CONSTRUCTION OF THE UMGENI WATER

DARVILL WASTE WATER CONTRACT NO. 2013/136

TREATMENT WORKS UPGRADE C3: SCOPE OF WORK
C3.100

together. Before closing the joints, the flanges must be parallel to each other, with all
bolts inserted in the bolt holes. After the fittings have thus been aligned and well
supported, the joint shall be bolted up to a uniform tightness using torque wrenches to
achieve the required compression force on the gasket. Diagonally opposing bolts shall
be tightened sequentially.
If and where full face gaskets are used, the jointing material shall be flush with, or
protrude beyond, the outer circumference of the flange (this in not applicable to raised
face flanges). On completion of the joint, the flanges and bolts shall be protected as
described in Clause PSL 3.9.3.8.
PSL 5.2.3 Welding (Steel Pipelines DN 600 or Greater)
Delete the title and replace with Welding (Steel Pipelines).
st
Delete the 1 sentence and replace with:
Field welding of steel pipelines shall be carried out in accordance with the relevant
requirements of the latest version of API 1104. The Contractor, prior to
commencement of welding, shall produce a qualified welding procedure in
accordance with the latest version of API 1104, for the intended sizes, processes,
positions and consumables to be used on this project.
Welding shall be carried out by welders who are competent in terms of the procedure
approval test given in API 1104. Prior to commencement of welding, the current
qualification of each welder must be produced in accordance with the welding
procedure. Should constant repairs be required on welds carried out by one particular
welder, the Engineer may request that the welder be re-tested or removed from the
project.
Add to the Sub-clause:
Examination of Welds
The Contractor shall include in his prices for the manufacture of pipes, bends, fittings
and specials for the cost of carrying out, under the supervision of the inspector
appointed by the Employer, examination of shop welds on the following basis:
(a) Manufacture of Pipes (Not applicable to pipes supplied by the Employer)
i) FIVE percent random radiographic examination of all welds deposited by an
approved automatic process.
ii) TEN percent random radiographic examination of all welds deposited
manually or semi-automatically, and repairs to welds done by an automatic process
(should repairs exceed 25% of the tests the percentage of examination shall be
increased to 20%).
(b) Field Welds
Radiographic testing will be performed on butt welds and dye penetrant testing on
fillet welds. Welds will be tested and adjudicated in accordance with API 1104
and will be tested with the following frequencies:
The first 10 welds executed by each Welder will be tested. Thereafter, if no
discontinuities are discovered, 10% of his/her further welds, chosen at random by the
Engineer, will be tested. If during the 10% testing, discontinuities are discovered both
welds immediately adjacent to the defective weld will be tested. If these joints are
found acceptable testing will remain at 10%. If, however, defective welds continue to
be evident, testing will be increased to 100%. Only once the welding has returned to
an acceptable standard and at the discretion of the Engineer, will the percentage be
reduced again.

BSC Item 2013/136

CONSTRUCTION OF THE UMGENI WATER
DARVILL WASTE WATER CONTRACT NO. 2013/136
TREATMENT WORKS UPGRADE C3: SCOPE OF WORK
C3.101

Repairs of welds will be permitted in accordance with approved repair procedures.

Repairs shall be re-examined using the relevant non-destructive testing method. All
costs associated with the repair of defective welds will be borne by the Contractor.
(c) Welds in Fabricated Bends, Fittings and Specials
i) ONE HUNDRED percent radiographic examination of all weld deposited
manually or semi-automatically in bends, fittings and specials which cannot be
hydraulically tested because they have a plain end.
ii) TEN percent radiographic examination of all welds deposited manually or
semi automatically in all flanged bends, fittings, and specials which are to be tested
hydraulically.
The Engineer shall in all cases determine which welds are to be radiographed on the
quantity basis specified above. All radiographs and records thereof made by the
Contractor shall be made available to the Engineer to enable him to determine
whether the welds are acceptable or not and no lining or wrapping of pipes shall be
permitted until the welds have been accepted by the Engineer. To avoid any
unnecessary delays, at the option of the fabricator, radiographs may be approved by
the manufacturer's inspectors subject to them being subsequently submitted to, and
approved by the Engineer.
When a section of the weld is shown by radiography to be unacceptable and, if the
limits of the deficient weld are not defined by the radiograph, additional radiography
shall be carried out at the Contractor's expense until the limits of the deficiency are
determined.
Repairs shall be made to defective welds at the Contractor's expense. All repair welds
shall be identified with a stamp marking, indicating which welder conducted the repair.
Repaired welds shall be radiographed at the Contractor's expense but, after any
repair welder has had ten consecutive repairs approved, the extent of the radiography
of the repairs conducted by the welder may be decreased by agreement between the
Engineer and the Contractor.
Production Testing of Welds (Not applicable to pipes supplied by the Employer)
The Contractor shall also include in his prices for the supply of pipes the cost of
carrying out at the factory, non-destructive tests of shop production welds (additional
to the qualification tests for welding procedure) on the following basis:-
One pipe from each one hundred pipes produced shall be selected at random and
specimens for two guided cold bend tests and one transverse tensile test shall be cut
therefrom and tested in accordance with SABS 719:1971, Section 7.
In the case of the guided cold bend tests, where welding is carried from one side only,
bend - specimens shall be tested with the rest of the bend in tension; where welded
from both sides the specimens shall be tested with the inner and outer welds in
tension alternately.
Tensile tests shall be carried out as for the qualification tests.
The pipes from which successfully tested specimens have been taken shall be
trimmed to the maximum possible length and shall be accepted by the Employer for
payment purposes as full standard pipe lengths.
In the event of the welds of any pipe failing to reach the standard of acceptance, such
pipe shall be rejected. Two further plate coupons shall be prepared from different
pipes, selected at random by the Engineer, for each specimen that has failed to reach
the required standard. In the event of such additional tests proving to be satisfactory
repairs to the pipe originally failing any test will be permitted by the Engineer and such
repairs and subsequent re-test shall be at the Contractor's expense. In the event of
the additional tests also failing to reach the required standard the Engineer shall have
the right to reject the entire batch of pipes from which the coupon plates were cut.
BSC Item 2013/136