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WELDING SPECIFICATION SP4/01 ENGINEERING1.0WI37.MTS.104Revision 5 DFTENGINEERINGPURPOSEThis Work Instruction describes the process and system used to ensure that sound engineeringpractice and statutory requirements are met in regard to Welding. The adoption of AS/NZS ISO3834 for specifying quality requirements for fusion welding provides assurance that weld qualityis maintained throughout the life cycle of the equipment.This work instruction previously referenced SP4/01.2.0SCOPEThis applies to all forms of welding carried out on SIMEC Mining and Liberty Primary SteelWhyalla plant.3.04.0REFERENCES3.1AS/NZS ISO 38343.23.33.4ISO 14731AS 179 6AS I37.MTS.185- Quality Requirements for Fusion Welding ofMetallic Materials (refer Parts 1 to 5)- Welding Coordination Tasks and Responsibilities- Certification of Welders and Welding Supervisors- Welding, Brazing and Cutting of Metals – Glossaryof Terms- Welding Management Flowcharts- Scope of Work- Closure Welds for Pipework (under development)- Hot Taps for Pipework (under development)DEFINITIONSCompanyLiberty Primary Steel or SIMEC Mining businesses in WhyallaCECentral EngineeringManager EngineeringManager of Central Engineering, Liberty Primary SteelContractorDefined as Manufacturer in AS/NZS ISO 3834 for all welding operations who are Companyapproved vendors.ManufacturerAs defined in AS/NZS ISO 3834 and includes and is not limited to internal and external resourcescarrying out fabrication work for the Company.Welding Co-ordinatorCompany representatives nominated by Manager Engineering or Contractor representatives,who reviews the technical and quality requirements of welding work prior to commencement,monitors welding conformity being performed and validates welding conformity at completion.Any PRINTED copies of this procedure are UNCONTROLLEDPage: 1 of 35
WELDING SPECIFICATION SP4/01 ENGINEERINGWI37.MTS.104Revision 5 DFTENGINEERINGISO 14731 provides guidelines on the tasks, responsibilities and competencies of a welding coordinator function.Closure WeldThe technique of carrying out a final pipe connection weld that cannot be practically pressuretested to assess the integrity of the weld joint.Hot Tap WeldThe technique of welding and sealing a branch fitting to a pipe that is in service and pressurisedusing a mechanical method of creating an opening in that pipe by drilling or cutting within theattached fitting for pressure containment of the fluid service during welding.ITPInspection and Test Plan sets out quality assurance controls, inspection points before and duringmanufacture / fabrication of items. These include but are not limited to materials certificates,dimensional checks, welding procedures, welder qualifications, painting and NDE. testing alongwith Witness, Surveillance and Hold Points.MDRManufacturer Data Report is a report produced by the Manufacturer and submitted to theCompany Welding Coordinator for review and approval, certifying that all items have beenconstructed, inspected and tested in compliance with the requirements of the applicablestandard(s), design drawings and specifications.The relevant sections shall be indexed.This report shall include and is not limited to (where applicable); material test certificates, welderqualifications, qualified weld procedures and supporting WPQR, inspection records, NDE / NDTreports, heat treatment records, pressure test certificates, ITP., weld maps and weld traceabilityrecords, weld consumable certificates, dimensional records, coating records calibrationcertificates, statutory approvals, concessions/deviations, certificates of any other tests orinspections as required by applicable standards or specifications.NDE / NDTNon Destructive Examination (or Testing)Weld TraceabilityIs the ability to retrieve by records and drawings for each weld to a specific location, and providesinformation on the; weld procedure used, the identification of the welder, date when welded,unique identification number of the weld, drawing number, weld consumable batch number,materials welded, NDE / NDT report numbers, inspector identification and inspection results.WPQRWeld Procedure Qualification Record that contains all the recorded weld parameters, materials,personnel and test results supporting the development of a proven weld procedure according tospecified requirements.Scope of WorkEither documented in Form 31.01 Scope of Work for tendering or an internal document detailingthe scope of work for internal use.Any PRINTED copies of this procedure are UNCONTROLLEDPage: 2 of 35
WELDING SPECIFICATION SP4/01 ENGINEERING5.0WI37.MTS.104Revision 5 .1The Company Welding Procedures shall be registered in the Company’squality document system.5.1.2The Welding Coordinator is responsible for registering any new or revisedCompany Welding Procedures.Responsibility5.2.1CE is responsible for the control and content of Company Welding Procedures.The authority for changes and or new Company Welding Procedures is theManager Engineering or their nominee.5.2.2The Contractor is responsible for the control and content of their own WeldingProcedures.Issue of the Company Welding Procedures to Contractors5.3.1Company Welding Procedures are intended for Company use only. It ispreferred that the Contractor provides their own Welding Procedures whichmust be approved by the Welding Coordinator.5.3.2Controlled Copies of Company Welding Procedures shall only be issued bythe Supply Department to all approved Contractors. Uncontrolled copies shallnot be issued. Other supporting documentation will not be provided by theCompany.Minimum Quality Criteria for Equipment Classes5.4.1Part I Minimum Quality Criteria for Equipment Classes shall be referenced todetermine the minimum quality criteria based on the equipment classes beingconsidered.5.4.2Part II General Requirements for All Welding applies to all equipment classes.5.4.3Part III Structural Welding applies to all structural work including and not limitedto beams, columns, bracing, supports, stairs, platforms, ladders, and otherrelated aspects.5.4.4Part IV Boilers, Pressure Equipment, Pressure Pipework and CryogenicPipework applies to pipework carrying flammable or corrosive liquids or gasesor hydraulic fluid or plumbing.5.4.5Part V Welding of Oxygen, Nitrogen and Argon Pipework applies to pipeworkcarrying Oxygen, Nitrogen and Argon.5.4.6Part VI Flammable Gas Pipework applies to all pipework carrying natural gas,liquefied petroleum gas (LPG), blast furnace gas and coke ovens gas.Any PRINTED copies of this procedure are UNCONTROLLEDPage: 3 of 35
WELDING SPECIFICATION SP4/01 ENGINEERING6.0WI37.MTS.104Revision 5 DFTENGINEERING5.4.7Part VII Brazed and Soldered Connections for Pressure Pipework applies toall pipework brazing and soldering of pipework other than domestic waterpipework.5.4.8Part VIII Storage Tanks applies to all low pressure storage tanks including andnot limited to process tanks, open tanks, closed tanks, hazardous materialtanks.5.4.9Part IX Closure Welds for Pipework applies to pipe welds where a final closureweld is not practical and not feasible to be proof tested by a pressure testmethod.5.4.10Part X Hot Taps for Pipework applies to pressure equipment when it is notfeasible or is impractical to take the equipment or piping out of service, or topurge or clean by conventional pendix 1Appendix 2Appendix 3Appendix 4Appendix 5Appendix 6Appendix 7Appendix 8Appendix 9Welding SpecificationWeld Traceability Record SampleWeld Map SampleNDE / NDT Request Form SampleInspection and Test Plan SampleManufacturers Data Report Index SampleClosure Weld Inspection Record SampleHot Tap Inspection Record SampleWelding Flowchart SampleAny PRINTED copies of this procedure are UNCONTROLLEDPage: 4 of 35
Appendix 1SIMEC Mining and Liberty Primary SteelWELDING SPECIFICATIONSpecification ScopeThis specification covers all welding and fabricating work including hardsurfacing.PART IMinimum Quality Criteria for Equipment ClassesPART IIGeneral Requirements for all WeldingPART IIIStructural WorkPART IVBoilers, Pressure Equipment and Pressure PipeworkPART VOxygen, Nitrogen and Argon PipeworkPART VIFlammable Gas PipeworkPART VIIBrazed and Soldered Connections for Pressure Pipework.PART VIIIStorage TanksPART IXClosure Welds for PipeworkPART XHot Taps for PipeworkGeneral fabrication items such as spares which may not be covered by AS/NZS1554 Parts 1 to 7 are to meet the permissible levels of weld imperfections asdetermined by Table 6.2 of AS/NZS 1554.1 SP unless otherwise noted.Any PRINTED copies of this procedure are UNCONTROLLEDPage: 5 of 35
PART IMINIMUM QUALITY CRITERIA FOR EQUIPMENT CLASSESCriteria to be Considered for the Following Equipment ClassesStructuralCriteriaRelevant Parts ofWI37.MTS.104GPSP/FPPart II,IIIPart II,IIICranes andLifting DevicesLead MechanicalEngineerWeldingCoordinatorStatutory RegulatorWeldingCoordinatorStatutory Regulator(A,B,C only)PressureEquipment OfficerStatutoryRegulatorPressure Equipment OfficerYESCompulsoryCompulsoryRefer to AS/NZS 1554Parts 1 to 7 or equivalentCompulsoryRefer to AS/NZS 3992 or equivalent (eg. ASME IX)Ensure that Welders areCompetent and Qualified.Compulsory6. Material CertificatesrequiredYES7. Heat Treatment certificaterequiredNO8. NDE / NDT report requiredVisual Only9. Hydrostatic Test certificaterequiredLEGEND:NO:YES:Compulsory:API 620 orEquivalentPart II, VIIINO10. Submit MDR report toWelding Coordinator forreview and approvalHazard LevelsA,B,C,DPart II,III2. Obtain Plant Registration5Closure Welds &Hot Tap WeldsPart IX, XStatutoryRegulator4. Ensure that all WeldingProcedures are QualifiedClass 3Storage TanksPart II,IV,V,VI,VIILead Structural EngineerNOClass 1&2Boilers andPressure VesselsPart II,III1. Obtain Design Approval3. Submit ITP to WeldingCoordinator for review andapprovalPressure PipingAS4041 or equivalentCompulsoryCompulsoryYESYESNot ApplicableNOYESCompulsoryYESYESYESCompulsoryNot ApplicableCompulsoryLeak TestCompulsoryThis criteria does not have to be considered.This criteria must be considered, however a code or specification may exempt this requestThis criteria shall be carried out.Any PRINTED copies of this procedure are UNCONTROLLEDPage: 6 of 35
PART II - GENERAL REQUIREMENTS FOR ALL WELDING1.Conformity to Drawings and SpecificationsAll work must be carried out in strict accordance with any drawings or specifications issued by theCompany. The Welding Coordinator will only develop Welding Flowcharts if the drawings andspecifications are registered and approved as Issued For Construction.Welding Flowchart(s) shall be developed by the Welding Coordinator when there are weldingactivities and prior to a Scope of Work being issued.All work shall comply with the latest editions, revisions and supplements of all relevant specifications,standards, codes and regulations whether referenced in this specification. If any alterations are foundnecessary in either design or welding data specified on the drawing or this specification, the Companymust approve such alterations or amendments in writing. It is the Contractor's responsibility to ensurethat this written agreement is obtained.2.3.4.Non-Compliant Work2.1Work carried out by the Contractor that does not meet the required specifications and / orstandards, will be repaired and re-inspected by the Contractor at the Contractor's cost. TheWelding Coordinator decision on this matter shall be final.2.2Only two repair attempts are permitted for all materials, and failure on the second attempt willrequire total weld removal at a minimum 100mm each side of the defect area.2.3Welding shall be free of slag and weld spatter, whether a protective coating is applied or not.Inspection3.1Visual, NDE / NDT, destructive, or specialist inspectors shall meet the qualification andexperience requirements as required by the applicable welding standard or specification, or asagreed by the Welding Coordinator.3.2The Contractor shall carry out and bear the full cost of inspections nominated by a Standard orby the Company at Tender stage.3.3The Company reserves the right to carry out any type of inspection in addition to the above.This includes visual, NDE / NDT, destructive and any other form of inspection. The cost ofinspections in addition to those required above (3.1) will be incurred by the Company if thework is found to be satisfactory. If a weld is found to be non-compliant, then Section 2 applies.3.4Company representatives must at all times be given right of access for inspection purposes.The cost of providing this access at the work site will be incurred by the Contractor, unlessotherwise agreed to by the Company. This includes the cost of all scaffolding, or other accesssystems to enable the Company's representatives to carry out the necessary inspections.Welding Procedures4.1Tack Welding is considered part of the same quality and workmanship requirements as theweld.4.2Welding of dissimilar metals shall have a dedicated qualified and approved Welding Procedure.Any PRINTED copies of this procedure are UNCONTROLLEDPage: 7 of 35
5.6.7.4.3Welding for hard surfacing shall have a dedicated qualified and approved Welding Procedure.4.4The Contractor shall be responsible for using a technically sound and proven WeldingProcedure, that is supported by a WPQR meeting the applicable standard.4.5If the Company provides a Welding Procedure for a specific task, it remains the Contractor'sresponsibility to ensure that they can successfully perform the welding operation defined in theCompany’s Welding Procedure.4.6Pre-qualified procedures are preferred as they are proven to be reliable, conservative and costeffective in reducing mechanical testing requirements. This does not eliminate the requirementfor a WPQR.4.7Repair of new welds shall utilise the same Weld Procedure as used in production.Qualifications of Welding Personnel5.1Welding and welding operators shall be qualified in accordance with the relevant Codes andStandards prior to commencement of welding. Welding qualification by the first production weldis permitted only if approved by the Company.5.2Qualified Welders shall produce suitable evidence of qualification as specified in 5.1, otherwisethey shall be prohibited from performing welding work for the Company.5.3In all cases the Contractor is to maintain a list of welding personnel and their qualifications.This list shall be submitted to the Company on request.Welding Supervision6.1In all cases the Contractor shall provide appropriate supervision during welding operations.6.2Welding Supervisors shall be appointed and have the authority and control of the quality ofwelding operations.6.3Welding Supervisors shall meet the qualification/competency requirements of the applicableWelding Standard or Specification. A Certificate 10 to AS 1796 is deemed competent for thesupervision of all welding work.6.4The Welding Supervisor is responsible for ensuring quality documentation, such as; weldmaps, weld traceability, ITP’s, NDE / NDT requests and MDR documentation are compiled andcompleted as required in Part I.Welding Consumables7.1General7.1.1Welding consumables shall be in accordance with the specified Welding Standard orSpecification.7.1.2Welding consumables shall be positively identified in packaging or stampings, withbatch certificates supplied.7.1.3Any welding consumables that cannot be positively identified, shall be discardedappropriately.Any PRINTED copies of this procedure are UNCONTROLLEDPage: 8 of 35
7.1.47.27.3Ferrous Consumables.7.2.1All welding consumables used shall meet hydrogen-controlled requirements of 5 - 10mlper 100g of deposited weld metal.7.2.2Where not covered by Manufacturer’s recommendations, hydrogen-controlledelectrodes shall be stored and used under the following conditions:oElectrodes shall be stored in their unopened packets or cartons in a reasonablydry place adequately protected from the effects of weather.oElectrodes which have been wet, or which have had the flux covering damagedshall not be used whether dried or not and discarded appropriately.oElectrodes shall be drawn from heated ovens and put in hot boxes set at 110oCfor direct use.7.2.3Cellulosic welding electrodes (eg. E4111) are only limited to be used where specifiedin an approved qualified Welding Procedure.7.2.4All low carbon and carbon manganese steel consumables shall meet Grade 2 impactrequirements or better, unless otherwise specified in an Australian Standard orclassification.7.2.5Submerged arc flux, gas metal arc and flux-cored wire shall be clearly identified andstored in a dry location at a temperature above 20oC. The identification shall statemanufacturer, grade and batch number.Non-Ferrous Consumables.7.3.18.Welding consumables shall be stored in a clean, dry and sealed storage area, inaccordance with the Manufacturer’s recommendations.Non-Ferrous consumables shall be stored separately from Ferrous materials toeliminate cross contamination.Buried Pipelines and PipeworkUnless specified otherwise by the Company:9oAll pipework under roadways shall be subject to 100% radiography continuing a distance of 3metres on either side of the roadway.oAll buried pipework that carries lethal, hazardous or harmful contents must be radiographed tomeet Standard or Code requirements. If any joint fails radiography, the Company reserves theright to require 100% radiography. This includes pipework encased in concrete.Prohibited Welding ProcessesGMAW is prohibited, unless written authority is obtained from the Company.Any PRINTED copies of this procedure are UNCONTROLLEDPage: 9 of 35
10.11.Material Certification10.1Material Test certificates shall be obtained by the Contractor before Manufacturingcommences.10.2All Material Test certificates shall be incorporated into the MDR and forwarded to the WeldingCoordinator for review and approval.Weld TraceabilityMarked up drawings (eg. weld maps) detailing all welded joint locations and weld identificationnumbers shall be provided by the Contractor with corresponding weld traceability records on allwelding work, except for Structural Welding classified as AS/NZS 1554.1 GP.12NDE / NDT12.1 NDE / NDT service providers shall have a certified quality system to NATA and AS ISO / IEC17025. Personnel performing NDE / NDT shall be certified to Level 2 according to AS 3998 /AS ISO 9712, or equivalent as agreed by the Company.12.2 NDE / NDT shall be performed according to specified standards and approved drawings. NDE/ NDT requests shall be issued by the Company or the Contractor to the NDE / NDT serviceprovider before commencing work.12.3 NDE / NDT service providers shall make available all records and reports to the Company andthe Contractor for review and approval.13.Stainless Steel Welding13.1 All stainless steel welding and materials shall be managed suitably to prevent crosscontamination with ferrous materials. This includes segregated/sheltered areas and use ofseparate non-ferrous, cutting, grinding or cleaning discs or brushes.13.2 All stainless-steel welds shall be cleaned and descaled after weld completion on the same shift.Purging of stainless-steel pipework shall be undertaken as specified by the Weld Procedure.Any PRINTED copies of this procedure are UNCONTROLLEDPage: 10 of 35
PART III - STRUCTURAL WORK1.ApplicationThis specification applies to all structural work as listed in the applicable standards below.2.Applicable Standards2.1All materials and workmanship supplied by the Contractor shall conform to the latestamendments of the following Standards. The Contractor is also required to conform to otherrelevant standards referenced in these documents.2.2The following Standards also apply:AS/NZS 1554.1Welding of Steel StructuresAS/NZS 1554.2Arc Stud Welding (Steel Studs to Steel)AS/NZS 1554.3Welding of Reinforcing SteelAS/NZS 1554.4Welding of High Strength Quench and Tempered SteelsAS/NZS 1554.5Welding of Steel Structures Subject to High Levels of Fatigue Loading.AS/NZS 1554.6Welding of Stainless Steel for Structural PurposesAS/NZS 1554.7Welding of Sheet Steel StructuresAS/NZS 2980Qualification of welders for fusion welding of steelsAS/NZS 1665Welding of Aluminium StructuresAS 1566Copper and Copper Alloys - Rolled Flat ProductsAS 1567Copper and Copper Alloys - Wrought Rods, Bard and SectionAS 1674.1Safety in Welding and Allied Processes - Part 1 Fire PrecautionsAS 1674.2Safety in Welding and Allied Processes - Part 2 ElectricalAS 1796Certification of Welders and Welding SupervisorsAS 1988.1Welding of Ferrous Castings – Part 1 Steel CastingsAS/NZS 2576Welding Consumables for Build-up and Wear ResistanceAS 3990Mechanical Equipment - SteelworkAS 4100Steel StructuresAS/NZS 5131Structural Steelwork – Fabrication and ErectionAny PRINTED copies of this procedure are UNCONTROLLEDPage: 11 of 35
3.4.Application of SP and FP Categories to AS/NZS 15543.1AS/NZS 1554 Part 1 Weld Category SP shall be applied for structural purposes.3.2AS/NZS 1554 Part 5 Weld Category FP shall be applied for fatigue purposes.3.3Welding to AS/NZS 1554 Part 6 (Stainless Steel) shall meet the requirements of internal weldquality Level 1B, external weld quality Class B and a surface finish Grade II.3.4Unless approved in writing by the Company, the levels of NDE / NDT specified in the respectiveparts of AS/NZS 1554 shall be the minimum to be performed in all cases.Application of GP Category to AS/NZS 15544.15.AS/NZS 1554 Part 1 Weld Category GP shall be applied for general purpose use. GP welds forstructural items must be clearly annotated on the approved design drawing.NDE / NDT for Cranes and Lifting Equipment5.1All welds shall be subject to 100% magnetic particle examination.5.2Fabricated Girders5.2.1All girder tension flange butt welds shall be subjected to 100% radiographic orultrasonic examination.5.2.2The lower 30% of all girder web butt welds shall be subjected to 100% radiographicor ultrasonic examination.5.2.3All web to flange girder welds shall be subjected to 100% ultrasonic examination.Any PRINTED copies of this procedure are UNCONTROLLEDPage: 12 of 35
PART IV - BOILERS, PRESSURE EQUIPMENT AND PRESSURE PIPEWORK1.ApplicationThis specification applies to pressure vessels, pressure pipework and pressure componentsmanufactured to comply with the AS/NZS 1200. Any repair, alteration or maintenance work carriedout on boilers, pressure equipment or pressure pipework is to be done in accordance with this part.2.Applicable Standards2.1All materials and workmanship provided by the Contractor shall conform to the latestamendments of the following Standards. The Contractor is also required to conform to otherrelevant standards referenced in these documents.2.2All Standards listed in Part III, Section 2.2 apply to this part where applicable. Thefollowing Standards also apply:AS/NZS 1200AS 1210AS 1228AS 1432AS 1572AS 1579AS/NZS 1596AS 1697AS 2129AS 2885AS/NZS 3788AS 3814AS 3920AS/NZS 3992AS 4037AS 4041AS 4458AS/NZS 5601ASME BPVC.IXASME BPVC.VIII.IASME BPVC.VIII.IASME BPVC.VIII.IASME B31.1ASME B31.3ASME B31.4BS 46772.3Pressure EquipmentPressure VesselsPressure Equipment – BoilersSteel StructuresCopper and copper alloys - Seamless tubes for engineering purposesArc welded steel pipes and fittings for water and wastewaterThe storage and handling of LP GasInstallation and Maintenance of Steel Pipe Systems for GasFlanges for Pipes, Valves and Fittings.Pipelines - Gas And Liquid Petroleum Known As The Saa PipelineCodePressure Equipment - In-service inspectionIndustrial and commercial gas-fired appliancesPressure Equipment - Conformity assessmentPressure Equipment - Welding and brazing qualificationPressure Equipment - Examination and testingPressure Piping.Pressure Equipment - ManufactureGas installations SetSection IX – Welding Brazing and Fusing QualificationsSection VIII – Rules for Construction of Pressure Vessels Div 1Section VIII – Rules for Construction of Pressure Vessels Div 2Alternative rulesSection VIII – Rules for Construction of Pressure Vessels Div 3Alternative rules for High Pressure VesselsPower PipingProcess PipingPipeline Transportation Systems for Liquids and SlurriesSpecification for Arc Welding of Austenitic Stainless Steel Pipework forCarrying FluidsThe use of socket welded connections should be avoided, but where used shall comply withthe requirements of AS4041, particularly for the thermal expansion gap.Any PRINTED copies of this procedure are UNCONTROLLEDPage: 13 of 35
3.4.Hydraulic Systems3.1All butt welds shall have a GTAW root run for all pipe sizes.3.2MMAW is allowable only on hydraulic pipe work greater than DN50 unless otherwise approvedby the Company.3.3GTAW shall be used on smaller pipe work DN50.3.4Tack welding or welding using GTAW for non-ferrous pipework shall be internally purged usinga suitable shielding gas.3.5Oxy fuel gas welding or brazing is not permitted on hydraulic pipework.3.6Socket welded joint connections shall only be used on hydraulic pipework after the Contractorobtains approval from the Welding Coordinator and Hydraulics Officer. All socket welded jointconnections shall be in accordance with AS4041 or equivalent.Repairs and Alterations4.1Any repairs or alterations to boilers, pressure equipment or pressure pipework shall be designedand approved by competent persons as per Part I of this document.Any PRINTED copies of this procedure are UNCONTROLLEDPage: 14 of 35
PART V - WELDING OF OXYGEN, NITROGEN, AND ARGON PIPELINES1.ApplicationThis specification applies to all pipework carrying oxygen, nitrogen and argon and it is not designedto limit or restrict any requirement the Company's Power and Services Manager requires in additionto this specification. The Company will supply such additional requirements in writing to theContractor.2.Applicable Standards and Specifications2.1All materials and workmanship supplied by the Contractor shall conform to the latestamendments of the following Standards. The Contractor is also required to conform to otherrelevant standards referenced in these documents.2.2All Standards listed in Part IV, Section 2.2 apply to this part where applicable. Thefollowing Standards also apply:Ferritic SteelsAS 4041ASME BPVC.IXPressure PipingSection IX – Welding Brazing and Fusing QualificationsAustenitic SteelsAS 4041ASME BPVC.IXBS 4677Pressure PipeworkSection IX – Welding Brazing and Fusing QualificationsSpecification for Arc Welding of Austenitic Stainless Steel Pipework forCarrying FluidsNon - Ferrous MaterialsAS 4041ASME BPVC.IX3.Pressure PipingSection IX – Welding Brazing and Fusing QualificationsSpecific Requirements3.1Design ApprovalThe pipework must satisfy the requirements of AS4041 and Company SpecificationQP38.08 Standard for the Transportation and Distribution of Oxygen by Pipeline.3.2Pressure Testing and Leak TestingAll pressure testing and leak testing will be in accordance with the requirements of CompanySpecification QP38.08 Standard for the Transportation and Distribution of Oxygen by Pipeline.Documentation of pressure testing is required by the Company.3.3CleanlinessCompany Specification QP38.08 Standard for the Transportation and Distribution of Oxygenby Pipeline specifies the cleanliness required for internal Oxygen pipework, therefore anywelding operations will require specific cleaning quality procedures and contamination controlto be approved by the Company prior to commencement of work.Any PRINTED copies of this procedure are UNCONTROLLEDPage: 15 of 35
4.Radiography4.1Standard of Acceptance for Radiography (All Materials)The standard of acceptance for Radiography is AS 4037 Class 1. In addition to therequirements of AS 4041 the maximum root penetration and maximum internal protrusion limitdue to misalignment or mismatched bore sizes is 1mm in total on Oxygen pipework.4.2Levels of Radiography4.2.1 Above Ground PipeworkNDE / NDT requirements and weld acceptance levels shall be as per AS4037 for thenominated Design Class of piping unless noted otherwise.4.2.2 Buried Pipework100% radiographic examination shall be conducted at welded joints on all undergroundpipework and pipework to be encased in concrete.5.Socket Weld ConnectionsSocket welded connections generally are not permitted on Oxygen, Nitrogen and Argon pipelines.The Contractor must seek written approval from the Company if socket welded connections areintended to be used. Generally, consideration will only be given to the use of these connections onpipelines of DN10 or less.6.Soldering and BrazingThe Contractor shall receive written approval from the Company to solder and braze joints. Brazingand soldering must be performed in accordance with Part VII. Generally, welding will be the onlyacceptable method of joining Oxygen, Nitrogen and Argon pipelines and consideration will only begiven to allow soldering or brazing on copper pipework of DN20 or less.Any PRINTED copies of this procedure are UNCONTROLLEDPage: 16 of 35
PART VI – PIPEWORK FOR FLAMMABLE GAS1.ApplicationWelding of pipework conveying Town Gas, Natural Gas, Liquefied Petroleum Gas in the vapourphase, Tempered Liquefied Petroleum Gas, Blast Furnace Gas, Coke Ovens Gas, Simulated Gas orany similar substance.2.Applicable Standards2.1All materials and workmanship supplied by the Contractor shall conform to the latestamendments of the following Standards. The Contractor is also required to conform to otherrelevant standards referenced in these documents.2.2All Standards listed in Part IV, Section 2.2 apply to this part where applicable. Thefollowing Standards also apply:AS 1697AS 4041AS/NZS 56012.Installation and Maintenance of Steel Pipe Systems for GasPressure PipingGas installations SetSpecific Requirements2.1Design ApprovalThe pipework must satisfy the requirements of AS4041 Class 2A piping or AS1697 as aminimum.2.2Pressure Testing and Leak TestingAll pressure
WELDING SPECIFICATION SP4/01 - ENGINEERING WI37.MTS.104 Revision 5 DFT ENGINEERING Any PRINTED copies of this procedure are UNCONTROLLED Page: 1 of 35 1.0 PURPOSE This Work Instruction describes the process and system used to ensure that sound engineering practice and statutory requirements are met
