1 Scope
This standard specifies the acceptance requirements of destructive test as well as radiographic testing, ultrasonic testing, magnetic particle testing and penetration testing on pipeline erection and welds.
This standard is applicable to the erection and welding of carbon and low-alloy steel pipeline and their fittings, long-distance pipeline for transmission of crude petroleum, petroleum products and fuel gases, as well as pipeline networks of compressor station and pump station. The applicable types of welds include butt joint, fillet joint and overlap joint.The welding may be done by a shielded metal-arc welding, submerged arc welding, gas tungsten-arc welding, gas metal-arc welding, flux-cored arc welding, oxyacetylene welding, or flash butt welding process or by a combination of these processes. The welds may be produced by position or roll welding or by a combination of position and roll welding.
2 Normative References
The following normative documents contain provisions which, through reference in this standard, constitute provisions of this standard. For dated references, subsequent amendments (excluting error corrections) to, or revisions of, any of these publications do not apply. However, all parties coming to an agreement according to this standard are encouraged to study whether the latest editions of these documents are applicable. For undated references, the latest edition of the normative document referred to applies.
GB/T 3091 Welded Steel Pipes for Low Pressure Liquid Delivery (neq ISO 559)
GB/T 3375 Welding Terminology
GB/T 5117 Carbon Steel Covered Electrodes (eqv ANSI/AWS A5.1)
GB/T 5118 Low Alloy Steel Covered Electrodes (neq ANSI/AWS A5.5)
GB/T 5293 Carbon Steel Electrodes and Fluxs for Submerged Arc Welding (eqv ANSI/AWS A5.17)
GB/T 8110 Welding Electrodes and Rods for Gas Shielding Arc Welding of Carbon and Low Alloy Steel (neq ANSI/AWS A5.18)
GB/T 8163 Seamless Steel Tubes for Liquid Service (neq ISO 559)
GB/T 9711.1 Petroleum and Natural Gas Industries-Steel Pipe for Pipelines-Technical Deivery Conditions-Part 1: Pipes of Requirement Class A (eqv ISO 3183-1)
GB/T 10045 Carbon Steel Flux Cored Electrodes for Arc Welding (eqv ANSI/AWS A5.20)
GB/T 12470 Low-alloy Steel Electrodes and Fluxs for Submerged Arc Welding
GB/T 13793 Steel Pipes with a Longitudinal Electric (Resistance) Weld (neq JIS G3444)
GB/T 14957 Steel Wires for Melt Welding
GB/T 14958 Steel Wires for Gas Shielded Welding
GB/T 17493 Low Alloy Steel Flux Cored Electrodes for Arc Welding(eqv ANSI/AWS A5.29)
SY/T 0327 Mechanized Ultrasonic Examination of Girth Butt Welds in Oil and Steel Pipeline(neq ASTM E1961, API Std 1104)
SY/T 5037 Spiral Submerged Arc-welded Steel Pipe for Pipelines for Low Pressure Fluid Service
SY/T 5038 Spiral Submerged Arc-welded Steel Pipe for Pipelines for Ordinary Fluid Service(ncq API Spec 5L)
JB/T 7902 Wire Type Image Quality Indicator
Management Regulations on the Assessment and Supervision of Non-destructive Testing Personnel for Special Equipment GUOZHIJIANGANG[2003]NO.248 issued by the General Administration of Quality Supervision, Inspection and Quarantine (AQSIQ) of the People's Republic of China
API Spec 5L Specification for Line Pipe
API Std 1104 Welding of Pipelines and Related Facilities
ASTM E92 Standard Test Method for Vickers Hardness of Metallic Materials E
ASTM E165 Standard Test Method for Liquid Penetrant Examination
ASTM E709 Guide for Magnetic Particle Examination
ASTM E747 Standard Practice for Design, Manufacture and Material Grouping Classification of Wire Image Quality Indicators (IQI) Used for Radiology
ASTM E1025 Standard Practice for Design, Manufacture, and Material Grouping Classification of Hole-type Image Quality Indicators (IQI) Used for Radiology
AWS A5.1 Covered Carbon Steel Arc Welding Electrodes
AWS A5.2 Iron and Steel Oxyfuel Gas Welding Rods
AWS A5.5 Low Alloy Steel Covered Arc Welding Electrodes
AWS A5.17 Carbon Steel Electrodes and Fluxes for Submerged-arc Welding
AWS A5.18 Carbon Steel Filler Metals for Gas Shielded Arc Welding
AWS A5.20 Carbon Steel Electrodes for Flux Cored Arc Welding
AWS A5.28 Low-alloy steel Filler Metals for Gas Shielded Arc Welding
AWS A5.29 Low-alloy Steel Electrodes for Flux Cored Arc Welding
BS 7448 Fracture Mechanics Toughness Tests Part 2: Method for Determination of KIC, Critical CTOD and Critical J Values of Metallic Materials
3 Terms and Definitions
The following terms and definitions are applicable to this standard.
3.1
Company
The owner company or the engineering agency in charge of construction. The company may act through an inspector or another authorized representative.
3.2
Contractor
Includes the primary contractor and any subcontractors engaged in work covered by this standard.
3.3
Weld
The completed weld joining two sections of pipe, a section of pipe to a ftting, or two fttings.
3.4
Qualified welding procedure
A tested and proven detailed method by which sound welds with suitable mechanical properties can be produced.
3.5
Qualified welder
A welder who has demonstrated the ability to produce welds that meet the requirements of Chapter 5 or 6..
3.6
Root bead
The first or stringer bead that initially joins two sections of pipe, a section of pipe to a fitting, or two fittings.
3.7
Hot welding
The second bead that is done immediately after completing root bead.
3.8
Filling welding
The bead that is done after completing root bead or hot welding and before covering welding.
3.9
Covering welding
The outmost forming bead.
3.10
Position welding
Welding in which the pipe or fitting is held stationary.
3.11
Roll welding
Welding in which the pipe or fitting is rotated while the weld metal is deposited at or near the top center.
3.12
Automatic welding
Arc welding with equipment that performs the entire welding operation without manual manipulation of the arc or welding wire (electrode) other than guiding or regulating.
3.13
Semiautomatic welding
Arc welding with equipment that controls only the filler-metal feed. The advance of the welding is manually controlled.
3.14
Pit
A partially low-lying part that is produced on the weld surface or weld back after welding and is lower than the surface of parent metal.
3.15
Imperfection
A discontinuity or irregularity that is detectable by methods outlined in this standard.
3.16
Defect
An imperfection of suffcient magnitude to warrant rejection based on the stipulations in this standard.
3.17
Repair
Any rework on a completed weld that requires welding to correct a fault in the weld that has been discovered by visual or nondestructive testing and is beyond this standard's limits of acceptability.
3.18
Welder
A person who makes a weld.
4 General Requirements for Welding
4.1 Equipment
Welding equipment shall be suitable for the work and shall be maintained in a condition that ensures acceptable welds, continuity of operation, and safety of personnel. Equipment that does not meet these requirements shall be repaired or replaced.
4.2 Materials
4.2.1 Pipe and fittings
This standard applies to the welding of pipe and fittings that conform to the lastest edition of the following specifications:
GB/T 3091 Welded Steel Pipes for Low Pressure Liquid Delivery
GB/T 8163 Seamless Steel Tubes for Liquid Service
GB/T 9711.1 Petroleum and Natural Gas Industries-Steel Pipe for Pipelines-Technical Deivery Conditions-Part 1: Pipes of Requirement Class A
GB/T 13793 Steel Pipes with a Longitudinal Electric (Resistance) Weld
SY/T 5037 Spiral Submerged Arc-welded Steel Pipe for Pipelines for Low Pressure Fluid Service
SY/T 5038 Spiral Submerged Arc-welded Steel Pipe for Pipelines for Ordinary Fluid Service
API Spec 5L Specification for Line Pipe
Applicable ASTM specifications.
This standard also applies to materials with chemical and mechanical properties that comply with one of the specifications listed above, even though the material is not manufactured inaccordance with the specification.
Foreword I
1 Scope
2 Normative References
3 Terms and Definitions
4 General Requirements for Welding
4.1 Equipment
4.2 Materials
5 Welding Procedure Qualification
5.1 Procedure Qualification
5.2 Record
5.3 Procedure Specification
5.4 Procedure Changes
5.5 Welding of Test Pipe Joints --Butt Welds
5.6 Testing of Welded Joints --Butt Welds
5.7 Welding of Test Pipe Joints --Fillet Welds
5.8 Testing of Welded Joints --Fillet Welds
6 Qualification of Welders
6.1 General
6.2 Single Qualification
6.3 Multiple Qualification
6.4 Visual Examination
6.5 Destructive Test
6.6 Radiography-- Butt Welds Only
6.7 Retesting
6.8 Records
7 Pipe Orifice Welding
7.1 General
7.2 Alignment
7.3 Use of Lineup Clamp for Butt Welds
7.4 Bevel
7.5 Weather Conditions
7.6 Working Clearance
7.7 Cleaning between Beads
7.8 Position Welding
7.9 Roll Welding
7.10 Identification of Welds
7.11 Pre- and Post-heat Treatment
8 Inspection and Testing of Weld joints
8.1 Rights of Inspection
8.2 Methods of Inspection
8.3 Qualification of Inspection Personnel
8.4 Certification of Nondestructive Personnel
9 Acceptance Standards for Nondestructive Testing
9.1 General
9.2 Rights of Acceptance
9.3 Radiographic Testing
9.4 Magnetic Particle Testing
9.5 Liquid Penetrant Testing
9.6 Ultrasonic Testing
9.7 Visual Acceptance Standards for Undercutting
10 Repair and Removal of Defects
10.1 Authorization for Repair
10.2 Repair Procedure
10.3 Acceptance Criteria
10.4 Supervision
10.5 Welder
11 Procedures for Nondestructive Testing
11.1 Radiographic Test Methods
11.2 Magnetic Particle Test Method
11.3 Liquid Penetrant Test Method
11.4 Ultrasonic Test Method
12 Automatic Welding with Filler Metal Additions
12.1 Acceptable Processes
12.2 Procedure Qualification
12.3 Record
12.4 Procedure Specification
12.5 Essential Variables
12.6 Qualification of Welding Equipment and Operators
12.7 Records of Qualified Operators
12.8 Inspection and Testing of Production Welds
12.9 Acceptance Standards for Nondestructive Testing
12.10 Repair and Removal of Defects
12.11 Radiographic Testing
13 Automatic Welding without Filler-Metal Additions
13.1 Acceptable Processes
13.2 Procedure Qualification
13.3 Record
13.4 Procedure Specification
13.5 Essential Variables
13.6 Qualification of Equipment and Operators
13.7 Records
13.8 Quality Assurance of Production Welds
13.9 Acceptance Standards for Nondestructive Testing
13.10 Repair and Removal of Defects
13.11 Radiographic Procedure
Appendix A (Normative) Alternative Acceptance Standards for Girth Welds
A.1 General
A.2 Additional Requirements for Stress Analysis
A.3 Welding Procedure
A.4 Quali?cation of Welders
A.5 Inspection and Acceptable Limits
A.6 Record
A.7 Example
A.8 Repairs
A.9 Nomenclature
Appendix B (Normative) In-service Welding
B.1 General
B.2 Quali?cation of In-Service Welding Procedures
B.3 In-Service Welder Quali?cation
B.4 Suggested In-Service Welding Practices
B.5 Inspection and Testing of In-Service Welds
B.7 Repair and Removal of Defects
Appendix C (Informative) Technical Differences between This Standard and API Std 1104:1999 and Reasons
Appendix D (Informative) Welder Test Record
Appendix E (Informative) References
