25194-3PS-GAW-004 Rev4

Bechtel France S.A.S.

Reliance Petroleum Limited Jamnagar Export Refinery Project

Project Engineering Specification

25194-3PS-GAW-004

(Previously Issued as 22960-3PS-GAW-004 with Form 167 at Rev.10A)

Welding, NDE & PWHT for Fabricated Piping(Form 167)

4 01/02/07 Re-Issued for Construction JW EF DH PKS

3 04/10/06 Re-Issued for Construction EF JW DH PKS

2 01/03/06 Re-Issued for Construction JW AF WL PKS

1 21/02/06 Issued for Construction JW AF WL

Rev Date Revision By Chkd Appr Client

25194-3PS-GAW-004 Rev. 4 Page 1 of 31

Reliance Petroleum LimitedJamnagar Export Refinery Project

Revisions ListingRevisions to this Specification at Rev.4

Page # Document Revision

12 GAW-004 Note. 9.3.4 for Carbonate Service addedNote. 9.3.5 for Sulphuric Acid lines in the Alkylation Unit addedNote. 9.3.6 For the Flare System added

14 GAW-004 11.15 - Summary of NDE. N08020 and N08825 added.

15 GAW-004 Note 6. Revised

16 GAW-004 Appendices Description added

23 GAW-004 Alloy N08020 & N08825 added to Tables

All 167 Page numbers revised/added

4 -50 167 Service Codes added

1 167 WPG-5A,5B & 5C Carbonate classes addedWPG-12A (LTCS) added

3 167 WPG-47 added

9 167 Piping Class EC12X added

10 167 Piping Class EC14EY added

12 167 Piping Class EC18EH, EC18EN added

15 167 Piping Class EC32EI added

18 167 Piping Class EC34EY added

19 167 Piping Class EC38EN added

22 167 Piping Class EC62EX Design changed to B31.4 and API 5LX60 added. Piping Class EC62EZ added

30 167 Piping Class EK34EM deleted

31 167 Piping Class EK3AEM added

34 167 Piping Class EL12EL added

35 167 Piping Class EL32EL, EM12EA, EN12EN, EN12EM added

36 167 Piping Class EN60EY, EN62EA, EP109J, ES10ET, ES10EU added

39 167 Piping Class ES32EC added

40 167 Piping Class ES32EE added

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41 167 Piping Class ES32EM, ES32EP added

42 167 Piping Class ESJ2EF, EU14EH, EU34EH added

43 167 Piping Class EW10AA, EW10AB, EW10AF added

45 167 Piping Class EZ109A, KG06BD, KG06DA, KG06DD added

46 167 Piping Class KGD601, PC12EA, PC12EB, PC12EC, PC12ET added

47 167 Piping Class PC32EA, PC32EB, PC62CA, PC6EA, PC62EB, PL12EA added

48 167 Piping Class PL12EB, PL32EA, Pl32EB, PL32EC, PL62EA, PS10EB added

49 167 Piping Class PS10EC, PS10ED, PS30EB, PS30EC, PS30ED, PS60EB PS60EC, PS60ED added

50 167 Piping Class PSJ0CB, TEST added

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Contents

1. Scope............................................................................................................................................ 4

2. Codes, Standards and Project Documents.......................................................................................

3. Procedure Qualification..................................................................................................................

4. Welder Qualifications.....................................................................................................................

5. Preparation of Materials for Welding.............................................................................................

6. Welding Processes..........................................................................................................................

7. Welding Electrodes and Consumables............................................................................................

8. Heat Treatment...............................................................................................................................

9. General Welding Requirements......................................................................................................

10. Weld Metal Quality......................................................................................................................

11. Non-Destructive Examination (NDE)...........................................................................................

Appendix 1 - Additional Requirements for Low Alloy Steel Piping

Appendix 2 - Additional Requirements for Stainless Steel and Nickel Base Alloy Piping

Appendix 3 - The Indian Boiler Regulations - Latest Edition

Appendix 4 - NDT specification for typical cases not directly covered by existing specification or codes

Figure 1 - Delta Ferrite Diagram

Appendix 5 - Form 167

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1. Scope

1.1. This document specifies the requirements for welding, heat treatment and non-destructive testing for fabrication of piping to be installed in the Reliance Petroleum Limited Refinery Complex, Jamnagar, India. This specification is applicable to shop fabrication and site (field) welding, and inspection of piping in accordance with the Codes listed in section 2.

1.2. Requirements specific to particular material groups and alloys are given in the appendices.

1.3. In the event that additional Process Licensor requirements are not specified in this document these shall be addressed in writing to the Purchaser.

2. Codes, Standards and Project Documents

2.1. Unless otherwise stated, the following Codes, Standards and Project Documents shall be of the latest issue (including revisions, addenda and supplements) and are considered part of this specification.

ASME B31.3 Chemical Plant and Petroleum Refinery Piping

ASME B31.1 Power Piping

ASME B31.4 Liquid Transportation systems for Hydrocarbons and other liquids.

ASME Section II, Part C,2004 Welding Rods, Electrodes and Filler Materials

ASME Section V, 2004 Non-Destructive Examination

ASME Section IX, 2004 Welding and Brazing Qualifications

NACE RP-0472-2000 Methods and Controls to Prevent In-Service Cracking of Carbon Steel Welds in P-1 Materials in Corrosive Petroleum Refinery Environments

NACE MR0103-2005 Materials Resistant to Sulphide Stress Cracking in Corrosive Petroleum Refining Environments

IBR Indian Boiler Regulations

API 1104 Welding of Pipelines and Related Facilities (Marine Pipeline to 1161-40-P-SS-113)

UOP SPECIFICATIONS

(where applicable)

8-11-9 Standard specification “piping”

8-12-5 Standard specification “Fabrication of piping”25194-3PS-GAW-004 Rev. 3 Page 5 of 31


560XXX-801-0 Project Specification (Unit XXX) Materials Notes (Where XXX is the applicable unit No)

PROJECT SPECIFICATION

3PS-PL-006 Piping Fabrication

3PS-PL-001 Piping Material Classes

3PS-PL-007 Piping Erection and Testing

3PS-GAW-027 Internal Lining of Piping Spools

3. Procedure Qualification

3.1. Welding procedures are welding procedure specifications (WPS) accompanied by qualified welding procedure qualification records.

3.2. Only CONSTRUCTION MANAGER approved WPS, with qualified WPQR are to be used for welding. All welding shall be carried out by qualified welding personnel only.

3.3. Separate WPS with their appropriate WPQR, are to be submitted to the CONSTRUCTION MANAGER within the time stated in the Request for Bids, Purchase Orders and/or Contract, and prior to commencement of fabrication and/or welding. Welding operations shall not commence until WPS have been reviewed and approved by CONSTRUCTION MANAGER, and welder qualifications have been verified.

3.4. All welding procedure specifications (WPS) submitted to CONSTRUCTION MANAGER shall include welding details and appropriate test results (WPQR) in accordance with the applicable Design Code and/or Job Specification(s).

3.5. SELLER/CONTRACTOR standard WPS/WPQR forms are acceptable provided they meet the requirements and essential variables of the relevant Design Code and relevant specifications. All documents shall be fully legible and shall be in English, with test certificates independently witnessed and signed.

3.6. The SELLER/CONTRACTOR shall complete the Form 167A by listing the applicable Welding Procedure for each piping class in the columns provided. Completed forms, plus future revisions, shall be submitted to the CONSTRUCTION MANAGER for approval (see Attachment One).

3.7. Any revision to WPS/WPQR shall be submitted to the CONSTRUCTION MANAGER for review and approval.

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3.8. The SELLER/CONTRACTOR is responsible for the submittal of sub-suppliers and/or sub-contractors welding, NDE and PWHT procedures to the CONSTRUCTION MANAGER.

3.9. Repair welding procedure specifications shall be submitted to the CONSTRUCTION MANAGER for review and approval prior to commencement of work.

3.10. No welding will be accepted that is not covered by a CONSTRUCTION MANAGER approved WPS.

3.11. For carbon steel in Sour Service, each welding procedure test shall be subject to hardness testing, during procedure qualification testing whereby the Weld, Fusion Line, and Heat Affected Zone (HAZ) shall not exceed a Vickers Hardness of 248 Hv10

For the weld metal 248 Hv10 is the maximum allowable reading, but the average shall be less or equal to 210 Hv10.

In addition each new weld qualification (performed for this project) shall be hardness tested using a portable hardness tester, in accordance with section 11.14 of this document, if the material or service for which it is to be used requires production hardness testing.

3.12. Weld Procedure Qualifications shall include impact testing when required by the applicable Code.

4. Welder Qualifications

4.1. Welder qualification records shall be reviewed in accordance with the appropriate Code and approved by the CONSTRUCTION MANAGER or his representative. The review and approval of the records shall be done at the SELLERS/CONTRACTORS works or the construction site by the CONSTRUCTION MANAGER or his representative. Records shall NOT be submitted to the CONSTRUCTION MANAGERS head office.

5. Preparation of Materials for Welding

5.1. All welding preparation details are to be in accordance with CONSTRUCTION MANAGER approved drawings and WPS.

5.2. All preparation methods shall be carried out to recognised industry Standards, Project Specifications and/or Code requirements.

5.3. Flame cut bevels in carbon and low alloy steel shall be machined or ground back a minimum of 2 mm. For stainless steels and non-ferrous alloys, flame cutting is not allowed. Bevels shall be prepared by plasma cutting or machining.

5.4. Oil, moisture, rust, scale, sand, paint, metallic coatings (e.g. Zinc), or other foreign matter shall be removed from the weld surface and adjacent base material prior to welding.

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6. Welding Processes

6.1. The following welding processes are approved for use:

6.1.1. Shielded Metal Arc Welding (SMAW)Gas Tungsten Arc Welding (GTAW)Submerged Arc Welding (SAW)Gas Metal Arc Welding (GMAW) Spray/Pulse Transfer OnlyGas Shielded Flux Cored Arc Welding(GSFCAW)

6.2. Use of alternative arc fusion welding processes is subject to CONSTRUCTION MANAGER approval. SELLER/CONTRACTOR should clearly identify the proposed welding process, welding experience, level of automation and metal transfer mode.

6.3. The root pass of welds in all materials except Galvanised Iron shall be performed using the GTAW (TIG) process for the following applications:

1. All pipes of nominal diameter less or equal to 2”.

2. All single sided alloy steel, stainless steel and nickel alloy piping .

For large diameter piping where there is access inside the pipe to allow double sided welding, GTAW root may be omitted.

3. All piping defined in UOP specification 560667-801- 0 section 10 for unit 261 (Parex)

6.4. Flux shielded welding (SMAW, SAW, FCAW) of low alloy steels shall be carried out using basic low hydrogen consumables. Low hydrogen consumables shall be stored and treated (baked) to produce maximum deposited weld metal hydrogen content of 5 ml/100 g.

6.5. The use of SAW for 9Cr-1Mo piping in the delayed coker (units 371/ 372) is subject to CONSTRUCTION MANAGER APPROVAL .

6.6. GTAW welding shall be carried out with the addition of filler metal and with the use of high frequency starting units.

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7. Welding Electrodes and Consumables

7.1. All welding electrodes and consumables shall be subject to CONSTRUCTION MANAGER approval as part of the WPS.

SMAW electrodes for welding of carbon steel shall be in accordance with the following:

Material Specification Classification*

Carbon Steel AWS A-5.1, ASME SFA-5.1 E6010 or E70XX

* - Electrode coatings designated XX may be 15, 16 or 18.

E6010 shall be used for root runs only.

Use of E6013 and E7010 electrodes shall be subject to CONSTRUCTION MANAGER’s approval.

Bare electrodes for GMAW, GTAW or SAW of carbon steel shall be in accordance with the following:

Material Specification Classification

Carbon Steel AWS A-5.17, ASME SFA-5.17 orAWS A-5.18, ASME SFA-5.18

----

Flux cored electrodes for GSFCAW of carbon steel shall be in accordance with AWS A5.20, ASME SFA 5.20.

For low alloy steel and stainless steel requirements, see appendices 1 and 2.

7.2. All welding consumables shall be supplied with manufacturer’s certification.

7.3. The electrode/consumable chemistry shall meet the requirements of the base material, and shall be selected such that the deposited weld metal exhibits mechanical properties equal to or in excess of the base material.

7.4. For any dissimilar metal weld applications welding consumables and procedure shall be subject to CONSTRUCTION MANAGER approval.

7.5. All welding electrodes/consumables shall as a minimum, be stored and used in accordance with the manufacturer’s recommendations. The SELLER/ CONTRACTOR shall produce a welding consumable handling procedure, which is subject to CONSTRUCTION MANAGER approval.

7.6. Carbon, low alloy and stainless steel electrodes and consumables shall be stored separately.

7.7. For submerged arc welding, alloying is not permitted via the flux.

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7.8. For welding of P91 piping, welding consumable brand is an essential variable and is subject to CONSTRUCTION MANAGER approval.

8. Heat Treatment

8.1. Preheat

8.1.1. Preheats shall be in accordance with that specified by the applicable Design Code. In no instance shall the preheat be less than 10 C. Minimum preheats shall be specified on the SELLER/CONTRACTOR WPS.

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

8.1.3. Minimum preheat requirements shall apply to all types of welding, including tack welds, temporary attachments, repair welds, seal welds of threaded joints and thermal cutting.

8.1.4. If a welding joint is wet or has surface moisture or condensation, it shall be dried by heating.

8.1.5. Approved temperature indicating crayons, thermocouples, or contact pyrometers shall be used to measure preheat and interpass temperatures.

8.2. Interpass Temperature

8.2.1. Maximum interpass temperature shall be stated on SELLER/CONTRACTOR WPS.

8.2.2. Maximum interpass temperature for austenitic stainless steels shall not exceed 175C. This includes dissimilar welds between austenitic stainless steel and carbon steel.

8.2.3. Unless specified otherwise, maximum interpass temperature for P-1 materials shall be 250C.

8.3. Post Weld Heat Treatment

8.3.1. Post Weld Heat Treatment (PWHT) shall be in accordance with the applicable Design Code and/or Project Specification.

8.3.2. A written PWHT procedure shall be submitted to the CONSTRUCTION MANAGER for approval. The procedure shall include calibration of equipment and, location and type of thermocouples.

8.3.3. PWHT requirements shall be clearly identified on SELLER/CONTRACTOR WPS.

8.3.4. Exothermic PWHT is not allowed.

8.3.5. All flange faces and threaded connections shall be protected against oxidation during heat treatment.

8.3.6. Carbon steel piping containing AMINE at any level of concentration shall be post weld heat treated (see Form 167A).

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8.3.7. Carbon steel piping in process areas containing CAUSTIC at any level of concentration shall be post weld heat treated.(See form 167A). For offsite areas, post weld heat treatment is only required for higher concentrations.

8.3.8. Carbon steel piping in DELAYED COKER (units 371 and 372), which is in sour service, shall be post weld heat treated. (see form 167A).

9. General Welding Requirements

9.1. Welding Equipment

9.1.1. SELLER/CONTRACTOR and their sub-suppliers and/or sub-contractors shall maintain all equipment in good working order. Earth connections shall make good contact with the work, and regular calibration checks shall be carried out on all machines.

9.2. Technique

9.2.1. Vertical down welding shall not be used without CONSTRUCTION MANAGER approval.

9.2.2. All welds shall be cleaned of foreign material (slag etc.) down to clean metal, both on completion of each pass and when the weld is finished.

9.2.3. Single pass welding procedures are not acceptable.

9.2.4. All piping butt welds shall be full penetration welds.

9.2.5. A minimum of two passes shall be used on socket and seal welds.

9.2.6. Weld peening shall not be used without CONSTRUCTION MANAGER approval.

9.2.7. All tack welds shall be made by qualified welders. The required preheat temperature shall be attained prior to tack welding. Tack welds, which are to be incorporated into the final weld, shall be thoroughly cleaned, prepared at each end, and inspected for cracks. Any cracked tacks shall be removed before welding the joint.

9.3. Weld Repairs

9.3.1. For the repair of a weld, either the original WPS or one originally submitted as a designated repair WPS shall be used.

9.3.2. Repair plans that use welding for repair of welds or base metals, when allowed, shall be submitted to CONSTRUCTION MANAGER for review and approval, prior to use. A repair plan shall include the following:

The method of defining the type and the extent of the defect.

Methods used for removing the defect and testing conducted to ensure that the defect has been removed.

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Welding procedure employed and NDE procedure(s) used to inspect the completed repair.

9.3.3. All repaired welds shall as a minimum, be inspected using the original testing method. Additional test methods may also be required, if deemed necessary by the CONSTRUCTION MANAGER.

9.3.4. For Carbonate Service, new piping classes have been generated and identified on attached Form 167; PWHT is required at 650o.C for a minimum soak time of 2 hours for all sizes.

9.3.5 For Sulphuric Acid lines in the Alkylation Unit, it is a licensor requirement to prevent root protrusions. A GTAW root pass is mandatory for all piping in these systems to provide a flush root bead.

9.3.6 For the Flare System (Main, acid, & FCC/Coker), piping classes have been repeated and procured as non-sour grades. It is confirmed that sour service conditions apply during upset conditions, due to upset conditions hardness testing on these systems is required in accordance with Section 3.11 of this Specification. The same hardness testing applies to water draw-off lines from crude tanks that are in sour service.

10. Weld Metal Quality

10.1. All welding shall meet the requirements of the applicable Design Code and Specifications stated in Section 2.

10.2. Arc strikes outside the welding groove shall be removed by disc grinder, and minimum design wall thickness shall be maintained.

10.3. Weld(s) containing cracks and their cause shall be reported to the CONSTRUCTION MANAGER or his representative. If cracking is found during NDE, examination levels shall be increased at CONSTRUCTION MANAGER’s discretion, until the cause of the cracking has been identified, and steps taken to prevent its reoccurrence. Welds containing cracks may be repaired by welding, unless stated otherwise in writing by the CONSTRUCTION MANAGER or his representative.

10.4. Acceptance standards for welds shall be in accordance with the applicable Design Codes and Specifications.

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11. Non-Destructive Examination (NDE)

11.1. All NDE shall be carried out in accordance with the applicable Code and/or Specification. For Carbon steel (P-No.1) NDT can be performed before PWHT. The minimum NDE percentage level stated on Form 167A shall apply.

11.2. A document listing the relevant NDE procedures, methods and techniques shall be submitted to the CONSTRUCTION MANAGER for review and approval. Site/NDT agencies shall adhere strictly to such procedures approved by CONSTRUCTION MANAGER. Any subsequent revision on the approved procedure shall be submitted to the CONSTRUCTION MANAGER for further approval. The ultrasonic examination procedure shall be in compliance with section V, article 5 and shall be approved by CONSTRUCTION MANAGER. In case of stainless steel, detailed procedures shall be submitted for approval on a case to case basis. For applicability of UT, Form-167a shall be strictly followed.

11.3. Submittal of individual NDE procedures for review will be defined in the Request for Bids, Purchase Orders and/or Contract.

11.4. All welds shall be uniquely identified for NDE examination and records.

11.5. For each piping class, the percentage of welds to be examined (NDE%) as listed on the Form 167A, shall be taken as the percentage of each welders joints to be examined.

11.6. Where NDE level is less than 100%, the welds for NDE shall be selected to cover work of each welder or welding operator. This includes progressive examination in accordance with ASME B31.3 Section 341.3.4.

11.7. NDE levels specified shall include socket welds in piping systems which shall be liquid penetrant or magnetic particle examined.

11.8. The frequency of inspection for each piping class is specified in the attached 167A form. In addition 100% Radiography shall be applied to the following:

1. All butt welds to valves.

2. All butt welds to vessel nozzles.

11.9. All tack welds and temporary attachments outside weld joint areas shall be cut off (not hammered), the area dressed with a grinder and examined by MPI/DPI.

11.10. All NDE for acceptance shall be carried out after any PWHT, when applied. Except for Carbon steel (P-No. 1) where NDT can be performed before PWHT.

11.11. All NDE shall be performed by personnel qualified to a recognised National or International Standard (e.g. PCN, ASNT Level II as a minimum, etc.). The CONSTRUCTION MANAGER or his representative shall review certification of NDE personnel at the SELLER/CONTRACTOR works site. Certification shall NOT be submitted to the CONSTRUCTION MANAGERS head office.

11.12. The results from all NDE shall be interpreted by personnel qualified by ASNT level II or equivalent.

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11.13. Magnetic particle inspection shall be carried out using electromagnetic yokes. D.C. prods are not permitted. The strength of the electromagnet (lifting power) shall be checked each shift.

11.14. Production Hardness Testing

Hardness testing of completed welds shall be carried out using portable hardness testing machines (Telebrineller or approved equivalent) on the following services:

Carbon Steel in Sour Service - one reading on the centre of every butt weld with Telebrineller or approved equivalent, max. hardness permitted 200 HB. Any butt welds exceeding hardness level shall be reported, and either removed and re-welded or subjected to a PWHT at 1100F min and re-tested.

Low Alloy Steel (1¼, 2¼, 5 and 9 Cr) - after PWHT one reading on each weld and one adjacent to each weld:

Max. Hardness Permitted - 225 HB (1¼ and 2¼ Cr)

- 241 HB (5 and 9 Cr)

Hardness testing frequency is reduced to 10% for furnace heat treated welds.

11.15. Summary of levels of NDE required.

INSPECTION LEVELS IN %

MATERIAL SERVICE VISUAL MPI/DPI

(Note 4)

RT/UT (Note 5 &

8)

HARDNESS

Carbon Steel Utility ProcessProcess (sour)

100100100

555

555

NA (Note 7)NA

100 (Note 1)

11/4 Cr ½ Mo ProcessSteam

100100

1010

10010

100 (Note 2)(Note 3 & 6)

21/4 Cr 1 Mo 5 Cr ½ Mo 9 Cr 1 Mo

ProcessProcessProcess

100100100

101020

100100100

100 (Note 2)100 (Note 2)100 (Note 2)

316, 316L Process & Utilities

100 5 5 NA

304, 304H, 321, 347

Process & Utilities

100 10 100 NA

N06625N08800N08020N08825

Process & Utilities

100 10 100 NA

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Notes:

1. Hardness tests are only required on butt welds.

2. Hardness tests are only required on 10% of butt welds if piping is PWHT in a furnace.

1. Hardness tests are only required on butt welds subject to PWHT.

4. For carbon steel and stainless steel MPI/DPI to be performed on socket welds and branch welds. Anywhere if the requirement is found to be not covered by form 167A, therein clause 11.15 of this specification to be followed.

Up to 1 ½” NB MT/PT to be performed on all type of weld joints except as specifically indicated in form 167A. Where specifically RT is required as per form 167A a fine grain film such as Agfa D2/D4 or Kodak MX 100/125 together with thicker lead screens shall be used with proper processing technique to get required sensitivity, contrast and density. All the above parameters are to be fixed by establishing radiography procedure by the contractor.

For low alloy steel MT/PT shall also be performed on butt welds and branch welds at level specified in the Form 167.

Only approved aerosol can applications shall be used for MT or PT testing.

5. RT/UT to be performed on butt welds only.

6. Piping in accordance with ASME B31.1/IBR shall have levels of NDE as specified on in Form 167, and Appendix 3 of this Specification.

7. Deleted

8. Ultrasonic examination of welds shall be performed strictly in accordance with ASME Section V, Acceptance criteria shall be as per ASME Section VIII Div-1 Appendix 12

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APPENDICES

1. Additional Requirements for Low Alloy Steel Piping2. Additional Requirements for Stainless Steel and Nickel Base Alloy Piping

3. THE INDIAN BOILER REGULATIONS, Latest Revision

4. NDT Specification for typical cases not directly covered by existing Specification or Codes.

5. FORM 167

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APPENDIX 1

Additional Requirements for Low Alloy Steel Piping

This appendix is supplementary to the requirements outlined in the main body of this document and applies to all low alloy steels (ASME P-Numbers P4, P5A and 5B).

Welding Process

Flux Shielded Welding (SMAW, SAW, FCAW) shall be carried out utilising basic low hydrogen consumables treated (baked ) to produce a maximum weld metal hydrogen content of 5 ml/100g

The root pass of butt welds shall be performed by GTAW for all low alloy steel piping.

Welding Consumables

Unless otherwise stated the following Specifications shall be of the latest issue and are considered a part of this appendix:

AWS A-5.5, ASME SFA-5.5 Specification for Low Alloy Steel Covered Arc Welding Electrodes

AWS A-5.23, ASME SFA-5.23 Specification for Low Alloy Steel Electrodes and Fluxes for Submerged Arc Welding

AWS 5.4, ASME SFA 5.4 Stainless Steel Electrodes for Shielded Metal Arc Welding

AWS 5.9, ASME SFA 5.9 Bare Stainless Steel Welding Electrodes & Rods

AWS 5.22, ASME SFA 5.22 Stainless Steel Electrodes for Flux Cored Arc Welding and Stainless Steel Flux Cored Rods for Gas Tungsten Arc Welding

AWS 5.28, ASME SFA 5.28 Low-Alloy Steel Electrodes and Rods for Gas Shielded Arc Welding

AWS 5.29, ASME SFA 5.29 Low Alloy Electrodes for Flux Cored Arc Welding

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SMAW electrodes shall be in accordance with the following:


1¼Cr-½Mo AWS A-5.5, ASME SFA-5.5 E80XX - B2

2¼Cr-1Mo AWS A-5.5, ASME SFA-5.5 E90XX - B3

5Cr-½Mo AWS A-5.5, ASME SFA-5.5 E80XX – B6

9Cr-1Mo AWS A-5.5, ASME SFA-5.5 E80XX – B8

* - Electrode coatings designated XX above may be 15, 16 or 18.^ - For large catalyst carrying piping, 5Cr-½Mo materials electrode coatings may be 15 or 16.

Bare electrodes for Gas Shielded Arc Welding (GMAW, GTAW) shall be in accordance with the following:


1¼Cr-½Mo AWS A-5.28, ASME SFA-5.23 ER80S-B2

2¼Cr-1Mo AWS A-5.28, ASME SFA-5.28 ER90S-B3

5Cr-½Mo AWS A-5.28, ASME SFA-5.28 ER80S-B6

9Cr-1Mo AWS A-5.28, ASME SFA-5.28 ER80S-B8

SAW welding consumables for Low Alloys shall be in accordance with the following:


1¼Cr-½Mo AWS A-5.23, ASME SFA-5.23 EB2

2¼Cr-1Mo AWS A-5.23, ASME SFA-5.23 EB3

5Cr-½Mo AWS A-5.23, ASME SFA-5.23 EB6

9Cr-1Mo AWS A-5.23, ASME SFA-5.23 EB8

The product analysis (weight %) content of Sn and P for welding consumables for 1¼Cr-½Mo pressure containing components :

Sn 0.015%

P 0.012%

The maximum room temperature tensile strength of all pressure containing welds shall be 100,000 psi (7030Kg/cm2).

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Impact Testing

Qualification of weld procedures for all 2¼Cr-1Mo, and 1¼Cr-½Mo pressure containing welds shall include Charpy V-Notch impact testing at -18ºC. Impact tests shall be conducted in accordance with the test requirements ASME VIII Div. 1.

Dressing of Welds

In hydrocarbon service, all 1¼Cr-½Mo and 2¼Cr-1Mo fillet welds attached to pressure containing components shall be ground to a smooth, concave contour (hydrocarbon piping only)

Preheat and Post Weld Heat Treatment

Preheat levels as per ASME B31.3 shall be applied when flame cutting all low alloy steels.

Upon completion or interruption of low alloy steel shop welds and field run pipe to pipe welds, the welds and adjacent base material shall be uniformly heated to 300oC (max.) wrapped with ceramic fibre insulation blankets before being allowed to cool below the minimum preheat temperature.

For field ‘tie-in’ welds preheating shall be carried out using electrical resistance pads or coils controlled by thermo-couples or approved temperature indicating crayons (e.g. Tempil Sticks). Welding should be completed in one operation. If this is not practical, the weld shall be at least completed to a minimum of one third of the pipe wall thickness.

Upon completion of field ‘tie-in’ welds, the joints shall be uniformly heated (Post Heat) to 300oC before cooling under wraps.

For any interruption in welding for P No 5B material, where design code ASME B31.1 applies, all joints, including shop and field, shall be held at or above the maximum preheat temperature (300 maximum) prior to completion of welding.

All 1 1/4 Cr - 1/2 Mo and 2 ¼ Cr- 1Mo piping shall be post weld heat treated in accordance with ASME B31.3 (see Form 167A). For hydrocarbon and steam piping of all thickness shall be PWHT . 5Cr and 9Cr piping shall be PWHT in accordance with the Code.

For 9Cr-1Mo-V material the holding temperature shall be in accordance with approved WPS.

Non Destructive Examination

All 1¼Cr-½Mo, 2¼Cr-1Mo, 5Cr-½Mo & 9Cr-1Mo hydrocarbon piping butt welds, whether shop or field fabricated are to be radiographed 100% (see Form 167A).

Hardness Testing

Production and WPQR hardness testing shall be carried out after PWHT, one reading on each weld and one adjacent to each weld. The hardness testing frequency is reduced to 10% for furnace heat treated welds. The hardness requirements are given in section 11.14 of this specification.

2¼Cr-1Mo Testing Requirements (UOP Process Units only)

If 2¼Cr-1Mo piping classes are used in UOP process units, the following UOP materials testing requirements shall apply:

25194-3PS-GAW-004 Rev. 3 Page 19 of 31


Welding materials (consumables) for 2¼Cr-1Mo shall also be in accordance with the following: Mn and Si levels shall be maintained at the lowest possible levels consistent with good

weldability.

Each batch or heat of welding consumables and covered electrodes, including the wire flux combinations used in fabrication shall be analysed for P, Sn, Sb and As.

Analysis shall be performed on deposited weld metal. The Temper Embrittlement Factor, X shall be a maximum of 15 part per million.

X = (10P+4Sn+5Sb+As)/100Element concentrations are in parts per million

Impact energy vs. temperature (transition) curves shall be developed from weldments representing each batch or heat of welding consumables, covered electrodes, and wire flux combinations for each welding process used in production welds.

A minimum of six sets of three impact tests (of material subjected to the same heat treatment as the completed item) shall be conducted for each curve. Sample locations shall be as specified by the ASME code.The six sets of impact tests shall be performed at different temperatures. The generated transition curve shall clearly define the transition zone and upper shelf. The maximum test temperature shall correspond to the upper shelf energy level.

Step Cooling Tests shall be performed on weldments representing each batch or heat of welding consumables, covered electrode and wire flux combinations for each welding process used in production welds.

Step cooling shall be in accordance with the following temperatures, holding times and cooling rates to the next lowest temperature:

Temperature, C

593538524496468315

Holding Time, Hour

1152460100

Cooling rate to the next temperature, C

per hour5.65.65.62.828

air cool

Impact tests of each Step Cool Test sample shall be performed and transition curves developed following the procedure in the previous section.

Acceptance criteria for the material shall be in accordance with following:

CvTr40 + 2.5 SCvTr40SC 10C

Where:

25194-3PS-GAW-004 Rev. 3 Page 20 of 31


CvTr40 = Charpy V-notch 40 ft-lb impact energy transition temperature of completely heat treated specimens, before step cooling.

SCvTr40SC = The shift in Charpy V-notch 40 ft-lb impact energy transition temperature, after step cooling.

APPENDIX 2 Additional Requirements for Stainless Steel and Nickel BasedAlloy Piping

This appendix is supplementary to the requirements outlined in the main body of this document.

25194-3PS-GAW-004 Rev. 3 Page 21 of 31


Unless otherwise stated the following Specifications shall be of the latest issue and are considered a part of this appendix:

AWS A-5.4, ASME SFA-5.4 Stainless Steel Electrodes for Shielded Metal Arc Welding

AWS A-5.9, ASME SFA-5.9 Bare Stainless Steel Welding Electrodes & Rods

AWS A-5.11, ASME SFA-5.11 Specification for Nickel and Nickel Alloy Welding Electrodes for Shielded Metal Arc Welding

AWS A-5.14, ASME SFA-5.14 Specification for Nickel and Nickel Alloy Bare Welding Electrodes and Rods

AWS A-5.22, ASME SFA-5.22 Stainless Steel Electrodes for Flux Cored Arc Welding and Stainless Steel Flux Cored Rods for Gas Tungsten Arc Welding

SMAW electrodes shall be in accordance with the following:

Material Specification Classification*

Type 304 AWS A-5.4, ASME SFA-5.4 E308XX

Type 304H AWS A-5.4, ASME SFA-5.4 E308HXX

Type 304L AWS A-5.4, ASME SFA-5.4 E308LXX

Type 316 AWS A-5.4, ASME SFA-5.4 E316XX

Type 316H AWS A-5.4, ASME SFA-5.4 E316HXX

Type 316L AWS A-5.4, ASME SFA-5.4 E316LXX

Type 321 or 321H AWS A-5.4, ASME SFA-5.4 E347XX

Type 347 or 347H AWS A-5.4, ASME SFA-5.4 E347XX

N06625 AWS A-5.11, ASME SFA-5.11 ENiCrMo-3




- Electrode coatings designated XX above may be 15, 16 or 18.

Bare electrodes for inert Gas and SAW shall be in accordance with the following:


Type 304 AWS A-5.9, ASME SFA-5.9 ER308

25194-3PS-GAW-004 Rev. 3 Page 22 of 31


Type 304H AWS A-5.9, ASME SFA-5.9 ER308H

Type 304L AWS A-5.9, ASME SFA-5.9 ER308L

Type 316 AWS A-5.9, ASME SFA-5.9 ER316

Type 316H AWS A-5.9, ASME SFA-5.9 ER316H

Type 316L AWS A-5.9, ASME SFA-5.9 ER316L

Type 321 or 321H AWS A-5.9, ASME SFA-5.9 ER321 or ER347

Type 347 or 347H AWS A-5.9, ASME SFA-5.9 ER347

800H AWS A-5.14, ASME SFA-5.14 ERNiCr-3

N06625 AWS A-5.14, ASME SFA-5.14 ERNiCrMo-3




For stainless steels and nickel base alloys, flame cutting is not allowed. Bevels shall be prepared by plasma cutting or machining.

Only stainless steel brushes shall be used on stainless steels and nickel base alloys.

Prior to welding of stainless steels and nickel base alloys, the weld joint shall be cleaned. The oxide layer shall be removed by grinding to a bright surface followed by cleaning with acetone or a similar solvent.

The root pass of butt welds for stainless steels and nickel base alloys shall be performed using the GTAW process.

Bore purging with inert Argon or Nitrogen gas is required for stainless steel welds.

For ambient temperature service, austenitic stainless steel welding materials for pressure boundary and load bearing welds shall contain a minimum delta ferrite content of five percent (WRC Ferrite No. 5), based upon chemical analysis and the WRC Delta Ferrite Diagram (See Figure 1).

The ferrite content of stainless steel welding materials for temperature service above 472C shall not exceed nine percent (WRC Ferrite No. 10).

For cryogenic service below minus 70C, austenitic stainless steel welding consumables shall be selected to produce weld deposits with an optimum ferrite content and chemical composition to balance the requirements for hot cracking resistance and low temperature toughness. Each batch of welding consumables shall be tested and certified.

Stainless steel weld procedure qualification tests for cryogenic service shall include impact tests on weld metal as per ASME B31.3 Table 323.2.2.

25194-3PS-GAW-004 Rev. 3 Page 23 of 31


Shielding gas for GTAW and GMAW of nickel base alloys shall be commercially pure argon or a mixture of argon and 5-10% hydrogen.

Maximum interpass temperature for austenitic stainless steels shall not exceed 175C. This includes dissimilar welds between austenitic stainless steel and carbon steel.

25194-3PS-GAW-004 Rev. 3 Page 24 of 31


APPENDIX 3

THE INDIAN BOILER REGULATIONS, Latest Revision

1.0 TESTS ON COMPLETED WELDS ON PIPELINES

1.1 Classification

For the purpose of tests, pipelines shall be divided into two classes:

Class I - Pipelines for service conditions in which any one of the following limits is exceeded:-

Design temperature 281o C (425oF)

Design Pressure 17.6 kg/cm2 (250 lbs/sq in)

Feed Water 24.6 kg/cm2 (350 lbs/sq in)

Class II - Pipelines for service conditions in which none of the foregoing limits is exceeded.

1.2. Identification of Welds

The Welders’ identification mark shall be stamped without indentation, or stencilled adjacent to each completed weld.

1.3. Tests for Class I pipelines

(i) Where the completed pipelines are not subjected to hydraulic test:

Where the completed pipelines are not tested by the application of hydraulic pressure,the welds shall be subjected to the following inspection procedure:-

Piping over 102 mm. (4 in.) bore - All butt-welds shall be subjected to non-destructiveexamination by radiographic or other approved methods. The entire circumference of the first five welds made by each welder shall be non-destructively examined. If these are found to be satisfactory and the Inspecting Officer or Inspector is in other respects satisfied with the welding technique, methods of control and supervision employed, relaxation in the extent of non-destructive examination may be considered, but this relaxation shall in no case permit the non-destructive examination of less than one-third of the circumference of each of the remaining welds made by the welder concerned.

Piping 102 mm (4 in.) bore and under, but not less than 38 mm (1 1/2 in.) bore - Five per cent of the butt-welds made by each welder with a minimum of two welds per welder, selected at random shall be subjected to non-destructive examination by either radiographer or other approved methods or may be cut out for visual examination and bend tests.

Piping less than 38 mm (1 1/2 in.) bore - Special tests are not normally required but two per cent of the welds by each welder on a pipeline may be cut out from the pipeline for visual examination and bend tests.

(ii) Where the completed pipelines are subjected to hydraulic test :

Where the completed pipelines are tested by the application of hydraulic pressure, the weldsshall be subjected to the following inspection procedure:-

Piping over 102 mm (4 in.) bore - Ten per cent of the welds made by each Welder on a pipeline with a minimum of two welds per welder, selected at random, shall be subjected to non-destructive examination by radiographic or other approved methods.

25194-3PS-GAW-004 Rev. 3 Page 25 of 31


Piping 102 mm. (4 in.) bore and under, but not less than 38 mm. (1 1/2 in.) bore – Two per cent of the welds made by each welder on a pipeline with a minimum of one weld per welder, selected at random, shall be subjected to non-destructive examination by radiographic or other approved methods or may be cut out for visual examination and bend tests.

Piping less than 38 mm (1 1/2 in.) bore - Special tests are not normally required, but two per cent of the welds by each welder on a pipeline may be cut out from the pipeline for visual examination and bend tests.

1.4. Tests for Class II pipelines

(i) All pipelines under this classification shall be subjected to hydraulic test on completionof erection.

(ii) On completion of the first ten production welds made by each welder, one of the welds shall be cut out for test purposes or alternatively, the welder shall prepare a test specimen made up of two similar lengths of piping welded in a position as closely representative of a selected production weld as is practicable. The test specimen shall be subjected to visual examination and bend tests.

(iii) Two per cent of the remainder of the welds made by each welder shall be selected at random and cut out for test purposes, or, alternatively, the welders shall prepare a test specimen made up of two similar lengths of piping welded in a position as closely representative of a selected production weld as is practicable. The test specimen shall be subjected to visual examination and bend tests.

1.5. Re-tests - If any test specimen is unsatisfactory, two further weld specimen for re-test shall be selected from the production welds and subjected to tests. In the event of failure of any of the re-test specimens, the production welds carried out by this welder subsequent to the previous test shall be subject of special consideration.)

25194-3PS-GAW-004 Rev. 3 Page 26 of 31


Appendix 4 - NDT Specification for typical cases not directly covered by existing Specification or Codes

S No CASE DESCRIPTION

NDT REQUIREMENT REFERENCE CODE

REMARKS

CATEGORY D PROCESS LINES/ OTHER THAN CATEGORY D/ HIGH PRESSURE & TEMPERATURE LINES

1. Branch opening on or close to Weld seams not meeting clause 5.6.3 of 3PS-PL_006.

DP test on either side of the branch connection along the weld for 150 mm (min).

Radiograph on either side of the branch connection along the weld seam for 150 mm (min).

ASME B31.3-328.5.4 - h/ASME SEC VIII DIV I – UW14.

Interpret as per the code of fabrication and repair accordingly.

2. RF-pad masking welded seam.

DP test the portion of the weld which is getting masked and 40 mm(min) weld length on either side & pad test at 3.5 Kg/sqcm for 10 minutes and drop in pressure is an indication of leak. This requirement is applicable only to fire water services of Non category D.

Radiograph the portion of the weld which is getting masked and 40 mm(min) weld length on either side & pad test at 3.5 Kg/sqcm for 10 minutes and drop in pressure is an indication of leak.

ASME B31.3-328.5.4 -g&h.


3. Saddle pads for supports.

DP test the portion of the weld which is getting affected during welding of the pad and

Radiograph the portion of the weld which is getting masked and 40mm(min) weld length on either side.

ASME B31.3-328.5.4 –h


25194-3PS-GAW-004 Rev. 3 Page 27 of 31


40mm(min) weld length on either side.

4. Seam staggering not meeting separation of 90 deg or 10 times thickness whichever is less.

Ensure the staggered seam by DP and subsequent by Hydrotest.

Radiograph 150mm (min) length of the staggered seams including the Circular seam.

25194-3PS-PL-006

ASME SEC VIII DIV I UW-9(d).


5. Seam staggering (tapping close to CS/LS or pipe support close by CS/LS) not meeting 40 mm or twice of thick of pressure part

Ensure the staggered seam by DP and subsequent by Hydrotest.

Ensure the staggered seam by RT only in the area, which does not meet the requirement of 40mm or twice the thickness of pressure part, but in no case less than 75mm and subsequent by Hydrotest.

25194-3PS-PL-006


25194-3PS-GAW-004 Rev. 3 Page 28 of 31


6. Wherever minimum distance (edge to edge) as specified in PL-006 between circumferential butt/fillet welds can not be met, the following additional NDT shall be followed. Also the minimum distances between fillet/socket welds shall be specified.

For Butt welds 100% PT/MT

For Fillet welds 100% PT/MT

For Butt weld 100% RT/UT

For Fillet welds 100% MT/PT

25914-3PS-PL-006


7. PWHT is not required for fillet welds at slip-

1/ PWHT not required for P-No. 1 materials

1/ PWHT not required for P-No. 1 materials when weld throat thickness is

25194-3PS-GAW-004 Rev. 3 Page 29 of 31


on flanges and sock welds in piping 2 inch nominal bore and below and for attachment of External non-pressure parts such as lugs or other Pipe Supporting elements in all piping sizes under the following conditions:.

when weld throat thickness is 16mm (5/8 in.) or less, regardless of base metal thickness.

2/ PWHT not for P-No. 3, 4, 5, or 10A materials when weld throat thickness is 13mm (1/2 in.) or less, regardless of base metal thickness, provided that not less than the recommended preheat is applied, and the specified minimum tensile strength of the base material is less than 490 MPa (71 ksi).

16mm (5/8 in.) or less, regardless of base metal thickness.

2/ PWHT not for P-No. 3, 4, 5, or 10A materials when weld throat thickness is 13mm (1/2 in.) or less, regardless of base metal thickness, provided that not less than the recommended preheat is applied, and the specified minimum tensile strength of the base material is less than 490 MPa (71 ksi)

ASME B31.3 Section 331.1.3 (b)

Interpret as per the code of fabrication

25194-3PS-GAW-004 Rev. 3 Page 30 of 31


Figure 1

DELTA FERRITE DIAGRAM

30282624222018161412108642

30

28

26

24

22

20

18

16

14

12

10

8

6

4

2

00 32 34 36 38 40

No Fer

rite5%

Fer

rite

10% Ferr

ite

20% Ferrite

80% Ferrite

100% Ferrite

40% FerriteAustenite

Martensite

A + M

M + FA + M + F

A + F

FerriteF+M

Chromium Equivalent = %Cr + % Mo + 1.5 x %Si + 0.5 x %Nb

Nickel E

quivalent = %N

i + 30 x %C

+ 0.5 x %M

n

25194-3PS-GAW-004 Rev. 3 Page 31 of 31