caltexwelding nysb910-1 ras061808

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1047 ID: 7002D---0001-1 MFK page 1REV: 01-08-97 PAGE: 1 TIME: 14:37 OP: GZ BASE S2

Revised 3/95 NYS-B9.101 of 38

CALTEX MATERIAL AND EQUIPMENT SPECIFICATION NYS-B9.10

GENERAL WELDING REQUIREMENTS

A SCOPE

This Specification covers the Purchaser’sminimum requirements for the welding of refineryequipment. It shall be used as a guide for welding, including welding inspection of all commonlyused materials during the fabrication of vendor-supplied equipment, site construction, andsubsequent repair or modification.

It addresses primarily the welding of pressure-containing equipment (including piping). It does notattempt to cover all possible combinations of different materials, thicknesses, etc.

Specific detailed information shall be developed where this Specification is considered inapplicable.A list of references and a bibliography are included.

Note that, in this Specification, all references to the term Contractor indicate the fabricationcontractor.

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CONTENTS

A SCOPE 1

DEFINITION OF TERMS 4

1.0 CODE COMPLIANCE 5

2.0 RESPONSIBILITIES 2.1 Contractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52.2 Purchaser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3.0 GENERAL REQUIREMENTS 3.1 Quality Assurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63.2 Weld Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

4.0 WELDING PROCESSES 6

5.0 WELDING CONSUMABLES 7

6.0 WELDING QUALIFICATION 6.1 Welding Procedure Specification (WPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96.2 Procedure Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96.3 Welder Performance Qualification (WPQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

7.0 WELD JOINT DESIGN 11

8.0 PREPARATION FOR WELDING 11

9.0 PREHEATING AND INTERPASS TEMPERATURES 12

10.0 WELDING PRACTICES 13

11.0 PROTECTIVE LININGS 14

12.0 WELD REPAIRS 14

13.0 POSTWELD HEAT TREATMENT (PWHT) 13.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1413.2 Common Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1513.3 Relaxation and Waivers of PWHT Requirements . . . . . . . . . . . . . . . . . . . . . . . . . .15

14.0 SOCKET- AND SEALWELDING OF PIPING 14.1 Socketwelding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1614.2 Sealwelding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1614.3 Valves and Unions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1714.4 Annealing by Torch Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1714.5 Bridgewelding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

15.0 QUALITY CONTROL 15.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1815.2 Non-destructive Examination (NDE) - General Requirements . . . . . . . . . . . . . . . . . 18

15.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1815.2.2 Hardness Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1915.2.3 Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1915.2.4 Ultrasonic Testing (UT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2015.2.5 Liquid Penetrant and Magnetic Particle Testing (LP and MP) . . . . . . . . . . . . . . 2015.2.6 Positive Materials Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2015.2.7 Ferrite Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

15.3 Hydrostatic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

16.0 SPECIFIC ADDITIONAL REQUIREMENTS FOR PRESSURE VESSELS ANDHEAT EXCHANGERS

16.1 General Non Destructive Examination (NDE) Requirements . . . . . . . . . . . . . . . . . 2116.2 Heavy Wall Carbon Steel Pressure Vessels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

16.2.1 Non-destructive Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2216.2.2 Other Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

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16.3 Carbon Steel Pressure Vessels and Heat Exchangers for Low TemperatureOperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

16.3.1 Welding General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2216.3.2 Welding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2216.3.3 Welding Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2316.3.4 Preheating for Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2316.3.5 Post Weld Heat Treatment (PWHT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2316.3.6 Impact Testing of Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2316.3.7 Radiograph of Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2316.3.8 Ultrasonic Inspection of Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2316.3.9 Magnetic Particle Inspection of Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2416.3.10 Hardness Testing of Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

16.4 Carbon Steel Pressure Vessels and Heat Exchangers in Sour Services . . . . . . . . . . . 2416.4.1 Post Weld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2416.4.2 Magnetic Particle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2416.4.3 Ultrasonic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

16.5 Clad Carbon and Low Alloy Steel Pressure Vessels and Heat Exchangers . . . . . . . . 2516.5.1 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

17.0 SPECIFIC REQUIREMENTS FOR FABRICATED PIPING AND TUBING 17.1 Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2517.2 Weld Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2617.3 Extent and Type of Non-destructive Examination . . . . . . . . . . . . . . . . . . . . . . . . . 2617.4 Test Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

17.4.1 Hardness Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2717.4.2 Positive Material Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2717.4.3 Limitations to Imperfections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

17.5 Special Requirements for Offsite LPG and Propylene Piping . . . . . . . . . . . . . . . . . 2817.5.1 Welding Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2817.5.2 Welding Procedure Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2817.5.3 Weld Procedure Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2817.5.4 Post Weld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2817.5.5 NDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

PURCHASER’S APPROVAL CHECKLIST 29

LIST OF REFERENCES 29

BIBLIOGRAPHY 30

APPENDIX I SELECTION OF WELDING CONSUMABLES 31

APPENDIX II SUMMARY OF PREHEAT AND PWHT REQUIREMENTS 34

APPENDIX III MINIMUM SOCKET AND SEALWELD DIMENSIONS 36

APPENDIX IV WELDED JOINT CATEGORY 37

LIST OF FIGURESFIGURE 1 Illustration of Welded Joint Locations typical of Categories A, B, C and D . 37

LIST OF TABLESTable 1 Upper Hardness Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Table 2 Minimum NDE Requirements Fabricated Piping and Tubing . . . . . . . . . . . 27Table 4 Selection of SMAW Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Table 5 Selection of GTAW Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Table 6 Summary of Owner’s Preheat and PWHT Requirements . . . . . . . . . . . . . . 34

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DEFINITION OF TERMS

Welding Procedure Specification (WPS)is an instruction sheet for performing the welding. It provides directions for welding to ensure construction Codecompliance and that other requirements are met. It details the required variables for a specific application to assurerepeatability by properly trained welders and welding operators. The WPS serves as a guideline for the welder to followin making procedure qualification test pieces. Often called “welding procedure”.

Welding Qualificationis the performance of tests and preparation of documents to show that satisfactory welded or brazed joints can be made.Unless otherwise agreed by the Purchaser, the rules given in ‘ASME Boiler and Pressure Vessel Code - Section IX’shall be used for welding qualification.

Procedure Qualification Record (PQR)is a document providing details of the actual welding variables used to produce an acceptable test weld, and the results ofthe tests conducted on the weld, for the purpose of qualifying a specific WPS.

Welder Performance Qualification (WPQ)refers to the demonstration of a welder or welding operator’s ability to produce satisfactory welds, meeting a prescribedstandard, and the record of the results; sometimes called “welder qualification”.

Qualified WelderA welder or welding operator who is qualified and approved to weld in accordance with this Specification.

Weldmentnormally means an assembly which contains one or more welded joints. Includes the zone in the base material affectedby welding heat input, ie the heat affected zone (HAZ).

Quality Systemis a documented management system for quality assurance usually covered by a Contractor’s or Vendor’s QualityManual. A Quality System is also expected to include a Quality Plan, providing detailed quality control procedures.Quality Plans require the Purchaser’sapproval before fabrication commences.

Purchaseris that party designated by the facility Owner, responsible for placing orders or contracts.

Contractor/Vendoris that party contracted to supply goods or services, in compliance with a purchase order or contract. This may involveeither shop fabrication or field construction. For the purposes of this Specification, the two terms shall be consideredinterchangeable.

Project Specificationsare the Owner’s project-specific instructions which supplement, and take precedence over, the Owner’s GeneralEngineering (GPS-series) Specifications or Material and Equipment Specification (NYS-series).

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Corrected 3/97 NYS-B9.105 of 38

1.0 CODE COMPLIANCE

(i) Weldments shall, as a minimum, comply with the requirements of the appropriate equipmentcode of construction, as modified by this Specification.

(ii) Structures not attached to pressure parts may be welded in accordance with ‘AWS D1.1Structural Welding Code-Steel’.

(iii) Unless the Purchaserotherwise agrees, only welders qualified in accordance with SectionIXof the ASME Code shall be assigned to welding in accordance with this Specification. This includestackwelding of parts prior to full welding, and also the welding of any temporary attachments to thecomponents.

(iv) Deviations from this Specification may be considered by the Purchaser, but only where theContractor can demonstrate that they conform with good welding practice. Any deviation shallhave the Purchaser’sprior approval.

2.0 RESPONSIBILITIES

2.1 Contractor

Unless otherwise specified in Project Specificationsor Purchase Order, the Contractor’sresponsibilities shall be as follows:

(a) Develop Welding Procedure Specifications (WPS) and conduct the necessary qualificationtests as specified in the applicable construction code and contractual documents, providing awritten Procedure Qualification Record (PQR). The Purchaserwill review, evaluate andapprove the results of the qualification tests.

(b) Qualify welders and prepare Weld Procedure Qualification records (WPQs). Certify thequalification records with an affixed signature of a responsible person.

(c) Properly execute the work, providing qualified supervision to ensure that only appropriate

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welding procedures and qualified welders are used, and that all requirements of thisSpecification and the Purchaser Order are met in full.

(d) Obtain the Purchaser’sapproval for welding material selections, etc, where such approvalrequirements are specified in this Specification and the relevant Purchaser Order.

(e) Take the necessary precautions to protect the work and welder from deleterious weather
conditions while the welding is in progress. Welding shall not be performed when the work isexposed to:
— high winds, as defined by the Purchaser— ambient temperatures less than 07C (327F)— high humidity, as defined by the Purchaser— rain, snow or ice.

.2 Purchaser

(i) Unless otherwise specified, the Purchasershall exercise the following responsibilities:

(a) Approve the brand of welding consumables to be used.
(b) Approve all non-destructive testing procedures, and specify the locations for radiography and
other non-destructive testing.(c) Approve and monitor the procedures used for both pre- and postweld heat treatments.

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Corrected 3/97NYS-B9.106 of 38

(d) Inspect and approve, or reject, all materials and work in progress, and the finished work beforeit is released for service.

(ii) Inspection by the Purchaserdoes not relieve the Contractor or the Vendor of theirresponsibilities or place any onus upon the Purchaserfor Quality Control and/or compliance withthe Purchaser Order.

3.0 GENERAL REQUIREMENTS

3.1 Quality Assurance

(i) The Contractor shall have in place and shall adhere to a documented Quality System,comprising a Quality Manual and Quality Plan containing the detailed quality control proceduresnecessary to fulfil the requirements for weldment quality stipulated in this Specification.

The Quality Manual shall include procedures covering requirements for:

(a) Materials documentation.(b) Materials traceability.(c) Weld consumable traceability, conditioning, issue control.(d) Weld procedure specification and qualification, and welder performance qualification.(e) Rectification of defective work, and the recording thereof.(f) Preheat/Post Weld Heat Treatment (PWHT) Controls/records.(g) Non-Destructive Examination records.

(ii) For each contract, or Purchase Order placement, the Contractor shall prepare and use aQuality Plan, approved by the Purchaser. This Plan shall identify and list sequentially each qualitycontrol activity to be performed, and identify who will be involved in witnessing, observing orreviewing the activity.

3.2 Weld Properties

(i) Weldments shall have properties that match the mechanical properties of the base materials.

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(ii) The deposited weld metal shall have resistance to deterioration, (eg, corrosion, embrittlement,hydrogen damage, creep, etc,) at least equal to that of the base material under the proposed serviceconditions.

(iii) The resistance of the base material to deterioration in service shall not be impaired bywelding.

(iv) When material toughness is a design criterion, weld metal and heat-affected zone impactproperties shall meet the minimum requirements of the base material.

(v) The hardness of all completed ferritic steel weldments on pressure parts of equipment shall berestricted to the upper limits given in Table1 in §15.2.2.

.0 WELDING PROCESSES

(i) The following welding processes are acceptable:

— Submerged arc welding (SAW). Note that manual submerged arc welding is not permitted on
pressure-containing parts.
— Shielded metal arc welding (SMAW)
— Gas tungsten arc welding (GTAW) — Gas metal arc welding (GMAW) with or without flux-cored wire.

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The use of other welding process requires the Purchaser’sapproval.

(ii) The use of gas welding is generally not permitted. However, subject to the Purchaser’sapproval, it may be used for special work, eg, boiler tube welding, small bore pipework.

(iii) GTAW and GMAW processes are only permitted where suitable shelter, approved by thePurchaser, has been provided.

(iv) The root pass of single sided welds for ‘alloy’ steels, including stainless steel and nickelalloys, shall be made by the GTAW process with inert gas backing, unless it has been shownconclusively that acceptable root pass welds will result from the use of another process.

(v) GTAW welding may be used for the root pass of carbon steels without the use of inert gasbacking, provided that it can be shown to produce satisfactory welds.

(vi) GMAW procedures utilising the ‘short circuiting’ metal transfer mode shall be limited to:

— Groove welds in materials 10mm (3⁄8in) maximum thickness— Root passes (in groove welds of greater thickness)— Filletwelds may be made on material of any thickness, provided the size is limited to 10mm leg

length.

In addition, the following requirements shall be adhered to:

— Downhill weld progression shall be permitted only on root passes.— The ‘short circuiting’ metal transfer mode shall not be used for pressure-containing parts in

furnaces.— Open-root welds shall be back chipped, ground and rewelded.— 100% Ultrasonic Examination (UT) shall be conducted on all pressure-containing welds which

utilise the ‘short circuiting’ mode of transfer. However, UT is not required for welds whichutilise this process solely for the root pass.

(vii) When welding aluminium bronze, the GTAW process with the electrode negative and heliumgas shielding is preferred. GMAW welding with the electrode positive, and argon or argon/heliumgas shielding may also be used.

(viii) For welding cast austenitic stainless steels, such as ‘ASTMA608’ HK40 and HP50, the

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GTAW process shall be used to avoid the resultant inferior creep strength of SMAW and GMAWdeposits.

.0 WELDING CONSUMABLES

(i) Welding rods, electrodes, filler metals and fluxes shall be fully specified in the WPS and PQRby the use of the relevant ASME classification, where this is applicable. However, the Ownerrequires that all welding consumables shall be of the low-hydrogen type, except that E60xx
electrodes may be used with the Purchaser’sapproval for welds in material less than 20mm thick.
(ii) Selection of welding consumables shall be based on the guidance and requirements of Tables
3, 4 and 5 in AppendixI. Preferred types of consumables to be used for various materials andapplications are stated, including those for welding dissimilar metals.
(iii) Prior to using non-ASME filler metals and fluxes (ie, materials without an ASMEclassification), the relevant physical and mechanical properties and chemical analyses of thesematerials shall be submitted to the Purchaserwith the request for using non-ASME materials.Advance written approval is required from the Purchaserfor the use of non-ASME materials.

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(iv) PQR documents for procedures specifying ‘G’ classification electrodes for which chemicalcomposition is not completely controlled by ‘ASME Section II PartC’ shall be separately producedfor each manufacturer, grade and heat of the electrode so classified.

(v) When it is proposed to use welding materials outside the limits specified by the weldingmaterial manufacturer, procedure qualification tests are required for each lot, batch or heat ofmaterial used in production welding.

(vi) All welding consumables shall be a recognised brand, approved by the Purchaser.

(vii) For alloy steel consumables, Material Test Certificates (as defined in ‘NYS-A1.50’) shall beprovided for each batch of consumables. Material Test Certificates for equipment fabricated withaustenitic stainless steel consumables shall include ferrite content.

(viii) Where impact testing is required for the equipment, consumable manufacturer’s Material TestCertificates showing weld metal impact properties are required by the Purchaser.

(ix) The Purchaser’sapproval is required when any alloy addition to the weld deposit is madevia the flux. Preferably, all alloy additions shall be from the core wire.

Note: Certain manufacturers of low alloy steel consumables use carbon steel corewires. This rarely results in problems with alloy deficiency. However, when usingaustenitic steel consumables with carbon steel core wires, ‘lean starts’ are a commonproblem.

(x) The Purchaser’sapproval is required for the use of weld metal which does not match thecomposition of the parent metal. Thus, the use of ferritic alloy steel consumables with carbon steelparent material shall be subject to the Purchaser’sapproval.

Note: The latter requirement is due to the possibility of deleterious effect, arisingfrom such use, (eg, electrodes containing small percentages of molybdenum mayresult in excessive hardness, deposits containing nickel may have reduced resist-ance to sulphide stress corrosion cracking (SSCC), vanadium may promote stressrelief cracking, while niobium may lower weld metal notch toughness).

(xi) Only ‘basic’ neutral (non-active) fluxes shall be used for submerged arc welding, unless
otherwise agreed with the Purchaser. Note that the use of active fluxes containing ferro-siliconand/or ferro-manganese, whereby silicon and/or manganese is transferred from the flux to the welddeposit, may lead to the development of unacceptably hard welds. Where active fluxes are approvedby the Purchaser, restrictions shall be imposed on production welding current parameters to ensure deposited weld metal is of acceptable hardness. See §15.2.2(ii) Table 1
(xii) Lime-coated austenitic stainless steel electrodes, ASME Usability Designation15, arepreferred for welding austenitic stainless steels, since there is a greater tendency to lose alloying
elements in the arc during welding with titanium coated (Designation16) electrodes.
(xiii) When welding dissimilar metals, the weld consumable shall match the composition of thehigher alloy of the two materials being joined.

For example: 11⁄4Cr 1⁄2Mo joined to 21⁄4Cr 1Mo shall be welded with a 21⁄4Cr 1Mo
consumable. The reason for this is that hardness testing after PWHT will be able todetermine if the correct heat treatment has been carried out.
(xiv) ENiCrFe-2 or ERNiCr-3 filler metals may only be used at component design temperatures upto 8167C (15007F). For component design temperatures greater than 8167C (15007F), InternationalNickel Inconel 617 filler metal or Inconel 117 electrodes shall be used.

(xv) The use of copper coated wire consumables for SAW or GMAW welding of low alloy (eg,11⁄4Cr 1⁄2Mo, 21⁄4Cr 1Mo) steels requires the Purchaser’sapproval.

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(xvi) Production weld deposits for carbon steel weldments shall meet the A1 chemical compositionof ‘ASME SectionIX TableQW 442’. In addition, the combined amounts of Cr, Ni and Mo shallnot exceed 0.25%. The Purchasermay permit relaxation of this clause when the weldment isPWHT.

(xvii) When using Type 308, 316, 317 and 347 filler metals for design temperature applicationsabove 5387C (10007F), as-deposited carbon content in production welds shall be 0.040% minimum.

6.0 WELDING QUALIFICATION

6.1 Welding Procedure Specifi cation (WPS)

(i) The Contractor shall prepare, and submit for the Purchaser’sapproval, a WPS for eachwelding procedure intended for use. Each WPS must list any supporting PQR.

(ii) WPSs shall conform to the requirements of the applicable construction code. In addition, allrequirements of the Purchaser, as indicated in the Purchase Order and this Specification, shall beincluded.

(iii) All WPSs developed specifically for the Purchasershall be reported on Standard Form‘SF-A-635 Weld Procedure Specification and Qualification Record’ and submitted for thePurchaser’sapproval, prior to carrying out the procedure qualification tests.

(iv) The Contractor’s existing qualified WPSs may be accepted by the Purchaserwithoutrequalification, or reporting on Standard Form ‘SF-A-635’. If, however, the Purchaserrequires anexisting WPS to be requalified, reporting of the WPS is required on Standard Form ‘SF-A-635’ forthe Purchaser’sapproval.

(v) Any change in an essential variable in a WPS, as defined in the designated construction code,requires that an amended WPS be resubmitted for the Purchaser’sapproval.

(vi) Welding current and travel speed shall be considered as essential variables.

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(vii) WPSs submitted for review shall be accompanied by weld maps correlating welds to theappropriate WPS. Weld maps shall show the location of all pressure envelope welds. Equipmentdrawings shall indicate the weld seams to which the particular WPS applies.

(viii) WPSs shall include joint dimensional tolerances.

(ix) WPSs for ferritic steel weldments shall include upper hardness limits, per Table1 in §15.2.2.

(x) Unless otherwise agreed with the Purchaser, WPSs for heat exchangers, tube/tubesheetjoints shall be in accordance with ‘EEMUA143’, with the restriction that all such welds shall be
strength welds, with a minimum of two weld passes, irrespective of the welding process employed.
(xi) Alteration to an approved WPS is not permitted without the Purchaser’sapproval, even if
the proposed change is not an essential variable in the applicable construction code. (This may be ofimportance, eg, where components are designed for low temperature service).
.2 Procedure Qualifi cation

(i) Procedure qualification tests on WPSs shall be carried out as required by the designatedconstruction code and the Purchaser’srequirements, as indicated in the Purchase Order and thisSpecification.

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(ii) Procedure qualification test reports (PQRs) for WPSs developed specifically for thePurchaser, and for the Contractor’s existing WPSs requiring requalification, shall be made on‘SF-A-635’ together with the appropriate WPS (‘SF-A-635’ is a dual WPS/PQR document). Notethat the procedure qualification testing shall not proceed until the Purchaserhas approved theassociated WPS.

(iii) The capability to make welds in which the HAZ is not susceptible to environmental cracking,or fabrication underbead cracking, shall be proven during the qualification of the weld procedure.

(iv) Hardness surveys shall be made during the qualification of welding procedures to determinethe maximum hardness in a typical weld cross-section. This will usually be the darkest etched partof the weld HAZ, and be located adjacent to the fusion zone near the capping pass. The firstindentation in the HAZ shall be placed as close to the fusion line as possible. Refer to standard form‘SF-A-635’. Upper Hardness Limits are given in Table 1 in §15.2.2.

(v) Where hardness surveys are not included in an existing PQR, a limited requalifi cation of aWPS may be allowed, subject to the Purchaser’sapproval, by requiring only a macro sectionexamination and a Vickers hardness survey to supplement the relevant PQR.

(vi) Procedure qualification tests for austenitic weld deposits shall include determination of theferrite number, either by calculation using the De Long Diagram, or by measurement using aPurchaser-approved procedure.

Production tests shall show between 3FN to 10FN ferrite if equipment is to be postweld heat treated(PWHT). If not PWHT, ferrite content may be increased up to 12FN. Change of position, eg,horizontal to overhead, shall be regarded as an essential variable, since this may have a significanteffect on ferrite content of the deposit.

(vii) Welding procedures for submerged arc welding shall be requalified whenever the weldingflux or wire is changed from one manufacturer to another, or from one manufacturer’s grade toanother grade from the same manufacturer. Equivalence under ‘ASME Section II, Part C’ shall notbe considered adequate for substitution without requalification, unless approved by Purchaser.

(viii) PQR tests for alloy steel welding procedures shall include chemical analysis for the principalalloying elements in the weld deposit.

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.3 Welder Performance Qualifi cation (WPQ)
(i) All welders and welding operators used on the fabrication of any pressure envelope and directattachment thereto shall be qualified in accordance with ‘ASME SectionIX’ or another Purchaser-specified code. This includes tackwelding and welding of both permanent and temporary
attachments. Qualification shall be on the basis of mechanical tests. Results shall be recorded.
(ii) Each welder shall be qualified for each welding process and position used in production
welding.
(iii) The Purchasershall approve operators of arc air gouging and/or gas cutting equipment.

(iv) Tests on weld procedures involving GTAW roots shall be carried out using the same testcoupon material as designated in the WPS.

(v) Tests on weld procedures where pre-heat is required shall be carried out using the same testc

Odss

oupon material as designated in the WPS.

therwise, test coupon material used for welder qualification tests does not have to be the same as
esignated in the WPS, unless the Purchaserotherwise specifies. In general, P-1 material (carbonteel) can be substituted for a wide range of materials, including some low alloy steels, stainlessteels and nickel-based alloys.

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7.0 WELD JOINT DESIGN

(i) Weld joints shall be free from discontinuities and crevices where corrosive substances canconcentrate.

(ii) Joints in pressure parts of any equipment, and critical structural joints as specified by thePurchaser, shall, wherever access is possible, be full penetration buttwelds, welded from bothsides. Where access is restricted, making backwelding impractical, the WPS shall be developedrecognising that weld quality must be equal to a double welded joint.

(iii) Square close butt preparations are prohibited unless back chipped and back welded.

(iv) The use of permanent backing strips is not permitted for pressure parts. In the case ofstructural attachments, the Purchaser’sapproval is required, except for the annular plate buttweldson storage tanks, where backing strips are mandatory.

(v) Dimensions and tolerances for weld joints designed for fusible metal inserts shall be asspecified by the insert manufacturer.

(vi) Where plates or pipe walls are to be welded to an abutting plate or pipe wall of differentthickness, a transition taper shall be provided to avoid stress concentration effects. Additionally,single welded joints in a pipe or plate must fit essentially flush on the back-side to prevent rootdefects such as incomplete penetration. The taper shall comply with any requirement specified inthe construction code. The Contractor shall submit details of the transition taper for thePurchaser’sapproval.

(vii) Welds for all permanent attachments to pressure parts, both internal and external, shall becontinuous penetration or filletwelds. Intermittent welding is not permitted, except as specificallyapproved by the Purchaser.

(viii) Longitudinal buttwelds shall be at least 5t apart (where t= material thickness), with aminimum separation of 50mm (2in).

Circumferential buttwelds shall also be separated by the same distance.

(ix) Welding of attachments to pressure parts shall be kept clear of longitudinal and girth welds to

8

a minimum distance of 75mm (3in). When attachments are welded and it is not possible to avoidoverlapping seams, the seam weld to be covered shall be ground flush, 100% radiographically
examined (RT) and liquid dye penetrant (DP) or magnetic particle (MP) inspected before theattachment is fitted.
(x) Pipe welding shall generally be in accordance with the following requirements:

(a) The welding ends shall be bevelled to 307 or 371⁄27 by machining or grinding, leaving a 1.6mm(1⁄16in) maximum root face.

(b) Pipe ends shall be spaced to provide a root gap of 1.6mm (1⁄16in) to 3.2mm (1⁄8in), depending
upon the thickness of the materials being welded.
(xi) Where Class150 slip-on flanges are specified, weld dimensions shall be as shown inAppendix III.

.0 PREPARATION FOR WELDING1
(i) All weld bevels in material 38mm (1⁄2in) thick and over shall be examined by the magnetic
particle or liquid dye penetrant method in accordance with §9.3 of ‘ASME SA-20’. Laminationsexceeding 12mm shall be repaired. The Purchaser’sadvance written approval is necessary prior tothe repair being carried out.

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(ii) The base metal of welded joints shall be clean, free of rust, grease, paint, etc, in the region ofthe joint.

(iii) For clad materials, the alloy cladding shall be stripped back by mechanical grinding aminimum of 5mm at all joints, prior to welding the base metal. Refer to ‘SD-C-99663’. ThePurchasershall approve the method of testing to ensure all alloy material is removed.

(iv) Where alloy steel attachments are to be welded to carbon steel (eg, refractory anchors, loosepanel linings), a clean surface for welding shall be prepared by grinding.

(v) Nickel and nickel alloys can be embrittled by sulphur, phosphorous, lead, zinc and other lowmelting point metals and alloys which may be present in marking materials, die lubricants, picklingliquids, dirt accumulated in storage, furnace slag and cinder, etc. Any foreign substance, even thosewhich are not embrittling, can burn into the surface of the metal at high temperatures. Cleanlinessbefore heating, welding or thermal cutting is therefore essential.

(a) All surfaces to be welded shall be thoroughly cleaned by abrasive means, to a distance of25mm (1in) from each cutting or welding edge. A degreasing operation shall be carried outimmediately prior to welding.

(b) Gaseous fuels may be used for heating and cutting, provided that sulphur is less than 0.01% byvolume.

(vi) “Arc-air” may be used for cutting or gouging with the following restrictions:

(a) It shall be used only on carbon steels.(b) The surfaces affected by the process shall be ground to a bright finish before welding, except

as in §(d) below.(c) The Purchaserreserves the right to check and approve the capability of arc-air equipment

operators.(d) For storage tank welding and welding of structural steelwork, grinding as in §(b) above may be

waived when the Contractor can show to the complete satisfaction of the Purchaserthat the“arc-air” operatives have been trained, and that supervision is such that the cut/gouged surfacesare clean, completely free of dross, etc, and that welding on the surfaces involved will notresult in problems with weld quality.

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(vii) Double welded butt joints on pressure parts shall have the root pass back-dressed, (eg,chipped, before welding the second side of the joint) and shall be magnetic particle or liquid dye
penetrant tested after back chipping.
(viii) When fusible metal inserts are used, the Contractor shall closely control the machining andfit-up for these inserts to the tolerances specified by the insert manufacturer.

.0 PREHEATING AND INTERPASS TEMPERATURES

(i) Preheat temperature and application shall be determined by the Contractor in accordancewith the Table 6, Appendix II, and the following paragraphs. The proposed data shall be recordedon ‘SF-A-635’ and submitted for the Purchaser’sapproval

(ii) Modern low carbon, low sulphur, micro-alloyed steels (%V × %Nb.0.003) require specialconsideration. The Pcm factor developed by Ito and Bessyo provides a useful guide to preheatingsuch alloys. See the Bibliography for reference papers by YIto etal, and RIrving.

(iii) Preheat is required for thermal cutting of low alloy CrMo steels. 1007C (2107F) minimum for11⁄4Cr 1⁄2Mo, 1507C (3007F) minimum for 21⁄4Cr 1Mo.

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(iv) When welding dissimilar metals, the preheat (and PWHT) requirements of the base metalsinvolved shall be maintained, notwithstanding the use of austenitic or high nickel consumables,except as permitted in this Specification or agreed with the Purchaser.

(v) As a general rule, the maximum preheat and interpass temperatures shall not be more than507C (1207F) above the minimum specified.

(vi) The preheat and interpass temperatures shall be determined by means of a contact pyrometer,or by thermocouples attached to the base metal on both sides of the welding groove. Whenapproved by the Purchaser, sulphur-free crayons indicating temperature may be used.

(vii) Preheat temperature shall extend for a distance not less than 75mm (3in) on each side of theweld.

(viii) Preheat shall be uniformly applied, measured by suitable means and maintained throughoutwelding.

10.0 WELDING PRACTICES

(i) Access structures for in situ welding shall be rigid and secure, protected from the weather,and shall enable the welder to work safely on all parts of the joint while maintaining the correctangular relation of the electrode to the work. Working clearance around welds shall be 400mm(15.75in) minimum.

(ii) Wherever possible, the assembly shall be positioned so that the welding can be donedownhand, especially where low hydrogen electrodes are used.

(iii) The temperature of the work shall be maintained in the preheat range during welding. It isparticularly important that this is complied with during tackwelding, the welding of any temporaryattachments and when work has been interrupted. Interruption of welding before joint completionshould be avoided whenever possible, especially for materials that require PWHT.

(iv) Each pass shall be cleaned thoroughly and visually examined for cracks and porosity. Defectsshall be removed before starting the next pass.

(v) All tacking shall be done with approved procedures, employing the same electrode or fillerwire specified for the butt- or filletwelds of the equipment, and the same preheat. Such welds shallgenerally be removed and not incorporated in the finished welds. However, the Purchasermay
waive this requirement when tacks are proved to be sound and can be fully fused into the root, orwhen all the root will be removed in preparing for second side welding. Any such waivers requirethe Purchaser’sapproval.
(vi) All double-welded butt joints in pressure parts shall have the root pass back chipped beforewelding the second side of the joint. All butt joints shall be magnetic particle (MP) or liquid dyepenetrant (DP) tested after back chipping.

(vii) Arc strikes on pressure parts should be avoided. If they occur, the surface shall be properlyconditioned to eliminate surface stress raisers. Such surfaces shall be examined by either the
magnetic particle or liquid penetrant examination. Any defects found shall be removed and thesurface repaired and re-examined.
(viii) Welds located in any pressure part (regardless of the material, thickness or service) shall be
subject to 100% examination by appropriate nondestructive examination after any severe formingoperations (ratio of thickness to local radius greater than 5%) before any subsequent fabrication. Forming operations include spinning, pressing and rolling. The nondestructive examinationtechnique employed shall be approved by the Purchaser.

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(ix) On the principle that weld metal volume shall always be minimised, Base metal “build-up”for whatever purpose, including “buttering”, shall be limited and is subject to the Purchaser’sapproval. Surface preparation, welding procedure and NDE require special consideration to ensureweldments are free from defects.

(x) All welding on any equipment that is to be postweld heat treated shall be completed prior toPWHT. Where attachments must be installed after PWHT, the method of attachment and weldingprocedure shall be approved by the Purchaser.

NO WELDING IS PERMITTED AFTER PWHT.

(xi) Temporary attachments welded to pressure parts shall be minimised. Where they arenecessary, the welding shall be carried out with approved procedures employing the sameelectrodes or filler wire specified for the associated pressure part and with the same preheat.

(xii) Temporary attachments shall be removed by grinding. Care must be taken not to grind theshell thickness to below the original material thickness. The surface where such welds have beenremoved shall be properly conditioned to eliminate surface stress raisers. Such surfaces shall beexamined by either the magnetic particle or liquid penetrant method or examination.

(xiii) When fusible inserts are used, they shall be fully fused into the final joint.

11.0 PROTECTIVE LININGS

(i) Integrally clad and weld overlaid materials shall be welded in accordance with drawing‘SD-C-99663’. Refer to §16.5.

(ii) Loose linings are not permitted on new equipment, except with the approval of thePurchaser. When installed on existing equipment for maintenance purposes, panels shall notexceed 0.6m by 0.3m (2ft by 1ft). Each panel shall contain six equispaced slots approximately75mm by 9.5mm (3in by 3⁄8in) and a tapped 1⁄8in NPT test hole. Individually filletweld each paneland prove airtight. After the air test, fill the groove between adjacent sealwelds and re-air testpanels. Finally, weld up the test hole and check this weld with liquid penetrant.

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(iii) Welding procedures for applying deposit linings shall be approved by the Purchaser. Theweld deposit shall provide an undiluted layer of the specified thickness, generally necessitating agreater overall deposit thickness to allow for base metal dilution.

2.0 WELD REPAIRS

Weld repairs shall only be made with the Purchaser’sapproval and in compliance with thisSpecification. The Purchaseras a result may specify further NDE.

3.0 POSTWELD HEAT TREATMENT (PWHT)

3.1 Introduction

(i) Postweld Heat Treatment (PWHT) may also be required for process reasons; if so, it will bespecified in the purchase order. Code requirements are included for information only.

(ii) Table 6 of AppendixII indicates the circumstances under which PWHT for specific weldingis required. The balance of this section contains general requirements.

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13.2 Common Requirements

(i) Equipment to be PWHT shall be clean, free of oil, grease, paint, etc. Refer also to §8.0(v).

(ii) Equipment to be PWHT shall be blocked and supported as necessary to avoid deformationduring PWHT.

(iii) A sufficient number of thermocouples shall be attached to the equipment, and temperaturerecorders shall be used to verify that required heating and cooling rates, PWHT temperature andholding time have been achieved. The Purchasershall approve the number and location of thethermocouples.

(iv) The temperature difference between any two thermocouples shall not exceed 1207C (2507F),including during heating and cooling.

(v) During PWHT, the Contractor shall ensure even heating and cooling of the structure,accurate temperature measurement and that the correct holding temperature is maintained for therequired length of time. A PWHT report, to include relevant recorder charts, is required for finalrecords.

(vi) All welding, including the attachment of lugs, stiffening rings, structural clips, etc, shall becompleted prior to PWHT. If equipment is ground after PWHT, it shall be done carefully and thearea inspected afterwards by appropriate non-destructive examination.

(vii) PWHT shall be carried out in furnaces or by use of electric resistance elements, unless thePurchaseragrees to alternative methods.

(viii) Torch PWHT is restricted to piping socket and sealwelds. Refer also to §14.4(i) and §(ii).

(ix) The Exo-anneal process may be used for heat treatment of pipe welds, subject to thePurchaser’sapproval. Time and temperature achieved must be verified on the first weld for eachchange in piping alloy, pipe thickness and whenever a change in piping geometry requires adifferent Exo-anneal kit. Verification shall be made using chart-recorded time versus temperatureinformation from thermocouples attached to the weld. Verification is not required for carbon steelwelds. The process is not permitted for austenitic stainless steels.

1

(x) Following PWHT of carbon and ferritic alloy steels, it may be necessary to cool slowly from
the PWHT temperature to 4007C (7507F) in order to obtain satisfactory hardness. A cooling rate of5 er hour is usually satisfactory. This shall be determined in the weld procedureq
3.3 R

(cePsw

(trvs

57C (1307F) p
ualification test.
elaxation and Waivers of PWHT Requirements

i) The ‘ASME’ and ‘ANSI’ codes allow a degree of relaxation of PWHT requirements underertain conditions (the applicable construction codes need to be checked in this respect). For
xample, PWHT is not mandatory for small size filletwelds in P1 materials. In other circumstances,WHT temperatures may be reduced and soaking times extended. These changes are applicableubject to the Purchaser’sapproval. Neither of the above examples of relaxation shall be allowed hen PWHT is required for environmental resistance.
ii) For carbon steels, where PWHT is difficult, it has sometimes been permissible to hold aemperature of, say, 2007C (4007F) for 2-3 hours after welding to allow hydrogen diffusion and toeduce the risk of underbead cracking. Temper bead welding has also been used to reduce hardness
alues in weld HAZs, but is not permitted if PWHT is required for environmental resistance. Alluch options are subject to the Purchaser’sapproval.

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(iii) The Holloman-Jaffe parameter (Hp) may be used to determine permissible variations in timeat temperature for the PWHT of carbon and low alloy steels, subject to approval by the Purchaser.

Hp = T(20 + log t) × 10–3

Where: T = PWHT temperature in 7K (7K = 7C + 273)t = time, hours

This parameter can be used to ensure that variations in PWHT times at temperature do not falloutside the limits set by the specified temperature range.

Example:Consider a PWHT of four hours at 6007C (8737K), with a permitted temperaturevariation of 6207C.For T = 6007C, Hp = 873 (20 + log 4) × 10–3 = 18Similarly For T = 6207C, Hp = 18.4and For T = 5807C, Hp = 17.6Thus parametric range = 17.6 − 18.4Assume different times for a PWHT at the nominal temperature of 6007C.For t = 2 hours, Hp = 17.7For t = 10 hours, Hp = 18.3Both of these values are within the range of Hp values determined four hours’ PWHT at6007C 6 207C and, hence, are likely to give properties which fall within acceptablelimits.

Note that the use of the parameter will not be permitted to reduce the PWHT temperature below theminimum specified, except with the Purchaser’sapproval.

(iv) Pressure vessel codes do not permit local PWHT that does not include a completecircumferential band of the vessel. This requirement shall not be waived unless PWHT involvesheat treating complete formed plates or heads with or without attachments, prior to their installationin the equipment. In such cases, the Purchaser’sprior approval is required.

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4.0 SOCKET- AND SEALWELDING OF PIPING

4.1 Socketwelding

(i) For socketwelding, care shall be taken to ensure that a minimum clearance of 1.6mm (1⁄16in)and a maximum of 3.2mm (1⁄8in) remain between the male and female ends at the bottom of thesocketwelded fitting. A spacer ring of suitable thickness may be used to seat the male end in thesocket, provided that the material of the ring is porous and will permit gases to escape to the boreduring welding.

(ii) Preheat and PWHT are required per §9.0 and §13.0.

(iii) The dimensions of filletwelds for SW flanges are given in Appendix III.

(iv) The dimensions of filletwelds for socketwelds other than flanges are given in Appendix III.

4.2 Sealwelding

(i) When sealwelding threaded connections, they shall be made up dry, clean and wrench tight toengage the make-up length for the internal thread, as specified in ‘ASME B1.20.1’ for taper pipethreads. Thread lubricant, compound or sealing tape shall not be used, as this will detrimentallyaffect weld quality.

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(ii) For sealwelds on threaded connections, the following procedures may be adopted:

(a) PWHT is not required for carbon steel and ferritic alloy steels where the chromium content isless than 2%, provided matching weld metal is used and the completed weld is cooled slowly,under insulation.

(b) PWHT is not required for ferritic alloy steels when the system operating temperature is below4007C (7507F), provided that:

— a high nickel filler metal is used (eg, International Nickel Inco Weld A, Inconel182, Inconel82), or Type309Mo austenitic SS, and;

— the weld is covered with insulation immediately after welding to allow slow cooling.

For both §(a) and §(b) above, preheat temperature requirements continue to be mandatory. Refer to§9.0.

(iii) The dimensions of thread sealweld fillets shall be the same as for socketwelds except that, inaddition, all exposed threads shall be covered. Dimensions are as given in Appendix III.

14.3 Valves and Unions

When socket- or sealwelding valves and unions, it is important to have a good clean fit-up to avoidcracking and/or distortion. The following precautions shall be taken during welding:

(a) When socket- or sealwelding valves and unions, the parts to be welded, including the ends ofpipe, the insides of valves and sockets and mating faces of unions, shall be solvent washedbefore making up to remove manufacturer’s protective oils or greases which could burn orvaporise during welding.

(b) Valves shall be closed handtight before welding or preheating. After welding, valves must bechecked for ease of operation and effective stem sealing.

(c) Preferably, unions shall be made up with nuts handtight prior to welding. If this is not possible,any exposed mating faces shall be suitably protected against arc strikes, weld spatter, etc,during welding.

14.4 Annealing by Torch Heating

1

(i) Where PWHT of seal and socketwelded components is unavoidable and furnace or electric
resistance methods are not practicable, subject to the Purchaser’sconsent, annealing may be bytorch heating to the appropriate temperature for approximately 20minutes, followed by cooling instill air. It is important that the torch be kept moving continuously, that no part of an alloy material exceeds a temperature of 7607C (14007F) and that all areas of weld and heat affected zone reach thePWHT temperature.
(ii) Subject to the Purchaser’sconsent, socketwelds made on carbon steel lines in caustic andamine service shall be stress relieved by heating to 650-6757C (1200-12507F) for five minutes andcooling in still air.

Note: when torch heating is allowed by the Purchaserfor either of the above, additional controlmeasures may be imposed, such as the Purchaser’sInspector being present during the operation.Additional control measures shall be at the Contractor’s expense.

4.5 B

B‘

N

ridgewelding

ridgewelding, where required (eg, socket joints on lines subject to vibration), shall be as shown onSD-L-10276’.

ote that the use of integrally forged fittings is the preferred alternative to bridgewelding.

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15.0 QUALITY CONTROL

15.1 General

(i) Weld inspection and testing shall be carried out in accordance with the requirements of therelevant Design/Construction Code for the equipment concerned, as supplemented by therequirements of this Specification.

These requirements shall be included in the Contractor’s Quality Plan.

(ii) All welders/welding operators shall mark their welds with their individual marks or low stressstamps. Nickel alloys and austenitic stainless steel welds shall not be marked, but a sketch shall besupplied by the Contractor showing weld seams and welder identification.

(iii) Welds not identified as described in §15.1(ii) shall be rejected, unless shown to be ofacceptable quality by appropriate non-destructive examination at the Contractor’s expense.

(iv) The Purchaser’sInspector reserves the right to call for supplementary inspection and NDE.The costs for such supplementary testings where required to clarify inconclusive or questionableexamination results shall be paid for by the Contractor , otherwise the Purchaserwill pay.

(v) Repair welds shall be re-heat treated if required, and inspected and tested as specified by thePurchaser.

(vi) Surfaces shall not be painted, nor the equipment shipped until the Purchaser’s inspection iscomplete.

15.2 Non-destructive Examination (NDE) - General Requirements

15.2.1 General

(i) NDE shall be carried out as required by the design/construction code for the equipmentconcerned, and this Specification.

(ii) All NDE Technicians shall be independently qualified, to the satisfaction of the Purchaser.

(iii) Unless otherwise agreed by the Purchaser, all NDE required, other than Positive MaterialsIdentification (PMI) and Ferrite Number (FN) determination, shall be carried out after PWHT,except that welds which will become inaccessible by reason of welded closures which themselvesrequire PWHT shall be examined before such closures are welded.

(iv) All surfaces to be examined by NDE methods shall be prepared to permit a proper
interpretation of the test method.
(v) The Contractor may at his own expense carry out any intermediate NDE he deems necessaryor desirable to ensure a quality product.

(vi) The production welds attaching pins or studs for external insulation and fireproofing supportswill be hammer tested at the discretion of the Purchaser’s inspector.

(vii) All welds must be given a visual examination in addition to the type of specific non-destructive examination specified.

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15.2.2 Hardness Testing

(i) Hardness testing shall be carried out on all ferritic steel welds on pressure parts of equipment.

(ii) It is considered impracticable to test for local high hardness regions in the heat affected zone(HAZ) of production welds, thus the hardness of weld deposit only will be determined. Whereresistance to sulphide stress corrosion cracking is required, whilst this cannot be guaranteed byrestricting weld metal hardness, Table1 contains the upper limits which should provide reasonableprotection, unless tensile stress levels and the environment are exceptionally unfavourable.

TABLE 1 Upper Hardness Limits

Base Material Weld ProcedureVickers HV10 Hardness Survey (I)

Production Weld TestsTelebrinell Reading (HB) (2)

Carbon Steels 235 (3) 200

Low Alloy Steels containing,2Cr

248 225

Low Alloy Steels containing.2Cr

248 241

12Cr 4Ni Steel 254 241

Notes:1. Required on all Procedures per ‘SF-A-635’ (this includes weld metal and HAZ).2. At frequency per ‘NACE0472’ (weld metal only). SMAW welds using E60XX electrodes do not require

testing; however, welds with E7-XX electrodes shall be tested.3. 250HV10 maximum for atmospheric oil storage tanks - refer to ‘NYS-D1.10’, 275HV10 maximum for

structural welds not attached to pressure parts.

(iii) The composition of ferritic alloy steels will generally require restrictions, additional to thoseimposed by applicable NYS Specifications, in order to meet the above hardness limits. Forexample, for 12% Cr 4% Ni steel, the carbon content shall not exceed 0.03% so that, after weldingand heat treatment (double temper), the hardness is not in excess of RC23 (254V). (Refer to ‘NACE

1

MR0175’).

(iv) The deposited weld metal shall be hardness tested at the frequency specified in ‘NACE0472’,
plus such additional welds as may be required to ensure testing of each weld procedure.
(v) Brinell hardness testing on production welds to verify compliance with requirements shall beperformed using ‘Telebrinell’ portable macro hardness testing equipment, or other Purchaser-approved instruments.

(vi) Hardness testing is not required on SMAW welds when AWSE 60XX electrodes are used.

( oduction weld hardness testing shall be carried out on the process side of equipmentwm

5.2.3 R

(

(ed

(

vii) Pr
henever access is possible, except for clad or weld overlaid components, when testing will beade on the non-clad/overlaid side.
adiography

i) Radiography shall be in accordance with the Design Code and this Specification.

ii) Radiographic film shall be fine grain, high definition, high contrast film (Kodak TypeAA,quivalent or better). Film density shall be within the range of 2.0 to 3.5 as determined by filmensity specimens or by densitometer.

iii) Fluorescent intensifying screens shall not be used.

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(iv) The Contractor may propose ultrasonic testing in lieu of radiography. Such substitutionrequires the Purchaser’sapproval.

15.2.4 Ultrasonic Testing (UT)

When ultrasonic testing is specified, the requirements, including rejection limits, of ‘ASME VIIIDiv 1 Appendix12’ shall apply. The Contractor shall submit a complete procedure for thePurchaser’sapproval.

15.2.5 Liquid Penetrant and Magnetic Particle Testing (LP and MP)

(i) Locations to be examined by liquid penetrant or magnetic particle testing are given below.Test procedures shall comply with ‘ASMEV Articles 6 and 7’. Welds shall be blend ground priorto examination.

— Attachment welds of supports, lifting lugs, davit supports, etc.— Nozzle neck-to-shell or head welds on pressure vessels and heat exchangers.— Saddle support wrapper plate-to-shell/pipe welds.— All internal attachment welds on ferritic alloy or PWHT exchangers.— Pressure welds under pads.— Locations where temporary attachments were welded to the pressure envelope during

fabrication.

(ii) Cracks and defects shall be repaired and retested.

(iii) For austenitic stainless steel and nickel alloys, dye penetrant testing materials shall meet therequirements of ‘ASMEV, Article 6’, for the control of sulphur and halides.

(iv) Welds shall be thoroughly cleaned after inspection.

15.2.6 Positive Materials Identifi cation

(i) While the method used for PMI control is subject to the Purchaser’sprior approval, theOwner’s preferred methods are:

1

(a) X-ray fluorescence spectrometric analysis using the ‘X-met Analyser’ manufactured byOutokumpu Electronics.

(b) ‘Texas Nuclear Analyser’ Model9266 or equivalent.
(c) Automatic spark emission spectroscopic analysers (the use of spark emission spectroscopic
analysers such as the ‘Clandon Metascope’ will not normally be acceptable).

(ii) The Contractor shall agree with the Purchaser’sthe elements which require to be analysedand the acceptable ranges for each particular Purchase Order.

(iii) The deposited weld metal for all non-carbon steel welding procedures shall be analysed toensure the weld alloy content is at least equal to that specified for the base metal.

(iv) All PMI checks on finished components shall be done after fabrication but prior to PWHT(when applicable), and the Contractor shall submit a written statement guaranteeing that allmaterials are correct.

(v) The Purchaser’s inspector will require to examine PMI records before equipment is packedready for despatch from the Contractor’s plant.

5.2.7 Ferrite Number

(i) The test for Ferrite Numbers (Austenitic Stainless Steels) shall conform to the following:

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(a) A ‘Severn’ ferrite scope, or Purchaser-approved equivalent, instrument shall be used tomeasure the ferrite number (FN).

(b) Instruments shall be calibrated in accordance with ‘AWSA4.2’ standard procedures forcalibrating magnetic instruments to measure the delta ferrite content of austenitic stainless steelweld metal.

(c) Ferrite determinations on thick wall piping, over 19mm, shall be made before PWHT.

15.3 Hydrostatic Testing

(i) Generally, all welding shall be hydrostatically strength tested. Testing may be waived byPurchaser in the case of certain less hazardous services, eg, low pressure utility piping.

(ii) Hydrostatic testing for pressure equipment shall conform to the requirements of the pertinentspecification as follows:

(a) Vendor shop and field fabricated piping and furnace tube assemblies shall be tested inaccordance with ‘NYS-L1.10’.

(b) Unfired pressure vessels shall be tested in accordance with ‘NYS-C2.10’.(c) Storage tanks shall be tested in accordance with ‘NYS-D1.10’.(d) Water cooled steam surface condensers shall be tested in accordance with ‘NYS-E1.10’.(e) Shell and tube heat exchangers shall be tested in accordance with ‘NYS-E1.20’(f) Air-cooled heat exchangers shall be tested in accordance with ‘NYS-E1.30’.

(iii) For ferritic alloy pressure parts greater than 38mm (11⁄2in) thick, and for heavy wall carbonsteel pressure vessels to ‘NYS-A1.31’, final hydrotesting shall not be carried out until twodaysafter PWHT.

16.0 SPECIFIC ADDITIONAL REQUIREMENTS FOR PRESSURE VESSELS AND HEATEXCHANGERS

1

The following additional welding requirements apply to equipment specified in:

— Pressure vessels to ‘NYS-C2.10’.— Water-cooled steam condenser equipment to ‘NYS-E1.10’— Shell and tube heat exchangers to ‘NYS-E1.20’.
— Air-cooled heat exchangers to ‘NYS-E1.30’.
6.1 General Non Destructive Examination (NDE) Requirements

(i) Spot radiography is a minimum requirement ie, the no-radiograph case is not acceptable. As aminimum, all intersections involving ‘ASME VIII Div 1’ Category A, B and C welds (or the designCode equivalents), refer to AppendixIV of this Specification’ shall be radiographed in such a
manner as to cover all relevant welder/procedure combinations.
(ii) ‘ASME VIII Div 1 Category D’ (ie nozzle-branch connection) welds, or their equivalents,
shall be ultrasonically tested as follows (in lieu of Code radiographs requirements):
(a) Full radiography case - 100% of all welds.
(b) Minimum radiography case - 100% of one weld in four, as a minimum but with all relevant
welder/procedure combinations being inspected.

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(c) Set-on nozzles - all welds.

(iii) In the event that ultrasonic inspection of welds of the minimum radiograph case aboverequires any repair welds, then all Category D welds shall be ultrasonically examined, after PWHTif applicable.

(iv) Skirt attachment welds on vertical pressure vessels and heat exchangers shall beultrasonically tested when operating metal temperature at the point of attachment exceeds 3007C(5727F).

16.2 Heavy Wall Carbon Steel Pressure Vessels

NB: these requirements are additional to and/or override those given in §16.1, and apply to vesselsspecified in ‘NYS-A1.31’.

16.2.1 Non-destructive Examination

(i) All category A, B and D joints shall be 100% radiographed, except category D joints thatcannot be fully radiographed shall receive 100% UT.

(ii) All weld pad build-ups for internal or external attachments shall be 100% UT.

(iii) Specified weld NDE will not be carried out until two days after completion of PWHT.

16.2.2 Other Requirements

The Purchaser’sother requirements will be noted in the Purchase Requisition.

16.3 Carbon Steel Pressure Vessels and Heat Exchangers for Low Temperature Opera tion

Note that the following requirements, applicable to pressure vessels and heat exchangers specifiedin ‘NYS-A1.32’, are additional to and/or override those given in §16.1.

1

1

6.3.1 Welding General

(i) Where back welding is not possible, GTAW shall be used for the root pass, with filler wiresthat give the required impact properties, refer to §5.0.

(ii) The weld bevels of stub end nozzles shall be in accordance with details to be defined by thePurchaser. The size and schedule or thickness of the adjoining piping will be specified on thePurchaser’sSetting Plan or Vessel Specification Sheet.

(iii) Temporary attachments shall be cut off above the parent plate without damaging it and the
surface shall be ground smooth.
6.3.2 Welding Procedures

(i) Procedures shall represent actual welding conditions including the brand of electrode which
will actually be used.
(ii) The welding procedure qualification for the main vessel welds shall utilise the maximumthickness of plate to be used in the fabrication. Where the maximum thickness plate involves more
than one cast, the test plate shall be taken from material having the highest carbon equivalent.

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(iii) A separate procedure is required to cover welding of the erection dogs and attachment ofmiscellaneous clips and brackets (except studs and nuts for fireproofing). At least two weld passesare required for such welds.

(iv) After the Purchaser’sapproval of the Contractor’s welding procedures, no changeswhatsoever (whether involving essential or non-essential variables) are permitted. Any changes willrequire resubmission of the procedure for the Purchaser’sapproval.

16.3.3 Welding Consumables

(i) Welding rods, electrodes and filler metals shall comply with ‘ASMEII PartC’ but withimpact properties meeting the requirements of §16.3.6.

(ii) The use of alloy welding rods, electrodes, filler metals and fluxes is prohibited.

16.3.4 Preheating for Welding

Minimum preheat temperature for all welds, including those for temporary attachments, shall be937C (2007F) for thickness up to 50mm (2in) and 1497C (3007F) for thicker material, but in no caselower than that required by the approved welding procedure.

16.3.5 Post Weld Heat Treatment (PWHT)

(i) The entire vessel shall be PWHT treated at 6357C 6 147C (11757F 6 257) after fabrication.Minimum holding time and other heat treatment requirements shall be in accordance with theDesign Code.

(ii) No welding, flame dressing, etc, whatsoever is permitted on vessels after PWHT unless re-heat treatment is undertaken.

16.3.6 Impact Testing of Welds

1

1

(i) Charpy impact tests shall be carried out in accordance with the Design Code procedure.Impact energy and test temperatures shall be in accordance with ‘NYS-A1.32’.

(ii) Impact tests at the design minimum temperature shall be carried out on all weld procedure
test pieces. Three sets each of three specimens (comprising one lot) shall be taken to check weldmetal, heat affected zone and parent plate. These tests shall be made for the weld deposit of eachbatch of electrodes.
(iii) For field fabricated vessels, the test shall be repeated after two and three heat treatment
cycles, and for shop fabricated vessels after two heat treatment cycles using the simulated PWHTper ‘ASMESectionII’, Part A, specification SA-20 Supplementary Requirement S3.
6.3.7 R

F

6.3.8 U

Tpu

adiograph of Welds

ull radiographic examination for a joint efficiency of 1.0 is required.

ltrasonic Inspection of Welds

he full length of all welds attaching nozzles, branches and reinforcement plates to shell and endlates, and at least 10% of the length of all other attachment welds to pressure components, shall beltrasonically tested.

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16.3.9 Magnetic Particle Inspection of Welds

(i) Magnetic particle testing (not dye penetrant), shall be carried out upon (after final post weldheat treatment, where applicable) the following:

(a) Inside and outside of all vessel welds including nozzles.(b) Support structure welds.(c) Vessel bracket and clip welds including erection dogs, back gouged areas prior to welding.(d) The entire knuckle area of forged heads (after post forming heat treatment).(e) Forgings (after machining).(f) Weld preparation of joints prior to welding where the shell thickness is 25mm (1in).

(ii) Welds must be blend ground prior to testing.

(iii) Only the wet magnetic particle testing procedure per ‘ASME SectionV’ shall be used. Thereshall be no linear indications.

16.3.10 Hardness Testing of Welds

The Brinell hardness testing of production welds shall be carried out on the following weld areas:

(i) Every 8m (25ft) internally of main seam welds.

(ii) Every 30m (100ft) externally of main seam welds.

(iii) The inside of each nozzle weld, where practicable.

(iv) Two external nozzle attachment welds for each welding procedure.

There shall be at least two hardness tests on each weld joint.

16.4 Carbon Steel Pressure Vessels and Heat Exchangers in Sour Services

1

1

Note that these requirements, applicable to pressure vessels and heat exchangers specified in ‘NYS-A1.33’, are additional to and/or override those given in §16.0.

6.4.1 Post Weld Heat Treatment

The vessel shall be stress relieved at 6357 6 147C (11757F 6 257F) after fabrication is completed.
The minimum holding time shall be one hour; other heat treatment requirements shall be in accordance with the design code of the vessel. Welding on PWHT vessels is prohibited. If repairs or modifications are necessary, these may be made, with the Owner’s permission, provided that the vessel is reheat-treated.
6.4.2 Magnetic Particle Inspection

(i) A wet fluorescent magnetic particle inspection (WFMPI) in accordance with ‘ASMESectionV’ shall be performed on the inside surface (process side) of all longitudinal andcircumferential welds in shells, heads and conical transitions, all nozzle-to-vessel welds, and all
internal attachment welded to pressure parts such as tray support rings, downcomer bolting bars,internal pipe support clips, vortex breakers, etc, (including any temporary erection attachments onthe pressure envelope). The inspection shall be carried out before PWHT, and again aftercompletion of the shop hydrotest.

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(ii) Prior to performing WFMPI, the surface of the welds shall be prepared to a SSPC SP6 finish(commercial blast) as a minimum and blend ground. The surface preparation shall include sufficientdistance on each side of the weld to permit a magnetic particle yoke to make contact with theprepared surface area (a minimum 200mm (8in) wide band centred on the weld).

(iii) Due to the potential for arc strikes, only the magnetic yoke method is to be used. Acceptancecriteria shall be per Appendix6 of ‘ASME SectionVIII, Division 1’. A test report shall be preparedand it shall map the location of all relevant indications that were removed and all remaining non-relevant indications. The map shall be included in the manufacturer’s final documentation sent tothe Purchaser.

16.4.3 Ultrasonic Testing

Where the equipment size and/or geometry does not permit access to the internal surface of thewelds, an ultrasonic examination from the outside of the vessel shall be performed on all buttweldsin shells, heads and conical transitions after completion of the shop hydrotest. Since the samegeometry constraints will apply in the field, this information will be used for the baseline data offuture ultrasonic inspections.

Ultrasonic examination is not required for welds attaching internal non-pressure parts to pressureparts.

16.5 Clad Carbon and Low Alloy Steel Pressure Vessels and Heat Exchangers

Note: these requirements are specific to pressure vessels and heat exchangers specified in‘NYS-A1.34’.

16.5.1 Welding

Details for welded joints shall comply with ‘SD-C-99663’.

1

1

7.0 SPECIFIC REQUIREMENTS FOR FABRICATED PIPING AND TUBING

Note that these welding requirements apply to piping and tubing fabricated in accordance with
‘NYS-L1.10’.
7.1 Responsibility

(i) The Contractor shall be responsible for ensuring that all testing progresses at the same rateas fabrication.

(ii) The Purchaser’s inspector shall be responsible for:

(a) Selecting which welds are to be subjected to non-destructive examination in accordance withthe requirements of this Specification.

(b) Selecting the locations for radiographs and interpreting the results.(c) Deciding where and what supplementary testing is required.(d) Deciding on the acceptability of any test method substitutions proposed by the Contractor .(e) Deciding on the acceptability of the Contractor’s non-destructive examination procedures and

operators.

CES 98



17.2 Weld Consumables

Fusible metal inserts such as EB (Electric Boat) inserts, T or J type, may be acceptable, with thePurchaser’sapproval, for making root passes on pipe welds.

17.3 Extent and Type of Non-destructive Examination

Testing shall be in accordance with this section and the Purchaser Order.

The following general requirements should be read in conjunction with Table 2, which providesspecific requirements for different piping or tubing sizes and material types. Note that the Tablealso discriminates between GMAW welding and all other types of welding.

(i) Positive Material Identification (PMI) is required for all steels, except Carbon Steels.

(ii) For alloy steels, PMI is also required for each weld and also for each component of the pipingor furnace coil assembly. Ferrite content shall be measured on each weld. The percentage of ferriteshall be within the range 3-12. However, for thick wall pipe, over 19mm wall where PWHT isrequired, the range shall be 3-9%.

(iii) All non-destructive testing, except PMI, to be carried out after PWHT (if any) has beencompleted (except as otherwise required by this Specification).

(iv) Each buttweld inspection is to be carried out over the full circumference of the pipe or tube.Where the percentage of buttwelds to be inspected is less than 100%, locations for inspection are tobe approved by the Purchaser’s inspector. The first two joints made by each welder must beincluded.

(v) All furnace tube welds are subject to 100% NDE. All other percentages in Table 2 apply topiping only.

(vi) Table 2 lists the preferred NDE methods to be used. Alternatives, such as Liquid Penetrant(LP) or Magnetic Particle Inspection (MPI), may be considered, but shall be subject to the
Purchaser’sInspector’s discretion.
(vii) Where LP or MPI is accepted or specified, this shall apply to all attachments, branch, socket-and sealwelds (all requirements specified for socket welds also apply to sealwelds). Branch weldsshall be examined before and after addition of any reinforcement.

(viii) Where LP is used, testing shall be carried out after welding the root pass and again afterwelding capping pass. Test materials to be chloride free and all traces of foreign matter shall beremoved after testing.

(ix) Where flange rating is Class 1500lb or above, radiography shall be 100% unless a GTAWroot is used, in which case the percentage shall be 25%.

(x) All specified NDE requirements for Carbon Steel material apply to the case where the
Owner’s Carbon and Manganese limitations are met, ie: C max = 0.25% and/or, Carbon Equivalent max (C + Mn/6) = 0.41%
(xi) Radiography is not required for Piping Specifications ‘A2’, ‘A4’, ‘A5’, ‘A6’, ‘B7’ and ‘B15’.

(xii) Wherever ANSI Class 150lb or higher rated piping cannot be hydrotested, all welds shall be100% radiographed with all of the pipe joint included in the radiograph.

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TABLE 2 Minimum NDE Requirements Fabricated Piping and Tubing

Material PreferredMethod

% pipe buttweldsto be inspected

HardnessTesting

Max Weld DepositHardness

LESS THAN NPS 2 - All welds other than GMAW

CS RT 5% (1) Yes (2) 200 HB

Austenitic SS RT 10% No –

Ferritic alloys RT 100% Yes (3) 225 or 241 when .2% CR

NPS 2 AND LARGER - All welds other than GMAW

CS RT 5% (1)(4) Yes(2) 200 HB

Aus SS ≤12mm thk RT 10% No –

Aus SS .13mm thk RT 100% No –

Ferritic alloy steels RT(5) 100% Yes (2) 225 or 241 when .2% CR

ALL PIPE SIZES - GMAW welding only

CS Ultrasonic 100% (1) Yes (2) 200 HB

Notes:1. Piping to specs C10 and D3 shall be subject to 100% radiography of whole pipe joint.2. One weld metal hardness test required for every 20 welds. Hardness testing is not required for SMAW welds

with AWS E 60XXelectrodes.3. One weld metal hardness test required for every weld.4. When piping minimum design metal temperature is below 07C (327F), radiography shall be 100% with all of

the pipe joint included in the radiograph, except for piping specifications C9/C9A, 10% is required.5. For Cr/Mo steels over 1in thk, at least 2 days shall elapse between completion for welding and non-destructive

testing.

17.4 T uirements

17.4.1 H

H

(

((

(

17.4.2 P

P

(

est Req

ardness Testing

ardness Tests shall conform to the following:

a) Hardness tests shall be carried out using a Telebrineller portable hardness tester or aPurchaser-approved equivalent.

b) At least 10% of welds on furnace heat treated spools or batches shall be tested.c) Frequency of testing on other welds shall comply with ‘NACERP0472’ or one weld in 20 as a

minimum for carbon steel welds. For low chromium alloy steel welds, each weld will betested.

d) If hard welds are found, they shall be re-PWHT if applicable, or removed.

ositive Material Identifi cation

MI requirements are as follows:

a) The onus is on the Contractor to prove to the Purchaserthat, on final assembly and prior tocommissioning, all components including weld metal in non-carbon steel fabricated piping and

CES 98



tubing assemblies are of the correct chemistry. However, the Purchaserexpects that theContractor will have in place procedures for checking that components and weld consumablesare of the material ordered, and that their issue is controlled to ensure that the materials usedduring fabrication are correct.

(b) At final assembly, pressure-retaining fasteners and gaskets shall be checked at a frequencyspecified in ‘ISO2859-1’ (1989) to ensure that correct materials are installed.

17.4.3 Limitations to Imperfections

Welds shall comply with the limitations to imperfections as defined in ‘ANSIB31.3’ except that theterm ‘100% radiography’ as defined therein shall be taken as including ‘100% radiographic and100% ultrasonic’ inspections as shown in Table 2. Random radiography shall consist ofradiography of the entire length of at least 5% of the welds.

Failure to meet the above requirements, for any joint, will require a doubling of the percentage ofjoints to be inspected by the specified method, and failure of any joint under these conditions willrequire 100% testing. Costs for increased testing by the specified method above the minimumsshown on Table2 shall be paid for by the Contractor .

17.5 Special Requirements for Offsite LPG and Propylene Piping

In addition to the foregoing, piping to Purchaser’sSpecifications C9 and C9A shall be subject tothe following additional requirements.

17.5.1 Welding Consumables

E7016-1 or E7018-1 SMAW welding electrodes shall be used for all welding. Test certificates arerequired for each batch of electrodes, including impact test results.

17.5.2 Welding Procedure Specifi cation

All welding shall be multipass using the SMAW process. Heat input shall be between 1-5 KJ/mm.

17.5.3 Weld Procedure Qualifi cation

1

1

Impact testing of weldments is not required.

7.5.4 Post Weld Heat Treatment

All welds shall be PWHT at 600-6507C (1100-12007F) for one hour.

7.5.5 NDE

(i) Radiography shall be 10% of buttwelds (ie, 10% of welds shall be completely radiographedfull circumference).

(ii) Limits on allowable defects shown by radiography shall be as per ‘ANSIB31.3’ for the 100%radiography case.

(iii) All other welds shall be 100% magnetic particle inspected.

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PURCHASER’S APPROVAL CHECKLIST

§1.0(iii) §6.1(i) §8.0(iii) §13.3(i)

§1.0(iv) §6.1(iii) §8.0(vi)(c) §13.3(ii)

§2.1(a) §6.1(iv) §9.0(i) §13.3(iii)

§2.1(d) §6.1(v) §9.0(iv) §13.3(iv)

§2.2(i) §6.1(x) §9.0(vi) §14.4(i)

§3.1(ii) §6.1(xi) §10.0(v) §14.4(ii)

§4.0(i) §6.2(ii) §10.0(viii) §15.2.1(iii)

§4.0(ii) §6.2(v) §10.0(ix) §15.2.2(v)

§4.0(iii) §6.2(vi) §10.0(x) §15.2.3(iv)

§5.0(iii) §6.2(vii) §11.0(ii) §15.2.4

§5.0(vi) §6.3(iii) §11.0(iii) §15.2.6(i)

§5.0(ix) §7.0(iv) §12.0 §15.2.7(i)(a)

§5.0(x) §7.0(vi) §13.2(iii) §16.3.2(iv)

§5.0(xi) §7.0(vii) §13.2(vi) §17.2

§5.0(xv) §8.0(i) §13.2(ix) §17.4.1(a)

LIST OF REFERENCES

NYS-A1.31 Thick Wall Pressure Vessels and Heat ExchangersNYS-A1.32 CS Pressure Vessels and Heat Exchangers for Low Temperature OperationNYS-A1.33 CS Pressure Vessels and Heat Exchangers in Sour ServicesNYS-A1.34 Clad Carbon and Low Alloy Steel Pressure Vessels and Heat ExchangersNYS-A1.50 Basic Requirements for Submission of Bids and Execution of Contracts for Major EquipmentNYS-C2.10 Unfired Pressure VesselsNYS-D1.10 Storage Tanks to API650NYS-E1.10 Water Cooled Steam Surface Condenser EquipmentNYS-E1.20 Shell and Tube Heat ExchangersNYS-E1.30 Air cooled Heat ExchangersNYS-L1.10 Fabricated Steel Piping and Tubing Assemblies (For Service above 3207F)

SF-A-635 Weld Procedure Specification and Qualification RecordSD-L-10276 Root Valve Bridge-welding Details for Piping and Pressure Casings Subject to VibrationSD-C-99663 Welding Details for Clad Steel Vessels

ASME B1.20.1 Pipe Threads (except Dryseal)ANSI B31.3 Chemical Plant and Petroleum Refinery Piping

ASME Section II Power BoilersPart A Ferrous Material SpecificationsPart C Specifications for Welding Rods, Electrodes and Filler MetalsASME Section V Nondestructive ExaminationASME VIII Div 1 Pressure VesselsASME Section IX Welding and Brazing Qualifications

ASTM A608 Specification for Centrifugally Cast Iron-Chromium-Nickel High-Alloy tubing for Pressureapplication at High Temperatures

BS 4870 Pt:3 Arc Welding of Tube to Tube-plate Joints in Metallic MaterialsBS 5135 Specification for Arc Welding of Carbon and Carbon Manganese Steels

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EEMUA 143 Recommendations for Tube End Welding: Tubular Heat Transfer Equipment Part 1 -Ferrous Materials

NACE RP 0472-87 Methods and Controls to Prevent In-service cracking of Carbon Steel Welds in P-1Materials in Corrosive Petroleum Refining Environments

NACE MR 0175-92 Sulphide Stress Cracking Resistant-Metallic Materials for Oilfield Equipment

BIBLIOGRAPHY

“Determination of Necessary Preheat Temperature in Steel Welding,”N. Yorioka, H. Suzuki, S. Ohshita, S. Saito, AWS Welding Research Supplement June 1983 p. 147 - 153.

“Effects of Steel Inclusions and Residual Elements on Weldability,”P. Hart, Metal Construction October 1986.

“Analysis of Delta Ferritic Data from Production Welds on StainlessSteel Pipe,”Hebble, Canonico, Edmonds, Goodwin & Nanstad. Welding Journal September 1985.

“Preheat: The Main Defense Against Hydrogen Cracking,”R. Irving, Welding Journal July 1992.

“HAZ Cracking in Thick Sections of Austenitic Stainless Steels Parts Iand II,”R.D. Thomas Jr. Welding Journal December 1984.

“Carbon Equivalent, Hardness and Cracking Tendency Relationship inC-Mn Microalloyed Structural Steels,”Y. Ito, M. Nakanishi, Y. Komizo. Joining and Materials October 1988.

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Revised 3/95 NYS-B9.10Appendix I (sheet 1 of 3) 31 of 38

APPENDIX I - SELECTION OF WELDING CONSUMABLES

TABLE 3 Selection of Welding Consumables

ALLOY C.S. C 1⁄2 Mo 1 1⁄4 Cr1⁄2 Mo

2 1⁄4 Cr1 Mo

5 Cr1⁄2 Mo

7-9 Cr1 Mo

12 CrS.S.

304S.S.

316LS.S.

321/347S.S.

MONEL

16 16 16 16 16,15 15 15 15 15 15 16

MONEL J J J J J, H H H H H H ERNiCu-7

321/347S.S.

13/12,14 *

13/12,14 *

13/12,14 *

13/12,14 *

13/12,14 *

13/12,14 *

15 10,12 10,11,12

12

F, H F, H F, H F, H F, H F, H H G G G

316LS.S.

13/11* 13/11 * 13/11* 13/11* 13/11* 13/11* 15 10,11,12

11

F, H F, H F, H F, H F, H F, H H G, ER316L

ER316L

304S.S.

13/14*

13/14*

13/14*

13/14*

13/14*

13/14*

15 10,17

F, H F, H F, H F, H F, H F, H H G

12Cr 13, 15 13, 15 13, 15 13, 15 13, 15 13, 15 9, 15
S.S.
F, H F, H F, H F, H F, H F, H I

7-9Cr1 Mo

8 8 8 8 8 8

ABCDE**

BCDE**

BCDE**

CDE**

DE**

E

7 7 7 7 7
5 Cr 1⁄2 Mo
ABCD**

BCD**

BCD**

CD**

D

21⁄4 Cr1 Mo

6 6 6 6

ABC ** BC**

BC**

C

11⁄4 Cr1⁄2 Mo

5 5 5

AB ** B B

C 1⁄2 Mo 4 4

C.S. 1, 2, 3

A

Legend

Numbers in rows refer to Table 4(SMAW)Letters in rows refer to Table 5(GTAW)

* Use 13 as a “Buttering”Layer and 11, 12 or 14 tocomplete the Joint

** Use lower alloy for root runonly

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Revised 3/95NYS-B9.10Appendix I (sheet 2 of 3)32 of 38

TABLE 4 Selection of SMAW Consumables

No. TYPE AWS a NOTES

1Carbon SteelAll PositionDeep Penetration

SFA 5.1E6010

FOR BASE METAL WITH:1. Minimum specified tensile strength not exceeding 60,000 psi2. Maximum thickness 3⁄4in.3. Design minimum temperature above 07C (327F)

2Carbon SteelAll PositionMedium Penetration

SFA 5.1E6012E6013

As for 1 and where joint preparation is good.Not for root runs on single sided buttwelds

3Carbon SteelLOW HYDROGEN

SFA 5.1E7015E7016E7018

FOR BASE METAL WITH:1. Minimum specified tensile strength not exceeding 70,000 psi2. Design minimum temperature above - 467C (-507F)3. Use E6010 for root run on single sided buttwelds when design min. T . 07C4. Where design minimum temperature is between 0 & -487C (32 & -547F). UseE7016-1 or E7018-1, each batch to be impact tested in all sizes used

4C1⁄2 Mo SFA 5.5

E7010-A1E7018-A1

511⁄4 Cr1⁄2 Mo SFA 5.5

E8016-B2E8018-B2

621⁄4 Cr 1 Mo SFA 5.5

E9015-B3E9018-B3

75 Cr1⁄2 Mo SFA-5.4

E502-15

89 Cr 1 Mo SFA-5.4

E505-15

912 Cr SFA-5.4

E410 NiMo -15PWHT, if used, not to exceed 6207C (11507F)May be used for ASTM CA6NM castings

10308 S.S. SFA-5.4

E308L-15Strength at elevated temperature is lower than E308H. See no 17 below.Deposit is approx 19Cr 9Ni composition. Not acceptable for 304L base materialwelding unless 0.03% Max C in deposit

11316L S.S. SFA-5.4

E316L-15

12347 S.S. SFA-5.4

E347-15

13309 Mo S.S.or 309L

SFA-5.4E 309Mo-15

Use as an initial ‘buttering layer’ for all austenitic stainless steel deposits on CMnand low alloy base material

14309 Cb S.S. SFA-5.4

E 309 Cb-15Watch for ‘hot short’ problems and sigma formation on PWHT

15HIGHNICKEL

SFA 5.11E NiCrFe-2

Preferred consumables are INCOWELD A, and GRINI 7NOTE INCONEL 182 (E NiCrFe-3) is also acceptable

16MONEL400

SFA 5.11E NiCu-2

Preferred consumable is MONEL 190

17304H S.S. SFA-5.4

E 308H-15For structures such as FCCU regenerator cyclones, where high temperature strength

is required

Note:1. For SMAW welding of all alloy steels, low hydrogen electrodes shall be used.

2. SMAW electrodes, SAW fluxes and flux-cored wire shall be conditioned in accordance with manufacturer’srecommendations before welding. As most welding fluxes are hygroscopic, consumables shall be stored in controlledatmospheres at all times. Adequate precautions shall be taken to prevent subsequent deterioration after withdrawal fromstorage and before use.

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Revised 3/95 NYS-B9.10Appendix I (sheet 3 of 3) 33 of 38

TABLE 5 Selection of GTAW Consumables

NO. TYPE AWS a NOTES

A Carbon Steel SFA 5.18ER70-S2

Minimum design temperature shall be above -297C (-207F)

B 11⁄4 Cr 1⁄2 Mo SFA 5.28ER80S-B2

C 21⁄4 Cr 1 Mo SFA 5.28ER90S-B3

ER90S - B3L preferred if PWHT operation questionable

D 5 Cr 1⁄2 Mo SFA 5.9ER502

E 9 Cr 1 Mo SFA 5.9ER505

F 309L SFA 5.9ER309L

Strength at elevated temperature is less than for ER309

G 347 SFA 5.9ER347

Avoid excessive base metal dilution since low ferrite contentwill increase crack sensitivity

H HIGHNICKEL

SFA 5.14ER NiCr-3

INCONEL 82 preferred

I 12 Cr SFA 5.9ER410-NiMo

PWHT (if used) not to exceed 6207C (11507F)May be used for ASTM CA 6mm castings

J HIGHNICKEL

SFA 5.14ER Ni 1

NICKEL 61 preferred

CES 98


Revised 3/95 NYS-B9.10Appendix II (sheet 1 of 2) 34 of 38

APPENDIX II - SUMMARY OF PREHEAT AND PWHT REQUIREMENTS

TABLE 6 Summary of Owner’s Preheat and PWHT Requirements

SPECIFICATION & SCOPE MATERIAL PREHEAT &INTERPASS TEMP

7C (7F)

PWHT TEMP.7C (7F) & TIME

Pressure Vessels and Piping - CS, CMo, CrMosteels- Shell & Heads ASME VIII Div 1 & Proj Spec50mm (2in) thick max.- SMAW, GMAW, SAW & GTAW weldingprocesses- Also covers 50mm (2in) max thickness heatexchangers- PWHT requirement per Proj Spec and purchaseorder- Fabrication of steel pipe and furnace tubes perNYS-L1.10

P-1 C.S.In accordance with ‘BS5135’ (1)

593-649 (1100-1200)Time per Code but 1 hr min. Forpiping to B31.3, PWHT if thk.19mm (3⁄4in), 1 hr min.

P-3 C1⁄2 Mo(2)

93-149 (200-300) 635-677 (1175-1250)Required if thickness .13mm(1⁄2in). Time per Code but 1 hr min.

P-4 1-11⁄4 Cr 149-204 (300-400) 718-746 (1325-1375)1 hr/inch 2 hrs min (3)

P-5 2-9 Cr 204-316 (400-600) 718-746 (1325-1375)1 hr/inch 2 hrs min (3)

Pressure Vessels, Piping and Furnace Tubes.PWHT req’d where thickness at weld is 19mm(3⁄4in) or greater

Aust SS 10(50) min pre-heat,Max Interpass Temp150 (300)

Where thickness .19mm (3⁄4in)871-899 (1600-1650),2 hrs min. (4)

SPECIAL CASES

12 Cr 4Ni Castings (ASTM CA6 NM) 93-204 (200-400) Double Temper1st at 677 (1250), 2 hrs min.2nd at 607 (1125) max - 4 hrs min.

Aluminum Bronze No pre-heat. Max 649-704 (1200-1300) where
Interpass 200 (400) thickness .25mm (1in) (5)
12 Cr 405/410S (6) 704-760 (1300-1400) 2 hrs min.

Seal & Socket WeldingRefer §14.0

, 2 Cr 149-204 (300-400) Cool Slowly Under Insulation

2-9 Cr 204-316 (400-600) As above (7)

Skin Points on furnace tubes 1-9 Cr Top end of rangesgiven above (7)

Hold 93-121 (200-250) for 1 hrafter welding then cool slowlyunder insulation

ose linings and cladding - 410S, 405, Cr Steel, Aust SS,As for Base Material As for Base Material
Vessel lo Monel (8)
Notes:

1. (i) ‘BS 5135 Specification for Arc Welding of Carbon and Carbon Manganese Steels’. The use of Hydrogen Scale D is notpermitted since the necessary control under certain shop and site conditions is considered to be impracticable. However, thePurchaser will consider a reduction in preheat temperature of up to 507C (1207F) if a general rather than a local preheat isused. Interpass temperatures shall be maintained within the relevant preheat temperature range.

(ii) As an alternate to the above, the Contractor may use 957C (2007F) when the material thickness is less than or equal to38mm (2in) or 1507C (3007F) for greater thicknesses. Refer to §9(ii) for special considerations for modern low-carbon,low-sulphur, micro-alloyed steels.

(iii) Generally, carbon steels less than 38mm (11⁄2in) thick do not require preheat except where a high degree of restraint, orambient temperatures below 107C (507F), or low heat input, or a carbon equivalent in excess of 0.41% (short formula), areinvolved. In such cases, preheat is required either to avoid hydrogen cracking or to meet the specified hardnessrequirements.

2. Carbon molybenum steels are not approved for new construction, this information is provided for welding on existing CMo equipment only.

CES 98


Revised 3/95NYS-B9.10Appendix II (sheet 2 of 2)35 of 38

TABLE 6 Notes— cont.

3. (i) Heat treatment required for all thicknesses of P4 & P5 materials.

(ii) To avoid over-tempering, a lower temperature PWHT shall be used for higher strength Normalised and Tempered(N&T) or Quenched and Tempered or (Q&T) materials.

(iii) In the case of ferritic alloy steels containing over 2% Cr, this heat treatment shall be completed after welding andwithout allowing the weldment to cool below 2007C (4007F), except in the case of joints where an austenitic stainless steelor high nickel weld rod has been used. Should this not be practicable, subject to the Purchaser’sapproval, the finishedweld shall be heated to 6007C (11007F), wrapped with insulation and allowed to cool. It shall then be postweld heat treatedas above, when convenient.

4. (i) When PWHT of TP321/TP347 austenitic stainless steels is required in accordance with AppendixII, the procedure shallbe as follows:

(a) Heat to 4507C (10007F) and hold for one hour/inch thickness.(b) Heat as quickly as possible to 870-9007C (1600-16507F) and hold for two hours.(c) Remove all insulation and cool in still air.

(ii) The requirement for this heat treatment is based on the need to reduce long range stress and reduce grain boundaryprecipitates, which in the power industry have been the cause of cracking in thick sections. The effect of the heat treatmenton associated materials in the system shall be critically assessed.

(iii) The use of this procedure requires careful consideration and shall be subject to the Purchaser’sapproval.5. 11⁄2 hours minimum, add 1⁄2 hr for each inch above one inch in thickness at the weld. Cooling rate not to exceed 2607C

(5007F)/hr.

6. Types 410S and 40512Cr Steel under 6mm in thickness, when welded with high nickel or 309Mo stainless steelelectrodes, do not require preheat provided that ambient and metal temperatures are above 207C (687F). However, thismaterial may embrittle when in service at temperatures above 3157C (6007F), and the application of preheat (315-3707C(600 - 7007F)) will then assist weldability.

7. Weld with a high nickel electrode.

8. Loose linings are not acceptable for new construction, or where this specification requires the base material to be PWHT.

CE

S 98

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Revised 3/95

Appendix III (sheet 1 of 1)

APPENDIX III-MINIMUM SOCKET AND SEALWELD DIMENSIONS

l 900 included in GPS-L1.
Details applies to all Caltex Piping Specifications up to C
NY

S-B

9.1036 of 38

All dimensions in the tables of this drawing are in inches.

These weld dimensions shall also apply to sealwelds on threaded joints. Additionally, all exposed threads shallbe covered.

Tabulations cover pipe sizes/schedule/flange rating combinations referred to in GPS-L1.

CES 98


Revised 3/95 NYS-B9.10Appendix IV (sheet 1 of 2) 37 of 38

APPENDIX IV - WELDED JOINT CATEGORY

DEFINITION

CategoryAs used herein, this term defines the location of a joint in a vessel, but not the type of joint. The“Categories” established by this paragraph are for use elsewhere in this Specification to definespecial requirements regarding joint type and degree of inspection for certain welded pressurejoints. Since these special requirements, which are based on service, material and thickness, do notapply to every welded joint, only those joints to which special requirements apply are included inthe categories. The special requirements will apply to joints of a given category only whenspecifically so stated. The joints included in each category are designated as joints of Categories A,B, C and D and are described after Figure 1. Figure 1 illustrates typical joint locations included ineach category

FIGURE 1 Illustration of Welded Joint Locations typical of Categories A, B, C and D

Category ALongitudinally welded joints within the main shell, communicating chambers, transitions indiameter, or nozzles; any welded joint within a sphere, within a formed or flat head, or within theside plates of a flat-sided vessel; circumferential welded joints connecting hemispherical heads tomain shells, to transitions in diameters, to nozzles, or to communicating chambers.

Category BCircumferential welded joints within the main shell, communicating chambers, nozzles, ortransitions in diameter, including joints between the transition and a cylinder at either the large orsmall heads other than hemispherical to main shells, to transitions in diameter, to nozzles, or tocommunicating chambers.

When buttwelded joints are required elsewhere in this Specification for Category B, an angle jointconnecting a transition in diameter to a cylinder shall be considered as meeting this requirement,p the angle (see Figure 1) does not exceed 30 degrees. All requirements pertaining to theb

CWhfl

rovided
uttwelded joint shall apply to the angle joint.
ategory Celded joints connecting flanges, Van Stone Laps, tubesheets, or flat heads to main shell, to formed

eads, to transitions in diameter, to nozzles, connecting one side plate to another side plate of aat-sided vessel.

CES 98


Revised 3/95NYS-B9.10Appendix IV (sheet 2 of 2)38 of 38

Category DWelded joints connecting communication chambers or nozzles to main shells, to spheres, totransitions in diameter, to heads, or to flat-sided vessels, and those joints connecting nozzles tocommunicating chambers (for nozzles at the small end of a transition in diameter, see Category B).

Circumferential Transition JointAn angle joint connecting a transition in diameter of a cylinder shall be considered as Category B,provided the angle does not exceed 307. Otherwise, it shall be Category A.

caltexwelding nysb910-1 ras061808

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