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PETROM SAEXPLORATION & PRODUCTION

DIVISION

PROJECT NO: 180530 DOC NO: 18053000MESPC- 0009 2 of 31

REVISION DESCRIPTION SHEET

Rev. Para. Revision Description

0 Issued for Internal Review

1 ISSUED FOR CLIENT REVIEW

A APPROVED FOR DESIGN

A1 APPROVED FOR DESIGN INCORPORATING CLIENTS LATE COMMENTS

HoldNo.

Para. Descript ion of Hold

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EXPLORATION & PRODUCTIONDIVISION


TABLE OF CONTENTS

1.0 SCOPE..............................................................................................................................................5 1.1 General......................................................................................................................................5 1.2 Definitions..................................................................................................................................5 1.3 Abbreviations.............................................................................................................................5

2.0

CODES AND STANDARDS..............................................................................................................6

2.1 Codes and Standards................................................................................................................62.2 Order of Precedence .................................................................................................................7

3.0 PROCEDURES SUBMITTAL REQUIREMENTS..............................................................................74.0 PREHEAT..........................................................................................................................................8

4.1 General Requirements...............................................................................................................84.2 Ferritic Steels.............................................................................................................................94.3 Austenitic Stainless Steels and High-Nickel Alloys....................................................................9

4.4

Aluminium and Aluminium Alloys...............................................................................................94.5 Welding Dissimilar Metals or Thicknesses ................................................................................9

4.6 Preheat Maintenance for Circumferential Butt Joints ................................................................95.0 INTERPASS TEMPERATURE........................................................................................................106.0 HEAT INPUT ...................................................................................................................................107.0 POST WELD HEAT TREATMENT (PWHT)....................................................................................108.0 WELDING........................................................................................................................................11

8.1 General....................................................................................................................................11

8.2

Tack Welds..............................................................................................................................11

8.3

Base Metal Preparation...........................................................................................................11

8.4 Proprietary Items .....................................................................................................................128.5 Welding Items Coated with Low Melting Point Metals.............................................................128.6 Welding Items in Hydrogen Service.........................................................................................128.7 Welding Items in Wet Hydrogen Sulfide Service .....................................................................12

9.0 WELDING ELECTRODES AND CONSUMABLES .........................................................................129.1 Ferritic Steels...........................................................................................................................139.2 Austenitic Stainless Steel, High-Nickel Alloys, Duplex Stainless Steels..................................139.3

Aluminium and Aluminium Alloys.............................................................................................13

9.4 Ferritic to Austenitic Steels and to High-Nickel Alloys .............................................................139.5 Consumables Storage .............................................................................................................139.6 Gases ......................................................................................................................................14

10.0 WELD QUALITY CONTROL ...........................................................................................................1410.1 Repair and Rejection ...............................................................................................................14

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10.2.16

Requirements for weld overlays and clad material ..............................................................19

APPENDIX A: ACCEPTABLE WELDING PROCESSES............................................................................21APPENDIX B: SPECIFIC ITEMS TO BE INCLUDED IN WELDING PROCEDURES ................................23APPENDIX C: FILLER METAL SELECTION GUIDE FOR WELDING FERRITIC STEELS.......................24APPENDIX D: ACCEPTABLE FILLER METALS FOR JOINING FERRITIC STEELS................................25APPENDIX E: PWHT REQUIREMENTS FOR FERRITIC STEELS ...........................................................27APPENDIX F: ACCEPTABLE FILLER METALS FOR JOINING AUSTENITIC STAINLESS STEELS ......28APPENDIX G: B31.3 TABLE 323.3.5..........................................................................................................29

APPENDIX H: EXTENT OF NON DESTRUCTIVE TESTING ....................................................................30

APPENDIX I: WELDING CONSUMABLE DOCUMENTED BY BATCH TESTING.....................................31

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1.0 SCOPE

1.1 General

This specification establishes the minimum WELDING,PWHT and NDE requirements forequipment including but not limited to pressure vessels, heat exchangers, coolers, towers,columns, fired heaters, tanks, process and utility piping, manufactured of carbon, low alloy steelsand stainless steels.The specification also covers requirements weld overlays and cladmaterials. Vessels and piping in Sour Service, shall comply with NACE MR0175/ISO 15156

1.2 Definitions

The following definitions are used in this document

Client PETROM

Contractor The Party that carries out all or part of the design, engineering,procurement, construction, commissioning, management or otherservices of the Project directly for the Client.

Purchaser Party purchasing goods, equipment or material.

Sub-Contractor Party that provides services specified by Contractor.

Supplier Vendor or Manufacturer of goods, equipment or material specified byPurchaser.

Sub-Supplier Party supplying goods, equipment or material specified by theSupplier.

National Standard Authoritative publication recognised and accepted by the country inwhich the equipment is to be installed.

1.3 Abbreviations

The following abbreviations are used in this document;

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASTM American Society testing Materials

AWS American Welding Society

CRA Corrosion Resistant Alloy

DPI Dye Penetrant Inspection

EGW Electrogas Welding

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WPAR Weld Procedure Approval Record

WPQ Welder Performance Qualification

WPQR Weld Procedure Qualification Record

QC Quality Control

2.0 CODES AND STANDARDS

The Supplier shall ensure that the equipment or material which is the subject of any resulting

Purchase Order, shall comply with the current revision of the Codes, Standards or Directivesapplicable on the date a Purchase Order is awarded.

This does not relieve Supplier of the responsibility for notifying Purchaser in the event that asubsequent revision to a Code, Standard or EU Directive becomes in force during the period ofmanufacture and supply of the material or equipment specified in the Purchase Order.

2.1 Codes and Standards

SR EN 13445 Parts1-6 Unfired Pressure Vessels

SR-EN-13480 Metallic industrial piping

SR EN 287-1

SR EN 1597-1

Qualification test of welders-Fusion welding- Part 1steels

Welding consumables, Test methods, part 1 : Testpiece for all weld metal test specimens in steel ,nickel and nickel alloys

SR EN-ISO-15607 Specification and qualification of welding proceduresfor metallic materials General rules

SR CR-ISO-15608 Welding Guidelines for a metallic material groupingsystem

SR EN 15614-1 Specification and qualification of welding proceduresfor metallic materials. Welding procedure test. Arcwelding of steels & nickel alloys

SR EN ISO 15609-1 Specification and qualification of welding proceduresfor metallic materials, Welding procedurespecification

SR EN ISO 15610 Specification and qualification of welding proceduresfor metallic materials- qualification based on testedwelding consumables

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ASME Section VIII, DIV 1 Boiler and pressure Vessels Code Design andFabrication of Pressure Vessels

ASME Section IX Boiler and Pressure Vessel Code - Welding andBrazing Qualifications

ASME B31.3 Process Piping

ASME B31.1 Power Piping

ASTM A262 Detecting Susceptibility to Intergranular Corrosion inAustenitic Stainless Steels

ASTM E562 Standard Test Method for Determining VolumeFraction by Systematic Manual Point Count

ASTM G48 Standard Test Methods for Pitting and CreviceCorrosion Resistance of Stainless Steels and RelatedAlloys by Use of Ferric Chloride Solution

SR EN ISO 3834 Pt 2 Quality requirements for fusion welding of metallicmaterials-part 2: Comprehensive qualityrequirements

ISO 9712 Non-destructive Testing - Qualification andCertification of Personnel

SR EN 10204 Metallic products Types of Inspection Documents

SR EN ISO 14343 Welding Consumables - Wire Electrodes, Wires and

Rods for Arc Welding of Stainless and Heat ResistingSteels Classification

API RP 582 Welding Guidelines for the Chemical, Oil and GasIndustries

NACE MR0175/ ISO15156 Petroleum and natural gas industries-Materials foruse in H2S-containing Environments in oil and gasproduction

NACE MR0103 Materials Resistant to Sulfide Stress Cracking inCorrosive Petroleum Refining Environment

2.2 Order of Precedence

In order of priority, equipment shall conform to the following documents:

Local Codes Laws and Regulations

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Forms QW 482 and QW 483. The following additional general requirements shall be appliedwhere appropriate:

Supplier shall prepare and qualify welding procedures to cover all welding situations,including weld repairs. Supplier shall also qualify all welders and/or welding operators.

The complete set of Welding Procedure Specifications (WPS) and Procedure QualificationRecords (PQR) shall be submitted together with the preliminary outline drawings asrequested by subsequent paragraphs of this specification. Contractor reserves the right toreject sets of WPS/PQR that are not complete.

All welding procedures shall be identified by number and all welds shall be referenced toWPS identifying number on fabrication drawings. Supplier shall submit an index of all WPSrequired for the job, including the supporting WPQR.

No welding shall be performed until the reviewed WPS/WPQR have been approved by thePurchaser.

Any comment/acceptance given by the Purchaser does not relieve the Supplier from theirresponsibility. The Purchaser can issue further comments if deviations from Codes,Specifications and Engineering Practice are discovered.

Specific information that must be included in Supplier's weld procedures and/or restrictionswhich must be complied with are the following:

All WPQRs for all materials shall include a HV10 hardness survey

WPQRs for sour service applications shall include a hardness survey in accordance with therequirements of NACE MR0103.

WPQR for carbon steels with a minimum metal design temperature (MDMT) of 0C andbelow shall include Charpy impact testing of the Weld metal, Fusion Line and Fusionline+2mm at the MMDT. The acceptance criteria shall be in accordance with therequirements of ASME B31.3, paragraph 323.3, and table 323.3.5, extract in Appendix G:

Detailed information specified in paragraph QW 201.1, of ASME Code, Section IX.

Definite minimum preheat and interpass temperature and, if necessary, correspondingmaximum temperatures. (Maximum interpass temperature limits must be specified forstainless steels and non-ferrous materials).

Definite range of holding temperature, holding time, and maximum heating and cooling ratedfor post weld heat treatment.

In addition to WPS/PQRs and prior to the commencement of welding the Supplier shall submitthe following documents for approval:

NDE Procedures

Production Test Procedures

Consumable Storage and Control Procedures

PMI Procedures

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temperature may be below -18C, but heated structure or shelter around the area beingwelded could maintain the temperature adjacent to the weldment at -18C or higher.

The method of preheating shall be selected on a case-by-case basis dependednt upon thejoint configuration for field welding of sour service piping >25mm wall thickness,preheating shall be via thermostatically controlled blankets.

The method of preheat shall be stated in the WPS and shall not be changed withoutPurchaser approval.

The minimum preheat temperature shall be maintained throughout the welding cycle.

Minimum preheats shall also be used for tack welding and thermal cutting.

A minimum distance of 75mm either side of the weld preparation shall be subject topreheating.

Preheats for weld repairs shall be 50C higher than that applicable for initial welding.

Method of temperature measurement to be Thermocouple or pyrometer.

4.2 Ferritic Steels

The minimum preheat temperature for carbon and alloy steels shall be as per the requirementsbelow, and the minimum value stated could be dependent on a combination of the requirements.The Supplier is requested, under their full responsibility, to establish the minimum preheattemperatures related to: chemical analysis, thickness, welding process and heat input, restraintof the parts being joined, etc.

a) For piping and piping components, as given in ASME B31.3, or in ASME B.31.1.b) It shall be ascertained that specified preheat, if required, prevails throughout thickness of

parts being welded and not just at the surfaces.c) Neither welding, even of temporary attachments, nor striking of arcs are permitted

without the specified preheat.

4.3 Austenitic Stainless Steels and High-Nickel Alloys

For all thicknesses of austenitic stainless steel, Incoloy and high nickel alloys except Hastelloy,preheat shall be at least 20C, preheat shall not exceed 175C.

4.4 Aluminium and Aluminium Alloys

a) In gas-shielded arc welding of aluminium and aluminium alloys, preheating of parts to bewelded is only required if:

1) The temperature of the parts is below 10C2) GTAW of parts thicker than 5 mm with alternating current3) GMAW of parts thicker than 25 mm.

b) When preheating is required, a preheating temperature in the range of 65C to95C h ll b d A hi h h ti t t h ll t b d l th i

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5.0 INTERPASS TEMPERATURE

5.1 The maximum interpass temperature and method of measurement shall be as stated onthe WPS. The following requirements shall be met:

Material GroupMaximumInterpass

Temperature

Carbon and low alloysteels 250C

410/410S 315C

405 175C

Alloy 20Cb-3 175C

CA6NM 345C

Austenitic StainlessSteel (P-8)

175C

Duplex Stainless (P-

10H) 150C

Ni-Cu Alloy 400 150C

Alloy C-276 175C

Alloy 600 175C

Alloy 625 175C

Alloy 800, 800H,800HT

175C

6.0 HEAT INPUT

For welding procedures subject to impact testing the following minimum requirements shallapply:

Heat input shall be calculated and recorded for each weld run of WPQR. The record shallform part of the WPQR.

First 5 production welds of each welder, welding parameters of root, hot pass and fill passesshall be monitored and recorded.

10% of production welds, welding parameters of root, hot pass and fill passes shall bemonitored and recorded. The production welds to be monitored shall be at the Purchasersdiscretion.

Production weld monitoring shall be undertaken on each pass with calibrated equipment.

Any welds welded outside the parameters of the approved WPS shall be rejected.

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Materials subject to a tempering heat treatment, the maximum PWHT shall be at least 10oCbelow the tempering temperature.

For Furnace PWHT, piping spools shall be adequately supported to prevent distortion duringheat treatment and have at least one thermocouple attached to each spool.

PWHT requirements shall be clearly identified on Suppliers WPS and relevant Drawings. Whenrequired, PWHT shall be conducted at the range detailed on the approved WPS for 1 hour per25 mm of thickness, but not less than 1 hour. Direct flame impingement by torch or furnace

burner during PWHT is not permitted.

For carbon steel piping classes in amine and caustic service, all pressure retaining welds, andattachment welds to the pipe, shall be PWHT.Piping in Amine service shall be heat treated in accordance with the requirements of API RP945. The minimum heated band width shall meet the requirements of API RP 945.All sizes and wall thicknesses of P4 and P5 alloy steels shall be PWHT.In case PWHT is specified for process reason, stainless steel, which is supplied as chemicallystabilised (321 or 347) and is subsequently welded (except for socket and seal weld) shall

receive a thermal stabilisation heat treatment after welding. The heat treatment shall consist ofheating the material to 900C +14C for 4 hours followed by air-cooling.No welding or heating shall be performed after PWHT, and all NDE shall be carried out afterPWHT.

8.0 WELDING

8.1 General

a) The welding processes listed in Appendix A "Acceptable Welding Processes" of thisspecification are acceptable for fabrication subject to the limitations stated therein. Requestto use any other welding process shall be submitted to Purchaser for approval.

b) Unless written permission has been granted, all butt joints which are accessible from bothsides shall be back gouged or ground to sound metal after welding the first side and thenback welded on the reverse side.

c) Butt weld joints shall be made using a root pass deposited by the GTAW (TIG) process,except that for carbon steel piping the use of E-6010 electrodes for root pass welding bySMAW is also acceptable. The use of consumable insert rings for GTAW is prohibited.

d) For materials and material combination of P-Number or S-Number of 3 or greater (except P-Number 8), each combination of welding process requires qualification as a combination,unless specifically approved by Purchaser. A process used only for root passes can bequalified separately.

8.2 Tack Welds

All tack welds shall be made in accordance with a previously approved WPS and shall be

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c) Appropriate Preheating shall be carried out prior to any gouging taking place.d) Prior to welding, all oil, grease, dirt, rust and excessively thick or loose scale shall be

removed from the surfaces of the joint and the adjacent base metal within one inch from theedge of the joint. Oil and grease shall not be removed by heating with a torch.

e) CRA materials to be prepared by machining and grinding only.f) It is very important when welding ferritic steel components which are internally clad with 12%

Cr or 18% Cr-8% Ni materials, to remove the high chrome material prior to any cutting orwelding operation.

g) To insure complete removal of residual cladding from previously clad surfaces, all surfaces

shall be etched with an 8% nitric acid solution or similar solution approved by Purchaser.Acid etching and grinding shall be repeated as required until high chrome material iscompletely removed prior to welding or cutting. For other clad materials an appropriate testprocedure shall be proposed by Supplier and accepted by Purchaser.

8.4 Proprietary Items

Welding of proprietary items such as alonised pipe, etc. is not permitted without prior writtenacceptance from Purchaser.

8.5 Welding Items Coated with Low Melting Point Metals

a) Parts painted with zinc rich paints or hot dip galvanized shall not be welded to any pressureequipment, unless the zinc in the area adjacent to the zone to be welded is completelyremoved by grit blasting or grinding prior to welding. Removal of the zinc rich areas byburning is not permitted.

b) Components coated with low melting point materials such as lead, zinc, cadmium, etc. shallnot be welded to carbon or stainless steel.

8.6 Welding Items in Hydrogen Service

For all plates, piping and piping components in hydrogen service having an hydrogen partialpressure above 6.9 bara or as noted on drawings or requisitions all welds in contact with theprocess fluid shall be full penetration.

8.7 Welding Items in Wet Hydrogen Sulfide Service

a) For all plates, piping and piping components in wet hydrogen sulfide service the hardness ofwelds shall meet the requirements of NACE MR 0103.

b) Socket welds are prohibited.

9.0 WELDING ELECTRODES AND CONSUMABLES

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9.1 Ferritic Steels

Filler metals for similar and dissimilar welds in ferritic steels shall meet with requirements ofAppendix C of this specification unless written permission is given by the Purchaser.

9.2 Austenitic Stainless Steel, High-Nickel Alloys, Duplex Stainless Steels

Filler metals for joining similar and dissimilar stainless steel shall meet the requirements of

Appendix F of this specification, including notes unless written permission is given by thePurchaser.

Filler metals for joining similar and dissimilar high-nickel alloys shall meet the requirementsof API RP 582.

Filler metal for joining austenitic-ferritic (duplex) stainless steel shall be selected on the basisof the recommendation from base material supplier.

Supplier shall submit the Data Sheet of filler metals together with the welding book.

9.3 Aluminium and Aluminium Alloys

Filler metals for joining similar and dissimilar aluminium and aluminium alloys shall meet with therequirements of API RP 582. Alternatives to be approved by Purchaser.

9.4 Ferritic to Austenitic Steels and to High-Nickel Alloys

a) For Carbon and Low Alloy steels welded to 300 series austenitic steels with operatingtemperatures below 370C and in the absence of thermal cycling and PWHT requirementsType 309 or 309L Stainless Steel filler metal shall be used. For these dissimilar base metal

combinations with operating temperatures above 370C, either Inconel welding electrode182 (ENiCrFe-3), Inconel filler metal 82 (ERNiCr-3), Incoweld A (ENiCrFe-2) or equivalentshall be used. These filler metals are also an acceptable alternate to Type 309 for lowertemperature service except where the environment contains sulphur. If the environmentcontains sulphur above 370C, or thermal cycling conditions are anticipated and/or PWHT isrequired, consult Purchaser for further requirements.

b) For carbon and low alloy steels welded to Inconel, Incoloy or Monel, and in absence ofthermal cycling and of PWHT requirements, filler metals listed in API RP 582 shall be used.

If PWHT and/or thermal cycling are involved, consult Purchaser for further requirements.

9.5 Consumables Storage

Detailed written procedures for the systematic receipt, storage, handling, issue and control ofwelding consumables shall be submitted to the Purchaser for approval

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9.6 Gases

Shielding and purging gases shall be welding grade, with a dew point of less than or equal tominus 40C, with the essential variables of composition, purity and flow rate stated on the WPS.Active shield gases shall only be used with specific Purchaser approval.

10.0 WELD QUALITY CONTROL

10.1 Repair and Rejection

a) Defects, which are outside of the limits of the applicable Codes and Standards, thisSpecification, project Specifications and other requirements stated in the Contract/PurchaseOrder, shall be cause for rejection. Supplier shall take such remedial action as is necessaryto secure acceptance. Such work shall be subject to Purchaser approval, and shall beundertaken at the sole expense of Supplier.

b) All weld repairs shall be carriered out to qualified WPS/WPQR approved by the Purchaser.

c) Complete repair of a weld shall include the removal of the weld, re-bevelling of new weldpreparations, and re-welding.

d) All welds undertaken using non-approved or unqualified procedures, or unqualifiedwelders/welding operators shall be completely removed and reinstated using only approvedand qualified procedures and welders/operators.

e) All repairs shall be fully documented, including, but not limited to, repair method, weldingprocedure and qualification, welder qualification, and shall be in accordance with thisspecification and shall be subject to Purchaser approval

f) Welds containing cracks shall be completely removed and the reason for the crackingdetermined to the satisfaction of the Purchaser, before repair welding is permitted.

g) Unacceptable defects shall be removed by chipping, grinding, machining and/or arc-airgouging. When arc-air gouging is applied all carbon, copper, and other debris, includingcarburised material, shall be completely removed by grinding, or other mechanical means,until sound material is achieved. A minimum 5mm shall be removed by such mechanicalmeans.

h) Gouging of quenched and tempered steels or other high strength steels shall not bepermitted.

i) For partial repairs, the cut-out portion shall be sufficiently deep and long to remove thedefect. The ends of the cut-out shall be a gradual taper from the base of the cut to the

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10.2 Non Destruct ive Examination (NDE)

The Supplier shall submit to the Purchaser for approval detailed NDE procedures. NDE shall becarried out in accordance with the approved procedures.

The Supplier shall be responsible for all quality and progress inspection; however, the Purchaserreserves the right to perform audit inspections necessary during the fabrication or construction.

The Supplier facilities and records shall be accessible for inspection at all reasonable times bythe Puchasers representative.

The Purchasers representative may reject any materials, methods of fabrication, or fabricateditems, which fail to meet the requirements of applicable codes, specifications, procedures,drawings, purchase orders, industry standards of workmanship, or any document recognised inthe Contract.

The Purchaser shall nominate the welds to be tested when percentage NDE is required.

10.2.1 Extent of NDE

The method(s) and extent of NDE shall be as indicated in Appendix H. All NDE shall be carried-out in accordance with the applicable Code and/or Specification.

A quality plan listing the relevant NDE procedures, methods and techniques applied during eachstage of manufacture, for each item, shall be submitted to Purchaser for approval prior to thecommencement of welding. Any subsequent revision to the document shall be submitted toPurchaser for approval.

10.2.2 Acceptance Criteria

Acceptance criteria shall be in accordance with ASME B31.3 Table 341.3.2 for NORMALSERVICE.

10.2.3 NDE Personnel Qualifications

Personnel qualified to ISO 9712 Level II (e.g. PCN, CSWIP or ACCP), or EN 473 or aPurchaser approved alternative, shall perform all NDE.

Original wet copy certificates attesting to personnel certification shall be made available forreview by the Purchaser.

Supplier shall maintain a list of all approved personnel and qualifications Purchaser shall have

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10.2.5 Radiographic Testing

All radiographic procedures shall meet the requirements of ASME Section V Article 5.

X-ray techniques shall be used for shop-fabricated piping up to 25 mm thickness and where theX-ray technique is impractical; gamma ray may be used subject to Purchaser approval. In eachcase, the technique shall be qualified using source side IQI wire type penetrameters.

Lead screens and fine grain film shall be used.

Film density shall be 2.0 - 3.0 (range may be extended up to 3.5 if high intensity viewing screensare used) measured through the thickest part of the weld.

10.2.6 Magnetic Particle Inspection (MPI)

All MPI Procedures shall meet the requirements of ASME Section V, Article 7.

Magnetic particle inspection shall be confined to surface inspection of magnetic materials. Alsoin such a case the magnetic particle testing may be substituted for liquid penetrant inspection.

All weld areas to be examined by MPI shall be sufficiently smooth to avoid false indications.

Electrode or probe arc strike areas shall be removed by grinding.

10.2.7 Liqu id Dye Penetrant Inspection (DPI)

All DPI Procedures shall meet the requirements of ASME Section V, Article 6.

DPI shall be carried out with strict adherence to the procedures recommended by themanufacturer of the penetrant system.

Liquid dye penetrant inspection shall be carried out within a base metal temperature range ofbetween 16C and 52C.

When it is impractical to obtain a temperature range described in the above paragraph, therequirements of ASME Section V, Article 6 paragraph T653(latest edition) shall be employed.

All DPI consumables shall be removed and metal surface wiped clean on completion of DPI.

10.2.8 Ultrasonic Testing (UT)

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10.2.10 Production Hardness Testing

a) The following hardnesses shall not be exceeded in the base material, weld metal, and/orheat affected zones of piping and equipment:

Maximum Hardness

Non-Sour Service Sour ServiceBase

Material

HB HV HB HVP-1 285 300 237 248

P-3 225 230 225 230

P-4 225 230 225 230

P-5 241 253 241 253

P-6 241 253 241 253

P-7 241 253 241 253

If other hardness limits are mentioned in equipment job specification, those values shall govern.

b) To verify the compliance with above hardness limitations, the following shall apply asminimum:For piping and piping components - at least one hardness measurement shall be taken on10% of the welds on pipe which does not require PWHT and one on each furnace batch ofpiping which is heat treated after welding, hot forming, and hot bending. At least onehardness measurement shall be taken on 100% of those joints which are locally heat-treated.

c) Areas to be checked shall be located by the Purchasers Inspector. If hardnessmeasurements exceed the limitations, the Purchaser shall be contacted for furtherresolution.

d) Purchaser acceptance shall be obtained for all multiple stress relieves beyond that requiredby code, item drawing, or this specification when used for the purpose of decreasinghardness.

e) Where two or more different base materials are joined, the maximum hardness of the weldmetal shall not exceed the lesser of the hardness required for the base materials involved.The hardness of each heat affected zone shall not exceed the hardness requirement for theadjacent base material.

f) Additional Requirements for Welding Procedure Qualification1) P d lifi ti t t f ldi t l l ifi d P 1 P 3 P 4 P 5 P 6 d

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line shall be foreseen, so that the passes of all processes are crossed by linesparallel to the first/second lines.

4) The hardness tests specified shall be carried out with Vickers Pyramid (HV10) orwith Brinnel std. ball 10HB3000.

5) If the manufacturer already holds record of hardness tests (on cross section),performed other than indicated above, he may be exempted, only after Purchaserwritten approval, to produce a new coupon to perform hardness test, providing that:

Weld hardness is detected on the weld surface of production welds with thematerial removed as minimum as possible to permit the test.

The ball for hardness detection is as small as necessary to avoid a blendedreading in HAZ (blending between weld, HAZ and base metal hardness).

10.2.11 Ferrite Measurements of Solid Austenitic Stainless Steels

The welding consumables for austenitic stainless steels shall produce weld deposits with therange of ferrite levels as follows:

Temperature

Range

Ferrite (%) Frequency of Test

-196C to -100C < 3 to 5 WPQR & PRODUCTIONTEST

-100C to +427C 3 to 10 WPQR

Over +472C < 3 to 5 WPQR & PRODUCTIONTEST

The need for conducting ferrite measurements on austenitic stainless steel productionweldments shall be specified on Material Requisitions and shall conform to the following

restrictions:

a) Ferrite measurements shall be taken both in the as-welded condition prior to PWHT andafter PWHT if any (if magnetic gages are used).

b) Ferrite measurements shall be performed in the centre of the weld utilising a Ferritscope.c) The chemical analysis samples shall be removed from the centre of the weld deposit at a

thickness of 2 mm from the weld surface.d) An annual calibration certification shall be available for the inspector.e) A minimum of 2 measurements shall be taken on each piping circumferential and

longitudinal (if fabricated) joint. A minimum of one ferrite measurement shall be taken on allnozzles penetration welds. Measurement sites shall be designated by the PurchasersInspector.

f) When ferrite measurements of solid austenitic stainless steel are required in production, theyshall be reported in the PQR; test methods acceptable values, etc. shall be the same as forproduction welds.

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10.2.13 Workmanship

a) Unless otherwise specified, reinforcement of butt weld on plate joints shall not exceed thefollowing:

Plate Thickness(mm)

Max. Thickness ofReinforcement

(mm)

Up to 13 incl. 2

Over 13 to 25, incl. 2.5

Over 25 to 50, incl. 3

Over 50 4

b) Weld reinforcement of pipe joints shall not exceed 2 mm for wall thickness up to andincluding 13 mm or 3 mm for wall thicknesses over 13 mm and shall be dressed to blendsmoothly into the adjacent surface.

c) Internal penetration on single welded butt joints shall not exceed 3 mm.

10.2.14 PQR Witnessing

a) The qualification of welding procedures and of welders shall be in accordance with ASMECode, Section IX or EN15614-1and performed at the presence of a recognised independentthird party/organisation.

b) Welder and Welding Operator Qualification Tests can be carried out to EN-ISO-9606 orASME section IX and records shall be available for evaluation by the Purchasers Inspectorat all times.

10.2.15 Sub-Suppliers

a) Use of Sub-Suppliers by the Supplier for any operations required is prohibited without priorpermission and approval by Purchaser. Sub-Suppliers include other plant locations than themain, or identified plant of the Supplier.

b) All the requirements of this document, including all the herein referenced documents, codes,specifications, procedures, etc. are applicable to the Sub-Suppliers and are to be included inSuppliers purchase orders.

10.2.16 Requirements fo r weld overlays and clad material

The PQR quantitative chemical analysis shall report all elements for which specific values aregiven in ASME section 2 Part C.

Weld overlay shall have the required chemistry to a depth the specified overlay thickness.

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Filler metal for weld overlay, clad restoration ( at seams of clad equipment ) shall be selectedfrom below table:

CLADDING MATERIAL WELD OVERLAY MATERIALSFIRST LAYER

TOP LAYER(S)

405 / 410S ENiCrFe-2OR

ENiCr-3

ENiCrFe-2OR

ENiCr-3(NOTES 1&2)

304 SS;304L SS

E/ ER309 ;E / ER309L

E / ER308E / ER308L

316 SS316L SS

E / ER309MoE / ER309MoL

E / ER316E / ER316L

317L SS E / ER309MoL E / ER317L( NOTE 3)

321 / 347 SS E / ER309Cb E / ER347

MONEL ENiCu-7* E / ERNiCu-7

ALLOY 600, 800,800H,800HT (NOTE4)

ENiCrFe-2 OR ERNiCr-3**

ALLOY 600, 800,800H,800HT (NOTE5)

Filler metal ERNiCrCoMo-1 ORElectrodes ENiCrCoMo-1

Filler metal ERNiCrCoMo-1 ORElectrodes ENiCrCoMo-1

* For GMAW overlays , the first layer shall be deposited by ENICu-7 OR ENi-1

** All layers

NOTE 1 - For design temperature above 538 deg, C, specific requirements shall be requestedfrom the purchaser

NOTE 2 E / ER309 may be used for all layers when design temperature is less than371 deg. C and thermal cycling conditions are not anticipated.

NOTE 3 A minimum of two layers shall be deposited with E / ER 317L.

NOTE 4 Design temperature applications thru 816 deg, C

NOTE 5 - Design temperature applications over 816 deg, C

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APPENDIX A: ACCEPTABLE WELDING PROCESSES

Welding Process

Items to be specifiedin WeldingProcedures

(see APPENDIX B)

Restriction(see below)

SMAW - Shielded Metal Arc A,B 16

GTAW - Gas Tungsten Arc A,B,C,D,E,F,H,K 1,13

PAW - Plasma Arc A,B,C,D,E,F,H 1

GMAW - Gas Metal Arc

-Fine Wire (Short ArcMicro Wire)

A,B,E,F,H,K 1,2,3,12,13

- CO2 Spray Arc A,B,E,H,K 12,13

- Inert Gas (MIG) A,B,E,F,H,L,K 1,12,13

- Pulsed Arc A,B,E,F,H,L,K 1,2,3,12,13FCAW - Fluxed-cored Arc

- CO2 shielded A,B,E,H,I 5,9,11,18

- Self-shielded A,B,H,I 5,9,11,14,18

SAW - Submerged Arc A,B,G,H,L,J 4,5,8,10,11,15

EGW - Electrogas A,B,E,H,L,J 6,9

ESW - Electroslag A,B,D,G,H,L,J 6,9,5,17

OFW - Oxy Fuel Gas 7

RESTRICTIONS:

Unless otherwise authorised in writing by purchaser, use of these welding processes is subject toindicated restrictions:

1. Internal purging with inert gas is required for consumable insert welding of all materials and forroot/second passes of single welded butt joints in materials with over 3% total alloy content.

2. Manual short arc or pulsed arc welding is:

a) Allowed for root pass welding of butt joints in any material regardless of thickness.b) Allowed for full thickness butt welds and fillet welds in pressure parts, structural supports

and equipment internals if the thickness of either material at the joint does not exceed 9 mm.) N t ll d h l t i l h t i k ff t th i t it f ld h

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d) Not allowed where large material mass heat sinks affect the integrity of welds, as withcouplings, weldolets, branch welds, fillet welds on slip-on flanges, socket-welded flangesand fittings, etc., where the thickness of either material at the joint exceeds 9 mm.

e) Allowed for piping of nominal diameter > 90 mm, and only where the direction of travel isindicated in the procedure.

f) Shall not be used to deposit filler passes or cover passes in the down hill direction.

4. The use of neutral flux (non-voltage sensitive) is required for submerged arc welding of carbon steelbase metals thicker than 25 mm and for all materials other than carbon steel. If voltage sensitive

flux is used, each production weld shall be tested for hardness. Max. allowed hardness is 200 HB.

5. The use of alloy wire and neutral flux, rather than alloying through the flux, is required where an alloyweld deposit is desired.

6. Welding shall be followed by appropriate normalising treatment to restore notch toughness to basematerial and weldments.

7. Prohibited.

8. Use of manual submerged arc welding is not permitted. The manufacturer and brand name or gradeof flux shall be specified in the welding procedure.

9. This welding process is not acceptable for field welding.

10. Start and run off pads of same material as base material shall be used on all longitudinal seams.

11. The flux and wire combination actually used shall be the same used in the procedure qualification.

12. Gas Metal Arc Welding shall not be used for welding attachment of nozzles to vessels.

13. When this welding process is used for field welding, suitable precautions shall be taken to shield thewelding area from wind or drafts which could interfere with the shielding gas protection.

14. Self-shielded flux-cored arc welding, without external shielding gas, of carbon or alloy steels is notacceptable for pressure parts or for welds subject to vibration.

15. Individual beads deposited by standard automatic processes shall not exceed 6 mm deep.

16. Only low-hydrogen electrodes shall be used for shielded metal arc welding of all carbon and lowalloy steels, except for root pass welding of single welded joints as specified in the relevant para ofthis specification.

17. The use of this process for welds, weld overlay, clad restoring is subject to Purchaser authorization

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APPENDIX B: SPECIFIC ITEMS TO BE INCLUDED IN WELDING PROCEDURES

CODE USED INAPPENDIX A

DESCRIPTION

AWelding current type, polarity, amperage and voltage(s) includingappropriate ranges.

BFiller metal type, classification, A-number and F number whereclassified. If no classification is available, give Manufacturer'sdesignation.

C Non consumable electrode

D Arc starting aids or devices

E Shielding gas composition and flow rate of internal gas purging.

F Composition and flow rate of internal gas purging.

GAWS classification, if any, and manufacturers trade name or

designation for welding flux.H Travel speed for mechanised welding

ISpecial requirements such as constant potential power sources,pulse setting, wire feed or oscillation rates, electrode stick-out, etc.(as applicable)

J Single or multiple arcs

KSpecific precautions that will be taken for welding if applicable, toprevent wind or drafts from interfering with the shielding gasprotection.

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DIVISION


APPENDIX C: FILLER METAL SELECTION GUIDE FOR WELDING FERRITIC STEELS

MATERIALTO BE

WELDEDC.S.

C-0.5Mo

Mn-Mo

1.25Cr-0.5Mo

2.25Cr-Mo

5Cr-0.5Mo

9Cr-1Mo

410 S(NOTE

1)

Carbon SteelA/B

VB/CW

B/DW

B/EX

B/FY

B/GZ

B/HZ

IW

C-0.5MoCW

C/DW

C/EX

C/FY

C/GZ

C/HZ

IX

Mn-MoDW

D/FY

D/GZ

D/HZ

IX

1-1/4Cr 1/2MoEW

E/FY

E/GZ

E/HZ

IZ

2-1/4Cr 1Mo

F

Y

F/G

Z

F/H

Z

I

Z

5Cr 1/2MoGZ

G/HZ

G/IZ

9 Cr 1 MoHZ

H/IZ

410 S(Note 1)

IZ

NOTE 1: Only applicable to non-pressure 410 S parts not exceeding 10mm in thickness.

Filler Metal Code (see APPENDIX D)

P.W.H.T. (see APPENDIX E)

X/X

X

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APPENDIX D: ACCEPTABLE FILLER METALS FOR JOINING FERRITIC STEELS

Submerged ArcFillerCodefrom

App. C

Manualshieldedmetal arc

(7) (8)Wire

Flux(9)

FluxCoredArc

GasTungsten

Arc

Gas MetalArc

AE6010 (1)E6011 (1)

CarbonSteel

(10) (11)Neutral

E70T-1E70T-5

ER70S-3ER70S-2ER70S-6


BE7018E7015E7016

CarbonSteel

(10) (11)Neutral

E70T-1E70T-5



C

E7018-A1

E7015-A1E7016-A1

EA2

EA3Mn-Mo

Neutral

E70T5-A1

E80T1-A1

E81T1-A1

ER80S-D2(Mn-Mo)

ER80S-D2(Mn-Mo)

D(2)

E9018-D1(6)

E9015-G(3)

EA3 Neutral

E80T1-A1

E81T1-A1

ER80S-D2(Mn-Mo)

ER80S-D2(Mn-Mo)

E(4)

E7016-B2L

E7018-B2LE8016-B2E8018-B2

EB2 Neutral

(1.25Cr

0.5Mo)E81T1-B2

ER80S-B2

ER70S-B2L

ER80S-B2

ER70S-B2L

F(4)

E9015-B3E8015-B3LE8018-B3LE9018-B3

EB3 Neutral

(2.25Cr1.0Mo)E91T1-

B3

ER90S-B3ER80S-

B3L

ER90S-B3ER80S-

B3L

GE502-15

(5Cr)ER502 Neutral E502T-1 ER80S-B6 ER80S-B6

HE505-15

(9Cr)_ _ E505T-1 ER80S-B8 ER80S-B8

I(5)E309L-15E309L-16

ER309L NeutralE309T1-

1ER309L ER309L

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7. E6012, E6013, E7014, E7020 and E7024 electrodes are not suitable for welding non-pressure attachments to pressure components.

8. Low hydrogen electrodes shall be stored and used only in accordance with electrodemanufacturer's instructions.

9. Welding electrodes shall have the alloying agents in the wire and not in the flux.

10. Manganese-Molybdenum steel electrode wires may be used provided that the weld metal

hardness does not exceed 200 BHN.

11. Electrodes specified in ASME SFA 5.17 and electrode classification EM12K specified inASME SFA 5.23, shall not be used for submerged arc welding carbon steels having aminimum specified tensile strength of 482 N/mm2 or higher, where PWHT is specified.

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APPENDIX E: PWHT REQUIREMENTS FOR FERRITIC STEELS

TEMPERATURE RANGE (C)

Code fromAppendix C

Piping & PipingComponents

See note(s)

V 600-650 (1)

W620-675 (4)635-660 (5)

(1), (2)

X 700-745 (2), (3), (6)

Y 700-760 (2), (3), (6)

Z 700-760 (2), (3), (6)

NOTES:

1. Weldment is only to be PWHT if required by Codes and/or by service requirements. IfPWHT is required, use the indicated temperature range for holding temperature. Heatingand cooling rates and holding time shall be as per requirements of applicable ASME, PipingCode, or applicable Codes, unless otherwise specified.

2. PWHT over 660 C may damage properties of CS, C-1/2 Mo and Mn-Mo steels. Suppliershall be responsible to procure materials that will satisfy specified materials properties after

PWHT at the specified temperatures. Mill test reports shall be based on test samples postweld heat treated at the specified temperature.

3. Where restraint conditions necessitate the practice of PWHT the chrome-molybdenum alloysteels immediately upon completion of welding, it is recommended that the welds be cooledto 120-150C after welding and prior to initiating the PWHT.

4. Use for alloy steels having a minimum specified tensile strength equal to 482 N/mm2, orless, for thicknesses greater than 19 mm.

5. Use for alloy steels having a minimum specified tensile strength greater than 482 N/mm2 forall thicknesses.

6. Welds for all thicknesses shall require PWHT. Use the indicated temperature range for theholding temperature. Heating and cooling rates and holding time shall be as per therequirements of the applicable ASME Code

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APPENDIX F: ACCEPTABLE FILLER METALS FOR JOINING AUSTENITIC STAINLESS STEELS(1) (2) (4) (5)

MATERIALSTO BE

WELDED

301302304(6)

304L309

309S310

310S

316(3)(6)

316L(3)

317(3)

321(6)

347(6)(7)

348

301302304(6)

308 308 308308309

308309

308 308 308 308 308

304L 308L 308308309

308 308L 308 308L 308L 308L

309309S

309 309309316

316309

317309

347309

347309

348309

310310S

310 309316

309316

309 309 309 309

316(3) (6)

316 316 316 316 316 316

316L(3)

316L 316316L321

316L347

316L348

317(3)

317317321

317347

317348

321(6) 321347 321347 347348

347(6) (7)

347347348

348 348

NOTES:

1. Deposited type 300 stainless steel weld metal shall have a delta ferrite content as specifiedin this specification.

2. Low carbon filler wires will result in lower tensile strengths. They shall only be used ifspecifically requested by purchaser or specifically approved in writing.


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EXPLORATION & PRODUCTION

DIVISION


APPENDIX G: B31.3 TABLE 323.3.5


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EXPLORATION & PRODUCTION

DIVISION


APPENDIX H: EXTENT OF NON DESTRUCTIVE TESTING

GROUP METHODBUTT

WELDSBRANCH

CONNECTIONSATTACHMENT

WELDSSOCKETWELDS

BUTTBEVELS

CRACKED TACKS ARCSTRIKE REMOVAL

TEMPORARYATTACHMENT

REPAIRWELDS

Visual 100% 100% 100% 100% 100% 100% 100%

Radiography 100% - - - - - 100%

Ultrasonic 100% - - - - -

Surface Crackdetection

100% 100% 100% 100%100% WHEN

WALL THICK. 25mm

100% 100%

1

Al l mat erials i nclasses:

900#1500#2500#10000#

and austenitic andduplex stainless

steels and Ni Alloysin 600# classes Hardness

[1] 10% 10% 10% 10% - - 100%

Visual 100% 100% 100% 100% 100% 100% 100%

Radiography 5% [2] - - - - - 100%

Ultrasonic - - - - - - -

Surface Crackdetection

20% 20% 20% 20%100% WHEN

WALL THICK. 25mm

100% 100%

2

Al l mat erials i nclasses:

150#

300#

and other materialsnot listed as Group

1 in 600# classesHardness

[1] 10% 10% 10% 10% - - 100%

NOTES:

1. Materials in sour service and carbon/low alloy steels in amine service.

2. Buyer has the option to specify 100% radiography where deemed necessary e.g. dissimilar welds.


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APPENDIX I: WELDING CONSUMABLE DOCUMENTED BY BATCH TESTING

SCOPE

The purpose of the batch testing is to verify that the consumables remains nominally equivalent to that used for welding procedure qualification, with respect tochemistry and mechanical properties. For this specification a batch (or lot) is defined as the volume of product identified by the supplier under one uniquebatch/lot number, manufactured in one continuous run from batch controlled raw materials.

Each individual product (brand name and dimensions) shall be tested once per batch, except for solid wire originating from the same heat, where one diametermay represent all. SAW fluxes do not require individual testing, while SAW wires shall be tested in combination with a selected, nominal batch of flux. Chemical

Analysis for solid wires and metal powders the analysis shall represent the product itself. For coated electrodes and cored wires the analysis shall represent the

weld metal, deposited according to EN 26847.

The analysis shall include:

MECHANICAL PROPERTIES

Unless otherwise specified the properties shall represent all weld metal, deposited and testedaccording to prEN 1597 part1. Properties tested shall include: Theneed for other types of tests, such as: shall be evaluated for the application in question.

DOCUMENTATIONBatch tests shall be documented by an inspection certificate 3.1B to EN 10204, with reference to a recognised product classification standard and containing allspecified test results.