specimens
2 root & 2 face
Macro examination
Hardness test
Bend test
Note
Section 8
Section 9
Section 10/11
Section 12
Note
See 4.4.1
See 4.4.3
See 4.4.4
See 4.4.5
See 4.4.6
CW
Cap
Th
Original Weld HAZ
Fill(s)
Hot Pass
Root Pass
CW
Table 4:
Extent of testing for partial penetration repair:
Test Piece
Partial
Penetration
Repair to leave a
minimum of
3mm parent
metal.
1 off
Type of inspection
Visual examination
MPI examination
Type of test
Impact test
Macro examination
Hardness test
Bend test
30 10
To Be Qualified
100%
100%
100%
100%
Extent of testing
1 specimens
4 sets cap
1 test specimens
1 test specimens
2 face
Note
Section 8
Section 9
Section 10/11
Section 12
Note
See 4.4.1
See 4.4.3
See 4.4.4
See 4.4.5
See 4.4.6
CW
Excavation Boundary
Original Weld HAZ

Original Weld Metal
To Be Qualified =3 mm
CW

Page 15 of 54
Table 5:
Extent of testing for single pass cap repair
Test Piece
Single Pass Cap
Repair
1 off
Type of inspection
Visual examination
MPI examination
Type of test
Macro examination
Hardness test
Bend test
100%
100%
100%
Extent of testing
1 test specimens
1 test specimens
1 face
Note
Section 8
Section 9
Section 12
Note
See 4.4.4
See 4.4.5
See 4.4.6
CW
Single Pass Cap Repair
Th
Original Weld Metal
CW
4.3.12
Repairs shall be carried out centred at the 6 oclock position. All stages of the repair welding
qualification (including gouging {note-gouging pre-heat to be qualified} and grinding of repair
excavation see Section 7.2.3) shall be carried out with the test pipe in its required fixed position.
The ends of the pipe shall be closed off and no access to the inside shall be allowed.
4.3.13
Results of procedure qualification testing shall be recorded on WPQ record forms in accordance with
EN 288-9:1999 and this specification (see also Section 4.1.4).
4.3.14
Test samples shall be removed from the locations shown in Appendix 1.
4.3.15
Welders who weld the procedure(s) may be qualified on acceptance of the procedure(s). However,
where two welders are used on one weld extra samples may be required to comply with the
requirements stated in Table 9.
4.4
MECHANICAL TESTING OF WELDING PROCEDURE QUALIFICATION TEST WELDS
4.4.1
Transverse Tensile Testing

Two transverse (cross weld) tensile tests shall be performed according to EN 895.
If the specimen breaks in the weld metal or HAZ, it shall be considered unacceptable unless it can be
proven that the achieved values for Yield Strength and Ultimate Tensile strength are in excess of
those required for All Weld Tensile Tests as specified in 4.4.2.
4.4.2
All Weld Tensile Testing

Actual weld properties shall be demonstrated by the performance of All Weld Metal Tensile Tests,
parallel to the weld axis. The actual type and size of test specimen is dependent on the
diameter/wall thickness of the involved line pipe and the applied type/number of consumables in the
involved weld.
From each procedure 4 round bar test specimens, of the largest possible size, will be tested. Two
specimens shall be taken as close as possible to the weld root area and two specimens as close as
possible to the weld cap area.
After testing, a macro shall be prepared from the broken test specimen. If the sample demonstrates
that the test included any FL/HAZ or pipe material then the test will be considered invalid and shall
be re-done.
The resulting Yield Strength shall be greater than the highest recorded yield strength of the base
material (see Section 3.3) and as a minimum this shall exceed the SMYS by at least 100 Mpa.

Page 16 of 54
The resulting Tensile Strength shall be greater than the highest recorded tensile strength of the base
material (see Section 3.3) and as a minimum this shall exceed the SMTS by at least 80Mpa.
.
4.4.3
With GDF SUEZ approval, these tests may be substituted with cross weld tensile tests with full
stress/strain curves.
Charpy V-Notch impact testing
Test specimens shall be taken and prepared in accordance with EN-10045-1 in such a way that the
axis of the notch is perpendicular to the pipe surface. Test specimens and testing for impact test
shall be in accordance with this specification for position and temperature of testing and with EN
875 for dimensions and testing (see also Appendix 2).
Each set shall comprise of three full size specimens taken with the notch (The notch line shall be cut
through the pipe thickness) in the following locations, (see Appendix 2A):
a) weld centre line
b) weld fusion line
c) weld fusion line + 2mm
d) weld fusion line + 5mm
For partial penetration repairs the following samples shall be taken, (see Appendix 2B):
a) weld fusion line to existing weld
b) weld centre line
c) weld fusion line
d) weld fusion line + 2mm
Test specimens with Charpy V-notch shall be used and sampled from 2 mm below the outer surface
of the pipe and transverse to the weld. When the pipe wall thickness exceeds 20 mm, four more sets
are required, in the same circumferential locations, but taken within 2 mm of the inside surface of
the pipe. The minimum absorbed energy values shall be as stated in Table 6:
Table 6:
Charpy requirements weld testing:
Specified minimum yield

strength of steel:
Average of
3 specimens
Single Specimen*
Test
Temperature
All
50 Joule (J)
40 Joule (J)
20C**
*Note 1: only one single value may be below the average requirement.
**Note 2: Unless Design Temperature is lower in which case Design Temperature applies.
The percentage [%] shear at the fracture surface shall be recorded and be a minimum of 50%.
Refer to the Scope of Work for details.
4.4.4
Macrography
Two macro sections of the welds shall be prepared and examined in accordance with EN 1321. The
test pieces shall be polished and etched for macrographic examination of the weld. The weld
cross-section shall be examined for good weld profile and sufficient penetration free of significant
inclusions or other defects. It shall also serve to confirm the amount of weld passes that have been
deposited and their compliance with the pWPS.
4.4.5
Hardness Testing
Hardness surveys shall be carried out on both macro sections, in accordance with EN 1043-1. The
Vickers method HV10 shall be used, as detailed in Appendix 3. Results of hardness tests shall be
below the maximum values specified in Table 7. Permanent records of macro sections shall be kept
by means of photo-macrographs showing all hardness indentations.
Table 7:
Hardness value requirements:

Hardness location
Hardness HV10
Weld metal and HAZ:
root
250
Weld metal and HAZ:
cap
275

Page 17 of 54
4.4.6
Bend Testing,
Specimens and testing for butt joints shall be in accordance with EN 910.
The diameter of the former or inner roller shall be 4t and the bending angle shall be 180 for parent
metal with elongation A 20%. For parent metal with elongation < 20% the following formula shall be
applied:
d=
(100 x ts )
A
- ts
where
d is the diameter of the former or the inner roller
ts is the thickness of the bend test specimen
A is the minimum tensile elongation required by the material specification
During testing, the test specimens shall not reveal any one single flaw > 3 mm in any direction. Flaws
appearing at the corners of a test specimen shall be ignored in the evaluation.
4.4.7
Chemical Analysis
Quantitative chemical analyse of the weld cross-section shall be made in the root zone and filler
passes to verify the chemical elements as per the chemistry requirement of the applicable
consumable specification.
4.4.8
CTOD Testing
If required in the Scope of Work, CTOD testing shall be carried out according to BS 7448:part
2.:1997. 3 (three) Centre of Weld samples shall be taken and 6 (six) Fusion Line samples (of which 3
may be used). Testing shall be carried out at 0C.
4.5
PERMITTED WELDING PROCEDURE QUALIFICATION RETESTS
4.5.1
Welding Procedure Qualification re-tests are not permitted without the approval of GDF SUEZ.
4.5.2
Where re-tests are permitted, they shall be limited to:

a) Tensile Tests - if one test fails to comply with the specified mechanical requirements, two further
test specimens shall be taken.
b) All Weld Tensile - if one test fails to meet the minimum specified requirements for the base
material, two more tests shall be taken.
c) Hardness Tests - if one test fails to comply with the specified mechanical requirements, two
further test specimens shall be taken for each one that failed.
d) Bend Tests - if one test fails to comply with the specified requirements, two further test
specimens shall be taken.
e) Charpy-V Notch Impact Tests - if one Charpy value from a set of three test specimens falls below
the minimum individual value specified in 4.4.3, then three further tests shall be carried out. All
three re-test specimens shall meet the requirements of 4.4.3 and the mean value of all six tests
shall be calculated and shall meet the specified minimum average value.
4.5.3
If any single (permitted) re-test subsequently fails, no further re-testing shall be allowed and the test
shall be deemed to have failed (see clause 4.6).
4.6
FAILURE OF WELDING PROCEDURE QUALIFICATION TESTS
4.6.1
Should a procedure qualification test fail any of the required visual, non-destructive and/or
mechanical tests or permitted re-tests, it shall be regarded as not complying with the requirements of
this specification. The cause of failure shall be established, rectified and the WPS revised as
appropriate, before the qualification test is repeated.
4.7
BRAZING AND ALUMINOTHERMIC WELDING OF ANODIC BONDING LEADS
4.7.1
Full details of the joining technique, proposed procedure and associated equipment shall be
submitted to GDF SUEZ prior to use and be in conformance with the manufacturers
recommendations.

Page 18 of 54
4.7.2
The procedure shall be qualified (in accordance with EN 12732:2000 Annex H) by making three
consecutive test joints in the presence of GDF SUEZ on materials to be used in production and
representing the upper quartile of the carbon equivalent range.
4.7.3
The electrical resistance shall be measured and should not exceed 0.1. The mechanical strength of
the joint shall be tested by means of a sharp blow from a 1kg. Hammer.
4.7.4
All three joints shall be sectioned and prepared for metallographic examination. The following tests
should be performed on the sections:
a)
Copper contamination measurement: The depth of copper contamination below the surface of
the pipe material shall be measured metallographically. The fusion line of the weld or braze
should not be more than 1mm below the pipe surface. Intergranular copper penetration of the
pipe material shall not exceed 0.5mm beyond the fusion line when a micro-section is
examined at a magnification not exceeding x50.
b)
Hardness survey: Each section shall be tested using a 10kg load. A transverse should be
made across the weld zone as shown below and should consist of at least 6 impressions; two
in the heat affected zone each side of the weld/braze and one in the parent metal each side of
the weld/braze. The hardness value shall not exceed 325HV 10. See the figure 1:
Weld/Braze metal
Parent Metal Surface
2
3
Weld heat affected zone (visible after etching)

Note: Hardness impressions 2, 3, 4 and 5 should be entirely within the
heat-affected zone and located as close as possible to the fusion boundary
Figure 1:

Requirements for hardness traverse and impressions

for brazing and aluminothermic welding.
Page 19 of 54
4.8
WELD PROCEDURE QUALIFICATION RECORD(S)

The Weld Procedure Qualification Record(s) shall contain the following documentation and be
precluded with a check list sheet (see example below) showing the contents of each package:
Table 8:
Checklist WPQ Records

WPQ: 010-013
168.3mm x 18.3mm (L450QO PSL2) Pipe to Pipe
Designation: Mainline Welding
WPQ
(Pre) WPS
As Runs
Weld Visual Inspection Report
Weld Radiographic Inspection Report
Weld Ultrasonic Inspection Report
Weld M.P.I Report
Mechanical Test Results
Material Certificate(s)
Consumable Certificate(s)
Material Cutting List
Welders Details
NDT Technician Qualifications
Following a final review of the packages, each checklist shall be signed off by GDF SUEZ,
CONTRACTOR and the CERTIFYING AUTHORITY.

Page 20 of 54
5.
QUALIFICATION OF WELDERS
5.1
GENERAL
5.1.1
The use of pre-qualified welders is not allowed. Each welder or welding machine operator shall
be qualified in accordance with EN 287-1:2004 or EN 1418:1998 and this specification prior to
the start of production welding by making a test weld using the qualified welding procedure. This
will comprise of a minimum of one half-circumference weld for welder qualifications and for
repair welders sufficient weld to allow for removal of all mechanical test samples (note that
defect removal by gouging and grinding forms part of repair welder qualification). The test
welds shall be performed with the pipe in the same position as will be found in production
welding. Each welding machine operator (for submerged arc welding) shall produce one
complete weld.
5.1.2
CONTRACTOR shall ensure that only qualified welders and welding operators are employed during
construction, welding within the permissible range, position and process for which they are qualified.
5.1.3
The following applications shall be qualified:

Welding Process
Welding Position
Filler Material (including combinations). The welder is only allowed to use the type of filler
material for which he has been approved (i.e. cellulosic only qualifies cellulosic)
Pipe Material
Girth weld or weldolet
5.1.4
The following ranges can be qualified in accordance with EN 12732:

DN 50 qualifies all diameters up to and including DN 100 (category small diameter)
DN 150 qualifies all diameters between DN 100 and DN 250 (category medium diameter)
DN 400 qualifies equal to or greater than DN 250 (category large diameter)
5.1.5
If a welder fails a qualification test, the result shall be provided to GDF SUEZ. The welder or welding
operator may carry out a retest (new test joints of the same type as the rejected one), provided the
cause of failure is determined and not attributed to inadequate training. If the retest meets the
specification requirements, the test will be considered satisfactory. Any welder failing a qualification
test shall not be permitted further testing without prior GDF SUEZ approval and without a period of
appropriate training.
5.2
WELDER CERTIFICATE
5.2.1
CONTRACTOR shall operate a scheme for welder qualification certification certificates and welder
identification, which shall be provided to GDF SUEZ for approval prior to the qualification programme
commencing.
5.2.2
The pipeline welder certificate shall be similar to that proposed in EN 287-1. The certificate shall
clearly indicate the standard to which the welders certification has been performed, i.e. This
Specification/EN12732/EN 287-1.
5.2.3
The duration of validity for the certificate is 6 months. NDT records shall be maintained for the
purpose of extending the validity of the welder certificates.
5.2.4
The original certificate is non-transferable and shall be in the possession of the welder or
CONTRACTOR (at the production location) during execution of the work
5.2.5
The original certificates shall be signed by GDF SUEZ.

Page 21 of 54
5.3
RE-QUALIFICATION OF WELDERS
5.3.1
Re-qualification of welders or operators is required if any change is made to the welding procedure,
which necessitates re-qualification of said welding procedure.
5.3.2
GDF SUEZ reserves the right to require the re-qualification of welders or welding machine operators if
repair rates are encountered in production welding by any one or more operators, which in GDF
SUEZ's opinion are excessive (refer also to Section 7.5)
5.4
ANODE CABLE PIN BRAZERS

Prior to carrying out production work, each operator shall complete three test joints, witnessed by
GDF SUEZ, which should pass the tests for electrical continuity and mechanical strength described in
Section 4.5. A list shall be produced identifying all qualified pin brazers and this shall be approved
by GDF SUEZ and displayed at the work location.
5.5
WELDER QUALIFICATION: WELD INSPECTION AND TESTING

Each test weld shall undergo visual inspection, non-destructive testing, and destructive testing in
accordance with the following table. Non-acceptable results shall constitute the rejection of the test.
Table 9:
Test Piece
Butt Weld or
Half Butt
Weld
Test Piece
Full and
Partial
Penetration
Repair
Test Piece
Cap Repair
Test Piece
Weldolet
Welder Qualification Tests Requirements per Welder

Type of inspection
Visual examination
Radiographic examination*
MPI examination
Type of test
Macro examination
Bend test
Type of inspection
Visual examination
MPI examination
Type of test
Macro examination
Bend test
Type of inspection
Visual examination
MPI examination
Type of test
Macro examination
Bend test
Type of inspection
Visual examination
MPI examination
Type of test
Macro examination
100%
100%
100%
Extent of testing
1 test specimen
2 root & 2 face
100%
100%
100%
Extent of testing
1 test specimen
2 root & 2 face (FP)
2 face (PP)
100%
100%
100%
Extent of testing
1 test specimen
2 face
100%
100%
Extent of testing
4 test specimen
Note
Section 8
Section 9
Section 12
Note
See 4.4.4
See 4.4.6
Note
Section 8
Section 9
Section 12
Note
See 4.4.4
See 4.4.6
Note
Section 8
Section 9
Section 12
Note
See 4.4.4
See 4.4.6
Note
Section 8
Section 12
Note
See 4.4.4
*Note: For Automatic Processes (MAG/MIG) when the wall thickness exceeds 8mm Ultrasonic
Examination shall be carried out in accordance with Section 10 or 11 (in accordance with EN
12732).

Page 22 of 54
6.
PRODUCTION WELDING
6.1
GENERAL
6.1.1
Production welding shall not commence until the qualified welding procedures, qualified welders and
qualified inspection personnel lists have been reviewed and approved by GDF SUEZ.
6.1.2
At every welding station / location the relevant approved welding procedure specifications (W.P.S.)
and approved welders lists shall be clearly displayed.
6.1.3
If the requirements specified in the approved WPSs are not being complied with then this shall be
cause for rejection of the weld or welds in question.
6.2
(LINE) PIPE PREPARATION
6.2.1
The weld bevels and adjacent surfaces for a distance of 100 mm shall be free from surface defects,
coating, moisture, grease, paint or rust immediately prior to welding.
6.2.2
Line pipe will be supplied by GDF SUEZ with the end preparation as specified in the line pipes
material specification. Should CONTRACTOR elect to use a different bevel approval shall be obtained
from GDF SUEZ, and the bevel design shall be incorporated in the weld procedure specifications.
6.2.3
For pipe-to-fitting welds where wall thickness changes are involved, the joint design in accordance
with EN 12732:2000 Annex C shall be provided by CONTRACTOR for GDF SUEZ's review. All changes
of section shall have a smooth and uniform finish.
6.2.4
Any pipe bevel showing evidence of end area lamination shall be immediately reported to GDF SUEZ
in writing and then cut back until the laminated section is removed, and re-bevelled. After re-bevelling
the pipe end shall be wet magnetic particle inspected and ultrasonically inspected over a distance of
100 mm from the bevel, in accordance with EN 10246-18 and EN 10246-17, to ensure that no
further laminations are present. Any linear indication greater than 10 mm in any direction shall be
cause for rejection.
6.2.5
Field bevels shall be made by machine tool (automatic or hand controlled). Thermal cutting is not
acceptable. The bevel ends shall be smooth and uniform and dimensions shall be in accordance with
the qualified welding procedure specification.
6.2.6
Burrs, small score marks, indentations or other small defects within the joint preparation shall, at the
discretion of GDF SUEZ be ground out, otherwise the joint shall be re-prepared. Any damage to line
pipe by field welding machines shall be reported to GDF SUEZ prior to repair in accordance with the
line pipe specification.
6.2.7
Bevels and the pipe's external surface within 50 mm of the bevel shall be cleaned by power tools to a
bright finish prior to lining up the pipe.
6.3
ALIGNMENT
6.3.1
Internal line-up clamps shall be used when possible and shall not be removed until 100% of the root
run and hot pass are completed. When external line-up clamps are used the equipment shall be
subject to review by GDF SUEZ prior to welding.
6.3.2
For the welding of fittings and flanges the line-up procedure shall be provided for GDF SUEZ review.
6.3.3
Welding shall be continuous as far as possible and no joint shall be accepted when subjected to
interruptions not covered by the Welding Procedure Qualification. Strong-backs shall not be used.
6.3.4
Hammering or heating shall not be used for correction of misalignment. Spacer tools shall be used to
check final fit-up.

Page 23 of 54
6.3.5
The alignment of abutting pipe ends shall be such as to minimise the internal offset between
surfaces. Any offset greater than 1.5 mm, provided it is carried by dimensional variations within the
specified permitted tolerances (see Table 10), shall be equally distributed around the circumference
of the pipe or fittings.
Table 10: Permitted misalignment of surfaces (EN 12732:2000 Table G1)
Wall Thickness (T)
T 10 mm
10mm < T 25.4 mm
Permissible
external misalignment
0.3 x T
20% of T or 3 mm whichever
is less
Permissible
internal misalignment
1 mm on entire circumference
10% of T or 2 mm whichever
is less
6.3.6
Any misalignment shall be reduced to a minimum by rotation of the pipes to obtain the best fit. When
a pipe with a longitudinal weld is used, the seams on adjacent pipes shall be spaced a minimum of
30 apart and preferably in the 10 to 2 o'clock position.
6.3.7
The minimum distance between two circumferential welds shall be 3 times the pipe diameter or
minimum 500 mm, whichever is greatest.
6.4
WEATHER PROTECTION
6.4.1
Welding shall not be performed when the weather conditions and/or lack of weather protection do
not permit satisfactory workmanship or adequate inspections.
6.4.2
Shelters/tents shall be provided/used giving adequate protection, from wind, rain, draft and cold, to
the area of welding.
6.5
TACK WELDS
6.5.1
The works shall be set-up, properly spaced and supported and tack welded in accordance with the
welding procedure that is to be employed for the root run. Where preheat is required for the root run,
this shall be applied prior to tack welding and maintained until the joint is completed.
6.5.2
Tack welds shall be a minimum of 25 mm long and spaced evenly around the joint circumference.
6.5.3
Tack welds may be incorporated into the final joint provided they are ground to a suitable feather
edge at each end to ensure adequate fusion with the root run.
6.5.4
Tack welding shall only be carried out by qualified welders.
6.6
STRAY ARCS
6.6.1
Arcs shall only be struck on fusion faces. Precautions shall be taken to prevent stray arcs, especially
on the pipe where the earth clamp is fitted.
6.6.2
Positions where stray arcs have accidentally occurred shall be repaired. Repairs shall be carried out
to an agreed procedure. The procedure shall include the removal of defective material by grinding,
checking by Magnetic Particle examination for cracks and checking that wall thickness is within
permitted tolerances.
6.7
INTER-RUN CLEANING
6.7.1
Each run of weld metal shall be cleaned of slag and flux deposits by either hand or power tools
before the next run is applied, as required.
6.8
PREHEAT AND INTERPASS TEMPERATURE
6.8.1
The minimum required preheat temperature shall be 100C.

Page 24 of 54
6.8.2
At no time shall the pre-heat exceed that of the qualified welding procedure by more than 50 C
except where required in 6.8.3
6.8.3
For welding of flanges to pipe the pre-heat shall be increased to a temperature 50 C higher than the
qualified pipe to pipe W.P.Q.
6.8.4
The interpass temperature shall never exceed the maximum temperature specified in the qualified
welding procedure, and at no time shall the temperature become high enough to damage the pipe's
protective coating. The interpass temperature measured immediately before the start of the
subsequent weld run shall not be less than the minimum preheat temperature. In principal, and
dependant on material selection, the maximum allowable interpass temperature is 250C.
6.8.5
Preheat shall be applied using electrical or gas methods such that the required temperature is evenly
distributed around the entire circumference of the joint and extending at least 75 mm on either side
of the joint area.
6.8.6
Preheat temperatures shall be checked using thermal indicating crayons, digital thermometers,
thermocouples or contact pyrometers.
6.8.7
Preheat temperatures shall be measured approximately 75mm from both sides of the weld / bevel,
around the pipes circumference. Interpass temperature shall be measured adjacent to the weld.
6.8.8
Preheat for repair welds shall be applied uniformly around the whole circumferential weld.
6.8.9
Maximum interpass temperature shall be monitored on a regular basis to ensure adherence to the
project specific approved WPS. If interpass temperature is seen to be exceeded the regularity of
monitoring shall be increased so as to satisfy GDF SUEZ that the specified parameters are being met.
6.9
PARTIALLY COMPLETED WELDS
6.9.1
Whenever possible, joints shall not be left partially completed. The welding of fittings shall be
completed in one cycle.
6.9.2
When production conditions are such that pipe to pipe joints have to be left partially completed the
following conditions shall apply:
a) The minimum number of runs deposited before cooling shall be as qualified in the approved
welding procedure.
b) When vertical-down welding is used, the second run (hot pass) shall be deposited immediately
after completion of the root run (stringer bead), and the time lapse shall not be greater than that
used in the procedure qualification test, with a maximum of 15 minutes.
c) Upon discontinuation of welding the joint shall be wrapped in dry insulation, heat resistant
material with a waterproof backing and shall be cooled in a slow and uniform manner.
d) Prior to recommencement of welding the joint shall be reheated to within the specified
preheat/interpass temperature range.
e) No welds shall be left partially completed overnight.
6.10
POST-WELD HEAT TREATMENT

Not required unless by the approved WPQ.
6.11
MATERIAL TRACEABILITY AND WELD IDENTIFICATION
6.11.1
CONTRACTOR shall employ a procedure for material traceability and weld identification (See also the
requirements of section 10.3). Welders foreman shall track welders performance and identify
problems regarding individual welders. GDF SUEZ shall be advised of specific problems.
6.11.2
Identification marks adjacent to welds shall be by crayon, weather proof chalk or by some other
appropriate means. The use of hard stamps is not permitted. Identification marks shall not be
removed until after the welds have been visually and non-destructively inspected.

Page 25 of 54
6.11.3
CONTRACTOR's material traceability and weld identification procedure shall be submitted to GDF
SUEZ for approval prior to commencement of work.
6.12
PRODUCTION WELD TESTS
6.12.1
When specified in the Scope of Work, CONTRACTOR shall allow for and carry out Production Weld
Tests (PWT) as detailed in EN 12732, GDF SUEZ may request, at any time, a weld to be removed by
cutting the pipeline, leaving sufficient material on both sides of the weld to accommodate the
required mechanical testing. CONTRACTOR shall re-join and re-weld the pipeline.
6.12.2
The removed weld shall be mechanically tested as required for WPQ test welds (see section 4.)
6.12.3
If the weld fails to meet the minimum specified requirements, detailed in section 4., all production
welds produced before the date of testing shall be regarded as not meeting specification
requirements and are subsequently rejected until CONTRACTOR can demonstrate, to the satisfaction
of GDF SUEZ and the CERTIFYING AUTHORITY, that all production welds do have the minimum
required mechanical properties.

Page 26 of 54
7.
REPAIR WELDING
7.1
GENERAL
7.1.1
CONTRACTOR shall notify GDF SUEZ of CONTRACTOR's intention to repair a weld before commencing
the repair. Weld repairs are permitted for defects located in the filling and cover passes (i.e. partial
penetration repairs) and shall be at least 50 mm long. Repairs at root or including the root shall be
minimized and such repairs shall be subject to special approval of GDF SUEZ on a case to case basis.
7.1.2
Only one attempt at a weld root repair shall be performed. If it is still unacceptable, the entire weld
must be replaced. Should the weld be removed (cut-out) the re-bevelling, by machining, shall be such
that the entire prior heat affected zone is removed.
7.1.3
Weld repairs shall only be carried out by qualified welders working to written, qualified and GDF SUEZ
approved procedures.
7.1.4
Only one attempt at any repair in the weld body shall be allowed unless express GDF SUEZ and
CERTIFYING AUTHORITY approval is given to attempt a second repair. Should this second repair also
be un-acceptable according to the Acceptance Criteria agreed for the project, the complete weld shall
be removed.
7.1.5
Repairs shall be limited to a maximum of 20% of the weld circumference (EN 12732:2000 Section
6.7). If more than 20% of the weld exhibits defects requiring repair, or if several defective weld
sections amount to this length overall, the weld joint in question shall be cut out and re-welded
unless otherwise agreed by GDF SUEZ.
7.2
DEFECT REMOVAL
7.2.1
Weld defects shall be removed by grinding, machining or air-arc gouging (followed by grinding).
7.2.2
If air-arc gouging is used then the defect area shall be subsequently cleaned by grinding and wire
brushing to a bright metal finish to remove all contaminated material. The cut-out portion shall be
sufficiently deep and long to remove the defect. At the ends and side of the cut there shall be a
gradual taper from the base of the cut to the surface of the weld metal. The width and profile of the
cut shall be such that adequate access for re-welding is provided. The excavation shall be cleared by
magnetic particle inspection prior to re-welding to ensure complete removal of the defect.
7.2.3
In the event that the defect is close to the weld root and the whole thickness of the weld seam is to
be removed, the new gap opening at the weld root shall remain within the qualified root gap
tolerances defined in the WPS. Gouging is only allowed up to 3mm from the internal surface of the
pipe after which grinding shall be used to remove the remaining area.
7.2.4
Welds found with cracks shall be repaired by complete removal of the weld i.e. by cutting out a
section of pipe containing the weld.
7.2.5
External defects such as undercuts and pin-holes shall be repaired by re-capping the weld for a
minimum distance of 38 mm past both ends of the defect. This distance shall be measured parallel
to the length of the weld. The re-capped area shall be dressed to a smooth profile. Re-capping shall
only be permitted if the maximum hardness has been shown to be within the acceptance limits of
this Specification by previous qualification or in-situ portable hardness testing. The in-situ testing
procedure and equipment shall be subject to GDF SUEZ's review and shall be calibrated and
certified.
7.3
INSPECTION OF WELD REPAIRS

Each repair weld shall be subjected, as a minimum, to the same inspection and documentation
requirements as the original weld.

Page 27 of 54
7.4
RECORD OF WELD REPAIR

A full record of all repairs shall be maintained by CONTRACTOR. The record shall include the
following:
Weld number
Type and size of defect
Circumferential location (defined to an approved system)
Estimate of the depth (assessed by ultrasonic test where possible)
Where possible, the name of the welder who produced the defect
Repair welding procedure number
Name of repair welder
Copy of the inspection reports for the repair
Date of repair.
7.5
WELD REPAIR RATE

If the weld repair rate during production reaches a level that is unacceptable to GDF SUEZ (above 5%
of weld numbers but taking into consideration initial welding during start-up) and there appears to be
a consistent re-occurrence of a specific defect, CONTRACTOR should halt production and carry out an
investigation into the cause. CONTRACTOR shall inform GDF SUEZ of any reasons for high repair rates
and issue his proposals to alleviate such problems. Any such proposed changes must be within the
essential variable range already qualified. If this is not the case a re-assessment shall be made
relating to the suitability and continued acceptability of the qualified welding procedure(s).
If the cause of repairs is traced to lack of good workmanship, GDF SUEZ may request the removal of
the responsible welder(s) from the production line.

Page 28 of 54
8.
INSPECTION AND TESTING OF PRODUCTION WELDS
8.1
VISUAL INSPECTION
8.1.1
CONTRACTOR shall visually inspect every weld to a GDF SUEZ approved procedure and for
compliance with EN12732. All visual inspection shall be documented by CONTRACTOR.
8.1.2
Visual inspection shall be carried out at all stages of fabrication and shall include:
a) inspection of weld preparations and set-up prior to start of welding;
b) after tack-up (where applicable)
c) completed weld.
8.2
NON-DESTRUCTIVE TESTING
8.2.1
All welds and repaired welds shall be non-destructively tested (NDT) in accordance with NEN 36502:2003, EN 12732:2000 and EN 288-9:1999 and as required by this specification. NDT shall be
carried out according to written procedures, which shall be submitted to GDF SUEZ for approval prior
to the commencement of work.
8.2.2
All NDT procedures shall be approved by CONTRACTORs Level 3 specialist.
8.2.3
In principal all production girth welds shall be inspected 100% by an automatic ultrasonic system
(AUT) as outlined in Section 11, supplemented where appropriate by other inspection methods.
Other welds such as flange welds may be inspected by radiography (see Section 9) subject to GDF
SUEZ approval.
8.2.4
In specific cases GDF SUEZ may agree to the application of (X-) radiography (see Section 9) to
mainline production welds.
8.2.5
Magnetic Particle Inspection shall be carried out on;

a) welds with suspected defects in the root area, when accessible;
b) welds in which defects have been detected by radiography, UT or AUT and where additional
inspection is necessary to confirm removal of the defects.
Both wet and dry methods may be used, depending on the temperature of the object to be examined.
The wet method based on water or oil shall be used when the temperature is below 50C and the dry
method is applicable above temperatures of 50C.
8.3
ACCEPTANCE CRITERIA NDT
8.3.1
For the Acceptance Criteria of NDT refer to Section 13 of this Specification.

Page 29 of 54
9.
RADIOGRAPHY
9.1
RADIOGRAPHIC PROCEDURES
9.1.1
Prior to the start of production radiography CONTRACTOR shall provide to the GDF SUEZ a detailed
Radiographic Procedure in compliance with EN 1435:1997, EN 12732:2000 and this specification.
As a minimum the procedure shall include the following:
a)
Project name and job number
b)
Procedure number and revision
c)
Technique
d)
type of equipment and kilo Volt (kV) rating
e)
type of film
f)
intensifying screens
g)
shielding
h)
source size
i)
geometric relationship defined by sketch
j)
limit of film coverage
k)
tube voltage or source strength and exposure time
l)
material thickness range
m)
type of image quality indicator
n)
processing
9.1.2
The radiation source shall be x-ray unless otherwise agreed by GDF SUEZ. The single wall, single
image technique shall always be used, unless otherwise agreed with GDF SUEZ.
9.1.3
Wire type image quality indicators, in accordance with EN 462-1 shall be used.
9.1.4
Film type and screens shall comply with the requirements of EN 1435:1997. For Weld Procedure
Qualification only very fine grain (Agfa D4 or equivalent) film with lead screens should be used.
9.2
PROCEDURE RADIOGRAPHS
9.2.1
Three radiographs shall be taken to qualify each radiographic procedure qualification test, prior to
use on production or qualification welds. These radiographs shall establish the minimum
radiographic quality level for all production radiography. Subject to GDF SUEZ agreement, the
adequate quality of these radiographs shall result in qualification of the radiographic procedure.
Should any variables in the procedure specification change, the radiographic procedure shall be requalified. Fogging shall be reported, see 9.8.2.
9.2.2
For procedure qualification Image Quality Indicators shall be placed on both the source side and the
film side of the weld. Minimum IQI sensitivity shall be as stated in EN1435:1997.
9.2.3
A Radiographic Qualification Technique Sheet shall be produced showing all required and achieved
values. This must be approved by GDF SUEZ prior to commencement of any production activities.
This may be qualified on WPQ material but nipples must not be sent for mechanical testing prior to
approval of the technique(s).
9.2.4
One of the radiographic procedure qualification films shall be available in the production line
darkroom along with the approved technique sheet, for reference purposes, to prove that production
radiographs are being produced to the same quality as that qualified.
9.3
PRODUCTION RADIOGRAPHY
9.3..1
Production Radiography (if agreed) shall be carried out on completion of welding and in accordance
with the qualified radiographic procedure.
9.3.2
Facilities and viewing conditions shall be in accordance with ISO 25580. Radiographs shall be
viewed dry.
9.3.3
Where possible, the IQI shall be placed on the source side of the weld being examined. Where this is
not possible, film side IQI may be used and marked as F.

Page 30 of 54
9.3.4
Film density shall lie in the range 2.0 - 3.6 in the weld area. The density measurement shall be made
in the area of the weld image. A minimum of 5cm overlap shall be required to prove coverage of the
diagnostic film length. CONTRACTOR shall have a calibrated densitometer available for GDF SUEZ
use in the event of disputes.
9.3.5
A continuous number tape shall be used and lead letters shall be affixed to each section of the weld
being Radiographed. The images of these letters shall appear on the Radiograph to ensure
unequivocal identification of the section.
9.3.6
The zero data shall be at the top of the pipe and the direction in which the film numbering system
has been applied shall be defined alongside the weld using weather proof paint, chalk, crayon or felt
pen. The zero data and numbering direction for both Double Joint and Firing Line welds shall be in
the same direction.
9.3.7
To determine the absence of backscatter a letter "B" shall be affixed to the unexposed side of the
film.
9.3.8
Films of weld repairs shall be marked with the original number with the suffix R. The complete
circumference of the weld shall be examined.
9.4
RADIATION PROTECTION
CONTRACTOR shall be responsible for the protection and monitoring of Radiographic personnel and
shall ensure that all work is performed in accordance with the relevant Health and Safety Regulations
and in accordance with the Contract for the safety of all personnel. CONTRACTOR shall be
responsible for notification of the use of Radiography as required by Statutory Regulations. Breaches
of Radiographic safety shall not be permitted and may result in removal of the offending party(ies)
from the work-site, at GDF SUEZ's sole discretion.
9.5
QUALIFICATION OF RADIOGRAPHERS
9.5.1
Radiographic Interpreters shall be qualified to a minimum of Level 2 according to the requirements

of EN-473 and shall have at least 2 years proven experience in pipeline welding film interpretation
and be specifically trained to identify indications of copper contamination in welds made by
automatic systems, where these are utilised.
9.5.2
Radiographic examination shall be performed by personnel qualified as a minimum to Level 2

according to EN-473.
9.5.3
GDF SUEZs Representative retains the right to reject any NDT personnel who, in his opinion, do not
conform and/or perform to the required standards.
9.6
FILM IDENTIFICATION
As a minimum, the identification on the film shall include:
GDFS-Project-Material-Diam. x w.t. - Weld Number; {R (Repair) or RW (Re-weld)} - Date
9.7
FILM PROCESSING
Film shall be processed on site in such a way as to allow storage for a minimum of 7 years without
deterioration. CONTRACTOR shall submit a procedure for ensuring processing chemicals have been
removed to GDF SUEZ for approval.
9.8
STORAGE OF UNEXPOSED FILMS
9.8.1
All unexposed film shall be stored in a clean dry place where surrounding conditions will not be
detrimental to the emulsion.

Page 31 of 54
9.8.2
When requested by GDF SUEZ, CONTRACTOR shall develop a sample of unexposed film, which shall
have a fogging density of less than 0.3.
9.9
STORAGE OF RADIOGRAPHS
On completion of the Work, CONTRACTOR shall submit all the documentation detailed in section
15.3. CONTRACTOR shall store all radiographs for a period of 7 years in a controlled environment. On
request of GDF SUEZ, CONTRACTOR shall make Radiographs/films available, together with viewing
facilities, for re-checking.

Page 32 of 54
10.
MANUAL ULTRASONIC TESTING
10.1
The Manual Ultrasonic Testing procedure shall be in accordance with NEN 3650-2:2003 and EN
12732:2000 (EN 583-1 and EN 1714:1997). CONTRACTOR shall submit detailed procedure and
technique sheets for ultrasonic testing to GDF SUEZ for approval prior to the start of production.
10.2
GDF SUEZ shall be invited to witness all technique qualifications, which result in the production of
the relevant technique sheets. Should any of the variables of the technique(s) change, following
approval, the ultrasonic procedure shall be re-qualified.
10.3
Manual Ultrasonic Testing shall be carried out by personnel qualified as a minimum to Level 2
according to EN-473.
10.4
Manual Ultrasonic Testing may only be used in lieu of radiographic examination with prior, written
approval of GDF SUEZ.

Page 33 of 54
11.
AUTOMATED ULTRASONIC TESTING (AUT)
11.1
APPROVAL OF CONTRACTOR, OPERATORS AND SYSTEM
11.1.1
The NDT contractor shall be an independent and accredited by GDF SUEZ. Proven historical data
showing the validity of the AUT system shall be submitted to GDF SUEZ for approval.
11.1.2
When an automatic ultrasonic system is deemed acceptable to GDF SUEZ, the operator responsible
for the final interpretation and sentencing of the welds shall, besides being in possession of an EN
473 level 2 Ultrasonic qualification and further independent or GDF SUEZ qualification(s) in
AUT/TOFD, prove to GDF SUEZ that he has sufficient knowledge and experience of Lay barge
interpretation and welding technology in order to be able to identify weld defects inherent to the
welding system(s) being used.
11.1.3
As long as the Good Workmanship Acceptance Criteria described in this specification is used there is
no requirement for the NDT contractor to carry out a qualification test using blind tests to prove the
conventional pulse-echo/ through transmission technique system and the time of flight diffraction
technique.
11.2
AUT SYSTEM
11.2.1
Time of flight diffraction shall be included to improve interpretation of ultrasonic pulse-echo

responses and accurate sizing in through-thickness dimension. In principal all sizing will be executed
by means of pulse-echo technique.
11.2.2
A mechanised manipulator shall rotate the ultrasonic transducer-array, including the time of flight
unit, around the girth weld while signals are processed, recorded and available for immediate
interpretation in one single rotation.
11.2.3
The NDT contractor shall design an ultrasonic inspection system specific to the typical weld
configuration and material acoustics used for the project. CONTRACTOR will deliver relevant data of
typical weld bevel preparation, dimensions and actual (test) material. In case phased array
equipment is used along with a combination of various pipe manufacturers/suppliers, a special
calibration block will be manufactured from pipe delivered by each supplier.
11.2.4
As a minimum the following attributes shall be implemented in the design of the ultrasonic system:
a) The weld volume shall be proportionally divided into through-thickness inspection zones,
depending on the weld geometry, the weld process (layer height) and the pipe wall thickness,
between 2.5 mm and 4.0 mm (the actual zone height shall be determined from macros
produced during weld procedure qualification).
b) Each inspection zone shall represent, by gate setting a proportional weld volume, a fusion line
and at least a 2 mm heat affected zone.
c) Detection of weld defects according to the requirements of EN 12732:2000 and NEN 36502:2003 and identification in terms of sizing through-thickness and length.
d) Discrimination between embedded and surface breaking defects.
e) Detection of transverse and longitudinal weld defects.
f) Detection of stacked defects.
11.2.5
Probes for each zone shall be designed to produce optimum detection, sizing and determination
("through-thickness" and length) of weld defects, therefore:
a) probe characteristics of reference reflector shall prove at least 12 dB echo response above noise
level of the target path, without interference by adjacent (reflected) signals of mode conversion
disturbances by (weld cap, pipe surface or weld root) geometry reflectors
b) depending on weld geometry (focussed) probes of various angles shall be necessary
c) through-thickness discrimination between zones shall be between 6 dB and 12 dB
d) Transit distance measurements in the root zone shall visualise the root pattern.
e) Probe data sheets shall be made available to GDF SUEZ.

Page 34 of 54
11.2.6
Time of flight diffraction (longitudinal scan with respect to the weld centre line), in accordance with
EN 583-6 shall be implemented to improve:
a) detection of volumetric defects
b) discrimination of weld defects and weld geometry
c) accurate sizing of weld defects in through-thickness direction
d) detection of unfavourably oriented defects for impulse-echo techniques
e) detection of transverse weld defects.
11.2.7
The maximum allowable circumferential scanning velocity shall be determined according to Vc Wc

PRF/3.
11.2.8
Wc is the narrowest 6dB beam width of the appropriate probes and PRF is the effective pulse
repetition frequency per probe.
11.2.9
The mechanised manipulation system shall be designed and interfaced with the GDF SUEZ specified
requirement for bare pipe ends:
11.3
CALIBRATION BLOCK FOR PULSE-ECHO AND THROUGH-TRANSMISSION TECHNIQUE
11.3.1
Calibration shall be carried out by using a specially machined block mounted in a representative pipe
segment so that the complete mechanised manipulation system shall form a part of the calibration.
11.3.2
The calibration block shall be manufactured from project pipe. In case a phased array transducer is
used for the inspection, a special calibration block shall be manufactured using material from each
pipe supplier.
11.3.3
A calibration scan shall always be carried out after a rejected weld. The print out of the calibration
runs shall become part of the repair record.
11.3.4
The calibration block shall contain reference reflectors (see table 11 for tolerances) simulating weld
defects which, at least:
a) Simulate fusion defects using 2 mm flat bottom holes and 1 and 2 mm deep surface notches
including a notch perpendicular to the scan direction
b) Check measuring point density and weld volume coverage using 2mm through-thickness drilled
holes located at the weld centre line.
Table 11:
Tolerances of reflectors:
Tolerance of machined reflectors
Hole diameters
FBH
All pertinent angles
Notch depth
Notch length
Central position of all reference reflectors per weld zone
0,1 mm
0,25 mm
1
0,1 mm
0,5 mm
0,1 mm
GDF SUEZ shall have the opportunity to witness the dimensional control checks of the calibration
blocks.
11.3.5
The frequency of calibration shall be agreed between CONTRACTOR and GDF SUEZ, however, should
CONTRACTOR establish, during calibration, that the equipment has a sensitivity of less than the
agreed lower tolerance, all welds examined since the previous calibration shall be re-examined.
11.3.6
As a minimum recalibration is required:

a) After a weld repair has been called and prior to scanning the repaired weld
b) When differences of material acoustics might occur
c) If calibration results amplitudes vary more than 2dB from 80% FSH
d) Wall thickness change.
e) After equipment breakdown.
f) If the gate settings need to be adjusted by more than 1mm.
g) If required by GDF SUEZ.

Page 35 of 54
11.4
CALIBRATION TIME OF FLIGHT DIFFRACTION TECHNIQUE:
11.4.1
The time of flight system shall be calibrated at the actual pipe by gain setting using grain noise and
registered and set for the project (EN 583-6).
Settings are only allowed to be changed after GDF SUEZ approval.
11.4.2
The ability of the system to produce diffraction signals shall be proved by means of machined
notches (see table 12 for tolerances of notch sizes) positioned through the weld centre line (internal
and external surface) with a length of 10 mm, a depth of 2,5 mm and a width of 0,5 mm. Additional a
notch with a depth of 1.0mm shall be machined in order to prove the systems capability to detect 1.5
mm embedded defects in the root or cap zone.
Table 12:
Tolerances of notches:
Tolerance of machined notches

Notch depth
Notch length
Notch width
Note: The top angle shall be a maximum of 60.
0,1 mm
0,5 mm
0,1 mm
11.4.3
A calibration check is required on actual data (material acoustics, distance between transducers and
wall thickness) via calculated difference of time of flight between creeping wave and longitudinal
back wall / root reflection or mode converted back wall signals.
11.5
PROCEDURE
11.5.1
The procedure shall contain at least the following information:

a) name of project
b) project and job number
c) procedure number and revision number
d) specific to pulse echo:
i. equipment: mechanized scanner, transducers, monitor/display, multi channel ultrasonic
processor
ii. method of reporting (shall be one A4 format per weld)
iii. system set up; sketch weld volume, inspection zones, probe array, probe positioning,
probe angles, probe identification, target paths and gate settings
iv. programming and recording per inspection zone; channel and probe setting,
amplification, gate setting, go-no-go setting, analogue setting, transit distance setting,
minimum and maximum over trace.
v. description examination/execution; positioning manipulator ("zero point setting"), weld
and scan identification, scan velocity, coupling, process checks (coupling, probe
positioning, surface conditions, registration, hard copy)
vi. recalibration
vii. sizing technique and anticipated accuracy
viii. monitor display setting.
ix. the calculations made regarding the interaction rules.
e) specific to TOFD
i. see pulse echo d) i, ii, iii, iv, vi, vii and viii.
ii. programming and recording, sample frequency, amplification (A-scan)
iii. calibration on actual pipe (B-scan); visualize creeping wave signal and longitudinal back
wall/root reflection and mode converted back wall signals, averaging (signal/noise ratio
verses acceptable scan velocity), amount of A-scans per mm, calibration check by
calculation
iv. interpretation guide
f) acceptance criteria (may be a separate procedure), as per Section 13
g) couplant used
h) surface temperature limits

Page 36 of 54
11.6
INSPECTION
11.6.1
Pulse echo and TOFD shall be combined to form part of the inspection and shall be executed in one
single rotation around the pipe.
The mechanised manipulator and recording system shall be capable of locating weld defects within
an accuracy of 1,0 mm.
11.6.2
11.6.3
A check on the accuracy of the encoding system shall be automatically performed on every scan.
11.6.4
Real time inspection of the weld and weld defects shall take place on a monitor/display including
characterizing, sizing and assessment.
11.6.5
As a summary, inspection results shall be recorded on one A4-format per weld.
11.7
PULSEECHO AND THROUGH TRANSMISSION TECHNIQUE
11.7.1
Prior to the commencement of weld inspection, the sensitivity setting shall be calibrated to 80% FSH
of all separate reference reflectors.
11.7.2
During weld inspection, all indications with an echo response > 40% FSH shall be recorded
11.7.3
All indications with an echo response > 40% FSH shall be evaluated on length and position
(inspection zone) according to the GDF SUEZ approved acceptance criteria.
11.7.4
The length of a weld defect shall be determined by the point at which the reflected pulse amplitude
amounts to less than 40% FSH. Beam width effects shall be compensated for.
11.7.5
Through thickness of a weld defect shall be assumed as the height of the inspection zone(s).
Accurate sizing of through thickness shall be conducted by TOFD.
11.7.6
Transit distance threshold shall be set between 5% FSH and 40% FSH to discriminate weld flaws
from geometry.
11.8
TIME OF FLIGHT DIFFRACTION
11.8.1
Before commencing weld inspection, TOFD shall be calibrated on the stamped calibration block and
actual pipe.
11.8.2
TOFD shall be used as additional interpretation to pulseecho responses and/or accurate through
thickness sizing ( 2.5 mm) shall be conducted by straightening and/or linearizing.
11.9
REPEAT INSPECTION
11.9.1
GDF SUEZ reserves the right to have any inspection repeated or confirmed, possibly by radiographic
examination of the ultrasonically inspected areas.
11.9.2
If any doubt is raised as to the calibration/accuracy and/or integrity of the system, GDF SUEZ
reserves the right to require CONTRACTOR to prove the system. If the performance is found to be
incorrect, the NDT contractor will be required to repeat the inspection of welds examined since the
last proven acceptable calibration, at his own expense.
11.10
SURFACE CONDITION AND TEMPERATURE
11.10.1
The weld and adjacent pipe surface shall be cleaned by the welding contractor over a sufficient
(ultrasonic inspection) width, in order to remove any surface defects such as weld spatters, flux, slag
etc. which may impede the movement and coupling of the transducers over the pipe surface.
11.10.2
The inspection may only take place when the temperature of the metal is in the range 0C 60C. In
case phased array is used, the calibration block temperature shall be within 5C of the surface under
examination.

Page 37 of 54
11.11
COUPLANT
11.11.1
To provide an acoustic coupling between the probes and the object to be inspected, water or a nongreasy liquid or paste, which can be washed off by water, shall be used.
11.11.2
Continuity of coupling shall be assured (and recorded) by through-transmission measurements.
11.12
ULTRASONIC EQUIPMENT PULSE-ECHO AND THROUGH TRANSMISSION
11.12.1
The ultrasonic equipment shall provide an adequate number of separate channels to assure
separate presentations in one single rotation around the weld.
11.12.2
The ultrasonic instrument linearity (horizontally and vertically) shall not exceed 5% from ideal, to be
determined according to the procedures detailed in:
a) ASME Boiler and pressure vessel code, section 5: article 4, mandatory appendices numbers I
and II and article 5 mandatory appendices numbers I and II (July 2001)
b) EN 12668-3
11.12.3
At GDF SUEZ request, (re)calibration certificates shall be made available.
11.12.4
Each separate channel shall provide:

a) The amplitude and the transit distance information
b) An adjustable gate setting (start, length)
c) The gain adjustment
d) The FSH threshold setting and recording (5% - 100%)
e) A signal delay to provide coherent presentation
f) A recording output per gate:
exceeded preset threshold amplitude, and
analogue amplitude presentation, and
transit distance presentation.
11.13
ULTRASONIC EQUIPMENT TOFD

The ultrasonic instrument shall meet the requirements of EN 583-6 for automated TOFD inspection,
including:
a) minimum signal digitising with a sample rate of 100 MHz
b) at least one A-scan per 2 mm circumferential length.
11.14
PROBES
All probes shall comply with the requirements of EN 12668-2.
11.15
MONITOR/DISPLAY
Real time inspection shall take place on a 20 inch (diagonal) monitor/display with a resolution
(SVGA) of at least 800 x 600. The maximum scan resolution shall be 2 mm/scan.
11.16
STORAGE
NDT contractor shall store all the relevant digitised data in a safe place for at least 10 years
(according to EN ISO 9001). Within this period the NDT contractor shall assure the availability of
digital copies of the original ultrasonic results (along with viewing software) at GDF SUEZs request.

Page 38 of 54
11.17
QUALIFICATION OF AUT SYSTEM
11.17.1
The NDT equipment and procedure(s) shall be qualified by calibration and technical justification.
11.17.2
Calibration blocks shall be made from each steel manufacturer or source of supply and calibration
scans shall be carried out before and after each weld scan (call-in and call-out) using the calibration
block of the pipe joint(s) supplier(s) making up the weld.
11.18
INSPECTION OF WELD REPAIRS
11.18.1
Each repair weld shall be subjected, as a minimum, to the same inspection and documentation
requirements as the original weld.
11.18.2
In the case of a weld repair, special attention shall be given to the positioning of the scanner band.
Due to the fact that the resulting width of the repaired area of the weld is usually greater than that of
the original weld, it is possible that the repaired area will be outside the gate settings. This can be
avoided by scanning the weld with the band in an offset position compared with its original
position. The AUT operator shall measure the centreline and the angle of the new gap prior to
commencement of the repair welding. After the repair welding is finished, the first scan shall be
made with the band on the original position to confirm that the defect has been removed. A second
scan shall then be made with the band positioned on the centreline of the repaired area.
11.18.3
If the TOFD scan shows any relevant indications in the repaired area, a manual ultrasonic
examination shall be carried out which shall be completely witnessed by GDF SUEZ.

Page 39 of 54
12.
SURFACE EXAMINATION
12.1
MAGNETIC PARTICLE INSPECTION (MPI)
12.1.1
CONTRACTOR shall submit a detailed MPI procedure to GDF SUEZ for approval.
12.1.2
CONTRACTOR's procedure shall be in accordance with EN 1290:1998 for wet (or dry for excavations)
Magnetic Particle Inspection. The yoke method shall be used for all MPI. The use of permanent
magnets is not allowed. The use of any other method shall be subject to GDF SUEZ approval.
12.2.3
Magnetic particle operators shall be qualified to Level 2 according to EN-473.
12.2
DYE PENETRANT INSPECTION (DPI)
12.2.1
CONTRACTOR shall submit a detailed DPI procedure to GDF SUEZ for approval.
12.2.2
Dye Penetrant Inspection shall be carried out in accordance with EN 571-1:1997 using Chloride-free
dye.
12.2.3
Dye Penetrant Inspectors shall be qualified to Level 2 according to EN-473

Page 40 of 54
13.
INTERPRETATION AND ACCEPTANCE CRITERIA FOR N.D.T.
13.1
ACCEPTANCE CRITERIA VISUAL

a) Surface breaking defects are not acceptable. Excess weld metal should be uniform and not more
than 3mm in height. It should merge smoothly and gradually into the parent metal and not
extend beyond the original joint preparation by more than 2mm. No area should have the weld
face lower than the adjacent pipe surface.
b) The root bead or any concavity shall merge smoothly into the adjacent surface but at no point
shall the weld be thinner than the pipe thickness.
c) Any undercut shall not exceed 0.5mm in depth and 50mm in length
d) The angle of incidence between the parent metal and weld shall be a minimum of120 (see
figure below taken from EN 12732:2000 Annex E)
120
Figure 2:
13.2
Angle of incidence between parent metal and weld
ACCEPTANCE CRITERIA RADIOGRAPHY

Acceptance criteria for Radiographic examination shall be in accordance with Appendix 4 of this
specification.
13.3
ACCEPTANCE CRITERIA MANUAL ULTRASONIC TESTING

Acceptance criteria for Manual Ultrasonic Testing shall be in accordance with Appendix 5 of this
specification.
13.4
MECHANISED PULSE ECHO + TOFD: INTERPRETATION AND SIZING OF WELD DEFECTS
13.4.1
Relevant weld defects

Indications are deemed to represent relevant weld defects when:
a)
a pulse echo response of > 40 % FSH is obtained; based on a reference reflector size of
3.0mm flat bottom hole.
b)
TOFD diffraction signals are measurably differentiated by having height in the thickness
direction in combination with phase reflection;
c)
TOFD diffraction signals are detected in combination with a local interference of the lateral
wave, typical to the pipe outer surface;
d)
TOFD diffraction signals are differentiated from the bottom reflection signals typical to the
normal pattern of the penetration, or the pipe inner surface;
e)
single TOFD diffraction signals occur in clusters or in evenly spread patterns.
13.4.2
Identification of weld defects

The identification of weld defects shall take place in terminology of h x lmax, where:
a)
h is the maximum allowable height dimension of a weld defect in mm;
b)
lmax is the maximum allowable length of a weld defect in mm in a circumferential direction.

Page 41 of 54
13.4.3
Definition of surface breaking and embedded weld defects

A difference is made between surface breaking and embedded weld defects, where weld defects
near to the surface in the zones adjacent to the pipe inner and outer surfaces are deemed surface
breaking in case of insufficient resolution of the ultrasonic system or when the distance between the
surface and the defect is less than the maximum height of the defect. Defects in all other zones
located between the inner and outer zones are classed as being embedded.
13.4.4
Misalignment
Pulse-echo response near the noise level (0 % FSH) in combination with TOFD (see paragraph
13.4.1), where diffraction signals fade in and fade out gradually to the normal root pattern and run
parallel to it, are deemed misalignments.
13.4.5
Determination of through thickness weld defect height

The primary means of defining the height of a weld defect in the through thickness direction shall
be examination of the pulse-echo response, where after TOFD assisted correction/confirmation and
visual examination shall take place. The following methodology shall be applied to the aforesaid:
a) Weld defects detected by means of pulse-echo response are expected to have a through
thickness height equal to the number of inspected zones where the defect has been observed.
b) The observed values shall be corrected and/or confirmed by means of TOFD in the following
manner:
1) A weld defect in the root zone (= root penetration + zone height) shall principally be a
surface breaking defect, where the through thickness measurements (h) from the pipe
inner surface shall be rounded of at 1,5 mm, 2,0 mm or 2,5 mm.
2) A detected weld defect in the zones between the root zone and the zone adjacent to the
outer pipe surface shall be deemed to have a height of at least the inspected zone, unless
an alternate value is confirmed by means of TOFD.
3) A weld defect detected in the zone adjacent to the outer pipe surface shall principally be
deemed to be surface breaking, with a minimum height of at least the height of the
inspected zone, unless an alternate value is confirmed by means of TOFD.
c) Where defects manifest on the pipe outer surface or in case of misalignment, defect heights
shall be corrected on the basis of visual examination but only after confirmation by GDF SUEZ
13.5
ACCEPTANCE CRITERIA MECHANISED PULSE ECHO + TOFD

Acceptance criteria for Automated Ultrasonic Testing shall be in accordance with Appendix 6 of this
specification.
13.6
ACCEPTANCE CRITERIA MAGNETIC PARTICLE INSPECTION
13.6.1
Any weld or area tested by means of MPI shall be unacceptable if:

a) any crack or crack like indication, regardless of size, is revealed;
b) any linear indication is found;
c) any rounded indication >2 mm is found;
d) more than 3 rounded indications > 1.5mm, in line and with a distance between the indications of
less then 1.5mm measured from edge to edge, are found.
13.7
ACCEPTANCE CRITERIA DYE PENETRANT INSPECTION
13.7.1
Any weld or area tested by means of DPI shall be unacceptable if any defects as specified for MPI are
revealed.

Page 42 of 54
14.
REPORTING OF N.D.T.
14.1
GENERAL
CONTRACTOR should use standard NDT reports/forms giving all relevant details to the NDT
technician in order to facilitate correct inspection methods and reporting standards.
NDT reports refer to those for Visual Inspection, Radiography, Ultrasonic Inspection(s), Dye Penetrant
Inspection and Magnetic Particle Inspection.
In principal the following information, but not limited to, SHALL be clearly shown on reports:
a)
GDF SUEZ name
b)
GDF SUEZ project number
c)
GDF SUEZ platform number or location
d)
Unique report number
e)
Specific details as to the weld numbers examined.
f)
Drawing number and revision number
g)
Certifying Authority (and Registration number where applicable)
h)
Standard or Procedure Number (Approved) and Revision
i)
Acceptance Criteria
j)
Technicians name, qualification, level and certificate number
k)
Shift being worked ( day, night or 0.00-12.00, 12.00-24.00)
l)
Material type
m)
Pre or post heat treatment (where applicable)
n)
Material thickness
o)
Surface condition and temperature
p)
Welding preparation and technique used (i.e V SMAW)
14.2
SPECIFIC MPI
a)
b)
c)
d)
e)
f)
14.3
SPECIFIC DYE PENETRANT

a)
b)
14.4
Consumables used
Times used during application for penetration, cleaning and development.
SPECIFIC ULTRASONIC
a)
b)
c)
d)
e)
f)
g)
14.5
Method used
Yoke or magnet ID
Current used
Field strength
Lighting used and light strength
Consumables used, contrast paint, ink etc
Equipment type and ID

Probes used (including frequency, diameters, angles etc.)
Couplant used
Calibration and reference block
Sensitivity
Transfer correction
Range
SPECIFIC AUT
a)
b)
c)
d)
e)
Equipment used
Location of defects (zone, upstream, downstream, depth)
Details of defect (height, start, end and length)
A written note shall be generated for the marking up of defects.
Print outs of scans shall contain the time and date of examination

Page 43 of 54
14.6
SPECIFIC RADIOGRAPHIC:
a)
b)
c)
d)
e)
f)
g)
h)
i)
Radiation source, size and ID

Type and size of film
Exposure time in kV and mA minutes
Technique used
Thickness of material and weld reinforcement.
Films shall be identified separately (i.e Weld FL (DJ) 01 film 1, 2, 3 and 4 if applicable)
Interpretation and sentencing per film according to the Approved Acceptance Criteria
Qualification type and level of Interpreter
Acceptance of interpretation by CONTRACTOR

Page 44 of 54
15
DOCUMENTATION
15.1
GENERAL
15.1.1
CONTRACTOR shall provide all documentation, in the English language, to GDF SUEZ for review as
required by the Purchase Order, this Specification and other referenced Specifications.
15.1.2
CONTRACTOR's documentation procedures shall be subject to review and approval by GDF SUEZ.
15.2
INITIAL SUBMISSIONS
15.2.1
Prior to the commencement of procedure qualification and production CONTRACTOR shall provide
the following documentation for review by GDF SUEZ. Documentation shall include but not be limited
to the following:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
Quality Plan;
Test and Inspection Plan;
Quality Assurance Manual;
Proposed Welding Procedure Specifications including repairs;
Welding Procedure Qualification Matrix;
Joint Designs;
Line-up procedure;
Welding Consumable Technical Information (Manufacturer's);
Welding Consumable Batch Test Certificates;
Line-up Clamp Details
Test Equipment Calibration Certificates;
Film Processing Procedure;
Radiographic Safety Procedures;
N.D.T. Procedures and Procedure Qualification Reports;
N.D.T. Operator Qualification Certificates.
Evidence of quality reviews, of internal systems audits and corrective action requests;
Details of CONTRACTOR's Q.C. personnel and equipment;
15.3
FINAL DOCUMENTATION
15.3.1
Within 4 weeks of completion of the order, CONTRACTOR shall deliver to GDF SUEZ a Manufacturing
Record Book (MRB) containing, as a minimum, the following documentation:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
15.3.2
Purchase Order (PO) and variations to PO.

CONTRACTOR's daily/weekly/monthly reports issued to GDF SUEZ.
all approved queries and concessions
manufacturing procedures.
quality control/inspection procedures.
non-destructive testing procedures and qualification records.
welding procedure(s) and qualification test results.
copies, in sequential order, of all GDF SUEZ issued approvals.
all inspection and test reports and certification recording the results of inspection and testing
as specified in this specification;
visual inspection and N.D.T. Reports
welder qualification records
approved list of qualified welders
dimensional control reports
hydrostatic test records
heat treatment records
pipe fabrication certificates (see 15.3.2)
weld tracking sheets (see 15.3.3)
Pipe fabrication certificates are supplied to the CONTRACTOR with/for each length of pipe.
CONTRACTOR shall maintain a material traceability system locating the correct position/place of
each length of pipe.

Page 45 of 54
15.3.3
The Weld Tracking Sheet or As Laid Record shall contain the following minimum information:
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
pipe number and length

weld number
pipe number and length
material heat number
material certificate number (see 15.3.2)
date welded
shift (day/night)
welding procedure used
name/type and batch no(s) of weld consumables
report numbers of all applicable test and inspection reports
15.4
STORAGE BY CONTRACTOR
15.4.1
After approval of the MRB, CONTRACTOR shall make 3 electronic (pdf) copies. The original plus 2
electronic copies shall be submitted to GDF SUEZ. CONTRACTOR shall store 1 copy of the MRB,
together with all Radiographs, for a period of 7 years (see 9.9).
15.5
DELIVERY DOCUMENTATION
15.5.1
During the fabrication/construction phase, extra copies of the in 15.3.1 listed documentation shall
be furnished by CONTRACTOR upon the request of GDF SUEZ and/or the CERTIFYING AUTHORITY,
e.g. NDT reports and Weld tracking sheets.

Page 46 of 54
APPENDIX 1:
MECHANICAL TEST REQUIREMENTS PIPE WELDS

Appendix 1A Sample locations mainline weld
Note: In case of welded pipe the welds may be located directly across from each other in the 12 oclock
position.
Appendix 1B

Sample locations Full Penetration Repair
Page 47 of 54
Appendix 1C
Sample locations Partial Penetration Repair
Appendix 1D

Sample locations Cap Repair
Page 48 of 54
APPENDIX 2:
IMPACT TESTING DETAILS

Appendix 2A
Charpy details mainline weld and full penetration repair
Appendix 2B

Charpy details partial penetration repair
Page 49 of 54
APPENDIX 3:
HARDNESS TESTING DETAILS
CW
2 mm APPROX
Weld Metal
HAZ
Mid weld
2 mm APPROX
CW
H.A.Z.:
From Fusion Line and into unaffected Base Metal at Fusion Line, Fusion Line +2mm, Fusion Line +5mm for each
transverse location. Spacing between tests in H.A.Z. shall be 0,5mm.
WELD METAL:
At least 5 indentations for each transverse location, the outer two shall be 2mm from the fusion lines and the
remainder equally spaced.

Page 50 of 54
APPENDIX 4:
RADIOGRAPHIC ACCEPTANCE CRITERIA:
The following Acceptance Levels for radiography are based on Table G.2.2 (Tier 1) of EN 12732:2000.
DEFECT
DEFECT ACCEPTANCE LEVELS
External Profile
Weld reinforcement shall be uniform and not less than 1 mm. Maximum Height shall be
3mm.
The cap shall merge smoothly with the parent metal and not extend beyond the original
joint preparation by more than 3mm each side. Surface breaking defects are not
acceptable.
Internal Profile
The root bead or any concavity shall merge smoothly into the adjacent surface but at no point
should the weld be thinner than the pipe thickness.
Root Concavity
Root concavity is acceptable if the density of the image is no greater than that of the
adjacent parent material. If the defect image is darker than the adjacent parent metal, it
shall be classed as incomplete root penetration. Root concavity shall not exceed 25% of the
weld circumference.
Cap Undercut
Length: 50mm
Total: 50mm in 300mm or 15% of circumference (if less)
Depth: 1mm or 0.1 x T if less
Root Undercut
Length: 25mm
Depth: 1mm or 0.1 x T if less
Crack
Any form of crack or suspected crack shall be considered unacceptable regardless of its size
or its location and the weld cut out.
Crater Cracks
4mm
Excessive Root
Excess penetration: 2mm maximum with localised 3mm.
Penetration
Incomplete Root
Any individual imperfection due to incomplete root penetration or lack of fusion at weld root
Penetration or
and cap shall not exceed 25mm in length.
Lack of Root or
The total length of such imperfections shall not exceed 25mm in any 300mm or 8% of
Cap Fusion
circumference (if less).
Incomplete Fusion Any individual imperfection due to incomplete fusion due to cold lap between two adjacent
due to cold lap,
weld beads or between the weld metal and the base metal that is not open to the surface,
Lack of Sidewall
shall not exceed 50mm in length. The total length of such imperfections in any continuous
and Lack of Inter300mm length of weld shall not exceed 50mm. For any weld less than 300mm in length, the
run Fusion
aggregate length of indications of incomplete fusion due to cold lap shall not exceed 15% of
(not in root or
the weld length (if less).
capping beads)
Worm Holes
Not Acceptable
Hollow Bead
Length: 50mm
Inclusions
12mm in 300mm and 4 in 300mm
Slag
Length: 50mm
Burn Through
Any Burn Through shall not be acceptable if the image is darker than that of the parent
adjacent metal.
Burn through producing a darker image than that of the adjacent parent metal is not
acceptable if its length exceeds 0.33WT, with a maximum of 6mm.
Only two burn throughs are allowed in any 300mm of weld.
Porosity
Porosity shall not exceed a total area when projected radially through the weld, of 2% of the
projected weld area in the radiograph, calculated by multiplying the length of the weld
affected by porosity, with a minimum of 150mm, by the maximum width of the weld.
An isolated pore greater than 0.25WT(max.3mm) in any direction shall be considered
unacceptable.
High Density
GDF SUEZ has the right to reject any indication on (excessive) density alone even if the length
Indications
or dimensions of that defect appear to be within the acceptance limits. CONTRACTOR shall
notify GDF SUEZ of any indications having a high density.
Copper Induced
Any indication showing suspected copper or copper crack like indications shall be rejected
indications
and the weld removed.
Defect
100mm in 300mm or 15% of pipe circumference (if less), excluding porosity.
Accumulation
Note: Root Concavity is not included in accumulation calculations unless is causes the weld
thickness to be less than that of the pipe.
Defect Interaction Inherent in defect accumulation criteria.

Page 51 of 54
APPENDIX 5:MANUAL ULTRASONICS ACCEPTANCE CRITERIA

The following Acceptance levels for manual ultrasonic testing are in accordance with EN 12732:2000 Tables
G.3.1 and G.3.2
Recording of indications
Calibration standards and fault reflection lengths using the Distance Gain Size method
Wall thickness (T)
Calibration level
Sensitivity setting
Fault reflection lengths
In mm
circular disc reflector
amplitude below
to be recorded above
diameter, in mm
calibration level by dB
this length (mm)
6 < T 15
1.0
6
10
15 < T 20
1.5
6
10
20 < T 40
2.0
6
10
Assessment of indications using the Distance Gain Size method
Maximum allowable numbers and sizes of reflectors
Wall thickness T*
Number of indications
Maximum allowable
In mm
per m of seam
lengths of reflectors per
echo**
mm
-6 T 10
5
10
and 2
20
10 < T 20
10
10
and 3
20
and 1
10
20 < T 40
10
10
and 4
25
and 1
10
40 < T 60
10
10
and 4
30
and 1
10
NOTES:
Echo level above

calibration level
dB
6
6
6
6
12***
6
6
12***
6
6
12***
If wall thicknesses differ, the lower wall thickness shall be decisive
**
For confirmed volume defects (not in vicinity of the surface), fault lengths exceeding the
calibration levels by up to 6dB can be allowed up to 1.5 times the allowable length.
Confirmation may take the form of a radiographic examination.
***
The acceptability of single, large defects shall be confirmed on the basis of random samples, e.g.
by means of radiographic examination.

Page 52 of 54
APPENDIX 6:
Mechanised Pulse Echo + TOFD Acceptance Criteria
General
All relevant indications shall be examined in accordance with this section. In the case of two unequal wall
thicknesses, the thinnest dimension shall be applied.
A group of indications in which the individual defect lengths are deemed acceptable, shall be accepted only when
the group is found to comply with all of the conditions stated for interaction.
In the event that the AUT contractor applies a software program utilising the above mentioned interaction rules,
the software shall be made available to GDF SUEZ for validation prior to the commencement of pipeline
installation.
Indications which do not comply with conditions of the aforesaid shall be treated as one single indication.
Furthermore, the defective dimensions (h and l) shall be measured, including the distance between the
indications and the table below shall be applied for evaluation of the defects.
Sizing (In-)Accuracy
1. If no validation testing to NEN 3653 is performed, the Sizing (In-)Accuracy to be applied shall be 1.5mm
for the root and fill and 2mm for the cap. These values may be adjusted after validation testing has
proven a better sizing accuracy.
2. If no validation to NEN 3653 is carried out, the acceptance of the proposed defects shall be confirmed by
Curved Wide Plate Testing, using proposed Surface Breaking Defects only.
Acceptance criteria based on good workmanship
Maximum allowable defect length (l) in mm

Wall thickness (mm)
6 Wt 10
10 < Wt 25
WQT / repairs
11234567-
Surface breaking
20
10
Not acceptable
25
20
0
20
10
Not acceptable
Embedded
30
15
10
50
40
25
25
10
10
Defect Height (h)

1.5 2.5
2.5 3.0
3.0 3.5
1.5 2.5
2.5 3.0
3.0 3.5
1.5 2.5
2.5 3.0
3.0 3.5
Only 1 defect, or summation / interaction of smaller defects, as agreed is allowed in any 12.5%
of Weld Circumference Length;
Maximum Allowable Defect Square Area is 7.0 %, including Threshold and Sizing (In)Accuracy, in
any 12.5% of Weld Circumference Length.
Threshold Root / Cap 40% of 2mm Notch
Threshold Embedded 40% of 3mm FBH.
Indications in ROOT below threshold, may be full circumference, 360.
Maximum Misalignment (Hi-Low) 10% of Wall Thickness, if greater then the value (mm) over 10%
to be added to the actual defect height for evaluation.
No weld flaws are allowed in the weld area where longitudinal/spiral weld crosses with
circumferential weld
CONTRACTOR shall also have data and information available to identify (suspected) copper
induced cracking. Welds containing (suspected) copper induced cracking shall be cut out.

Page 53 of 54
Interaction Rules
Interaction Rules shall be applied as per API 1104 2005 Errata 1 2007, modified as follows:
Interaction exists if;
ab-
S < ((2c1+ 2c2) / 2) + sizing (in)accuracy)

S1 < ((2c1+ 2c2) / 2) + sizing (in)accuracy), or
S2 < ((2a1+ 2a2) / 2) + sizing (in)accuracy)
Embedded = when ligament (d) > than flaw height + Sizing (In)Accuracy, (2a).

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Specification 580 Rev. 0 - Pipelines Welding and NDT Testing

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Specification 580 Rev. 0 - Pipelines Welding and NDT Testing

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TABLE OF CONTENTS

REFERENCED CODES, STANDARDS AND SPECIFICATIONS .........................................................................7

QUALIFICATION OF WELDING PROCEDURES ............................................................................................12

QUALIFICATION OF WELDERS ..................................................................................................................21

GDF SUEZ E&P Nederland B.V.

INSPECTION AND TESTING OF PRODUCTION WELDS................................................................................29

MANUAL ULTRASONIC TESTING................................................................................................................33

AUTOMATED ULTRASONIC TESTING (AUT) ................................................................................................34

SURFACE EXAMINATION ..........................................................................................................................40

GDF SUEZ E&P Nederland B.V.

INTERPRETATION AND ACCEPTANCE CRITERIA FOR N.D.T. .......................................................................41

REPORTING OF N.D.T. .............................................................................................................................43

GDF SUEZ E&P Nederland B.V.

GDF SUEZ E&P Nederland B.V.

TERMS AND DEFINITIONS

GDF SUEZ E&P

Engineering and Installation Contractor appointed by GDF

Any authority required by law and/or as nominated by GDF

indicates a mandatory requirement.

indicates a preferred method.

GDF SUEZ E&P Nederland B.V.

Automatic Ultrasonic Testing

REFERENCED CODES, STANDARDS AND SPECIFICATIONS

CODES AND STANDARDS

All Work covered by this Specification shall be performed by CONTRACTOR, as a minimum, in

Requirements for Steel Pipeline Transportation Systems.

Gas supply systems-Welding Steel pipe work - Functional requirements.

API 1104: 2005 Errata

Welding of Pipelines and Related Facilities

Fracture mechanics toughness tests: CTOD.

Metallic materials Charpy impact test Part 1: Test method.

Metallic Products Types of inspection documents.

Characterization and verification of ultrasonic examination equipment. Part 2: Probes .

Characterization and verification of ultrasonic examination equipment. Part 3:

Non-destructive examination of welds Magnetic particle examination of welds.

Qualification and certification of NDT personnel. General principals.

Non-destructive testing-Penetrant testing-Part 1: General principals.

Non-destructive testing-Ultrasonic examination -Part 1: General principals.

TOFD technique as a method for detection and sizing of discontinuities.

Welding consumables Fluxes for submerged arc welding Classification.

Destructive tests on welds in metallic materials-Impact tests-Test specimen location,

Destructive tests on welds in metallic materials Transverse tensile test.

Destructive tests on welds in metallic materials Bend tests.

Non destructive examination of fusion welds visual examination.

Welding consumables Shielding gases for arc welding and cutting.

General requirements for the competence of testing and calibration laboratories.

Quality Management Systems : Requirements

GDF SUEZ E&P Nederland B.V.

Consumables shall be in accordance

GDF SUEZ E&P Nederland B.V.

STORAGE AND HANDLING OF WELDING CONSUMABLES

Cellulosic consumables shall always be kept in their original container.

GDF SUEZ E&P Nederland B.V.

All welders shall be qualified as set out in Section 5 of this Specification.

GDF SUEZ E&P Nederland B.V.

QUALIFICATION OF WELDING PROCEDURES

WELDING PROCEDURE SPECIFICATIONS

GDF SUEZ E&P Nederland B.V.

WELDING PROCEDURES - ESSENTIAL VARIABLES

Additional requirements for essential variables:

PROCEDURE QUALIFICATION TEST WELDS

For qualification of delays between runs refer to 6.9 of this specification.

GDF SUEZ E&P Nederland B.V.

Extent of testing complete butt weld: