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FFS-SU-5216-A

STRUCTURAL WELDING AND INSPECTION FOR OFFSHORE PLATFORMS

APPLICATION: FLOATING AND FIXED PLATFORMS, FPSO

This document is the confidential property of Chevron U.S.A. Inc. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of Chevron U.S.A. Inc. Neither the whole nor any part of this document may be reproduced, stored in any retrieval system or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of Chevron U.S.A. Inc.

Rev

Date

Description

Author

Sponsor

12/08

Initial release Replaces CIV-SU-1.15-A (1997)

 

CWAN

A

02/09

General revision

JLPY

CWAN

08/09

Errata change - Table 4, item 3,Magnetic Particle data changed to reference table footnote 10

JLPY

CWAN

Structural Welding and Inspection for Offshore Platforms

FFS-SU-5216-A

CONTENTS

1.0

Scope

3

2.0

References

3

2.1 Purchaser

Documents

3

2.2 Industry

Codes and Standards

3

3.0

Terminology

5

3.1 Acronyms

5

3.2 Definitions

5

4.0

Technical Requirements

5

4.1 Item

Definition

5

4.2 Environmental

Conditions

6

4.3 Weld

Fabrication Requirements

6

4.4 Supplier

Requirements

17

4.5 Documentation

Requirements

17

5.0

Quality Assurance Provisions

18

5.1 General

Extent of Inspection

18

5.2 Inspection

Procedures

23

Cleaning

5.3 and Repairing of Pipe Ends

25

5.4 Tests

25

5.5 Conformance Inspections

Quality

25

5.6 Welding

Repairs

27

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1.0

SCOPE

 

1. This specification defines minimum technical requirements for welding and welding inspection of both fixed and floating facilities. Floating, Production, Storage, and Offloading (FPSO)/ Floating Storage and Offloading (FSO) decks and modules are included. Quality Assurance Provisions for hulls are also included, except for FPSO/FSO hulls.

2. This specification also applies to shop, yard, and offshore welding.

3. This specification is for both ABS (American Bureau of Shipping) and non-ABS classed

 

facilities.

a. If non-ABS class facilities are being fabricated, ABS rules are not applicable.

b. If ABS class facilities are being fabricated, ABS rules shall apply.

 

4. Supplier shall be solely responsible for providing complete and operable packages in full accordance with all applicable industry codes and standards, government regulations, and purchaser technical requirements.

5. Any exceptions to the requirements of this specification shall be submitted in writing for resolution by Purchaser.

2.0

REFERENCES

 

1. The following documents are referenced herein and are considered part of this specification.

2. Use the edition of each referenced document in effect on the date of the publication of this

 

specification.

 

3.

Any conflicts between the referenced documents shall be identified to Purchaser in writing for resolution. In general, when resolving conflicts, the following order of precedence shall apply:

 

a. Purchase order

b. Purchaser drawings

c. This specification

d. Referenced Purchaser standards

e.

Referenced industry codes and standards

2.1

Purchaser Documents

 

FFS-SU-5160

Hull Fabrication for Floating Structures

FFS-SU-5215

Structural Steel and Other Materials

2.2

Industry Codes and Standards

American Petroleum Institute (API)

RP 2A-WSD

Recommended Practice for Planning, Designing and Constructing Fixed Offshore Platforms-Working Stress Design

RP 2X

Recommended Practice for Ultrasonic and Magnetic Examination of Offshore Structural Fabrication and Guidelines for Qualification of Technicians

Spec 2B

Specification for the Fabrication of Structural Steel Pipe.

Spec 2H

Specification for Carbon Manganese Steel Plate for Offshore Structures

Structural Welding and Inspection for Offshore Platforms

FFS-SU-5216-A

Spec 2MT1

Specification for Carbon Manganese Steel Plate with Improved Toughness for Offshore Structures

Spec 2W

Specification for Steel Plates for Offshore Structures, Produced by ThermoMechanical Control Processing (TMCP)

Spec 2Y

Specification for Steel Plates, Quenched-and-Tempered, for Offshore Structures

RP 2Z

Recommended Practice for Preproduction Qualification for Steel Plates for Offshore Structures

American Society of Mechanical Engineers (ASME)

SFA 5.20

Specification for Carbon Steel Electrodes for Flux Cored Arc Welding (Identical with AWS Specification A5.20-95)

SFA 5.29

Specification for Low-alloy Steel Electrodes for Flux Cored Arc Welding (Identical with AWS Specification A5.29/A5.29M:2005.)

Boiler and Pressure Vessel Code

Section V, Non-Destructive Examination

American Society for Testing and Materials (ASTM)

A

36

Standard Specification for Carbon Structural Steel

E

165

Standard Test Method for Liquid Penetrant Examination

E

709

Standard Guide for Magnetic Particle Examination

E

1290

Standard Test Method for Crack-Tip Opening Displacement (CTOD) Fracture Toughness Measurement

American Welding Society (AWS)

A4.3

Standard Methods for Determination of the Diffusible Hydrogen Content of Martensitic, Bainitic, and Ferritic Steel Weld Metal Produced by Arc Welding

A5.20

Specification for Carbon Steel Electrodes for Flux Cored Arc Welding

A5.29

Specification for LowAlloy Steel Electrodes for Flux Cored Arc Welding

D1.1

Structural Welding Code-Steel

British Standards Institute (BSI)

BS 5762

Methods for Crack Opening Displacement (COD) Testing

BS 7448-1

Fracture Mechanics Toughness Tests - Part 1: Method for Determination of KIC, Critical CTOD and Critical J Values of Metallic Materials

BS EN 10225

Weldable Structural Steels for Fixed Offshore Structures - Technical Delivery Conditions

BS EN ISO 3690

Welding and Allied Processes - Determination of Hydrogen Content in Ferritic Steel Arc Weld Metal

Structural Welding and Inspection for Offshore Platforms

FFS-SU-5216-A

3.0

TERMINOLOGY

3.1

Acronyms

ABS—American Bureau of Shipping

CE—Carbon Equivalent

COD—Crack Opening Displacement

CTOD—Crack-Tip Opening Misplacement

FCAW-G—Flux Core Arc Welding - Gas Shielded

FCAW-S—Flux Core Arc Welding - Self Shielded

FL—Fusion Line

GMAW—Gas Metal Arc Welding

GTAW—Gas Tungsten Arc Welding

HAZ—Heat Affected Zone

LAST—Lowest Anticipated Service Temperature

MT—Magnetic Particle Technique

PQR—Procedure Qualification Record

PT—Liquid Penetrant Technique

RT—Radiographic Technique

SAW—Submerged Arc Welding

SMAW—Manual Shielded Metal Arc Welding

UT—Ultrasonic Technique

WPS—Welding Procedure Specification

VT—Visual Inspection

3.2

Definitions

Joint—Intersection where one or more tubular or structural shape stubs are connected. The joint area shall include stiffeners, diaphragms, and transition pieces, as specified by accepted drawings.

T-junction—Point where a longitudinal seam weld on a tubular intersects a circumferential weld. It can be located at either a buttweld between two tubulars or a full penetration weld between a chord and a brace.

4.0

TECHNICAL REQUIREMENTS

4.1

Item Definition

Structural welding and inspection includes the materials, equipment, workmanship, testing, and other items required to weld and inspect offshore steel structures.

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4.2 Environmental Conditions

Welding material and procedures shall be suitable for the environmental conditions as specified in AWS D1.1.

4.3 Weld Fabrication Requirements

4.3.1

General

1. Structural welding shall be in accordance with AWS D1.1 or more restrictive requirements specified in this document. Welds are subject to review, inspection, and acceptance by Purchaser representatives, ABS surveyor, and Purchaser-furnished marine surveyor.

2. Unless otherwise specified, welds shall be full penetration welds.

3. Members shall be well fitted and firmly tacked into place before welding.

a. Tack welding shall be performed according to the same qualified welding procedure that governs the connection and shall only be performed by qualified welders.

b. Supplier shall include, as part of the welding procedure specification, a procedure for repair of wide gaps. This procedure shall be in accordance with AWS D1.1.

c. Buttering members in place is acceptable if welders are qualified in accordance with Section 4.3.6, item 4 and Figure 2 of AWS D1.1.

4. When welding joints with features (such as special fittings, heavy wall pipe, appurtenances, and corners) that would make obtaining interpass fusion difficult, the weld shall be contoured after each pass with a grinder to improve the welders pass-to- pass accessibility.

5. Acceptable methods of welding are the Shielded Metal Arc (SMAW), Submerged Arc (SAW), Gas Metal Arc (GMAW), Flux-Cored Arc-Gas Shielded (FCAW-G), and Gas Tungsten Arc (GTAW) processes.

a. Short circuiting the GMAW-S process shall be used only for welding of the deck plate and non-critical structural items such as handrails.

b. GMAW-S is also acceptable for root passes in primary (as defined by AWS D1.1) structural welds, when the remainder of the weld is made from one or both sides using SAW, FCAW-G, or SMAW.

c. Self Shielded Flux Core Arc Welding (FCAW-S) process requires Purchaser acceptance.

6. Tack welding, seal welding, and welding of temporary attachments (including scaffolding supports and tie-downs) shall be performed in accordance with the accepted welding procedures.

7. When weld-through primers are used during fabrication, they shall be included in the weld procedure qualifications. Use of weld-through primers shall require written acceptance by Purchaser prior to the start of fabrication.

8. Temporary attachment welds to structural members or deck plate shall be removed by severing with an oxy-acetylene torch or by carbon air arc gouging the attachment no closer than 0.12 inches (3 mm) from the surface of the structural member, then ground flush and inspected using the Magnetic Particle Technique (MT).

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9. When seal welding the deck plate to secondary or primary (as defined by AWS D1.1) structural members, a small sealer bead size of 1/8 inch (3 mm) shall be used to avoid excessive distortion. Auto carriage seal welding in 1G or flat position using FCAW-G or GMAW is preferred when practicable.

10. Fairing or heat straightening deck plate and structural members distorted by welding is allowed using a procedure accepted by the Purchaser.

4.3.2 Welding Consumables

1. Electrodes with a low hydrogen covering shall be purchased in a hermetically sealed

container.

2. Unless otherwise specified in the manufacturer’s recommendations, immediately after opening, electrodes shall be stored in an oven at a temperature of 250F (121C).

a. If electrodes have not been stored, or if the sealed container shows evidence of damage, the electrodes shall be dried for at least two hours at a temperature between 450F (232C) and 500F (260C) before being used.

b. Wet electrodes shall be discarded.

3. Low hydrogen electrodes shall be used for SMAW welding.

4. Non-low hydrogen electrodes (e.g., E-6010) may be used for root pass welding on one sided tubular joints only.

5. Permanent backup bars shall not be used except when specifically accepted by

Purchaser.

6. Backing rings shall be allowed only on structural braces less than 24 inches (610 mm) in diameter, when qualified and used in accordance with Supplier’s accepted welding

procedures.

7. For gas shielded processes (FCAW-G, GTAW, and GMAW), the wind speed adjacent

to the arc shall be a maximum of 5 mph, to allow adequate gas coverage of the molten

puddle.

8. The following requirements apply to FCAW-G:

a. FCAW-G consumables shall be low hydrogen type, as tested and certified by the consumable manufacturer.

b. Low hydrogen type consumables shall be defined as those with a diffusible hydrogen content less than 8 ml/100 gm of deposited weld metal (AWS A5.20 and AWS A5.29 “H4” or “H8” electrode classification) as measured by the mercury or gas chromatograph method (BS EN ISO 3690 or AWS A4.3).

c. Flux-cored wire shall be kept clean and dry prior to use and at all times while on the wire feeder.

d. Wire that shows any signs of rust or contamination shall be discarded.

e. Maximum bead width and layer thickness shall be controlled for all FCAW welding to ensure adequate toughness of the weld and Heat Affected Zone (HAZ).

When impact testing is required, the maximum bead width and layer thickness shall be qualified as part of the welding procedure and stated on the Welding Procedure Specification (WPS) and Procedure Qualification Record (PQR).

1)

Structural Welding and Inspection for Offshore Platforms

FFS-SU-5216-A

2)

Maximum bead width and layer thickness for production welding shall be limited to the maximum qualified for the welding procedure, and in any case, the maximum bead width shall not exceed 3/4 inch (19 mm).

3)

When impact testing is not required, the maximum bead width shall be limited to 3/4 inch (19 mm).

f. Maximum wire diameter for out of position welding (3G, 4G, 5G, and 6G) shall be as in Table 1.

Table 1: Maximum Wire Diameter for Out of Position Welding

Thickness of Thinner Material Joined

Maximum Wire Diameter FCAW-G

Less than 3/8 inch (9.5 mm)

0.052 inch (1.2 mm)

Greater than or equal to 3/8 inch (9.5 mm)

1/16 inch (1.6 mm)

g. The flat position and horizontal positions (1G and 2G) shall be limited to 3/32 inch (2.4 mm) maximum wire diameter

9. Consumables for the gas-shielded FCAW-G process shall conform to the AWS/ASME SFA 5.20 or SFA 5.29 classifications: E7XT-1H8, E7XT-1MH8, E7XT-5H8, E7XT5MH8, E8XT1-XH8, E8XT1-XMH8, E8XT5-XH8, or E8XT5-XMH8.

4.3.3 Welding Procedure Qualifications

1. Qualification tests shall be performed in accordance with AWS D1.1 by an independent testing laboratory as directed by Purchaser.

2. Weld procedure qualification testing shall be carried out by and at the expense of

Supplier.

3. Purchaser shall witness new weld procedure qualification tests.

4. Where previously qualified procedures are submitted for review and acceptance, adequate documentation of the results from an independent testing laboratory shall be

included.

5. Actual values of essential variables shall be recorded for each pass as part of the welding procedure qualification, and the data records shall be submitted with the qualifications for Purchaser review and acceptance.

6. Welding procedures shall be qualified by nondestructive testing (NDT) and mechanical testing. Acceptance criteria for welding procedure qualification nondestructive examination (NDE) shall be in accordance with Table 2.

a. Pre-qualified procedures as defined by AWS D1.1 are not allowed. However, records of previous qualification for a welding procedure may be submitted for acceptance in lieu of new qualifications, and may be accepted if each requirement of this specification is met.

b. Unless otherwise specified, mechanical testing shall include tensile, bend, Charpy V-notch, hardness, and macrosection tests in accordance with AWS D1.1 and this specification.

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c. CTOD testing of weld metal shall be required for all welding procedure qualifications on Type I, I-X, II, and II-X steels (refer to FFS-SU-5215) with thickness equal to or greater than 2-1/2 inches (63.5 mm).

Table 2:

Weld Flaw Acceptance Levels

 

Inspection Procedure

Acceptance Criteria

Minimum NDE 1 Operator Qualification 2

Visual

 

AWS D1.1, Paragraph 6.9

AWS Certified Welding Inspector (CWI) 3

Ultrasonic

AWS D1.1 Section 6, Part F or API RP 2X

API RP 2X - T, K, Y Welds Level C; Other Welds Level A 5

ASNT Level II and tested per API RP 2X

Radiographic

AWS D1.1 Section 6, Part E

AWS D1.1, Paragraph 6.12

ASNT Level II

Magnetic

ASME Section V, Article 7 Clause T725.1 or T725.2 and Clause T731 and T734; or ASTM E 709

AWS D1.1, Paragraph 6.10

ASNT Level II

Particle

Dye Penetrant 4

ASTM E 165

AWS D1.1, Paragraph 6.10

ASNT Level II

1 Or Purchaser-accepted equal. 2 Supplier shall submit current updated certifications of NDE operators to Purchaser for review. 3 Qualified in accordance with AWS D1.1, Paragraph 6.1.4. 4 When accepted by Purchaser representative. 5 For Hull Structures UT to Level A for both Cyclic and Non-Cyclic Service.

7. For all welding on Type I, I-X, II, and II-X steels (refer to FFS-SU-5215) with thickness equal to or greater than 2-1/2 inches (63.5 mm). The preheat, heat input, and interpass temperature shall be within the prequalified ranges in accordance with API RP 2Z.

8. AWS D1.1 limits on qualified thickness ranges shall be followed except for the following additional requirements:

a. For welding procedures where CTOD testing is required, the maximum thickness shall be limited to the thickness of the CTOD test coupon.

b. For T-K-Y connections in a pipe with a wall thickness greater than or equal to 1 inch (25 mm), a large-scale 6GR test shall be required. The test joint shall be similar to AWS D1.1, Figure 4.27 except for the following changes:

1)

Minimum outside diameter shall be 12-3/4 inches (324 mm).

2)

Minimum wall thickness shall be 1 inch (25 mm).

3)

Minimum length of each pipe nipple shall be 12 inches (305 mm).

9. The following limits for additional essential variables shall apply to all welding procedures. (A change in an essential variable beyond the specified limits requires a new qualification.)

a. An increase in the Carbon Equivalent (CE) greater than 0.03 percent versus the base material used for the procedure qualification for production base material CE through 0.45. Above 0.45 production base material CE, a new qualification is required if the procedure qualification CE is exceeded.

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b. A change in the process of manufacture for the base material, outside the following groups:

1)

Quenched and tempered steels (i.e., API Spec 2Y)

2)

TMCP or controlled-rolled steels (i.e., API Spec 2W)

3)

Normalized or as-rolled steels (i.e., API Spec 2H or 2MT1)

c. An increase of more than 50F (28C) over the maximum interpass temperature attained on the procedure qualification for Type I, I-X, II, and II-X steels only.

d. A change greater than ± 25 percent in the heat input of any welding pass from the average value calculated for the procedure qualification test.

1)

Heat inputs for fill passes and cap passes shall be grouped separately in determining the average heat input qualified.

2)

The minimum heat input for the cap pass shall not be less than the lowest heat input pass adjacent to base metal on the procedure qualification.

e. Any change in the electrode or electrode/flux brand name or place of manufacture, when the Charpy V-notch impact test temperature is lower than 0F (-18C) (i.e., Type I and I-X steels only).

10. The following limits for additional essential variables shall apply to all welding procedures where CTOD testing of weld metal is required as part of the procedure qualification. (A change in an essential variable beyond the specified limits requires a new qualification.)

a. Any increase in thickness of the base material versus that used for the procedure qualification.

b. Any increase in the maximum preheat, heat input, or interpass temperature versus the procedure qualification.

c. Any change in the type of power supply (constant voltage or constant current) or wire feeder (constant feed or voltage sensing) for flux cored arc welding (FCAWG) only.

d. Any change in the electrode or electrode/flux brand name or place of manufacture (i.e., Type I, I-X, II, and II-X steels only).

11. If a temper bead technique is used to control the maximum hardness of the HAZ, then any change in the bead sequence or placement of the temper bead shall require a new

qualification.

12. Welding procedure qualifications shall include a microhardness traverse of the HAZ, weld metal, and base metal.

a. Traverses shall be made 0.04 inch (1 mm) below the I.D. and O.D. surfaces and at midthickness. (See Figure 1.)

b. Hardness impressions shall be spaced 0.08 inch (2 mm) apart except for the HAZ area where spacing shall be 0.04 inch (1 mm) apart.

c. Hardness values greater than 325 Vickers using a 22 lb. (10 kg) load are not acceptable and shall require a new procedure qualification.

d. Supplier shall furnish test data to Purchaser representative for acceptance.

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Figure 1:

Base Metal, Weld, and Heat Affected Zone of Typical Weld for Guidance In Making Microhardness Traverses

Note: Welding procedure qualifications shall include a 10 kg Vickers micro hardness traverse of the

Note: Welding procedure qualifications shall include a 10 kg Vickers micro hardness traverse of the HAZ, weld metal and base metal. Traverses shall be made 1 mm below the I.D. and O.D. surfaces and at mid-thickness. Hardness impressions shall be spaced 2 mm apart except for the HAZ area where spacing shall be 1 mm apart.

13. Charpy V-notch impact testing of both the weld metal and heat affected zones shall be required on all welding procedure qualifications.

a. Testing shall be in accordance with AWS D1.1 Part D, except that notch locations shall be at the weld center line, fusion line, FL+1 mm, FL+3 mm, and FL+5 mm.

b. Acceptance criteria for both weld metal and HAZ specimens shall be as shown in Table 3. Projects may change to less stringent requirements as determined by LAST (Lowest Anticipated Service Temperature).

Table 3:

Acceptance Criteria for Weld Metal and HAZ Specimens

Steel Type

Test Temp

Minimum Average

Minimum Single Value

I

40F (40C)

25

ft-lbs. (34 J)

20

ft-lbs. (27 J)

I-X

40F (40C)

30

ft-lbs. (41 J)

25

ft-lbs. (34 J)

II

0F (18C)

25

ft-lbs. (34 J)

20

ft-lbs. (27 J)

II-X

0F (18C)

30

ft-lbs. (41 J)

25

ft-lbs. (34 J)

III, IV, V,VI

32F (0C)

20

ft-lbs. (27 J)

15 ft-lbs. 20 J)

c. For Type III, IV, and V steels, only weld metal impact tests are required.

d. For Type III, IV, and V steels, a single set of HAZ specimens with the notch location as shown in AWS D1.1, Part D, Figure 4.40 “Zone C” shall be tested and reported for information only.

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14. CTOD toughness of the HAZ shall be prequalified in accordance with API RP 2Z or BS EN 10225. Provided that the heat input for all welding processes is within the pre-qualified range, further CTOD testing of the HAZ by Supplier shall not be

required.

15. CTOD testing of weld metal shall be required for all welding procedure qualifications on Type I, I-X, II, and II-X steels with thickness equal to or greater than 2-1/2 inches (63.5 mm).

a. Weld metal CTOD testing shall be performed on the thickest steel to be welded for each steel type, using the highest preheat, heat input, and inter-pass temperature permitted by the welding procedure to be qualified.

b. For plate test coupons, CTOD testing on a 3G position coupon qualifies CTOD procedure for all other positions.

c. For pipe test coupons, CTOD testing on a 5G position coupon, with CTOD specimens removed at 3:00 or 9:00 o’clock locations, qualifies the CTOD procedure for all other positions.

d. Except for the CTOD tests, other AWS D1.1 rules apply for qualifying all position welding.

e. Specimens shall be tested in the as-welded condition with the notch located at the centerline of the weld.

f. Tests shall be performed according to ASTM E 1290 or BS 7448-1, although previously qualified procedures where testing was performed according to BS 5762 are also acceptable.

g. A minimum of three valid CTOD test results shall be obtained.

16. CTOD specimens shall be tested in the as-welded condition.

a. Test temperature shall be 14F (10C).

b. Acceptance criteria for material up to 60 ksi yield strength shall be:

1)

0.010 inch (0.25 mm) for Type I and II plates up to 3 inches (76 mm) thick

2)

0.015 inch (0.38 mm) for Type I and II plates greater than 3 inches (76 mm) thick

3)

0.012 inch (0.30 mm) for Type I-X and II-X plates up to 3 inches (76 mm) thick

4)

0.018 inch (0.46 mm) for Type I-X and II-X plates greater than 3 inches (76 mm) thick

4.3.4 Welding Equipment

1. Condition of Equipment

a. To ensure the production of sound welds, welding machines, line-up clamps, beveling machines, cutting torches, tools, supplies, and other equipment used in conjunction with the welding work shall be kept in good mechanical condition.

b. Welding machines shall have adequate controls for making the current adjustments necessary for all welding requirements.

c. Sufficient meters, portable or permanent, shall be provided to calibrate machines and to regulate voltage and amperage as needed.

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2. Grounding of Equipment

a. Grounding of welding machines shall be in accordance with API RP 2A-WSD Section 12.7 and the following:

1)

Welding machines shall be individually grounded to the platform or portion of the platform being welded.

2)

Welding cables shall be completely insulated to prevent stray currents.

3)

During offshore installation, no welding machine shall be grounded to floating equipment during welding on the structure and cables shall not be allowed to hang in the water.

4)

Connecting several welding machines to a common ground cable that is connected to the structure being welded shall control stray currents if adequately sized and properly insulated from the barge or vessel containing welding machines.

b. Grounding cable lugs shall be tightly secured to grounding plates.

1)

Lug contact shall be thoroughly cleaned to bare metal.

2)

One or more cables connected in parallel may be used to meet minimum cross-section requirements.

3)

Ground clamps for pipe shall be designed to prevent arcing on the pipe material.

c. Ground straps with a cross-section adequate for carrying the maximum possible short-circuit current shall be installed between the jacket and pile/conductor while making splices.

4.3.5 Preheat and Interpass Temperatures

1. Welding preheat and interpass temperatures shall be as specified in Supplier’s qualified welding procedure, but shall not be less than the recommended temperatures in AWS D1.1, Table 3.2.

a. The alternative methods for determining preheat given in AWS D1.1, Annex I may be used, if accepted by Purchaser in writing.

b. If any metal is damp or less than 50F (10C), a minimum preheat of 100F (38C) shall be required regardless of thickness.

2. Preheat shall be performed by using oxy-fuel bulbous type torches, induction, or electric resistance heat. Cutting torches shall not be used for preheating.

3. Maximum interpass temperatures shall not exceed the limit established by the welding procedure qualification. (See Section 4.3.3, item 9c and item 10b). In cases where the WPS does not specify a limit, the maximum interpass temperature shall not exceed 500F (260C) without written Purchaser acceptance.

4.3.6 Welder Qualifications

1. Welders shall be qualified by destructive testing; radiography may be performed in lieu of destructive testing.

2. Records of previously qualified welders may be submitted to Purchaser for acceptance in lieu of new qualifications, and may be accepted if all of the requirements of this specification are met.

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3. Welders shall be required to demonstrate their ability to control preheat, heat input, and interpass temperature in accordance with the WPS, and to comply with written practices for filler metal handling as a part of the qualification testing.

4. Welders who shall perform buttering of members in place shall be required to demonstrate their ability by passing a special qualification test (known as the “butter box test”) as described in Figure 2 for each welding position required to perform the required buttering.

5. Welder qualification testing shall be carried out by, and at the expense of, Supplier.

6. Purchaser shall witness the testing.

a. If Purchaser is not satisfied with the results of the qualifying tests, the welder shall not be employed on Purchaser work.

b. Any welder who fails to qualify shall not be allowed to retest without the written acceptance of Purchaser.

7. Records of the results of all qualifying tests shall be maintained by Supplier and submitted to Purchaser.

8. Supplier shall furnish all welding materials, equipment, and labor for the qualifying tests, including coupon cutting machines and testing equipment.

9. If radiographic testing is performed, radiographs shall be made available for Purchaser

review.

10. Supplier shall remove the following from the project immediately:

a. Any welder who, in the opinion of Purchaser, is not careful, skilled, or experienced, or who is incompetent or negligent in the proper performance of duties.

b. Any welder whose cumulative weld reject rate (either radiography or ultrasonic) exceeds 10 percent, based upon a minimum of 20 welds, shall not be used until retrained and requalified.

11. Notwithstanding any other radiography requirements of codes or of this specification, the first five full penetration production welds completed by each welder shall be subjected to 100 percent testing by radiography or ultrasonic examination.

4.3.7 Weld Identification and Marking

1. Prior to fabrication, Supplier shall establish a comprehensive numbering system that provides unique identification of each weld and each qualified welder.

2. The numbering system shall be used for identification purposes at each weld, on all shop drawings, and for indexing all NDT inspection reports and repairs.

3. Prior to commencement of fabrication, Supplier shall supply Purchaser with details of the identification system, along with any subsequent revisions or modifications.

4. Paint markers or low stress (rounded dot) die stamps shall be used for weld

identification.

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Figure 2:

Butter Box Test Specimen and Requirments

Requirements: 1. A separate butter-box qualification shall be required for each welding position to be

Requirements:

1. A separate butter-box qualification shall be required for each welding position to be used, except that any other position also qualifies for the 2G welding position. The 1G position is shown. The 2G position would have the MK 1 plate in the flat position.

2. The material is ASTM A 36 or better quality.

3. The material size dimensions are minimum.

4. A 3-inch (75 mm) wide macro cross section is removed from the approximate center of the weld and both sur- faces are polished and etched.

5. Welder must have at least one start and stop for each pass in the macro section region.

Acceptance Criteria:

1. There shall be no cracks.

2. There shall be complete fusion to base metal and between adjacent layers of weld metal.

3. Undercut shall not exceed 1/32 inch (1 mm).

4. The maximum dimension of any slag inclusion shall not exceed 3/32 inch (2.5 mm). The sum of the greatest dimension of all slag inclusions on each macro etched surface shall not exceed 1/4-inch (6.5 mm).

5. The maximum dimension of any porosity shall not exceed 1/16 inch (1.6 mm). The sum of the greatest dimen- sion of all porosity greater than 1/32 inch (1 mm) shall not exceed 1/4 inch (6.5 mm).

6. The combination of the cumulative sums allowed in 4 and 5, above, shall not exceed 1/4 inch (6.5 mm).

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4.3.8 Workmanship

In addition to AWS D1.1, workmanship shall comply with the following requirements:

1. Surfaces of metal to be welded shall be free of fins, tears, cracks, loose scale, slag, rust, oil, paint, and other defects that would adversely affect the quality or strength of the weld.

2. Welding shall proceed in a manner that minimizes residual stresses or distortions.

a. The finished structure shall be as free from distortion as much as possible.

b. Supplier shall be responsible for preventing or correcting distortion and for maintaining alignment within a specified tolerance, by Purchaser-accepted procedures such as use of strong backs.

c. Purchaser shall be the judge of these factors and shall have the right to delay the work, if excessive distortion becomes evident, until such time as corrective methods can be successfully applied.

3. When more than one weld pass is deposited on a joint, each pass shall be thoroughly cleaned by wire brushing and chipping before the next pass is applied.

4. Welds shall not be quenched or cooled other than by contact with the natural

atmosphere.

a. Welds shall be protected from rapid cooling caused by rain, wind, or inclement weather.

b. Purchaser shall determine if adequate protection has been provided for welding to continue.

5. Weld tabs shall be used prior to welding beam flanges to minimize porosity on flange ends.

6. Mouse holes for welding access shall be shown on detail drawings and shall not exceed specified size. All mouse holes shall be sealed by one of the following methods:

a. Completely seal welding by returning fillet welds through the opening on small beams as applicable.

b. Cover both sides with 1/4-inch (6 mm) thick plate, fully seal welded on large beams and built-up girders.

c. Fill with a joint filler in lieu of welding.

1)

This is a less preferred method and is restricted to small size mouse holes.

2)

For this option, Supplier must submit a procedure, including product data for the joint filler compound to be used, for Purchaser acceptance.

3)

Joint filler material shall be compatible with surface preparation and painting procedures.

4.3.9 Safety

1. Safety shall be in accordance with the following:

a. Purchaser HES requirements

b. Good safe practices (AWS D1.1, Section 1.7 and Annex R)

c. OSHA standards

2. Supplier shall provide suitable wind guards and welders’ platforms when, as judged by Purchaser, conditions warrant.

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4.4 Supplier Requirements

1. The work shall be performed by Supplier for Purchaser.

2. All welding and inspection shall be in accordance with this specification and referenced specifications, codes, and standards.

3. Supplier shall keep a competent English-speaking superintendent or foreman on the jobsite at all times during the performance of the work.

4. Any written or verbal instructions given to the superintendent or foreman by Purchaser shall be construed as having been given to Supplier.

4.5 Documentation Requirements

Documentation shall be provided in accordance with the specification and the following requirements:

1. Prior to commencement of fabrication, the proposed welding procedures shall be submitted on suitable forms for acceptance by Purchaser. Purchaser reserves the right to request further submission of procedures of any component fabrication.

2. Prior to commencement of fabrication, Supplier shall submit the following documentation to Purchaser for acceptance:

a. Quality assurance manual

b. Supplier’s fabrication and QA/QC organizations, and lines of reporting

1)

Inspection subcontracting plan

2)

Resumes of inspectors and supervisors

c. NDE procedures (for each NDE method)

1)

Details for implementing code requirements

2)

Reject rate reporting methods

3)

Sample data sheets for all reports

4)

UT operator qualification test procedures and test piece design

d. Traceability Procedures

Detailed descriptions, sample drawings and data sheets showing how each piece can be traced.

e. Welding Control

1)

Welding consumables storage control methods

2)

Preheat QA methods

3)

Field QA methods for proper WPS application

4)

Itemized list of inspection hold points for Supplier and Purchaser

5)

Notification procedures and sample forms for both hold points and ongoing inspections

3. Additional information may be requested by Purchaser to demonstrate Supplier(s) understanding, planning, and readiness to meet code and specification requirements.

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4. Upon completion of fabrication of items covered by this specification, two copies of the following documentation shall be supplied to Purchaser:

a. Full NDT reports for all welds tested

b. A final identification numbering system, cross-referenced to the NDT reports covered above

5. During fabrication, Supplier shall submit the following to Purchaser:

a. Daily: A copy of the NDT Reports for the previous day.

b. Weekly: The cumulative weld reject rates by weld process for each welder and for the total job.

1)

Weld reject rates shall be reported independently for radiography and ultrasonic inspection.

2)

The radiography reject rate is the number of films rejected divided by the total number of films.

3)

The ultrasonic reject rate is the length of defect rejected divided by the total weld length inspected.

5.0 QUALITY ASSURANCE PROVISIONS

Quality assurance provisions shall comply with the following requirements.

5.1 General Extent of Inspection

5.1.1 Extent of Nondestructive Inspection

Supplier shall perform NDT inspections (locations and methods) in accordance with requirements of Table 4 for all structures except hulls. NDE for hulls shall be per Table 5.

Table 4:

Extent of Inspection (Except for Hull Structures 1,2,3 (1 of 2)

   

Percent of Total Weld Length 4

 

Visual

Ultrasonic

Magnetic

Radio

Particle 5

graphy

Location/Type of Weld

   

Tubular Connections

 

1.

Brace to chord welds, all T, K, or Y connections

 

100

100

100

 

2.

Circumferential butt welds

 

100

 

10

100

6,7,8

3.

Longitudinal butt welds

9

100

100

10

 
   

11

100

10

10

10

   

12

100

10

10

10

Other Connections

 

4.

Full penetration welds on launch leg ring stiffeners, seafastening, longitudinal and transverse truss connections, launch lugs, and all padeyes

 

100

100

100

 

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Table 4:

Extent of Inspection (Except for Hull Structures 1,2,3 (2 of 2)

   

Percent of Total Weld Length 4

 

Visual

Ultrasonic

Magnetic

Radio

Particle 5

graphy

5.

Pile offshore girth welds

 

100

100

100

 

6.

Fillet welds, anode connections, and full penetration welds at other locations

 

100

 

100

 

7.

Flange and web splices and flange intersections

 

100

   

100

13

8.

Web intersections

 

100

100

   

9.

Floor plates and handrails

 

100

     

10.

Girder web to flange connections (full penetration)

 

100

100

20

 

11.

Girder stiffener to flange (full penetration)

 

100

100

20

 

Welder Qualification

   

100

14

 

100

14

1 For each weld, applicable spot tests shall be evenly distributed over that weld’s length.

 

2 Ultrasonic inspections shall not be allowed where radiographic inspection has been specified unless Purchaser acceptance is obtained for each case.

3 Steel materials having a thickness greater than or equal to 3/4 inch (19 mm) and that are subject to through thickness stresses from weld connections, shall be ultrasonically inspected for laminations at the weld location prior to welding. This may be waived by Purchaser for steels having improved through thickness properties. It may also be added elsewhere by Purchaser at critical locations that have high through thickness stresses.

4 Inspected welds shall include ends as a minimum for partially inspected welds. Balance of weld length to be inspected on partially inspected welds shall be applied at random locations along the weld length.

 

5 When accepted in writing by Purchaser on a case-by-case basis, dye penetrant inspections may be substituted for magnetic particle inspection in areas where magnetic particle inspection is impossible due to lack of

6 Radiography of circumferential seams shall include 4 inches (102 mm) of each intersecting longitudinal seam.

7 Members with a diameter less than 16 inches (406 mm) that fall under Note 10 shall be 10% inspected.

 

8 Purchaser shall allow the substitution of ultrasonic and magnetic particle inspection for radiography of full penetration closing butt joints made from one side.

9 Node cans and other tubulars fabricated from material Type I or Type I-X.

 

10 The longitudinal weld on submerged-arc welded pipe shall be magnetic particle tested for a distance of 4 inches (102 mm) on each end of the pipe. Inspection shall be done on both the inner and outer surfaces of the pipe.

11 Brace end stubs and other tubulars fabricated from material Type II or II-X.

 

12 All tubulars not covered by Notes 9 and 11.

 

13

With prior Purchaser acceptance, ultrasonic inspections may be substituted for radiographic inspection of web splices, flanges splices, and flange intersections made offshore at the installation site.

14

Notwithstanding any other radiography requirements of codes or of this specification, the first five full penetration production welds completed by each welder shall be subjected to 100 percent testing by radiography or ultrasonics.

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Table 5:

Extent of Inspection for Hull Inspection Only 1,2,3 (1 of 3)

   

Percent of Total Weld Length

 

Visual

Ultrasonic

Magnetic

Radio

Particle

graphy

Location/Type of Weld

 

General Examination Requirements for All Steel Areas as Identified as Special or Primary on Structural Steel Drawings

       

1. Welded Connections

100

100

   

2. Butt Welds

100

10

4

100

100

3. T-Butt Welds

100

100

100

 

4. Window, cut-outs, and manway welds

100

100

   

after reinstatement

5.

Welded Connections and Splices not

100

 

10

5

 

other covered (Fillet and Groove Welds)

 

6.

Purchasers Option to UT examine

 

</=100 6

   

along weld cap for cracks

Examinations for Specific Components of Special and Primary Steel Areas

 

Fabricated Structural Pipe and Cones

       

7.

Longitudinal Weld Seams (including the

100

   

10

7

extreme ends) (Meeting API 2B

requirements)

8.

Longitudinal Weld Seams cut and

 

Ends 8 & 10

   

coped subsequent to original NDE of the

longitudinal Seam Welds

9.

Circumferential Weld Seams (Meeting

100

 

100

100

9

or exceeding API 2B requirements)

 

Plate Girders and Box Girders and Rolled Shapes (Additional examinations shall be performed as specified by Purchaser to define limits of unacceptable welding)

       

10. Flange Splices in Flange Shapes

100

100

100

 

11. Full penetration welds in flange to web

100

100

100

 

connections of fabricated girders

12.

Fillet weld flange to web connections

100

 

100

 

in plate girders and box girders

13.

Straight Beam Lamination checks of

 

10

   

flanges of plate girders for 4 in (101.6mm) each side of weld

Web Stiffeners

       

14.

Web Stiffener Fillet Welds including

100

 

100

 

weld termination points (e.g., cope holes)

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Table 5:

Extent of Inspection for Hull Inspection Only 1,2,3 (2 of 3)

   

Percent of Total Weld Length

 

Visual

Ultrasonic

Magnetic

Radio

Particle

graphy

15.

Full Penetration Welds of Stiffeners to

100

100

100

 

Flange/Web connections

16.

Straight Beam Lamellar Tearing.

 

100

   

Check of both stiffeners and flange surfaces - 4 in. (100 mm) each side of

weld

Ring Stiffeners and Bulkheads

       

17.

Fillet welds joining Stiffeners or

100

 

100

 

Bulkheads to tubular connections and ring stiffeners to flange, including terminations points (i.e., cope holes)

18.

Full Penetration welds in ring,

100

100

100

 

stiffeners, bulkheads, and their attachment points

19.

Straight Beam Lamination/Lamellar

 

100

   

Tearing Check of full length of base metal of full penetration weld attachment area

before and after attachment

Plate Girder, Box Girder, and Beam Intersections

       

20.

Welds in girder-to-girder, beam-to-

100

 

100

 

beam, and beam-to-girder intersections

21.

Full Penetration welds in girder-to-

 

100

   

girder, beam-to-beam, and beam-to-girder intersections

22.

Straight Beam Lamination/Lamellar

 

100

   

Tearing Check of full length of base metal area under tee-butt welds in girder-to- girder intersections, both before and after welding

Truss and Tubular Joint Connections

       

23.

Welds in chord-to-web connections

100

 

100

 

and tubular joint connections, including backup rings, stiffeners, and other joint

stiffening

24.

Full Penetration welds in cord-to-web

100

100

100

 

connections and tubular joint connections,

including ring stiffeners and other joint stiffening

25.

Straight Beam Lamination/Lamellar

 

100

   

Tearing check of base metal area under full penetration connection welds and chord end of brace welds after completion of welding

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Table 5:

Extent of Inspection for Hull Inspection Only 1,2,3 (3 of 3)

   

Percent of Total Weld Length

 

Visual

Ultrasonic

Magnetic

Radio

Particle

graphy

Padeyes and Padears

       

26.

Straight Beam Lamination/lamellar

 

100

   

tearing check to be performed of structure based material for full length of padeye or padear contact area before welding

27.

Welds in padeye and padear and in

100

 

100

 

the attachment weld of padeye and padear to structure. (Partial Penetration

and Fillets)

28.

Full Penetration welds in padeye/

100

100

100

 

padear and full penetration attachment of

padeye/padear to structure

Extent of Nondestructive Examination of Secondary Category Steel

       

29. All Fillet, Butt, and Groove Welds

100

 

20

10

 

30. Full Penetration Butt Welds

 

10

11

   

1 Inspection and NDE Coverage are identified as “Special”, “Primary” and “Secondary” as defined in FFS-SU-5160-A.

Extent of NED and/or acceptance requirement to be applied is dependent on joint loading type, type of weld, and welding process used.

*

When drawings do not identify the structural category, the Supplier shall obtain clarification from Purchaser or the Design Engineer regarding the NDE levels to be applied.

*

*

Every assembly, component, connection, and material is subject to visual and/or dimensional inspection and/or

NDE. As a minimum, inspection and NDE shall be performed at the point during fabrication, outlined in Table 6.

For each weld, applicable spot tests shall be evenly distributed over that weld’s length, unless specified otherwise in Table 5. Partially inspected welds shall included ends as a minimum.

3 When reference is made to UT, RT may be substituted for weld joints with a thickness less than or equal to 0.4 in. (10mm). RT may be substituted for UT for weld joints greater than 0.4 in. (10mm) and less than 1 in (25 mm) with the prior acceptance of the Purchaser.

4 If UT detects unacceptable defects missed by 100% RT, then 100% UT to be performed on concerned weld.

5 PT may be substituted for MT when approved by Purchaser.

 

6 45 degrees, 4 MHz probe – Scanning shall be once in each direction covering full weld width. Sensitivity to be to ASME V scanning sensitivity +6 dB. Any Indications to be reported.

7 100% UT may be substituted for 100% RT.

8 Min Length 6 in. (150mm) each end of each pipe or cone. Purchaser may also specify two additional 12 in, (300mm) length locations of each pipe or cone seam.

9 100% UT can be substituted for 100% RT.

10 Extent of 20% MT Examination.

* For welds greater than 3 feet (1 m) in length, this shall comprise 20% of the length of each weld

 

* For welds 3 feet (1 m) and less in length, this shall comprise the full length of one weld in every five similar welds.

11 Extent of 10% UT Examination.

* For welds greater than 3 feet (1 m) length this shall comprise 10% of the length of each weld.

 

* For welds 3 feet (1m) and less in length, this shall comprise the full length on one weld in every ten similar welds.

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Table 6:

Type of Inspection (General) for Hull Structures (FPSO/FSO)

 

Fabrication Stage

 

Visual

Dimensional

NDE

Fit up for welding

 

X

X

 

After back gouging

 

X

   

On completion of welding

 

X

X

X

After removal of defects, prior to repair welding

 

X

X

X

On completion of repair welding

 

X

X

X

After toe grinding

 

X

X

X

After removal of temporary attachments

 

X

X

X

Table 7:

Base Metal Flaw Acceptance Level (Hull Components Only )

 
     

Minimum NDE

Examination Type

Inspection

Procedure

Acceptance Criteria

 

Operator

Qualification 1,2

Ultrasonic (straight beam for laminations)

AWS D1.1 Section 6, Part F or API RP 2X

Any base metal indication at welded connection, determined via UT to be a lamination of transverse dimensions greater than 0.12 in. (3mm) and/or a length in excess of 1 in. (25 mm), and which exhibits a 50% or greater loss in back reflection, shall be rejected. It shall be reported to the engineer for disposition

ASNT Level II

Ultrasonic (straight beam for lamellar tears)

AWS D1.1 Section 6, Part F or API RP 2X

Any base metal indication at welded connection, interpreted as a lamellar tear, shall be rejected. 3

ASNT Level II

1 Or Purchaser accepted equal. 2 Supplier shall submit current updated certifications of NDE operators to Purchaser for review. 3 Purchaser shall be notified and specific review of the repair shall be obtained prior to starting the repair.

5.1.2 Maximum Weld and Base Material Flaw Size

The acceptable maximum weld flaw size for each area of the structure shall be in

accordance with Table 2 and Table 7 for base metal examinations for hull structures

5.2 Inspection Procedures

5.2.1 NDE Procedures and Operator Qualifications

1. NDE methods, acceptance criteria, and operator qualifications shall be in accordance with Table 2.

2. Supplier shall submit the NDE procedures to Purchaser for acceptance.

5.2.2 Stages of Inspection

1. As a minimum, the stages of inspection of welded joints by Supplier shall be as specified in the specifications.

2. Hold points or release points shall be agreed to by Purchaser and Supplier prior to assembly, welding, NDT, and painting of platform components.

3. Inspection at fit-up prior to first pass shall be visual and dimensional.

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4. Inspection following root pass or back gouging shall normally be visual only, unless one or more of the other techniques described in Section 5.5.2 are required to explore the extent of visually observed flaws, or unless previous production performance indicates that unacceptable flaws may be present.

5. Inspection at weld completion shall be carried out in accordance with Table 4 and Table 5.

6. With the exception of the shop fabrication of tubular cans, welds shall be nondestructively examined no sooner than 48 hours after welding, unless otherwise authorized by Purchaser.

a. In the case of welds whose inspection is critical to the fabrication schedule, exceptions to the 48-hour wait may be made on a case-by-case basis.

b. Higher temperature preheat or maintaining preheat for a bake period after welding must be done when exceptions are granted.

c. Supplier shall submit individual exceptions with the reason for minimizing delay and the proposed preheat procedure for Purchaser representative acceptance prior to the making of the subject weld.

7. If difficulty is experienced in evaluating defects revealed by radiography, ultrasonic testing also shall be used to facilitate interpretation or vice versa.

8. Inspection after blasting and/or priming shall be visual.

5.2.3 Weld Profile Control

1. For tubular connections:

a. Where controlled weld profiling has been considered in the fatigue analysis by the use of the S-N curve X, Section 5.4 of API RP 2A-WSD, a capping layer shall be applied so that the as-welded surface merges smoothly with the adjoining base metal and approximates the concave profiles shown in API RP 2A-WSD, Figure 11.1.3.

b. Fatigue-critical connections where the X curve is used for design shall be clearly noted on the design drawings.

c. For tubular joints requiring weld profile control, the weld toes on both the brace and chord side shall receive 100 percent magnetic particle inspection (per Table 4).

2. For non-tubular connections:

a. Weld profiles shall comply with AWS D1.1-2002, Section 5.24 and Figure 5.4.

b. Final grinding marks shall be transverse to the weld axis.

5.2.4 Arc Strikes and Temporary Weldments

1. Purchaser may require that any welder who continually arc burns the material be removed from the work by Supplier.

2. Arc strikes not covered by subsequent weld passes shall be ground out and repaired as necessary in accordance with a procedure acceptance by Purchaser, and inspected by magnetic particle technique examination (MT).

3. After temporary attachments are removed, the welded areas shall be ground smooth and inspected by MT before coating.

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5.3 Cleaning and Repairing of Pipe Ends

1. Immediately prior to aligning pipe for welding, the beveled ends of each joint and the area immediately adjacent to the weld shall be thoroughly cleaned of paint, rust, mill scale, and dirt by accepted methods to avoid defects in the completed welds.

2. If the ends of pipe are dented so that the ends cannot be correctly aligned and, in the opinion of Purchaser representative, the dent is minor and the steel not stretched, severed, split, or the strength of the steel endangered, the pipe may be straightened with a jack or properly applied impact bronze-faced sledge or flatter.

3. When weld-through primers are used, the weld bevel and adjacent area shall be thoroughly cleaned (by grit blasting, grinding, power buffing, or Purchaser-accepted equal) prior to primer application.

5.4 Tests

5.4.1 General

1. Supplier shall furnish all necessary labor and equipment for the transportation and preparation of pipe, plate, and other materials for testing.

2. Supplier shall be responsible for the cost of all downtime associated with the testing of

welds.

5.4.2 Qualification of NDT Personnel

1. NDT personnel shall have the qualifications required by Table 2 and shall be subject to Purchaser acceptance.

2. Purchaser reserves the right to retest and reject any and all NDT personnel at any time.

5.4.3 Welding Samples

1. Purchaser reserves the right to test any welding samples as necessary to verify the quality of the work.

2. Supplier shall be responsible for the cost of cutting and replacing samples found to be

defective.

3. Purchaser shall be responsible for the cost of cutting and replacing samples found not to be defective.

5.5 Quality Conformance Inspections

5.5.1 General

1. This section defines the minimum technical requirements for the inspection of offshore platform fabrication.

2. Supplier shall inspect all work during fabrication.

a. Sufficient inspections shall be made by Supplier to ensure that the materials, fabrication, and testing comply in all respects with the requirements of this specification. Supplier shall issue an Inspection and Test Plan (ITP) a minimum of three months prior to start of fabrication.

b. Inspections by Purchaser shall not relieve Supplier from responsibility for implementing any quality assurance procedures (included in ITP) necessary to ensure that the requirements and intent of this specification are satisfied.

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3. Purchaser shall notify Supplier before construction begins of the stages of fabrication at which special examinations shall be made.

a. Supplier shall give at least 24-hour notice to Purchaser before each stage is reached.

b. Purchaser shall, however, have the right to examine work at any stage, and to reject defective material or workmanship whenever found.

4. Supplier shall provide safe Purchaser access to the fabrication facility at all times during work in progress.

a. Purchaser shall be at liberty to inspect the fabrication at any stage and to reject any part not complying with this specification.

b. When in the opinion of Purchaser, any section requires inspection, Supplier shall thoroughly clean the section of all excess and waste materials (such as sand, slag, or welding electrodes) and allow sufficient time for the section to be properly inspected.

5. Supplier shall have copies of the latest edition of the specifications and codes referred to in this specification, and make them readily available to inspection personnel involved in this project.

6. Supplier shall furnish, install, and maintain in a safe operating condition any scaffolding, ladders, walkways, and lighting necessary for safe and thorough inspection by Purchaser.

5.5.2 Methods of Nondestructive Inspection of Welds

The following are methods of nondestructive inspection of welds:

1. Visual Inspection (VT)

a. All welds shall be visually inspected at each of the stages listed in Section 5.2.2

b. Weld profile requirements shall be in accordance with Section 5.2.3.

2. Radiographic technique for welding inspection (RT)

a. Supplier shall submit the radiographic examination procedure to Purchaser for acceptance.

b. Supplier’s radiographic examination procedure shall be capable of detecting the weld flaws permitted by Table 2 and shall comply with the requirements of AWS

D1.1.

c. Cutting of holes for insertion of radiographic or x-ray sources shall not be carried out without Purchaser acceptance.

3. Ultrasonic Examination (UT)

a. Supplier’s ultrasonic examination procedure shall be submitted to Purchaser for acceptance.

b. As a minimum, Supplier’s procedure shall be capable of detecting the weld flaws permitted by Table 2 in all welds, including joint stub to tubular welds.

4. Magnetic Particle (MT) and Liquid Penetrant (PT) Inspection

Note

Supplier shall submit the selected inspection procedure to Purchaser for acceptance.

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5.6 Welding Repairs

1. A weld repair specification, including the method for removal of defects, preparation of weld area, subsequent nondestructive testing, and the minimum and maximum repair length/depth shall be prepared by the Supplier and submitted to Purchaser for written acceptance.

2. The weld repair specification shall be accepted before any welding is performed.

3. Supplier shall repair (in accordance with the accepted welding repair specification) or replace (at no expense to Purchaser) all welds made by Supplier that do not meet the requirements of this specification or the appropriate codes and standards.

4. Supplier shall be responsible for the cost of testing the repaired portion of the weld.

a. Welds shall be 100 percent visually inspected and nondestructively examined, in accordance with all of the NDE requirements for the original weld.

b. Additionally, for a repair of length “L,” the original weld shall be subject to a repeat NDE for a distance of 0.5L from each extremity of the repair. If further unacceptable defects are discovered during the additional NDE, the entire weld shall be re-examined.

5. Supplier shall obtain Purchaser acceptance prior to attempting any weld repairs or removal of defects except those in the cover pass (cap repairs).

6. If, in Purchaser’s considered opinion, the proposed repair of a defect would be either non- productive or would be detrimental to the completed facility, Supplier shall not repair the defect but cut out the weld and redo the work.

7. For all repairs to welds in Type I, I-X, II, and II-X steels, the repair procedures shall be

qualified.

8. Application of the repair procedures shall be limited by the same essential variables as specified in Section 4.3.3 for all other welding procedures including item 10

9. The following is recommended for repair welding procedure qualification test coupons on tubular members (qualification on tubular members qualifies for plate repairs). Other proposals may be submitted to Purchaser for acceptance.

a. One coupon is required for each cycle of weld repair.

b. Three tubular diameters or 24 inches (610 mm), whichever is less, is required on each side of the joint to simulate member restraint. If plate coupons are proposed to Purchaser, sufficient restraint must be added to the repair qualification coupon assembly.

c. The tubular member test position shall be 5G with vertical up weld progression.

d. Weld repair areas and mechanical tests shall be taken at the 3 o’clock or 9 o’clock positions.

e. The original weld shall be removed to 50 percent of the coupon thickness by gouging or grinding.

1)

The location of the excavation area shall include base metal and weld metal of the first weld (or first repair weld).

2)

The centerline of the excavation shall be at the approximate quarter point of the original weld (or first repair weld).

Structural Welding and Inspection for Offshore Platforms

FFS-SU-5216-A

f. Repair welding procedure qualifications shall include a microhardness traverse of the HAZ, repair weld metal, and original weld metal.

1)

Traverses shall be made 0.04 inches (1 mm) below the O.D. surfaces and at mid- thickness that includes repair weld metal depth. (See Figure 1.)

2)

Hardness impressions shall be spaced 0.08 inches (2 mm) apart except for the HAZ area where spacing shall be 0.04 inches (1 mm) apart.

3)

Hardness values greater than 325 Vickers using a 22 lb (10 kg) load, are not acceptable and shall require a new repair procedure qualification.

4)

Supplier shall furnish test data to Purchaser representative for acceptance.

g. Charpy V-notch impact testing of HAZ, repair weld metal, and original weld metal shall be required on all repair welding procedure qualifications.

1)

Testing shall be in accordance with AWS D1.1 Part D, except that notch locations shall be at the repair weld centerline, fusion line (at base metal and at original/repair weld dilution zone), FL+1 mm, FL+3mm, and FL+5 mm.

2)

Acceptance criteria for repair weld metal, original weld metal, and HAZ specimens shall be the same as Section 4.3.3, item 13.

3)

CTOD testing of repair weld metal is not required if weld metal CTOD testing has already been performed provided the consumable brand and place of manufacture has not changed.