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TECHNICAL CENTER & PROJECTS (TC&P)

TECHNICAL CENTER (Engineering)

ENGINEERING SPECIFICATION

Specification for “Pin Brazing”

DOC. NO. 30-99-37-0015

THIS DOCUMENT IS INTENDED FOR USE BY ADNOC ONSHORE AND ITS NOMINATED
CONSULTANTS, CONTRACTORS, MANUFACTURERS AND SUPPLIERS.

Project No.: MASTER Rev : 1 Page : 1 of 26


ENGINEERING SPECIFICATION
Specification “Pin- Brazing”

Document No. : 30-99-37-0015 Rev :1


Project No. : MASTER Page : 2 of 26

Document Control

Control Document Information:


Document Owner Technical Centre
Document Author Mohamed Fawzy Abou El-Azm , (SSW), TC(ENG)
Document Custodian Draughting Team
Document Security Code 5 – Public
Document Number 30-99-37-0015

This is a controlled document and being maintained on electronic media. Any hard copies made
are considered uncontrolled and may not be the latest version. Any employee of ADNOC
Onshore, and its authorised 3rd Parties, are responsible for ensuring they are referring and using
the latest version of the record and conform to the Copyright information.
Specialist Cathodic Protection, Engineering Support

Name Signature Position Date

Prepared By M.Fawzy SSW/M


Reviewed By S. Al Ankar ESM

Endorsed By A.A. Al Rashedi VPTC

Copyright © 2017 ADNOC Onshore


(The Abu Dhabi Company For Onshore Petroleum Operations Ltd – Trading as ADNOC Onshore).

All rights reserved. No part of this publication may be reproduced, distributed, transmitted in any
form or by any means, including photocopying, recording, or other electronic, mechanical methods,
without the prior written permission of the owner.

For ADNOC Onshore internal permissions please refer to the Delegation of Operational
Authorities.

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ENGINEERING SPECIFICATION
Specification “Pin- Brazing”

Document No. : 30-99-37-0015 Rev :1


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The table below is a brief summary of the most recent revisions to this document. Details of all
revisions are held on document by the issuing department.

Sr. Rev.
Date Description of revision
No. No.

1 0 June 2011 First Issue

December ISSUED AS ADNOC ONSHORE STANDARD


2 1
2017 SUPERSEDES ES 30.99.53.0015

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ENGINEERING SPECIFICATION
Specification “Pin- Brazing”

Document No. : 30-99-37-0015 Rev :1


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TABLE OF CONTENT
1. GENERAL ................................................................................................................................................ 5
1.1. INTRODUCTION ...................................................................................................................................... 5
1.2. Scope ....................................................................................................................................................... 5
1.3. General Requirement ............................................................................................................................. 6
1.3.1. PIN-BRAZING .................................................................................................................................. 6
1.3.2. CABLE CONNECTION TO PIPELINE ............................................................................................. 7
1.3.3. “PIN-BRAZING” TO EXISTING PIPELINES ................................................................................... 8
1.4. DEFINITIONS, GLOSSARY AND ABBREVIATIONS............................................................................. 9
General Definitions: ...................................................................................................................................... 9
1.5. Abbreviations ....................................................................................................................................... 12
1.6. APPLICABLE STANDARDS, SPECIFICATIONS AND CODES .......................................................... 13
2. HEALTH, SAFETY AND ENVIRONMENT ............................................................................................ 14
3. QUALITY ................................................................................................................................................ 14
4. PIN BRAZING QUALIFICATION REQUIREMENTS ............................................................................ 14
5. Test Sample and No. of Tests ............................................................................................................. 16
6. Qualification of operators for “Pin-Brazing” ..................................................................................... 18
7. “PIN-BRAZING” PROCEDURE ............................................................................................................ 19
8. Pin-Brazing Performance and inspection .......................................................................................... 21
9. ANNUXURE: .......................................................................................................................................... 24

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1. GENERAL
1.1. INTRODUCTION
This Engineering Specification (ES) stipulates the minimum requirements for “Pin –Brazing”
in the context of installation of cathodic protection equipment for production facilities in
ADNOC Onshore.

“Pin –Brazing” connections shall be used for existing pipelines. “Pin-Brazing” shall also be
applicable for new pipelines which are non-piggable. Welded pads can be used for
piggable as well as non-piggable lines. However, only welded pads are to be used for
piggable lines as these provide the reference points during the MFL survey.

Welded pads installation and welding shall be incompliance with DOC.Ref.No.30-99-00-


0041-2 (latest revision).

Conditions under which “Pin-Brazing” can be used for installation of CP equipment are
stated in ES 30-99-37-0001.

1.2. Scope

“Pin-Brazing” shall be used primarily for connecting CP to structures. “Pin-Brazing” shall not
be used for the cable connections which involve flow of DC current e.g. CP drain cable.

No brazing or welding to pressurized pipeline or pressure containing equipment shall be


performed.

Contractor shall specify that all work related to anode installation shall be described in an
“Installation Procedure Specification (IPS)”; which shall include at least the followings:
 Specification of materials and equipment to be used, including certificates and
material data sheets.
 Receipt, handling and storage of anodes and materials for anode installation.
 Reference to brazing procedure specifications and qualification of personnel
carrying out brazing.

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 Inspection and testing of installed anode.


 Documentation of materials and inspection records.

All brazing/welding associated with anode installation shall be in compliance and qualified
according to the applicable construction specification and recognized standard. Only
qualified brazier (brazing operators)/ welders shall be used. In addition ASME IX could be
used as a supporting reference including:
 Article XI: Brazing General Requirements
 Article XII: Brazing procedure qualifications
 Article XIII: Brazing Performance Qualifications
 Article IV: Brazing Data

This ES shall be referred to in relevant Project documentation issued to the Consultants in


the design, construction and monitoring and maintenance of such facilities. This ES shall
also be used when any new pipelines (owned by ADNOC Onshore or any other Operator)
cross existing ADNOC Onshore pipelines and Foreign Service test facilities are installed at
the crossing locations.

1.3. General Requirement


1.3.1. PIN-BRAZING

Pin Brazing is used to ensure a safe electrical connection to different types of steel
structures in general and for pipeline in particular. This method is preferred usually because
its advantages including:
 minimum thermal effects on the steel because of low melting of solder (650° F or
345° C),
 Short heating time,
 Fast installation performance and versatility by the portable nature of the equipment.

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“Pin-Brazing” material shall be compatible with pipeline material. The penetration of brazing
metal into the pipeline shall not exceed 1 mm. The hardness of the base metal of pipeline
at the pin brazing location shall remain within the original pipeline requirement.

The “Pin-Brazing” shall either be direct braze type or threaded (M10 size) type, for each
cable connection a separate pin shall be used.

1.3.2. CABLE CONNECTION TO PIPELINE

The cable connection to pipeline shall be designed to ensure adequate mechanical


strength and electrical continuity while preventing damage to pipeline; therefore mechanical
and electrical tests are required to confirm performance and integrity.
Cable connections of “Pin-Brazing” shall not be carried out on bends or within 300 mm from
the welds. A separate “Pin-Brazing” connection shall be made for each cable. The
minimum separation between two connections shall be 300 mm.

All grades of cable connections shall be fully encapsulated to comply with the original
coating standards. Encapsulating materials shall be selected from ES 30-99-37-0005; a
holiday test shall be conducted before backfilling.

With application of cables connected to the structures through “Pin-Brazing” connections;


the cable shall be looped around the equipment/pipeline to avoid any damage to the
connection by cable pulling.

This document covers the procedure that shall be followed in the context of CP cable
connections in ADNOC Onshore pipelines/flowlines using pin brazing technique.

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1.3.3. “PIN-BRAZING” TO EXISTING PIPELINES

1.3.3.1. Pre-Job Requirement


For existing pipeline pin brazing is mandatory for “monitoring cable” while for “current
carrying cable” it is preferred to use welded pad; thus in case it is not possible to use a
welded pad connection to the existing pipeline, then pin brazing connection may be
allowed.
The connection shall be looped around the pipe to avoid damage to the connections by
accidental pulling of the cable.
 Live pipelines
Though “Pin-Brazing” is a safe technique, a caution needs to be exercised while
making the connections to existing live lines which shall be off-service and
subjected to all HSE relevant actions and precautions.

Brazing/welding not permitted to pressurised pipeline or pressure containing


equipment.

“Pin-Brazing” shall not be undertaken if the wall thickness of existing live pipeline is
less than 0.25” (6.35 mm).

UT with Zero probes shall be done to check actual existed thickness and lamination
for the area of “Pin-Brazing”.

In case; it is not possible to braze the pin to the existing pipeline due to safety
reasons, use of other technique such as conductive epoxy and a pad shall be
proposed (A bolt is welded to a pad and the pad is attached to the pipeline using
conductive epoxy); thus a concession request in terms of “Technical Deviation (TD)”
is required to be issued by Contractor/Vendor and escalated to ADNOC Onshore for
review and approval if viable.

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1.4. DEFINITIONS, GLOSSARY AND ABBREVIATIONS

The following definitions and abbreviations, used in this document, are defined below:

General Definitions:

Company: ADNOC Onshore

Consultant: The person or organisation appointed by the


Company for Front End Engineering / Detailed
Engineering of Pipeline / Structures

EPC The person or organisation appointed by the


Contractor: company for Engineering, Procurement and
Construction of Pipeline / Structures

Contractor: The person or organisation that supplies the


company with products or / and services.

Vendor/ The person or organisation that supplies the


Manufacturer: company with materials and/or equipment.

Pin Brazing A person qualified to undertake pin brazing


Operator: operations

User: The person or organisation that reads, and uses


the information, in this and other Specifications

Shall: Indicates a mandatory requirement

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Should: Indicates a recommendation.

May: Indicates a possible course of action.

1.4.1. Specific definitions:


 Cathodic protection: the process is to reduce or prevent corrosion of metal
structures in contact with an electrolyte by the flow of direct current from the
electrolyte into the structure surface.

 Drain point: the point on the structure or pipeline where the connection of the
negative terminal of the cathodic protection voltage source is made to conduct
(drain) the returning current from the structure or pipeline to the voltage source.

 Electrolyte: A liquid or the liquid component in a composite material in which electric


current flows by the movement of ions. For the purposes of this Specification
electrolyte shall indicate either soil and/or water.

 Foreign structures / pipelines : metal structures or pipelines, other than the structure
or pipeline under consideration, in contact with the same electrolyte as the structure
and which are or may become under the influence of the structure's / pipeline’s
cathodic protection system.

 Foreign structures / pipelines: may be owned by the Company or other companies


and may or may not be equipped with cathodic protection.

 Natural potential: the structure or pipeline to electrolyte potential measured when no


cathodic protection is applied and polarization caused by cathodic protection is
absent.

 "OFF" potential or Instantaneous “OFF” Potential : the structure or pipe to


electrolyte potential measured immediately after the cathodic protection system

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switched off and the applied electrical current stops flowing to the structure or
pipeline surface, but before polarization of the structure or pipeline has decreased.

 "ON" potential - the structure or pipeline to electrolyte potential measured while the
cathodic protection system is continuously operating.

 Pipeline: the pipeline or pipelines with associated equipment as defined in the


scope of the cathodic protection design contract.

 Pipe to soil potential: the difference in electrochemical potential between a pipeline


or foreign structure/pipeline and a specified reference electrode in contact with the
electrolyte. Similar terms such as structure to soil potential, pipe to electrolyte
potential, pipe to (sea) water potential are sometimes used as applicable in the
particular context.

 Stray currents - electrical currents running through the electrolyte, originating from a
foreign DC source, causing interaction with the corrosion and cathodic protection
processes of the structure. Stray currents may also originate from the structure's
cathodic protection system and act upon foreign structures / pipelines.

 Structure: The electrically continuous steel plant or equipment to be protected using


cathodic protection (not inclusive of pipeline).

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1.5. Abbreviations
AC: Alternating Current
Ag/AgCl: Silver/Silver Chloride as used for the Silver/Silver Chloride
type of reference electrode
CP: Cathodic Protection
Cu/CuSO4: Copper/Copper Sulphate as used for the Copper/Copper
Sulphate type of reference electrode
BPS: Brazing Procedure Specification
DC: Direct Current
DP: Drain Point
FBE: Fusion Bonded Epoxy (Coating)
FEED: Front End Engineering Design
FED: Front End Design
GA: General Arrangement
ICCP: Impressed Current Cathodic Protection
IPS: Installation Procedure Specification
IIW: International Institute of Welding
IPS: Installation procedure specification
ITP: Inspection and Test Plan
Pcm: Parameter for Crack Measurement
PE: Polyethylene (Coating)
PP: Polypropylene (Coating)
PVC: Poly Vinyl Chloride
Q/T: Quenched and Tempered
RE: Reference Electrode
STP: Standard Test Point
TMCP: Thermo Mechanically Controlled Process
WPS: Welding Procedure Specification

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1.6. APPLICABLE STANDARDS, SPECIFICATIONS AND CODES


The following Standards, Specifications and Codes shall be applied in accordance with
the requirement of this specification. All listed documents shall be of the latest issue. In the
event of any conflicting requirements ADNOC Onshore ES shall prevail.

The standards can be listed as under:

1.6.1. ADNOC Onshore Engineering Specifications

ES-30.99.37.0001: Cathodic Protection Design

ES-30.99.37.0003: Cathodic Protection Materials and


Equipment

ES-30.99.37.0005: Cathodic Protection Construction,


Installation, Testing and
Commissioning

ES-30.99.37.0013: Painting and coating of New


Equipment

ADNOC Onshore procedure HSE Manual Vol 10

1.6.2. International Standards:

National Association of Corrosion Engineers (NACE) Standards

SP-0169: Control of external corrosion on underground


or submerged metallic piping system

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2. HEALTH, SAFETY AND ENVIRONMENT


Contractor / Pin Brazing Operator shall be responsible for safety of personnel, equipment
and environment. The installation and operating procedures shall ensure safe working
practices. All relevant requirements of ADNOC Onshore Health, Safety and Environment
(HSE) procedure manual shall be met. Contractor / Pin Brazing Operator shall be familiar
with local safety rules and practices and implement these in the work. Necessary work
permits shall be obtained as per Company procedures prior to commencement of pin
brazing activities.
Pin brazing operator shall wear protective equipment during all site activities.

3. QUALITY
All testing laboratories and/or NDT subcontractors utilised in qualification or production pin-
brazed joints shall be certified and accredited to ISO 17025.

NDT such as PT,MT ,and UT shall be performed by qualified as per PCN Level II or ASNT
ACCP level II (at least) ,all visual inspection shall by conducted by visual inspectors have a
valid qualification certification to AWS CWI or CSWIP 3.1.
Inspectors
Essential variables for “Pin-Brazing”
The following shall be considered as essential variables for “Pin-Brazing” qualification

4. PIN BRAZING QUALIFICATION REQUIREMENTS

4.1. Essential variables for “Pin-Brazing”

The following shall be considered as essential variables for “Pin-Brazing” qualification:

i. Base material grade and chemical composition:


 A change in material grade
 A change in the supply condition (TMCP, Q/T, normalized or hot rolled)
 Any increase in Pcm of more than 0.02%, IIW Carbon equivalent (CE)of more than
0.03 and C content of more than 0.02% for C-Mn line pipe.

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ii. Technology :
 The process or technique of “Pin-Brazing”
 Brand name of the technology provider of “Pin-Brazing” including any of material
consumables (Type, composition, make and model of brazing pin), and equipment
(Make, type and model)
 Cable dimension
 Range of equipment settings for “Pin-Brazing”
 The equipment earth connection area
 Method for cleaning and preparation of cable ends and cable attachment area.
 The minimum preheat or working temperature

4.2. Qualification of procedures for “Pin-Brazing”

1. Full details of the technique used and associated equipment shall be submitted to the
Company prior to prior to Qualification of procedure

2. Qualification for “Pin-Brazing” shall be performed on test samples which are


representative for the size and thickness of the production base material and the
number of test pieces shall be minimum five (5) and sufficient to obtain all required
tests.

3. The chemical composition of the test pieces shall be representative for production
conditions and be selected in the upper range of chemical composition.

4. Brazing Procedure Specification (BPS) shall be qualified prior to any “Pin- Brazing.

5. “Pin-Brazing” operator once qualified for a particular type / size of pipeline does not
have to be re-qualified for similar pipe.

6. All pre-qualified operators need to be pre-qualified again after an interval of three years
from previous qualification. This period shall be reduced to one year if the operator
does not carry out any “Pin-Brazing” after the pre-qualification or there is no “Pin-
Brazing” activity for one year.

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5. Test Sample and No. of Tests

The nominated pin brazing operator shall pin-braze five threaded studs to a sample pipe.
In case of existing pipe where it is not possible to get the exact pipe equivalent pipe sample
(has equivalent chemical and mechanical properties under the same production standard )
shall be used for pin brazing qualification test. The connections shall be 100 mm apart.

The type and number of destructive tests for procedure qualification are given in the below
(Table-1) of “Qualification of Procedures for Pin Brazing” with methods and acceptance
criteria specified here after:

Test Joint Minimum number of each specified test

Electrical
Thickness of Mechanical Copper Pull
Resistance Hardness
Base material Strength Penetration Test
Test

All Five (5) Five (5) Five (5) Five (5) Five (5)

Table-1

The numbers of tests refer to the total number of tests from all pieces.
Hardness test shall be made on specimens selected for copper penetration measurements.
5.1. Electrical Resistance
 The connections shall pass a 500 V megger test before being subjected to any
other test.
 Electrical resistance of the joint shall not exceed 0.1 Ohm.
5.2. Mechanical Strength
 Each test brazing shall be securely fixed and tested with a sharp blow from 1.0 kg
hard rubber headed hammer.
 The brazing shall withstand the hammer blow and remain firmly attached to the
base material and show no sign of tearing or cracking.

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5.3. Copper Penetration


 Two test specimens shall the sectioned transverse to the anode electrical lead and
2 test specimens parallel with the anode electrical lead.
 The specimens shall be prepared and etched for metallographic examination. The
examination shall be performed at a magnification of 50X.
 The macro sections shall be visually examined under optical magnification to verify
that there is no lack of fusion at the braze.
 The fusion line of the brazing/weld shall at any point not be more than 1.0 mm
below the base material surface of the pipe.
 Intergranular copper penetration of the braze material shall not exceed 0.5mm
beyond the fusion line when examined at 50X magnification.
5.4. Hardness
 The macro sections shall be subjected to a hardness survey using a Vickers 10 Kg
load (HV10).
 HV10 hardness tests shall be made on each of the specimens for copper
penetration measurements.
 For steel; ISO 6507 shall be used for Vickers scale while ISO 6506 for Brinell scale.
 Indentations shall be performed on a traverse line across the weld/brazing zone.
The traverse shall consist of minimum 6 indentations:two in the heat affected
zone(HAZ) on each side of the weld/brazing, two in the HAZ under the weld/brazing
and two in the base material on each side of the weld/brazing. The HAZ
indentations shall be made as close to the fusion line as possible. The spacing
between the impressions shall be as per the applied ISO standard or 0.5mm which
is lower.
 The maximum hardness shall not exceed the limits given in the linepipe
specification and pipeline specification as applicable for the intended service and
type of material. In addition the acceptable limits of ISO 15156 for the applicable
material. For C-Mn and low alloy steels, the hardness shall not exceed 248 HV10.
 A colour photo-micrograph, including the hardness survey, shall be included with
test results.

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5.5. Pull Test


 The test specimen shall be mounted in a tensile testing machine and secured in the
cable in one end and the base material in the other end.
 Force shall be applied until the specimen breaks. The specimen shall break in the
cable.
 Three connections shall be tested by loading the cable in the direction of lay.
 The joint shall withstand a load of 100 kg when tested on an approved tensile
testing machine. The specimen shall break in the cable.
 The test shall be witnessed by company’s representative and the results shall be
submitted for approval.
 “Pin-Brazing” shall proceed after the written approval has been received for the
“Pin-Brazing” procedure and the test results.
 Pin-Brazing” Qualification records shall be as per the format under (appendix – A).

6. Qualification of operators for “Pin-Brazing”

 In general; all personnel involved in “Pin-Brazing” related tasks shall have adequate
qualifications and understanding of brazing technology. The qualification level shall
reflect the tasks and responsibilities of each person in order to obtain the specified
quality level.
 The qualification test shall be carried out with the same equipment to be used
during production welding, and should be at the actual premises, i.e. work shop,
yard, and marine vessel. Use of other premises shall be specially agreed.
 “Pin-brazing” Operators that have performed a qualified procedure test are thereby
qualified.
 Other “Pin-brazing” operators shall each complete three test pieces made in
accordance with the procedure specification under realistic conditions before
carrying out operation work. Each test piece shall pass the test for electrical
resistance and mechanical strength according to the table-1 of “Qualification of
Procedures for Pin Brazing”, in addition to visual inspection and DPT.

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 “Pin-Brazing” operator once qualified for a particular type / size of pipeline does not
have to be re-qualified for similar pipe.
 All pre-qualified operators need to be pre-qualified again after an interval of three
years from previous qualification. This period shall be reduced to one year if the
operator does not carry out any “Pin-Brazing” after the pre-qualification or there is
no “Pin-Brazing” activity for one year.

7. “PIN-BRAZING” PROCEDURE
7.1. General

 Connections shall be performed by “Pin-Brazing” technique supported by qualified


brazing procedure approved by ADNOC Onshore.
 “Pin-Brazing” shall only be carried out by personnel skilled, experienced, and
qualified in such joining technique and certified as per this specification.
 The anode cable attachments shall be located at least 150 mm away from any weld.
 For cable preparation cable cutters shall be used. The insulation shall be stripped
for the last 50 mm of the cable to be attached. The conductor core shall be clean,
bright and dry.
 Greasy and oily conductor cores shall be cleaned with residue free solvent or
dipped in molten solder. Corroded conductor cores shall be cleaned to bright metal
with brush or other means.
 If defects are found on any finished brazed joint, Contractor shall repair the defect
and pay all resulting expenses, including re-installation, excavation, re-insulation,
re-coating work,….,etc (as applicable)
 The following sections explain the steps involved in “Pin-Brazing” and test to be
done at site:
7.2. Drying
 The area where the “Pin-Brazing” shall be carried out shall be dry free from any
moisture, mist or humidity significant indications.
 Wet conductor cores shall be dried by rapid drying residue free solvent, alcohol or
hand torch.

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 Heating to remove humidity shall be carried out in certain cases such as mandatory
preheating by applicable specifications for pipeline construction and welding
requirements.
 “Pin-Brazing” under any circumstances may not be exposed to heat influences
above 100oC, e.g. during a subsequent application of hot-applied coating or rapping
or insulation.

7.3. Pin-Brazing Tools and Materials


 Contractor shall ensure that only equipment and material, correctly sized for the
work, are used.
 Consumables shall be available at site prior to commencement of installation
activities.
 “Pin-Brazing” procedure shall be referred to ensure that installation activities are
being carried out as per this specification and the applicable project requirement.

7.4. Cleaning of Pin-Brazing Area


 Prior to attachment of pin braze studs; the surface of the structure shall be
thoroughly cleaned. Grinded of the “Pin-Brazing” and earthling area until an even
and clean surface is achieved.
 The area of cable attachment, Pin-Brazing” and equipment earth connection shall
be cleaned for an area of minimum 50 mm to 550 mm. All mill scales, rust, grease,
paint, primer, corrosion coating, and dirt shall be removed and the surface prepared
to finishing degree St 3 according to ISO 8501-1. The surface shall be bright, clean
and dry when welding/brazing is started.
 “Pin-Brazing” shall be placed at least 300 mm from other brazed joints.
 Removal of 150 mm X 50 mm coating area from the top of the pipe, radius of all
corners being not less than 5 mm.
 Removal of any existed coatings should be carried out carefully by rasp for
example, especially for polyethylene or polymers in order to ensure the surrounding
coating is not lifted or damaged.

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 Removal of the pipeline primer epoxy coating is achieved by a light grinding, using a
grinder included in the kit of “Pin-Brazing”.
 The cleaned are shall have a smooth ellipsoid shape. Great care should be taken so
as not to produce any cuts or grooves on the surrounding coating.

8. Pin-Brazing Performance and inspection


8.1. Application
 The qualified “Pin-Brazing” procedure and supplier instructions of materials,
consumables & tools shall be strictly followed.
 The size of the “Pin-Brazing” pins and the ferrules shall be in accordance with the
supplier’s instructions, taking into consideration the size of the sleeves.
 After termination of the “Pin-Brazing”, the top shall be removed and the strength of
the “Pin-Brazing” shall be tested by hammering lightly on the side of the “Pin-
Brazing”.

8.2. Defective Pin-Brazing

 If the ferrule is not held against the steel and is in partial contact then the arc can
escape out of the gap and this will result in the side of the pin burning away. This
bond must be classed as defective and the bond reworked.

 If during the “Pin-Brazing” the operator moves the brazing gun, the pin will not braze
to the steel. This bond must be classed as defective and the bond reworked.

 Defective connections can be removed by hammer and any residual matter can be
cleaned with grinder.

NOTE:
 Prior to “Pin-Brazing”, UT Thickness Check shall be conducted for existing lines.

 UT Lamination checks shall be done on existing as well as new pipelines.

Security Code: 5 - Public


ENGINEERING SPECIFICATION
Specification “Pin- Brazing”

Document No. : 30-99-37-0015 Rev :1


Project No. : MASTER Page : 22 of 26

8.3. Tests on production job at site


Following tests shall be performed by quality and inspection staff operator at site to ensure
the integrity of each joint:

a) Megger Test
 The connections shall pass a 500 V Megger test before being subjected to any
other test.
 The electrical continuity shall be checked and measured according to a documented
procedure with an instrument capable of verifying an electrical resistance of 0.1 ohm
(maximum) such as using of an Ohmmeter.

b) Hammer Test
 The connections shall be mechanically tested by tapping the lug with a sharp blow
with a 1 Kg hard rubber headed hammer.

c) NDE Examination
 The NDE scope shall be as a minimum visual inspection by qualified inspector with
CSWIP 3.1 or AWS CWI or equivalent
 Dye penetrant testing (DPT) for associated joints produced by “Pin-Brazing”; by
qualified NDE inspector holding PCN Level II or ASNT ACCP Level II.
 Brazed anode leads not meeting the requirements shall be removed and the
affected area shall be removed by grinding.
 Brazed anode leads that are attached directly onto pressure containing parts the
ground areas shall blend smoothly into the surrounding material. Complete removal
of defects shall be verified by local visual inspection and polishing and etching to
confirm removal of copper penetration. The remaining wall thickness in the ground
area shall be checked by ultrasonic wall thickness measurements to verify that the
thickness of the remaining material is more than the specified minimum.
Imperfections that encroach on the minimum permissible wall thickness shall be
classified as defects.

Security Code: 5 - Public


ENGINEERING SPECIFICATION
Specification “Pin- Brazing”

Document No. : 30-99-37-0015 Rev :1


Project No. : MASTER Page : 23 of 26

 All these tests and examinations shall be logged and reported in formal formats.
Subsequent to completed anode installation, compliance with drawings for anode
installation shall be confirmed.

8.4. Insulation and Corrosion Protection


The “Pin-Brazing” areas of the pipeline cable connections shall be insulated and protected
against corrosion incompliance with ES 30-99-37-0003 and ES 30-99-37-0005 specifically
and technical recommendations of “Pin-Brazing” supplier in general.

8.5. Documentation
The following documents list shall be progressively elaborated and issued, also shall be
part of the documentation handing over at completion of the warded scope of work;
 The Final location of anodes shall be documented on as-built drawings.
 Reports of Electrical continuity (verification measurements)
 Strength testing (light hammering) shall be reported and documented.
 All NDT inspection and NDT reports for visual inspection , PT,&UT.
 Brazing procedure specification (BPS) and its supporting procedure qualification
record (PQR)
 List of brazing operators (braziers) supported with their certification copies.
 Brazing equipment components list and all relevant data sheets and calibration
certificates
 Traceability sheets for all joints produced by “Pin-Brazing”
 Contractor may specify further requirements to anode installation documentation.

Security Code: 5 - Public


ENGINEERING SPECIFICATION
Specification “Pin- Brazing”

Document No. : 30-99-37-0015 Rev :1


Project No. : MASTER Page : 24 of 26

9. ANNUXURE:

A. Pin-Brazing Procedure Qualification Record

CP Vendor: Date:

Operator’s Name:
Test Connection No:

Equipment

Manufacturer: Type:

Equipment No:

Base Metal :

Pipe Diameter: Wall Thickness:

Coating :

Method of Pre – Cleaning:

Pin-Brazing Process and Type of Attachment

Cable Size:

Brazing Pin Type / Size (Threaded / M 10):

Volts: Duration:

Signature of Operator _______________________ Date ____________________

Signature of Engineer’s rep. ____________________ Date __________________

Electrical Resistance Test Results

Resistance Connection in Ohms:

Security Code: 5 - Public


ENGINEERING SPECIFICATION
Specification “Pin- Brazing”

Document No. : 30-99-37-0015 Rev :1


Project No. : MASTER Page : 25 of 26

Hardness Test Results

Sample No. ________________________________________________________

Depth HAZ __________________________

Braze penetration Hardness HV10 _____________________

Distance to Impression from last impression ______________________

Hardness HV10

Axis A
Axis B

Pull Test

Load ________________________

Point of failure ___________________________

Signature of test supervisor ___________________ Date ______________

Signature of Client representative_________________ Date _____________

Security Code: 5 - Public


ENGINEERING SPECIFICATION
Specification “Pin- Brazing”

Document No. : 30-99-37-0015 Rev :1


Project No. : MASTER Page : 26 of 26

B. Contractor Testing Information Form

Sheet No.___________
PROJECT
Report No. __________
OWNER ADNOC Onshore
MAIN CONTRACTOR
C.P. CONTRACTOR
APPROVED PIN
BRAZING OPERATOR
PIN-BRAZING TO PIPELINE

LOCATION
DATE OF PIN BRAZING
Pipe U/T test done Pin-Brazing as Hammer Resistance Remarks
Material / before pin- per approved Test Test
Thickness brazing procedure

REMARKS: _________________________________________
____________________________________________________
_________________________________________________________
COMPLETED BY CHECKED BY APPROVED BY
COMPANY
NAME
SIGNATURE
DATE

Security Code: 5 - Public