Professional Documents
Culture Documents
Rev
Date
Description
12/08
Initial release
Replaces CIV-SU-1.15-A (1997)
02/09
General revision
JLPY
CWAN
08/09
JLPY
CWAN
Author
Sponsor
CWAN
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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
5.0
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FFS-SU-5216-A
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
2.2
Purchaser Documents
FFS-SU-5160
FFS-SU-5215
RP 2X
Spec 2B
Spec 2H
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FFS-SU-5216-A
Spec 2MT1
Spec 2W
Spec 2Y
RP 2Z
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.)
E 165
E 709
E 1290
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
BS 7448-1
BS EN 10225
BS EN ISO 3690
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TERMINOLOGY
3.1
Acronyms
FFS-SU-5216-A
Definitions
JointIntersection 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-junctionPoint 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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FFS-SU-5216-A
Environmental Conditions
Welding material and procedures shall be suitable for the environmental conditions as specified in
AWS D1.1.
4.3
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-topass 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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FFS-SU-5216-A
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 manufacturers 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 Suppliers 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).
1) 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).
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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
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
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FFS-SU-5216-A
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:
Visual
Acceptance Criteria
AWS D1.1, Paragraph 6.9
Ultrasonic
Radiographic
ASNT Level II
Magnetic
Particle
ASNT Level II
ASNT Level II
Purchaser-accepted equal.
shall submit current updated certifications of NDE operators to Purchaser for review.
3Qualified in accordance with AWS D1.1, Paragraph 6.1.4.
4When accepted by Purchaser representative.
5For Hull Structures UT to Level A for both Cyclic and Non-Cyclic Service.
2Supplier
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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FFS-SU-5216-A
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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FFS-SU-5216-A
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
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:
Steel Type
I
I-X
II
II-X
III, IV, V,VI
Test Temp
40F (40C)
40F (40C)
0F (18C)
0F (18C)
32F (0C)
Minimum Average
25 ft-lbs. (34 J)
20 ft-lbs. (27 J)
30 ft-lbs. (41 J)
25 ft-lbs. (34 J)
25 ft-lbs. (34 J)
20 ft-lbs. (27 J)
30 ft-lbs. (41 J)
25 ft-lbs. (34 J)
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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FFS-SU-5216-A
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 oclock 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.
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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FFS-SU-5216-A
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
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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FFS-SU-5216-A
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
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FFS-SU-5216-A
Requirements:
1.
2.
3.
4.
5.
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.
The material is ASTM A 36 or better quality.
The material size dimensions are minimum.
A 3-inch (75 mm) wide macro cross section is removed from the approximate center of the weld and both surfaces are polished and etched.
Welder must have at least one start and stop for each pass in the macro section region.
Acceptance Criteria:
1.
2.
3.
4.
5.
6.
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FFS-SU-5216-A
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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FFS-SU-5216-A
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. Suppliers 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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FFS-SU-5216-A
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
5.1
Table 4:
Ultrasonic
Magnetic
Particle5
100
100
Radio
graphy
Location/Type of Weld
Tubular Connections
1.
100
2.
100
3.
10
1006,7,8
100
100
10
11
100
10
10
10
100
10
10
10
100
100
100
12
Other Connections
4.
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FFS-SU-5216-A
Table 4:
Ultrasonic
Magnetic
Particle5
100
100
5.
100
6.
100
7.
100
8.
Web intersections
100
9.
100
10.
100
100
20
11.
100
100
20
100
10013
100
10014
Welder Qualification
1For
Radio
graphy
10014
each weld, applicable spot tests shall be evenly distributed over that welds length.
2Ultrasonic
inspections shall not be allowed where radiographic inspection has been specified unless Purchaser
acceptance is obtained for each case.
3Steel
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.
4Inspected
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.
of circumferential seams shall include 4 inches (102 mm) of each intersecting longitudinal seam.
with a diameter less than 16 inches (406 mm) that fall under Note 10 shall be 10% inspected.
8Purchaser
shall allow the substitution of ultrasonic and magnetic particle inspection for radiography of full
penetration closing butt joints made from one side.
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.
12All
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:
FFS-SU-5216-A
Radio
graphy
104
100
100
100
100
100
100
100
100
Visual
Ultrasonic
1. Welded Connections
100
100
2. Butt Welds
100
3. T-Butt Welds
Location/Type of Weld
General Examination Requirements for
All Steel Areas as Identified as Special
or Primary on Structural Steel
Drawings
105
</=1006
Ends8 & 10
107
100
100
100
1009
100
100
100
100
100
100
100
100
10
Web Stiffeners
14. Web Stiffener Fillet Welds including
weld termination points (e.g., cope holes)
100
100
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Table 5:
FFS-SU-5216-A
Visual
Ultrasonic
Magnetic
Particle
100
100
100
Radio
graphy
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
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FFS-SU-5216-A
Table 5:
Ultrasonic
Magnetic
Particle
Radio
graphy
100
100
100
100
100
100
2010
100
1011
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 welds length, unless specified otherwise
in Table 5. Partially inspected welds shall included ends as a minimum.
3When
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.
4If
UT detects unacceptable defects missed by 100% RT, then 100% UT to be performed on concerned weld.
5PT
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.
7100%
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.
10Extent
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.
11Extent
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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FFS-SU-5216-A
Visual
Dimensional
On completion of welding
Table 7:
NDE
Examination Type
Inspection
Procedure
Ultrasonic
(straight beam for
laminations)
AWS D1.1
Section 6, Part F or
API RP 2X
ASNT Level II
Ultrasonic
(straight beam for
lamellar tears)
AWS D1.1
Section 6, Part F or
API RP 2X
ASNT Level II
Acceptance Criteria
1Or
5.1.2
5.2
Inspection Procedures
5.2.1
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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FFS-SU-5216-A
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
5.2.4
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FFS-SU-5216-A
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
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
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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FFS-SU-5216-A
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
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FFS-SU-5216-A
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 Purchasers considered opinion, the proposed repair of a defect would be either nonproductive 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 oclock or 9 oclock
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).
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FFS-SU-5216-A
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.
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