USACE / NAVFAC / AFCESA / NASA UFGS-33 52 90.00 20 (August 2008)
---------------------------------
Preparing Activity: NAVFAC Superseding
UFGS-33 52 90.00 20 (April 2007)
UNIFIED FACILITIES GUIDE SPECIFICATIONS
References are in agreement with UMRL dated January 2009
SECTION 33 52 90.00 20
WELDING FOR POL SERVICE PIPING
08/08
NOTE: This guide specification covers the requirements for welding of piping
and piping system components used for petroleum, oil and lubricants (POL) under
pressure, including modification to existing hydrant fueling systems.New hydrant
fueling systems are not covered by this specification.
The following guidance is offered the designer. ANSI/ASME B31.3 - Chemical Plant
and Petroleum Refinery Piping is applied to on-installation POL farm and fuel
distribution systems. ANSI/ASME B31.4 - Pipeline Transportation Systems for
Liquid Hydrocarbons and Other Liquids applies to off-installation transport
pipelines or pipelines delivering fuel to the installation.
Comments and suggestions on this guide specification are welcome and should
be directed to the technical proponent of the specification. A listing of technical
proponents, including their organization designation and telephone number, is
on the Internet.
Recommended changes to a UFGS should be submitted as a Criteria Change Request
(CCR).
Use of electronic communication is encouraged.
Brackets are used in the text to indicate designer choices or locations where
text must be supplied by the designer.
PART 1 GENERAL
1.1 REFERENCES
NOTE: This paragraph is used to list the publications cited in the text of
the guide specification. The publications are referred to in the text by basic
designation only and listed in this paragraph by organization, designation,
date, and title.
Use the Reference Wizard's Check Reference feature when you add a RID outside
of the Section's Reference Article to automatically place the reference in the
Reference Article. Do not use the Reference Wizard's Check Reference feature
to update the issue dates, as this document is specific to the standards listed.
This guide specification will be updated when the standards are updated.
References not used in the text will automatically be deleted from this section
of the project specification when you choose to reconcile references in the
publish print process.
The publications listed below form a part of this specification to the extent referenced. The publications are
referred to within the text by the basic designation only.
[AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING (ASNT)ASNT RP SNT-TC-1A(2006) Recommended Practice][AMERICAN WELDING SOCIETY (AWS)AWS A2.4(2007) Standard Symbols for Welding, Brazing and Nondestructive ExaminationAWS A3.0(2001) Standard Welding Terms and Definitions Including Terms for Adhesive Bonding, Brazing, Soldering, Thermal Cutting and Thermal SprayingAWS A5.1/A5.1M(2004; Errata 2004) Carbon Steel Electrodes for Shielded Metal Arc WeldingAWS A5.10/A5.10M(1999; R 2007) Bare Aluminum and Aluminum Alloy Welding Electrodes and RodsAWS A5.18/A5.18M(2005) Carbon Steel Filler Metals for Gas Shielded Arc WeldingAWS A5.20(2005) Carbon Steel Electrodes for Flux Cored Arc WeldingAWS A5.22(1995; R 2005) Stainless Steel Electrodes for Flux Cored Arc Welding and Stainless Steel Flux Cored Rods for Tungsten Arc WeldingAWS A5.3/A5.3M(1999; R 2007) Specification for Aluminum and Aluminum-Alloy Electrodes for Shielded Metal Arc WeldingAWS A5.32/A5.32M(1997; R 2007) Welding Shielding GasesAWS A5.4/A5.4M(2006) Stainless Steel Electrodes for Shielded Metal Arc WeldingAWS A5.9/A5.9M(2006) Specification for Bare Stainless Steel Welding Electrodes and RodsAWS C5.5/C5.5M(2003) Recommended Practices for Gas Tungsten Arc WeldingAWS D1.1/D1.1M(2008) Structural Welding Code - SteelAWS D10.10/D10.10M(1999) Local Heat Treatment of Welds in Piping and TubingAWS D10.11/D10.11M(2007) Recommended Practices for root Pass Welding of Pipe Without BackingAWS D10.12/D10.12M(2000) Recommended Practices and Procedures for Welding Plain Carbon Steel PipeAWS D10.4(1986; R 2000) Recommended Practices for Welding Austenitic Chromium-Nickel Stainless Steel Piping and TubingAWS D10.7/D10.7M(2008) Guide for Shielded Arc Welding of Aluminum and Aluminum Alloy PipeAWS QC1(2007) AWS Certification of Welding InspectorsAWS WHB-4.8(1998) Welding Handbook, vol II, Materials and ApplicationsAWS Z49.1(2005) Safety in Welding, Cutting and Allied Processes][ASME INTERNATIONAL (ASME)ASME B31.3(2008) Process PipingASME B31.4(2006) Pipeline Transportation Systems for Liquid Hydrocarbons and Other LiquidASME BPVC SEC V(2007; Addenda 2008) Boiler and Pressure Vessel Code; Section V, Nondestructive Examination][ASTM INTERNATIONAL (ASTM)ASTM E 329(2008) Standard Specification for Agencies Engaged in the Testing and/or Inspection of Materials Used in ConstructionASTM E 94(2004) Radiographic Examination][U.S. NAVAL SEA SYSTEMS COMMAND (NAVSEA)NAVSEA T9074-AS-GIB-010/271(1999; Notice 1) Requirements for Nondestructive Testing Methods]1.2 DEFINITIONS
Definitions shall be in accordance with AWS A3.0 except as follows:
a. Weld slag is defined as the crystalline residue remaining on the weld surface following
a weld procedure which uses flux as a shielding method.
b. POL service piping consists of piping and components used for petroleum, oil and lubricants
(POL) under pressure or gravity force including modifications to existing hydrant fueling systems.
1.3 SUBMITTALS
NOTE: Submittals must be limited to those necessary for adequate quality control.
The importance of an item in the project should be one of the primary factors
in determining if a submittal for the item should be required.
A “G” following a submittal item indicates that the submittal requires Government
approval. Some submittals are already marked with a “G”. Only delete an existing
“G” if the submittal item is not complex and can be reviewed through the Contractor’s
Quality Control system. Only add a “G” if the submittal is sufficiently important
or complex in context of the project.
For submittals requiring Government approval on Army projects, a code of up
to three characters within the submittal tags may be used following the "G"
designation to indicate the approving authority. Codes for Army projects using
the Resident Management System (RMS) are: "AE" for Architect-Engineer; "DO"
for District Office (Engineering Division or other organization in the District
Office); "AO" for Area Office; "RO" for Resident Office; and "PO" for Project
Office. Codes following the "G" typically are not used for Navy projects.
Submittal items not designated with a "G" are considered as being for information
only for Army projects and for Contractor Quality Control approval for Navy
projects.
Government approval is required for submittals with a "G" designation; submittals not having a "G" designation
are [for Contractor Quality Control approval.][for information only. When used, a designation following the
"G" designation identifies the office that will review the submittal for the Government.] The following shall
be submitted in accordance with Section 01 33 00 SUBMITTAL PROCEDURES:
SD-01 Preconstruction Submittals
Welding procedure qualification; [G][; G, [_____]]
Welding Operations; [G][; G, [_____]]
Detailed procedures which define methods of compliance to contract drawings and specifications.
SD-02 Shop Drawings
POL Service Piping; [G][; G, [_____]]
Detail drawings showing location, length, and type of welds; and indicating preweld and postweld
heat treatment and NDE as required. The drawings shall show the welding procedure specification
(WPS) to be used at each weld location.
Pigging Plan; [G][; G, [_____]]
SD-06 Test Reports
Welding Reports
Written records and drawings indicating location of welds made by each welder or welding operator.
Examinations, Inspections and Tests
SD-07 Certificates
Qualifications; [G][; G, [_____]]
Welder and welding operator performance qualification certificates. Welding inspectors and
NDE personnel certificates. Qualifications of testing laboratory or the Contractor's quality
assurance organization.
1.4 GENERAL REQUIREMENTS
NOTE: The drawings should be checked to ensure that any supplementary information
required has been shown and that there is no conflict between the drawings and
the specifications.
Project drawings must indicate, or text of project specifications must specify,
the welding procedures, and size, length, type, and location of the welds, as
necessary. Project drawings and/or specifications must indicate that factory
applied internal and external coatings be stopped one (1) inch from a girth
weld leaving a 2" uncoated area for welding.
This section covers the welding of Petroleum, Oil and Lubricant (POL) Service systems. Deviations from applicable
codes, approved procedures, and approved detail drawings will not be permitted without prior written approval
by the Contracting Officer. Materials or components with welds made offsite will not be accepted if the welding
does not conform to the requirements of this specification, unless otherwise specified. Procedures shall be
developed by the Contractor for welding all metals included in the work. Welding shall not be started until
welding procedures, welders, and welding operators have been qualified. Qualification testing shall be performed
by an approved testing laboratory, or by the Contractor if approved by the Contracting Officer. Costs of such
testing shall be borne by the Contractor. The Contracting Officer shall be notified at least 1 week in advance
of the time and place of the tests. If the Contracting Officer elects to witness the tests, the qualification
tests shall be performed at or near the worksite. The Contractor shall maintain current records of the test
results obtained in the welding procedure, welding operator, welder performance qualifications, and nondestructive
examination (NDE) procedures readily available at the site for examination by the Contracting Officer. The procedures
for making transition welds between different materials or between plates or pipes of different wall thicknesses
shall be qualified. Unless otherwise specified, the choice of welding process shall be the responsibility of
the Contractor.
1.5 PERFORMANCE
NOTE:
The paragraphs will be edited and bracketed portions inserted if necessary to
ensure proper implementation of the CONTRACTOR QUALITY CONTROL PROGRAM. The
specification writer or design engineer must indicate how much quality control
of welding is needed for each project and who is to be responsible; i.e., primarily
the Contractor or the Government.
In many cases a project may not require 100 percent testing of welds by NDE
methods. The designer must determine the required methods and the extent of
inspection and testing, and must indicate the extent in this or other sections
of the project specifications or on the project drawings by notes, NDE symbols,
or other means. The referenced applicable publications will be used for guidance
in determining inspection and testing requirements.
The specifications or drawings must clearly indicate which joints require 100
percent NDE inspection, (all underground joints require 100% Radiographic Testing
(RT) which joints require random NDE inspection, and which NDE methods are to
be employed for each joint.
The Contractor shall be responsible for the quality of all joint preparation, welding, and examination. All
materials used in the welding operations shall be clearly identified and recorded. The inspection and testing
defined in this specification are minimum requirements. Additional inspection and testing shall be the responsibility
of the Contractor when he deems it necessary to achieve the quality required.
1.6 QUALIFICATIONS
Welding procedures, welders, and welding operators previously qualified by test may be accepted for the work
without requalification, provided that all of the following conditions are fulfilled:
a. Copies of the welding procedure specifications, the welding procedure qualification record,
and the welder and welding operator certifications are submitted and approved in accordance
with paragraph SUBMITTALS.
b. Testing was performed by an approved testing laboratory or approved technical consultant
or by the Contractor's approved quality assurance organization.
c. The welding procedures, welders, and welding operators were qualified in accordance with
[ASME B31.3], [ASME B31.4], and base materials, filler materials, electrodes, equipment, and
processes conformed to the applicable requirements of this specification.
d. The requirements of paragraph "Renewal of Qualification" below are met and records showing
name of employer and period of employment using the process for which qualified are submitted
as evidence of conformance.
1.6.1 Welding Operations
The Contractor shall provide a description of how the critical welding operations will be accomplished. Provide
the welding procedures to be used for each operation, the sequence of welding to minimize heat distortion, sequence
of welding piping sections both in the trench and outside, machine welding if used, and multiple welders on same
pipe weld.
1.6.2 Welding Procedure Specification and Qualification Records
The Contractor shall record in detail and shall qualify the Welding Procedure Specifications for every proposed
welding procedure. Qualification for each welding procedure shall conform to the requirements of [ASME B31.3
,] [ASME B31.4,] and to this specification. The welding procedures shall specify back purge gas requirements,
end preparation for butt welds including cleaning, alignment, and root openings. Preheat, interpass temperature
control, and postheat treatment of welds shall be as required by approved welding procedures, unless otherwise
indicated or specified. Copies of the welding procedure specifications and weld procedure qualification record
results for each type of welding required shall be submitted in accordance with paragraph SUBMITTALS. Approval
of any procedure does not relieve the Contractor of the sole responsibility for producing acceptable welds.
Welding procedures shall be identified individually and shall be referenced on the POL service piping shop drawings.
1.6.3 Welder and Welding Operator Performance
Each welder and welding operator assigned to work shall be qualified in accordance with [ASME B31.3,] [ASME B31.4
].
1.6.3.1 Certification
Before assigning welders or welding operators to the work, the Contractor shall provide the Contracting Officer
with their names together with certification that each individual is performance-qualified as specified. The
certification shall state the type of welding and positions for which each is qualified, the code and welding
procedure specification under which each is qualified, date qualified, and the firm and individual certifying
the qualification tests. The Contractor shall provide a summary table showing all welders and the WPS with which
they are qualified to weld.
1.6.3.2 Identification
Each particular weld shall be identified with the personal number, letter, or symbol assigned to each welder
or welding operator. To identify welds, written records indicating the location of welds made by each welder
or welding operator shall be submitted, and each welder or welding operator shall apply the personal mark adjacent
to the welds using a rubber stamp or felt-tipped marker with permanent, weatherproof ink or other methods approved
by the Contracting Officer that do not deform the metal. Identification by die stamps or electric etchers will
not be allowed.
1.6.3.3 Renewal of Qualification
Requalification of a welder or welding operator shall be required under any of the following conditions:
a. When a welder or welding operator has not used the specific welding procedure for a period
of 3 months; the period may be extended to 6 months if the welder or welding operator has been
employed on another welding procedure.
b. When a welder or welding operator has not welded with any procedureduring a period of 3
months, all the personal qualifications shall be considered expired, including any extension
by virtue of a. above.
c. There is specific reason to question the person's ability to make welds that will meet the
requirements of the specifications.
d. The welder or welding operator was qualified by an employer, other than those firms performing
work under this contract, and a qualification test has not been taken within the preceding 12
months.
e. Renewal of qualification for a specific welding procedure under conditions a., b., and d.,
above, needs to be made on only a single test joint or pipe of a thickness, position, or material
required by the welding procedure specifications to reestablish the welder's or welding operator's
qualification for the previous qualification.
1.6.4 Test Reports
Test reports shall consist of the following.
a. Records made by the AWS certified inspector for all duties performed per paragraph 4.2 of
AWS QC1.
b. All NDE (radiograph, ultrasound, etc.) reports with unique weld ID for each weld tested.
c. "Weld Maps". These maps/drawings correlate the shop drawings submitted to the NDE reports.
The NDE report that shows a weld number as acceptable is correlated with weld number on the
drawings.
d. Provide the location of each weld, what procedure was used, which welder did the weld, the
results of the visual test, and the results of the NDE.
1.6.5 Inspection and NDE Personnel
NOTE:
Coordinate with paragraph Performance.
All inspection and NDE personnel shall be qualified in accordance with the following requirements. The contractor
shall submit the qualifications of all the testing personnel that will perform all field tests for review by
the Contracting Officer. The qualifications of all personnel on the job site that will perform welding inspections
and NDE shall be submitted for approval. All inspectors and NDE personnel shall have a minimum of one (1) year
experience inspecting the piping material being used and five (5) years in military or commercial aircraft hydrant
fueling systems or truck fueling systems, petroleum refineries, power generating plants, or chemical process
plants.
1.6.5.1 Inspector Certification
Welding inspectors shall be qualified in accordance with [AWS QC1],[ASME B31.3, Chapter VI].
1.6.5.2 NDE Personnel
NDE personnel shall be certified in accordance with Chapter VI, ASME B31.3 for each NDE procedure he is required
to use, and a written procedure for the control and administration of NDE personnel training, examination, and
certification shall be established. The procedures shall be based on appropriate specific and general guidelines
of training and experience recommended by ASNT RP SNT-TC-1A.
1.6.5.3 Testing Agency
The testing agency, testing laboratory, technical consultant or contractor's approved quality assurance organization
shall meet the requirements of ASTM E 329.
1.7 DELIVERY, STORAGE, AND HANDLING
All filler metals, electrodes, and other welding materials shall be delivered to the site in manufacturers' original
packages and stored in a dry space until used. Packages shall be properly labeled and designed to give maximum
protection from moisture and to insure safe handling.
1.7.1 Material Control
NOTE: If additional requirements are necessary regarding limits on out-of-oven
exposure time, refer to AWS D1.1/D1.1M.
Materials shall be stored in a controlled access and clean, dry area that is weathertight and is maintained at
a temperature recommended by the manufacturer. The materials shall not be in contact with the floor and shall
be stored on wooden pallets or cribbing.
1.7.1.1 Damaged Containers
Low-hydrogen steel electrodes shall be stored in their sealed shipping container. If the seal is damaged during
shipment or storage, and the damage is not immediately detected, the covered electrodes in that container shall
be rebaked in accordance with the manufacturer's instructions prior to issuance or shall be discarded. If a
container is damaged in storage and the damage is witnessed, the electrodes from that container shall be immediately
placed in a storage oven. The storage oven temperature shall be as recommended by the manufacturer or the welding
material specification.
1.7.1.2 Partial Issues
When a container of covered electrodes is opened and only a portion of the content is issued, the remaining portion
shall, [within 1/2 hour]; [within the limits established by AWS D1.1/D1.1M] be placed in a storage oven.
1.7.2 Damaged Materials
Materials which are damaged shall be discarded. Covered electrodes which are oil or water-soaked, dirty, or
on which the flux has separated from the wire shall be discarded.
1.8 SYMBOLS
Symbols shall be in accordance with AWS A2.4.
1.9 SAFETY
Safety precautions shall conform to AWS Z49.1.
PART 2 PRODUCTS
2.1 WELDING MATERIALS
NOTE: Normally, selection of the electrodes is done by the Contractor. In
special cases, if the selection of the proper electrode is critical to the design,
the designer may specify the electrodes to be used. In special cases it also
may be necessary to specify the welding process.
The selection of electrodes should be limited to non covered for all root passes.
Covered electrodes may be allowed for fill passes after the root pass is completed.
This will eliminate formation of weld slag on the interior of the pipe. Weld
process for root passes is restricted to Gas Tungsten or Gas Metal Arc Welding
to provide for a clean weld on the initial pass.
In tight or confined spaces where oxygen supply may be a concern, use of a back
purge gas may be re-evaluated and a covered electrode may be allowed. This condition
should be addressed by the Designer and the Contracting Officer on a case by
case basis.
Welding materials for carbon steel, stainless steel and aluminum shall comply with AWS WHB-4.8. Welding equipment,
electrodes, welding wire, and fluxes shall be capable of producing satisfactory welds when used by a qualified
welder or welding operator using qualified welding procedures. All field girth root pass welds shall be made
with non-covered electrodes or welding wire. External welds on the pipe such as attaching pipe supports may be
made with covered electrodes or welding wire. Electrodes, welding wire and/or fluxes shall be in accordance
with Table 1. Welding materials for aluminum and aluminum alloy shall comply with AWS D10.7/D10.7M.
TABLE I.
AWS Process Alloy Consumable Use
Example (1)
AWS A5.1/A5.1M SMAW Low Carbon E7018, E6010 Fill
AWS A5.4/A5.4M SMAW Stainless E308L, E309L Fill
AWS A5.3/A5.3M SMAW Aluminum Fill
AWS A5.9/A5.9M GTAW/GMAW Stainless ER308L,ER309L Root and Fill
AWS A5.10/A5.10M GTAW/GMAW Aluminum Root and Fill
AWS A5.18/A5.18M GTAW/GMAW Low Carbon E70S-3,E70S-6 Root and Fill
AWS A5.20 FCAW Low Carbon E71T1-1 Fill
AWS A5.22 GTAW/FCAW Stainless E308LT1-1 FCAW Fill
GTAW-Root
AWS A5.32/A5.32M GTAW/GMAW All Shielding Gas
__________________________________________________________________
Note(1): The consumable material designations shown are examples only and are not intended to limit
the Contractor's selection of consumable materials.
PART 3 EXECUTION
3.1 WELDING OPERATIONS
Welding shall be performed in accordance with qualified procedures using qualified welders and welding operators.
Welding shall not be done when the quality of the completed weld could be impaired by the prevailing working
or weather conditions. The Contracting Officer shall determine when weather or working conditions are unsuitable
for welding. Welding of hangers, supports, and plates to structural members shall conform to Section
05 05 23 WELDING, STRUCTURAL.
Welding shall be performed in accordance with [ASME B31.3]; [ASME B31.4] and the applicable portions of [AWS D10.4
]; [AWS D10.7/D10.7M]; [AWS D10.10/D10.10M]; [AWS D10.11/D10.11M]; [AWS D10.12/D10.12M]; [AWS C5.5/C5.5M]
All joints unless indicated otherwise, in carbon steel, aluminum and stainless steel piping systems shall be
welded. Unless otherwise approved, all girth welds shall be complete penetration groove welds made in accordance
with qualified welding procedures. The root pass on stainless steel and carbon steel pipe shall be by the GMAW
or GTAW process.
a. Weld Preparation shall comply with the requirements of ASME B31.3 and the qualified Welding
Procedure Specification. The use of "rice paper" as purge blocks is not permitted. Contractor
shall submit alternate method for approval.
b. Backing Rings. The use of backing rings for making or repairing welds will not be permitted.
3.1.1 Base Metal Preparation
Oxy-fuel cutting shall not be used on austenitic stainless steel or nonferrous materials.
Mechanical grinding of thermal cut ends shall be used to remove the heat affected area but should be limited
to maximum 1/8".
3.1.2 Weld Joint Fit-Up
Parts that are to be joined by welding shall be fitted, aligned, and retained in position during the welding
operation by the use of bars, jacks, clamps, or other mechanical fixtures. End welds shall be properly aligned
prior to welding in accordance with Chapter V of ASME B31.3. Welded temporary attachments shall not be used
except when it is impractical to use mechanical fixtures. When temporary attachments are used, they shall be
the same material as the base metal, and shall be completely removed by grinding or thermal cutting after the
welding operation is completed. If thermal cutting is used, the attachment shall be cut to not less than 6 mm
1/4 inch from the member and the balance removed by grinding. After the temporary attachment has been removed,
the area shall be visually examined.
3.1.3 Preheat and Interpass Temperatures
Preheat temperatures shall meet the requirements specified by [ASME B31.3,] [ASME B31.4]. However, in no case
shall the preheat be below 10 degrees C 50 degrees F for ferritic steel or austenitic stainless steel, or 0 degrees
C 32 degrees F for nonferrous alloys. The maximum interpass temperatures shall not exceed 149 degrees C 300
degrees F for austenitic stainless steels, nickel alloys, and copper alloys; and 260 degrees C 500 degrees F
for carbon steels. Preheat techniques shall be such as to ensure that the full thickness of the weld joint preparation
and/or adjacent base material, at least 75 mm 3 inches in all directions, is at the specified temperature. Preheating
by induction or resistance methods is preferred. When flame heating is used, only a neutral flame shall be employed.
Oxy-fuel heating shall not be used on austenitic stainless steel; however, air-fuel heating is acceptable if
controlled to insure that the surface temperature does not exceed 66 degrees C 150 degrees F. Interpass temperatures
shall be checked on the surface of the component within 25 mm 1 inch of the weld groove and at the starting location
of the next weld pass, and for a distance of about 150 mm 6 inches ahead of the weld, but not on the area to
be welded.
3.1.4 Production Welding Instructions
a. Welding shall not be done when the ambient temperature is lower than minus 18 degrees C
0 degree F.
b. Welding is not permitted on surfaces that are wet or covered with ice, when snow or rain
is falling on the surfaces to be welded, or during periods of high winds, unless the welders
and the work are properly protected.
c. Gases for purging and shielding shall be welding grade and shall have a dew point of minus
40 degrees C minus 40 degrees F or lower.
d. Back purges are required for austenitic stainless steels and nonferrous alloys welded from
one side and shall be set up such that the flow of gas from the inlet to the outlet orifice
passes across the area to be welded. The oxygen content of the gas exiting from the purge vent
shall be less than 2 percent prior to welding. The flow rate shall be that required by the
approved weld procedure specification.
e. The purge on groove welds shall be maintained for at least two passes or 5 mm 3/16 inch
whichever is greater.
f. Removable purge dam materials shall be made of expandable or flexible plugs, such as Plexiglas,
plywood (which shall be dry when used), etc. Wood dams shall be kiln-dried quality. Nonremovable
purge dams and purge dam adhesives shall be made of water soluble materials. Purge dams shall
not be made of polyvinyl alcohol.
g. Any welding process which requires the use of external gas shielding shall not be done in
a draft or wind unless the weld area is protected by a shelter. This shelter shall be of material
and shape appropriate to reduce wind velocity in the vicinity of the weld to a maximum of 8
km/hour 5 mph (440 fpm).
h. Tack welds to be incorporated in the final welds shall have their ends tapered by grinding
or welding technique. Tack welds that are cracked or defective shall be removed and the groove
shall be retacked prior to welding. Temporary tack welds shall be removed, the surface ground
smooth, and visually inspected. For low-alloy and hardenable high-alloy steels, the area shall
be magnetic particle examination inspected.
i. Grinding of completed welds is to be performed only to the extent required for NDE, including
any inservice examination, and to provide weld reinforcement within the requirements of [ASME B31.3
,] [ASME B31.4,]. If the surface of the weld requires grinding, reducing the weld or base material
below the minimum required thickness shall be avoided. Minimum weld external reinforcement
shall be flush between external surfaces.
j. Each qualified welder shall be assigned an identification symbol. All welds shall be permanently
marked with the symbol of the individual who made the weld.
NOTE: Designer to include Specification Section 33 52 43.00 20 and
33 52 10 if carbon steel and stainless steel are to be connected
k. Direct welded connection of carbon steel and stainless steel shall not be made. [See Section
33 52 43.00 20, AVIATION FUEL DISTRIBUTION AND DISPENSING and Section 33 52 10 SERVICE PIPING,
FUEL SYSTEMS for method of connection.]
3.1.5 Postweld Heat Treatment
a. Postweld heat treatment shall be performed in accordance with [ASME B31.3,] [ASME B31.4,]. Temperatures
for local postweld heat treatment shall be measured continuously by thermocouples in contact with the
weldment.
b. Postweld heat treatment of low-alloy steels, when required, shall be performed immediately upon completion
of welding and prior to the temperature of the weld falling below the preheat temperature. However,
postweld heat treatment may be postponed after the completion of the weld, if, immediately after the
weld is completed, it is maintained at a minimum temperature of 149 degrees C 300 degrees F or the preheat
temperature, whichever is greater, for 2 hours per 25 mm inch of weld thickness.
3.2 EXAMINATIONS, INSPECTIONS, AND TESTS
NOTE: Coordinate with paragraph Performance.
Weld inspection and NDE shall be performed by the Contractor to detect surface and internal discontinuities in
completed welds. The services of a qualified commercial inspection or testing laboratory or technical consultant
meeting the requirements of paragraph "Inspection and NDE Personnel", approved by the Contracting Officer, shall
be employed by the Contractor. All tack welds, weld passes, and completed welds shall be visually inspected.
In addition, [magnetic particle] [liquid penetrant] examination shall be performed on root passes. [Radiographic]
[Liquid penetrant] [Magnetic particle] [or] [Ultrasonic] examination shall be required as indicated below. When
inspection and testing indicates disqualifying defects in a weld joint, the weld shall be repaired by a qualified
welder in accordance with paragraph CORRECTIONS AND REPAIRS. The Contractor shall submit weld inspection and
NDE field testing reports to the Contracting Officer.
The person performing the weld inspection shall perform the following:
a. Verify that the base materials and consumable welding materials conform to the specifications
and that welding filler metals used are as specified for each base material.
b. Verify that the welding equipment to be used for the work is appropriate for use with the
welding procedure specification and has the capability to meet the applicable requirements of
the welding procedure.
c. Verify that only approved or qualified welding procedures are used for the work.
d. Verify that the edge preparation or joint geometry meet the requirements of the welding
procedure and drawings.
e. Verify that the specified filler metals are used and that filler metals are maintained in
proper condition, per requirements, or as recommended by the manufacturer.
f. Verify that the technique and performance of each welder, welding
operator, and tack welder are as specified.
g. Verify that the work conforms to requirements of the applicable
standards, drawings, or other documents.
h. Verify that the work inspected is identified and documented in
accordance with specified requirements.
i. Prepare clear and concise reports and verify that records of the
results of examinations are maintained.
j. Verify the approved WPS pre-heat and post heat procedures are being used.
NOTE: For modifications to existing stainless steel hydrant systems iinsert
the following paragraph:
[Welders found making defective welds shall be removed from the work or shall be required to be requalified in
accordance with ASME B31.3.]
NOTE: Coordinate with Paragraph Performance
This paragraph is to be edited based on the piping code used for design. Both B31.3 and B31.4 allow for different
percentages of additional testing with B31.3 generally being more stringent. The selection of B31.3 or B31.4
should be consistent with the application. See UFC 3-460-01 "Design: Petroleum Fuel Facilities". For modification
to existing hydrant systems at paragraph 3.2.2 insert the following lst paragraph.
3.2.1 Visual Inspection
Weld joints shall be inspected visually as follows:
a. Before welding - for compliance with requirements for joint preparation, alignment and
fit-up, and cleanliness.
b. During welding - for cracks and conformance to the approved welding procedure.
c. After welding - for cracks, contour and finish, bead reinforcement, undercutting, overlap,
weld slag on the interior of the pipe and size of welds. Visual examination of the interior
of the pipe may be performed by any of the remote means allowed by ASME BPVC SEC V, visual inspection.
3.2.2 NDE Testing Frequency
[All pipe field welds, including high point vent pipe tees, weld-o-lets, sock-o-lets and low point drain pipe,
shall be examined by radiographic methods to determine conformance to the paragraph "Acceptance Standards."
The services of a qualified commercial or testing laboratory approved by the Contracting Officer shall be employed
by the Contractor for testing of piping welds. Costs of testing, including retesting of repaired welds, shall
be borne by the Contractor.]
Provide 100% radiographic testing for all underground piping. Provide random ragiographic testing in accordance
with [ASME B31.3]; [ASME B31.4] for all aboveground piping. The inspection shall include an examination of welds
made by each welding operator or welder. If the testing reveals that any welds fail to meet minimum quality
requirements, an additional percent of the welds in that same group shall be inspected in accordance with [ASME B31.3
]; [ASME B31.4]. If all of the additional welds inspected meet the quality requirements, the entire group of
welds represented shall be accepted and the defective welds shall be repaired. If any of the additional welds
inspected also fail to meet the quality requirements, that entire group of welds shall be rejected. The rejected
welds shall be removed and rewelded, or the rejected welds shall be 100 percent inspected and all defective weld
areas removed and rewelded.
3.2.3 NDE Testing
NOTE: Delete any NDE method not required. If magnetic particle inspection
is required, specify whether wet or dry particle method is appropriate.
For modifications to existing Hydrant Systems choose only radiographic from
the lst paragraph and include the 2nd paragraph.
NDE shall be as required by [ASME B31.3], [ASME B31.4] and in accordance with written procedures. Procedures
for [radiographic] [liquid penetrant] [magnetic particle] [or] [ultrasonic] tests and methods shall conform to
ASME BPVC SEC V. The approved procedure shall be demonstrated to the satisfaction of the Contracting Officer.
In addition to the information required in ASME BPVC SEC V, the written procedures shall include the timing of
the NDE in relation to the welding operations and safety precautions.
[The services of a qualified testing agency approved by the Contracting Officer shall be employed by the Contractor
for testing of piping welds. Costs of testing, including retesting of repaired welds, shall be borne by the
Contractor. Procedures for radiographic inspection shall be in accordance with NAVSEA T9074-AS-GIB-010/271 or
ASTM E 94. Weld ripples or surface irregularities that might mask or be confused with the radiographic image
of any objectionable defect shall be removed by grinding [and], [or] other suitable mechanical means. The weld
surface shall be merged smoothly with the base metal surface.]
3.2.4 Inspection and Tests by the Government
The Government may perform inspection and supplemental nondestructive or destructive tests as deemed necessary.
The cost of supplemental NDE will be borne by the Government. The correction and repair of defects and the reexamination
of weld repairs shall be performed by the Contractor at no additional cost to the Government. Inspection and
tests will be performed as required for visual inspection and NDE, except that destructive tests may be required
also. When destructive tests are ordered by the Contracting Officer and performed by the Contractor and the
specimens or other supplemental examinations indicate that the materials and workmanship do not conform to the
contract requirements, the cost of the tests, corrections, and repairs shall be borne by the Contractor. When
the specimens or other supplemental examinations of destructive tests indicate that materials or workmanship
do conform to the specification requirements, the cost of the tests and repairs will be borne by the Government.
When destructive tests are made, repairs shall be made by qualified welders or welding operators using welding
procedures which will develop the full strength of the members cut. Welding shall be subject to inspection and
tests in the mill, shop, and field. When materials or workmanship do not conform to the specification requirements,
the work may be rejected at any time before final acceptance of the system containing the weldment.
3.3 ACCEPTANCE STANDARDS
NOTE: These acceptance standards were taken from ASME B31.3 and B31.4 and are
suitable for most jobs. Evaluations of indications, as given in ASME B31.3
and B31.4, are applicable to these standards. Specific project design requirements
may necessitate revision or expansion to cover different items of work and varying
standards of acceptance. In no case shall the acceptance criteria be less conservative
than the criteria specified by the standard applicable to the work. If actual
conditions exceed these limits of ASME B31.3 or B31.4, this requirement shall
be expanded or revised as required. For modifications to existing hydrant systems
and stainless steel systems select the 2nd paragraph below and delete the first
paragraph.
[Acceptance standards shall be in accordance with ASME B31.3 paragraph 341.3.2, Chapter VI in addition to the
following specified items.]
[Interpretation of test results and limitations on imperfections in welds shall comply with the requirements
of 100% radiography, per ASME B31.3. Chapter IX, Table K341.3.2A. For hydrant systems and stainless steel systems
the evaluation shall be based on severe cyclic conditions in addition to the following-specified items.]
3.3.1 Visual
The following indications are unacceptable:
a. Weld Slag on the interior of the pipe.
3.3.2 Magnetic Particle Examination
The following relevant indications are unacceptable:
a. Any cracks and linear indications.
b. Rounded indications with dimensions greater than 5 mm 3/16 inch.
c. Four or more rounded indications in a line separated by 2 mm 1/16 inch or less edge-to-edge.
d. Ten or more rounded indications in any 3870 square mm 6 square inches of surface with the
major dimension of this area not to exceed 150 mm 6 inches with the area taken in the most unfavorable
location relative to the indications being evaluated.
3.3.3 Liquid Penetrant Examination
Indications with major dimensions greater than 2 mm 1/16 of an inch shall be considered relevant. The following
relevant indications are unacceptable:
a. Any cracks or linear indications.
b. Rounded indications with dimensions greater than 5 mm 3/16 inch.
c. Four or more rounded indications in a line separated by 2 mm 1/16 inch or less edge-to-edge.
d. Ten or more rounded indications in any 3870 square mm 6 square inches of surface with the
major dimension of this area not to exceed 150 mm 6 inches with the area taken in the most unfavorable
location relative to the indications being evaluated.
3.4 CORRECTIONS AND REPAIRS
Disqualifying defects shall be removed and repaired as specified in [ASME B31.3,] [ASME B31.4,] unless otherwise
specified. Disqualifying defects discovered between weld passes shall be repaired before additional weld material
is deposited. After defect removal is complete and before rewelding, the area shall be examined by the same
test method which first revealed the defect to ensure that the defect has been eliminated. After rewelding,
the repaired area shall be reexamined by the same test method originally used for that area. Any indication
of a defect shall be regarded as a defect unless reevaluation by NDE or by surface conditioning shows that no
disqualifying defects are present.
3.4.1 Defect Removal
Defective or unsound weld joints shall be corrected by removing and replacing the entire weld joint, or for the
following defects corrections shall be made as follows:
a. Excessive Convexity and Overlap: Reduce by removal of excess metal.
b. Excessive Concavity of Weld, Undersized Welds, Undercutting: Clean and deposit additional
weld metal.
c. Excessive Weld Porosity, Inclusions, Lack of Fusion, Incomplete Penetration: Remove defective
portions and reweld.
d. Crack in Weld or Base Metal: Remove crack throughout its length, including sound weld metal
for a distance of twice the thickness of the base metal or two inches, whichever is less, beyond
each end of the crack, followed by the required rewelding. Complete removal shall be confirmed
by magnetic particle inspection for carbon steel or liquid penetrant inspection for stainless
steel. Inspection procedures shall comply with the requirements of ASME B31.3.
e. Poor Fit-Up: Cut apart improperly fitted parts, and reweld.
3.4.1.1 Methods of Defect Removal
The removal of weld metal or portions of the base metal shall be done preferably by chipping, grinding, sawing,
machining, or other mechanical means. Defects also may be removed by thermal cutting techniques. If thermal
cutting techniques are used, the cut surfaces shall be cleaned and smoothed by mechanical means to remove the
heat affected zone. In addition, a maximum of 1/8-inch of metal shall be removed by mechanical means from the
cut surfaces of stainless steel.
Wherever a defect is removed, and repair by welding is not required, the affected area shall be blended into
the surrounding surface eliminating sharp notches, crevices, or corners.
3.4.1.2 Rewelding
Repair welds shall be made using an electrode or filler wire smaller than that used in making the original weld.
Rewelding shall be done using qualified welding procedures. The surface shall be cleaned before rewelding.
Repair welds shall meet the requirements of this specification.
3.4.1.3 Peening or Caulking
The use of force (peening) or foreign materials to mask, fill in, seal, or disguise any welding defects shall
not be permitted.
NOTE: The intent of the following paragraph is to require cleaning of the piping
system as it is being installed. The designer shall include Section 15899 for
modifications to hydrant systems and Section 13004 for other POL service piping
systems.
3.5 MAINTAINING CLEANLINESS OF PIPING
The Contractor shall keep the interior and ends of all new piping affected by the Contractor's operations thoroughly
cleaned of foreign matter and water before and after being installed. Piping systems shall be kept clean during
installation by means of plugs or other approved methods. When work is not in progress, open ends of piping
and fittings shall be closed so that no water or other foreign substance will enter the pipes or fittings. Piping
shall be inspected before placing into position. The interior of each length of pipe shall be cleaned after
welding; A swab, with a leather or canvas belt disc to fit the inside diameter of pipe, shall be pulled through
each length of pipe after welding in place. It shall be the Contractor's responsibility for insuring that the
interior of the piping is free of foreign matter including weld slag when it is connected into the system.
NOTE: Select the following paragraph if a high degree of cleanliness is required
such as modifications to an existing hydrant fueling system. For existing systems
review piping details and devices to determine if the system can be pigged or
modified so it can be pigged.
3.5.1 [Pigging Plan
The pigging plan shall be submitted for approval by the Contracting Officer. The pigging plan shall provide
a minimum of two runs through the system with each set of pigs. There shall be a minimum of two types of pigs,
polyurethane and foam. More types of pigs (brushes, scrapers etc.) or runs may be required depending on the
type of debris found in the system. The pigging plan shall be submitted to the Contracting Officer for approval.]
3.6 COMMISSIONING
For commissioning of POL service piping systems see section 33 08 55 COMMISSIONING OF FUEL FACILITY SYSTEMS.
For repairs or modifications to hydrant systems see Section 15899 "Commissioning of Hydrant Fuel Systems."