DEP SPECIFICATION

STRUCTURAL STEEL FABRICATION OF SMALL

DEEPWATER OFFSHORE SKIDS, FACILITY PACKAGES,
AND SUBSEA SLEDS AND MANIFOLDS
Copyright Shell Group of Companies. No reproduction or networking permitted without license from Shell. Not for resale

(BASED ON AISC STEEL CONSTRUCTION MANUAL ASD,

API RP 2A-WSD AND AWS D1.1)

DEP 37.81.10.32-Gen.

September 2011
(Amendment A01 has been incorporated – September 2012)
(Amendment A02 has been incorporated – February 2013)
ECCN EAR99

DESIGN AND ENGINEERING PRACTICE

© 2011 Shell Group of companies

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior
written permission of the copyright owner or Shell Global Solutions International BV.

This document contains information that is classified as EAR99 and, as a consequence, can neither be exported nor re-exported to any country which is under an
embargo of the U.S. government pursuant to Part 746 of the Export Administration Regulations (15 C.F R. Part 746) nor can be made available to any national of such
country. In addition, the information in this document cannot be exported nor re-exported to an end-user or for an end-use that is prohibited by Part 744 of the Export
Administration Regulations (15 C.F.R. Part 744).

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PREFACE

DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions
International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and
maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international,
regional, national and industry standards.
The objective is to set the recommended standard for good design and engineering practice to be applied by Shell
companies in oil and gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility,
and thereby to help achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each
locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the
quality of their work and the attainment of the required design and engineering standards. In particular, for those
requirements not specifically covered, the Principal will typically expect them to follow those design and engineering
practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or
Manufacturer/Supplier shall, without detracting from his own respons bility, consult the Principal.
The right to obtain and to use DEPs is restricted, and is typically granted by Shell GSI (and in some cases by other Shell
Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and
other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three
categories of users of DEPs can be distinguished:
1) Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these
Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2) Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of
a Service Agreement or otherwise).
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with 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, Shell GSI disclaims
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, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The
benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these
companies, that may issue DEPs or advise 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 written consent of Shell GSI, 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 written consent of Shell GSI. The
copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell
GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.

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TABLE OF CONTENTS
1. INTRODUCTION ........................................................................................................ 5
1.1 SCOPE........................................................................................................................ 5
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 5
1.3 DEFINITIONS ............................................................................................................. 5
1.4 CROSS-REFERENCES ............................................................................................. 7
1.5 SUMMARY OF MAIN CHANGES ............................................................................... 7
1.6 COMMENTS ON THIS DEP ....................................................................................... 7
1.7 DUAL UNITS ............................................................................................................... 8
2. GENERAL REQUIREMENTS .................................................................................... 9
2.1 GENERAL ................................................................................................................... 9
2.2 STRUCTURE CATEGORY......................................................................................... 9
2.3 WORK, MATERIALS, AND SUPERVISION ............................................................... 9
2.4 REFERENCE COPIES ............................................................................................... 9
2.5 TYPICAL WELDING DETAILS DRAWING................................................................. 9
2.6 APPLICABLE DOCUMENTS .................................................................................... 10
2.7 INCONSISTENCIES ................................................................................................. 10
2.8 SIMILAR DETAILS .................................................................................................... 10
2.9 SUBCONTRACTORS ............................................................................................... 10
3. FABRICATION ......................................................................................................... 10
3.1 GENERAL FABRICATION REQUIREMENTS ......................................................... 10
3.2 FABRICATION AIDS ................................................................................................ 10
3.3 DIMENSIONS AND TOLERANCES ......................................................................... 11
3.4 CLEAN-UP REQUIREMENTS .................................................................................. 11
3.5 LIFTING PADEYES .................................................................................................. 11
3.6 BOLTING .................................................................................................................. 11
3.7 WELD TRACEABILITY ............................................................................................. 12
3.8 AS-BUILT DATA ....................................................................................................... 12
4. MATERIALS ............................................................................................................. 13
4.1 CONTRACTOR FURNISHED MATERIALS ............................................................. 13
4.2 STRUCTURAL STEEL ............................................................................................. 13
4.3 MISCELLANEOUS ITEMS ....................................................................................... 13
4.4 MILL CERTIFICATES ............................................................................................... 14
4.5 PRINCIPAL-FURNISHED MATERIALS ................................................................... 14
4.6 MATERIAL TRACEABILITY ..................................................................................... 14
5. WELDING ................................................................................................................. 15
5.1 SCOPE...................................................................................................................... 15
5.2 GENERAL ................................................................................................................. 15
5.3 MATERIAL REQUIREMENTS .................................................................................. 15
5.4 WELDING QUALIFICATIONS – PROCEDURES AND PERFORMANCE ............... 16
5.5 EXTENT OF WELDING ............................................................................................ 18
5.6 WORKMANSHIP AND TECHNIQUE ....................................................................... 18
6. INSPECTION ............................................................................................................ 20
6.1 GENERAL ................................................................................................................. 20
6.2 INSPECTION OF STRUCTURAL WELDING ........................................................... 20
6.3 FUNCTIONAL TESTING .......................................................................................... 21
7. PAINTING AND PROTECTIVE COATINGS ............................................................ 22
8. LOADOUT AND TIEDOWN ..................................................................................... 22
8.1 GENERAL ................................................................................................................. 22
8.2 TRANSPORTATION AND ARRANGEMENTS......................................................... 22
8.3 LOADING MATERIALS ............................................................................................ 22
8.4 DAMAGES ................................................................................................................ 22
9. REFERENCES ......................................................................................................... 23

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APPENDICES
APPENDIX 1 SPECIAL REQUIREMENTS FOR GMAW-S WELDING ................................ 24
APPENDIX 2 CHARPY IMPACT TESTING .......................................................................... 28
APPENDIX 3 TABLE OF DELIVERABLES .......................................................................... 30
APPENDIX 4 TYPICAL WELDING DETAILS DRAWING (US Customary Version) ......... 31
APPENDIX 5 TYPICAL WELDING DETAILS DRAWING (Metric Version) ........................ 36

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1. INTRODUCTION

1.1 SCOPE
This new DEP specifies requirements and gives recommendations for the fabrication of
structural steel skids, facility packages, subsea sleds, subsea manifolds, and other
miscellaneous structural steel structures. It is applicable for designs performed using
DEP 37.81.10.31-Gen.
EPP Projects Civil/Marine Engineering should be consulted on the use of this DEP for
applications outside those noted above.
This DEPapplies to small statically designed steel structures, less than 907 metric tons
(1000 short tons), that are not subject to significant global cyclic stress that may lead to
fatigue failure over the structural life.
Steel structures covered in this DEP are categorized as either a Type-A or Type-B
structure. The category is dependent on weight and/or function and is defined by the
Principal. See (2) for default category.
This DEP is based on:
• AISC-ASD
• AWS D1.1
• API RP 2A-WSD
The additional and/or modified requirements contained in this DEP form the complete
specification.
This DEP replaces the former SIEP standard DEP 37.81.10.32-EPP dated January 2010.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated
by them. Any authorised access to DEPs does not for that reason constitute an
authorization to any documents, data or information to which the DEPs may refer.
This DEP is intended for use in facilities related to offshore oil and gas exploration and
production facilities. This DEP may also be applied in other similar facilities.
When DEPs are applied, a Management of Change (MOC) process should be
implemented; this is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements could be more
stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable with regards to the safety, environmental, economic and legal aspects. In all
cases the Contractor shall inform the Principal of any deviation from the requirements of
this 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, the objective
being to obtain agreement to follow this DEP as closely as possible.

1.3 DEFINITIONS
1.3.1 General definitions
The Contractor is the party that 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 that manufactures or supplies equipment and
services to perform the duties specified by the Contractor.

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The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The word should indicates a recommendation.
1.3.2 Specific definitions

Term Definition
Accept,
The Principal’s written agreement that the submitted item has been
Accepted, or
performed in accordance with the requirements.
Acceptance
Approve,
Approved, or The Principal’s written approval process
Approval
Auditable Requirement that is observable, measurable, is neither vague nor
(requirement) ambiguous, and has finite acceptance/rejection criteria.
The detailed engineering drawings prepared for this project and all
Contract
official revisions to those drawings. The Tie Specification or General
Drawings
Data Sheet contains a list of those drawings.
The Principal’s right, but not obligation, to comment on the submitted
Review
item. Contractor may begin construction of the item following submittal.
Document, established by consensus and approved by a recognized
body, that provides, for common and repeated use, rules, guidelines or
Standard
characteristics for activities or their results, aimed at the achievement of
the optimum degree of order in a given context.
Standard, primarily pictorial, representing an item or configuration and
Standard
considered to have wide applicability in Shell International Exploration
Drawing
and Production – EP Projects.
Shall mean any person or company having a subcontract with any
Subcontractor
Contractor to perform work covered under this DEP.
Structures shall include skids and packages weighing less than 455
Type A
metric ton (500 short tons), except for subsea structures.
Structures shall include skids and packages weighing more than 455
Type B metric ton (500 short tons) but less than 907 metric tons (1000 short
tons), and subsea structures (sleds and manifolds) regardless of weight.

1.3.3 Abbreviations

Term Definition
API American Petroleum Institute.
ASME American Society of Mechanical Engineers.
AWS American Welding Society.
BOP Bead on Plate.
BS British Standard.
DEP Design and Engineering Practice.
EPP SIEP - Exploration and Production – Projects.
ID Internal Diameter.
FY Specified Minimum Yield Stress

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Term Definition
ISO International Standards Organization.
NDT Non Destructive Testing
OU An Operating Unit of the Royal Dutch/Shell Group.
PQR Procedure Qualification Record
PQT Procedure Qualification Testing
QA/QC Quality Assurance / Quality Control.
SIEP Shell International Exploration and Production.
SWL Safe Working Load.
WPS Welding Procedure Specification.

1.4 CROSS-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 (9).

1.5 SUMMARY OF MAIN CHANGES

Amendment A02

In this Amendment, the Figures shown in (Appendix 4) and (Appendix 5) have been
replaced with higher quality images.

1.6 COMMENTS ON THIS DEP

Amendment A01
Amendment A02

Comments on this DEP may be submitted to the Administrator using one of the following
options:

Shell DEPs Online Enter the Shell DEPs Online system at

https://www.shelldeps.com
(Users with access to
Shell DEPs Online) Select a DEP and then go to the details screen for
that DEP.
Click on the “Give feedback” link, fill in the online
form and submit.

DEP Feedback System Enter comments directly in the DEP Feedback

(Users with access to System which is accessible from the Technical
Shell Wide Web) Standards Portal http://sww.shell.com/standards.
Select “Submit DEP Feedback”, fill in the online form
and submit.

DEP Standard Form Use DEP Standard Form 00.00.05.80-Gen. to record

(Other users) feedback and email the form to the Administrator at
[email protected].

Feedback that has been registered in the DEP Feedback System by using one of the above
options will be reviewed by the DEP Custodian for potential improvements to the DEP.

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1.7 DUAL UNITS

This DEP contains both the International System (SI) units, as well as the corresponding
US Customary (USC) units, which are given following the SI units in brackets. When
agreed by the Principal, the indicated USC values/units may be used.

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2. GENERAL REQUIREMENTS

2.1 GENERAL
A Scope of Work document may be issued by Principal, detailing the project-specific
general requirements. The Scope of Work shall supplement / supersede the specific
requirements contained within (2).
Alternative codes for the fabrication, welding, and inspection of the structure may be
proposed by Contractor for approval by the Principal, prior to the start of fabrication. The
proposed codes shall provide a basis with an equivalent set of requirements for the
fabrication, welding and inspection. The specific requirements in this DEP, Contract
Drawings, and Standard Drawings shall apply.

2.2 STRUCTURE CATEGORY

Structures shall be categorised as either Type-A or Type-B by the Principal. The default
categories are as follows:
• Type-A structures shall include skids and packages weighing less than 455 metric
tons (500 short tons), except for subsea structures.
• Type-B structures shall include skids and package weighing more than 455 metric
tons (500 short tons) but less than 907 metric tons (1000 short tons), and subsea
structures (sleds and manifolds) regardless of weight.
The requirements in this DEP are applicable to both Type-A and Type-B structures unless
indicated otherwise.

2.3 WORK, MATERIALS, AND SUPERVISION

2.3.1 Work
All work performed under this DEP shall be strictly in accordance with the Contract
Drawings and/or Standard Drawings and this DEP.
2.3.2 Materials
Contractor-furnished material shall be new, except as specified below, and of the size,
grade, and quality required in this DEP. Temporary bracing, erection aids, scaffolding, etc.,
shall be furnished by Contractor and need not be new if safe and serviceable.
All Contractor-furnished items shall be subject to inspection, testing, and Approval.
2.3.3 Inspection
Inspection shall be carried out per this DEP, including the requirements contained in
(Appendix 4) or (Appendix 5) “Typical Welding Details”drawing.

2.4 REFERENCE COPIES

Contractor shall maintain reference copies of this DEP at locations readily accessible to the
work sites.

2.5 TYPICAL WELDING DETAILS DRAWING

“Typical Welding Details” drawing for structural steel, skids, and miscellaneous items, as
shown in (Appendix 4) or (Appendix 5), is a part of this DEP. This drawing defines steel
designations and properties, welding and inspection requirements, and typical structural
details and tolerances. This drawing is included in reduced size at the end of this DEP and
may also be included in the Contract Drawings.

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2.6 APPLICABLE DOCUMENTS

All work and material shall be in accordance with this DEP. Refer to (Appendix 3) for a list
of documents requiring submittal for approval or review by the Principal .
NOTE: Additional submittals may be required for documentation purposes as stated within this DEP.

2.7 INCONSISTENCIES
Contractor shall carefully study and compare Contract Drawings and/or Standard Drawings,
this DEP, and other instructions and shall report at once to the Principal any error,
inconsistency, or omission.

2.8 SIMILAR DETAILS

Details of appurtenances, clearly indicated on any of the Contract Drawings and/or
Standard Drawings as typical, shall apply to similar beams, joints, etc., even though not
clearly indicated on other Contract Drawings and/or Standard Drawings.

2.9 SUBCONTRACTORS
Approval of all Subcontractors shall be obtained from the Principal prior to the start of the
subcontractor work.
It shall be Contractor’s responsibility to ensure that all work done by the Subcontractors is
in accordance with this DEP.
The Principal’s inspection rights also apply to all work done by the Subcontractor.

3. FABRICATION

3.1 GENERAL FABRICATION REQUIREMENTS

Contractor shall completely fabricate the structure(s) and its components in accordance
with this DEP and applicable Contract Drawings and/or Standard Drawings.
Contractor shall completely coat the structure(s) and its components in accordance with the
Principal-approved coating system and applicable Contract Drawings and/or Standard
Drawings.
Fabrication shall conform to AISC’s Manual Of Steel Construction and AWS D1.1, as well
as API RP 2A -WSD, where applicable. AWS D1.1 shall govern in case of conflict with
AISC’s Manual Of Steel Construction (ASD) or API RP 2A-WSD.
Contractor shall submit the proposed procedures for skid/package fabrication and assembly
for review by the Principal prior to the start of fabrication.
Any proposed changes in this DEP and/or Contract Drawings and/or Standard Drawings
desired by Contractor shall be submitted for Approval before ordering material or starting
fabrication.
Contractor shall test-fit all field installed components after coating system, including
insulation, is applied.

3.2 FABRICATION AIDS

Fabrication aids are any items used to aid fabrication that are not detailed on Contract
Drawings and/or Standard Drawings. This includes such items as temporary erection
braces, sling stops, scaffolding supports, padeyes, dogs, walkways, etc. Welding of
fabrication aids to the structure shall be performed in accordance with an approved
procedure for the structural materials being welded.
Fabrication aids shall not be welded to any process equipment or the base plates to
process equipment.
All fabrication aids shall be removed unless otherwise approved by the Principal.

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The Principal reserves the right to restrict the location and welding of such items.

3.3 DIMENSIONS AND TOLERANCES

Except as noted otherwise on the Contract Drawings, all tolerances shall be in accordance
with AISC’s Manual of Steel Construction, API Spec 2B, and API RP 2A-WSD, as
applicable.
Centerline dimensions for field tie-ins or connections shall be within 6 mm (¼ inch)
tolerance. This applies to the dimension between adjacent tie-in points and to the overall
dimensions.
Shims used under continuous beams in skids and packages to adjust for difference in
elevation of different beam sizes shall be field-verified prior to welding due to tolerances in
plate and beam heights.
For Type-B structures, Contractor shall develop a dimensional control procedure for the
Principal approval and report on dimensional accuracy on a biweekly basis.

3.4 CLEAN-UP REQUIREMENTS

3.4.1 Welding Clean-up
Contractor shall clean the weld area of slag, splatter, and other debris to allow complete
examination.
3.4.2 Removal of Fabrication Aids
Fabrication aids shall be cut no closer than 3 mm (1/8 inch) to base material. “Washing
Off” of fabrication aids with an oxygen-fuel torch shall not be permitted on steels with FY
greater than 317MPa (46 ksi). Final removal shall be by mechanical means with edges
smoothed or rendered flush to the base material. Once the fabrication aid is removed, the
attached area shall be inspected to the specified level required by the Principal.

3.5 LIFTING PADEYES

Material used for lifting padeyes shall be in accordance with the contract drawings and shall
be free of any laminations.
If cheek plates are required, they shall be permanently attached before drilling or boring the
hole.
For Type-B subsea structures, all welds attaching the padeye to the structure shall be
inspected after welding and again after load testing.
For Type-B subsea structures, all lifting padeyes and slings shall be load-tested to the
requirements of the Principal. Lifting capacity of all padeyes and lifting points shall be
clearly marked, identifying the safe working load, the angle of lift, and the number of lifting
points.
Example: Four padeyes, 25 tons capacity each, no angle limitation, total capacity of
100 tons:

Stamp: 4x
SWL 25 tons
0 - 90°

3.6 BOLTING
Bolts shall be as noted on the welding detail drawings.
Bolts, nuts and washers shall be galvanized or coated with Sermagard, or equivalent
material approved by the Principal.

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3.7 WELD TRACEABILITY

For Type-B structures, Contractor shall submit a plan to ensure weld traceability for the
Principal approval. As a minimum, this procedure shall consist of weld numbers, unique
welder ID, weld location, NDT requirements and NDT results, and weld ID drawings.

3.8 AS-BUILT DATA

Contractor shall develop an As Built data book, or “as approved” by the Principal, that shall
contain at a minimum:
a) Material MTR’s
b) Two-Way Material Traceability (For Type B structures only)
c) Weld Procedures
d) Welder Qualifications and PQRs
e) NDT Reports
f) As-Built Drawings
g) Non-Conformance Reports and Site Queries
h) Weld / Material Repair
i) Weight and Center-Of-Gravity
j) Final Dimensional Surveys

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4. MATERIALS

4.1 CONTRACTOR FURNISHED MATERIALS

The surface of the material shall be free of defects and laminations such that a quality paint
job is obtained. Substitutions shall not be made without Approval.

4.2 STRUCTURAL STEEL

Steel material shall be as indicated on the Contract Drawings and/or (Appendix 4) or
(Appendix 5) “Typical Welding Details” drawing.
All material shall meet the Pcm requirements shown on the detailed welding drawings. Any
material that does not meet the requirement shall be approved by the Principal on a case-
by-case basis.

4.3 MISCELLANEOUS ITEMS

All grating shall be steel or phenolic as specified on the Contract Drawings. For Type-B
subsea structures, grating shall be galvanized steel.
All steel grating, ladders, handrails, and miscellaneous hardware shall be hot-dipped
galvanized.
Steel Grating:
All steel grating shall be at least 38 mm x 5 mm (1½ inch x 3/16 inch) serrated bar grating
with 30 mm (1-3/16 inch) on center bearing bars and 102 mm (4 inch) on center cross bars
and the grating shall be hot dipped galvanized. Fixed panels should be attached to the
supporting beams by spot welding every fourth bearing bar with 5 mm (3/16 inch) double
fillet welds, 38mm (1½ inch) long. Steel grating shall be used for subsea application and
may be 25 mm x 5 mm (1 inch x 3/16 INCH) serrated bar grating provided dropped object
strength requirements are met.
Grating termination “fingers” for short pieces supported at only both ends (simple span) and
grating hatches shall be corrected by tacking 6 mm (1/4 inch) banding bar (flat bar) to
prevent the grating from sliding (see Figure 4.3-1).

Figure 4.3-1 Typical Grating Banding Bar Detail

Phenolic Grating:
Phenolic grating shall be slip resistant and have ultraviolet stabilizer. Phenolic grating
manufacturer shall be approved by the Principal.
All phenolic grating shall have 38 mm (1-1/2 inch) bearing bars spaced on 38 mm
(1-1/2 inch) centers, and be approved by the Principal. All phenolic grating shall be
attached to the beams using a fastening system. Fasteners are required at the end of each

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grating section and every other support beam, spaced no more than 406 mm (16 inch)
apart (i.e., 3 fasteners for a 914 mm [3’] wide panel at each tie-down location).
Every piece/panel of grating shall have a minimum of six grating fasteners. Additionally,
each panel shall have three fasteners per beam crossing. If manufacturer’s requirements
are more restrictive, manufacturer’s requirements shall govern.
Fastening system shall be approved by the Principal.
Mechanical fasteners are not designed to resist lateral forces (skidding equipment on
grating).

Grating – General:
Grating bearing bars shall be supported at both ends. Cantilevered grating shall be
acceptable only with the Principal approval.
Edge grating panels free to move due to location of a hole in the decking, or at the edge of
the platform and not restrained by a minimum of two fixed handrail posts or sockets, shall
be restrained by one of the following methods:
a) Two – 6 mm x 26 mm x 67 mm (¼ inch x 1 inch x 3 inch) long bars, seal welded to
the supporting steel beam on the free side of the grating. One bar shall be located
near one end of the grating panel edge, and the other bar near the other end of the
grating panel edge. The bars shall be located to allow maximum 13 mm (½ inch) or
less grating panel movement in the direction of the free edge.
b) The entire grating panel shall be secured to the supporting steel beams using
mechanical fasteners.
c) Secure the free edge of the grating from moving by using a minimum of two –
19 mm (¾ inch) wide stainless steel banding straps, looped around the grating and
the supporting steel beam, and tightened to prevent grating movement.

4.4 MILL CERTIFICATES

The manufacturer’s mill certificates shall be used to verify compliance to the specified
requirements of all steel furnished by Contractor.
Contractor shall submit legible copies of these mill certificates to the Principal for review
prior to receipt of material at fabrication yard.

4.5 PRINCIPAL-FURNISHED MATERIALS

Principal-furnished items applies only be those items specified in the Scope of Work. They
will be delivered to Contractor’s yard by the Principal’s furnished transportation. Contractor
shall provide special storage for the Principal-furnished items when indicated in the scope
of work.
Tubular steel elements will normally be plain-ended, double random length (as defined in
API Spec 5L, Table 11) and free from defects, excessive mill scale and rust.

4.6 MATERIAL TRACEABILITY

For Type-B structures, Contractor shall develop a material traceability procedure for
approval by the Principal. The procedure shall show unique markings for each piece of the
structure. The number shall be easily traceable to the location, weld requirements, NDT
requirements and results, left over original pieces, and as-built drawings.

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5. WELDING

5.1 SCOPE
This section covers the materials, welding, and inspection required for fabrication of steel
structures for steel skids and miscellaneous items.

5.2 GENERAL
5.2.1 General Authority for Welding
The general authority for welding shall be AWS D1.1 and (Appendix 4) or (Appendix 5)
“Typical Welding Details” drawing with exceptions, clarifications, or additions as noted
herein.
Welding symbols shall be interpreted in accordance with AWS A2.4.
5.2.2 Welding Processes
The shielded metal arc welding (SMAW), submerged arc welding (SAW) and flux cored arc
welding (FCAW) processes are approved by the Principal. Other processes may be
submitted to the Principal for consideration.
The use of gas metal arc welding (GMAW) may be approved by the Principal for specific
applications; however, additional restrictions and limitations shall be applicable as given in
(Appendix 1).
Capacitance discharge stud welding shall only be used on steels with FY less than or equal
to 317 MPa (46 ksi).
Direct fastening studs (powder actuated, pneumatic, or gas powered systems) may be used
on all steels, subject to approval by the Principal. The studs shall be located no closer than
50 mm (two inches) from any weld or free edge. Paint damage must be repaired with
special attention given to the backside of beams and plates.
5.2.3 Qualification Records
Records of final weld procedure testing, welder and welding operator qualification test
results shall be submitted to the Principal for approval.

5.3 MATERIAL REQUIREMENTS

5.3.1 Classification of Steels
All steel shall conform to the steel manufacturing specification and any additional
requirements as shown in (Appendix 4, Table A-1) or (Appendix 5, Table A-1) “Typical
Welding Details” drawing.
The material and welding requirements for each steel grade on the drawing are divided into
“Pre-Qualified” for pre-approved steels and “Qualified by Testing” for steels to be qualified
by testing. If Contractor-selected steel is not listed as one of the “designated” steels, or the
manufacturer’s documentation is not available, then the requirements for “Qualified by
Testing” section shall apply.
The welding consumables shall be selected, qualified and tested in accordance with the
AWS filler metal requirements for the specified “Base Metal Groups” as shown in (Appendix
4, Table A-1) or (Appendix 5, Table A-1) “Typical Welding Details” drawing.
5.3.2 Substitution of Steels
Higher strength steels may be substituted for lower strength steels. Substitution of steels
with higher strength requires the use of more stringent welding procedures appropriate to
the higher strength level. Substitution of steels of a lower strength group shall not be
permitted without the Principal’s approval prior to use.

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5.4 WELDING QUALIFICATIONS – PROCEDURES AND PERFORMANCE

5.4.1 General
All welding shall conform to AWS D1.1 and any additional requirements as shown in
(Appendix 4) or (Appendix 5) “Typical Welding Details” drawing.
The material and welding requirements for each steel grade on the drawing are divided into
“Pre-Qualified” for pre-approved procedures for “designated” steels and “Qualified by
Testing” for procedures of “non-AWS prequalified” steels to be qualified by testing. If
Contractor-selected steel is not listed as one of the “designated” steels or the procedure is
not an AWS pre-qualified procedure, then the requirements for “Qualified by Testing”
section shall apply.
AWS “Pre-Qualified” procedures are approved for square or rectangular shaped tubes less
than 325 mm (12-3/4 inch) and FY less than or equal to 317 MPa (46 ksi).
Additional qualification testing is required to supplement the AWS pre-qualified procedures
for the steels with FY greater than 317 MPa (46 ksi).
Welding procedures requiring “Qualification by Testing” shall be qualified prior to their use
in production by procedure qualification tests.
Previously qualified welding procedures may be submitted to the Principal for approval. The
previous qualified welding procedures shall meet the requirements in this section to be
considered for approval.
All welding shall be limited to approved Welding Procedure Specifications (WPS).
The following documentation shall be provided for each WPS:
• Welding Procedure Specifications (WPS) with parameters covering the essential
variables for the welding process (see AWS Form E-1) for all welding procedures.
• The required test results (PQR) per AWS D1.1 (see AWS Form E-1) including
copies of the mill certificates, mechanical test results, and a suitable photo
macrograph.
All procedures shall conform to the limitations for the minimum pre-heat and interpass
temperatures as specified in (Appendix 4, Table A-2) or (Appendix 5, Table A-2) “Typical
Welding Details” drawing.
Approved WPS’s shall be posted at each applicable work location and made readily
available to each welder, welding operator, and tacker.
5.4.2 Welding Procedures Qualifications
The Principal shall approve all Welding Procedure Specifications (WPS) to be used for all
welding.
The Principal shall approve the independent testing laboratory to be used for all weld
qualification testing.
The Principal shall be provided the opportunity to witness procedure qualification welding,
non-destructive testing (NDT), sectioning, and mechanical properties testing.
Test qualification requirements shall be in accordance with procedure qualification testing
requirements of AWS D1.1 for the steel to be welded and the supplemental requirements of
(Appendix 4, Table A-1) or (Appendix 5, Table A-1) of the “Typical Welding Details”
drawing.
All material used in qualifying weld procedures and welders shall meet the material
requirements shown on the welding sheets. This includes the Pcm value. If possible,
material at the higher Pcm range shall be selected for qualification tests.

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Essential Variables
a) When Charpy toughness testing is not required for weld metal or HAZ per(Appendix
4, Table A-1) or (Appendix 5, Table A-1), the essential variables specified per AWS
D1.1 for the welding process shall apply.
b) When Charpy toughness testing is required, any change in essential variables that
may affect the resulting toughness properties shall be prohibited without
re-qualification. The following additional items shall be considered essential
variables:
• A change in flux core wire manufacturer.
Charpy Testing
All impact testing for toughness shall be in accordance with (Appendix 2).
The Charpy requirement for welding procedures to join two different types of steel (e.g.,
250 MPa to 414 MPa – [GR36 to GR60]) shall be selected from (Appendix 4, Table A-1) or
(Appendix 5, Table A-1) applicable to the lower type joined (e.g., 250MPa – [GR36]).
However, all limitations on heat input preheat, etc.; applicable to either grade shall be
observed.
Joint details for testing shall conform to the details shown on the (Appendix 4) or
(Appendix 5) “Typical Welding Details” drawing of the Contract Drawings and/or Standard
Drawings and the provisions of (Appendix 2).
5.4.3 Additional Welding Procedure Requirements for Type-B Structures
The following hardness requirements apply to Type-B structures. These requirements are
in addition to (5.4.2).
All WPS’s used for Type-B structures, regardless of whether they fall into the pre-qualified
or qualified by testing category, shall be qualified by macrosection microhardness survey
and bead-on-plate (BOP) hardness testing as follows.
5.4.3.1 PQT Weld
A PQT weld shall be made using the WPS for each base-metal with each welding
consumable to be permitted by the WPS using PQT plate or pipe, as applicable, complying
with AWS D1.1 Table 4.2, 4.3 or 4.4, as applicable. One macrosection shall be extracted
from near the middle of the PQT weld. Macrosections shall be polished to a metallographic
finish and etched in a 5-10% Nital solution.
5.4.3.2 Macrosection Microhardness Survey
A Vickers microhardness survey utilizing an applied load of 10 kgf (i.e., HV 10) shall be
performed on a macrosection from the test weld in accordance with EN 1043-1. Hardness
test indention locations shall be as recommended by EN 1043-1.
5.4.3.3 BOP Test
A BOP weld pass and Vickers microhardness survey shall be made on each base metal
with each consumable to be permitted by the WPS in accordance with BSI BS 7363
Type 2. The length of the deposited bead shall not exceed the minimum permissible bead
length for the WPS. This pass shall be made with the lowest permissible heat input and
preheat temperature applicable to the WPS being qualified.
Location of hardness readings shall be as shown in Figure 9 of BSI BS 7363. Additionally,
an all-weld-metal hardness reading shall be obtained. Hardness measurements shall be
HV 10.
5.4.3.4 Acceptable Microhardness
The maximum acceptable microhardness for the hardness traverses required by (5.4.3.2)
and (5.4.3.3) shall be 350 HV10, unless specifically approved otherwise by the Principal
and Contractor, if applicable.

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5.4.4 Welder and Welding Operator (Performance) Qualifications

Welder tackers and welding operators shall be qualified in accordance with AWS D1.1.
Welder Qualification test records shall be submitted. The following additional requirements
apply:
a) All welders making complete joint penetration welds from one side only in tubular T-,
Y-, and K-connections shall qualify on the AWS 6GR test. For square or rectangular
tubulars less than 325mm (12-3/4 inches), welders need only qualify on the AWS
6G test.
b) Properly documented previous qualification tests of welders, welding operators, and
tackers conducted by the same Contractor and witnessed by the Principal, or
conducted by a third-party independent testing laboratory, may be accepted.
c) Applicable previous welder qualifications, in accordance with Section IX of ASME,
may be accepted for all structural welding according to the hierarchy of AWS D1.1,
except as noted in (a) above.

5.5 EXTENT OF WELDING

5.5.1 Complete Joint Penetration Welds
All intersecting and abutting parts shall be joined by complete joint penetration groove
welds unless noted otherwise. This includes “hidden” intersections, such as may occur in
overlapping braces and pass-through stiffeners. Welds shall be made from both sides
where practicable; indicated double bevels may be symmetrical or asymmetrical, at
Contractor’s option.
Run on and run off tabs shall be required wherever practicable. Tabs shall be removed and
ground flush with the adjoining metal surface.
Butt joints in pipe over 610 mm (24 inches) in diameter, and in box sections with flange
widths 610 mm (24 inches) and over, shall be welded from both sides. Butt joints in smaller
members may have backing rings except for drive pipes to spud wells.
5.5.2 Seal Welds
Unless specified otherwise, all faying surfaces shall be sealed against corrosion by
continuous fillet welds. Seal welds need not exceed 3 mm (1/8 inch) in size regardless of
base metal thickness, provided a low hydrogen welding process is used with proper
preheat and electrode moisture control.
5.5.3 Tack Welds
The preheat requirements for tack welds shall be based on the requirements for the base
metal and weld process. The minimum length of tack welds shall be 50 mm (2 inches).
All tack welds shall be made by a qualified tack welder, using a qualified weld procedure
approved by the Principal.

5.6 WORKMANSHIP AND TECHNIQUE

5.6.1 General
General workmanship and technique requirements shall be as follows:
a) Preheat and interpass temperatures shall be established to develop the specified
properties in the weldment, but shall not be less than those recommended by the
steel manufacturer or those specified in (Appendix 4, Table A-2) or (Appendix 5,
Table A-2) on the “Typical Welding Details” drawing, and shall be as required by
the approved WPS.
b) Electrode and flux moisture control (baking, storage ovens, exposure times, etc.)
shall be in accordance with AWS D1.1, except that the re-drying or bake-out
temperatures shall be superseded by the temperature ranges specified by the
applicable electrode manufacturers.

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c) No arc strikes outside of the weld groove shall be permitted. Repair of inadvertent
arc strikes shall be done by grinding followed by visual and Magnetic Particle
inspection.
d) The root side of complete joint penetration groove welds shall be back-gouged,
using grinding, air-arc gouging or chipping, to sound metal before any weld is
applied to the backside. The groove shall be prepared by grinding to provide the
proper shape and bevel for the welding procedure. Oxy-fuel gouging shall not be
permitted.
5.6.2 Preparation
Requirements for the acceptance of surfaces to be welded shall be as follows:
a) Surfaces produced by carbon-arc gouging or cutting, or surfaces showing carbon
deposits due to oxy-fuel cutting or heating, shall be dressed by blasting, grinding,
brushing, or chipping, as required to remove carbon residue.
b) The workmanship criteria for the maximum surface roughness of weld bevel faces
shall be as shown in AWS C4.1, Surface Roughness Guide, Sample 3.
c) Surfaces of complete joint penetration groove welds shall be free of primers or
coatings. Anti-spatter compounds shall not be applied to surfaces to be welded
including weld bevels and weld beads. Such compounds may be applied to
completed welds after acceptance by visual examination.
Requirements for fit-up shall be as follows:
a) In-place fitting and trimming should be avoided. However, when fitting and trimming
in-place is necessary, Contractor should shift the member away from the connection
before trimming is begun.
b) The Principal, at its option, may require that weld fit-up and preheat temperature be
checked and accepted prior to placing the first pass. Any deviation from the WPS,
such as wide gaps or inadequate preheat, shall be rectified before welding
commences.
5.6.3 Weld Repairs
Contractor shall develop a weld repair process and include it in each weld procedure.

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6. INSPECTION

6.1 GENERAL
Contractor shall furnish sufficient supervisory/quality control personnel to ensure that
materials and workmanship meet the requirements of this specification, and other codes
and specifications cited herein. Welding Inspectors, with qualifications in accordance with
AWS D1.1, shall be required. Additional testing and inspection may be performed at the
Principal’s prerogative, to verify that these requirements have been met. The Principal
shall approve all Quality Control Staff prior to starting fabrication.
The Principal shall have the right to inspect any and all equipment, material, coatings, or
workmanship involved in the construction and assembly of any component covered under
this DEP. Contractor shall provide free entry at all times for any personnel or equipment to
any work or component location so that verification inspection and testing may be
performed.
Principal may elect to use any applicable nondestructive testing method to perform
verification inspection and testing, including radiography, ultrasonics, magnetic particle,
liquid penetrants, hardness, etc.
Inspection for Type-A and Type-B structures shall be in accordance with AWS D1.1 and
(Appendix 4) or (Appendix 5), “Typical Welding Details”. Additionally, for Type-B structures,
Contractor shall develop an Inspection and Test Plan for the Principal’s approval.

6.2 INSPECTION OF STRUCTURAL WELDING

AWS D1.1 shall be the authority for inspection of structural welds. The quality of all
structural welds shall be in accordance with AWS D1.1 with the appropriate sections for
beams, structural shapes, and tubular construction. For inspection purposes, all welds
shall be considered as being transverse to primary tensile stress.
6.2.1 Visual Examination (VT)
All welds shall be visually inspected. Final weld profiles shall be as detailed on
(Appendix 4) or (Appendix 5) “Typical Welding Details” drawing, or as called for in
applicable sections of AWS D1.1. For surfaces to be painted, all indications of porosity are
unacceptable.
6.2.2 Radiographic Examination (RT)
Radiographic inspection of welds for API Spec 2B pipe shall be in accordance with
(Appendix 4, Table C-1) or (Appendix 5, Table C-1).
6.2.3 Ultrasonic Examination (UT)
Ultrasonic inspection of groove welds shall be in accordance with AWS D1.1. Ultrasonic
inspection of API Spec 2B pipe shall be in accordance with Table C-1 of the specification
drawings in (Appendices 4 and 5).
The extent of ultrasonic inspection shall be as per the drawings, or as a minimum, the
following:
a) 100% of all intersecting welds in tubular joints (tubular T-, Y-, and K-connections).
b) 100% of all non-tubular truss connections.
c) 100% of all butt welds in truss members and in top flanges of cantilevered beams.
Acceptability shall be in accordance with AWS D1.1 and Tables 6.2.3-1 through 6.2.3-3,
unless specified otherwise in the Contract Drawings:

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Table 6.2.3-1. Structural Tubes

Structural Tubes

Diameter Diameter
< 325 mm (12 - 3/4 in) > 325 mm (12 - 3/4 in)

Statically Loaded Cyclically Loaded

Non-Tubular Connections Tubular Connections

Table 6.2.3-2. Rolled Shapes

Rolled Shapes

AISC-ASD* AISC-ASD*
Group I to III Group IV & V
Statically Loaded Cyclically Loaded
Non-Tubular Connections Non-Tubular Connections
*Note: AISC-ASD Properties Table 1 and Table 2 refer to ASTM A6 (1989) Groups.

Table 6.2.3-3 Fabricated Shapes

Fabricated Shapes
(Including Stiffeners)

t < 25 mm (1 in) t >25 mm (1 in)

Statically Loaded Cyclically Loaded

Non-Tubular Connections Non-Tubular Connections

6.2.4 Magnetic Particle Examination (MT)

Magnetic particle inspection of welds shall be in accordance with AWS D1.1 using AC
magnetizing current with “Wet – Black Ink”. Acceptability shall be in accordance with AWS
D1.1. The extent of magnetic particle inspection shall be in accordance with (Appendix 4)
or (Appendix 5) “Typical Welding Details” drawing.

6.3 FUNCTIONAL TESTING

The Scope of Work issued by the Principal will detail the project-specific general
requirements for functional testing, including static and dynamic testing of skids / packages
with rotating equipment, hydrotest and other test conditions required by the
Manufacturer/Supplier.
Contractor shall be responsible for the detailed design engineering required to safely and
effectively conduct the test.

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7. PAINTING AND PROTECTIVE COATINGS

All surface preparation and the application of paint, protective coatings, and galvanizing
shall be in accordance with the Scope of Work, applicable Contract specifications and
applicable Contract Drawings and/or Standard Drawings as specified in the Principal’s
Contract Documents.
Corrosion protection system for Type-B subsea structures shall adhere to
DEP 37.81.20.31-Gen.

8. LOADOUT AND TIEDOWN

8.1 GENERAL
Contractor shall furnish all engineering, supervision, personnel, materials, equipment and
appurtenances necessary at Contractor’s yard to loadout and tie down all items on the
Principal-furnished transportation. Truck-loaded items shall be safely secured for highway
transportation as required by applicable Operating Unit and Governmental regulations
(49 CFR Parts 392 and 393 or applicable local requirements).
Contractor shall assume sole responsibility for proper and safe execution of all loadout
operations, but the location and arrangement of components on barge(s) and the method
and points of tie-down shall be determined by the Installation Contractor and Certified by
(Principal) Marine Surveyor.
Contractor shall be responsible for all barge-ballasting operations during loadout and shall
also be responsible for ballasting to the towing condition, as specified by the Installation
Contractor and Certified by (Principal) Marine Surveyor.
Contractor shall submit to the Principal the loadout / lift plan with all supporting calculations
prior to loadout.
If Contractor is required to make delivery of the finished item to any of the Principal’s
terminals or other designed location, the same responsibility applies on the part of
Contractor for proper and safe execution of loadout operations and delivery.

8.2 TRANSPORTATION AND ARRANGEMENTS

Contractor shall notify the Principal five (5) days prior to completion so that the Principal
may schedule transportation. Contractor shall then make every effort to meet the five (5)
day target date and complete said loadout in the shortest possible time.

8.3 LOADING MATERIALS

All cradles, rigging, slings (w/certification of testing), shackles (w/certification of testing),
lines, etc., required to place and tie down the items on the Principal-furnished
transportation, shall be furnished by Contractor. Tie-down material will not be returned to
Contractor and shall be considered as expendable.

8.4 DAMAGES
Contractor shall report and repair damages caused during loadout, regardless of the cause
of damage. Repair of damages, including touch-up painting, shall be made in accordance
with the Principal-approved coating system, applicable Contract specifications, applicable
Contract Drawings and/or Standard Drawings.

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9. REFERENCES
In this DEP, reference is made to the following publications:
NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards/.
Amendment A02

SHELL STANDARDS

DEP feedback form DEP 00.00.05.80-Gen.

Structural steel design of small deepwater offshore skids, facility
packages, and subsea sleds and manifolds (based on AISC Steel DEP 37.81.10.31-Gen.
Construction Manual ASD, API RP 2A-WSD and AWS D1.1)
Galvanic anodes for marine structures and pipelines – Specification
DEP 37.81.20.31-Gen.
and qualification – Modifications to ISO 15589-2

INDUSTRY STANDARDS
US Department of Transportation (DOT) Code of Federal
Regulations 49: Transportation

Part 392: Driving of commercial motor vehicles 49 CFR Part 392

Part 393: Parts and accessories necessary for safe operation 49 CFR Part 393
American Institute for Steel Construction (AISC) - Steel Construction
AISC 325 (2011)
Manual, Working Stress Design
API RP 2A-WSD Twenty-
Recommended Practice for Planning, Designing, and Constructing
First Edition; Errata and
Fixed Offshore Platforms – Working Stress Design.
Supplement 3: October 2007
Specification for the Fabrication of Structural Steel Pipe API Spec 2B
Specification for Line Pipe. API Specification 5L
Standard Specification for General Requirements for Rolled
ASTM A6
Structural Steel Bars, Plates, Shapes, and Sheet Piling
Standard Test Methods and Definitions for Mechanical Testing of
ASTM A370
Steel Products
Standard Test Methods for Notched Bar Impact Testing of Metallic
ASTM E23
Materials
Standard Symbols for Welding, Brazing, and Nondestructive
AWS A2.4
Examination.
Criteria for Describing Oxygen-Cut Surfaces and Oxygen Cutting
AWS C4.1
Surface Roughness Gauge.
Structural Welding Code (Steel). AWS D1.1:2008

Method for Bead-on-Plate (BOP) Test for Welds BSI BS 7363

Destructive Tests on Welds in Metallic Materials Hardness Testing –
Part 1: Hardness Test on Arc Welded Joints EN 1043-1

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APPENDIX 1 SPECIAL REQUIREMENTS FOR GMAW-S WELDING

1.1 LOCATION
Table A1.1-1 provides information regarding the permitted locations and restrictions for
GMAW-S (short-arc) welding.
Table A1.1-1 Permitted Locations and Restrictions for GMAW-S Welding

LOCATION STEEL TYPES RESTRICTIONS

Pipe Mills, Pile or Brace Rack All Root-pass only

13mm (½ inch) maximum member

230 to 317MPa thickness (including reinforcement)
All other shop and yard locations
(GR33 to GR46)
Root pass only for thicker members

Greater than
All other shop and yard locations Not Allowed
317MPa (GR46)

1.2 REQUIREMENTS
GMAW-S may only be used providing the following requirements are met:
a) For joints with dissimilar steel groups, the restrictions applicable to the
lower group apply.
b) The root-opening shall be detailed per AWS D1.1 for T-, Y-, and
K-connections. All other details shall be as qualified. The root-face shall
vary from 0 mm (0/32 inch) to 1 mm (1/32 inch) featheredge.
c) Weld groove preparation shall include either grinding or filing of beveled
surfaces to bright metal prior to fit-up, or blasting of the groove preparation
prior to welding. “Prior to” is defined as within the same working shift,
which precludes the reformation of surface oxide. Any contact with
moisture shall require re-preparation. Welding of flame-cut surfaces
without cleaning, as described above, is not acceptable.
d) Only 0.9 mm (0.035 inch) diameter ER70S-2, ER70S-3, or ER70S-6
electrodes shall be used. Regardless of how the process “feels” to the
welder, the following amperage values (Table A1.2-1) shall be used:

Table A1.2-1. Amperage Values

Steel Thickness Volts Minimum Minimum Wire

mm (inches) Amperage Feedspeed

3mm (1/8”)<
_ t < 6mm (¼”) 17-19 130 200 ipm

6mm (¼”)<
_ t < 10mm (3/8”) 18-20 140 220 ipm

10mm (3/8”) <

_ t 19-21 150 240 ipm

Notes: 1) Measurement of wire feed speed is more accurate than relying on ammeters.
2) Voltage shall be measured at the wire feeder to the work. Use a constant potential power source.
3) Adjust travel speeds so that each pass is 5mm (3/16-inch) maximum thickness.
4) Maintain 10mm (3/8-inch) to 13mm (½-inch) electrode stickout.

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e) Grind convexity of root-pass. Power brush between passes where

multi-pass welding is permitted. (Not applicable where followed by SAW for
the subsequent passes.)
f) Welder shall maintain the arc on the leading edge of the weld pool (puddle).
g) Welder shall test with a 2G plus a 5G-pipe coupon to qualify for all pipe
positions. Alternatively, the welder may test only in the position required for
production (e.g., 5G for pile rack). For T-, Y-, and K-connections, the
welder shall pass a test conforming to the 6GR configuration of AWS D1.1
except that the test arrangement shall be in a 2G plus a 5G position.
h) Welder Qualification Tests shall be done with side bends; radiography
alone is not acceptable.
i) All production welding where GMAW-S is permitted shall be subjected to
the Fillet Weld Break Test for GMAW-S, as described in (Appendix1;1.3).
Contractor shall provide adequate test bars at each location where
GMAW-S is to be used.
1.3 FILLET WELD BREAK TEST
1.3.1 Scope
This provides an additional test for incomplete fusion when the GMAW-S welding process
is employed on the Principal work.
1.3.2 Application
This test may be administered by the Principal any time that GMAW-S is being used.
Particular attention will be given to cases where the Principal does not have a prior history
of satisfactory performance by a Contractor and to cases where short-arc is to be used as
stringer pass on Group III steels.
1.3.3 Testing
a) Test Specimen:
The fillet weld break test shall be as shown in Figure A1.3-1.
Amendment A01

Two flat bars, no smaller than 13 mm (½ inch) by 100 mm (4 inch) and

150 mm (6 inches) long, shall be used. The welder shall make a 90 mm
(3-1/2 inch) long fillet weld in any representative position selected by the
Principal.
The test weld shall be made in close proximity to the joint to be welded or
the joint already completed by the welder under examination. The welding
machine shall have essentially the same settings as those used or to be
used in production.
b) Test Results Required:
To pass the visual inspection, the fillet weld shall present a uniform
appearance and shall be free of overlap, cracks, and excessive undercut.
There shall be no porosity visible on the surface of the weld.
The fillet weld shall be broken by any suitable method, such as, by
hammering or use of a pry-bar in such a manner that the root of the weld is
in tension.
The specimen shall pass the test if it bends flat upon itself and shows full
fusion to root. If the fillet weld fractures, the fractured surface shall show
complete fusion to the root of the joint and shall exhibit no inclusion,
incomplete fusion, or porosity larger than 2mm (3/32 inch) in its greatest
dimension. The sum of the greatest dimensions of all inclusions,

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incomplete fusion, and porosity shall not exceed 5mm (3/16 inch) in the
75mm (3 inch) long fillet weld.
c) Retests:
In the case where a welder fails to meet the requirements, an immediate
retest shall be permitted. The retest shall consist of two test welds of the
same type and position on which the welder failed. Both retest specimens
shall meet the original test requirements stated in (2) above for the welder
to pass on retest.
If a retest fails and the welder has not made any production welds, the
Principal will notify the welder’s supervisor that the welder needs further
training or help in adjusting his machine. No further attempts at production
welding by this welder with short-arc shall be made until the problem is
rectified and two successful retests are made.
If a retest fails in the case where a welder has completed some production
welding, all welds made by this welder since his last successful fillet weld
break test, shall be carefully and thoroughly re-inspected at no cost to the
Principal. If practicable, the re-inspection shall be done with a different NDE
method than that used on the original inspection (i.e., welds that have been
x-rayed shall be re-inspected by ultrasonics while welds that have been
ultrasonically inspected shall be x-rayed). In addition, all of the provisions of
the preceding paragraph shall apply.

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Figure A1.3-1 Test Specimen

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APPENDIX 2 CHARPY IMPACT TESTING

2.1 LOCATION
The test locations for Charpy V-notched specimens taken from welded test joints made to
determine other weld joint properties shall be as shown in Figure A2.1-1.
2.2 PROCEDURE
The impact specimens shall be machined and tested in accordance with ASTM A370 and
E23, for Type A Charpy (simple beam) impact specimens.
The longitudinal centerline of each specimen shall be transverse to the weld axis. The
base of the notch shall be perpendicular (normal) to the surface. The standard 10mm x
10mm specimen shall be used where the thickness is ½ inch or greater; for thinner
materials, the largest possible sub-size specimen (7.5 mm x 10 mm or 5 mm x 10 mm)
shall be used. In the case of sub-size specimen, the base of the notch shall be
perpendicular to the 10 mm face. When sub-size specimens are used, there shall be no
change in the required test temperature or energy requirements.
The positioning of the notch for locations B, C, and D, as shown in Figure A2.1-1, shall be
done by first machining the 10 mm x 10 mm square bars or sub-size rectangular bars out of
the test weld at the appropriate depths. These bars should be made over-length to allow
for exact positioning of the notch. Next, the bar should be etched with a mild etchant such
as 5% - 10% nital to reveal the location of the weld fusion line and heat affected zone.
Finally, the center line of the notch shall be accurately located along the longitudinal center
line of the Charpy bar from a reference point formed by the intersection of the fusion line as
shown on the plane of the test specimen, perpendicular to the axis of the weld.
2.3 REQUIREMENTS
The result of an impact test at each designated location shall be the average (arithmetic
mean) of the results of the three specimens tested. This average value shall meet or
exceed the stated Charpy requirement and no single value of any set of three shall be
more than 7 Joule (5 ft-lbs) below the stated requirement.
If more than one specimen’s energy value is below the stated requirement, or if any one
specimen’s energy value is more than 7 Joule (5 ft.-lbs) below the stated requirement, a
retest of three additional specimens shall be made, each of which shall have a value equal
to or exceeding the stated Charpy requirement.
Impact tests at temperatures at or below those given in (Appendix 4, Table A-1) or
(Appendix 5, Table A-1) of the “Typical Welding Details” drawing will be accepted, provided
that the stated performance is met. Charpy qualifications that do not meet the stated
requirements, but were previously accepted by the Principal, will be reviewed on a
case-by-case basis.

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Figure A2.1-1 Charpy V-Notched Test Locations

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APPENDIX 3 TABLE OF DELIVERABLES

DOCUMENTS REQUIRING SUBMITTAL

DOCUMENT SUBMITTAL TIMING SHELL ACTION REF.

Alternative Codes Prior to Award. APPROVE 1.1

Contractor Furnished Items As Required. APPROVE 2.2.2
List of Subcontractors Prior to use. APPROVE 2.10
Fabrication Procedures 2 weeks prior to start of fabrication. REVIEW 3.1
Coating System 2 weeks prior to start of coating. APPROVE 3.1
Proposed Changes Prior to ordering material or starting APPROVE 3.1
fabrication.
Dimensional Control 2 weeks prior to start of fabrication APPROVE 3.3
Procedure
Weld Traceability Procedure 2 weeks prior to start of fabrication APPROVE 3.7

As-Built Data 2 weeks after completion of APPROVE 3.8

fabrication
Proposed phenolic grating 2 weeks prior to start of fabrication. APPROVE 4.3
and fasteners (if applicable)
Mill Certificates 2 weeks before incorporating any REVIEW 4.4
of the material into the structure.
Material Traceability 2 weeks prior to start of fabrication APPROVE 4.6
Procedure
Proposed direct fastening 2 weeks prior to start of fabrication. APPROVE 5.2.2
system (if applicable)
Weld Procedure Qualification 2 weeks prior to start of fabrication. APPROVE 5.2.3
Testing
Testing Laboratory Prior to Testing. APPROVE 5.4.2
Welding Procedure 2 weeks prior to start of fabrication. APPROVE 5.4.2
Specification
Inspection and Test Plan 2 weeks prior to start of fabrication APPROVE 6.1

Contractors QC staff 2 weeks prior to start of fabrication. APPROVE 6.1

Loadout / Lift Plan 2 weeks prior to loadout. APPROVE 8.1

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APPENDIX 4 TYPICAL WELDING DETAILS DRAWING (US Customary Version)

Amendment A02

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APPENDIX 5 TYPICAL WELDING DETAILS DRAWING (Metric Version)

Amendment A02

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