AS 2885.2-2002

1 - AS 2885.2-2002 PIPELINES-GAS AND LIQUID PETROLEUM - WELDING
4 - PREFACE
6 - CONTENTS
7 - 1 SCOPE AND GENERAL
7 - 1.1 Scope
7 - 1.2 Qualification and approval
8 - 1.3 Application
9 - 1.4 Referenced documents
9 - 1.5 Definitions
9 - 1.5.1 Accessory
9 - 1.5.2 Approved and approval
9 - 1.5.3 Burn-off rate
9 - 1.5.4 Component
9 - 1.5.5 Construction
9 - 1.5.6 Defect
9 - 1.5.7 Design temperatures
9 - 1.5.8 Diameter
9 - 1.5.9 Discontinuity
10 - 1.5.10 Engineering critical assessment (ECA)
10 - 1.5.11 Engineering design
10 - 1.5.12 Environment
10 - 1.5.13 Essential variable
10 - 1.5.14 Fitting
10 - 1.5.15 Fluid
10 - 1.5.16 Gas
10 - 1.5.17 Heat input (arc energy)
10 - 1.5.18 Hot repair
10 - 1.5.19 Hot tap
11 - 1.5.20 Hydrogen assisted cold cracking (HACC)
11 - 1.5.21 Imperfection
11 - 1.5.22 Inert gas
11 - 1.5.23 In-service welding
11 - 1.5.24 Inspector
11 - 1.5.25 Location class
11 - 1.5.26 Mainline pipework
11 - 1.5.27 Matching (undermatching)
11 - 1.5.28 Matching ratio
11 - 1.5.29 May
11 - 1.5.30 Natural gas
11 - 1.5.31 Nominal thickness
12 - 1.5.32 Non-planar discontinuity
12 - 1.5.33 Operating authority
12 - 1.5.34 Operator
12 - 1.5.35 Pig
12 - 1.5.36 Pig trap (scraper trap)
12 - 1.5.37 Pipeline assemblies
12 - 1.5.38 Planar defect
12 - 1.5.39 Preheat temperature
12 - 1.5.40 Pre-tested pipe
12 - 1.5.41 Shall
12 - 1.5.42 Should
13 - 1.5.43 Sour service
13 - 1.5.44 Thickness for design internal pressure
13 - 1.5.45 Weld metal deposition repair
13 - 1.5.46 ERROR !!!
13 - 1.5.47 Yield strength
13 - 1.6 Rounding of numbers
13 - 1.7 Carbon equivalent (CE)
13 - 2 MATERIALS
13 - 2.1 General
13 - 2.2 Consumables
13 - 2.2.1 Electrodes for manual metal-arc welding
14 - 2.2.2 Wires for automatic welding
14 - 2.2.3 Storage and handling of consumables
16 - 3 POST-WELD HEAT TREATMENT AND POST-WELD COOLING
16 - 3.1 Post-weld heat treatment
16 - 3.2 Post-weld cooling
17 - 4 WELDING POSITIONS
17 - 4.1 Designation
17 - 4.2 Limits of qualified positions
21 - 5 QUALIFICATION OF A WELDING PROCEDURE
21 - 5.1 Purpose of qualifying a welding procedure
21 - 5.2 Documentation and approval
21 - 5.3 Methods of qualification
23 - 5.4 Welding procedure specification
23 - 5.5 Changes in a welding procedure
23 - 5.5.1 Change in an essential variable
24 - 5.5.2 Change in other than an essential variable
24 - 5.6 Test piece size
24 - 5.7 Test piece material
24 - 5.8 Preparation and assembly of test pieces
24 - 5.9 Test conditions
25 - 5.10 Supervision of the test weld
25 - 5.11 Identification of the test weld
30 - 6 ASSESSMENT OF THE TEST WELD TO QUALIFY A WELDING PROCEDURE
30 - 6.1 Method of assessment
31 - 6.2 Visual examination
31 - 6.3 Non-destructive examination
31 - 6.4 Destructive tests
31 - 6.4.1 Types of test and number of test specimens
31 - 6.4.2 Fracture toughness tests
32 - 6.4.3 Transverse butt tensile strength test
32 - 6.4.4 Transverse guided side bend test
33 - 6.4.5 Macro test-Cross-section examination
33 - 6.4.6 Hardness test
33 - 6.4.7 Charpy V-notch impact test
34 - 6.4.8 Crack tip opening displacement (CTOD) test
34 - 6.4.9 Notched tensile test
37 - 6.5 Repeated tests
37 - 6.5.1 Visual examination and non-destructive examination
37 - 6.5.2 Destructive testing
37 - 6.5.3 Cause of failure
37 - 6.5.4 Record of results
37 - 6.6 Period of validity
37 - 6.7 Disqualification of a qualified welding procedure
41 - 7 QUALIFICATION OF A WELDER OR OPERATOR
41 - 7.1 Purpose of qualifying a welder
41 - 7.2 Categories and scope of welder or operator qualification
41 - 7.3 Methods of qualification
41 - 7.4 Qualification by testing
42 - 7.5 Essential variables for welders and operators
44 - 7.6 Test piece
44 - 7.7 Assembly of test pieces
44 - 7.8 Automatic welding equipment
44 - 7.9 Categories of test welds
44 - 7.9.1 General
44 - 7.9.2 Test welds for Category1 (multiple qualification)
44 - 7.9.3 Test welds for Category 2 (partial qualification)
44 - 7.9.4 Test welds for Category 3 (operator qualification)
45 - 7.10 Making a test weld
45 - 7.11 Supervision of a test weld
45 - 7.12 Identification of a test weld
45 - 8 ASSESSMENT OF TEST WELDS FOR WELDER OR OPERATOR QUALIFICATION
45 - 8.1 Method of assessment
45 - 8.2 Visual examination
45 - 8.3 Non-destructive examination
46 - 8.4 Repeated test
46 - 8.4.1 General
46 - 8.4.2 Repeated failure
46 - 8.5 Record of results
46 - 8.6 Classification of categories of welds
46 - 8.7 Portability of a welder's or operator's qualification
46 - 9 WELDER OR OPERATOR QUALIFICATION AND DISQUALIFICATION
46 - 9.1 Reciprocity of a welder's or operator's qualification
46 - 9.2 Period of validity
46 - 9.3 Qualification record
47 - 9.4 Disqualification of a welder's or operator's qualification
47 - 10 DESIGN OF A WELDED JOINT
47 - 10.1 General
47 - 10.2 Butt welds between components of equal nominal wall thickness
47 - 10.3 Butt welds between components of unequal nominal wall thickness
47 - 10.4 Reinforcement of a butt weld
47 - 10.5 Fillet weld
47 - 10.5.1 Dimensions of a fillet weld
48 - 10.5.2 Fillet welding a lug, boss or pad
48 - 10.5.3 Miscellaneous fillet welds
48 - 10.6 Welding of threaded joints
48 - 10.7 Reinforcement of a welded branch connection
48 - 10.8 Reinforcement of multiple openings
48 - 10.9 Forged branch fitting
48 - 10.10 Fabricated elbow or bend
48 - 10.11 Effect of fittings upon pig passage
48 - 10.12 Offset of longitudinal welds
49 - 10.13 Distance between welds
51 - 11 PRODUCTION WELDS
51 - 11.1 Welding process
51 - 11.2 Welding equipment
51 - 11.3 Welder and welding procedure
51 - 11.4 Supervision of welding
51 - 11.5 Safety in welding
51 - 11.5.1 General
52 - 11.5.2 Welding site
52 - 11.6 Storage and handling of electrodes, filler rods and fluxes
52 - 11.7 Welding in adverse climatic conditions
52 - 11.8 Preparation for welding
52 - 11.9 Method of making the weld preparation
52 - 11.10 Accuracy of alignment
52 - 11.11 Line-up clamp
52 - 11.12 Tack welds
52 - 11.13 Working clearance
52 - 11.14 Placement of weld passes
52 - 11.15 Arc strike and arc burn
53 - 11.16 Cleaning
53 - 11.17 Peening
53 - 11.18 Insert patching
53 - 11.19 Preheat and interpass temperature
53 - 11.19.1 General
53 - 11.19.2 Application of preheat and interpass temperature
53 - 11.19.3 Extent of heating
53 - 11.19.4 Monitoring of preheat and interpass temperature
53 - 11.19.5 Condensation
53 - 11.20 Post-weld heat treatment
53 - 11.21 Identification of a production weld
53 - 12 WELDING ON A PIPELINE AFTER COMMISSIONING OR AFTER HYDROSTATIC TEST
53 - 12.1 General
54 - 12.2 Safety
54 - 12.3 Hot repair of a leaking gas-filled pipeline
54 - 12.4 Where gas is not escaping
54 - 12.5 Pipelines containing petroleum fluids other than lean natural gas
55 - 12.6 Qualification of welder(s)
55 - 12.7 Qualification of supervisors and inspectors
55 - 12.8 Fit-up before welding and cutting
55 - 12.9 Examination and testing
55 - 12.10 Criteria of acceptance
55 - 13 WELDING ONTO AN IN-SERVICE PIPELINE
55 - 13.1 General-Pipeline containing flammable or pressurized fluid
56 - 13.2 Laminations and inclusions
56 - 13.3 Lining
56 - 13.4 Safety
56 - 13.5 Inspection before welding
56 - 13.6 Ultrasonic examination before welding
56 - 13.6.1 Purpose of examination
56 - 13.6.2 Method
56 - 13.6.3 Criteria of acceptance
56 - 13.7 Welding consumables
57 - 13.8 Heat input
57 - 13.9 Qualification of welding procedures
57 - 13.10 Welding sequence
59 - 13.11 Qualification of welder(s)
59 - 13.12 Qualification of supervisors and inspectors
59 - 13.13 Fit-up before welding
59 - 13.14 Examination and testing
59 - 13.15 Criteria of acceptance
59 - 13.16 Welding of test assembly
59 - 14 ASSESSMENT OF PRODUCTION WELDS AND REPAIR WELDS
59 - 14.1 General
59 - 14.2 Qualification of personnel
59 - 14.3 Responsibilities
60 - 14.4 Methods of examination
60 - 15 VISUAL EXAMINATION
60 - 15.1 Purpose
60 - 15.2 Method of examination
60 - 15.3 Extent of visual examination
60 - 15.4 Criteria of acceptance
60 - 15.4.1 All welds
60 - 15.4.2 Butt welds
60 - 15.5 Undercut depth measurement
61 - 16 NON-DESTRUCTIVE EXAMINATION
61 - 16.1 Purpose
61 - 16.2 Qualification of organizations undertaking non-destructive examination
61 - 16.3 Qualifications of personnel
61 - 16.4 Methods
61 - 16.5 Amount of non-destructive examination
61 - 16.5.1 General
61 - 16.5.2 Butt welds and tee-butt welds
64 - 16.5.3 Welder's or operator's work
64 - 16.6 Exemption from radiographic or ultrasonic examination
64 - 16.7 Timing of non-destructive examination
64 - 17 RADIOGRAPHIC EXAMINATION
64 - 17.1 General
65 - 17.2 Safety and protection from ionizing radiation
65 - 17.3 Density
65 - 17.4 Image quality
65 - 17.5 Undercut depth measurement
67 - 17.6 Interpretation and assessment of radiographs
67 - 17.7 Criteria of acceptance
67 - 17.8 Report of radiographic examination
67 - 17.9 Retention of radiographs
68 - 18 QUALIFYING A RADIOGRAPHIC PROCEDURE
68 - 18.1 Radiographic procedure
68 - 18.2 Method of qualifying the radiographic procedure
69 - 18.3 Test conditions
69 - 18.4 Criteria of acceptance
69 - 18.5 Radiographic procedure specification documentation
69 - 18.6 Period of validity
69 - 19 ULTRASONIC EXAMINATION
69 - 19.1 Manual Ultrasonic examination
69 - 19.1.1 General
69 - 19.1.2 Purpose
69 - 19.1.3 Method
70 - 19.1.4 Surface preparation
70 - 19.1.5 Sensitivity
70 - 19.1.6 Assessment
70 - 19.1.7 Criteria of acceptance
70 - 19.1.8 Report
70 - 19.1.9 Qualification of personnel
70 - 19.2 Mechanized ultrasonic examination
70 - 19.2.1 General
70 - 19.2.2 Purpose
70 - 19.2.3 Method
71 - 19.2.4 Reference standard
71 - 19.2.5 Reference reflectors
71 - 19.2.6 Procedure
72 - 19.2.7 Calibration verification frequency
72 - 19.2.8 Criteria of acceptance
72 - 19.2.9 Report
72 - 19.2.10 Retention of raw data
72 - 20 MAGNETIC PARTICLE TESTING
72 - 20.1 Purpose
72 - 20.2 Method
73 - 20.3 Qualification of personnel
73 - 20.4 Criteria of acceptance
73 - 21 DYE-PENETRANT TESTING
73 - 21.1 Purpose
73 - 21.2 Method
73 - 21.3 Qualification of personnel
73 - 21.4 Criteria of acceptance
73 - 22 CRITERIA OF ACCEPTANCE FOR GIRTH WELD DISCONTINUITIES
73 - 22.1 General
76 - 22.2 Tier 1 Criteria-Workmanship standard
76 - 22.2.1 Inadequate penetration
76 - 22.2.2 Inadequate penetration due to high-low
76 - 22.2.3 Incomplete fusion
76 - 22.2.4 Incomplete fusion due to cold lap
78 - 22.2.5 Root concavity
78 - 22.2.6 Burn-through
78 - 22.2.7 Slag inclusions
79 - 22.2.8 Porosity
80 - 22.2.9 Cracks
80 - 22.2.10 Undercutting
80 - 22.2.11 Accumulation of discontinuities
80 - 22.2.12 Coincident discontinuities
81 - 22.2.13 Pipe or fitting discontinuities
84 - 22.3 Tier 2 Criteria-Generalized fitness-for-purpose standard
84 - 22.3.1 General
85 - 22.3.2 Tier 2 acceptance criteria
85 - 22.4 Tier 3 Criteria-Engineering critical assessment
85 - 23 REPAIR OF AN UNACCEPTABLE WELD
85 - 23.1 General
86 - 23.2 Repair
86 - 23.3 Inspection
86 - 23.4 Criteria of acceptance
86 - 24 REMOVAL OF AN ARC BURN
86 - 24.1 General
86 - 24.2 Repair by grinding
86 - 24.3 Method of inspection
86 - 24.4 Criteria of acceptance
86 - 24.5 Cleaning after testing
88 - 25 CUTTING OUT AN UNACCEPTABLE WELD OR AN ARC BURN
88 - 26 RECORDS
93 - APPENDIX A - LIST OF REFERENCED DOCUMENTS
96 - APPENDIX B - EXAMPLE OF WELD PROCEDURE SPECIFICATION FORM
98 - APPENDIX C - EXAMPLE OF WELDING PROCEDURE QUALIFICATION RECORD FORM
101 - APPENDIX D - GUIDANCE ON 'GMAW' WELDING CONSUMABLES FOR MECHANIZED PIPELINE GIRTH WELDS
102 - APPENDIX E - SELECTION AND SPECIFICATION OF CELLULOSIC WELDING ELECTRODES
102 - E1 SCOPE
102 - E2 BACKGROUND
102 - E3 STRENGTH MATCHING
103 - E4 ELECTRODE QUALITY
103 - E5 RECOMMENDED SUPPLEMENTARY REQUIREMENTS
104 - E6 REFERENCES
105 - APPENDIX F - AVOIDANCE OF HYDROGEN ASSISTED COLD CRACKING (HACC)
105 - F1 SCOPE
105 - F2 BACKGROUND
105 - F3 HACC IN PIPELINE WELDING
105 - F4 WELD METAL HYDROGEN ASSISTED COLD CRACKING (HACC)
105 - F5 DETECTION OF HACC WITH NDE
106 - F6 THE EFFECT OF DELAY TIME
106 - F7 THE EFFECT OF STRENGTH
106 - F8 WELDING PROCEDURE QUALIFICATION
107 - F9 RECOMMENDED METHODS FOR 'DESIGNING-OUT' HACC FROM WELDING PROCEDURES
107 - F9.1 Restrictions
107 - F9.2 Welding of pipe
108 - F9.3 Welding of fittings
108 - F9.4 Repair welding
109 - APPENDIX G - ITEMS REQUIRING APPROVAL

Specifies requirements for materials, welding consumables, welding processes, weld preparations, qualifications of welding procedures and personnel, and fabrication and inspection for the construction and maintenance welding of pipelines down to 3.2 mm wall thickness designed and constructed in accordance with AS 2885.1. The welding of pipelines with wall thickness less than 3.2 mm is not precluded but is not expressly covered by this Standard.

This Standard specifies materials, welding consumables, welding processes, weld preparations, 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 AS 2885.1. The welding of corrosion resistant alloy steel pipelines, or pipelines with wall 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, oxyacetylene, or by a combination of these using a manual, semiautomatic, 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.

First published as part of AS CB28-1972.Revised and redesignated as AS 1697-1975.AS 1958 first published 1976.AS 2018 first published 1977.Second edition of AS 1697-1979.Third edition AS 1697-1981.Second edition of AS 1958-1981.Second edition of AS 2018-1981.AS 1958-1981 and parts of AS 2018-1981 and of AS 1697-1981 revised, amalgmated and redesignated AS 2885-1987.AS 2885-1987 revised and redesignated in part as AS 2885.2-1995.Second edition 2002. First published as part of AS CB28-1972. Revised and redesignated as AS 1697-1975. AS 1958 first published 1976. AS 2018 first published 1977. Second edition of AS 1697-1979. Third edition AS 1697-1981. Second edition of AS 1958-1981. Second edition of AS 2018-1981. AS 1958-1981 and parts of AS 2018-1981 and of AS 1697-1981 revised, amalgmated and redesignated AS 2885-1987. AS 2885-1987 revised and redesignated in part as AS 2885.2-1995. Second edition 2002.