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1、TECHNICAL SPECIFICATION WELDING OF PIPELINES AND RELATED FACILITIES (AMENDMENTS/SUPPLEMENTS TO ANSI/API STD 1104) DEP 61.40.20.30-Gen. June 1993 DESIGN AND ENGINEERING PRACTICE USED BY COMPANIES OF THE ROYAL DUTCH/SHELL GROUP This document is confidential. Neither the whole nor any part of this docu
2、ment may be disclosed to any third party without the prior written consent of Shell Internationale Petroleum Maatschappij B.V., The Hague, the Netherlands. The copyright of this document is vested in Shell Internationale Petroleum Maatschappij B.V., The Hague, the Netherlands. All rights reserved. N
3、either the whole nor any part of this document may be reproduced, stored in any retrieval system or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owner. PDF created with pdfFactory Pro trial v
4、ersion PREFACE DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of: Shell International Oil Products B.V. (SIOP) and Shell International Exploration and Production B.V. (SIEP) and Shell International Chemicals B.V. (SIC) The Hague, The Netherlands, a
5、nd other Service Companies. They are based on the experience acquired during their involvementwith the design, construction, operation and maintenance of processing units and facilities, and they are supplemented with the experience of Group Operating companies. Where appropriate they are based on,
6、or reference is made to, national and international standards and codes of practice. The objective is to set the recommendedstandard for good design and engineeringpractice applied by Group companies operating an oil refinery, gas handling installation, chemical plant, oil and gas production facilit
7、y, or any other such facility, and thereby to achieve maximum technical and economic benefit from standardization. The information set forth in these publications is provided to users for their consideration and decision to implement. This is of particular importance where DEPs may not cover every r
8、equirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual operating companies to adapt the information set forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs they sh
9、all be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will expect them to follow those design and engineering practices which will achieve the same level of
10、integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal or its technical advisor. The right to use DEPs is granted by SIOP, SIEP or SIC, in most cases under Service Agreements primarily with
11、 companies of the Royal Dutch/Shell Group and other companies receiving technical advice and services from SIOP, SIEP or SIC. Consequently, three categories of users of DEPs can be distinguished: 1)Operating companies having a Service Agreement with SIOP, SIEP, SIC or other Service Company. The use
12、of DEPs by these Operating companies is subject in all respects to the terms and conditions of the relevant Service Agreement. 2)Other parties who are authorized to use DEPs subject to appropriate contractual arrangements. 3)Contractors/subcontractors and Manufacturers/Suppliers under a contract wit
13、h users referred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards. Subject to any particular terms and conditions as may be set forth in specific agreements with users, SIOP,
14、SIEP and SIC disclaim any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof. The benefit of this discla
15、imer shall inure in all respects to SIOP, SIEP, SIC and/or any company affiliated to these companies that may issue DEPs or require the use of DEPs. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior writte
16、n consent of SIOP and SIEP, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior
17、written consent of SIOP and SIEP. The copyright of DEPs vests in SIOP and SIEP. Users shall arrange for DEPs to be held in safe custody and SIOP or SIEP may at any time require information satisfactory to them in order to ascertain how users implement this requirement. All administrative queries sho
18、uld be directed to the DEP Administrator in SIOP. NOTE: In addition to DEP publications there are Standard Specifications and Draft DEPs for Development (DDDs). DDDs generally introduce new procedures or techniques that will probably need updating as further experience develops during their use. The
19、 above requirements for distribution and use of DEPs are also applicable to Standard Specifications and DDDs. Standard Specifications and DDDs will gradually be replaced by DEPs. DEP 61.40.20.30-Gen. June 1993 Page 2 PDF created with pdfFactory Pro trial version TABLE OF CONTENTS PART IINTRODUCTION
20、 .4 1.1SCOPE 4 1.2DISTRIBUTION, APPLICABILITY AND REGULATORY CONSIDERATIONS 4 1.3DEFINITIONS 4 1.4ABBREVIATIONS 5 1.5CROSS-REFERENCES 5 1.6UNITS5 PART IIAMENDMENTS/SUPPLEMENTS TO ANSI/API STD 1104 6 SECTION 1 GENERAL6 SECTION 2 QUALIFICATION OF WELDING PROCEDURES FOR WELDS CONTAINING FILLER METAL AD
21、DITIVES8 SECTION 3 QUALIFICATION OF WELDERS.18 SECTION 4 DESIGN AND PREPARATION OF A JOINT FOR PRODUCTION WELDING20 SECTION 5 INSPECTION AND TESTING OF PRODUCTION WELDS . 26 SECTION 6 ACCEPTANCE STANDARDS FOR NON-DESTRUCTIVE TESTING. 28 SECTION 7 REPAIR AND REMOVAL OF DEFECTS.31 SECTION 8 PROCEDURES
22、 FOR NON-DESTRUCTIVE TESTING . 33 SECTION 9 AUTOMATIC WELDING36 SECTION 10AUTOMATIC WELDING WITHOUT FILLER METAL ADDITIONS 40 PART IIIREFERENCES 42 DEP 61.40.20.30-Gen. June 1993 Page 3 PDF created with pdfFactory Pro trial version PART IINTRODUCTION 1.1SCOPE This is a new DEP giving minimum requir
23、ements for the welding of pipelines and related facilities. This DEP is based on ANSI/API Std 1104, seventeenth edition, September 1988, plus Errata June 1989. Part II of this DEP gives amendments and supplements to ANSI/API Std 1104 in the form of replacements or additions to specific clauses and p
24、aragraphs. Clauses and paragraphs of ANSI/API Std 1104 which are not amended by this DEP shall remain applicable as written. Tables or Figures supplementary to those of ANSI/API Std 1104, have been referred to using a capital letter, e.g. Table A, Figure B. 1.2DISTRIBUTION, APPLICABILITY AND REGULAT
25、ORY CONSIDERATIONS Unless otherwise authorised by SIPM, the distribution of this DEP is confined to companies forming part of the Royal Dutch/Shell Group or managed by a Group Company, and to Contractors nominated by them (i.e. the distributioncode is “C“, as describedin DEP 00.00.05.05-Gen.). This
26、DEP is intended for use on pipeline projects for oil refineries,gas handling installations, chemical plants, supply/marketing installations and oil and gas production facilities. If national and/or local regulations exist in which some of the requirements may be more stringent than in this DEP the C
27、ontractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable as regards safety, economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements of this
28、 DEP which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned with the objective of obtaining agreement to follow this DEP as closely as possible. 1.3DEFINITIONS 1.3.1General definitions The Contrac
29、tor is the party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party which manufacture
30、s or supplies equipment and services to perform the duties specified by the Contractor. The Principal is the party which initiates the project and ultimately pays for its design and construction. The Principal will generally specify the technical requirements. The Principal may also include an agent
31、 or consultant authorised to act for, and on behalf of, the Principal. The word shall indicates a requirement. The word should indicates a recommendation. 1.3.2Specific definitions Where the term Company has been used throughout ANSI/API Std 1104, this shall be understood to mean the Principal as de
32、fined in paragraph 1.3 above. A Pipeline is a system of pipes and other components used for the transportation of fluids DEP 61.40.20.30-Gen. June 1993 Page 4 PDF created with pdfFactory Pro trial version between (but excluding) plants. A pipeline extends from pig trap to pig trap (including the pi
33、g traps), or, if no pig trap is fitted, to the first isolation valve within the plant. 1.4ABBREVIATIONS AWSAmerican Welding Society FCAWFlux Cored Arc Welding GMAWGas Metal Arc Welding GTAWGas Tungsten Arc Welding HAZHeat Affected Zone HV 10Vickers Hardness (10 kg load) IFIncomplete Fusion IFDIncomp
34、lete Fusion Due to Cold Lap IIWInternational Institute of Welding IPInadequate Penetration Without High-Low IPDInadequate Penetration Due to High-Low IQIImage Quality Indicator NDTNon Destructive Testing SMAWShielded Metal Arc Welding WPQTWelding Procedure Qualification Test(ing) WPSWelding Procedur
35、e Specification 1.5CROSS-REFERENCES Where cross-references to other parts of this DEP are made, the referenced section number is shown in brackets. Other documents referenced by this DEP are listed in (Part III). 1.6UNITS For simplicity, the common industry practice of indicating nominal pipe diamet
36、ers in inches has been followed. For other dimensions, SI units have been used. DEP 61.40.20.30-Gen. June 1993 Page 5 PDF created with pdfFactory Pro trial version PART II AMENDMENTS/SUPPLEMENTS TO ANSI/API STD 1104 SECTION 1 GENERAL 1.1SCOPE Replace as follows: This standard covers the arc welding
37、 of butt, fillet and socket welds in carbon and low alloy steel for oil, gas and utility pipelines and related facilities. The welding may be carried out by a shielded metal arc welding, submerged arc welding, gas tungsten arc welding, gas metal arc welding or flux cored arc welding process or combi
38、nation of these processes using a manual, semi-automatic or automatic welding technique or combination of these techniques. The welds may be produced by position or roll welding or by a combination of position and roll welding. Roll welding is only acceptable when using a fully automatic welding pro
39、cess. Oxyacetylene welding (otherwise known as gas welding) and flash butt welding processes shall not be used. The use of gas metal arc, gas tungsten arc and flux cored arc welding (except the self- shielding type) processes shall be restricted to construction areas protected against wind and draug
40、ht. This standard also covers the acceptance standards to be applied to production welds testedtodestructionor inspectedby radiographic,ultrasonicor magneticparticle techniques. It includes the procedures for inspection using these techniques. 1.5.1Pipe and fittings Replace as follows: This standard
41、 applies to the welding of pipe and fittings that conform to the following: a. API Spec 5L and Shell Group line pipe specifications with a maximum Grade of X70. b. Applicable specifications for fittings (e.g. ASTM, MSS, BS) and applicable Shell Group specifications providing amendments/supplements t
42、o these. 1.5.2Filler metal Replace as follows: 1.5.2.1Filler metal and fluxes Consumables shall conform to one of the following specifications: -AWS A5.1 -AWS A5.5 -AWS A5.17 -AWS A5.18 -AWS A5.20 -AWS A5.28 -AWS A5.29 DEP 61.40.20.30-Gen. June 1993 Page 6 PDF created with pdfFactory Pro trial versi
43、on All welding consumables shall be selected to produce welds with yield strength exceeding that specified for the parent material. Where steels with different specified properties are joined the weld metal yield strength shall match or exceed that of the higher strength grade. For sour service app
44、lications the deposited weld metal shall comply with the requirements of NACE MR0175. If low-hydrogen electrodes are selected the diffusible hydrogen content shall not exceed 10 ml/100 g in the resulting deposited weld metal. 1.5.2.2Storage and handling of filler metals and fluxes Replace as follows
45、: Electrodes shall be supplied in fully sealed packages and stored in a dry storage room with a maximum relative humidity of 50 percent. All manual types of electrodes shall be properly identifiable up to the time of usage, each electrode being distinguishable by proper coding. If the coding is dest
46、royed by baking, handling, or other causes, the electrodes shall not be used. Low hydrogen electrodes shall not be stored in heated cabinets containing electrodes of other types, such as rutile or organic type electrodes. Wire spools for automatic and semi-automatic processes shall be stored in cabi
47、nets with supplier wrapping not removed and remain clearly identifiable up to the time of usage. Unidentifiable wire shall not be used. Fluxshallbehandledandstoredinaccordancewiththefluxmanufacturers recommendations. Each batch of flux and wire shall be labelled with the information from the supply
48、container. Unidentifiable,damaged,wet,rustyorotherwisecontaminatedordeteriorated consumables shall not be used. 1.5.3Shielding gases 1.5.3.1Types Add the following: Unless otherwise indicated by the Principal the maximum variation of specified gas additions, e.g. 5 percent carbon dioxide, shall be 1
49、0 percent of the value stated. The moisture content shall correspond to a dew point not exceeding -30 C. 1.5.3.2Storage and handling Add the following: All shielding gas containers shall have clear identification labels which include the gas type. DEP 61.40.20.30-Gen. June 1993 Page 7 PDF created with pdfFactory Pro trial version SECTION 2 QUALIFICATION OF WELDING PROCEDURES FOR WELDS CONTAINING FILLER METAL ADDITIVES 2.1PROCEDURE QUALIFICATION Replace as follows: