CONOCO INDONESIA INC. LTD.

PROJECTS DEPARTMENT
SPECIFICATION
TITLE
WELDING SPECIFICATION FOR FLOWLINES
TO API 1104 : 1999

DOCUMENT NUMBER

REV

DATE

PAGE

84501-9230-2L-035

31 July 03

2 of 12

REVISION CONTROL SHEET

Latest
Rev

DATE ISSUED

PREPARED

REVIEWED

APPROVED

COMMENTS

14 Aug 02

S Malkin

C Fox

Alaister
McIntosh

Issued For Use

A0

1 Mar 03

Charlie Fox

Dean Hewitt

Alaister
McIntosh

Issued For Use

31 July 2003

Joe Kiefer

Charlie Fox

Alaister
McIntosh

Sections 5.1 & 5.2

revised

CONOCO INDONESIA INC. LTD.

PROJECTS DEPARTMENT
SPECIFICATION
TITLE
WELDING SPECIFICATION FOR FLOWLINES
TO API 1104 : 1999

DOCUMENT NUMBER

REV

DATE

PAGE

84501-9230-2L-035

31 July 03

3 of 12

TABLE OF CONTENTS
0

PROJECT SPECIFIC ADDENDUM.4

QUALITY CONTROL..............................................................................................6

MATERIALS ...........................................................................................................7

WELDING PROCESSES AND CONSUMABLES ..................................................7

WELDING PROCEDURE QUALIFICATION ..........................................................7

WELDER AND WELDING OPERATOR QUALIFICATION....................................8

FABRICATION .......................................................................................................8

POSTWELD HEAT TREATMENT ........................................................................ 11

NON DESTRUCTIVE TESTING ........................................................................... 11

REPORTS AND RECORDS ................................................................................. 12

CONOCO INDONESIA INC. LTD.

PROJECTS DEPARTMENT
SPECIFICATION
TITLE
WELDING SPECIFICATION FOR FLOWLINES
TO API 1104 : 1999

PROJECT SPECIFIC ADDENDUM

None Required

DOCUMENT NUMBER

REV

DATE

PAGE

84501-9230-2L-035

31 July 03

4 of 12

CONOCO INDONESIA INC. LTD.

PROJECTS DEPARTMENT
SPECIFICATION
TITLE
WELDING SPECIFICATION FOR FLOWLINES
TO API 1104 : 1999

INTRODUCTION

1.1

Scope

DOCUMENT NUMBER

REV

DATE

PAGE

84501-9230-2L-035

31 July 03

5 of 12

This document defines the minimum technical requirements for the Welding Specification
for Flowlines to API 1104 : 1999 - Welding of Pipelines and Related Facilities.
Contractor shall obtain Company written approval for any deviations from the
requirements of this document or specifications, standards and drawings referenced
herein or elsewhere in the Contract.
This document and the codes, specifications and referenced documents listed in 1.2
below are not intended to be all-inclusive. The requirements set forth do not relieve
Contractor of his responsibility to perform all services in a safe manner, to meet
applicable codes and standards, to comply with government regulations or to supply a
product capable of performing its intended service.
In addition to the requirements of API 1104 (and ASME B31.4 and/or ASME B31.8 if so
specified), the supplemental requirements of this specification shall apply and take
precedence. For any lines designated as sour service, NACE MR0175 shall also apply.
1.2

Codes, Specifications, And References

The latest editions of all applicable codes, specifications and references shall define the
minimum requirements applicable to the subject work and no statement contained in this
Specification shall be construed as limiting the work to such minimum requirements.
Wherever conflicts or omissions between codes, specifications and contract occur, the
most onerous condition shall apply. Contractor is responsible for reviewing the list below
and informing the Company of any omissions. All conflicts shall be formally brought to
the attention of the Company.
Applicable Codes
API Spec 5L

Specification for Line Pipe

API Spec 1104 : 1999

Welding of Pipelines and Related Facilities

ANSI B31.4

Pipeline Transportation Systems for Liquid Hydrocarbons

and Other Liquids

ANSI B31.8

Gas Transmission and Distribution Piping Systems

ASME BPVC Section V

Non Destructive Testing

CONOCO INDONESIA INC. LTD.

PROJECTS DEPARTMENT
SPECIFICATION
TITLE
WELDING SPECIFICATION FOR FLOWLINES
TO API 1104 : 1999

DOCUMENT NUMBER

REV

DATE

PAGE

84501-9230-2L-035

31 July 03

6 of 12

ASME BPVC Section IX

Qualification Standard for Welding and Brazing

Procedures, Welders, Brazers, and Welding and Brazing
Operators

NACE MR0175

Sulfide Stress Cracking

Oilfield Equipment

Draft: API RP 582

Recommended Practice and Supplementary Welding

Guidelines for the Chemical, Oil, and Gas Industries

Resistant Metallic Materials for

Company Specifications
84505-9200-9L-027

Welding Procedure and Welder Performance Qualification

84501-9230-2L-022

Seamless Flowlines to API 5L

84501-9230-2L-047

Seamless Stainless Steel (13Cr) Line Pipe to API 5L

84501-9230-2L-046

Submerged-Arc Welded Double Line Pipe To DNV

F101

84501-9230-2L-044

Seamless Duplex Stainless Steel (22Cr) Line Pipe

OS-

to API 5L
84501-9230-2L-042

Clad/Lined Line Pipe

84501-9230-2L-006

Pipeline Flanges and Fittings

84501-9230-2L-009

Induction Bends

84501-9230-2L-037

Automated Ultrasonic Girth Weld Testing to API 1104 : 1999

84501-9230-2L-039

NDT of Flowlines to API 1104 : 1999

QUALITY CONTROL

2.1

Contractor shall have a quality control system and quality control manual covering all
construction activities. Controlled copies of the quality control manual shall be available
for Company approval and for monitoring of all construction activities.

CONOCO INDONESIA INC. LTD.

PROJECTS DEPARTMENT
SPECIFICATION
TITLE
WELDING SPECIFICATION FOR FLOWLINES
TO API 1104 : 1999

DOCUMENT NUMBER

REV

DATE

PAGE

84501-9230-2L-035

31 July 03

7 of 12

2.2

Contractor shall establish a procedure to document and provide traceability of all primary
materials to their original mill certifications. The procedure shall identify methods for
maintaining the identity of material from manufacturing stages through transport, receipt,
storage, and final component fabrication. A system shall be employed for linking unique
inspection records, weld numbers, and welder identification.

2.3

Contractor shall establish detailed procedures for control of welding quality. The
procedures shall be submitted for review and approved by the Company before starting
fabrication and shall include as a minimum:

welding and weld repair

storage, control, and identification of welding consumables
welder qualification records
inspection/NDT
post-weld heat treatment, if required
monitoring the progress and quality of welding
material and NDT traceability

MATERIALS
The steel used for pipelines and fittings shall meet the requirements of project
specifications referenced in Section 1.2. API monogrammed steel shall be used
wherever possible unless specific approval is given in writing granting a waiver.

WELDING PROCESSES AND CONSUMABLES

Welding processes for pipeline welds shall comply with the requirements of API 1104
and Specification 84501-9200-9L-027 for acceptable processes, consumables, and the
requirements for consumable storage and handling.

WELDING PROCEDURE QUALIFICATION

5.1

Procedures shall be qualified for each combination of API diameter and nominal wall
thickness groups.

5.2

The allowable range of heat input rates to be applied by the welding processes for each
bead shall be clearly specified. The units used shall be kilo joules per mm.(kJ/mm)

5.3

Welding procedure qualifications shall comply with API 1104 and the supplemental
requirements of Specification 84501-9200-9L-027.

5.4

The qualification test piece shall meet the acceptance standards of API 1104 Section 6
for visual and radiographic examination.

5.5

The qualification test piece shall meet the mechanical property requirements of API 1104
with the following additions:

CONOCO INDONESIA INC. LTD.

PROJECTS DEPARTMENT
SPECIFICATION
TITLE
WELDING SPECIFICATION FOR FLOWLINES
TO API 1104 : 1999

5.3.1

5.3.2

DOCUMENT NUMBER

REV

DATE

PAGE

84501-9230-2L-035

31 July 03

8 of 12

Charpy tests shall be conducted according to ASTM A 370 on the weld metal and heat
affected zone at the locations given in Specification 84501-9200-9L-027.
5.3.1.1

For carbon steel, the test temperature shall be 10OC (18OF) lower than the
minimum service temperature, or -18OC (0OF), whichever is less. The minimum
absorbed energy shall be 36 ft-lb (41 J) average and 30 ft-lb (34 J) individual.

5.3.1.2

Where parent material toughness is not required, Charpy tests shall be

conducted at -18OC (0OF). Base metal and HAZ results shall be conducted for
information only. Minimum weld metal values shall be 20 ft-lb average and 15
ft-lb individual.

Hardness tests shall be conducted and meet the requirements specified in Specification
84501-9200-9L-027.
5.3.2.1

For sour service, welding procedures shall follow the additional requirements of
NACE MR0175 (Maximum 250 HV10), except for carbon steel pipe thickness of
9.5 mm and up, the maximum external HAZ hardness shall be 275 HV10
Vickers.

5.6

Qualification shall be conducted on production pipe material unless otherwise approved

by the Company.

WELDER AND WELDING OPERATOR QUALIFICATION

Welder and welding operator qualifications and testing shall meet API 1104 and the
supplemental requirements of Specification 84501-9200-9L-027.

FABRICATION

7.1

General

7.1.1 All fabrication shall confirm to API 1104, ASME B13.4, or ASME B31.8 as applicable and
the additional requirements of this specification. Any discrepancies in the referenced
codes and specifications shall be reported to the Company representative for resolution.

7.1.2 Welding shall comply with API RP 582. This document is currently in Draft form and will
be provided as a part of 84501-9200-9L-027. Welding Procedure and Performance
Qualification until it is available for sale by API.

7.1.3 Contractor shall submit descriptions of all welding equipment, types of machinery,
welding materials to be used, tools, and all other required items to the Company for
approval. This equipment shall consist of, but not be limited to: D.C. welding machines,
welding generators, equipment and machinery for cutting, bevelling, preheating and
post-weld heat treating (PWHT), internal and external lineup clamps, welding consumables, welders' tools, tents, and insulation blankets for weather protection
7.2

Marking

CONOCO INDONESIA INC. LTD.

PROJECTS DEPARTMENT
SPECIFICATION
TITLE
WELDING SPECIFICATION FOR FLOWLINES
TO API 1104 : 1999

DOCUMENT NUMBER

REV

DATE

PAGE

84501-9230-2L-035

31 July 03

9 of 12

7.2.1 Before materials are cut, permanent identification (heat/pipe numbers) shall be
transferred.

7.2.2 Each weld shall be marked with the identification symbol of the welder or welding
operator next to the weld area or records shall be maintained to identify the work of each
welder, i.e., weld numbers, shift, passes, left or right side of pipe, etc. Failure to use the
symbol or maintain adequate records shall be cause for rejection of the work and
removal of the weld.

7.2.3 For all welds, weld identification numbers shall be painted on the pipe coating using
contrasting colors. A reference between weld numbers and pipe numbers shall be
maintained. Each weld number shall be located from 1:00 to 5:00 and 7:00 to 11:00 next
to the weld. The width of each letter or number shall not be less then 19 mm ( in.).
Weld identification must be legible using sequential numbers and/or combination of
English block letters and numbers.
7.3

Non-ferrous Materials

7.3.1 Whenever possible, only stainless steel tools or grinding disks dedicated to stainless
steel shall be used. Material supports, internal purge dams, alignment clamps, and other
tools may be coated with a compatible material approved by the Company.

7.3.2 All duplex stainless steel welds shall be checked with a magnetic ferrite gage and have
40% to 60% ferrite.

7.3.3 The joint design and alloy filler metal for clad pipe must be such that the resulting weld
on the alloy clad side of the pipe will be equal in corrosion resistance and similar in
composition to the alloy cladding.
7.4

Butt Weld Alignment

7.4.1 Butt weld alignment shall meet the requirements of API 1104 (Sections 4.2 and 4.9.1),
the qualified weld procedure dimensional limitations, and the conditions of this section.

7.4.2 Internal grinding or machining may be conducted to improve root alignment if

misalignment is equal to or less than 3.2 mm. However, the taper shall not exceed 1 in 4
and the minimum wall thickness shall be maintained.

7.4.3 Company may consider Internal Clamp removal or Pulling on the Bead provided the
root pass is made by an automatic welding process and the thickness of the root deposit
is substantially greater than typical manual root passes. First passes on the I.D. of the
pipe are not considered by themselves to be completed root passes.

7.4.4 Longitudinal welds of adjacent pipes shall be staggered by at least 30O or 3 inches (75
mm), whichever is less.
7.5

Pressure Containing Welds

7.5.1 All pressure containing welds shall be made with a minimum of two passes with overlap
of starts and stops.

CONOCO INDONESIA INC. LTD.

PROJECTS DEPARTMENT
SPECIFICATION
TITLE
WELDING SPECIFICATION FOR FLOWLINES
TO API 1104 : 1999

7.6

DOCUMENT NUMBER

REV

DATE

84501-9230-2L-035

31 July 03

PAGE
10 of
12

Spacing of Welds

7.6.1 The spacing of welds shall meet the requirements of the following based on the type of
weld and attachment.

7.6.2 The maximum possible distance shall separate circumferential butt welds. However,
between piping fittings and tie-ins, etc., short pipe lengths may be required. In this
situation, butt welds shall not be within 75 mm or one nominal pipe diameter of adjacent
butt welds, whichever is greater. For pipe less than 3-inch (80 NB) nominal size, butt
welds should be separated from adjacent welds by the greater of four (4) times the wall
thickness, or one pipe diameter. Circumferential butt welds closer than the above limits
shall not remain without Company approval.

7.6.3 Branch/nozzle and other pressure attachment welds shall not be closer than 75 mm
(measured toe-to-toe) to adjacent pressure welds. Any cases that fail to meet this
criterion shall be approved by the Company representative before commencement of
fabrication.

7.6.4 Attachment welds that are not pressure containing, such as pipe support welds, are
generally not allowed on the surface of the pipeline. If such welds are part of the
approved design, then each shall be a minimum of 50 mm from any other pressure
containing welds (measured toe-to-toe).
7.7

Repairs

7.7.1 For all welding processes, repair procedures shall be qualified and approved by the
Company before use. These may be based on Company approved full penetration
groove welding procedures or specifically qualified for repairs.

7.7.2 Only low hydrogen welding processes shall be used for repairs.
7.7.3 For procedures based on carbon steel groove welding procedures, work piece
temperature shall be a minimum of 50OC higher than the minimum preheat temperature
required for the original approved welding procedure.

7.7.4 The maximum number of repair attempts shall be two.

7.7.5 Arc strike repair shall be by grinding to remove the arc strike (provided the minimum
acceptable thickness remains) or by cut out and re-welding.

7.7.6 Open root repairs shall not be made after the last tensioner for offshore pipeline welding
unless a stress analysis is performed by Contractor and approved by the Company.
7.8

Pipe Bends

Bends shall conform to ASME B31.4 and B31.8 for liquid and gas pipelines as
applicable, and the engineering drawings with the following additional limitations:
7.8.1 Bending shall be done according to procedures submitted by Contractor and approved
by Company before the start of the work. Contractor shall demonstrate the bending
procedures.

CONOCO INDONESIA INC. LTD.

PROJECTS DEPARTMENT
SPECIFICATION
TITLE
WELDING SPECIFICATION FOR FLOWLINES
TO API 1104 : 1999

DOCUMENT NUMBER

REV

DATE

84501-9230-2L-035

31 July 03

PAGE
11 of
12

7.8.2 The minimum bend radius shall be five (5) times the nominal pipe diameter. A greater
bend radius may be required because of the material grade, pipe size, and/or nominal
wall thickness.

7.8.3 Suitable allowance for pipe wall thinning due to the bending process shall be applied to
obtain the specified pipe wall thickness after bending.

7.8.4 Each bend shall have a smooth contour, free from buckling, cracks, and/or other
evidence of mechanical damage.

7.8.5 The difference between the maximum and minimum diameters at the ends of the
completed bend as defined by the engineering drawings shall not exceed the applicable
ASTM or API material specification for the straight pipe before bending. This
requirement does not include the extra tangent lengths that may be required for bend
pulling purposes.

7.8.6 The weld seam(s) on pipe with longitudinal welds shall be as near as possible to the
neutral axis of the bend.

POSTWELD HEAT TREATMENT

Post-weld heat treatment and/or stress relief procedures, if required, shall be according
to the requirements of ASME B31.4 or B31.8 as applicable.

NON DESTRUCTIVE TESTING

9.1

Non destructive testing shall comply with Specification 84501-9230-2L-37 and/or 845019230-2L-039 and the additional requirements of this specification. Contractor shall
submit and demonstrate the required examination procedures for Company approval
before any welding.

9.2

Company representative may be present during examinations/inspections. Contractor

shall give sufficient notice before any examination is scheduled to take place so that
Company can arrange to have a representative present before any welding occurs.

9.3

Radiographic Testing Method

Radiographic testing shall be carried out using x-ray.

9.4

One hundred percent (100%) NDT shall apply to all offshore pipeline welds. The extent
of inspection for other applications shall be as defined in contract documents, or ASME
B31.4 or B31.8 as appropriate. When less than 100 percent inspection is required, the
welds shall be selected to ensure that the work product of each welder or welding
operator doing the production welding is included.

CONOCO INDONESIA INC. LTD.

PROJECTS DEPARTMENT
SPECIFICATION
TITLE
WELDING SPECIFICATION FOR FLOWLINES
TO API 1104 : 1999

10

DOCUMENT NUMBER

REV

DATE

84501-9230-2L-035

31 July 03

PAGE
12 of
12

REPORTS AND RECORDS

The following reports and data shall be supplied to the Company representative.
Additionally, Contractor shall retain the radiographic film, a copy of the examination
procedures, and personnel qualifications used for the contracted work for five (5) years
or according to the contract requirements.

10.1

Mill test reports and certificates

10.2

Company approved welding procedure package

10.3

Welder and/or welding operator qualification test results

10.4

NDT reports and results

10.5

Material traceability documents