AS/NZS 2885.2:2016+A1
Pipelines - Gas and liquid petroleum - Part 2: Welding
Specifies the minimum requirements for safety, welding consumables, weld preparations, welding processes, qualifications of welding procedures and personnel, and fabrication and inspection requirements for the construction and maintenance welding of carbon and carbon-manganese steel pipelines down to 3.2 mm wall thickness designed and constructed in accordance with NZS/AS 2885.1. The welding of corrosion resistant alloy steel pipelines, or pipelines with nominal thicknesses less than 3.2 mm, is not precluded, but is not expressly covered by this Standard. The welding of such pipelines has to be given special consideration. The welding may be done by a manual metal arc, submerged arc, gas tungsten arc, gas metal arc, flux cored arc or by a combination of these using a manual, semi-automatic, or automatic welding technique or a combination of these techniques. The welds may be produced by position or roll welding, or by a combination of position and roll welding. This Standard is applicable to the welding of joints in or on pipelines, and the welding of pipeline assemblies manufactured from pipes and fittings.
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AS/NZS 2885.2:2016 PIPELINES-GAS AND LIQUID PETROLEUM - WELDING
PREFACE
CONTENTS
SECTION 1 SCOPE AND GENERAL
1.1 SCOPE
1.2 APPROVAL
1.3 QUALIFICATION
1.4 RETROSPECTIVITY
1.5 REFERENCED DOCUMENTS
1.6 DEFINITIONS
1.6.1 Approved and approval
1.6.2 Automated ultrasonic testing (AUT)
1.6.3 Automatic welding
1.6.4 Burn-off rate
1.6.5 Buttering
1.6.6 Carbon equivalent (CE)
1.6.7 Cellulosic welding
1.6.8 Competent person
1.6.9 Component
1.6.10 Construction
1.6.11 Crack tip opening displacement (CTOD) test
1.6.12 Defect
1.6.13 Design temperatures
1.6.14 Diameter
1.6.15 Discontinuity
1.6.16 Dye-penetrant inspection (DPI)
1.6.17 Electrical discharge machining (EDM)
1.6.18 Engineering critical assessment (ECA)
1.6.19 Engineering design
1.6.20 Environment
1.6.21 Essential variable
1.6.22 Finite element analysis (FEA)
1.6.23 Fitting
1.6.24 Fluid
1.6.25 Flux core arc welding (FCAW)
1.6.26 Full screen height (FSH)
1.6.27 Gamma radiography
1.6.28 Gas
1.6.29 Gas metal arc welding
1.6.30 Golden weld
1.6.31 Heat input (arc energy)
1.6.32 Hot repair
1.6.33 Hydrogen assisted cold cracking (HACC)
1.6.34 Imperfection
1.6.35 Inert gas shielding
1.6.36 In-service welding
1.6.37 Interpass temperature
1.6.38 Lamellar tearing
1.6.39 Licensee
1.6.40 Location class
1.6.41 Magnetic particle testing (MPT)
1.6.42 Mainline pipework
1.6.43 Manual metal arc welding (MMAW)
1.6.44 Matching (overmatching, undermatching)
1.6.45 May
1.6.46 Mechanized welding
1.6.47 Multiple wire system
1.6.48 Nominal thickness (tN)
1.6.49 Non-destructive testing (NDT)
1.6.50 NDT technician
1.6.51 Non-essential variable
1.6.52 Non-planar discontinuity
1.6.53 O-let
1.6.54 Peening
1.6.55 Phase array ultrasonics (PAUT)
1.6.56 Pig
1.6.57 Pig trap (launcher/receiver)
1.6.58 Pipeline assemblies
1.6.59 Planar defect
1.6.60 Probability of detection (PoD)
1.6.61 Post-weld heat treatment (PWHT)
1.6.62 Preheat maintenance temperature
1.6.63 Preheat temperature
1.6.64 Pretest
1.6.65 Procedure qualification record (PQR)
1.6.66 Proposed welding procedure specification (pWPS)
1.6.67 Radiographic testing (RT)
1.6.68 Shall
1.6.69 Should
1.6.70 Sour service
1.6.71 Specified minimum yield strength (SMYS)
1.6.72 Station
1.6.73 Time of flight diffraction (ToFD)
1.6.74 Undercutting adjacent to the cover pass [SUC (ext)]
1.6.75 Undercutting adjacent to the root pass [SUC (int)]
1.6.76 Ultrasonic testing (UT)
1.6.77 Weld metal deposition repair
1.6.78 Welding procedure specification (WPS)
1.6.79 Weldability
1.6.80 X-radiography
1.6.81 Yield strength (σY)
1.7 ROUNDING OF NUMBERS
1.8 PIPELINE ASSEMBLIES
SECTION 2 SAFETY
2.1 PRODUCTION WELDING
2.1.1 General
2.1.2 Electrical safety during welding
2.1.3 Welding environment
2.1.4 Equipment and compressed gases
2.1.5 Electric and magnetic fields (EMF)
2.2 WELDING OR CUTTING ON A PIPELINE AFTER COMMISSIONING
2.2.1 General
2.2.2 Risk assessment
2.3 SAFETY AND PROTECTION FROM IONIZING RADIATION
SECTION 3 QUALIFICATIONS
3.1 GENERAL
3.2 WELDING ENGINEERING
3.3 WELDING SUPERVISION
3.4 WELDING INSPECTION
3.5 WELDERS AND WELDING OPERATORS
SECTION 4 MATERIALS
4.1 GENERAL
4.2 CONSUMABLES
4.2.1 General
4.2.2 Storage and handling of consumables
SECTION 5 DESIGN OF A WELDED JOINT
5.1 GENERAL
5.2 BUTT WELDS BETWEEN COMPONENTS OF EQUAL NOMINAL THICKNESS
5.3 BUTT WELDS BETWEEN COMPONENTS OF UNEQUAL NOMINAL THICKNESS
5.4 REINFORCEMENT OF A BUTT WELD
5.5 LONGITUDINAL BUTT WELDS
5.6 FILLET WELD
5.6.1 Dimensions of a fillet weld
5.6.2 Fillet welding a lug, boss, pig bar or pad
5.6.3 Sleeve fillet welds
5.6.4 Flanges and forged socket fittings
5.7 WELDING OF THREADED JOINTS
5.8 REINFORCEMENT OF A WELDED BRANCH CONNECTION
5.9 REINFORCEMENT OF MULTIPLE OPENINGS
5.10 FORGED BRANCH FITTING
5.11 EFFECT OF COMPONENTS UPON PIG PASSAGE
5.12 OFFSET OF LONGITUDINAL WELDS
5.13 DISTANCE BETWEEN WELDS
5.14 LOCATION OF ALUMINOTHERMIC WELDS AND PIN BRAZING CONNECTIONS
5.15 ATTACHMENT OF ELECTRICAL CONDUCTORS
5.16 GOLDEN WELDS
SECTION 6 QUALIFICATION OF A WELDING PROCEDURE SPECIFICATION
6.1 WELDING PROCEDURE SPECIFICATION (WPS)
6.2 PURPOSE OF QUALIFYING A WELDING PROCEDURE
6.3 TYPES OF WELDS REQUIRING QUALIFICATION
6.4 METHODS OF QUALIFICATION
6.4.1 General
6.4.2 Qualification by testing
6.4.3 Qualification to an alternate approved welding Standard
6.4.4 Qualification by prequalification without testing
6.4.5 Qualification by the use of engineering
6.5 CHANGES IN A WELDING PROCEDURE
6.5.1 Change in an essential variable
6.5.2 Change in other than an essential variable
6.6 CONDUCT OF THE QUALIFICATION WELDS
6.6.1 Planning a procedure qualification weld
6.6.2 Test piece size
6.6.3 Test piece material
6.6.4 Preparation and assembly of test pieces
6.6.5 Test conditions
6.6.6 Identification of the test weld
6.6.7 Recording a test weld
6.6.8 Supervision of the test weld
6.7 PROVISONS FOR SPECIFIC WELDING METHODS
6.7.1 Cellulosic welding
6.7.2 Provisions for waveform power sources
6.7.3 Aluminothermic welding
6.7.4 Pin brazing
SECTION 7 ASSESSMENT OF THE TEST WELD TO QUALIFY A WELDING PROCEDURE
7.1 METHOD OF ASSESSMENT
7.2 VISUAL EXAMINATION
7.3 NON-DESTRUCTIVE TESTING
7.4 DESTRUCTIVE TESTS
7.4.1 Types of test and number of test specimens
7.4.2 Transverse butt tensile strength test
7.4.3 All-weld-metal tensile test (AWMT)
7.4.4 Transverse guided side bend test
7.4.5 Macro test—Cross–section examination
7.4.6 Hardness test
7.4.7 Fracture toughness tests
7.5 RE-TESTS AND FURTHER TESTING
7.5.1 General
7.5.2 Visual examination and non-destructive testing
7.5.3 Destructive testing
7.5.4 Cause of failure
7.6 RECORD OF RESULTS
7.7 PERIOD OF VALIDITY
7.8 DISQUALIFICATION OF A QUALIFIED WELDING PROCEDURE
7.9 ALUMINOTHERMIC WELDS AND PIN BRAZING CONNECTIONS
SECTION 8 WELDING POSITIONS
8.1 DESIGNATION
8.2 LIMITS OF QUALIFIED POSITIONS
SECTION 9 QUALIFICATION OF A WELDER OR WELDING OPERATOR
9.1 PURPOSE OF QUALIFYING A WELDER OR WELDING OPERATOR
9.2 SCOPE OF WELDER OR WELDING OPERATOR QUALIFICATION
9.3 METHODS OF QUALIFICATION
9.4 QUALIFICATION BY TESTING
9.5 ESSENTIAL VARIABLES FOR WELDERS AND WELDING OPERATORS
9.6 TEST PIECE
9.7 ASSEMBLY OF TEST PIECES
9.8 AUTOMATIC WELDING EQUIPMENT
9.9 MAKING A TEST WELD
9.10 SUPERVISION OF A TEST WELD
9.11 IDENTIFICATION OF A TEST WELD
9.12 QUALIFICATION OF ALUMINOTHERMIC WELDING AND PIN BRAZING OPERATORS
SECTION 10 ASSESSMENT OF TEST WELDS FOR WELDER OR WELDING OPERATOR QUALIFICATION
10.1 METHOD OF ASSESSMENT
10.2 VISUAL EXAMINATION
10.3 NON-DESTRUCTIVE TESTING
10.4 REPEATED TEST
10.4.1 General
10.4.2 Repeated failure
10.5 RECORD OF RESULTS
10.6 PORTABILITY OF A WELDER’S OR WELDING OPERATOR’S QUALIFICATION
SECTION 11 WELDER OR WELDING OPERATOR QUALIFICATION AND DISQUALIFICATION
11.1 RECIPROCITY OF A WELDER’S OR WELDING OPERATOR’S QUALIFICATION
11.2 PERIOD OF VALIDITY
11.3 QUALIFICATION RECORD
11.4 DISQUALIFICATION OF A WELDER’S OR WELDING OPERATOR’S QUALIFICATION
SECTION 12 PRODUCTION WELDS
12.1 WELDING PROCESS
12.2 WELDING EQUIPMENT
12.3 WELDER AND WELDING PROCEDURE
12.4 SUPERVISION OF WELDING
12.5 SAFETY IN WELDING
12.6 STORAGE AND HANDLING OF ELECTRODES, FILLER RODS AND FLUXES
12.7 WELDING IN ADVERSE CLIMATIC CONDITIONS
12.8 PREPARATION FOR WELDING
12.8.1 Edge preparation
12.8.2 Internal cleaning
12.9 METHOD OF MAKING THE WELD PREPARATION
12.10 ACCURACY OF ALIGNMENT
12.11 LINE-UP CLAMP
12.12 TACK WELDS
12.13 WORKING CLEARANCE
12.14 PLACEMENT OF WELD PASSES
12.15 ARC STRIKE AND ARC BURN
12.16 CLEANING
12.17 PEENING
12.18 INSERT PATCHING
12.19 PREHEAT AND INTERPASS TEMPERATURE
12.19.1 General
12.19.2 Application of preheat and interpass temperature
12.19.3 Extent of heating
12.19.4 Monitoring of preheat and interpass temperature
12.19.5 Condensation
12.20 POST-WELD HEAT TREATMENT (PWHT)
12.21 IDENTIFICATION OF A PRODUCTION WELD
SECTION 13 POST-WELD HEAT TREATMENT (PWHT) AND POST-WELD COOLING
13.1 POST-WELD HEAT TREATMENT
13.2 POST-WELD COOLING
SECTION 14 ASSESSMENT OF PRODUCTION WELDS AND REPAIR WELDS
14.1 GENERAL
14.2 METHODS OF EXAMINATION
14.3 PRODUCTION CUT-OUT WELDS
SECTION 15 WELDING AND CUTTING ON A PIPELINE AFTER COMMISSIONING OR AFTER HYDROSTATIC TESTING
15.1 GENERAL
15.2 SAFETY
15.3 HOT REPAIR OF LEAKING GAS-FILLED PIPELINES
15.4 WHERE GAS IS NOT ESCAPING
15.5 PIPELINES CONTAINING PETROLEUM FLUIDS OTHER THAN LEAN NATURAL GAS
15.6 QUALIFICATION OF WELDER(S)
15.7 QUALIFICATION OF WELDING SUPERVISORS AND WELDING INSPECTORS
15.8 FIT-UP BEFORE WELDING AND CUTTING
15.9 EXAMINATION AND TESTING
15.10 CRITERIA OF ACCEPTANCE
SECTION 16 WELDING ONTO AN IN-SERVICE PIPELINE
16.1 PIPELINE CONTAINING FLAMMABLE OR PRESSURIZED FLUID
16.2 PRECAUTIONS TO BE UNDERTAKEN BEFORE IN-SERVICE WELDING
16.2.1 Avoidance of hydrogen assisted cold cracking (HACC) and burn-through
16.2.2 Items to be considered before in-service welding
16.2.3 Risk assessment and risk management plan
16.3 LINING
16.4 SAFETY
16.5 INSPECTION BEFORE WELDING
16.6 ULTRASONIC TESTING BEFORE WELDING
16.6.1 Purpose of testing
16.6.2 Method
16.6.3 Criteria of acceptance
16.7 WELDING CONSUMABLES
16.8 PREHEAT
16.9 QUALIFICATION OF WELDING PROCEDURES
16.10 WELDING SEQUENCE
16.11 QUALIFICATION OF WELDER(S)
16.12 QUALIFICATION OF WELDING SUPERVISORS AND WELDING INSPECTORS
16.13 FIT-UP BEFORE WELDING
16.14 EXAMINATION OF TESTING
16.15 CRITERIA OF ACCEPTANCE
16.16 WELDING OF TEST ASSEMBLY
SECTION 17 CRITERIA OF ACCEPTANCE FOR GIRTH WELD DISCONTINUITIES
17.1 GENERAL
17.2 TIER 1 CRITERIA—WORKMANSHIP STANDARD (RT)
17.2.1 Inadequate penetration
17.2.2 Inadequate penetration due to high/low
17.2.3 Incomplete fusion due to cold lap
17.2.4 Root concavity
17.2.5 Incomplete fusion
17.2.6 Porosity
17.2.7 Slag inclusions
17.2.8 Burn-through
17.2.9 Cracks
17.2.10 Undercutting
17.2.11 Root slag intrusion
17.2.12 Accumulation of discontinuities
17.2.13 Coincident discontinuities
17.2.14 Pipe or fitting discontinuities
17.3 ULTRASONIC TESTING ACCEPTANCE CRITERIA (AUT, MUT, PAUT AND TOFD WHERE APPLICABLE)
17.3.1 General
17.3.2 Planar indications
17.3.3 Non-planar volumetric indications
17.3.4 Transverse indications
17.3.5 Tier 1 UT acceptance criteria—planar surface indications
17.3.6 Planar embedded indications
17.3.7 Transverse (T) indications
17.3.8 Volumetric cluster indications
17.3.9 Volumetric individual indications
17.3.10 Volumetric root indications
17.3.11 Cracking
17.3.12 Accumulation
17.3.13 Parent material discontinuities
17.3.14 Copper contamination/cracking
17.4 TIER 2 ACCEPTANCE CRITERIA—GENERALIZED FITNESS FORPURPOSE STANDARD
17.4.1 General
17.4.2 Tier 2 acceptance criteria
17.5 TIER 3 CRITERIA—ENGINEERING CRITICAL ASSESSMENT
17.5.1 General
17.5.2 ECA input assumptions
17.5.3 Coincident load conditions
17.5.4 Locations to be tested
17.5.5 Defect positions to be analysed
SECTION 18 VISUAL EXAMINATION
18.1 PURPOSE
18.2 METHOD OF EXAMINATION
18.3 EXTENT OF VISUAL EXAMINATION
18.4 CRITERIA OF ACCEPTANCE
18.4.1 All-welds
18.4.2 Butt welds
18.4.3 Alignment (high/low)
18.5 UNDERCUT DEPTH MEASUREMENT
SECTION 19 NON-DESTRUCTIVE TESTING
19.1 GENERAL
19.2 ORGANIZATIONS UNDERTAKING NON-DESTRUCTIVE TESTING
19.3 QUALIFICATIONS OF PERSONNEL
19.4 METHODS
19.5 AMOUNT OF NON-DESTRUCTIVE TESTING
19.6 NON-DESTRUCTIVE TESTING OF GOLDEN WELDS
19.7 EXEMPTION FROM RADIOGRAPHIC OR ULTRASONIC TESTING
19.8 TIMING OF NON-DESTRUCTIVE TESTING
SECTION 20 QUALIFYING A RADIOGRAPHIC PROCEDURE
20.1 RADIOGRAPHIC PROCEDURE
20.2 METHOD OF QUALIFYING THE RADIOGRAPHIC PROCEDURE
20.3 TEST CONDITIONS
20.4 RADIOGRAPHIC PROCEDURE SPECIFICATION DOCUMENTATION
20.5 PERIOD OF VALIDITY
SECTION 21 RADIOGRAPHIC TESTING
21.1 GENERAL
21.2 SAFETY AND PROTECTION FROM IONIZING RADIATION
21.3 DENSITY
21.4 IMAGE QUALITY
21.5 UNDERCUT DEPTH MEASUREMENT
21.6 GAS PORE DEPTH MEASUREMENT
21.7 INTEPRETATION AND ASSESSMENT OF RADIOGRAPHS
21.8 CRITERIA OF ACCEPTANCE
21.9 REPORT OF RADIOGRAPHIC TESTING
21.10 RETENTION OF RADIOGRAPHS
SECTION 22 ULTRASONIC TESTING
22.1 ULTRASONIC TESTING
22.1.1 General
22.1.2 Purpose
22.1.3 Method
22.1.4 Surface preparation
22.1.5 Sensitivity
22.1.6 Assessment
22.1.7 Criteria of acceptance
22.1.8 Report
22.1.9 Qualification of personnel
22.2 AUTOMATED ULTRASONIC TESTING (AUT)
22.2.1 General
SECTION 23 MAGNETIC PARTICLE TESTING
23.1 PURPOSE
23.2 METHOD
23.3 QUALIFICATION OF PERSONNEL
23.4 CRITERIA OF ACCEPTANCE
SECTION 24 DYE-PENETRANT TESTING
24.1 PURPOSE
24.2 METHOD
24.3 QUALIFICATION OF PERSONNEL
24.4 CRITERIA OF ACCEPTANCE
SECTION 25 REPAIR OF AN UNACCEPTABLE WELD
25.1 GENERAL
25.2 REPAIR METHODS
25.3 QUALIFICATION OF REPAIRS USING A DIFFERENT WELD PROCEDURE THAN THE ORIGINAL WELD
25.4 QUALIFICATION OF THE REPAIR WELDING PROCEDURE
25.5 INSPECTION
25.6 CRITERIA OF ACCEPTANCE
SECTION 26 REMOVAL OF AN ARC BURN
26.1 GENERAL
26.2 REPAIR BY GRINDING
26.3 METHOD OF INSPECTION
26.4 CRITERIA OF ACCEPTANCE
26.5 CLEANING AFTER TESTING
SECTION 27 CUTTING OUT AN UNACCEPTABLE WELD OR AN ARC BURN
SECTION 28 RECORDS
APPENDIX A - ITEMS REQUIRING APPROVAL
APPENDIX B - LIST OF REFERENCED DOCUMENTS
APPENDIX C - AVOIDANCE OF HYDROGEN ASSISTED COLD CRACKING (HACC)
C1 SCOPE
C2 BACKGROUND
C3 HACC IN PIPELINE WELDING
C4 WELD METAL HYDROGEN ASSISTED COLD CRACKING (WMHACC)
C5 DETECTION OF HACC WITH NDT
C6 THE EFFECT OF DELAY TIME
C7 THE EFFECT OF STRENGTH
C8 WELDING PROCEDURE QUALIFICATION
C9 METHODS FOR ‘DESIGNING-OUT’ HACC FROM WELDING PROCEDURES
C9.1 Restrictions
C9.2 Welding of pipe
C9.3 Welding of fittings
C9.4 Repair welding
APPENDIX D - SELECTION AND SPECIFICATION OF CELLULOSIC WELDING ELECTRODES
D1 SCOPE
D2 BACKGROUND
D3 STRENGTH MATCHING
D4 ELECTRODE QUALITY
D5 SUPPLEMENTARY RECOMMENDATIONS
D6 REFERENCES
APPENDIX E - WELD PROCEDURES ASSOCIATED WITH CHANGES TO THE WELDING CONSUMABLE CLASSIFICATION SYSTEM
E1 GENERAL
E2 SYSTEM CHANGES
E2.1 Strength
E2.2 Impact resistance
E2.3 Flux designations (MMAW)
E2.4 Usability designations (FCAW)
E2.5 Positional designations
E2.6 Weld metal hydrogen
E3 EXTENSION OF WELD PROCEDURE QUALIFICATION
E4 OTHER PROCESSES
APPENDIX F - ADDITIONAL RECOMMENDATIONS FOR AUTOMATIC/MECHANIZED WELDING OF PIPELINE GIRTH WELDS
F1 SCOPE
F2 AUTOMATIC/MECHANIZED WELDING SYSTEMS
F3 ITEMS FOR CONSIDERATION WHEN AUTOMATIC GMAW WELDING IS CONSIDERED
F3.1 Equipment
F3.2 Pipeline welding spread
F4 WELD PARAMETER MONITORING
F5 WELD PROCEDURE QUALIFICATION
F5.1 General
F5.2 Weld bevels
F6 INSPECTION
F7 OPERATORS
F8 CONSISTENCY WELDS
F9 FITTINGS
F10 REPAIR WELDS
APPENDIX G - GUIDANCE ON ‘GMAW’ WELDING CONSUMABLES FOR MECHANIZED AND AUTOMATIC PIPELINE WELDING PROCESSES
APPENDIX H - AUTOMATED ULTRASONIC TESTING (AUT) SYSTEM AND OPERATOR REQUIREMENTS
H1 SYSTEM REQUIREMENTS
H2 EQUIPMENT REQUIREMENTS
H2.1 General
H2.2 Inspection procedure
H2.3 System configuration
H2.4 Mode of use
H2.5 Set-up and calibration
H2.6 Calibration intervals
H3 AUT OPERATORS
H4 SYSTEM QUALIFICATION
H4.1 General
H4.2 Verification
H4.3 Changes to qualification
H4.4 System checks
H4.5 Documentation
H4.6 Weld dressing
H4.7 Welder qualification welds
H4.8 NDT of repaired areas
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AS/NZS 2885.2:2016 PIPELINES-GAS AND LIQUID PETROLEUM - WELDING
PREFACE
CONTENTS
SECTION 1 SCOPE AND GENERAL
1.1 SCOPE
1.2 APPROVAL
1.3 QUALIFICATION
1.4 RETROSPECTIVITY
1.5 REFERENCED DOCUMENTS
1.6 DEFINITIONS
1.6.1 Approved and approval
1.6.2 Automated ultrasonic testing (AUT)
1.6.3 Automatic welding
1.6.4 Burn-off rate
1.6.5 Buttering
1.6.6 Carbon equivalent (CE)
1.6.7 Cellulosic welding
1.6.8 Competent person
1.6.9 Component
1.6.10 Construction
1.6.11 Crack tip opening displacement (CTOD) test
1.6.12 Defect
1.6.13 Design temperatures
1.6.14 Diameter
1.6.15 Discontinuity
1.6.16 Dye-penetrant inspection (DPI)
1.6.17 Electrical discharge machining (EDM)
1.6.18 Engineering critical assessment (ECA)
1.6.19 Engineering design
1.6.20 Environment
1.6.21 Essential variable
1.6.22 Finite element analysis (FEA)
1.6.23 Fitting
1.6.24 Fluid
1.6.25 Flux core arc welding (FCAW)
1.6.26 Full screen height (FSH)
1.6.27 Gamma radiography
1.6.28 Gas
1.6.29 Gas metal arc welding
1.6.30 Golden weld
1.6.31 Heat input (arc energy)
1.6.32 Hot repair
1.6.33 Hydrogen assisted cold cracking (HACC)
1.6.34 Imperfection
1.6.35 Inert gas shielding
1.6.36 In-service welding
1.6.37 Interpass temperature
1.6.38 Lamellar tearing
1.6.39 Licensee
1.6.40 Location class
1.6.41 Magnetic particle testing (MPT)
1.6.42 Mainline pipework
1.6.43 Manual metal arc welding (MMAW)
1.6.44 Matching (overmatching, undermatching)
1.6.45 May
1.6.46 Mechanized welding
1.6.47 Multiple wire system
1.6.48 Nominal thickness (tN)
1.6.49 Non-destructive testing (NDT)
1.6.50 NDT technician
1.6.51 Non-essential variable
1.6.52 Non-planar discontinuity
1.6.53 O-let
1.6.54 Peening
1.6.55 Phase array ultrasonics (PAUT)
1.6.56 Pig
1.6.57 Pig trap (launcher/receiver)
1.6.58 Pipeline assemblies
1.6.59 Planar defect
1.6.60 Probability of detection (PoD)
1.6.61 Post-weld heat treatment (PWHT)
1.6.62 Preheat maintenance temperature
1.6.63 Preheat temperature
1.6.64 Pretest
1.6.65 Procedure qualification record (PQR)
1.6.66 Proposed welding procedure specification (pWPS)
1.6.67 Radiographic testing (RT)
1.6.68 Shall
1.6.69 Should
1.6.70 Sour service
1.6.71 Specified minimum yield strength (SMYS)
1.6.72 Station
1.6.73 Time of flight diffraction (ToFD)
1.6.74 Undercutting adjacent to the cover pass [SUC (ext)]
1.6.75 Undercutting adjacent to the root pass [SUC (int)]
1.6.76 Ultrasonic testing (UT)
1.6.77 Weld metal deposition repair
1.6.78 Welding procedure specification (WPS)
1.6.79 Weldability
1.6.80 X-radiography
1.6.81 Yield strength (σY)
1.7 ROUNDING OF NUMBERS
1.8 PIPELINE ASSEMBLIES
SECTION 2 SAFETY
2.1 PRODUCTION WELDING
2.1.1 General
2.1.2 Electrical safety during welding
2.1.3 Welding environment
2.1.4 Equipment and compressed gases
2.1.5 Electric and magnetic fields (EMF)
2.2 WELDING OR CUTTING ON A PIPELINE AFTER COMMISSIONING
2.2.1 General
2.2.2 Risk assessment
2.3 SAFETY AND PROTECTION FROM IONIZING RADIATION
SECTION 3 QUALIFICATIONS
3.1 GENERAL
3.2 WELDING ENGINEERING
3.3 WELDING SUPERVISION
3.4 WELDING INSPECTION
3.5 WELDERS AND WELDING OPERATORS
SECTION 4 MATERIALS
4.1 GENERAL
4.2 CONSUMABLES
4.2.1 General
4.2.2 Storage and handling of consumables
SECTION 5 DESIGN OF A WELDED JOINT
5.1 GENERAL
5.2 BUTT WELDS BETWEEN COMPONENTS OF EQUAL NOMINAL THICKNESS
5.3 BUTT WELDS BETWEEN COMPONENTS OF UNEQUAL NOMINAL THICKNESS
5.4 REINFORCEMENT OF A BUTT WELD
5.5 LONGITUDINAL BUTT WELDS
5.6 FILLET WELD
5.6.1 Dimensions of a fillet weld
5.6.2 Fillet welding a lug, boss, pig bar or pad
5.6.3 Sleeve fillet welds
5.6.4 Flanges and forged socket fittings
5.7 WELDING OF THREADED JOINTS
5.8 REINFORCEMENT OF A WELDED BRANCH CONNECTION
5.9 REINFORCEMENT OF MULTIPLE OPENINGS
5.10 FORGED BRANCH FITTING
5.11 EFFECT OF COMPONENTS UPON PIG PASSAGE
5.12 OFFSET OF LONGITUDINAL WELDS
5.13 DISTANCE BETWEEN WELDS
5.14 LOCATION OF ALUMINOTHERMIC WELDS AND PIN BRAZING CONNECTIONS
5.15 ATTACHMENT OF ELECTRICAL CONDUCTORS
5.16 GOLDEN WELDS
SECTION 6 QUALIFICATION OF A WELDING PROCEDURE SPECIFICATION
6.1 WELDING PROCEDURE SPECIFICATION (WPS)
6.2 PURPOSE OF QUALIFYING A WELDING PROCEDURE
6.3 TYPES OF WELDS REQUIRING QUALIFICATION
6.4 METHODS OF QUALIFICATION
6.4.1 General
6.4.2 Qualification by testing
6.4.3 Qualification to an alternate approved welding Standard
6.4.4 Qualification by prequalification without testing
6.4.5 Qualification by the use of engineering
6.5 CHANGES IN A WELDING PROCEDURE
6.5.1 Change in an essential variable
6.5.2 Change in other than an essential variable
6.6 CONDUCT OF THE QUALIFICATION WELDS
6.6.1 Planning a procedure qualification weld
6.6.2 Test piece size
6.6.3 Test piece material
6.6.4 Preparation and assembly of test pieces
6.6.5 Test conditions
6.6.6 Identification of the test weld
6.6.7 Recording a test weld
6.6.8 Supervision of the test weld
6.7 PROVISONS FOR SPECIFIC WELDING METHODS
6.7.1 Cellulosic welding
6.7.2 Provisions for waveform power sources
6.7.3 Aluminothermic welding
6.7.4 Pin brazing
SECTION 7 ASSESSMENT OF THE TEST WELD TO QUALIFY A WELDING PROCEDURE
7.1 METHOD OF ASSESSMENT
7.2 VISUAL EXAMINATION
7.3 NON-DESTRUCTIVE TESTING
7.4 DESTRUCTIVE TESTS
7.4.1 Types of test and number of test specimens
7.4.2 Transverse butt tensile strength test
7.4.3 All-weld-metal tensile test (AWMT)
7.4.4 Transverse guided side bend test
7.4.5 Macro test—Cross–section examination
7.4.6 Hardness test
7.4.7 Fracture toughness tests
7.5 RE-TESTS AND FURTHER TESTING
7.5.1 General
7.5.2 Visual examination and non-destructive testing
7.5.3 Destructive testing
7.5.4 Cause of failure
7.6 RECORD OF RESULTS
7.7 PERIOD OF VALIDITY
7.8 DISQUALIFICATION OF A QUALIFIED WELDING PROCEDURE
7.9 ALUMINOTHERMIC WELDS AND PIN BRAZING CONNECTIONS
SECTION 8 WELDING POSITIONS
8.1 DESIGNATION
8.2 LIMITS OF QUALIFIED POSITIONS
SECTION 9 QUALIFICATION OF A WELDER OR WELDING OPERATOR
9.1 PURPOSE OF QUALIFYING A WELDER OR WELDING OPERATOR
9.2 SCOPE OF WELDER OR WELDING OPERATOR QUALIFICATION
9.3 METHODS OF QUALIFICATION
9.4 QUALIFICATION BY TESTING
9.5 ESSENTIAL VARIABLES FOR WELDERS AND WELDING OPERATORS
9.6 TEST PIECE
9.7 ASSEMBLY OF TEST PIECES
9.8 AUTOMATIC WELDING EQUIPMENT
9.9 MAKING A TEST WELD
9.10 SUPERVISION OF A TEST WELD
9.11 IDENTIFICATION OF A TEST WELD
9.12 QUALIFICATION OF ALUMINOTHERMIC WELDING AND PIN BRAZING OPERATORS
SECTION 10 ASSESSMENT OF TEST WELDS FOR WELDER OR WELDING OPERATOR QUALIFICATION
10.1 METHOD OF ASSESSMENT
10.2 VISUAL EXAMINATION
10.3 NON-DESTRUCTIVE TESTING
10.4 REPEATED TEST
10.4.1 General
10.4.2 Repeated failure
10.5 RECORD OF RESULTS
10.6 PORTABILITY OF A WELDER’S OR WELDING OPERATOR’S QUALIFICATION
SECTION 11 WELDER OR WELDING OPERATOR QUALIFICATION AND DISQUALIFICATION
11.1 RECIPROCITY OF A WELDER’S OR WELDING OPERATOR’S QUALIFICATION
11.2 PERIOD OF VALIDITY
11.3 QUALIFICATION RECORD
11.4 DISQUALIFICATION OF A WELDER’S OR WELDING OPERATOR’S QUALIFICATION
SECTION 12 PRODUCTION WELDS
12.1 WELDING PROCESS
12.2 WELDING EQUIPMENT
12.3 WELDER AND WELDING PROCEDURE
12.4 SUPERVISION OF WELDING
12.5 SAFETY IN WELDING
12.6 STORAGE AND HANDLING OF ELECTRODES, FILLER RODS AND FLUXES
12.7 WELDING IN ADVERSE CLIMATIC CONDITIONS
12.8 PREPARATION FOR WELDING
12.8.1 Edge preparation
12.8.2 Internal cleaning
12.9 METHOD OF MAKING THE WELD PREPARATION
12.10 ACCURACY OF ALIGNMENT
12.11 LINE-UP CLAMP
12.12 TACK WELDS
12.13 WORKING CLEARANCE
12.14 PLACEMENT OF WELD PASSES
12.15 ARC STRIKE AND ARC BURN
12.16 CLEANING
12.17 PEENING
12.18 INSERT PATCHING
12.19 PREHEAT AND INTERPASS TEMPERATURE
12.19.1 General
12.19.2 Application of preheat and interpass temperature
12.19.3 Extent of heating
12.19.4 Monitoring of preheat and interpass temperature
12.19.5 Condensation
12.20 POST-WELD HEAT TREATMENT (PWHT)
12.21 IDENTIFICATION OF A PRODUCTION WELD
SECTION 13 POST-WELD HEAT TREATMENT (PWHT) AND POST-WELD COOLING
13.1 POST-WELD HEAT TREATMENT
13.2 POST-WELD COOLING
SECTION 14 ASSESSMENT OF PRODUCTION WELDS AND REPAIR WELDS
14.1 GENERAL
14.2 METHODS OF EXAMINATION
14.3 PRODUCTION CUT-OUT WELDS
SECTION 15 WELDING AND CUTTING ON A PIPELINE AFTER COMMISSIONING OR AFTER HYDROSTATIC TESTING
15.1 GENERAL
15.2 SAFETY
15.3 HOT REPAIR OF LEAKING GAS-FILLED PIPELINES
15.4 WHERE GAS IS NOT ESCAPING
15.5 PIPELINES CONTAINING PETROLEUM FLUIDS OTHER THAN LEAN NATURAL GAS
15.6 QUALIFICATION OF WELDER(S)
15.7 QUALIFICATION OF WELDING SUPERVISORS AND WELDING INSPECTORS
15.8 FIT-UP BEFORE WELDING AND CUTTING
15.9 EXAMINATION AND TESTING
15.10 CRITERIA OF ACCEPTANCE
SECTION 16 WELDING ONTO AN IN-SERVICE PIPELINE
16.1 PIPELINE CONTAINING FLAMMABLE OR PRESSURIZED FLUID
16.2 PRECAUTIONS TO BE UNDERTAKEN BEFORE IN-SERVICE WELDING
16.2.1 Avoidance of hydrogen assisted cold cracking (HACC) and burn-through
16.2.2 Items to be considered before in-service welding
16.2.3 Risk assessment and risk management plan
16.3 LINING
16.4 SAFETY
16.5 INSPECTION BEFORE WELDING
16.6 ULTRASONIC TESTING BEFORE WELDING
16.6.1 Purpose of testing
16.6.2 Method
16.6.3 Criteria of acceptance
16.7 WELDING CONSUMABLES
16.8 PREHEAT
16.9 QUALIFICATION OF WELDING PROCEDURES
16.10 WELDING SEQUENCE
16.11 QUALIFICATION OF WELDER(S)
16.12 QUALIFICATION OF WELDING SUPERVISORS AND WELDING INSPECTORS
16.13 FIT-UP BEFORE WELDING
16.14 EXAMINATION OF TESTING
16.15 CRITERIA OF ACCEPTANCE
16.16 WELDING OF TEST ASSEMBLY
SECTION 17 CRITERIA OF ACCEPTANCE FOR GIRTH WELD DISCONTINUITIES
17.1 GENERAL
17.2 TIER 1 CRITERIA—WORKMANSHIP STANDARD (RT)
17.2.1 Inadequate penetration
17.2.2 Inadequate penetration due to high/low
17.2.3 Incomplete fusion due to cold lap
17.2.4 Root concavity
17.2.5 Incomplete fusion
17.2.6 Porosity
17.2.7 Slag inclusions
17.2.8 Burn-through
17.2.9 Cracks
17.2.10 Undercutting
17.2.11 Root slag intrusion
17.2.12 Accumulation of discontinuities
17.2.13 Coincident discontinuities
17.2.14 Pipe or fitting discontinuities
17.3 ULTRASONIC TESTING ACCEPTANCE CRITERIA (AUT, MUT, PAUT AND TOFD WHERE APPLICABLE)
17.3.1 General
17.3.2 Planar indications
17.3.3 Non-planar volumetric indications
17.3.4 Transverse indications
17.3.5 Tier 1 UT acceptance criteria—planar surface indications
17.3.6 Planar embedded indications
17.3.7 Transverse (T) indications
17.3.8 Volumetric cluster indications
17.3.9 Volumetric individual indications
17.3.10 Volumetric root indications
17.3.11 Cracking
17.3.12 Accumulation
17.3.13 Parent material discontinuities
17.3.14 Copper contamination/cracking
17.4 TIER 2 ACCEPTANCE CRITERIA—GENERALIZED FITNESS FORPURPOSE STANDARD
17.4.1 General
17.4.2 Tier 2 acceptance criteria
17.5 TIER 3 CRITERIA—ENGINEERING CRITICAL ASSESSMENT
17.5.1 General
17.5.2 ECA input assumptions
17.5.3 Coincident load conditions
17.5.4 Locations to be tested
17.5.5 Defect positions to be analysed
SECTION 18 VISUAL EXAMINATION
18.1 PURPOSE
18.2 METHOD OF EXAMINATION
18.3 EXTENT OF VISUAL EXAMINATION
18.4 CRITERIA OF ACCEPTANCE
18.4.1 All-welds
18.4.2 Butt welds
18.4.3 Alignment (high/low)
18.5 UNDERCUT DEPTH MEASUREMENT
SECTION 19 NON-DESTRUCTIVE TESTING
19.1 GENERAL
19.2 ORGANIZATIONS UNDERTAKING NON-DESTRUCTIVE TESTING
19.3 QUALIFICATIONS OF PERSONNEL
19.4 METHODS
19.5 AMOUNT OF NON-DESTRUCTIVE TESTING
19.6 NON-DESTRUCTIVE TESTING OF GOLDEN WELDS
19.7 EXEMPTION FROM RADIOGRAPHIC OR ULTRASONIC TESTING
19.8 TIMING OF NON-DESTRUCTIVE TESTING
SECTION 20 QUALIFYING A RADIOGRAPHIC PROCEDURE
20.1 RADIOGRAPHIC PROCEDURE
20.2 METHOD OF QUALIFYING THE RADIOGRAPHIC PROCEDURE
20.3 TEST CONDITIONS
20.4 RADIOGRAPHIC PROCEDURE SPECIFICATION DOCUMENTATION
20.5 PERIOD OF VALIDITY
SECTION 21 RADIOGRAPHIC TESTING
21.1 GENERAL
21.2 SAFETY AND PROTECTION FROM IONIZING RADIATION
21.3 DENSITY
21.4 IMAGE QUALITY
21.5 UNDERCUT DEPTH MEASUREMENT
21.6 GAS PORE DEPTH MEASUREMENT
21.7 INTEPRETATION AND ASSESSMENT OF RADIOGRAPHS
21.8 CRITERIA OF ACCEPTANCE
21.9 REPORT OF RADIOGRAPHIC TESTING
21.10 RETENTION OF RADIOGRAPHS
SECTION 22 ULTRASONIC TESTING
22.1 ULTRASONIC TESTING
22.1.1 General
22.1.2 Purpose
22.1.3 Method
22.1.4 Surface preparation
22.1.5 Sensitivity
22.1.6 Assessment
22.1.7 Criteria of acceptance
22.1.8 Report
22.1.9 Qualification of personnel
22.2 AUTOMATED ULTRASONIC TESTING (AUT)
22.2.1 General
SECTION 23 MAGNETIC PARTICLE TESTING
23.1 PURPOSE
23.2 METHOD
23.3 QUALIFICATION OF PERSONNEL
23.4 CRITERIA OF ACCEPTANCE
SECTION 24 DYE-PENETRANT TESTING
24.1 PURPOSE
24.2 METHOD
24.3 QUALIFICATION OF PERSONNEL
24.4 CRITERIA OF ACCEPTANCE
SECTION 25 REPAIR OF AN UNACCEPTABLE WELD
25.1 GENERAL
25.2 REPAIR METHODS
25.3 QUALIFICATION OF REPAIRS USING A DIFFERENT WELD PROCEDURE THAN THE ORIGINAL WELD
25.4 QUALIFICATION OF THE REPAIR WELDING PROCEDURE
25.5 INSPECTION
25.6 CRITERIA OF ACCEPTANCE
SECTION 26 REMOVAL OF AN ARC BURN
26.1 GENERAL
26.2 REPAIR BY GRINDING
26.3 METHOD OF INSPECTION
26.4 CRITERIA OF ACCEPTANCE
26.5 CLEANING AFTER TESTING
SECTION 27 CUTTING OUT AN UNACCEPTABLE WELD OR AN ARC BURN
SECTION 28 RECORDS
APPENDIX A - ITEMS REQUIRING APPROVAL
APPENDIX B - LIST OF REFERENCED DOCUMENTS
APPENDIX C - AVOIDANCE OF HYDROGEN ASSISTED COLD CRACKING (HACC)
C1 SCOPE
C2 BACKGROUND
C3 HACC IN PIPELINE WELDING
C4 WELD METAL HYDROGEN ASSISTED COLD CRACKING (WMHACC)
C5 DETECTION OF HACC WITH NDT
C6 THE EFFECT OF DELAY TIME
C7 THE EFFECT OF STRENGTH
C8 WELDING PROCEDURE QUALIFICATION
C9 METHODS FOR ‘DESIGNING-OUT’ HACC FROM WELDING PROCEDURES
C9.1 Restrictions
C9.2 Welding of pipe
C9.3 Welding of fittings
C9.4 Repair welding
APPENDIX D - SELECTION AND SPECIFICATION OF CELLULOSIC WELDING ELECTRODES
D1 SCOPE
D2 BACKGROUND
D3 STRENGTH MATCHING
D4 ELECTRODE QUALITY
D5 SUPPLEMENTARY RECOMMENDATIONS
D6 REFERENCES
APPENDIX E - WELD PROCEDURES ASSOCIATED WITH CHANGES TO THE WELDING CONSUMABLE CLASSIFICATION SYSTEM
E1 GENERAL
E2 SYSTEM CHANGES
E2.1 Strength
E2.2 Impact resistance
E2.3 Flux designations (MMAW)
E2.4 Usability designations (FCAW)
E2.5 Positional designations
E2.6 Weld metal hydrogen
E3 EXTENSION OF WELD PROCEDURE QUALIFICATION
E4 OTHER PROCESSES
APPENDIX F - ADDITIONAL RECOMMENDATIONS FOR AUTOMATIC/MECHANIZED WELDING OF PIPELINE GIRTH WELDS
F1 SCOPE
F2 AUTOMATIC/MECHANIZED WELDING SYSTEMS
F3 ITEMS FOR CONSIDERATION WHEN AUTOMATIC GMAW WELDING IS CONSIDERED
F3.1 Equipment
F3.2 Pipeline welding spread
F4 WELD PARAMETER MONITORING
F5 WELD PROCEDURE QUALIFICATION
F5.1 General
F5.2 Weld bevels
F6 INSPECTION
F7 OPERATORS
F8 CONSISTENCY WELDS
F9 FITTINGS
F10 REPAIR WELDS
APPENDIX G - GUIDANCE ON ‘GMAW’ WELDING CONSUMABLES FOR MECHANIZED AND AUTOMATIC PIPELINE WELDING PROCESSES
APPENDIX H - AUTOMATED ULTRASONIC TESTING (AUT) SYSTEM AND OPERATOR REQUIREMENTS
H1 SYSTEM REQUIREMENTS
H2 EQUIPMENT REQUIREMENTS
H2.1 General
H2.2 Inspection procedure
H2.3 System configuration
H2.4 Mode of use
H2.5 Set-up and calibration
H2.6 Calibration intervals
H3 AUT OPERATORS
H4 SYSTEM QUALIFICATION
H4.1 General
H4.2 Verification
H4.3 Changes to qualification
H4.4 System checks
H4.5 Documentation
H4.6 Weld dressing
H4.7 Welder qualification welds
H4.8 NDT of repaired areas
Amendments
AS/NZS 2885.2:2016+A1
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