15156-2-2003 (BS en Iso)

Petroleum Development Oman L.L.
C
SP-1177 - SPECIFICATION FOR
WELDING OF CLASS 1 PIPELINES
(AMENDMENTS/SUPPLEMENTS TO API STD 1104)
Document ID SP-1177
Document Type Specification
Security Unrestricted
Discipline Materials & Corrosion
Owner Head of Materials Integrity – UEOC
Issue Date May 2016
Version 3.0
Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the whole
nor any part of this document may be disclosed to others or reproduced, stored in a retrieval system,
or transmitted in any form by any means (electronic, mechanical, reprographic recording or
otherwise) without prior written consent of the owner.
Version: 3.0
Petroleum Development Oman LLC Effective May-16
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Page 2 SP-1177 – Specification for welding of class 1 pipelines Printed 06/11/17

The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
Version: 3.0
i Document Authorisation
Authorised For Issue - May 2016

Version: 3.0
ii Revision History
The following is a brief summary of the 3 most recent revisions to this document. Details of all revisions
prior to these are held on file by the issuing department.
Version No. Date Author Scope / Remarks

Version 1.0 15/07/00 OTT/15 Revision and re-formatting of original issue of
ERD 43-02.
Version 2.0 10/10/05 UEC/11 Revised based on the field experience and
developments to the international standards
Version 3.0 10/05/16 UEOC/15X Revised based on the field experience and
developments to the international standards
iii Related Business Processes

Code Business Process (EPBM 4.0)
CP-117 Project Engineering Code of Practice
iv Related Corporate Management Frame Work (CMF) Documents

The related CMF Documents can be retrieved from the Corporate Business Control Documentation
Register CMF.
Doc. ID Document Title
SP-1171 Specification for Quality Assurance Requirements for Product and

Service
DEP 31.10.00.10-Gen Material traceability and positive material identification (PMI)
DEP 61.40.20.30-Gen. Welding of Pipelines and Related facilities

(Amendments/Supplements to ISO 13847:2000)

Version: 3.0
TABLE OF CONTENTS
i Document Authorisation ....................................................................................................... 3
ii Revision History ..................................................................................................................... 4
iii Related Business Processes.................................................................................................4
iv Related Corporate Management Frame Work (CMF) Documents......................................4
Part I Introduction.......................................................................................................................8
1.1 Scope..................................................................................................................................8
1.2 Distribution, Intended use and Regulatory Considerations.................................................8
1.3 Deviations .......................... ............................................................................................... 8
1.4 Cross-References ........................................................................................................ .......8
1.5 Summary of Main Changes ................................................................................................. 8
Part II .. Amendments/Supplements to API 1104.....................................................................................9

1.1 Scope .............................................................................................................................. 9
3 Terms, definitions, acronyms and abbreviations................................................................9
4 Specifications ......................................................................................................................... 9
4.1 Equipment ....................................................................................................................... 9
4.2 Materials ........................................................................................................................... 9
4.2.1 Pipe and Piping Components ......................................................................................... 9
4.2.2 Filler Metal and Fluxes.....................................................................................................9
4.2.2.1 Types..............................................................................................................................9
4.2.2.2 Storage and Handling ................................................................................................... 10
4.2.3 Shielding Gases ............................................................................................................ 10
5 Qualification of Welding Procedures for Welds Containing Filler Metal Additives . 10

5.1 Procedure Qualification .................................................................................................. 10
5.2 Record ............................................................................................................................ 10
5.3 Welding Procedure Specification.................................................................................. 11
5.3.1 General...........................................................................................................................11
5.3.2 Specific Information........................................................................................................11
5.4.2 Changes Requiring Qualification....................................................................................14
5.5 Welding of Test Joints - Butt Welds .............................................................................. 16
5.6 Testing of Welded Joints - Butt Welds ........................................................................... 16
5.6.1.1 Non-destructive testing of Welds..................................................................................16
5.6.1.2 Destructive testing of Welds.........................................................................................17
5.6.6 Macroscopic Examination and Hardness Tests ............................................................ 17
5.6.7 Charpy V-notch Impact Testing....................................................................................18
5.6.9 Retests.........................................................................................................................18
5.7 Welding of Test Joints - Fillet Welds and Branch welds ................................................ 19
5.8 Testing of Welded Joints - Fillet Welds and Branch Welds ........................................... 19
5.9 Records...........................................................................................................................20
6 QUALIFICATION OF WELDERS .......................................................................................... 20

6.1 General .......................................................................................................................... 20
6.2 Single Qualification ........................................................................................................ 20
6.2.1 General.......................................................................................................................................20

Version: 3.0
6.2.2 Scope..............................................................................................................................20
6.3 Multiple Qualification ...................................................................................................... 21
6.6 Non-destuctivr Testing - Butt Welds Only ...................................................................... 21
6.6.1 General...........................................................................................................................21
7 PRODUCTION WELDING ..................................................................................................... 21

7.1 General .......................................................................................................................... 21
7.2 Alignment ....................................................................................................................... 22
7.3 Use of Line-Up Clamp for Butt Welds ............................................................................ 22
7.4 Bevel .............................................................................................................................. 22
7.4.2 Field Bevel......................................................................................................................22
7.11 Preheat and PWHT ........................................................................................................ 22
7.12 Weld Separation............................................................................................................. 23
7.15 Fillet Welds and Branch Welds ...................................................................................... 23
8 INSPECTION AND TESTING OF PRODUCTON WELDS ................................................... 23

8.2 Methods of Inspection .................................................................................................... 23
8.3 Qualification of Inspection Personnel............................................................................. 24
8.4 Certification of NDT ........................................................................................................ 24
8.4.1 Procedures .................................................................................................................... 24
8.5 Extent of Inspection and Testing.................................................................................... 24
9 Acceptance Standards for Non-Destructive Testing ....................................................... 24

9.3 Radiographic Testing ..................................................................................................... 24
9.3.1 Inadequate Penetration Without High-Low ..................................................................... 24
9.3.2 Inadequate Penetration Due to High-Low ...................................................................... 24
9.3.3 Inadequate Cross-Penetration ........................................................................................ 25
9.3.4 Incomplete Fusion .......................................................................................................... 25
9.3.5 Incomplete Fusion Due to Cold Lap ............................................................................... 25
9.3.8 Slag Inclusions................................................................................................................ 25
9.3.10 Cracks............................................................................................................................. 25
9.3.14 Excess Reinforcement and Penetration ......................................................................... 25
9.6. Ultrasonic Testing..............................................................................................................26
9.6.2 Acceptance Standards.................................................................................................... 26
9.6.4 Acceptance criteria – AUT .............................................................................................. 26
9.6.4.1 General................... ........................................................................................................ 26
9.6.4.2 Linear indications ............................................................................................................ 26
9.6.4.3 Gas clusters: ................................................................................................................... 27
9.6.5 Acceptance criteria based on ECA ................................................................................... 27
9.8 NDT Evaluation Report ..................................................................................................... 27
10 REPAIR AND REMOVAL OF DEFECTS .............................................................................. 27

10.2.1 Company Authorisation ................................................................................................. 27
10.2.2 Cracks Repair ................................................................................................................ 28
10.2.3 Repair of defects other than Cracks...............................................................................28
10.3.3 Qualification .................................................................................................................. 28
SECTION 11 – PROCEDURES FOR NON-DISTRUCTIVE TESTING ...................................... 28

11.1 Radiographic Test Methods ........................................................................................... 28
11.1.1 General .......................................................................................................................... 28
11.1.2 Details of Procedure ..................................................................................................... 28
11.1.2.2 Film Radiography ......................................................................................................... 28
11.1.4 Type of IQIs ................................................................................................................. 29
11.1.7 Production Radiography ............................................................................................... 29
Version: 3.0
11.1.8 Identification of Images ................................................................................................ 29

11.1.10 Film Density ............................................................................................................. 29
11.1.10.4 Image Processing ........................................................................................................ 29
11.4 Ultrasonic Test Methods .............................................................................................. 30
11.4.1 General ......................................................................................................................... 30
12 Mechnized WELDING WITH FILLER METAL ADDITIONS .......................................... 30

12.1 Accceptable Processes...................................................................................................30
12.2 Procedure Qualification .................................................................................................. 30
12.4 Welding Procedure Specification ................................................................................... 30
12.5 Essential Variables......................................................................................................... 31
12.9 Acceptance Standards for Non-Destructive Testing ...................................................... 32
12.12 Ultrasonic Testing .......................................................................................................... 32
13 AUTOMATIC WELDING WITHOUT FILLER-METAL ADDITIONS ................................. 32
14 DOCUMENTATION ............................................................................................................... 33
14.1 General .......................................................................................................................... 33
Appendices to API Std 1104..................................................................................................... 34
A Alternative Acceptance Standards for Girth Welds ......................................................... 34
B In-Service Welding ............................................................................................................... 34
Table A – Charpy V-Notch Test Temperature......................................................................... 34
Table B – Charpy V-Notch Energy Requirements.................................................................. 35
Table C - Extent of Inspection.................................................................................................. 36
Table D – Definition of Film Types .......................................................................................... 36
Figure A – Location of Macro section and Impact Test Specimens .................................... 37
Figure B – Orientation and Location of Charpy Impact Specimens .................................... 38
Figure C – Hardness Indent Locations.....................................................................................39
Appendix 1- Glossary of Definitions, Terms and Abbrevations............................................39
Appendix 2 – Refernces............................................................................................................42
Appendix 3 – WPS and PQR ............................................................................................................. .45
User Comment Form ............................................................................................................................ 50

Version: 3.0
Part I Introduction
1.1 Scope
This SP specifies the minimum technical requirements for the welding of Class 1 pipelines as defined in
PDO SP-1211 where the applicable Code has been defined as ASME B31.4, ‘Transportation Systems for
Liquid Hydrocarbons and Other Liquids’ or ASME B31.8, ‘Gas Transmission and Distribution Piping
Systems’.
The basis of this specification is API Std 1104, Twenty-First Edition, September 2013 including
addendum 1-2014.
This document is not applicable to:

 Welding of Class 2 and Class 3 pipelines and flow lines as defined in SP-1211, (covered by PDO
specification SP-1174).
 Welding of duplex stainless steel pipelines (covered by PDO specifications SP-1097.
 Welding of on-plot pipework/process piping, pressure vessels, storage tanks (covered by PDO
specification SP-1173)
 Structural steelwork.
 Welding of CRA clad pipelines, CRA lined pipelines

 Manufacture of longitudinally welded pipe/mill products.
 Welding on pressurised pipelines (covered by PDO specification SP-1167)
1.2 Distribution, Intended Use and Regulatory Considerations

Unless otherwise authorised by PDO, the distribution of this SP is restricted to Contractors and
Manufacturers/Suppliers nominated by PDO. Any authorized access to this SP does not constitute an
authorization to any documents, data or information to which the SP refers.
This SP is intended for use in facilities related to oil and gas production, gas handling, and distribution.
1.3 Definitions
In the context of this SP, Principal’s means PDO’s CFDH Materials Integrity of the Company.
1.4 Cross-references
Where cross-references to other parts of this SP are made, the referenced section number is shown in
brackets ( ). Other documents referenced by this SP are listed in Appendix 2.
1.5 Summary of Main Changes

This SP is a revision of the SP of the same number dated October 2005 and has undergone major
changes.

Version: 3.0
Part II Amendments/Supplements to API Std 1104
1 GENERAL
1.1 Scope
Add the following :
Roll welding and semi-automatic processes shall not be used. Gas welding, self- shielded gas FCAW
welding and flash butt welding processes shall not be used.
GMAW, GTAW, and gas shielded FCAW shall be restricted to construction areas protected against wind
and draught.
3 TERMS, DEFINITIONS, ACRONYMS and ABBREVIATIONS

See also Appendix 1 of this specification.
4 SPECIFICATIONS
4.1 Equipment
Add the following:
Welding parameter measuring equipments shall be calibrated.
4.2 Materials
4.2.1 Pipe and Piping components
Replace existing section as follows:
Add the following:
F) Material in accordance with ISO specifications
The Contractor shall obtain verified copies of the materials certificates for all free-issue items to be
welded. Contractor-supplied items shall have original or verified copies of materials certification. Items
without materials certificates shall not be used unless they are re-certified by testing.
4.2.2 Filler Metal and Fluxes
4.2.2.1 Types
Only Company-approved Manufacturers shall be used. Other manufaturer’s may be accepted if a 3 years
track record is presented and agreed with Material Corrosion Integrity (M CI) TA 1
For sour service, the deposited nickel (Nickel) content in the weld metal does not exceed 1.0%.

Version: 3.0
The test certificate shall be in accordance with ISO 10474 type 3.1.B. Alternatively each batch of welding
consumables may be tested in accordance with applicable consumable classification specification.
All filler metals shall have classification society, e.g., Lloyd’s, DNV, type approval.
4.2.2.2 Storage and Handling
Add the following:
Contractor shall develop consumable handing procedure in line with consumable manufacturer
recommendations and approved by welding TA 3.
4.2.3 Shielding Gases
4.2.3.1 Types
Add the following:
Shielding and purge gases shall be certified as complying with ISO 14175 or equivalent. The purity or
component concentrations of the gas shall be as specified on the WPS and shall be the same for
procedure qualification and production welding.
5 QUALIFICATION OF WELDING PROCEDURES WITH FILLER

METAL ADDITIONS
5.1 Procedure Qualification
Add the following:
The WPS and PQR SHALL [PS] be approved by the welding TA-3 for each project.
All welding procedure qualification shall be done in Oman only and shall be witnessed by the Company
welding Inspector.
Previously qualified pipe to fitting/pipe to flange welding procedures may be employed subject to the
following:
 The PQR is fully in accordance with this specification.

 The WPS is amended to reflect the project specific details.
5.2 Record
Add the following:
The PQR shall include the following Documents:
 The actual welding details with all the details specified in clause 2.3
 Material certificates.
 Consumables certificates.
 PAMS printout of the welding parameters.
 Summary of welding parameters including heat input calculation
 PWHT records (as applicable)
Version: 3.0
 Visual inspection report.

 NDT reports.
 Laboratory test report.
5.3 Welding Procedure Specification

5.3.1 General
Add the following:
The WPS shall show the following non-technical information:

 Date
 Revision number
 Contract number
 Project title
 Contractor’s Logo
 Contractors signature and endorsement
 Client: PDO
 MDMT
 Service: Sour/Non-Sour
5.3.2 Specific Information
5.3.2.2 Materials
Add the following:
The WPS shall state the carbon equivalent (CE) range applicable for the materials to be welded. Based
on the product analysis, the CE shall be within the range of + 0.03 and – 0.06 units compared to the CE
of the material used in the supporting PQR.
When two materials with different CE are used, the range qualified is 0.06% below that of the lower CE
material and + 0.03% above that of the higher CE material provided impact testing is carried out at the FL
and FL+ 2mm positions on both sides of the of the test weld.
CE = % C + %Mn/6 + (%Cr + % Mo + % V)/5 + (%Cu + % Ni)/15
5.3.2.3 Diameters and Wall Thicknesses
The diameter range shall be as shown in the following table.
Test Weld Outside Diameter, D Qualified Diameter Range
< 323.9 mm 0.5 OD to 2 OD but not more than

323.9 mm
323.9 mm 0.5 OD to 1.5 OD
The wall thickness range shall be 0.75t to 1.25t of the test weld. For materials with SMYS < 360 MPa, the
thickness range may be 0.5 t to 1.5 t. For branches (including weld-o-lets) D means outside diameter of
the branch/weld-o-let at the weld toe.
Version: 3.0
5.3.2.4 Joint Design
Add the following:
The WPS shall include allowable tolerances of the bevel angle, root gap and root face. Permanent
backing bars shall not be used.
5.3.2.5 Filler Metal, Flux and Number of Beads
Add the following:
Low hydrogen consumables shall be used for grades with SMYS 485 MPa or higher except for root pass.
Details of the manufacturer/brand name shall be stated on the WPS for each pass. For SMAW,
maximum bead width should be restricted to 2.5 times the electrode diameter. Based on the minimum line
pipe thickness of 4.8 mm normally specified for pipelines, joints shall be completed with a minimum of
three beads.
In case ECA is used, all weld metal yield strength shall be determined during welding procedure
qualification testing and shall be greater by 10% (see note)than SMYS of line pipe concerned.
5.3.2.6 Electrical Characteristics
Add the following:
The Contractor shall control the welding parameters so that the heat input variation is not greater than
that of the qualified heat input range in accordance with clauses 5.3.2.17 and 5.4.2.15 of this
specification.
5.3.2.7 Flame Characteristics
Oxy-fuel gas welding shall not be used.
5.3.2.8 Position
Add the following:
WPSs for manually welded line pipe butt joints shall be qualified in the 5G position to cover production
welding 5G positions. Automatic welds shall be qualified for each position to be used in production.
Branches, attachment welds and ancillary piping may be qualified in the production welding position or, to
cover all positions, in the 6G position, at the option of the Contractor.
5.3.2.9 Direction of Welding
Add the following:
For the following, the root bead shall be deposited with a vertical-up progression:
 Tie-in welds
 Welds where an external line-up clamp is used
 Welds to fittings/flanges and branches
 Full penetration repairs

Version: 3.0
 Welds where temporary tack welds have been employed for alignment.
For the following, the complete weld shall be made with a vertical-up progression:
 Welds to valves
 Branch and Fillet welds.
5.3.2.10 Time between Passes
Add the following:
The hot (second) pass shall be deposited immediately after completion of the root run and the time lapse
shall not be greater than that used in procedure qualification. The maximum time for other passes shall
not be greater than that used in procedure
5.3.2.11 Type and Removal of Line-up Clamp
Replace last sentence as follows:
An internal or external line-up clamp shall be used for all girth welds except where it is demonstrated that
to do so would be impractical. An internal line-up clamp shall be used for butt welds in pipe above 323.9
mm (12”) OD. Where no line-up clamp is feasible, tack welding may be permitted subject to Company
welding TA 3 approval.
An internal line-up clamp shall not be removed until deposition is completed of the first two passes An
external line-up clamp shall not be removed until the root bead is at least 50% complete, equally
distributed around the joint.
When automatic GMAW process is used, internal line-up clamp may be removed after completion of one
complete root pass provided internal clamp is removed after lowering the pipe on to the skid.
The minimum number of passes to be deposited before the pipe is lowered off shall be stated.
See also clause 7.3 of this specification.
5.3.2.13 Preheat and Postweld Heat Treatment (PWHT)
Add the following:
The maximum interpass temperatures and temperature control methods shall also be specified.
See also clause 7.11.1 of this specification.
5.3.2.15 Shielding Flux
Add the following:
The AWS flux classification; manufacturer and brand name shall also be specified.
Add the following new sections, 5.3.2.18 – 5.3.2.21:

Version: 3.0
5.3.2.18 Heat Input Range
The allowable range of heat input rates to be applied by each welding process for each pass shall be
specified.
Heat Input (kJ/mm) = (Volts x Amps x 60) / (1000 x Welding Speed (mm/min.))
5.3.2.19 Number of Welders
The WPS shall designate the number of root pass welders and hot pass (second pass) welders.
For pipe larger than NPS 12”, a minimum of two welders shall be employed for all passes.
5.3.2.20 Partially Completed Joint
The minimum number of passes before the joint is allowed to cool to ambient temperature shall be
specified. The minimum shall be three passes or one third of the joint whichever is greater.
See also clause 7.13 of this specification.
5.3.2.210 Tungsten Electrode for GTAW
The AWS electrode class shall be specified in the WPS.
5.4.2 Changes Requiring Re-qualification
5.4.2.2 Base Material
Add the following additional essential variables:
 For line pipe welding (pipe to pipe), the welding procedure shall be qualified on project material.
 Any change in the pipe manufacturer if SMYS of the pipe material is greater than 415 MPa if the
service is sour.
 A change in heat treatment condition for materials (pipe/flange/fitting) of SMYS greater than or
equal to 415 MPa.
 Any change in carbon equivalent value outside the limits given in section 5.3.2.2 of this
specification.
5.4.2.4 Position
Add the following:
Any change in position outside the limits given in section 5.3.2.8 of this specification shall also constitute
an essential variable.
5.4.2.5 Pipe Diameter and Wall Thickness
Change title and replace as follows:

Version: 3.0
Any change outside the limits given in section 5.3.2.3 of this specification shall also constitute an
essential variable.
5.4.2.6 Filler Metal
Replace existing text as follows, retaining Table 1 for reference:
The following changes in the qualified WPS shall be considered as essential variables:
 A change of filler metal trade name

 A change of filler metal classification
 A change in the diameter of electrode or filler wire.
 Any relaxation in drying or other pre-treatment procedure
5.4.2.11 Shielding Flux
Replace existing text with the following:
Any change in wire/flux classification, manufacturer, or brand name shall constitute an essential variable.
5.4.2.13 Preheat
Add the following:
Any increase in the qualified maximum interpass temperature shall constitute essential variables.
Maximum interpass temperature shall not exceed 2500 C
Add the following new sections, 5.4.2.15 – 5.4.2.21:
5.4.2.15 Heat Input Range
Any change in average welding heat input per pass outside the range ± 15% of that qualified shall be
considered an essential variable.
For sour service, the heat input shall not fall below 10% from that recorded during procedure approval
testing.
5.4.2.17 Sequence of Weld Beads
Any change in the sequence of deposition, e.g. a change from temper bead deposition pattern, shall
constitute an essential variable.
5.4.2.18 Number of Welders
A change in the number of root pass and hot (second) pass welders shall constitute an essential variable.
5.4.2.19 Type and Removal of Line-up Clamp
Removal of the line-up clamp at a stage earlier than qualified shall constitute an essential variable.
Any change in type of line-up clamp is an essential variable.

Version: 3.0
5.4.2.20 Partially Completed joint
Any change in the minimum number of runs before the joint is allowed to cool shall constitute an essential
variable. The welding of tie-in joints, fittings and flanges shall be completed in one cycle.
5.4.2.21 Tungsten Electrode Classification
Where the GTAW process is used, any change in the tungsten electrode AWS class and size shall
constitute as an essential variable.
5.5 Welding of Test Joints - Butt Welds

The test weld shall be made under conditions which simulate production welding to a degree satisfactory
to the company. For pipeline welding procedure qualification, two full pipe lengths shall be welded
together using production welding line up clamping equipment. A further two pipe lengths shall be welded
if necessary to obtain the required number of specimens for testing. All qualification welding shall be
witnessed by the Company welding Inspector/
The Contractor shall give the Company a minimum of 48 hours’ notice of the intention to proceed with test
welding.
Immediately prior to test welding, the Contractor shall have available at the test site for Company
inspection, the following documents:
 WPS endorsed “Approved for Qualification”

 Materials certificates, or verified copies, traceable to the items to be welded.
 Batch certificates, or verified copies, traceable to the welding consumables.
 The approved consumable handling procedure.
The Contractor shall use calibrated portable arc monitoring system with hard copy facility. Alternatively
electrode run-out method may be used for SMAW.
5.6 Testing of Welded Joints - Butt Welds

Add the following sub-sections 5.6.1.1 & 5.6.1.2:
5.6.1.1 Non-Destructive Testing of Test Welds
Test welds shall be subjected to NDT as detailed below before sectioning for destructive testing in
accordance with 5.6.1.2.
The test weld shall not be subjected to PWHT or NDT until a minimum of 24 hours has elapsed after the
completion of welding. Where post-weld heat treatment is necessary, this shall be performed prior to
NDT.
The NDT shall consist of the following:

 Visual examination
 Magnetic particle testing
 Radiographic testing
 Ultrasonic testing on test welds where any bead has been deposited by GMAW.
 AUT if ECA is applied
Version: 3.0

NDT on all test welds shall be performed with the weld at ambient temperature using the equipment and
Company-approved procedures that will be employed for production. NDT of a test weld may serve as a
qualification test for the NDT procedures and shall be witnessed by the Company Inspector. For UT and
AUT procedure qualification, the Company NDT TA 2 shall witness..
The acceptance criteria shall be as stated in Section 9 of this specification. Any weld that fails to meet
the acceptance criteria shall not be offered for destructive testing.
Add the following sub-section:
5.6.1.2 Destructive Testing of Test Welds
Following Company approval of the NDT, all test welds shall be sectioned at the locations shown in
Figure 3 of API Std 1104 and Figure A of this specification. Sectioning and testing shall be performed at
a Company-approved test laboratory.
Testing for procedure qualification shall be performed in accordance with API Std 1104 and the additional
requirements of this specification. All testing shall be witnessed by a Company Welding Inspector. All test
reports shall be endorsed and signed by the testing organisation, the Contractor, and the Company
Welding Inspector, who witnessed the testing.
The test reports and the certificate of conformance shall be included in the PQR.
Add the following new sections, 5.6.6 – 5.6.9:
5.6.6 Macroscopic Examination and Hardness Tests
5.6.6.1 Preparation
Specimens shall be prepared for macroscopic examination by grinding to a minimum finish of 600 grit.
The prepared surfaces shall be etched using a suitable enchant to reveal clearly the weld, HAZ and the
presence of macro defects. The sections of the weld taken for macroscopic examination shall be used for
hardness testing.
5.6.6.2 Method
The hardness shall be measured in accordance with ASTM E92, using HV10. For pipe butt welds, the
hardness indentations shall be as shown in Figure C of this specification. For pipe of t less than 10
millimetres, the mid-thickness traverse may be omitted.
The macro-sections shall be examined at a minimum magnification of x5. Macro-photographs showing

the hardness indentations shall be included in the PQR.
5.6.6.3 Requirements
The macro-sections shall not show defects exceeding the acceptance standards given in Section 9 of this
specification.
For sour service, maximum hardness shall be in accordance with. ISO 15156 -2.
For non-sour service, maximum hardness shall be 350 HV10.

Version: 3.0
5.6.7 Charpy V-Notch Impact Testing
Impact testing shall be in accordance with ASTM A370 and this specification.
Each procedure qualification shall include impact testing when the nominal pipe wall thickness exceeds 5
millimetres.
5.6.7.1 Preparation
One set of three specimens shall be taken at each of the following positions:
 root weld centre line

 root fusion line (50% intersection of notch)
 root fusion line + 2 millimetres

When the wall thickness exceeds 20 millimetres, an additional set of three specimens shall be taken at
each of the following positions:
 cap weld centre line

 cap fusion line (50% intersection of notch)
 cap fusion line + 2 millimetres
These requirements are summarised in Figure B of this specification.
Specimens shall be 10 x 10 millimetres full size wherever possible. Where these dimensions are not
possible, sub-size 10 x 6.7 millimetres shall be extracted. If the latter are not possible, the specimens
shall be 10 x 5 millimetres. Where machining requirements reduce specimen thickness, the maximum
feasible thickness below 5 millimetres shall be tested and shall meet the acceptance criteria for 10 x 5
millimetre specimens.
When combination of welding processes or welding consumables are used, specimens representing each
process and consumables shall be tested for weld, FL and FL+2 m. Mode of metal transfer also constitute
to as a change in process.
5.6.7.2 Test Temperatures and Acceptance Criteria
The test temperature shall be in accordance with Table A of this specification. For each set of three
specimens, only one of the individual values may be below the minimum average energy requirement
with an absolute minimum as defined by the minimum individual acceptance criterion.
The acceptance criteria are detailed in Table B of this specification.
5.6.9 Retests
5.6.9.1 General
If the results of destructive testing are unsatisfactory owing to defective specimen preparation or a
localised weld defect, the Contractor shall inform the Company and obtain approval to proceed with
retests as detailed below.
5.6.9.2 Tensile Tests and Bend Tests
If one tensile or bend specimen does not meet the acceptance criteria, two additional specimens shall be
tested. Both of the additional specimens shall meet the acceptance criteria.

Version: 3.0
5.6.9.3 Hardness Tests
If one hardness result exceeds the specified maximum then three further impressions shall be made in
close proximity to that which failed such that they do not mutually interfere. If all of the further tests are
below the specified maximum then the test shall be accepted.
5.6.9.4 Charpy V-Notch Impact Tests
If the specified minimum average value has been achieved and more than one specimen is below the
specified minimum average value but not below minimum absolute value as given table B, a retest of
three further specimens shall be made. The location of the retest specimens shall be as close as
possible to the location of the original specimens. All three individual retest values shall equal or exceed
the specified minimum average value.
5.6.9.5 New Procedure Requirement
If the test joint fails to meet the minimum requirements, a new WPS proposal shall be established and
qualification welding and testing repeated.
5.7 Welding of Test Joints - Fillet Welds

Change title to:
5.7 Welding of Test Joints - Fillet Welds and Branch welds

Add the following at the end of the section
Low-hydrogen electrodes shall be used for all fillet welds and branches, wherever SMAW is used.
Test welding shall be witnessed by the Company Welding Inspector. Branch weld test joints shall be
welded using qualified butt weld procedure.
5.8 Testing of Welded Joints - Fillet Welds

Change title to:
5.8 Testing of Welded Joints - Fillet Welds and Branch Welds

Add the following at the start of the section:
Test welds shall be visually inspected and magnetic particle tested after a minimum of 24 hours has
elapsed from completion of welding. If the weld is deemed acceptable in accordance with the appropriate
acceptance criteria detailed in Section 9 of this specification and API Std 1104, it may be offered for
destructive testing.
Add the following new section:
5.8.4 Macroscopic Examination and Hardness Testing
Macroscopic examination and hardness measurement shall be carried out in accordance with section
5.6.6 of this specification. Specimens for examination and testing shall be extracted from locations
denoted in Figure A of this specification for butt welds. Hardness traverses shall be as shown in Figure C
of this specification and shall meet the requirements of this specification.
Version: 3.0
5.9 Records
The procedure qualification record shall include the following:
 Approved for qualification WPS

 Print-outs from the PAMS for each pass
 Visual inspection and NDT reports
 Heat treatment reports
 Original laboratory test certificates, including microphotographs
 Original or verified copies of materials certificates for the test coupon materials
 Original or verified copies of batch certificates for the consumables employed for test
welding.

The PQR shall be submitted to the Company Welding TA 3 for review and approval with the revised
WPS for production welding.
6 QUALIFICATION OF WELDERS
6.1 General
Add the following:
Welders employed on class 1 pipeline welding shall have demonstrated experience in Class I pipeline
welding.
Welders shall have a valid qualification within the validity defined in this specification or they shall be
qualified using the Approved For Construction WPS. Qualification shall be valid for a period of six
months. This period may be extended every six months when it can be shown by NDT from production
welding and demonstrated statistical repair rate of less than 3 %.
6.2 Single Qualification

6.2.1 General
The weld joint shall be welded fully by the welder.
6.2.2 Scope
Delete item c) and replace with the following:
C) Any change in AWS specification of welding consumables. Any change in AWS classification of
welding consumable.
The following additional essential variables also shall be met.

Version: 3.0
1. For base material grades of SMYS up to and including 415 MPa material strength not an
essential variable. For SMYS > 415 MPa, a welder qualification using material of a given
SMYS qualifies the welder for materials of equal or lower SMYS.
For mechanized welding, each operator shall be qualified for a particular part or parts of the operation of
making a weld joint. Under no circumstances shall a operator be employed on operations other than
those for which they have been tested, qualified and approved.
6.3 Multiple Qualification

Delete this section in its entirety.
6.6 Non-destructive Testing- Butt Welds Only

6.6.1 General
Add the following:
When GMAW is used for any pass, ultrasonic testing shall also be performed.
7 DESIGN AND PREPARATION OF A JOINT FOR PRODUCTION

WELDING
Change title as follows:
7 PRODUCTION WELDING
7.1 General
Add the following:
No production welding shall be carried out before the WPSs is 'Approved for Construction' by the welding
TA 3 and the welders qualified to weld using the approved WPSs.
The approved WPSs shall be available at the welding station.
Fusion faces and the surrounding surfaces within a minimum of 25 millimetres of the joint shall be free
from heavy scale, moisture, oil, paint, or any other substance which may have a deleterious effect on the
weld quality or progress.
Arcs shall be struck only on fusion faces. Stray arc strikes shall be removed by grinding. The ground
area shall be magnetic particle tested and thickness checked. Where the thickness is below the specified
minimum, the section of pipe shall be removed. The Contractor shall ensure a good earth connection and
periodically examine the condition of the earth cables and attachments. Any arcing from a poor
connection shall be treated as an arc strike. Connections shall be made to the work by copper or brass
clamps. Earth cables shall not be welded to pipeline components.
A Company-approved circular cap to prevent entry of foreign material shall be used to cover open ends of
the pipe when interruptions to work expected. Claw type plugs or any type liable to damage the pipe shall
not be used. All open ends of pipe strings shall be capped off and sealed when welding is completed.

Version: 3.0
7.2 Alignment
Add the following
Hammering, (apart from minor cold dressing using a bronze-headed hammer), welding of temporary
attachments or any other heating of the pipe shall not be permitted.
The maximum permitted offset at any one point shall be 2.0 millimetres for pipe up to and including 12
inch NPS and 3.0 mm for larger diameters. Misalignment in excess of these limits resulting only from
dimensional variations within the specified tolerances, or from abutment of two pipeline components of
different nominal thickness and the same outside diameter, may be rectified by tapering the bore of the
thicker component at an angle no steeper than 1:4.
When a pipe with one longitudinal seam is used, this seam shall be within the top 120 of the
circumference. The longitudinal seams of consecutive pipes shall be offset by at least 45 but need not
exceed 100 mm. Longitudinal welds in fittings are exempted.
Tack welds shall be avoided wherever possible. Where demonstrated to be unavoidable and approved
by the Company, temporary bar tacks shall be employed using suitable carbon steel material. Preheat
shall be employed if required by the WPS and welding parameters shall be in accordance with the
appropriate fill pass. Tack welders shall be qualified to weld with the WPS
Longitudinal welding on to the pipe (e.g. for the attachment of lugs or sleeves) shall not be permitted.
7.3 Use of Line-Up Clamp for Butt Welds

Internal line-up clamps shall be used for butt welds in pipe 400 mm OD and larger. External line-up
clamps may be used for butt welding smaller pipe sizes and for tie-in welds in any size of pipe, or for
special welds, such as connections to valves, flanges and fittings.
Pipe shall not be moved or lowered off until the second pass has been completed except as permitted in
5.3.2.11 for the automatic GMAW process.
7.4 Bevel
7.4.2 Field Bevel
Add the following:
After grinding, the bevelled edges shall be visually inspected. Any bevelled edge that has been damaged
shall be restored. Restoration involving welding is not permitted. Should any defect found, the pipe shall
be investigated and examined and shall meet original pipe requirements.
7.11 Preheat and PWHT

Add the following new sub-clauses 7.11.1 & 7.11.2
7.11.1.1 General
Preheat shall be applied and measured at 75 millimetres either side of the weld joint edge/toe.

Version: 3.0
7.11.1.2 Requirements
The minimum preheat shall be 50°C when the steel surface temperature is below 5°C or if moisture is
present.
For grades with SMYS 450 or higher, a minimum preheat temperature shall be 100°C unless more
preheat is required by the WPS
7.11.2 Post-Weld Heat Treatment
The minimum number of thermocouples to be used shall be three (3). These shall be equally spaced
around the weld circumference 25 mm from the weld to ensure that the heated circumferential band will
extend at least 25 mm beyond the weld on either side.
A temperature recording chart shall be used for each PWHT cycle. Thermocouples and recorders shall
have valid certificates of calibration.
Company approved post weld heat treatment procedure shall be available at work site.
Add the following new sections, 7.12 – 7.16:
7.12 Weld Separation

The minimum allowable distance between girth welds shall be D/2 or 250 mm, whichever is the larger.
There shall be no more than three girth welds in any 12 m length of pipeline.
Welds to branch connections shall be at least 100 mm from any girth weld. The minimum distance
between any adjacent welds other than two girth welds shall be the larger of 4t or 50 mm.
7.15 Fillet Welds and Branch Welds

All fillet welds shall be made using the SMAW process with basic low-hydrogen electrodes and/or with low
hydrogen welding processes. The welds shall be multipass made in the vertical up direction with a flat or
convex profile.
All branch welds shall be made using the SMAW process with basic low-hydrogen electrodes and/or low
hydrogen welding processes except for root. GTAW shall be used for root pass
8 INSPECTION AND TESTING OF PRODUCTON WELDS

8.2 Methods of Inspection
Delete Para. 3 and replace with below:
UT operators shall undergo demonstration test using the approved inspection procedure.
All butt welds shall be subject to either100% X-ray radiography or 100% automatic ultrasonic testing
(AUT). Welds made using GMAW for any pass shall be inspected with automated ultrasonic testing
(AUT). All attachment welds to the pipe surface and all set-on branch fitting connection welds shall be
subjected by 100% MT.

Version: 3.0
For offsite fabrication of pipeline spool pieces and the welding of fittings, there shall be a minimum delay
between completion of welding and NDT of 24 hours. For all field welding with cellulosic electrodes, there
shall be a minimum delay between completion of welding and NDT of 12 hours except when full GMAW is
used.
For tie-in joints, where the double wall, single image technique is employed, gamma radiography can be
substituted for X-ray radiography provided it is supplemented with recordable ultrasonic testing.
8.3 Qualification of Inspection Personnel

Add the following::
As a minimum, welding inspection personnel shall hold a valid qualification of one of the following:
 CSWIP Welding Inspector
 AWS Certified Welding Inspector
with 3 years experience as a welding Inspector.
8.4 Certification of NDT Personnel

8.4.1 Procedures
Add the following:
NDT level III personnel shall be approved by the Company NDT TA 2.
If, in the opinion of the Company, welding examination or non-destructive examination personnel fail to
perform to a satisfactory standard they shall be disqualified from the works
Add the following new sections 8.5 & 8.6:
8.5 Extent of Inspection and Testing

The extent of inspection of completed welds shall be as per Table C.
The Company shall have the final disposition on any weld. Any weld not accepted by the Company
shall be rectified in accordance with API Std 1104 and this specification.
9 Acceptance Standards for Non-Destructive Testing

9.3 Radiographic Testing
9.3.1 Inadequate Penetration Without High-Low (IP)
Add the following:
This condition is unacceptable for sour service if the individual flaw size is greater than 10 mm and
cumulative length is more than 20 mm in any 300 mm length of weld.
9.3.2 Inadequate Penetration Due to High-Low (IPD)
Add the following:

Version: 3.0
cumulative length is more than 20 mm in any 300 mm length of weld..
9.3.3 Inadequate Cross-Penetration (ICP)
Add the following:
cumulative length is more than 20 mm in any 300 mm length of weld.
9.3.4 Incomplete Fusion (IF)
Add the following:
cumulative length is more than 20 mm in any 300 mm length of weld
9.3.5 Incomplete Fusion Due to Cold Lap (IFD)
Add the following:
Areas of IFD which are separated by a distance not exceeding the length of the smaller indication shall be
treated as a single IFD.
For welds other than girth welds the acceptance criteria for the individual and aggregate length of defect
interpreted as IFD shall be one half of the values indicated in a. to c. in this clause.
9.3.8 Slag Inclusions
9.3.8.1
Add the following:
Copper inclusions shall not be acceptable.
9.3.10 Cracks
Cracks of any type shall be unacceptable.
9.3.14 Excess Reinforcement and Penetration
Weld reinforcement, when measured from the adjacent parent material surface, shall not exceed the
following values:
Wall thickness External weld reinforcement

(mm) (mm)
6.4 and under 2.0
6.4 - 12.7 3.0
Over 12.7 3.5

Version: 3.0
Internal protrusion of the weld root shall not exceed 2.0 mm for pipe thicknesses up to 12 mm and 3.0
mm for pipe thicknesses above 12 mm. When measuring internal protrusion, the line of the pipe bore
outside the HAZ should be taken as the reference. Local profile changes adjacent to the fusion line
should be discounted. For PE lined pipelines maximum internal protrusion shall be greater than 1.6 mm.
9.6 Ultrasonic Testing

9.6.2 Acceptance Standards
9.6.2.1 General
Indications interpreted as cracks are unacceptable.
9.6.4 Acceptance criteria – AUT
9.6.4.1 General
The general workmanship AUT acceptance criteria in (9.6.4.2 and 9.6.4.3) apply to pipelines of wall
thickness 12 mm and are equivalent to the radiographic acceptance criteria given in 9.4. The indication
sizes are stated as measured dimensions and are based on a measurement uncertainty of 1.5 mm for
both height and length. This uncertainty is the maximum permitted for any AUT system, which shall be
established by historical data and performance trials.
9.6.4.2 Linear indications
If any part of the indication lies within 2 mm of the inner or outer surface:
Height < 3.0 mm: Length: Wall thickness or 25 mm, whichever is less.
Height > 3.0 mm: Not acceptable.
For indications not within 2 mm of the inner or outer surface:
Height < 3.0 mm: length: 50 mm or 2 x wall thickness, whichever is less.
Height > 3.0 mm  5 mm or 0.25 t, whichever is less: Length: 12.5 mm
Height > 5 mm or 0.25t, whichever is less: Not acceptable.
The maximum allowable accumulated length of reportable indications in any 300 mm of weld shall be 100
mm or 3 x wall thickness, whichever is less.
The maximum allowable accumulated length of reportable indications in any weld is 12% of weld length.
Any indication signifying a crack or copper inclusion is not acceptable
Visually apparent linear defects (i.e. lack of fusion) on, or adjacent to, the external weld cap of a depth
greater than 1 mm are unacceptable.

Version: 3.0
9.6.4.3 Gas clusters:
Height > 3 mm or length > 25 mm is not acceptable
The interaction rules for defects shall apply in accordance with BS 7910 Figure 9.
For pipelines with wall thickness <12 mm, the AUT acceptance criteria shall be subject to the agreement
of the Principal
Add new clause:
9.6.5 Acceptance criteria based on ECA
AUT defect acceptance criteria based on an ECA may only be applied if agreed by the Welding TA 1.
Such an assessment shall be carried out in accordance with BS 7910 Level 2 or API 1104 (or other
assessment method acceptable to the Welding TA 1) and shall only be carried out when all pipeline
stresses and other design factors are known and when the fracture toughness of the weld and HAZ have
been established for all welding procedures and materials.
NOTE: It is therefore unlikely that such acceptance criteria could be accepted pre-contract.
Such defect acceptance criteria shall be based on the critical defect sizes, as determined by the ECA,
plus the AUT uncertainty in flaw sizing.
ECA is not acceptable for sour service.
Add the following new sections 9.8 to 9.10:
9.8 NDT Evaluation Report

An evaluation report shall be made stating the identification number of each weld inspected and the name
of the welder/operator together with the description of the inspection method and, if applicable, the reason
for rejection of the weld.
10 REPAIR AND REMOVAL OF DEFECTS

10.2.1 Company Authorisation
Add the following:
Single run repairs and root sealing runs shall not be permitted.
Welds on material with SMYS < 360 MPa may be repaired twice. Other materials shall be repaired once
only.
Repair weld grooves shall be visually and magnetic particle inspected prior to re-welding.
The repair shall have 150°C preheat for materials with SMYS > 415 MPa
The total repair length shall not exceed 40% of the total weld length.

Version: 3.0
For partial penetration repairs, the maximum length of a single repair portion shall be 30% of the total
weld length. For full penetration repairs, the maximum length of a single repair portion shall be 20% of
the total weld length. Groove taper shall be included in the measurements.
If post weld heat treatment is specified, this shall be applied to the whole welded joint.
10.2.2 Cracks repair

Replace existing section and replace as follows:
A weld containing shallow crater cracks or star cracks, which are located at the stopping point of weld
beads and which are the result of weld metal contraction during solidification, may be repaired provided
the length of the crater cracks does not exceed 4 mm. With the exception of these shallow crater cracks,
any weld containing cracks, regardless of size or location, shall be removed by cut-out.
10.2.3 Repair of defects other than cracks

Replace item c) with the following:
c) For grade L 415 and above, 1st repair requires repair weld procedure qualification in
accordance with 10.3. A separate procedure shall be qualified for each type of repair as defined 10.3.2
10.3.3 Qualification
Add the following
NDT as required for original welding procedure shall be done and shall meet requirements of section 9 of
this specification. Macro and hardness testing is also required. Impact and hardness testing is required
for all repair welding procedure qualifications.
 Method of defect removal

 NDT requirements to determine complete removal of defect
SECTION 11 – PROCEDURES FOR NON-DISTRUCTIVE TESTING

11.1 Radiographic Test Methods
11.1.1 General
Add the following:
Internal sources, (crawler units), shall be employed for the radiography of all field butt joints in pipe of 16
inch NPS or over, including repair welds where accessible. In cases where the sources cannot be placed
inside the pipe the double-wall/single-image technique shall be applied for diameters over 3 inch and
double-wall/double-image technique for diameters of 3 inches and below.
11.1.2 Details of Procedure
11.1.2.2 Film Radiography
Add the following:

Version: 3.0
Radiographs shall be made using slow film types defined in Table D.
11.1.4 Type of IQIs
11.1.5 Replace 1st and 2nd line by the following:
Wire type IQIs (image quality indicators, IQIs) in accordance with ISO 19232-1 shall be used.
11.1.7 Production Radiography
Add the following:
If cellulose electrodes are used, radiographs shall be taken after 12 hours of weld completion. If a low
hydrogen process is used, radiographs shall be taken after 24 hours of weld completion.
11.1.8 Identification of Images
Add the following:
On pipe diameters over 3 inches, a tape measure with lead numbers every 100 mm shall be placed
adjacent to the weld. The zero point shall be on the top of the pipe and the divisions shall run clockwise in
ascending order, viewed in the direction of pipeline laying progress. On diameters less than 3 inches,
each shot shall be designated by a lead letter placed on the pipe, i.e. A, B, C.
Where the weld has been dressed, markers in a form to be approved by the Company shall be placed
alongside the weld, but clear of the heat affected zone, to identify its position.
If sufficient space is available, the pipeline reference weld number and section number shall be included
in the radiograph identification.
Each weld shall be marked using indelible material, to provide reference points for the accurate relocation
of the position of each radiograph.
11.1.10 Film Density
11.1.10.1
Add the following:
Film shall be exposed so that the density through the weld metal is not less than 2.0 for gamma rays,
11.1.10.4 Image Processing
Delete and replace with the following:
Film or other images shall be processed so that the images are interpretable for the retention period in
the contract.

Version: 3.0
11.4 Ultrasonic Test Methods
11.4.1 General
Add the following:
AUT procedure performance demonstration testing shall be witnessed by Company specialized NDT TA-
2. Qualification of AUT systems, procedures and operators shall be in accordance DNV OS-F 101
appendix E.
NOTE: The use of realistic flaw reference samples based on the actual joint geometry and welding procedure are
required for the qualification purpose.
Interpretation of AUT of girth welds shall be done in accordance with DEP 37.81.40.32 – Gen.
Unless otherwise specified, the required accuracy of the AUT systems used for field inspection shall be
Category B when ECA(non-sour only) is applied and category C when ECA is not applied (i.e. when
workmanship applied) in accordance with DEP 37.81.40.32 – Gen. Table 1.
12 MECHANIZED WELDING WITH FILLER METAL ADDITIONS

12.1 Acceptable Processes
item d): Delete the word “without”.
item f): Delete the word “Semi-automatic”
12.2 Procedure Qualification

Delete reference to “semi-automatic” in 2nd last line.
Add the following:
Three consecutive complete qualification welds shall be made between either complete pipe joint lengths
or nipples as detailed in section 5.5 of this specification, following all the details of the WPS under
conditions which simulate those of the site production location. All three welds shall be non-destructively
tested and shall meet the requirements of section 9 of API Std 1104 and this specification and at least
one weld shall be destructively tested in accordance with section 5.6. Alternative acceptance criteria
based on ECA may be used, for non-sour service.
12.4 Welding Procedure Specification

12.4.2.2 materials
Replace as follows:
The contract materials to which the procedure applies shall be identified. Grouping of materials of
different pipe manufacturers, supply condition, diameter, wall thickness or steel specification/grade is not
allowed.
Version: 3.0
12.4.2.3 Diameters
Add the following:
Procedures shall be qualified for each combination of diameter and nominal wall thickness using contract
materials.
The numbers of beads required for each contract pipe thickness and the machine used for each bead
shall be clearly identified.
12.4.2.4 Wall-thickness group and number and sequence of beads
Delete entire clause and refer to above sub-section.
12.4.2.6 Filler Metal
Add the following:
Details of the filler metal manufacturer/brand identity shall be given together with a sketch showing the
location, number and deposition sequence of each weld bead.
12.4.2.7 Electrical characteristics
Add the following:
For pulsed arc welding the pulsing characteristics, including the frequency, amplitude, shape, base level,
delay and crater fill, shall be specified.
12.4.2.8 Position
Add the following:
For roll welding by the submerged arc or flux cored arc processes, the position of the electrode in relation
to the top centre (external welding) or bottom centre (internal welding) shall be stated and indicated by a
sketch.
12.5 Essential Variables

12.5.2.2 materials
Replace as follows:
A change of pipe manufacturer or manufacturing process or heat treatment condition shall constitute an
essential variable.
Any change in strength grade shall constitute an essential variable.
12.5.2.4 Wall thickness
Replace as follows:
Any change in nominal thickness by more than 1.6 mm shall constitute an essential variable.

Version: 3.0
12.5.2.5 Pipe Diameter
Replace as follows:
Any change in nominal diameter shall constitute an essential variable.
12.5.2.6 Filler metal
Replace as follows:
The requirements of clause 5.4.2.6 of this specification apply,
12.5.2.11 Shielding flux
Replace as follows:
Any change in wire, flux manufacturer or brand name shall constitute an essential variable.
Any change in AWS classification number for wire/flux shall constitute an essential variable.
Add the following new sub-section:
12.5.2.18 Number and sequence of weld beads
A change in the minimum number of the weld beads deposited or the sequence of deposition shall
constitute an essential variable.
12.9 Acceptance Standards for Non-Destructive Testing

Replace as follows:
The acceptance standards for non-destructive testing shall be in accordance with section 9 of API Std
1104 and this specification.
12.12 Ultrasonic Testing

Add the following:
Ultrasonic testing shall be in accordance with section 11.4 of API Std 1104 and this specification. For
Automated UT testing, refer 11 8.4.1 of this specification.
13 AUTOMATIC WELDING WITHOUT FILLER-METAL ADDITIONS

Automatic welding without the addition of filler metal shall not be used.

Version: 3.0
14 DOCUMENTATION
14.1 General
The Contractor shall maintain a record system which ensures weld traceability. The Contractor shall be
responsible for compiling the following document packages which shall be submitted to the Company
upon completion of the works:
(a)
 Certificate of Conformity
 Copy of approved Welding Procedure Register
 Copies of approved WPSs
 Copies of approved repair WPSs
 Copies of all supporting PQRs
 List of approved welders and their identification
 List of Company welders’ cards
 Copies of PDO endorsed Welders Qualification Cards
 List of approved NDT operators
 Copies of NDT operator qualification certificates
 List of Company-approved deviations to the Code and this specification
 Copies of Company-approved deviations to the Code or this specification
 List of consumable batch certificates
 Copies of consumable batch certificates
 List of materials certificates
 Copies of materials certificates
 List of test equipment
 Copies of calibration certificates
(b)
 List of as-built drawings
 As built drawings showing unique weld numbers
 List of weld history sheets
 Copies of weld history sheets which shall show for each weld
 weld number
 isometric and line number
 material specifications and identification
 the WPS employed
 the welders’ identity symbols
 date welded
 visual inspection disposition
 NDT reports where applicable (to be attached to weld history sheet)
 type of repair, if applicable, and WPS
 NDT reports for repairs (to be attached to weld history sheet)
 PWHT if applicable (chart to be attached to weld history sheet)
 batch number of consumables employed
 Radiographs – indexed and stored in a fireproof container
 List of site test records
 Copies of site test records
 List of non-conformances/corrective actions issued during external or internal audits
 Copies of non-conformances/corrective actions issued during external or internal audits

Version: 3.0
Appendices to API Std 1104
A Alternative Acceptance Standards for Girth Welds
A1 General
Add the following:
This clause is applicable only for applications utilizing automated/mechanized welding process and
inspected using automated UT system and the service condition is defined as non-sour.
For carbon steel pipelines, AUT defect acceptance criteria based on an ECA may only be applied if
agreed by the Company Welding TA 1. Such an assessment shall be carried out in accordance with BS
7910 Level 2 (or other assessment method acceptable to the Company Welding TA 1 and shall only be
carried out when all pipeline stresses and other design factors are known and when the fracture
toughness of the weld and HAZ have been established for all welding procedures and materials.
NOTE: It is therefore unlikely that such acceptance criteria could be accepted pre-contract.
Such defect acceptance criteria shall be based on the critical defect sizes, as determined by the ECA,
plus the AUT uncertainty in flaw sizing.
B In-Service Welding
Delete this Appendix in its entirety.
Table A – Charpy V-Notch Test Temperature
Nominal Wall Thickness (t) Test Temperature C*

mm
t <20 T
20 < t ≤ 30 T- 10
30< t < 30 T- 20
t> 40 T- 30
T = Minimum Design Temperature t = nominal thickness

Version: 3.0
Table B – Charpy V-Notch Energy Requirements
Steel Grade Specimen Size Charpy Energy (J)

ISO 3183 (mm)
Yield Strength Min Average Min Single
L245 10 X 10 27 19
10 X 6.7 21 15
10 X 5 18 13
L290 10 X 10 29 22
10X 6.7 23 17
10 x 5 19 15
L360 10 x 10 36 27
10 x 6.7 28 21
10 x 5 24 18
L415 10 x 10 41 31
10 x 6.7 32 24
10 x 5 27 21
L450 10 x 10 45 34
10 x 6.7 35 27
10 x 5 30 23
L485 10 x 10 48 36
10 x 6.7 37 28
10 x 5 32 24

Version: 3.0
Table C - Extent of Inspection
Inspected Item NDT Requirement
Visual RT UT MT/PT
Field butt welds 100% 100% (1) --
Field Tie-in welds 100% 100% 100% 100%
Repaired areas in butt welds. 100% 100% 100% 100%
Branch connections and fillet welds 100% -- (2) 100%
Pipe-cut back, and lamination checks prior 100% -- 100% 100%

to welding attachments or fittings
Field bevels 100% -- -- --
Following removal of arc strikes and crater 100% -- -- 100%

cracks, (see 7.2)
Notes: (1) Mechanized or automatic UT can be used to substitute RT
(2) Where practicable
Table D – Definition of Film Types
Film Type Speed Contrast Grain Equivalent to:
1 Slow Very high Very fine Kodak Industrex M

Kodak Industrex TMX
Kodak Industrex T
Agfa D2
Agfa D4
Fuji 50
2 Medium High Fine Kodak Industrex AX
Kodak Industrex AA
Agfa D5
Agfa D7
Fuji 100

Version: 3.0
Figure A – Location of Macro section and Impact Test Specimens

Top of pipe
Macrosection/hardness
Weld metal
Impact
Fusion line
specimens
A
Fusion line + 2mm
(a). Pipe diameters up to

and including 4 inches (114.3mm)
Top of pipe
Weld metal
Impact
Fusion line
specimens
Fusion line + 2mm
(b). Pipe diameters greater
than 4 inches (114.3mm)
Note: If additional impact specimens are required due to the wall

thickness exceeding 20 mm these shall be taken from location A

Version: 3.0
Figure B – Orientation and Location of Charpy Impact Specimens
_ 20mm
t< Notch
t 2mm
Weld metal specimen
C/L
Specimen axis
_ 20mm
t<
Notch
2mm
FL + 2
FL
Heat affected zone specimens
C/L
2mm
t > 20mm
2mm
Weld metal specimens
C/L
FL 2mm
FL + 2
t > 20mm
FL + 2 2mm
FL
Heat affected zone specimens

Version: 3.0
Figure C – Hardness Indent Locations
1.5 +- 0.5 mm
X X XXX X X X XXX X X
0.5t
1.5+- 0.5 mm
Hardness indentations in the HAZ spaced at 0.5mm
One indentation of every set of 3 shall be as close to the fusion line as

possible but shall not intersect it
1.5 +- 0.5 mm
0.5 X LEG LENGTH
Appendix 1 Glossary of Definitions, Terms and Abbreviations

Certain terms and abbreviations used in this document are defined below. The listed definitions shall be
considered to supplement those given in API Std 1104.
General Definitions

Version: 3.0
Contractor The party which carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a
project, or operation or maintenance of a facility. The Company
may undertake all or part of the duties of the Contractor.
Manufacturer/ Supplier The party which manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
Company Petroleum Development Oman LLC. The Company will
generally specify the technical requirements. The Company may
also include an agent or consultant authorised to act for, and on
behalf of, the Company.
User The Company, Consultant or Contractor who uses this
document.
Corporate Functional The person within the Company responsible for the discipline to
Discipline Head which the standard belongs
shall Indicates a requirement. Any deviation to a requirement shall be
approved by the CFDH.
should Indicates a recommendation. A deviation to a recommendation
shall be approved by the Company Welding TA 2.
may Indicates a possible course of action.
Specific Definitions
Nominal thickness Nominal thickness “t” shall have the following meanings:
(t) - butt joint; parent metal thickness, which for joints between
dissimilar thicknesses is that of the thinner material.
- fillet weld; parent metal thickness, which for joints between
dissimilar thicknesses is that of the thicker material.
- set-on branch connection; thickness of branch pipe at the
branch weld toe.
- set-through branch connection; thickness of main pipe.
Verified Copy A photocopy of an original document which has been re-
endorsed and signed by the organisation producing the
photocopy to verify that none of the information has been
adulterated.
Abbreviations
AFC Approved for Construction
ANSI American National Standards Institute
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASNT American Society for Non-destructive testing
ASTM American Society of Mechanical Engineers
AUT Automatic Ultrasonic Testing
AWS American Welding Society
BS British Standards
CE Carbon Equivalent

Version: 3.0
CFDH Corporate Functional Discipline Head

C Centigrade
CRA Corrosion Resistance Alloy
CSWIP Certification Scheme for Welding Inspection Personnel
D Nominal Outside Diameter
DCS Document Control Section
DEP Design and Engineering Practice
DNV Det Norske Veritas
ECA Engineering Critical Analysis
EFC European Federation of Corrosion
EMR Extra Moisture Resistant
ERS Engineering Research Station (British Gas)
FCAW Flux Cored Arc Welding
FL Fusion line
GMAW Gas Metal Arc Welding
GTAW Gas Tungsten Arc Welding
HAZ Heat Affected Zone
HSE Health, Safety and Environment
HV Vickers Hardness
ID Inside Diameter
IF Incomplete Fusion
IFD International Institute of Welding
IIW Incomplete Fusion due to Cold Lap
IQI Image Quality Indicator
ISO International Organization for Standardization
J Joule
LS Linear Surface
MPa Mega Pascal
MT Magnetic Particle Testing
NACE National Association of Corrosion Engineers
NDT Non-destructive Testing
NPS Outside Diameter
OD Nominal Pipe Size
PAMS Portable Arc Monitoring System
PCN Personnel Certification in NDT

Version: 3.0
PDO Petroleum Development Oman

PQR Procedure Qualification Record
PT Penetrate Testing
PWHT Post Weld Heat Treatment
QA/QC Quality Assurance/Quality Control
RT Radiography Testing
SAW Submerged Arc Welding
SMAW Shielded Metal Arc Welding
SMYS Specified Minimum Yield Strength
SP Specification
T Nominal Thickness
t Thickness of weld
TA Technical Authority, as defined in ERD 00-02 and PDO GU-272.
TWI The Welding Institute
UT Ultrasonic Testing
WPS Welding Procedure Specification
Appendix 2 References
In this specification, reference is made to the following publications:
Notes:
(1) See also additional references listed in API Std 1104 Section 1.3.
(2) Unless specifically designated by date, the latest edition of each publication shall be used together with any amendments.
PDO Standards
Technical Authorities System ERD 00-02
Guideline for Granting Technical Authority System GU-272
Specification for Welding of Duplex Stainless Steel Pipelines SP-1097
Specification for Welding on Pressurised Pipes SP-1167
Specification for Quality Assurance of Design, Construction and SP-1171

Engineering Works
Specification for Welding of Metals SP-1173
Specification for Welding of Class 2 Pipelines (Flow lines) SP-1174
On-shore Pipeline Engineering SP-1211

Version: 3.0
Health, Safety and Environmental Manual HSE Manual
Shell Group Standards

Welding of pipelines and related facilities (amendments/supplements DEP 61.40.20.30-Gen
to ANSI/API STD 1104)
Line pipe for Critical Service (Amendments/Supplements to ISO 3183) DEP 31.40.20.37-Gen
ASME Standards
Pipeline Transportation Systems for Liquid Hydrocarbons and Other ASME B31.4
Liquids
ASME B31.8
Gas Transmission and Distribution Piping Systems
API Standards
Welding of Pipelines and Related Facilities, API Std 1104
ASTM Standards
Standard Test Methods and Definitions for Mechanical Testing of ASTM A370
Steel Products
Standard Test Method for Vickers Hardness of Metallic Materials ASTM E92
AWS Standards
Filler Metal Procurement Guidelines AWS 5.01
NACE Standards
Sulphide Stress Cracking Resistant Metallic Materials for Oilfield NACE MR0175/15156
Equipment
British and European Standards
Non-destructive Testing – Image Quality of Radiographs – Part 1: EN 462-1
Image Quality Indicators (Wire Type) – Determination of Image Quality
Value
Welding – Recommendations for welding of metallic materials- Part 2: EN 1011-2

Arc Welding of Ferritic steels

Version: 3.0
International Standards
Quality Management Systems – Requirements ISO 9001
Non-Destructive Testing – Qualification and Certification of Personnel ISO 9712
Petroleum and natural gas industries – Steel pipe for pipelines – ISO 3183
Technical delivery conditions- Part 3:
Steel and Steel Products – Inspection Documents ISO 10474
Welding Consumables – Shielding Gases for Arc Welding and Cutting ISO 14175

Version: 3.0
Appendix 3 – WPS and PQR

Version: 3.0

Version: 3.0

Version: 3.0

Version: 3.0

Version: 3.0
User Comment Form

User Comment Form
If you find something that is incorrect, ambiguous or could be better in this document, write your
comments and suggestions on this form. Send the form to the Document Control Section (DCS).
They make a record of your comment and send the form to the correct CFDH. The form has spaces
for your personal details. This lets DCS or the CFDH ask you about your comments and tell you
about the decision.
Procedure Details Title: Issue
Date:
Number:
Page Number: Heading Number: Figure Number:
Comments:
Suggestions:
User’s personal details

Name: Ref. Signature: Date:
Ind.:
Phone:
Document Control Section Actions
Comment Date: CFDH
Number: Ref. Ind.:
Recd.: To CFDH:
CFDH Actions
Recd. Decision: Inits.: Ref. Date:
Date: Ind.:
Reject: 
Accept, revise at next issue: 
Accept, issue temporary amendment 
Comments:
Originator Date: Inits.: Document Date: Inits.:

Advised: Control
Section
Advised:


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Petroleum Development Oman L.L.

Document Type Specification

Discipline Materials & Corrosion

Owner Head of Materials Integrity – UEOC

Issue Date May 2016

This page was intentionally left blank

Page 2 SP-1177 – Specification for welding of class 1 pipelines Printed 06/11/17

Page 3 SP-1177 – Specification for welding of class 1 pipelines Printed 06/11/17

Version No. Date Author Scope / Remarks

iii Related Business Processes

iv Related Corporate Management Frame Work (CMF) Documents

Doc. ID Document Title

SP-1171 Specification for Quality Assurance Requirements for Product and

DEP 31.10.00.10-Gen Material traceability and positive material identification (PMI)

DEP 61.40.20.30-Gen. Welding of Pipelines and Related facilities

Page 4 SP-1177 – Specification for welding of class 1 pipelines Printed 06/11/17

ii Revision History ..................................................................................................................... 4

iii Related Business Processes.................................................................................................4

iv Related Corporate Management Frame Work (CMF) Documents......................................4

Part II .. Amendments/Supplements to API 1104.....................................................................................9

3 Terms, definitions, acronyms and abbreviations................................................................9

5 Qualification of Welding Procedures for Welds Containing Filler Metal Additives . 10

6 QUALIFICATION OF WELDERS .......................................................................................... 20

Page 5 SP-1177 – Specification for welding of class 1 pipelines Printed 06/11/17

7 PRODUCTION WELDING ..................................................................................................... 21

8 INSPECTION AND TESTING OF PRODUCTON WELDS ................................................... 23

9 Acceptance Standards for Non-Destructive Testing ....................................................... 24

10 REPAIR AND REMOVAL OF DEFECTS .............................................................................. 27

SECTION 11 – PROCEDURES FOR NON-DISTRUCTIVE TESTING ...................................... 28

11.1.8 Identification of Images ................................................................................................ 29

12 Mechnized WELDING WITH FILLER METAL ADDITIONS .......................................... 30

13 AUTOMATIC WELDING WITHOUT FILLER-METAL ADDITIONS ................................. 32

Appendices to API Std 1104..................................................................................................... 34

A Alternative Acceptance Standards for Girth Welds ......................................................... 34

B In-Service Welding ............................................................................................................... 34

Table A – Charpy V-Notch Test Temperature......................................................................... 34

Table B – Charpy V-Notch Energy Requirements.................................................................. 35

Table C - Extent of Inspection.................................................................................................. 36

Table D – Definition of Film Types .......................................................................................... 36

Figure A – Location of Macro section and Impact Test Specimens .................................... 37

Figure B – Orientation and Location of Charpy Impact Specimens .................................... 38

Figure C – Hardness Indent Locations.....................................................................................39

Appendix 1- Glossary of Definitions, Terms and Abbrevations............................................39

Appendix 3 – WPS and PQR ............................................................................................................. .45

User Comment Form ............................................................................................................................ 50

Page 7 SP-1177 – Specification for welding of class 1 pipelines Printed 06/11/17

This document is not applicable to:

 Welding of CRA clad pipelines, CRA lined pipelines

 Welding on pressurised pipelines (covered by PDO specification SP-1167)

1.2 Distribution, Intended Use and Regulatory Considerations

1.5 Summary of Main Changes

Page 8 SP-1177 – Specification for welding of class 1 pipelines Printed 06/11/17

Part II Amendments/Supplements to API Std 1104

3 TERMS, DEFINITIONS, ACRONYMS and ABBREVIATIONS

Welding parameter measuring equipments shall be calibrated.

Replace existing section as follows:

Add the following:

F) Material in accordance with ISO specifications

4.2.2 Filler Metal and Fluxes

Replace existing section as follows:

Page 9 SP-1177 – Specification for welding of class 1 pipelines Printed 06/11/17

4.2.2.2 Storage and Handling

Add the following: