000 A Ee 0020004

STAR RAFİNERİ, A.Ş.
CONTRACT Nº UNIT Nº
AEGEAN REFINERY PROJECT (ARP) STAR-C-01 000
CONTRACTOR DOC No: SH/OF
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PIPING WELDING GENERAL
STAR DOCUMENT No.
REQUIREMENTS SPECIFICATION 000-A-EE-0020004
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CONTENTS
1 GENERAL 4
1.1 Scope and field of application 4
1.2 Definitions 6
1.3 Abbreviations 7
1.4 Order of documents priority 8
2 PREPARATION FOR WELDING 8
2.1 Edge preparation 8
2.2 Cleaning 9
2.3 Fit-up, alignment and spacing 9
2.4 Hot adjustments 11
3 WELDING 12
3.1 Welding processes and equipment 12
3.2 Filler material and shielding gas 13
3.3 Welding procedure qualification 14
3.4 Welders / welding operators qualification and production defects rate performance 17
3.5 Weather conditions 17
3.6 Preheating / interpass 17
3.7 Root pass 18
3.8 Weld completion, fillet/socket and seal welds 19
3.9 Postheating 20
3.10 Dissimilar Welding 20
4 POSTWELD HEAT TREATMENT (PWHT) 21
4.1 General provisions 21
4.2 General treatment technique 22
5 QUALITY CONTROL OF WELDING AND ALLIED PROCESS ACTIVITIES 26
5.1 Planning and control of welding and allied process activities 26
5.2 Examinations 26
5.3 Repair of defects 26
5.4 Welds traceability 27
6 DOCUMENTS 28
This document is the property of TSGI Mühendislik İnşaat Limited Company. Its reproduction without a written permission is strictly forbidden.
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6.1 Welding Procedures Specifications and Qualification certificates 28

6.2 Records and other documents 28
ATTACHMENT I 30
ATTACHMENT II 31
ATTACHMENT III 35
ATTACHMENT IV 39
ATTACHMENT V 40
ATTACHMENT VI 42
ATTACHMENT VII 43
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1 GENERAL
1.1 Scope and field of application
This specification covers field and shop welding for piping and tube systems for Aegean
Refinery Project (ARP) at Aliağa, TURKEY.
This specification provides general requirements to be followed independently of pipe material,

and shall be considered jointly with relevant Project Specification/General Welding
Specification.
1.1.1 Herein below are listed the referenced Project Specifications/General Welding Specification:
000-A-EE-0024010 Technical Specification for Special Services
000-L-EE-0020003 NDE and Requirements for Piping
000-A-EE-0024016 General Specification - Carbon Steel Piping Welding
000-A-EE-0024017 General Specification - Carbon Molybdenum and Chromium-Molybdenum Steel

Piping Welding (except Grade 91)
000-A-EE-0024018 General Specification - Grade 91 Steel Piping Welding

000-A-EE-0024019 General Specification - Austenitic Stainless Steel Piping Welding
000-A-EE-0024020 General Specification - Carbon Steel Piping welding for Low Temperature
Service
000-A-EE-0024021 General Specification - Structural Steel Components Welding of Piping Supports
000-A-EE-0190429 Site Quality Control Welding And NDE Plan
STGPS-A14 rev.4 Welding and heat treatment requirements for equipment and piping
STGPS-L1 rev.5 Refinery piping
STGPS-L4 rev.5 Piping Material
STGPS-L7 rev.3 Reinforcement of welded branch
UOP St. 8-12-7 Fabrication of piping
Foster Wheeler DWG-12615802-2-50-1200 Materials of Construction Notes (applicable only for U-190)
Commentary Note:
UOP St. 8-12-7 is applicable only for UOP licensed UNIT:
U-415 Unsaturated LPG Merox
U-150 Hydrocracking Unit

U-160 CCR continuous catalyst regeneration reforming unit
U-410 Saturated regenerative caustic treatment LPG Merox unit
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1.1.2 This specification, together with the other referenced Project Specifications mentioned in the
design documents are to be considered as an addition to ASME B 31.1, ASME B 31.3, PED-
97/23/CE or other required Codes, or as a modification thereof in case of conflict (except for
regulations required by law).
In no case is this specification to be used to supersede, delete or lower applicable
Code/Law requirements.
1.1.3 The Subcontractor is responsible for ensuring that the requirements for welding, inspection,
examination and testing are met.
For this purpose Subcontractor shall designate an employee “Subcontractor Welding

Inspector” of his organization, who shall have not less than 5 years of experience in the
construction/inspection of pressure piping and shall hold a valid Certificate, as a minimum as:
• IIW – International Welding Inspector Standard (IWI-S) or
• CSWIP – Welding Inspectors (Level 2) or
• AWS – Certified Welding Inspector
1.1.4 The edition of the applicable codes, standards and specifications, if not otherwise specified, is
that in force on the date of contract signature.
Subcontractor shall make available at his field office, for the Contractor – Welding Quality
Control Supervisor (Contractor-WES) use, copy of the above documentation.
1.1.5 In the application of the welding specifications, the “piping class” must be considered, as
indicated on the relevant drawing, on the line tabulation sheet, or otherwise specified.
1.1.6 Deviation from requirements contained in this specification shall follow “Waiver guidelines
table” indicated in Attachment I. Waiver, if technically acceptable, are allowed only for
paragraph indicated in Attachment I.
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1.2 Definitions
The following words and expressions used in this document have the following meanings:
OWNER: STAR RAFİNERİ A.Ş.
CONTRACTOR: JV among Técnicas Reunidas (TR), Saipem, GS e&c and

Itochu.
SUBCONTRACTOR: Autonomous Construction Company responsible of performing
the activities of t he works described on this specification.
VENDOR: Means any part who delivers equipment and materials for
facilities/units.
PROJECT: Aegean Refinery Project (ARP) at Aliağa, Turkey.
FACILITIES / UNITS: The entire facilities, units, and plants to be constructed and
erected on, under, in or through owner’s jobsite.
JOBSITE: Owner’s property land at Izmir– Aliağa, Turkey on, under, in or

through which the required facilities are to be constructed.
CONTRACTOR welding inspector: Person entrusted by Contractor with the welding inspection and
supervision;
Heat affected zone: Portion of non-melted parent metal whose microstructure has
been affected;
MANUFACTURER: Firm which produces welding products, filler metals or welding
and allied process equipment;
Parent material / Base Metal: metallic material to be joined, or surfaced, by welding, braze
welding or brazing;
Welder Identification Card: Photo identification card issued by Contractor - Welding Quality
Control Supervisor to Subcontractor Welders/Welding
operators;
Welder: Person who performs manual or semiautomatic welding.
Welding operator: Person who operates adaptive control, automatic, mechanized
or robotic welding equipment.
Weldment: An assembly whose component parts are joined by welding;

Weld Metal: All metal melted during welding and retained in the weld;
Weld Zone: Zone containing the weld metal and the heat-affected zones.
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1.3 Abbreviations
AISI American Iron and Steel Institute
API American Petroleum Institute

ASME The American Society of Mechanical Engineers
AWS American Welding Society
BM Base Metal/Parent Metal

CS Carbon/Manganese Steel
EN European Standards and Regulations
FCAW Flux Cored Arc Welding

GCB Gradient Control Band
GMAW Gas Metal Arc Welding
GMAW-STT® Gas Metal Arc Welding-Surface Tension Transfer (Lincoln Electric trade mark)
GTAW Gas Tungsten Arc Welding
HAZ Heat Affected Zone

HB Heated Band
ICHAZ Intercritical Heat Affected Zone
ILAC International Laboratory Accreditation Cooperation
IIW International Institute of Welding
IQI Image Quality Indicator
ISO International Standards Organization
NDT Non Destructive Examination

NITAL10% 10% nitric acid (HNO3) in alcohol or methanol
NPS Nominal Pipe Size
PED Pressure Equipment Directive 97/23/EC
PQR Procedure Qualification Record) [include also terms WPAR (welding procedure
approval record and WPQR (welding procedure qualification record)]
PWHT Post-weld Heat Treatment
QCM Quality Control Manager
ReH Minimum yield strength at room temperature
RT Radiographic test
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SAW Submerged Arc Welding
SMAW Shielded Metal Arc Welding
SNT-TC-1A Recommended Practice for Non-destructive Testing Personnel Qualification

and Certification
T Thickness in mm of weldment/component
t Thickness in mm of deposited weld metal
TMCP Thermo Mechanical Control Process
UT Ultrasonic test
UTS Ultimate tensile strength
UT-TOFD Ultrasonic test – Time of Flight Diffraction
VILELLA 5ml HCl + 1g picric acid + 100ml ethanol or methanol
WES Welding Quality Control Supervisor

WI Welding Inspector
WM Weld Metal
WOPQ Welding Operator Performance Qualification

WPQ Welder Performance Qualification
WPQT Welding Procedure Qualification Tests
WPS Welding Procedure Specification

• For the welding terms, the definitions are given in CEN/TR 14599 and AWS A 3.0 “Welding
Terms & Definitions”.
1.4 Order of documents priority
• In the event of conflict between the various technical documents, the most stringent
requirements shall be applied.
2 PREPARATION FOR WELDING
2.1 Edge preparation
2.1.1 The preparation of edges to be welded shall be made by machining or by thermal cutting. In
the latter case, all grooves and irregularities and all oxidation shall be ground or filled off.
2.1.2 The edge preparation for butt joints shall be in any case designed to ensure the complete
penetration. The end preparation configurations shall be as indicated below:
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a) For piping with thickness up to 22 mm, the preparation shall be single-Vee groove, with 37°30'
(+2°30'/-2°30’) beveling and root face of 1.6 ± 0.8 mm (see Attachment II, fig. 1) and Fig.328.4.2
from ASME B31.3
b) For piping with thickness over 22 mm, the preparation shall also conform to ASME B31.3, Fig.
328.4.2.
2.1.3 The preparation of branch connections shall be set-on type as per figs. 2, 3, 4 (Attachment II)
and shall ensure full penetration. Set-in joint configuration as per ASME B31.3 Fig. 328.4.4 (c)
may also be used, in particular when the run pipe size allows a correct back gouging and re-
weld from the internal side.
Half couplings, in set-on configuration, shall be bevelled and fitted according to the surface of
the pipe on which they are to be welded.
2.1.4 Reinforcing pads preparation shall be as per fig. 5 (Attachment II) or as per ASME B31.3 Fig.
328.5.4D (4) in case of set-in configuration.
2.1.5 Types of preparation different from the ones stated above shall be accepted by the Contractor-
WES.
2.2 Cleaning
2.2.1 The edges to be welded shall be properly cleaned. In particular, any oil, grease, paint and
bitumen shall be removed by solvents.
Rust, oxide, earth, sand and any other material which could be detrimental to the weld shall be
removed by means of a wire brush or by grinding.
Edges coated with Aluminium flake weldable primers, previously approved by the Owner, may
be welded without coating removal provided that:
 Base material is Carbon steel

 Coating thickness is lower than 0,050 mm
2.2.2 Cleaning shall be extended for about 10 mm from the edge on the internal pipe surface by
grinding.
2.3 Fit-up, alignment and spacing
2.3.1 Components to be welded shall be aligned, spaced and fitted up so as to hold the edges, during
welding, at a proper distance to obtain full root penetration.
The root opening shall range from 2 to 4 mm for SMAW and GMAW process, and 1.5 to 3 mm
for GTAW process (see § 3.1.2).
2.3.2 Any misalignment of branch connection welds shall not exceed 1.5mm (see Fig. K328.5.4
ASME 31.3)
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Any misalignment between butt welding edges shall not exceed 1.5 mm, and care shall be
taken to distribute it along the circumference.
Should the misalignment be over 1.5 mm, the end of the pipe with the smaller inside diameter
shall be internally machined or ground, so as to reduce the misalignment to the prescribed
value. The machined area shall be tapered with a slope not greater than 1:4.
The residual thickness, after machining, shall be not lower, in any point, to the minimum design
thickness.
Edges misalignment corrections through weld metal build up on inside or outside diameter
require previous written acceptance by Contractor-WES of Subcontractor’s repair procedure
proposal.
Where a weld build-up is deposited finished surface shall be subject to 100%UT, using a
compression wave probe and 100%MT or PT.
2.3.3 In case of butt joints and branch connections, the fit-up of edges to be welded shall be
performed using pipe couplers, suitable connecting spacers of chemical analysis same as the
base metal or by tack welds to be removed during welding of the root pass. Removing of tack
welds may be avoided provided that tack welds length is at least 30 mm. In this case tack welds
shall be re-melted after grinding their edges. The type of fit up shall be indicated in the
applicable WPS.
2.3.4 Yokes tack welded to pipe shall only be used in accordance with an approved procedure and
tack welds shall be carried out following the provisions of the applicable accepted WPS by
qualified welders.
For piping thickness less than 8 mm, electrodes with diameter not over 2.5 mm shall be used
and care shall be taken to avoid undercuts on pipe.
The yokes shall be removed by grinding only, such as to avoid damage on the pipe.
Surface defects, caused by the removal of the yokes, shall be repaired following the provisions
of workmanship, finish and appearance given by the applicable material specifications with the
following exceptions:
a) repair by welding shall be carried out following the prescriptions of the repair procedure accepted
by the Contractor-WES;
b) all surface imperfections shall be ground or filled off, and 100%MT/PT inspected.
2.3.5 Piping components, to be joined by fillet weld, shall be fitted up by tack welds to be carried out
following the provisions of the applicable WPS.
During welding of the first pass tack welds shall be ground off.
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In socket weld fit-up (before welding), a gap of about 1.5 mm between the end of the pipe and
the socket bottom shall be provided. Use of Gap-a-Let® (trademarks of Galgage Company)
rings require previous Owner approval. Gap shall be spot checked, after welding gap shall be
between 1.5mm to 4mm. Socket welds shall conform to ASME B31.3 Fig 328.5.2c. Two welds
passes shall always be applied to socket welds.
2.3.6 It will not be allowed to weld temporary supports or anchorages to the piping, unless this is
accepted by the Contractor-WES. Any temporary welds, anyway, shall be made following the
same precautions used for the pipe welds.
2.3.7 Preventive strains or constraints, if necessary, may be provided to balance the effects of weld
shrinkage, particularly on welded branches.
2.3.8 The root pass and filling of the joint (as per § 3.8.1) shall be done within 24 hours from tack
welding unless approved otherwise by Contractor otherwise removal of tack welds and re-
cleaning operation shall be carried out.
2.3.9 If the external surfaces of the two components are not aligned, the weld shall be tapered
between the two surfaces with a slope not steeper than 1:4.
2.4 Hot adjustments
2.4.1 Hot adjustment isn’t allowed.
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3 WELDING
3.1 Welding processes and equipment
3.1.1 The welding processes to be used shall conform for each piping material to the relevant General
Welding Specification, and shall be accepted by the Contractor-WES, on the basis of the results
of WPQT (as per chap. 3.3).
Contractor-WES/OWNER is entitled to forbid the use of any welding process / filler metal which
gives systematic defects/poor mechanical properties.
Welding machines, cutting equipment, cables, PWHT apparatus and instruments shall comply
with the safety regulations required by the law and copy of their certification shall be submitted
for review to Contractor-WES, at the start of the project. The Subcontractor shall keep the
welding and allied processes plants in perfect working conditions and periodically shall check
and test the welding equipment as required by ISO 3834-2 and ISO 10012-1. Every 12 months
as a minimum equipment is to be calibrated and to be verified in house as per the procedure
000-A-EE-0190406.
Contractor-WES is entitled to ask anytime Subcontractor to demonstrate correct calibration of

equipment for welding and allied process (PWHT, Cutting, etc.)
3.1.2 The welding processes are shown hereinafter, as defined by AWS:
WELDING PROCESSES AWS/ASME
Gas Metal - Arc Welding GMAW
Flux Cored - Arc Welding FCAW
Gas Tungsten - Arc Welding GTAW
Shielded Metal - Arc Welding SMAW
Submerged - Arc Welding SAW
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3.1.3 Vertical weld downward technique is not allowed.
3.1.4 The use of backing rings are not allowed, unless previous written Owner approval is given.
3.1.5 When GTAW process is used, the welding units shall be equipped with devices for arc striking
and progressive arc extinguishing.
3.1.6 Welding procedures employing welding processes different from those listed above must not
be used, unless previous written acceptance is given by the Contractor – Materials, Corrosion
& Welding Engineering Function/OWNER.
3.2 Filler material and shielding gas
3.2.1 Electrodes, wires and fluxes shall conform for each piping material to the relevant General
Welding Specification for welding and shall be anyway of a type and trade mark accepted during
WPS review by Contractor-WES.
3.2.2 Subcontractor shall produce to the Contractor-WES/OWNER the certificates of conformity for
all welding consumables and gases prior to their use.
Subcontractor, as a rule, shall purchase the filler metals with “3.1 chemical and 2.2 mechanical’’
certificates showing properties according to the schedule J as per ASME BPVC Sect. II Part C
SFA-5.01. Level of testing to schedule K may be required for particular applications and only
when specified in the applicable General Welding Specifications (or in a project amendments
of these specifications) for the piping of various materials.
The batch definition, as a rule, shall be as follows:
Consumable Welding Process Lot Classification
Covered Electrodes SMAW C3
Bare Solid Electrodes and Rods GTAW, GMAW, SAW S2
Flux Cored Electrodes FCAW T2

Flux for Submerged Arc Welding SAW F2
Commentary Note:
Requested level of testing to the schedules as above, per ASME BPVC Sect. II Part C SFA-5.01 are more
restrictive than the minimum requirements deemed necessary for PED and related harmonized standard.
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Restrictions to the above definition of the lot quantity may be required for particular applications.
The different lot classifications (if any) shall be stated in the applicable General Welding
Specifications.
3.2.3 Each box or container of filler material shall be marked by the Manufacturer with the same
indications as the lot quoted on the certificates, as per §. 3.2.2.
3.2.4 Each electrode or wire shall be identified by a colour or mark applied by the Manufacturer.
3.2.5 Electrodes and fluxes shall be perfectly dry when used. For this purpose they shall be dried in
a suitable calibrated heating oven as per Manufacturer recommendations, including maximum
number of re-drying allowed. If the manufacturer does not recommend a maximum number of
re-drying cycles, the number must be 2.
Electrodes showing traces of oxidation or degraded coating shall not be used.
Electrodes and fluxes after they have been dried shall be kept in an oven and maintained at
the temperature recommended by the Manufacturer.
3.2.6 Subcontractor shall prepare and submit to Contractor-WES/OWNER for acceptance a written
procedure for drying, storing and handling welding consumables.
3.2.7 Welders using low hydrogen electrodes shall have at their disposal a portable heating container
from which they can draw each time the electrode to be used on work.
The heating container shall be capable to maintain a temperature of at least 80°C. The above
applies also for welding consumables used for tack and temporary welds.
3.2.8 At the end of the work shift, the low-hydrogen electrodes which have not been utilized, shall be
properly identified, as agreed with Contractor-WES (i.e. yellow marked) and placed in the drying
heater. Electrodes which have been left in the working areas shall be marked (i.e. red marked)
as non-conform and segregated, so as to ensure that they are not used.
3.2.9 Electrodes and fluxes contaminated with oil, grease, or paint or damaged must not be used.
Welding rods or wires, before being used, shall be properly cleaned from any rust, oil, grease,
paint or any other matter which could result detrimental to welding.
3.2.10 Shielding and backing gases employed in welding shall have a nominal composition and purity
as per the WPS issued by the Vendor and accepted during WPS/PQR review by Contractor-
WES.
During the work, Contractor-WES is entitled to require the chemical analysis of the gases while
they are used.
3.3 Welding procedure qualification
3.3.1 The welding procedures to be used and the welders / welding operators shall be previously
qualified according to the following Route Map:
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Design Code: ASME B 31.1 or ASME B 31.3

Welding procedures
Qualified according to: ASME BPVC Sect. IX
Welders / welding operators

Qualified according to: ASME BPVC Sect. IX
In additions to the provisions of the applicable codes the validity of PQR is 5 (five) years from
issue date.
In case of application, as Design code of ASME B31.1/B31.3, for a piping systems within the
scope of PED category 1 to 4, Subcontractor shall demonstrate that all Directive essential
requirements are followed and fulfilled. For a piping systems within the scope of PED category
2 to 4,relevant WPS/PQR shall be approved by Notified Bodies.
All standardized test (test complying with National/International Standard) shall be carried out
by laboratories with relevant test accredited by ILAC Full Members (for example for
TURKEY=TURKAK), Associates (for example for United Arab Emirates= ESMA), Affiliates (for
example for Kingdom of Saudi Arabia=SASO); accreditation certificate shall be always attached
to the PQR.
3.3.2 Any additional tests required by the applicable General Welding Specifications shall be
performed.
3.3.3 Procedure qualification record (ASME and EN), Welders qualifications (ASME and EN) and
any additional test certificates shall be issued by one of the following Authorities:
- AMERICAN BUREAU
- BUREAU VERITAS
- EDISON WELDING INSTITUTE
- INTERNATIONAL INSTITUTE OF WELDING (IIW) AUTHORISED NATIONAL BODY

INSTITUTES
- I.S.P.E.S.L.
- ISTITUTO ITALIANO DELLA SALDATURA
- LLOYD'S REGISTER
- REGISTRO ITALIANO NAVALE
- VdTÜV
Certifying Authorities other than those quoted above must be previously accepted by Contractor. The
above applies also to the qualification tests performed on site.
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3.3.4 For each application of the welding procedure or combination of welding procedures,
Subcontractor shall prepare the WPS.
The WPS shall be customized for the project and sufficiently detailed for this purpose.
This means that beside the essential, nonessential, and when required, supplementary
essential variables which shall be indicated as per applicable Codes (ASME Sect. IX, or
other required Code), the following information shall be always mentioned:
a) Material specifications of base metals or the different combination of base metals to be
joined.
b) Sketch of the actual joint details (butt joints pipe to pipe or pipe to butt welded fittings,
full penetration branch connections, full penetration set-on or set-in couplings to run pipe,
fillet welds to join pipe components with diameter less than 2 inches, etc.) showing all
the relevant geometric parameters and sizing.
c) Indications of the actual range of base metal thickness of production welds.
d) Filler metal and flux brand and trade mark.
e) Composition and purity of shielding or purging gases, if any.
f) PWHT (if any) parameters: actual production soaking temperature and time.
All WPSs, PQRs and Welding Table shall be submitted to Contractor-WES/OWNER for
acceptance/comments and collected in a unique welding book valid for the current project.
3.3.5 The WPQT shall be performed using electrodes, wires and fluxes (same AWS or EN
classification, unless otherwise required for each material by the General Welding
Specifications or for filler metal classified “G” according AWS for which WPQT shall be done
with the same brand and type to be used for production joint) accepted by Contractor-
WES/Owner during WPS review. When filler metal designated under AWS classification “G” is
used, the chemical analysis of filler metal shall be reported in WPS/PQR
3.3.6 The Contractor-WES/OWNER will be entitled to request to witness tests to be carried out.
Therefore, the Subcontractor shall notify Contractor-WES/OWNER of the date on which each
test has to be performed, at least ten working days in advance.
3.3.7 As a rule, the WPSs are required to be supported by fresh PQRs, when the applicable (material)
general welding specifications require structure metallographic assessments, corrosion tests,
tensile tests at elevated design temperatures, impact tests at cryogenic temperature or other
non-routines applications as in case of PWHT specified for welded joints on austenitic stainless
steel piping.
In case of piping materials supplied in particular heat treatment conditions to enhance their
mechanical properties (i.e. TMCP steels, quenched (accelerated cooling) and tempered,
followed or not by simulated cycles of PWHT), the base metals to be used for the welding
procedure qualification tests shall be selected from those of the same product analysis and
heat treatment condition supplied for the project.
3.3.8 Rounded specimens for transverse tensile tension test are not allowed, for new PQRs.
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3.4 Welders / welding operators qualification and production defects rate performance
3.4.1 All welders / welding operators shall be qualified by a Certifying Authority accepted by
Contractor in compliance with §. 3.3.3. For a piping systems within the scope of PED category
2 to 4, relevant Welder/Welding operator qualification shall be approved by Notified Bodies.
Anyway, the Contractor-WES/OWNER is entitled to witness the welding performance

qualification carried out at site and workshop therefore he must be informed at 24 hours in
advance of their performance.
3.4.2 Upon presentation of the qualification certificates and two (2) photos to the Contractor-WES,
each Welder/Welding operator properly certified shall be registered, issued a Welder
Identification Card (attachment VII) and assigned an unique Identification Symbol composed of
letters (subcontractor unique letters) and numbers, by the Contractor-WES. Identification
Symbol shall appear on a proper stamp, with which the welder / welding operator shall be
equipped (see §. 5.4).
3.4.3 Welder Identification Card must be carried at all times by the Welder/Welding operator and
must be presented for review upon Contractor-WES/OWNER request.
3.4.4 During the whole welding production, the welder / welding operator shall be subjected to quality
control and monitoring under the full responsibility of the Subcontractor and Contractor. The
monitoring shall be carried out as defined in Attachment III
3.5 Weather conditions
3.5.1 In the case of rain, snow or wind (particularly if sand or dust is present), the Subcontractor shall
provide proper protection for the parts to be welded and for the welder / welding operator, so
as to ensure correct performance of the work. Otherwise, no welding will be allowed.
3.5.2 Should the edges to be welded be wet or covered with dew, frost, or snow, welding can be
performed only after drying the joint by flame or other heating device.
3.5.3 In the case of low ambient temperature, preheating may be required, according to the welding
specifications for the various materials.
The above preheating shall be performed also for tack-welding, fit-up welding, and temporary
welds.
3.5.4 For welds with GTAW or GMAW process to be performed outdoors, suitable protection shall
be provided, to prevent any air drafts which might be detrimental to welding.
3.6 Preheating / interpass
3.6.1 Preheating / interpass requirements/limitation for the different materials are indicated for each
material in the relevant applicable General Welding Specification.
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3.6.2 Preheating can be performed by means of electric resistance, induction heaters, propane
heating torches, or gas burners. The Contractor-WES may accept, in particular cases, the use
of oxyacetylene flame torches, provided suitable nozzles are employed.
3.6.3 The temperature shall be checked by thermocouples, temperature indicating crayons, contact
thermometers, or an equivalent method accepted by the Contractor-WES.
3.6.4 The preheat zone shall be at or above the specified minimum temperature in all directions from
the point of welding for a distance “A” (see figure in Attachment IV). of the larger of 75 mm (3
in.) or 1.5 times the greater nominal thickness. The base metal temperature for tack welds shall
be at or above the specified minimum temperature for a distance not less than 25 mm (1 in.) in
all directions from the point of welding.
 Where practicable, the temperature shall be measured on the face opposite to that being
heated.
 Otherwise, the temperature shall be confirmed on the heated face at the time after removal of the
heat source related to parent metal thickness to allow for temperature equalization.
The time allowed for the temperature equalization shall be of the order of 2 min for each 25 mm
of parent metal thickness.
Interpass temperature shall be measured on the weld metal or the immediately adjacent parent
metal.
3.6.5 Each welder / welding operator performing welds, for which preheating is required, shall have
available the equipment for heating and for temperature checking.
3.6.6 Wherever it is found that the preheating provisions have not been followed, the Contractor-
WES is entitled to request the welds involved to be cut out.
3.7 Root pass
3.7.1 The root pass of butt joints and branch connections shall be such as to ensure full and regular
penetration.
3.7.2 Any precaution likely to avoid root undercuts, internal concavities and defective restarts shall
be taken.
Any crater defects or irregularities liable to jeopardize a good weld restart shall be removed;
slight overlay shall be made at each restart to ensure uniform weld penetration. Any excess of
metal on the bead shall be removed by grinding.
3.7.3 Once the welding has been started and until the joint has been completed, care shall be taken
to avoid displacements, shocks, vibrations or stresses which could damage the weld.
3.7.4 The striking of the arc must not be performed on the pipe wall outside the bevel (a suitable
plate may be used for this purpose). MT/PT to be performed after cleaning of arc strike, if the
arc strike becomes on pipe wall outside the bevel.
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3.7.5 When GTAW process is used, the arc shall be extinguished on the edge of the bevel, keeping
the molten pool under gas shielding until it solidifies.
3.7.6 It is forbidden to interrupt the welding and to allow the joint to cool down, before completion of
the root pass and hot pass (see Section 3.8.1 below)
3.7.7 On completion of the root pass, any visible defect or any bead irregularity which might be
detrimental to the next pass shall be ground off. When SMAW process is used, slag shall be
carefully removed. Penning is prohibited.
3.8 Weld completion, fillet/socket and seal welds
3.8.1 The filling of joint shall normally be carried out immediately after completion of the root pass,
unless otherwise required for each material by the General Welding Specifications.
If complete filling of the joint cannot be done, a minimum of at least 1/3 of the welding groove
thickness shall be filled before the weld will cool down; the pipe shall be properly supported and
shall not be moved.
After cooling and before welding is resumed, visual examination of the weld shall be performed
and certified by Subcontractor Welding Inspector, to assure that no cracks have formed.
3.8.2 The striking of the arc must not be performed on the pipe wall outside the bevel (a suitable
plate may be used for this purpose). MT/PT to be performed after cleaning of arc strike, if the
arc strike becomes on pipe wall outside the bevel.
3.8.3 Welds shall consist of continuous weld pass, each layer will be staggered at the start and stop
points, at least 20mm. On completion of each pass, all slag shall be carefully removed and all
defects or irregularities on the bead shall be ground off before welding the next pass.
On completion of welding, the joint shall be cleaned from slag and metal spattering. Penning is
prohibited. Any defects on the piping component, due to welding and fit-up operations, shall be
repaired as per §. 2.3.4.
3.8.4 Weld completion shall be done using stringer bead technique, with a bead width not greater
than 3 times the electrodes diameter.
3.8.5 On fillet welds the weld profile shall be regular, with equal leg lengths at about 45 degree.
3.8.6 The weld toes shall not be marked with a chisel or with a saw blade.
Filling of the toes is allowed provided no sharp cuts are produced.
3.8.7 For socket welds and for slip-on flanges at least two passes shall be performed.
3.8.8 Welding is not allowed on pipes or tubes containing water or other liquid or gas, without
Contractor-WES acceptance.
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3.8.9 Fillet welds (including socket welds) shall be as shown in figure 328.5.2.A of ASME B31.3. The
size of the fillet welds shall be determined in accordance with that figure.
The typical weld details for socket welding flanges, and minimum welding dimensions for other
socket welding components shall be in accordance which ASME B31.3 Fig.328.5.2B and
328.5.2C.
3.8.10 Seal welds are not permitted for the piping classes 1500 and over, and low temperature piping.
3.8.11 Seal welding shall be done by a qualified welder. Seal welds shall be with GTAW process and
shall cover all exposed threads.
3.8.12 Galvanized steel piping shall not be seal welded.
3.8.13 All threaded connections shall be seal welded, except in water and air services and screwed
relief valves, thermo wells and process drain plugs and for service as indicated in attachment
VI.
3.9 Post-heating
3.9.1 Post heating, when required, shall be performed immediately after completion of welding,
before the weld cools down.
3.9.2 The equipment indicated in chapter 3.6 for preheating shall be used for post heating.
3.9.3 Cooling shall be performed under dry insulation, unless the air is still and the ambient
temperature is > 20°C (when necessary, the insulation shall be dried in a heater or by heating
torches).
3.9.4 Post-heating temperatures shall be monitored and chart recorded by means of thermocouples.
3.10 Dissimilar Welding
3.10.1 Dissimilar welds between stainless steel and carbon or low alloy steels shall be avoided in
process services (Wet H2S service, Amine service, Caustic service, Hydrogen service, as
indicated in Specification n°000-A-EE-0024010) unless otherwise agreed with Owner and
Contractor – Materials, Corrosion & Welding Engineering Function.
3.10.2 If allowed (see restrictions of §3.10.1) dissimilar welds shall comply with STGPS-A14 rev.4.
3.11 Weldable Primers
Weldable Primers maybe used providing that a WPQT under witnessing of the OWNER has
been carried out using the same type and brand of weldable primers used for the production
joint and a root opening equal or smaller than the production ones. Consideration shall be given
to the additional limitations referenced in Section 2.2.1 of this specification.
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4 POSTWELD HEAT TREATMENT (PWHT)
4.1 General provisions
4.1.1 Heat treatment shall be performed whenever specified for each material by the relevant
General Welding Specification, or required by the applicable code, or indicated in the piping
isometric drawing; whichever is more stringent.
4.1.2 The equipment used for PWHT shall be suitable for the required performance.
For this purpose Subcontractor shall prepare a written PWHT procedure to be previously
submitted to Contractor-WES/OWNER for acceptance/comments, prior to starting the PWHT
work.
The PWHT procedure shall detail as a minimum:
 Applicable reference standard and specification;
 Type of heat treatment (stress relieving, normalization etc.);
 Extent of heat treatment (local or furnace);
 Type of heating elements (furnace and relative dimension, hot air, electric resistance, induction etc.);
 Position and extent of heating elements (only for local heat treatment);
 Position of the supports and how the heating elements are attached to the components;
 Type, position, extent and thickness of the insulation (only for local heat treatment);
 Type of thermocouples, compensating cables, extension cables used;
 Location and number of thermocouples required for each component size/diameter;
 Calibration / verification procedure for thermocouples;
 Need for shielding gas;
 Type of cooling;
 Environmental conditions, e.g. protection from wind and rain;
 Description of final NDT;
 Heat treatment parameters:

• Loading and unloading temperature;
• Heating and cooling rate;
• Soaking time and temperature;
All these information shall not be in conflict with the requirements given below in chapter 4.2 of
this specification.
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4.1.3 The execution of PWHT shall be performed by personnel with specific experience.
4.1.4 The Contractor-WES will be entitled to inspect the joints prepared for heat treatment, before
the insulation is applied.
4.1.5 In no case may a heat treatment be repeated without the Contractor-WES prior written
acceptance. Therefore, Subcontractor shall issue written request/procedure to Contractor-WES
for acceptance / rejection (request shall at least include base material certificate and weld test
proving that mechanical properties will not be altered by the new PWHT).
4.2 General treatment technique
4.2.1 Temperature and soaking time, heating, cooling rates and additional requirements / restrictions
on heat treatment control / operations are indicated for each material by the relevant General
Welding Specification.
4.2.2 PWHT shall be carried out in a furnace, or by resistance or induction equipment, or by any
other technique indicated in Owner specifications.
4.2.3 For local heat treatment the width of the soak band shall be in accordance with ASME B31.3
§331.2.6 or AWS D10.10 table 7 whichever is greater; heating band shall be in accordance
with AWS D10.10 table 8.
4.2.4 For local heat treatment the width of the gradient control band shall be in accordance with AWS
D10.10 table 8.
4.2.5 PWHT temperature measurement shall be done by means of thermocouples (for local heat
treatment thermocouples shall be fixed near the joint). Thermocouples shall be properly
insulated from the heating source.
4.2.6 The temperatures detected by each thermocouple shall be recorded as a function of time by a
temperature recorder instrument connected via a suitable compensating cable.
This recorder shall be calibrated on site with the proper type of thermocouple and compensating
cable to be used.
When recording temperatures, thermocouples numbers shall be automatically written by

recorder on recording chart.
4.2.7 Temperature recording shall start at 300°C during heating and end at 400°C during cooling.
Afterwards the joint shall be let cool down to ambient temperature without removing the
insulation.
In case of P91 material the specification 000-A-EE-0024018 will be applicable.
4.2.8 Number and location of measuring point of PWHT temperature shall be as per the following
tables:
- Minimum number of measuring points for furnace heat treatment:
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VOLUME OF FURNACE [m3] NUMBER OF MEASURING POINT
< 60 3
60 – 80 4
80 – 100 5
> 100 6
At least one measuring point shall be located in the back, in the middle and in the front of the
furnace. When more than three measuring points have to be settled, their location shall be planned
to cover the whole furnace volume.
- Minimum number of measuring points for local heat treatment of pipes:
NUMBER OF
OUTSIDE DIAMETER OF PIPE [inch] LOCATIONS
MEASURING POINTS
up to 6 1 At 12:00
8 and up to 12 2 At 12:00 and 6:00
14 and up to 18 3 At 11:00, 1:00 and 6:00
At 12:00, 3:00, 6:00

20 and up to 30 4
and 9:00
Number of control zones and associated

Over 30 thermocouples as required by circumferential
spacing of heaters
“In the PWHT’s charts and reports all the joints (dia ≤ 1-1/2”) controlled by one thermocouple and
under the same heating band will be clearly identified”.
4.2.9 Only type K (chromel-alumel) thermocouples are permitted. Compensating cables shall be
either type K or type KX. In particular cases other type of thermocouples or compensating
cables may be used if accepted by the Contractor–WES/OWNER.
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4.2.10 Thermocouples shall be attached to the weld by capacitance discharge welding only. After
welding the distance between the two welded ends shall be from 6 mm to 10 mm.
At least one thermocouple shall be located in the centre of the weld.

Other methods of attachment shall be accepted by the Contractor–WES.
4.2.11 Each weld to be heat treated shall be given an identification marking, to be shown on proper
drawings. In case of 100% radiographed welds, the relevant numbering may be used, otherwise
alphabetic letter to be read with the piping drawing number may be used.
4.2.12 PWHT temperature recording chart shall provide the following data:
 Vendor Name or logo;
 Chart progressive number;
 Weld identification marking (as per § 4.2.11.);
 Number or reference mark of the thermocouples;
 Starting date of the PWHT;
 Temperature and time scales;
 Stamp and signature of the Subcontractor and Contractor responsible for the PWHT.
Note: Date and weld number must be written on chart before the PWHT starts.
4.2.13 Before the execution of the heat treatment, the pipe or tube ends shall be plugged, so as to
avoid air drafts inside the pipe. Moreover, the pipe shall be duly supported to avoid distortion
and coupling surfaces of the flanges and the threaded parts included in the heated area, shall
be protected against oxidation.
The heated area shall be suitably protected against bad weather and any other factors likely to
affect the PWHT.
4.2.14 The Subcontractor shall fill in the accepted form and promptly submit to the Contractor-WES
the PWHT record along with the temperature recording chart for acceptance/comments.
4.2.15 PWHT record shows non-conformance data (for example: Soaking temperature; Soaking time;
Heating or cooling rate; or temperature differences between the thermocouples) against what
required in the Contractor-WES accepted PWHT procedures or codes or contractual
specification, Subcontractor shall issue a written request/procedure for remedial action to
Contractor-WES for acceptance / rejection.
If Contractor-WES consider that the only acceptable remedial action is the repetition of heat
treatment (typically necessary for non-conformance of Soaking temperature or time); written
request/procedure shall also include documentation asked at §.4.1.5.
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4.2.16 When hardness checks (to be performed in compliance with the relevant specification
requirements) are required after PWHT and the results are not in accordance with the
specification requirements; Subcontractor shall issue a written request/procedure for a new
PWHT to Contractor-WES for acceptance / rejection; written request/procedure shall also
include documentation asked at §.4.1.5.
4.2.17 Unless otherwise allowed in writing by OWNER, neither welding nor striking of arcs are
permitted after final PWHT.
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5 Quality Control of WELDING AND ALLIED PROCESS ACTIVITIES
5.1 Planning and control of welding and allied process activities
5.1.1 Before to start with welding and allied process activities Subcontractor shall issue the applicable
Quality Control Plan (QCP) and Inspection & Test Plan (ITP), as required by Contractor Quality
Assurance Specification, for Contractor-WES/OWNER acceptance/comments.
5.1.2 During the execution of the work, quality monitoring and inspections shall be carried out by the
Subcontractor following accepted Quality Control Plan (QCP) and Inspection & Test Plan (ITP)
with personnel qualified at the adequate level of competence, as well as by the Contractor-
WES, in order to ensure the compliance with the codes and specifications.
5.1.3 The Contractor-WES/OWNER shall have free access to all the places where the work is carried
out and where the documentation, the materials and the equipment connected with the work
are kept.
5.1.4 The Contractor-WES/OWNER shall be entitled to not accept personnel or equipment that,
according to his experience, are not suitable for the satisfactory performance of the work.
5.2 Examinations
5.2.1 The examinations type and percentage to be performed on the welds are set out in the
Specification spec. 000-L-EE-0020003 and additional requirements (if any) for each material by
the relevant General Welding Specification.
5.3 Repair of defects
5.3.1 Repair welding shall be performed using a properly procedure to be submitted for acceptance
to the Contractor-WES/OWNER. Repair procedure shall include at least:
 Defects types/origins
 Method of excavation: defects shall be removed by grinding or machining.
As a general rule excavation length shall be at least:

NPS ≤ 141,3mm minimum length 50mm
NPS > 141,3mm minimum length 100mm
The use of thermal processes such as arc-air or flame may be allowed case by case by the
Contractor-WES and applied only on piping materials and weld metal which do not risk to be
metallurgical adversely affected.
 NDT: The repaired joint shall receive the same NDT examination which permitted to detect the original
defects with the addition of other NDT methods if deemed necessary by Contractor-WES.
 Welding requirements (Contractor-WES/OWNER can ask a dedicated PQR: same component

thickness and excavation dimension).
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5.3.2 Weld joint found defective during final stage inspection (i.e. on completed joints) may be
repaired twice (except cracked welds that shall be always cut-out). If the weld is still not
acceptable after the second repair, then Contractor-WES/OWNER has the sole authority for
the decision to permit additional repair attempts or to require that the entire weld be cut-out.
5.3.3 Each repair shall be carried out within five working days from the request of repair. The
examination which ascertained the defect shall then be repeated.
5.3.4 If cutting of joint is required, the weld and HAZ shall be completely removed and the edges
shall be bevelled again. After the new weld has been carried out, all the examinations provided
for the joint shall be repeated.
5.3.5 When repair procedure has received Contractor-WES acceptance; Subcontractor before to
start with repair activity shall notify to Contractor-WES of the date on which repair activity shall
be done, at least two working days in advance.
5.4 Welds traceability
5.4.1 A traceability procedure shall be issued by Subcontractor for acceptance of Contractor-

WES/OWNER.
Accepted traceability procedures shall be maintained by Subcontractor for identifying the

correlation between the welds and welder/welding operator (that has carried out the welds)
through production, up to final test. Weld number together with welder / welding operator
identification symbol shall be recorded by Subcontractor-WI on relevant Daily Joint Fit-up and
Welding Report for Piping
5.4.2 The welder / welding operator who performs only the root pass on butt welds, shall punch his
identification symbol on the pipe, in two diametrically opposed points near the weld, before
starting the welding.
5.4.3 The welder / welding operator who performs the complete butt welds, shall punch his
identification symbol, using low stress punch (except when a different identification system is
provided in the welding specification relevant to the material), on two small zones (previously
cleaned and levelled with a brush) at least 25 mm from the edge of the weld in a diametrically
opposite position.
5.4.4 All welder/welding operator who performs different passes shall mark his identification symbol
on the pipe adjacent to the weld together with joint number, date, thickness, WPS and visual
check using permanent ink/paint. The ink or paint used must be free from low melting point
metals (Pb,Zn,Al,Cu), chlorides and halides. Weld number together with welder / welding
operator identification symbol shall be recorded by Subcontractor-W.I. on relevant “Daily Joint
Fit-up and Welding Report for Piping”; before that any fabrication sequence can alter/erase the
welder / welding operator identification symbol.
5.4.5 On Contractor-WES/OWNER judgement, welds without welder / welding operator symbol, with
the symbol not legible or without record on drawing (valid only for fillet weld), may be cut.
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6 DOCUMENTS
6.1 Welding Procedures Specifications and Qualification certificates
6.1.1 Welding Procedure Specifications (WPSs), Procedure Qualification Record (PQRs) and
Welders or Welding Operator Performance Qualification Certificates (WPQ/WOPQ) shall be
issued according to § 3.3.1. It shall be written in English, except where specified otherwise.
6.1.2 Subcontractor shall send to Contractor-WES the compiled “welding table” (see Attachment V),
the originals of Welding Procedure Specifications (WPSs) and Procedure Qualification Record
(PQRs), with two copies, at least ten working days before the beginning of the welding work.
6.1.3 Subcontractor shall also send to Contractor-WES the originals of the welders / welding
operators performance qualification certificates, with two copies, at least five days before the
welders start to work: this time may be reduced in case of qualification tests performed on site.
6.1.4 All the originals of the certificates will be returned to Subcontractor as soon as the Contractor-
WES has examined them.
6.2 Records and other documents
6.2.1 Signed original plus two copies of the following records/documents shall be submitted by the
Subcontractor to Contractor-WES/OWNER:
 Weld summary sheet
 Drawing with identification of welds with associated: WPS N°
Welder / Welding Operator Symbol
NDT summary form if any (see §. 6.2.2)
PWHT if any
Other test (ferrite-hardness-etc.) if any
 NDT records;
 PWHT charts [shall include signed judgement of competent personnel]
 Other test records when required by General Welding Specifications for various materials
The above mentioned records/documents shall be checked for acceptance/comments by the

Contractor-WES; Contractor-WES comments (corrective action) need to be implemented by
Subcontractor before to resubmit the documentation for acceptance of Contractor-WES.
After the records have been completed with the Contractor-WES acceptance and signature, the
original will be returned to Subcontractor.
6.2.2 Subcontractor shall weekly furnish to Contractor-WES:
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 Number of joints completed, tested and rejected including failure rate (%) accumulated and
weekly; split for each location (Field and workshop(s)) and each welder.
 Linear length of joints completed, tested and rejected including failure rate (%) accumulated
and weekly; split for each location (Field and workshop(s)) and each welder.
 For percentage line class the status of welder performance by LOT (see Attachment III) and
status of the progressive sampling results within each LOT performance.
The recording of the above mentioned welds shall be made by Subcontractor daily, and
Contractor-WES will be entitled to check it. The information shall be issued to OWNER weekly.
'Welder performance registers shall be submitted separately for 100% RT of Line classes and
the other percentages (e.g. 5%, 10%, 20%) to Owner on weekly basis.'
6.2.3 After all the welds belonging to a piping system have been completed (any repairs included),
post weld heat treated (when required) and examined, and the Contractor-WES has returned
to Subcontractor copy of the relevant records, Subcontractor shall draw up, “Piping Release for
Pressure Test” form to certify that the above piping system is ready for the hydraulic pressure
test.
6.2.4 During progress of work, unless otherwise specified records/documents, mentioned at § 6.2.1
shall be filed by Subcontractor in rooms deemed suitable by Contractor-WES and shall be
property of the Contractor / Owner after completion of the works.
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ATTACHMENT I
WAIVER GUIDELINES TABLE
Para. Action to be done by: Action to be done by: Action to be done by:
Subcontractor Contractor – WES Contractor – Materials,
Corrosion & Welding
Engineering Function
2.1.5 Issue WPS with proposed bevel Review of issued WPS and prepare
preparation written notification of acceptance or
rejection
2.3.6 Issue written procedure Review of issued procedure and
prepare written notification of
acceptance or rejection
3.1.4 Issue WPS (together with Review of issued WPS and prepare
indication of lines where written notification of acceptance or
Subcontractor want to apply it) rejection
3.1.6 Issue written proposal, including Review of issued proposal and
trial test plan prepare written notification of
preliminary acceptance (final
acceptance will be given after
receipt of satisfactory trial
results and OWNER approval)
or rejection.
3.6.2 Issue written procedure Review of issued procedure and prepare
written notification of acceptance or rejection
3.6.3 Issue written procedure Review of issued procedure and prepare
written notification of acceptance or rejection
3.8.8 Issue written request Review of issued request and prepare written
notification of acceptance or rejection
4.2.2 Issue written procedure Review of issued proposal

and prepare written
notification of acceptance
or rejection
notification for OWNER review/approval
notification of acceptance or rejection
notification for OWNER review/approval
Note: Time needed by Contractor – WES or Contractor – Materials, Corrosion & Welding Engineering Function to review the
Subcontractor waiver proposal, cannot be claimed by Subcontractor as delay time on fabrication schedule.
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ATTACHMENT II
EDGE PREPARATION AND FIT UP
37°30’ (+2°30’/-2°30’)
See also Fig. 328.4.2 ASME B31.3
2  4 (SMAW)
1.6  0.8
1.5  3 (GTAW)
Fig. 1 - BUTT JOINTS
A PIPE
45°
45° 2  4.5
12 2  4.5
45°
B PIPE
Fig. 2 - BRANCH CONNECTION WITH ØB > 1.5 ØA
A PIPE
12
45°
15°
2  4.5
2  4.5
15°
0  15 °
B PIPE R
Fig. 3 - BRANCH CONNECTION WITH ØR = ØA or ØB  1.5 ØA

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Internal bevelling
02
02
0  15° 15° 2  4.5
AAAA
2  4.5
15°
0  15° 15°
R
Fig. 4 - INCLINED BRANCH CONNECTION
Ø + 10
Ø
S
0.7 S 30°
45° 0.5 T
2  4.5
Fig. 5 - BRANCH CONNECTION WITH REINFORCEMENT
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Fig. 6 - BRANCH CONNECTION “ASSEMBLY DETAILS FROM STGPS-L7-3 Fig.B”
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Notes to Fig.6:
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ATTACHMENT III
WELDER / WELDING OPERATOR QUALITY MONITORING
NEW WELDER / WELDING OPERATOR
RADIOGRAPHY TEST OF THE FIRST TWO WELDED

JOINT DURING FIRST WORKING DAY
RT WITH NEGATIVE RESULT RT WITH POSITIVE RESULT
PRODUCTION
WELDING
Three Days Retraining

and Requalification (two
times only)
WEEKLY MONITORING
Commentary Note:
1)The “first working days two joints radiography welds” shall cover all the required essential welders
code/contractual specification variables, to be met by welders for carrying out their production welding [Example
with DESIGN CODE ASME B31.3: if a welder has to carry out production welds including vertical position has to
carry out the first two joints, at least, in 5G position]; otherwise has to repeat the two joints, to cover the un-matched
essential variables.
2) Welders shall be allowed to go through the Three Day Specific Training only twice. If the first two joints fail within
the third cycle the welder shall be disqualified.
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WEEKLY MONITORING PROCESS

In order to monitor the weld performance the following rules shall apply.
Linear Repair Rate
The target repair rate for the project is < 2%. The 2% shall be based upon linear repair length against
the linear radiographic tested length.
Linear Repair Length x 100 = Linear Repair Rate %
Linear Length Tested
Joint Repair Rate
The target repair rate for the project is < 5%. The 5% shall be based upon number of joints repaired
against the number of joints tested.
Joints Repaired x 100 = Joint Repair Rate %
Joints tested
Record shall be kept for the repair rate as defined in Section 6.2.2 of this specification. Reports
produced shall be based on the data entered into the WiTS welding control system.
In order to monitor trends and focus improvement actions the repair rate for each type of defect shall
also be reported.
Welder Site Qualification

The first two welds of each welder shall be radiographed. Relating to the initial qualification welds the
following rules shall apply:
• The welders shall not proceed until confirmation that the initial two welds are acceptable.
• Welds welded by two welders shall be considered as one weld for initial qualification purpose.
• If any of the initial two welds are rejected the welder shall be given three days further training
and then re-qualify. Only two re-qualifying sessions are allowed after which the welder will not
be permitted to weld on production joints.
Welder Performance Control

In order to control the overall welder performance on Site the following rules shall apply.
• The Subcontractor shall issue on a weekly basis the overall weld performance by individual
welder.
• Welder performance shall not be considered unless a welder has had tested at least 1000mm
of weld for linear repair rate and 20 welds for joint repair rate.
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Welder Performance Criteria and Corrective Action
• Cumulative welder’s performance between 2% - 5% (linear) or 5% -10% (joint) – a written

warning shall be issued. If welder does not improve the following week a further written
warning shall be given. If still no improvement then the welder shall be given three days
training and then re-qualify.
• Cumulative welder’s performance between 5% - 10% (linear) or 10% - 15% (joint) - the
welder shall be given three days training and then re-qualify.
• Cumulative welder’s performance >10% (linear) or >15% (joint)- shall be disqualified from
welding pressurized piping on the project.
Note: - All written warnings shall be signed by the welder.

Evidence of the action taken shall be issued to the Contractor.
Penalty Shots for Repairs. (Progressive sampling ASME B31.3 clause 341.3.4)
For percentage line classes radiography shall be carried out in accordance with the requirements of
000-L-EE-0020003. In order to ensure that the percentage radiography is distributed evenly between
welders the progressive sampling applied shall be controlled by Line Class and by welder LOTS as
defined below.
Sample radiography for welders shall be controlled by Progressive Sampling ‘LOTS’ of 20 welds
grouped together by weld date. Welds chosen for sampling shall as much as possible cover the
different materials/ diameters and welding processes of each individual welder.
During percentage radiography if a defect is found in any LOT progressive radiography shall be applied
as follows:
• A further two joints welded by the same welder within the LOT shall be radiographed. If no
further repairs are observed then the initial repair shall be repaired and tested as required by
project requirements. No further action is required.
• If a repair is detected in the first two sampled welds then two further joints (for each failed
weld) within the LOT shall be radiographed. If no further repairs are observed then the all
repairs shall be repaired and tested as required by project requirements. No further action is
required.
• If a repair is detected in the second two welds tested then 100% of the welds represented by
the progressive sampling LOT shall be examined and repaired as necessary.
Penalty Shots for Socket Welds

For percentage line classes where radiography is required for Socket Welds in order to ensure the
minimum clearance is achieved at the bottom of the socket, the progressive sampling process shall be
applied. The radiography shall involve just one shot (one radiographic film) and the sampling shall be
controlled in LOTS of 20 joints grouped together by weld date.
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During this radiography if the minimum clearance is not achieved progressive sampling shall be applied
as follows:
• A further two joints within the LOT shall be radiographed. If no further failures then the initial
joint shall be cut, re-welded and tested as required by project requirements. No further action
is required.
• If a minimum clearance failure is detected in the first two sampled joints then two further joints
(for each failed joint) within the LOT shall be radiographed. If no further failures are observed
then the all failures shall be cut, re-welded and tested as required by project requirements. No
further action is required.
• If a failure is detected in the second two joints tested then 100% of the joints represented by
the progressive sampling LOT shall be examined. All failures shall be cut, re-welded and
tested.
Improvement Monitoring
The Subcontractor shall report on a weekly basis the repair rate based on defect type. This shall be
reviewed by the Subcontractor looking at the causes of defects and the preventive action that could be
taken to reduce occurrence. Preventative action shall be reported and improvement shall be monitored.
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ATTACHMENT IV
POINTS OF MEASUREMENT FOR PREHEATING TEMPERATURE
For t mm <= 50: A = 1.5 * t, max. 75

mm
For t mm > 50: A = 75 mm
2248-000-A-EE-0020004 40/43
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REV 2 3 4 5 6 7
ATTACHMENT V:Welding table

Hardness
PROJECT: ……………..…..……………., DOC. No: …………….……..……………., REV: …..……., DATE: …..…/…...…/…..…., PAGE: …... / …….
OR CODE (C)
Charpy
SERVICE (S)
REQUIR. (3)
impact
C
PWHT
C
actual
Diameter 10” – 24”

½”-3”
4”-8”
range
PIPE SIZE
21.21- 30.18 mm
(2)
5.16 -18.26 mm
2.77 - 4.78 mm
actual
Thickness
range
A 106 Gr.B / A105
A 106 Gr.B / A105
A 106 Gr.B / A105

MATERIAL
(P. No. or
grade)
BASE
Butt weld
X
X
WELD JOINT
TYPE (1)
Branch
X
Fillet
X
X
SUPPORTING
3061/2010
3354/2010
4321/2010
PQR
GT-SM-02-AW-KV-HT
GT-SM-02-PW-KV-HT
GT-01-AW- HT
WPS
(4)
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PIPING
CLASS
A11C
A11C
A11C
Notes to the “welding table”:
(1) In “weld joint type” field check the cell relative to the actual production joint type.
(2) In “Pipe size” field actual production diameter and wall thickness of the joint shall be reported (in mm).
(3) In “Service or code requirement” field check the cell relative to the test / treatment required for code with the
letter “C” and the test / treatment required for service with the letter “S”.
(4) In this section main information concerning the documentation shall be reported.
2248-000-A-EE-0020004 42/43
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ATTACHMENT VI
ADDITIONAL REQUIREMENTS FOR SPECIAL SERVICES
VI-1 SOUR SERVICE

VI-1A Only full penetration welds shall be made; the root pass shall be done by the GTAW welding process.
Socket welds are not permitted.
VI-2 HYDROGEN SERVICE

VI-2A Only full penetration welds shall be made; the root pass shall be done by the GTAW welding process.
Socket welds and fillet welds are not permitted.
VI-3 FLUID CATEGORY M SERVICE
VI-3A Socket weld joints greater than DN 50 (NPS 2) are not permitted
VI-4 AMINE SERVICE
VI-4A Piping construction shall preferably be butt weld. The use of threaded and socket
weld connections shall be verified.
VI-5 HIGH PRESSURE SERVICE
VI-5A Socket weld fittings are not permitted.
VI-5B Fillet welds may be used only for structural attachments. Seal welds are not
permitted.
VI-6 FLUID CATEGORY M SERVICE
VI-6A Seal weld of threaded connections shall not be carried out.
VI-7 FLUID CATEGORY D SERVICE
VI-7A Seal weld of threaded connections shall not be carried out.
NOTE
Additional requirements (filler metals selection, PWHT, testing, etc.) directly related to base materials,
if any, shall be specified by the General Welding Specifications for various materials).
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ATTACHMENT VII
WELDER IDENTIFICATION CARD

VII-1 WELDER IDENTIFICATION CARD
VII-1A Welder Identification Cards are only valid for the project for which they are issued.
VII-2A Welder Identification Cards can be withdrawn by Contractor – WES at any time for cause if the
Subcontractor Welder/Welding Operator is not producing work of acceptable quality. Once
withdrawn, Welder Identification Cards will only reinstated upon receipt of written proof of three (3)
days training, and the successful completion of “FIRST WORKING DAYS TWO JOINTS
RADIOGRAPHY TEST” (as per attachment III).
VII-3A Welder Identification Cards shall be returned to Contractor – WES when the Subcontractor
welder/welding operator goes on home leave or is terminated from the project. Subcontractor
Welders/Welding Operator that returns to work within three months from home leave (to the same
project) may be reinstated without retesting.
VII-4A Sample of Welder Identification Card :

Will be used the latest form version IF-WLD-002 from document 000-A-EE-0190429 - Site Quality Control
Welding And NDE Plan
WELDER IDENTIFICATION CARD
Project : STAR Rafineri A.Ş. (STAR) / AEGEAN REFINERY PROJECT
Welder Name:
Types:
Welder Stamp No: PHOTO
We certify that the statements in this record are correct and that the test
coupons were prepared, welded and tested in accordance with the requirements
of Section IX of the ASM E BPV Code
P repared by: Checked by: A ppro ved by TSGI M I:
Date: Date: Date:
Actual Values Range Qualified

WPS Test Valid
Material Process Mat. Filler Deposit Filler
No. Dia. Position Dia. Position Date Date
Thk. Metal Mat. Thk. Metal
This card qualifies the welder for 6 months from the date of issue.
Form Code: IF-WLD-002_Rev.0

000 A Ee 0020004

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STAR RAFİNERİ, A.Ş.

6.1 Welding Procedures Specifications and Qualification certificates 28

1.1 Scope and field of application

This specification provides general requirements to be followed independently of pipe material,

000-L-EE-0020003 NDE and Requirements for Piping

000-A-EE-0024016 General Specification - Carbon Steel Piping Welding

000-A-EE-0024017 General Specification - Carbon Molybdenum and Chromium-Molybdenum Steel

000-A-EE-0024018 General Specification - Grade 91 Steel Piping Welding

000-A-EE-0190429 Site Quality Control Welding And NDE Plan

STGPS-L1 rev.5 Refinery piping

STGPS-L4 rev.5 Piping Material

STGPS-L7 rev.3 Reinforcement of welded branch

UOP St. 8-12-7 Fabrication of piping

UOP St. 8-12-7 is applicable only for UOP licensed UNIT:

U-415 Unsaturated LPG Merox

U-150 Hydrocracking Unit

U-410 Saturated regenerative caustic treatment LPG Merox unit

For this purpose Subcontractor shall designate an employee “Subcontractor Welding

OWNER: STAR RAFİNERİ A.Ş.

CONTRACTOR: JV among Técnicas Reunidas (TR), Saipem, GS e&c and

PROJECT: Aegean Refinery Project (ARP) at Aliağa, Turkey.

JOBSITE: Owner’s property land at Izmir– Aliağa, Turkey on, under, in or

Weldment: An assembly whose component parts are joined by welding;

AISI American Iron and Steel Institute

API American Petroleum Institute

AWS American Welding Society

BM Base Metal/Parent Metal

EN European Standards and Regulations

FCAW Flux Cored Arc Welding

GMAW Gas Metal Arc Welding

GTAW Gas Tungsten Arc Welding

HAZ Heat Affected Zone

ICHAZ Intercritical Heat Affected Zone

ILAC International Laboratory Accreditation Cooperation

IIW International Institute of Welding

IQI Image Quality Indicator

ISO International Standards Organization

NDT Non Destructive Examination

NPS Nominal Pipe Size

PED Pressure Equipment Directive 97/23/EC

PWHT Post-weld Heat Treatment

QCM Quality Control Manager

ReH Minimum yield strength at room temperature

SAW Submerged Arc Welding

SMAW Shielded Metal Arc Welding

SNT-TC-1A Recommended Practice for Non-destructive Testing Personnel Qualification

t Thickness in mm of deposited weld metal

TMCP Thermo Mechanical Control Process

UTS Ultimate tensile strength

UT-TOFD Ultrasonic test – Time of Flight Diffraction

VILELLA 5ml HCl + 1g picric acid + 100ml ethanol or methanol

WES Welding Quality Control Supervisor

WOPQ Welding Operator Performance Qualification

WPQT Welding Procedure Qualification Tests

WPS Welding Procedure Specification

1.4 Order of documents priority

2 PREPARATION FOR WELDING

2.1 Edge preparation

 Base material is Carbon steel

2.3 Fit-up, alignment and spacing

2.4 Hot adjustments

2.4.1 Hot adjustment isn’t allowed.

3.1 Welding processes and equipment