REQUIREMENT FOR GOLDEN WELD

1.0 INTRODUCTION
Final butt welds connecting components which have been successfully
tested may not be pressure tested provided it is demonstrated that pressure
test can’t be practically performed. The welding joint shall be considered a
golden joint, for that hydrotest is not applicable.

1.1 SCOPE
- This document describes the general requirement for golden welds
application on pipe spools with butt weld connection.
- This document is only applicable to a connection of straight length of
pipe to another length of pipe

1.2 APPLICABLE CODE AND STANDARD

2.0 PROCEDURE
2.1 GENERAL
- Approved Welding Procedure Qualification Record (WPQR) No. and
Approved Welding Procedure Specification (WPS) No. Shall be used for
the welding process.
- Welders shall be qualified for the particular procedure to which they are
welding in accordance with the requirement of ASME B31.3 All welding
electrodes used in production welding shall be as per the approved and
Qualified Welding Procedure.
- Conformance certificates shall be obtained for all welding electrodes
used in production welding.
- All production welding shall be witnessed by the Contractor’s welding
Inspector ( Certified CSWIP 3.1 or AWS-CWI) and Shell Inspector.
- Where it is necessary to remove coatings, it shall be conducted very
carefully in such a way that no damage or dent shall happen to the pipe
by using hammers and cutting tools.
2.2 WELDING
2.2.1 EDGE PREPARATION
- During the edge preparation, ensure that equipment used shall cause
no detrimental metallurgical effects to the edges to be welded.
- Carry out UT lamination check 150mm minimum beyond the proposed
weld location in line with the procedure ASTM E 213.
- After UT lamination check, carry out 100% MPI (wet method) on same
150mm minimum beyond weld location and on the bevelled edges of the
pipes in line with ASTM E 1444.
- The bevelled faces shall be free from planar defects, tears, moisture,
scales, rust, paint, grease and other matter that may be detrimental to
the weld.

2.2.2 EXTERNAL FIT-UP

- Ensure that longitudinal seams of adjacent pipes are located in the top
120o of the pipe circumference and with an offset of a minimum distance
on the circumference of half pipe diameter. The longitudinal seams of
adjacent pipes shall be offset by a minimum angle of 90 o or 250mm –
whichever gives the smaller offset.
- The adjoining ends of the pipes will be aligned with lifting equipment
using an external line-up clamp, to avoid tack welding in the groove and
to optimize alignment.
- The joint fit-up shall be checked to ensure that the root gap is within
the tolerance specified in the approved WPS. The required root gap shall
be attained by driving steel spacing tools into the joint between the
pipes.

2.2.3 WELDING (MANUAL) OPERATION

- Measurement of pre-heating shall be conducted before welding.
- Maintenance of preheat temperature and inter-pass temperature shall
be strictly monitored and recorded.
- Welding, by qualified welders only, shall be executed strictly in
accordance with the approved WPS.
- For Butt welding of piping components uniform root gaps as approved
WPS shall be provided.
- SMAW process shall be employed for the welding process
- Weld repair shall be implemented in accordance with the approved
repair WPS and shall be approved by s Inspector before any repair
commences.
- Prior to welding, the pipes shall be pre-heated with a propane gas
burning torch to a pre-heat temperature that is specified in the
approved WPS. The pre-heating is to remove moisture and other factors
that may affect the mechanical properties of the weld and also the pre-
heating temperature shall cover an area of at least 75mm width on
either side of the weld and shall be maintained over the full length of the
weld until welding is completed.
- Each run of weld metal shall be thoroughly cleaned with hand or power
tools before a further run is applied.

3.0 NON DESTRUCTIVE EXAMINATION (NDE)

- A qualified Inspector (Minimum CSWIP 3.1 or AWS-CWI) must
supervise all the welding operations to confirm the visual condition of
the weld at all stages of completion
- Carry out visual inspection of the root with a pen light to ensure defects
such as lack of root fusion were not present.
- During welding after ROOT PASS and HOT PASS, MPI (Dry Powder
Technique) shall be conducted.
- The Inspector shall ensure proper cleaning and slag removal between
passes
- After completion weld, 100% X-Ray shall be performed on the Butt
Weld.
- After X-Ray completion, carry out 100% UT and MPI (wet method) on
the Butt Weld.
- For all NDT checks, reports shall be issued as soon as Testing is
completed for SPDC review and approval

4.0 QA/QC DOCUMENTATION

The Contractor shall submit the following document to SPDC QA/QC and
Verification Team for review and approval.
- Approved WPS used
- Golden welds application check list (see attached) endorsed and
signed by the Contractor Welding Inspector and SPDC Site Inspector.
- Records of welding parameters and batch numbers of consumables.
- Visual and NDT reports