PETRONAS TECHNICAL STANDARDS
Welding for Chemical, Oil, and Gas Industries
(Amendments / Supplements to API RP 582)
PTS 15.12.01
January 2017
© 2017 PETROLIAM NASIONAL BERHAD (PETRONAS)
All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.
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FOREWORD
PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.
Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.
Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.
In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.
PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
consent of PETRONAS.
The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
PETRONAS that this requirement is met.
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ANNOUNCEMENT
As part of the recent transformation exercise, the PTS numbering system has been revised to 6-digit
numbers and drawings, forms and requisition to 7-digit numbers. All newly revised PTS will adopt this
new numbering system, and where required make reference to other PTS in its revised numbering to
ensure consistency. Users are requested to refer to PTS 00.01.01 (PTS Index) for mapping between
old and revised PTS numbers for clarity. For further inquiries, contact PTS administrator at
ptshelpdesk@petronas.com.my
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Table of Contents
1.0
INTRODUCTION ..................................................................................................... 5
1.1
SCOPE ............................................................................................................................ 5
1.2
GLOSSARY OF TERMS..................................................................................................... 5
1.3
SUMMARY OF CHANGES ............................................................................................... 7
2.0
AMENDMENTS AND SUPPLEMENTS TO API 582 ..................................................... 8
3.0
BIBLIOGRAPHY .................................................................................................. 114
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1.0
INTRODUCTION
This PTS provides the minimum technical requirements for welding of metals in oil and gas
industries. This PTS was developed to ensure the safe and reliable operations of the
equipment for offshore and onshore facilities. This PTS adopts API RP 582 with additional
requirements as an amendment and supplement based on PETRONAS lessons learnt and best
practices.
API RP 582 is intended to supplement the welding requirements of ASME BPVC Section IX and
similar codes, standards, specifications and practices.
1.1
SCOPE
This PTS applies to piping and pressure vessels for onshore and offshore, including subsea
facilities. In addition to the supplements and amendments, this PTS covers welding
requirements that are material specific for ferrous and non-ferrous materials.
This PTS excludes welding of pipelines and offshore structural steels.
1.2
GLOSSARY OF TERMS
1.2.1
General Definition of Terms & Abbreviations
Refer to PTS 00.01.03 for PTS Requirements, General Definition Of Terms, Abbreviations &
Reading Guide.
1.2.2
Specific Definition of Terms
No
1
2
3
Terms
High-alloy steel
Definition
Stainless steels, 12 Cr, 22 Cr, 25 Cr and higher
(e.g. ASME P6, P7, P8, P1 0J and P10K;
ISO TR 15608 Group 7, 8 and 10)
Steels from 0.5 Mo up to 9Cr-1Mo & Steels
Low-alloy steel
from 0.5 up to 9% Ni
(e.g. ASME P4, P5A, P5B, P5C;ISO/TR 15608
Group 4, 5, 6, 9)
Carbon manganese steels, including 0.3 and 0.5
Unalloyed steel
Mo steels
(e.g. ASME P1 and P3; ISO/TR 15608 Group 1, 2,
3 and 11)
Table 1.1: Specific Definition of Terms
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1.2.3
Specific Abbreviations
No
Abbreviations
Description
1
ASNT
American Society for Nondestructive Testing
2
Ceq
Carbon Equivalent
3
CMT
Cold Metal Transfer
4
DSS
Duplex Stainless Steel
5
DT
Destructive Testing
6
DWR
Dissimilar Weld Register
7
EBW
Electron Beam Welding
8
EGW
Electrogas Welding
9
ERW
Electric Resistance Welding
10
ESW
Electroslag Welding
11
EV
Essential Variable
12
FCAW
Flux-Cored Arc Welding
13
FCAW-S
Self-shielding FCAW
14
FN
Ferrite Number
15
FW
Friction Welding
16
GMAW
Gas Metal Arc Welding
17
GMAW-P
Pulsed Gas Metal Arc Welding
18
GMAW-S
Short-Circuit Gas Metal Arc Welding
19
GMAW-ST
Spray Transfer Gas Metal Arc Welding
20
GTAW
Gas Tungsten Arc Welding
21
GTAW-HW
Hot Wire Gas Tungsten Arc Welding
22
GTAW-P
Pulsed Gas Tungsten Arc Welding
23
GW
Gravity Welding
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1.3
No
Abbreviations
Description
24
HAZ
Heat Affected Zone
25
JPK
Jabatan Pembangunan Kemahiran
26
MDR
Manufacturer Data Record
27
MT
Magnetic Particle Testing
28
OES
Optical Emission Spectrometry
29
PQR
Procedure Qualification Record
30
PT
Liquid Penetrant Testing
31
PWHT
Post Weld Heat Treatment
32
QSET
Optimal Short Arc Parameter Setting
33
RMD
Regulated Metal Deposition
34
RT
Radiography Testing
35
SAW
Submerge Arc Welding
36
SDSS
Super Duplex Stainless Steel
37
SMAW
Shielded Metal Arc Welding
38
STT
Surface Tension Transfer
39
UTS
Ultimate Tensile Strength
40
VT
Visual Examination
41
WPS
Welding Procedure Specification
Table 1.2: Specific Abbreviations
SUMMARY OF CHANGES
This PTS 15.12.01(January 2017) replaces PTS 15.12.01 (February 2016).
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2.0
AMENDMENTS AND SUPPLEMENTS TO API 582
In this section, the reference clauses of API 582 are amended or supplemented. Existing
clauses are deleted or new sections are added as mentioned. Clauses of API 582 that are not
mentioned in this PTS shall apply and remain valid.
2
Normative References
Add the following
API TR 938-B, Use of 9Cr-1Mo-V (Grade 91) Steel in the Oil Refining Industry
ASME/Boiler and Pressure Vessel Code
- Section II, Materials Part D – Properties
- Section V Non-destructive Examination
- Section VIII-Rules for Construction of Pressure Vessels
ASTM A923, Standard Test Methods for Detecting Detrimental Intermetallic Phase in Duplex
Austenitic/Ferritic Stainless Steels;
ASTM E562, Standard Test Method for Determining Volume Fraction by Systematic Manual
Point Count;
AWS A4.3, Standard Methods for Determination of the Diffusible Hydrogen Content of
Martensitic, Bainitic, and Ferritic Steel Weld Metal Produced by Arc Welding;
AWS D10.11, Guide for Root Pass Welding of Pipe without Backing
WRC Bulletin 421, Welding Type 347 Stainless Steel – An Interpretative Report, R. David
Thomas Jr. and Robert W. Messler, Jr.
WRC Bulletin 452, Recommended Practices for Local Heating of welds in Pressure Vessels,
Joseph W. McEnerney and Pingsha Dong
SSPC-SP 5/NACE No. 1, White Metal Blast Cleaning
BS/ ISO 8501 Corrosion Protection of Steel Structures by Painting
NACE MR0175/ISO 15156 Petroleum and natural gas industries, Materials for use in H2Scontaining Environments in oil and gas production.
PTS 15.10.01 –Brittle Fracture of Metallic Materials
4
General Welding Requirements
Amend clause 4.1 to the following
PTS 15.12.06 Structural Steel Fabrication or local code requirements.
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Structural (nonpressure boundary) welding requirements shall comply with either PTS
15.12.06 Structural Steel Fabrication or AWS D1.1 or AWS D1.6.When approved by the Owner,
welding procedures may be qualified per ASME BPVC Section IX.
Amend Clause 4.2 to the following
Prequalified welding procedures shall only apply for structural section using Type III materials
as stated in PTS 15.12.06 and using SMAW process only.
Add new 4.5
Welding equipment and related instruments
(i)
Welding machines shall be calibrated and checked at least every 12 months, and
shall comply with relevant sections of equivalent AWS standard. All calibrated
equipment shall display valid calibration sticker.
(ii) Welding equipment and gauges shall be verified as calibrated prior to
commencement of production welds and also at regular interval per Contractor
or Manufacturer procedure agreed by the Owner.
(iii) Measurement of heat input and interpass temperature, during welding of Critical
Equipment, that may have impact on toughness shall be either taken
continuously or if agreed by the Owner, a minimum of 3 times per shift.
Contractor shall identify Critical Equipment for upstream and downstream
projects.
(iv) The continuous rated cycle of welding or cutting machines used shall be at least
30% more than the required duty.
(v) Gas cutting equipment shall be per ISO 5172 or equivalent AWS standard.
(vi) The Contractor or Manufacturer shall: (this is for project requirement)
a) Supply welding machines, cables, quivers, earthing clamps and all other
accessories that conform to an acceptable standard agreed by the Owner.
b) Maintain all welding and cutting equipment to ensure weld quality and
safety of the personnel.
c) Provide separate voltmeters and ammeters for all arc-welding processes
except for GMAW, FCAW and SAW welding processes.
d) Supply ovens for baking, drying and storage of electrodes. Ovens used
shall be capable of accurate temperature control, and of sufficient size to
allow uniform drying of the electrodes.
(vii) Welding equipment for GMAW, FCAW and SAW shall be fitted with ammeters
and voltmeters.
(viii) Welding machines shall be operated within the voltage and current ranges
specified in qualified WPS, else the machines shall be repaired or replaced by the
Contractor or Manufacturer.
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(ix) Attachment clamps welded for fit up and welding shall be considered as
temporary welds as specified in API RP 582 Section 12.4.
Add new 4.6
Non-destructive testing methods and extent
(i) The methods or techniques and extent of non-destructive testing (NDT) for
pressure containing equipment (e.g. pressure vessels, boilers, piping, pipelines
etc.), tank, and structural items are covered by other applicable PTS, the relevant
design code, and respective design/purchasing documents/specification.
Add new 4.7
Inspection and examination personnel
4.7.1
Qualification of Inspection & Examination Personnel
(i) The inspection and examination personnel used shall be individually approved by
the Owner.
(ii) The method of screening can be through interview and examinations or mock up
testing.
(iii) The minimum qualification of examination personnels are as follows:
NDT Methods
Qualification
Visual Examination (VT)
ASNT or ISO 9712, Level 2
Magnetic Particle Examination
(MT)
JPK or ASNT or ISO 9712, Level 2
Liquid Penetrant Examinations (PT)
JPK or ASNT or ISO 9712, Level 2
Radiography Examination (RT)
JPK or ASNT or ISO 9712, Level 2
Radiography Interpreter
JPK or ASNT or ISO 9712, Level 2
Ultrasonic Examination (UT)
JPK or ASNT or ISO 9712, Level 2
(iv) Supervisor assigned to lead and coordinate the NDT activities shall be at least
Level 3 qualified of the same certification.
(v) Alternative qualification shall be approved by the Owner, subject to satisfactory
demonstration of independence and control of the qualification procedure
endorsed by an NDT specialist. NDT specialist shall possess NDT Level III
certification.
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Add new 4.8
Equipment or piping in “Sour” or “Wet H2S” service shall be fabricated in accordance to PTS
15.01.05, PTS 12.30.02 and PTS 12.20.01.
If special root quality or profile is required, it should be specified in the drawings or
manufacturing specification.
Add new 4.9
For new piping fabrication, weld overlay or build up to increase base metal thickness to meet
minimum required wall thickness or strength is not permitted.
Add new 4.10
4.10 Before Welding
4.10.1 Welding Procedure Specification (WPS)
(i) WPS shall be submitted to the Owner for approval before performing the
procedure qualification.
(ii) Production weld shall not be carried out before welders have been qualified and
WPS and supporting PQR are approved by the Owner.
4.10.1.1 Approval
(i) WPS shall comply with local code requirements as well as ASME/BPVC Sec IX or
applicable section of ISO 15614, and also this PTS.
(ii) Approved WPS may be withdrawn if excessive repair rates not attributed to poor
welder skills are encountered.
4.10.1.2 Previously Qualified Procedures
(i) Previous qualified WPSs may be submitted for Owner’s approval if the
requirements of this PTS are complied. The WPS submitted shall be attached with
supporting PQR that have been witnessed by an Independent Third Party.
(ii) The contractor shall furnish references where the proposed WPS have been used.
4.10.1.3 Procedures to be Qualified
(i) All measurement records and essential variables parameter such as heat input or
arc energy determination shall be raw values.
(ii) Quality system of testing laboratories shall comply with ISO 17025 or equivalent.
Laboratory chosen for the testing may need to be pre-approved by the Owner.
4.10.2 Welding Procedure Qualifications
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(i) WPS shall be prepared and qualified according to ASME/BPVC Sec IX or ISO 15614
unless otherwise specified by local codes/regulations.
(ii) PQR shall include evidences or reports that proof that the chemical, mechanical
and hardness requirements specified by the Owner are met.
(iii) WPS submitted for Owner review shall have full PQR records.
(iv) “Highly restrained” joints or tube sheets with strength welded tube joints shall
use full size mock-up coupons. Contractor and Owner to agree on definition of
“Highly restrained” joints
(v) Production welding machines shall be used for welding production coupons of
ASME BPVC Sec VIII Div 2 vessels. If impractical and agreed by the Owner,
laboratory machines may be used provided the welding parameters are identical
to the parameters used for the production welding machines.
(vi) WPS intended to be used and extent of NDT for each weld shall be specified and
indicated inside General Assembly and/or Detailed Drawings.
(vii) Identifiers or Symbols as described in AWS D2.4 or ISO 2553 shall be used to
identify Field Welds on the drawings.
(viii)
Multi-pass fillet welds may be qualified using groove welds PQR per ISO
15614, however separate WPS’s for the multi-pass welds shall be submitted.
Single pass fillet weld for pressure retention shall be qualified separately per ISO
15614.
(ix) Using combination of PQR’s from various contractors is not permitted.
(x) The PQR form shall also include the following welding parameters on each pass
until completion
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
Welding current type and polarity, amperage and voltage
Travel / Wire feed Speed
Direction of travel for vertical welding
Welding consumable diameter
Welding technique (i.e string, weave, split layer)
Interpass temperature (i.e by use of Thermostick or Digital Thermometer)
Approximate width or weld pass
Approximate thickness of weld layer
Interpass cleaning method
Sequence and number of weld passes per layer
Treatment to back side (i.e Backgouged, Ground, Back-welded,
Inspection, Etc)
l) Heat Input
m) Preheat and Interpass Temperature
4.10.2.1 If specified by the Owner or required by the Local Code Requirement
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(i)
WPS intended to be used for Registered Equipment (e.g. Pressure Vessels or
Boilers) shall be approved if required by the Local Code Requirement in which
the equipment is intended to be registered, installed and operated. If the
equipment is fabricated outside the Local Code Requirement where the
equipment will be registered, installed and operated, the WPS shall be approved
by an independent third party inspection company.
(ii) Material certificates for base material, filler material, and composition of
shielding gases used shall be attached with the supporting PQR.
(iii) WPS for fillet and groove welds shall be submitted separately eventhough
procedure was qualified using groove weld.
(iv) Welders and Welding Operators performance test coupons shall be VT, RT, and
mechanically tested (i.e. bend test), and subjected to corrosion test if applicable.
Mechanical test pieces shall be taken per ASME BPV Code Sec IX. Corrosion
testing shall refer to Annex E.7
(v) When one of the following mechanical test specimens fails to meet the require
acceptance criteria, two additional specimens shall be prepared for res-testing:
a)
b)
c)
d)
e)
f)
Tensile test
Bend test
Impact test
Hardness test
Macro examination
Ferrite Content and Pitting Corrosion for DSS
(vi) The location of the two additional specimens shall reflect the location of the
failed specimen. If one or both of the retest specimens fail, then this shall be a
cause for rejection. A new weld shall be required.
(vii) The following examinations shall be carried out in the presence of the Owner or
an independent third party inspection company before cutting and removal of
the test coupon:
a) VT of butt welds shall include the root or internal of the pipe. For
austenitic and duplex stainless steel and high nickel austenitic alloys the
examination shall include the extent of oxidation.
b) PT or MT
c) RT and
d) UT (i.e. for weld made using GMAW, GTAW or FCAW only)
(viii) The acceptance criteria of the examination and testing shall be per the relevant
codes and this PTS. The acceptance criteria for the extent of oxidation shall be
per PTS 15.12.03.
(ix) Weld that fails the examination and testing specified shall not be used for the
DT.
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(x)
Production weld shall only commence after the WPS and PQR with supporting
examination and testing results are reviewed, verified and endorsed by the
Owner. The WPS and PQR shall be endorsed and stamped “Approved for
Construction” and signed by the Owner. The date and the project number shall
also be specified.
(xi) Charpy test beyond code requirements may be specified.
(xii) Mechanical tests of susceptible material shall be delayed for 24 hours after
completion of welding to cater for delayed hydrogen cracking.
4.10.2.2 Material
Requirements for materials that are not specified or stated in this PTS shall comply with the
normal codes and standards requirements plus specific PTS requirements and additional
requirements as advised by the Owner.
4.10.3 Welder and Welding Operator Qualification
4.10.3.1 Welder and welding operator shall be qualified per applicable codes (e.g. ASME BPVC
Sec IX, ISO 9606-3 to ISO 9606-5 or equivalent codes) and also the local code requirements.
4.10.3.2 Welder and welding operator validity period shall be set to a maximum of 6 months.
Extension may be granted after satisfactory review of the Welder’s Performance Register by
a third party inspection company.
4.10.3.3 Welder qualification tests shall be witnessed by the Owner if required.
4.10.3.4 Welder and welding operators shall be provided with either the followings:
(i) Badge bearing name, Welder Identification Number and photograph.
(ii) Contractor ID pass with photograph.
4.10.3.5 The welder identification number shall not be assigned to another welder, if the
welder ceased to work with the Contractor.
4.10.3.6 Contractor shall maintain record of Welders Performance Register. The register shall
be up to date and shall record as a minimum the followings;
(i) Welders name
(ii) Unique Welder Identification Number
(iii) Welding position
(iv) RT report number
(v) Welding inspection and examination results
(vi) Base material and consumable material
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(vii) Dimensional data (e.g. diameter, thickness etc.)
(viii) WPS’s number used
4. 10.3.7 Welder qualified in 6G position shall be used for all positions welding of pressure
retaining welds if required by the Owner.
4.10.3.8 Requalification test is required when the welder or welding operator does not use
the appropriate welding process of which the welder/ welding operator is qualified for a
period exceeding 6 month (structural) or 3 months (Piping), or when there are reasons to
question welder’s/ welding operator’s ability or performance.
4. 10.4 Weld Preparation
(i)
Materials, consumables and shielding gas shall have identification numbers that
are traceable to their material test certificates and gas composition analysis.
Materials shall be free from mechanical damage or corrosion.
(ii) Weld preparation shall be per ASME B16.25 or as qualified in the PQR.
(iii) Square butt joints are allowed for wall thickness below 2 mm (0.080 in) only.
(iv) Copper or Zinc or markers containing Chloride or other low melting point metal
shall not contaminate the bevel surface and adjacent areas.
(v) Opening for branch or nozzle connection of vessel or piping shall be examined
using UT prior to cutting. The area examined shall be free of lamination and nonacceptable discontinuities. Minimum of 75 mm (3 in) adjacent to the weld area
and also the intended weld area shall be inspected and examined.
(vi) The groove shall be bevelled to give an included angle of not less than 60 degrees
for single and double Vee and not less than 30 degrees for single and double
bevel. The root opening shall not be less than 2mm and not greater than 5mm
and the root face shall not be greater than 2mm. If the root opening is larger
than maximum specified, buttering of joint is required. Procedure for buttering
shall be submitted for owner approval on case by case basis. In any case, the
thickness of the buttering shall not be more than two times of the thinner section
or 19mm, whichever smaller.
(vii) The offset at structural butt joints shall not exceed T/10 (where T is the thickness
of the thinner material) or 6mm, whichever less.
(viii) The offset of longitudinal seams shall not exceed T/10 or 3mm, whichever is less.
For joints of the unequal pipe ends thickness, the external offset shall not exceed
1.5mm. All the offsets or misalignments greater than 2mm shall be machined or
ground to 1:4 tapered transition.
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4.10.4.1 Cutting and Bevelling
(i) Edge preparation and cleaning equipment (such as oxyacetylene flame cutting,
plasma cutting, grinding, brushing, etc.) used shall not affect significantly the
metallurgy of the base material. Cut edges shall be machined or bevelled by
grinding.
(ii) Edge preparation using plasma cutting shall be performed if practical using a
mechanically guided torch.
(iii) Manual hand-held bevelling with cutting torches is not permitted, unless allowed
by the Owner.
(iv) Flame cutting can be used for cutting and bevelling unalloyed and low alloy steel.
At least 3 mm of the flame cut edges shall be ground and dressed to bright metal.
(v) No dressing is required for cold-sheared plate if the thickness is not more than 10
mm (0.4 in).
(vi) The edges of Ni-steels (> 0.5% Ni) for low temperature application shall only be
cut either by machining or grinding. If permitted by the Owner, flame cutting can
be used, however at least 3 mm of the cut edges shall be ground or machined.
Cold shearing is not permitted.
(vii) VT shall be carried out on the edge surfaces. The edges shall be free from defects.
Surfaces with deep gouges and dents shall be rejected.
(viii) Bevelled edges that have been damaged shall be restored to the tolerances
specified in the applicable WPS.
(ix) Repair requiring major weld build up more than 6 mm (0.25 in) shall be performed
per qualified procedure.
(x) Weld build up of alloy material shall only be carried out if approved by the Owner.
(xi) Laminations detected by VT shall be examined further using UT, MT or PT before
removal.
(xii) High-alloy steels and clad steels should be cut using plasma cutting, and then
followed by grinding at least 3 mm (0.125 in) to bright metal.
(xiii) Depth of grinding can be reduced, for all of the above cases, if testing provides
evidence that the affected microstructure changes have been removed.
4.10.4.2 Spacing
(i) Longitudinal seams of pipe or vessel shall be staggered by a minimum of 45 degree
of rotation or 150 mm (6 in), whichever is lesser.
(ii) Longitudinal seams of horizontal pipes shall be position so that the weld is at the
top 120 degree of the pipe segment.
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(iii) Distance between toe to toe of two circumferential seams shall be minimum
50mm as specify in PTS 12.30.05
(iv) Distance between toe to toe of attachments to any weld shall be the lesser of
either 2 times the nominal thickness or 50 mm
4.10.4.3 Permitted Weld Detail
(i) Butt welds for vessels, process piping, and other pressure retaining equipment
shall be fabricated with full penetration welds.
(ii) Welding from both sides shall be performed whenever practical.
(iii) Welds with permanent backing strips or rings shall not be used unless approved
by the Owner.
(iv) Fusible inserts or removable backing strips may be used if approved by the Owner.
(v) Temporary backing strip, such as ceramics, fluxes, copper backing strips, etc., used
shall not alter the chemical composition of the weld metal. Strips used shall be
removed without damaging the welds and adjacent areas, and the welds and
adjacent areas shall be ground flush and cleaned.
(vi) Welds of low-alloy ferritic steels shall be examined using MT, after removal of
backing strips or other temporary attachments. The acceptance criteria shall be
as per design code.
4.10.4.4 Tack Welding and Clamping
(i) Tack welding shall be performed by qualified welders. The tack welding parameter
shall be as per the root welding parameters of the approved WPS.
(ii) The nominal composition of bars, bullets or bridges tacked shall be the same as
the base materials nominal composition.
(iii) Sufficient number of equally spaced tacks around the circumference shall be
made to temporarily support the loads.
(iv) Tacks that are not removed and intended to form part of the root welds shall be
ground to a taper edge to facilitate proper welding.
(v) Tack welds shall be completely removed if the tack weld has cracked or have poor
profile.
(vi) Clamp of joint fit up held by line-up clamps shall only be removed after the root
pass and hot pass has been completed.
(vii) Tack welds that are not removed shall be welded as per approved WPS (e.g
including preheat) by qualified welders. All tack welds shall be examined by VT
inclusive of examinations stated in the design specification.
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(viii) Tack welds are not permitted on the inside of the skirt between the head and the
skirt.
4.10.4.5 Alignment
(i) Permitted maximum misalignment for piping butt welds, if not specified in piping
code or purchasing specification, shall be:
Pipe Internal Diameter
Maximum misalignment
= 100 mm (4 in)
1.0 mm (0.04 in)
> 100 mm (4 in)
1.6 mm (0.0625 in)
Pipe Outside Diameter
Maximum misalignment
≤ 12 mm (0.5 in)
Pipe thickness/4
>12 mm (0.5 in)
3.0 mm (0.125 in)
(ii) Permitted misalignment for vessel and other equipment shall be per the design
standards.
(iii) Misalignment may be rectified by grinding or machining to a taper of 1:4. The
thickness after the rectification shall not be lower than the allowed minimum
tolerance.
(iv) Hot or cold reforming of piping or vessel walls or other pressure retaining
equipment shall not be carried out unless approve by the Owner.
4.10.4.6 Identification
(i) Welds shall be uniquely numbered.
(ii) Contractor shall prove that each weld can be identified at all phases of fabrication.
(iii) Weld unique number shall be stencilled adjacent to the weld before welding i.e.
during fit-up.
(iv) Records of weld unique and welder identification for each weld shall be
maintained and updated. These records shall be incorporated in the
documentation package.
(v) Identification number shall be maintained during grit-blasting and painting.
(vi) Welders shall stencilled their welder identification number adjacent to the welds
they have welded.
4. 10.5 Quality Assurance
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(i) The Contractor and subcontractor shall have a Quality Assurance system that is in
accordance to ISO 9000 series standards.
(ii) The Owner may perform audits or assessment to check and assure compliance by
the Contractor.
(iii) The Owner may reject any material, workmanship or processes that do not
comply with the specification. Full compliance does not discharge the Contractor
from the responsibility to perform additional test if there are any serious concerns
or doubt with regard to quality of the materials or works.
(iv) The Contractor may be required to issue a signed statement of compliance
confirming that the items has been constructed per the requirements specified in
the purchase order.
4. 10.6 Quality Conformance
(i) The Contractor shall submit Quality Plan and relevant procedures that are in
accordance to ISO 3834 or equivalent, for review and approval by the Owner,
before work commencement.
(ii) Fabrication shall be accepted by the Owner upon submission of proper reporting
on production welding and inspection activities by the Contractor.
(iii) Approval of the Quality Plan by the Owner does not discharge the Contractor the
responsibility to comply with the requirements of the Contract.
4. 10.7 Material Segregation
(i) The Contractor shall submit procedure for the segregation and control of all
materials used, and also control of tools to be used with the materials.
(ii) The fabrication area for stainless steel and other non-ferrous piping and
equipment shall be performed in separate location from fabrication of CarbonManganese and low alloy steels. Instead, the Contractor may submit a procedure
to prevent surface contamination, for review and approval by the Owner.
(iii) Titanium welding shall be performed in a dedicated fully enclosed area.
4. 10.8 Inspection and Test Plan (ITP)
(i) The contractor shall submit test package comprising of ITP and all the relevant
procedures to the Owner for review and approval, prior to start of welding and
fabrication.
(ii) Weld defect rates per WPS and per welder shall be recorded and updated.
(iii) For piping, the number of completed pipe welds are used to establish rejection
rates (i.e. number of repairs per number of completed welds). A rejection is any
weld that necessitates a repair. Rejection rates shall be agreed between
Contractor and Owner.
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(iv) For equipment, the total linear weld distance on a per-metre (or per-foot) basis
shall be used to establish the rejection rate (i.e. number of repair segments per
total number of one-metre segments). A rejection is any weld that necessitates a
repair within a one-metre segment.
4. 10.9 Records
Documentation required and compiled prior to welding shall include the following:
(i) Quality plan, ITP and QA/QC procedures
(ii) Weld plan/map
(iii) Approved WPS/PQR and repair procedures
(iv) Preheating and PWHT procedures
(v) WQT and welder register and copy of identification cards
(vi) NDT operators list and certificates
(vii) Copies of deviations approve by the Owner.
(viii) List and copies of material certificates
(ix) List of consumables batch and certificates
(x) List of test equipment and calibration certificates
(xi) Procedure for Control of Welding Consumables.
(xii) If required by the Owner, original WPS proposal, endorsed “Approved for
Qualification”
Add new 4.11
4.11
During Welding
4.11.1 Shop and Site Conditions / Weld protection
(i) The welding shall be carried out in a properly laid shop or site that is sheltered
from the environments (e.g. rain, snow, moisture, mist, excessive draft,
contaminants etc.) that may affect the quality of the welds. The proposed
methods and precautions (e.g. shelters and preheat/post weld heat treatment) to
ensure good weld quality shall be submitted by the Contractor for review and
approval by the Owner.
(ii) If the temperature is below 5 °C, both sides of the weld preparation shall be
preheated to approximately 50 °C or the preheat temperature specified in the
WPS or design code, whichever is higher.
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(iii) Protection shall be provided for equipment or facilities, at the vicinity of welding
works, that may be damaged or affected due to e.g. weld spatter, cutting droplets,
fumes, grinding particles, weld radiation, heat etc.
(iv) The use of tent type enclosure and welding habitat shall be approved by the
Owner. The approval may be withdrawn if the habitat or enclosures is ineffective
or inadequate.
4.11.2 Weld Integrity and Quality
4.11.2.1 The reverse side of double-welded joints shall be ground to sound metal and
examined using VT and PT or MT before depositing weld on the reverse side.
4.11.2.2 Weld starts and stops shall be staggered and shall be situated in the fusion path i.e.
not on the base metal for the final pass.
4.11.2.3 For welding of pipes or tubular with diameter greater than 500 mm, two or more
welders are required to weld simultaneously.
4.11.2.4 All material with thickness of 25mm and above shall be checked for lamination prior
to welding.
4.11.2.5 A split-layer technique shall be used for GMAW or FCAW in making all multipass welds
when the width of layer exceeds 16mm.
4.11.2.6 For SMAW, the width shall not exceed two and a half times the electrode diameter
or 12mm whichever is the least.
4.11.2.7 Welding sequence shall be developed to control distortion, shrinkage, warping,
creeping and the built-up of exercise internal stress in the structure before
commencement of welding
4.11.3 Weld Finish
(i) The Contractor shall submit a sample of a “smooth weld surface”, if specified in
design documentation, to the Owner for approval, prior to commence of the
welding work. The approved sample shall be used as a reference for VT.
(ii) Weld profile shall have a smooth contour. Abrupt ridges or valleys shall blend
smoothly with the base material. There shall be no undercut.
(iii) The minimum throat size for fillet welds that are concave or having unequal legs
shall not be less than 0.7 x Leg Length.
(iv) The root profile of “olet” fittings connection shall be as required for full
penetration butt welds. The contour shall be as sketched in Figure 1.
(v) Toe profile grinding or cosmetic grinding, if restricted by the Owner, shall only be
performed when specified in the design drawings or requested by the Owner.
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Figure 1: Weld Profile - Weldolets
4.11.4 The first pass of fillet welds in vibrating service shall have a convex profile, meanwhile
the final capping shall have a concave profile. The throat size shall not be less than the
size stated in the design documents. The effective weld size should be used for weld
in vibrating service. If required the weld shall be blend ground to achieve this
requirement.
4.11.5 Stray Arc Strikes
(i) Arc strikes shall be made on the fusion faces or on the previous weld deposit.
(ii) Arc strikes shall be removed by grinding or other appropriate method, and
followed by PT or MT to ensure that there is not defect. The material thickness,
to be measured by the Contractor, after grinding out the arc strike shall not be
lower than the minimum required thickness. Otherwise the component shall be
replaced or the weld repaired if permitted by the Owner.
(iii) Earthing connection shall be check and examine periodically by the Contractor.
Arching due to poor earthing connection shall be considered as stray arc strike.
(iv) Stainless steel clamps shall be used for the connection to the work. Earth cables
shall not be welded to the components.
4.11.6 Records
(i) The Contractor shall maintain daily record of all cut, QSET and repairs. The copies
shall be made available to the Owner if requested.
(ii) Detailed records, comprise of (i) weld identification serial numbers, (ii) weld
position, (iii) dates, (iv) WPS number, (v) welder names, and (vi) welder
identification number, of all weld numbers and pipe numbers, inclusive of weld
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repairs, shall be maintained by the Contractor. The records format and content
and the submission frequency shall be as agreed between the Owner and the
Contractor.
Add new 4.12
4.12
After Welding
4.12.1 Weld Inspection
(i) Inspection and examination of welds shall be performed before and after
completion of final PWHT. The final acceptance shall be on NDT result after PWHT.
(ii) Extent of inspection and examination shall be carried out per the ITP.
4.12.2 Repair of Welding Defects
(i) Repair or remedial actions (i.e. preparation, grinding and welding) shall only start
after Owner has been informed and approved the proposed rectification
methods.
(ii) A maximum of two attempts shall be allowed to repair a major weld defect in the
same area except DSS and SDSS. DSS and SDSS shall be only subject to 1 weld
repair unless otherwise agreed by Owner. The second attempt to repair the same
weld shall be done if permission is granted and proposed remedial action
approved by the Owner. If permission for the second repair is not granted, the
whole weld shall be removed.
(iii) The minimum width and length of excavated repair weld shall be 12.7mm and
76mm respectively. Where the size of weldment constraint the above, the width
of repair shall be one multiply the base metal thickness and the length shall be
the defect length plus an extended amount of the base metal thickness at both
ends of defect or 25mm whichever is longer.
(iv) Back purging, if required per the original weld, shall be re-established, in vessel,
process piping or equipment internal, if the remaining thickness at the excavated
area to be repaired is less than 5mm.
(v) Welding repair made on weld that have been PWHT shall be subjected to repeat
PWHT per the original WPS, unless otherwise approved by the Owner. A separate
PQR, if required by the Owner, shall be prepared to proof the mechanical
properties using the revised welding parameters or variables.
(vi) Hardness check on the repaired area shall be conducted and shall not exceed the
hardness value as specified by the specification.
(vii) Buttering to acceptable dimension prior to joining the parts by welding shall be
done when root opening is wider than those permitted in the WPS but not greater
than two multiply thickness of thinner member or 19mm, whichever is less.
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(viii) All buttering shall be done by qualified welders by using a stringer bead technique.
Weaving technique is not allowed to avoid excessive heat input which may be
detrimental and cause brittle fracture of base metal especially at HAZ.
(ix) Buttering shall be made in the flat position as far as possible and shall be done by
using low hydrogen electrode not more than 4mm in diameter.
(x) Any buttering made shall be checked by MT at buttered edges for any defect.
Surface defect found shall be removed by grinding until no more indication is
revealed by MT
(xi) The affected area, adjacent weld and base metal shall be preheated to a minimum
temperature as per approved WPS.
4.12.2.1 Defect Removal
(i) Steel with defects shall be excavated to an agreed depth using carbon arc gouging
or appropriate mechanical means, followed by grinding.
(ii) Non-ferrous materials with defects shall be excavated using mechanical means
only.
(iii) The excavated area shall have a profile that allow proper welding access. Defect
that are not detected by VT shall be followed with MT or PT, to ensure and confirm
complete removal of the defects.
(iv) Adequate preheat shall be performed for defect removal, if the material require
preheat for welding per the WPS.
4.12.2.2 Root Repairs
If accessible, weld repairs to the root of a single sided weld may be done from the
internal, if approved by the Owner.
4.12.2.3 Complete Weld Metal Removal and Subsequent Re-welding
(i) For material that are impact tested or as required by the Owner, the defective
weld metal inclusive of at least 5 mm of the HAZ / base metal on both sides of the
weld shall be removed, if complete removal of defective weld is deem necessary.
(ii) For materials that are non-impact tested, cut out and re-preparation can be done
once only.
4.12.2.4 Non-Destructive Examination
Welds that have been repaired shall be 100% re-examined using the original NDT
methods. The examinations shall include a minimum of 50 mm beyond both sides of
the repaired weld.
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4.12.2.5 Repair Procedure
(i) General repair procedure that include the following shall be submitted to the
Owner for approval, before commence of repair:
a) Defect excavation method
b) Profile and dimension of excavation before re-welding for:
 Repair of defect on capping
 Repair of mid thickness weld defect
 Repair of through thickness
c) Extent of inspections and examinations before re-welding
d) Repair WPS and supporting PQR. Application of original WPS and PQR for
weld repair shall require Owner’s approval.
(ii) The repair weld WPS shall be qualified as per this PTS. If required by the Owner,
the PQR shall be done by producing a typical production weld repair. Repair of
mid thickness and through thickness weld shall be qualified separately.
(iii) The extent of mechanical and NDT testing of repair weld PQR and the acceptance
criteria shall be as per the original weld.
(iv) Specific WPS’s for each defect might need to be developed for each weld repair
as required by the applicable repair code.
4.12.2.6 Repair Limitations
(i) The cause of cracks, if detected shall be analysed and investigated. A crack repair
procedure, based on the analysis and investigation results, shall be developed and
approved by the Owner before commencement of repair.
(ii) The total length of partial penetration and full penetration repairs shall not
exceed 30 % and 20 % of the weld length, respectively. Repair with dimension
exceeding the above length shall be considered and addressed as highly
restrained weld per 4.10.2.
(iii) The remaining ligament, for partial penetration repair, adopted for test weld, shall
be the smallest permitted in production.
4.12.3 Records
The documents required shall be as per PTS 12.20.06 or the followings for piping:
(i) Compliance certificate
(ii) List of as built drawings inclusive of weld maps
(iii) Copies of approved deviations
(iv) NDT reports
(v) List of repairs and associated repair procedures
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(vi) Pressure test certificates
(vii) Other documents as required by contract requirements e.g. painting & coating
reports, calibration records, water analysis reports, ITP’s, etc.
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5
WELDING PROCESSES
5.1
ACCEPTABLE WELDING PROCESSES
Add the following to 5.1
b) GTAW-HW (Hot wire)
Add new
j) EBW
k) LBW
5.2
Limitation of Welding Processes
5.2.1
General
Add the following to 5.2.1
Acceptance from the Owner is required for use of autogenous root pass.
For steel with more than 2 ¼ % Cr, as part of the welding procedure acceptance tests, the root
pass shall be inspected for signs of excessive oxidation if welding is performed without using
backing gas.
5.2.2
GTAW-P
Add the following to 5.2.2
Starting of arc by scratch technique is strictly prohibited.
Arc starting devices (e.g. high frequency, lift arc, crater eliminating slope out control, etc.)
shall be fitted to all GTAW machines. If not permitted by the local authorities, alternative
proposals shall be proposed to the Owner for approval.
The root pass of small-bore pipe less than DN 75 (NPS 3) shall be welded using GTAW, unless
otherwise approved by the Owner.
Welding of component with diameter DN 75 (NPS 3) and smaller shall be done using GTAW
throughout the weld thickness, if required by the Owner. All component with outside
diameter of 40 mm (1.5 in) or lower shall be welded throughout with GTAW.
5.2.3
GMAW-S
Add the following to 5.2.3(e)
Adaptive GMAW (e.g. STT, RMD, QSET and CMT), if used without backing gas, should be
avoided on the following equipment or piping:
(i) All material except CS, SS 304 and SS 316.
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(ii) Equipment with operating temperature greater than 450 °C.
(iii) Corrosive service e.g. O2, Cl containing low pH water.
(iv) Services that specify special quality root pass e.g. no oxides.
The above restriction may be waived if the mechanical and corrosion test results of the PQR
indicate that the required properties can be obtained without the use of backing gas.
5.2.5
FCAW
Add the following to 5.2.5
Fabrication shops or contractors intending to use FCAW shall be assessed and approved
individually based on evidences, experiences and past performance of using FCAW process.
Add the following to 5.2.5.1 (b)
Specified minimum impact requirements of the electrode used shall be validated by
mechanical testing in the PQR.
Add the following to 5.2.5.1
d) FCAW-S shall not be utilized for welding structural components to pressure or
containment boundary. It is not allowed for welding of lifting lugs or similar lifting
devices or tank bottom plates.
Add new 5.2.5.6
(i) Consumables used for production welding shall be restricted to the same
manufacturer brand/trade name as utilized in the PQR. QC system used shall
specify consumable control procedures.
a) Type T-12 or T-5 electrodes are preferred. T-1 electrodes are acceptable,
if impact properties can be verified. T-1 electrodes with maximum Nb
content of 0.02% shall be used to avoid low toughness.
b) Type EXXT-XX-J electrodes should be used if toughness of 27 J at -40 °C is
required.
(ii) WPS/PQR for ferritic steels shall also be qualified with impact testing, using a
minimum of 3 charpy V-notch specimens at temperature of -18 °C or lower or per
code requirement, whichever is lower. The average impact energy shall be at least
40 J and no single specimen with value of less than 27 J.
(iii) Besides the testing required by the codes, the hardness of ferritic steels in nonsour service shall also be performed and recorded in supporting PQR, with a
hardness traverse per section 12.6 of API RP 582 using Vickers hardness testing
equipment (ASTM E92). The maximum hardness value for P1 material is 275
HV10. NACE MR0103 or ISO 15156 hardness requirements shall be applicable for
sour service. Alternative traverses may be proposed for consideration by the
Owner.
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(iv) Welder shall be qualified by mechanical testing only, and RT of test coupons or
production welds is not permitted to be used in lieu of the mechanical tests.
Brinell hardness test shall be performed, on both sides of the coupon i.e. on the
root and cap surface, to increase data points on FCAW hardness. The hardness
value should be 200 HBW, and this value will not be used to pass or fail the welder.
(v) Hardness limit for carbon steel production weld is 200 HBW. Harness testing, e.g.
with telebrineller, shall be carried out on the 0.5 m of the first five welds welded
by each welder. The welder should undergo additional training if rejection rates
is higher than 2 welds, and the electrode and shielding gas quality should also be
checked.
Random hardness testing, spaced apart not exceeding 6 m to be carried out on remaining
welds i.e. at least 20% of circumferential welds of piping or one reading per weld seam on
category A and B welds of pressure vessel.
The welder should undergo additional training if the rejection rates is more than 10% based
on a minimum of 20 measurements. One welder per weld seam may be selected for the test.
P-8 group base metal does not require production hardness testing.
(vi) Welding area shall be protected against excessive crosswind ventilation.
(vii) Vertical down weld progression is not permitted.
(viii) The root pass shall not be welded using FCAW process, unless the root weld is
back gouged.
(ix) Short circuit transfer mode shall not be used.
(x)
Consumables shall be stored in the original package in a dry place:
Ambient Temperature °C
Max. RH%
15-21
80
21-27
60
27-32
45
32-38
30
Welding of pressure retaining weld shall use new FCAW coils in original
undamaged packing. The electrodes should be used within a shift after opening
the package. The spent or discard date should be marked in the spool once it is
opened.
Diffusible hydrogen “H” rating wires shall be treated per manufacturer
instruction.
Opened electrodes on wire feeders shall be protected against condensation.
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Oxidized electrodes shall be thrown away and removed from welding site.
(xi) Unidentified or corroded wire shall not be used. The identification shall comply
with the applicable consumable standards.
(xii) Extent of NDT examination shall be per project specification or construction class
rating of the equipment.
Minimum NDT coverage of FCAW-G for pressure retaining welds shall be per
“Spot RT” as specified in ASME/BPVC Sec VIII. Unless more stringent
requirements is specified in the project specification in which case such
documents shall govern.
(xiii) If FCAW-G is intended to be used for welding P1 through P5 and P15 materials
used in design temperature over 350 °C or below -29 °C, evidence of past
experiences i.e. list of past projects, and number of welds and the corresponding
rejection rates records, shall be submitted to the Owner
(xiv) Seamed flux cored wires shall not be kept on idled welding machines for more
than a shift.
5.2.6
EGW
Add new
d) Unless stricter requirements are stated by the Owner, all PQRs for EGW process
shall be qualified with impact testing at -18 °C.
e) For multiple pass vertical butt welding joints, the impact specimens shall be
sampled from the final weld pass. However, when the heat input of the first pass
is more than the second pass by 25%, impact test from first and final pass shall be
required. The HAZ specimens shall be oriented such that the base of the notch is
parallel to the fusion line.
5.2.7
SAW
Add new 5.2.7.4
5.2.7.4 Only fully mechanised SAW systems shall be used.
Add new 5.2.7.5
5.2.7.5 Repair welding of pressure vessels, storage tanks or pipelines shall not be perform
using SAW, unless written approval for each repair is obtain from the Owner.
Add new 5.2.7.6
5.2.7.6 Material used for run-on and run-off tabs shall have the same P-no. as the base metal.
Add new 5.2.7.7
5.2.7.7 The targeted dilution in weld overlay using SAW (strip electrode) is 14 % to 19 %.
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Add new 5.2.8
5.2.8
SMAW
5.2.8.1 E7024 shall be used for flat and horizontal fillet weld only. If E7024 is specified by a
tank fabricator and where permitted by API 650, E 7024-1 shall be used for tank fabrication
Add new 5.2.9
5.2.9
ESW
ESW welding is permitted for overlay welding purposes only. WPS for ESW shall be qualified
using the same consumable brand intended to be used for production welding.
Single layer overlay is permitted if approved by the Owner. Thickness of deposited pass should
not exceed 5 mm.
The targeted dilution is 9% to 14%.
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6
Welding Consumables (Filler Metal and Flux)
6.1
General
Add the following to General
(i)
Filler metal shall be ordered or procured per AWS A5.01 or equivalent ISO
document requirement.
(ii) Specified and actual mechanical properties and chemical analyses values of
welding consumables shall be equal to or greater than the base metal welded.
(iii) The Fabricator shall identify all proposed consumables with alloying elements
transferred from the flux, metal powder core, or electrode coating, to obtain the
required weld chemistry. The manufacturer shall indicate the alloying elements
that are transferred from the flux and sensitivity to welding variables or probable
weld metal composition that may develop during welding, if weld deposit
chemistry need to be controlled e.g. X-bar or X-factor or similar chemistry
restrictions. The manufacturer shall submit the required documents and
evidences with regard to the consumables for review and acceptance by the
Owner.
(iv) The same welding consumable manufacturer brand names and classifications as
used in supporting PQRs shall be used during production welding, for the welding
processes, materials and/or conditions specified below:
a) All welding processes, if normal operating temperature of P4 through P7
materials exceeds 350 °C and weld composition restriction is enforced; or
b) Impact test lower than -46 °C have been enforced by code or design
documents.
(v) Manufacturer supplying the consumables shall be accredited to ISO 9002 or
equivalent.
(vi) If alternative consumables are required to improve weld properties or corrosion
properties, Contractor shall propose to the Owner for approval prior to
commencement of the procedure qualification.
(vii) If filler metal for welding of dissimilar material is not covered in API RP 582, the
proposed filler metals shall be reviewed and agreed with the Owner for each
specific case.
(viii) FCAW wire shall have been manufactured not more than twelve months prior to
be used.
(ix) For low hydrogen covered electrons, the electrodes shall be rebaked only once.
Rebaked electrodes shall be totally used before issuing the newly baked
electrodes. The rebaked electrodes shall be discarded if they are not consumed
within eight (8) hours after issuance.
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(x)
The diffusible hydrogen contains shall be restricted to 11ml/100g for FCAW
electrode. The maximum hydrogen content for materials with SMYS of 420 MPa
and above shall be limited to 5ml/100g for SMAW electrode.
(xi) Baked electrode shall be transferred to a holding oven at 150°C. The electrodes
shall be transferred to heated quivers at 75°C and used within 8 hours or as per
supplier recommendation.
(xii) SAW flux shall be heated in a silo at 70°C
Amend clause 6.1.3 to the following
Groove and/or fillet welds shall be made with filler metals producing low hydrogen deposits
GTAW welding process should be used for all piping root weld. For DN less than 75mm, GTAW
shall be used for the root weld.
Add the following to 6.1.6
Certification of consumable
(i) Consumables shall have material certification inclusive of chemical analysis per
ISO 10474, Type 3.1 or AWS 5.01, and shall be supplied per their product data
sheet. Material certificate shall be original or certified true copy
(ii) Consumable or batch supplied, shall have unique marking traceable to the
relevant material certification.
(iii) Batch testing of consumables is allowed. If batch testing is done, welding and
testing shall be performed in accordance with typical WPS and certification
presented per PQR format. Base material intended to be used for production
welding or equivalent shall be used for the consumable product certification.
(iv) Fluxes for SAW shall be supplied with material certification complying with ISO
10474, Type 2.2, or AWS A5.01. Alternatives may be approved by the Owner.
(v) If mandated by the Owner, consumables shall be supplied from Manufacturers
that are acknowledged and certified by independent bodies e.g. ABS, DNV, Lloyd’s
Register, SGS etc.
(vi) Consumables used for low temperature services shall comply with PTS 15.10.01.
(vii) Consumables shall be specified in the WPS and PQR using their AWS classification
or ISO designation, whichever is applicable base on the design code. Welding
fluxes shall also be stated including the type and manufacturer.
6.4
Stainless Steel Welding (P-6, P-7, and P-8)
Delete section 6.4.2.2 and replace with the following
6.4.2.2 PTS 12.30.05 provide the acceptable FN value for Stainless Steels and other materials.
For general service the FN should be at least 3 FN, except for the following:
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(i) The FN for Type 347 shall be at least 5 FN. The FN may be reduced up to a
minimum of 3 FN provided that evidence or data demonstrating that hot cracking
will not happen is submitted to the Owner for review and approval.
(ii) Weld deposits with lower FN number down to zero may be required for e.g.
special corrosive service, cryogenic service, or non-magnetic application to
achieve the required material properties. Written procedures stating additional
precautions to prevent solidification cracks and the required evidences that
cracking will not occur should be submitted to the Owner for approval.
(iii) The FN for 16Cr-8Ni-2Mo weld shall be between 1 to 5 FN.
(iv) Data for filler metal with unquantifiable or not measurable ferrite e.g. E/ER 320
or E/ER 310 shall be submitted to the Owner for approval.
Add the following to 6.4.2.4
If PWHT (e.g. stress relief, stabilisation heat treatment or solution annealing heat treatment)
of weldment is required or the operating temperature of the equipment is greater than 450
°C, consumable selected shall be reviewed and approved by the Owner.
In high temperature service where E347-xx or ER347 filler or other Nb stabilised filler are used,
the minimum Nb composition shall be:




% Nb = 0.093% + 7.7 (% C – 0.013) + 6.6 (% N – 0.022) or Nb/C = 13.5 whichever is
greater for equipment used at temperature exceeding 500 °C and wall thickness
more than 14 mm
Nb/C = 12.6 for equipment used at temperature less than 500 °C and lower
thickness.
Liquation Number LN < 30 for FN > 8, and LN < 25 for 5 ≤FN ≤ 8.
LN = Nb/C + 100 X Phosphorus (P %) + 1000 X Sulphur (S %) (Ref WRC 421)
Add new 6.4.2.5
6.4.2.5 Ferrite Measurement
Ferrite measuring procedure taking into account the following, shall be submitted to the
Owner for review and approval:
(i) Control of ferrite on production weld. FN measurement of production weld shall
be checked using only either ferritescope or wet / OES chemistry analysis.
(ii) Control of ferrite on filler metals and estimated FN based on WRC-1992 diagram.
FN can be obtained from material test reports, weld test pads plus wet chemistry
techniques or optical emission spectrometry (OES)
(iii) WPS
(iv) Intended Service of equipment e.g piping, pressure vessel etc.
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Add new 6.4.2.6
6.4.2.6 FN of all stabilised stainless steel, and A-8 weld metal with design temperature less
than -29 °C or greater than 450 °C shall be measured. One per weld or one per meter of all
accessible welds shall be measured. Other options or techniques approved by the Owner may
be used to determine the FN of inaccessible areas.
6.5
Duplex Stainless Steel Welding
Add the following to 6.5.1
Ferrite measuring procedure taking in account the following, shall be submitted to the Owner
for review and approval:
(i) Control of ferrite on production weld. FN measurement of production weld shall
be checked using only either ferritescope or wet / OES chemistry analysis. Ferrite
measurements shall be conducted on the root side of the weld where accessible,
for single sided welded joints welded with GMAW and GTAW.
(ii) Control of ferrite on filler metals and estimated FN based on WRC-1992 diagram.
FN can be obtained from material test reports, weld test pads plus wet chemistry
techniques or optical emission spectrometry (OES)
(iii) WPS
(iv) Intended Service of equipment e.g piping, pressure vessel etc.
Add new 6.5.4
6.5.4
Consumables for duplex stainless steel (DSS) shall comply with the following:
(i) Flux used for SAW shall be basic flux.
(ii) Flux and filler metal used for the PQR shall be the same type and brand used for
production weld.
Beside the code requirements, chemical composition of consumables for grade UNS S32205
shall also comply with the composition stated in Table 3
No
Element
Min. Chemical Composition
1
Nitrogen, N
0.14%
2
Nickel, Ni
3
Molybdenum, Mo
3%
Table 3: Additional Chemical Composition Requirements
8%
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Add new 6.5.5
6.5.5 Besides the code requirements, consumables for super duplex stainless steel (SDSS)
shall comply with the composition stated in Table 4.
The PREN (PRE = %Cr + 3.3Mo + 16% N) of filler material shall be greater than the minimum
specified for the base material. Only SDSS consumable shall be used for welding SDSS. The
consumables used shall be of low hydrogen type i.e. 10 ml / 100 g of weld metal.
No
Element
Chemical Composition
1
Chromium, Cr
Min. 25%
2
Nickel, Ni
Min. 9%
3
Nitrogen, N2
Min. 0.15% - 0.2%
Table 4: Additional Chemical Composition Requirements
Add new 6.5.6
6.5.6 Inspection documents for consumables used shall comply with ISO 10474, Type 3.1 or
AWS A5.01. Consumables shall be traceable to batch certificate. Consumables that are
unidentifiable shall not be used.
Add new 6.5.7
6.5.7 To prevent hydrogen cracking in ferritic phase of DSS, SMAW consumables shall be
handled as low-hydrogen consumables with less than 10 mg / 100l.
Add new 6.5.8
6.5.8
If approved by the Owner, Ni based alloy filler material may be used.
6.6
SAW
Add the following to 6.6
Requalification shall be performed to proof the quality or performance parameter of low alloy
2 ¼ Cr-1Mo-V and P91 material using the same brand of consumable should the consumable
manufacturer has change the following:
(i) The composition of the filler metals or flux, or
(ii) The sources of the raw materials, or
(iii) If the testing is more than 10 months.
Flux shall be supplied in moisture proof containers and stored in a dry location.
The identification on the containers shall comply with the applicable consumable
standard.
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Flux from re-crushed slag shall not be used.
Use of recycled flux shall only be permitted if the procedure is approved by the
consumable manufacturer and the Owner. Recycled flux shall be treated per flux
manufacturer recommendations, and shall be free of fused slag, mill scale, dirt,
contaminant, or other foreign matter. Recycle flux shall be rebaked per
manufacturer instruction.
Fluxes shall not be left in machine hoppers when there is no welding activities
(e.g. overnight or non-productive shift) for prolonged period.
6.7 Electroslag Welding (for Corrosion Resistant Weld Overlay)
Add the following to 6.7
Multi-layer systems are normally preferred if total protection of the substrate is required.
The manufacturer shall provide references where single layer overlay with austenitic stainless
steel consumables has been applied successfully before using the single layer overlay. The use
of single layer overlay shall be approved by the Owner.
Overlay thickness is normally limited to 5 mm (0.2 in).
The thickness of the non-diluted composition shall be stated in the WPS. The parameter
controlling magnetic field shall be monitored during welding and shall be incorporated in the
WPS.
6.8
Consumable Storage and Handling
Add new 6.8.4
6.8.4 Extra moisture resistant (EMR) consumables with diffusible hydrogen content of not
more than 4-5 ml/100 g may be used without preheated storage for a maximum duration of
9 hours.
Electrodes that are left lying without proper storage at site or workshops or electrode with
damaged flux coatings shall be scrapped.
Wire for SAW, GMAW, and FCAW shall be clearly identified and stored in a dry place per
manufacturer instructions. The identification shall be in accordance with the applicable
consumable standard, and unidentifiable. Corroded wire shall not be used.
Consumables for SAW, GMAW, and FCAW shall only be withdrawn from storage area before
use. Unused consumables shall be returned immediately to storage area upon completion of
welding activities. Batch numbers shall be recorded in appropriate consumable issuance
records. Fluxes shall be stored in heated silo after issuance, per manufacturer instructions.
Low hydrogen welding consumables shall be kept in heated and properly control temperature
storage areas per manufacturer recommendations immediately upon opening. The electrode
intended for immediate use shall be stored in heated quivers. Non-EMR low hydrogen
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consumables shall not be used if the consumables have not been stored in heated quiver for
a duration of greater than 4 hours.
Electrodes shall be discarded if the electrodes have been damaged, exposed to moisture,
grease or contaminants that may induce hydrogen or oxygen and affect the quality of the weld
deposit.
Special QC procedure, for consumables with AWS 5.20 hydrogen rating of H4 (Specification
for Carbon Steel Electrodes for Flux Cored Arc Welding) or better or when vacpacs are
specified, shall be developed and certified to proof compliance with Manufacturer handling
requirements.
Baking and storage of consumables shall not be carried out in the same ovens. Ovens shall be
electrically heated and shall have automatic heat controls and visible temperature indication.
Baking, storage, issuance and return of consumables shall be controlled per approved
procedures with appropriate documented records.
The maximum relative humidity in the storage room shall not be more than 50%.
Consumables stored shall be clearly identified with brand name, classification and batch
number. Copy of batch certificate for all welding consumables shall be available at the
consumable store for reference.
All batches of wire and flux shall be labelled with the information from the supply container.
Bottles for all shielding gases shall have proper identification labels.
Handling of consumables shall be per procedure approved by the Owner. Storage shall be per
Manufacturer’s instructions for the specific consumable type.
Electrodes and fluxes shall be supplied in moisture resistant sealed containers and stored per
Manufacturer recommendations.
Wire spool for automatic or semi-automatic processes shall be stored in original packages.
Flux shall be supplied and stored in accordance with manufacturer recommendations.
Consumables shall be discarded if damaged, unidentified, wet, partially used, rusty or
contaminated.
Low hydrogen electrode shall not be stored together with other electrodes such as rutile or
organic type electrodes in the same heated cabinets.
Records of consumables storage, issuance and return, shall be maintained to ensure an
auditable trail at various stages of fabrication.
Welding flux traceability to specific welds and segments shall be developed and maintained
for welding of thick vessel wall with thickness greater than 100 mm.
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Partly used coil or spool of bare wire for automatic or semiautomatic welding may be reused
if promptly repackaged in new sealed container and stored as a new consumable after use
subject to Owner approval.
Bare wire coils or spools that are not sealed in containers after use or have been contaminated
with rust, grease or other contaminant shall not be used.
Wire shall be discarded if the wire cannot be cleaned without damage and deterioration.
Consumables shall be removed from site if the consumables are not identifiable, and weld
made using such consumables shall be cut out and rewelded if required by the Owner.
Add new 6.10
6.10
Carbon Steel
6.10.1 Restriction of F1 and F2 Filler
Pressure retaining welds shall not be welded using consumables categorised as “F1” and “F2”
in ASME/BPVC Sec IX unless approved by the Owner.
6.10.2 Restriction on “G” filler
Filler with “G” classification shall not be used for wet H2S or sour service designated
equipment.
PQRs shall include hardness test done per Section 12 of this PTS.
Filler with “G” classification or filler that have additional elements for de-oxidation (e.g. triple
de-oxidised fillers) or that may lead to hardening shall be reviewed and approved by the
Owner.
6.10.3 Low Hydrogen Consumables
If specified by the Owner, low hydrogen consumables (H4 or better) shall be used on P1
materials in any of the following conditions:
(i) Thickness of butt weld or throat of fillet weld is more than 13 mm.
(ii) Steel with tensile strength exceeding 490 N/mm2.
(iii) Equipment designated for wet H2S/sour service.
6.10.4 E6010 Electrodes
E-6010 cellulose-type coated electrodes shall not be used for welding root pass for H2S / sour
service.
GTAW shall be used for welding root pass of equipment for severe wet H2S (sour) service. Use
of GMAW is acceptable provided root bead quality requirement is comparable to GTAW.
Repair welding shall not be carried out using cellulosic type electrodes.
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6.10.5 SAW Procedures for Carbon Steels (P1)
The wire and flux combination for SAW shall be per Manufacturer recommended
combinations. Manganese and silicon build up in the weld should not exceed 1.65 % Mn and
0.80 % Si in the proposed combination.
6.10.6 Basic Low-Hydrogen Electrodes and Fluxes
Diffusible hydrogen content of weld deposit using basic low hydrogen electrodes and fluxes
shall not be greater than 10 ml/100 g weld metal.
6.10.7 Testing Hydrogen Level
If there is any concern with regard to welding consumable control level or if additional
moisture resistance is required to be ascertained, the hydrogen level shall be tested per
procedure in ISO 3690.
6.10.8 SMAW using Low Hydrogen Electrodes
For P-No. 1 material with tensile strength ≤ 416 N/mm2 and if SMAW is permitted for the root
pass, the root may be welded using E-6010 or E-6011 electrodes.
6.10.9 Preferential Weld Corrosion
Consumable chosen for internal root pass or internal capping of a double sided weld of butt
joints, shall match the nominal composition of the base metal. Addition of up to 0.5 % Mo is
permitted, however Ni (>0.3%) or Si (>0.5%) additions shall not be permitted.
Add new 6.11
6.11
Nickel Alloys
The main alloying additions shall not be added through the use of flux for both SAW and
SMAW consumables. The final alloy compositions may be attained by using supplementary
additions in the flux to cater for element losses during welding. Alternatively trimming an
appropriate alloy core wire analysis can be conducted.
High purity Argon per AWS 5.32 shall be used as shielding gas for GTAW.
Add new 6.12
6.12
Copper Alloys
AWS 5.7 ERCuNi or BS 2901 Pt 3, C18 consumables shall be used for GTAW welding of Grade
CN 102 (90/10). For other copper alloys, the consumables not listed in API RP 582 shall be
agreed with the Owner.
SMAW and SAW where the main alloying element addition are introduced through flux shall
not be used. The final alloy compositions may be attained by using supplementary additions
in the flux to cater for element losses during welding. Alternatively trimming an appropriate
alloy core wire analysis can be conducted.
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High purity Argon per AWS 5.32 shall be used as shielding gas for GTAW.
Add new 6.13
6.13
Titanium Alloys
The composition of shielding or backing gas minor constituent shall not vary by more than
10%.
Add new 6.14
6.14
Nickel Steels
6.14.1 3.5 % Ni
The restrictions listed below shall apply unless otherwise agreed by the Owner.
(i) Consumables for SMAW shall be per class 7016C2L, 7018C2L, 8016C2 or 8018C2.
(ii) Filler complying with AWS A5.28, ER 80S-Ni 2 shall be used for GTAW root pass
with SMAW filling for the remaining.
(iii) Filler complying with AWS A5.14, ER NiCr-3 shall be used for full GTAW weld.
(iv) Filler metal such as AWS ENiCrFe-2 or ENiCrFe-3 may be considered as an
alternative for more demanding application.
(v) Consumables Brand Name shall not be changed.
(vi) Austenitic stainless steel filler shall not be used.
(vii) Application of ENiCrMo-4 or other nickel base alloys shall require Owner approval.
Add new 6.15
6.15
6 % Mo Superaustenitic Stainless Steels
The change in the brand name or country of origin of consumables shall require Owner
approval.
Add new 6.16
6.16
P91
9Cr-1Mo-V (B9) consumables that can be considered are as follows:




SMAW: E9015-B9, E9016-B9 or E9018-B9 per A/SFA-5.5
GTAW: ER90S-B9 per A/SFA-5.28
SAW: EB9 as per A/SFA-5.23
FCAW: E91T1-B9 per A/SFA-5.29
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The preferred electrodes for SMAW for grade 91 is E9015-B9-H4. Prior approval from the
Owner shall be obtained for the use of E9018.
Filler material requirements:
No
Element
Composition (wt%)
1
Nb
0.05 max
2
Ni
0.04 max
3
Si
0.2 – 0.3 max
4
Ni + Mn
< 1.5 max
NOTE(S): The sum of Ni + Mn for welding repair of forging
per ASTM A 182 shall not exceed 1 %.
5
P
0.01 max
6
S
0.01 max
7
V
0.2 max
8
X bar
<15
NOTE(S): X bar is a measure of temper embrittlement, which is highly influenced by tramp elements. X-bar = (10P + 5Sb + 4Sn +
As) /100, where P, Sb, Sn, and As is in ppm.
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7
Shielding and Purging Gases
Add new 7.7
7.7
The application of soluble purge dams for minimizing the quantity of purge gas
requirement during piping fabrication shall be approved by the Owner. Procedures shall be
developed to ensure removal of the soluble purge dams after welding. The soluble purge dams
application shall be per Manufacturer’s recommendation.
Add new 7.8
7.8
High purity argon per AWS 5.32, helium or argon/helium mixture, as qualified and
stated in WPS and PQR, shall be used for back purging of titanium welds. The purge gas shall
be maintained after completion of welding until the temperature drops below 500 °C.
The back purging gas shall be maintained until completion of root and second pass for
austenitic, nickel and copper-nickel alloys.
The purge gas for 6Mo stainless steel shall be maintained until completion of at least 3 passes.
Add new 7.9
7.9
Prior to welding austenitic stainless steels, nickel alloys and copper-nickel welds, the
back purging gas shall be applied until the oxygen content of the exit gas falls below 1.0%. This
shall be checked using a calibrated oxygen meter.
For other materials, the oxygen content unless otherwise specified, shall not be more than
0.5% before welding.
Add new 7.10
7.10 For carbon steel if required, argon used as purging or backing gas shall be of highest
purity per AWS 5.32 with oxygen level less than 50 ppm.
Add new 7.11
7.11
Shielding gas bottles shall be identifiable and free from external corrosion.
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8
Preheating and Interpass Temperature
Add the following to 8.3
Temperature indicating crayons shall be certified free of chloride, lead and sulphur (less than
1 ppm) or any other low melting constituent. Crayons residue on the weld surface shall be
removed before welding.
Thermocouples shall be calibrated per procedure agreed by the Owner.
Calibrated contact pyrometers may be used.
Add the following Table to 8.5
Material Group
Maximum Interpass Temperature
P11A Group 1
175 °C
Unless otherwise specified in the WPS, the maximum interpass temperature for 3 ½ % Ni Steel
and Monel shall be 150 °C and 175 °C respectively.
Add new 8.6
8.6
Preheating is normally not required for C-Mn steel unless condensation of moisture is
possible.
Preheat of material designated for wet H2S services shall be per PTS 15.10.14
Preheat temperature for other materials shall be per the applicable code.
Minimum preheat of 100 °C shall be used for welding 3.5 % Ni steels.
Minimum preheat of 50 °C above the temperature specified in the relevant code shall be used
for reinforce branch fittings e.g. “olets”.
Add new 8.7
8.7
Preheat Heating Requirement
8.7.1 Preheating requirements shall comply with WRC-452 for pressure vessels and AWS
D10.10 for piping.
8.7.2
Cutting or welding torches shall not be used for preheating.
8.7.3 Fuel gas/air burner systems, high-velocity gas/oil burners or infrared radiators (either
locally or in a furnace), or electric resistance, or induction heating may be used for preheating
temperature ≤ 200 °C.
8.7.4 Electric resistance, induction heating or infrared radiators may be employed for
preheating temperature > 200 °C.
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8.7.5 Burners or electrical resistance heaters shall be used for preheating wall thickness ≤
19 mm.
8.7.6 Electrical resistance heating mats, induction heating or infrared radiators should be
used for thickness > 19 mm unless considered impractical due to access or location as agreed
with the Owner.
8.7.7 Portable oxy/fuel gas burners may be used for OD < 150 mm or attachment welds less
than 300 mm length.
8.7.8 Thermocouples shall be placed under resistance heater mats, except when there is
proof that the component temperature will not be higher than the lower critical
transformation temperature of the base material.
8.7.9 Preheating shall be carried out by electrical resistance or gas burner and shall be
checked by means of thermocouple, laser gun or temperature sensitive crayons whichever is
appropriate
8.7.10 Preheating temperature shall be established to a distance of at least 75mm from the
joint groove and through the wall thickness prior to welding. The minimum preheat
temperature shall be as per the approved WPS, project specification, or as recommended by
the reference design code and standard
8.7.11 Counterweights or support shall be installed to designated location to prevent or
minimize distortion, warping, creeping and internal stress prior to commencement of welding.
8.7.12 Welding activity in zone 2 classification area such as “live” facilities and or under
simultaneous operation (SIMOPS) shall follow requirement of Pressurised Habitat Guideline,
UHSE GU 0008 latest revision or based on Owner’s recommendation.
Add new 8.8
8.8
Stoppage of Welding Preheat
8.8.1 Usually the weld shall be completed before lowering the preheat temperature.
Reducing the preheat temperature is allowed for the following;
(i) Unalloyed steels (P1) with UTS of ≤ 450 N/mm2, or
(ii) Material with UTS 490 N/mm2 if weld thickness < 28 mm and welded using low
hydrogen consumables.
A minimum of 30% of the weld thickness shall have been completed prior to stoppage of
welding preheat.
For other materials, if permitted by the applicable code, at least the root and second shall be
completed before reducing the stoppage welding preheat.
The joint shall be cooled slowly under insulation blanket. Preheating temperature shall be reestablished to the required temperature before commencement of welding activities.
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8.8.2 MT or PT shall be performed if reduction in preheat temperature has occurred and
completed weld thickness is < 25 % of the total joint thickness.
9.0
Post Weld Heat Treatment (PWHT)
Add the following to 9.1
9.1.1
The PWHT procedure shall include at least the followings:
(i)
Name of Contractor and Subcontractor;
(ii) Applicable specification;
(iii) Materials of construction;
(iv) Equipment type;
(v) Method of heating (gas, electrical resistance, induction, furnace, etc.);
(vi) Fuel gas and method of atmosphere control (if gas-fired furnace);
(vii) Size and type of electrical element (if electrical resistance) and size and type of
coils (if induction);
(viii) Type, location and number of thermocouples;
(ix) Method of thermocouple attachment;
(x)
Details of loading and supporting arrangements to avoid distortion;
(xi) Provisions to avoid flame impingement (if flame heated);
(xii) Holding time and temperature;
(xiii) Heating and cooling rates;
(xiv) Type of recording equipment including number of channels;
(xv) Temperature chart recorder speed.
Add the following to 9.12
9.12.1 PWHT shall be done in fully enclose furnace, wherever possible
9.12.2 Adequate flame controls shall be provided for fuel-powered furnaces to prevent
oxidising furnace atmosphere. Flame impingement of the PWHT items is not permitted.
9.12.3 The temperature during heating or cooling shall not vary by more than 150 °C in any
4.5 m length, unless otherwise specified by the relevant code.
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9.12.4 The number of thermocouple installed shall be sufficient to ensure temperature or
thermal gradient of the item under PWHT are within the specified range.
9.12.5 One thermocouple shall be directly attached to the location with the thickest wall
thickness.
9.12.6 If several small spools are PWHT in one batch, at least one (1) out of four (4) of the
spool shall have attached a thermocouple.
Amended Table 5—PWHT Temperature and Holding Time with new foot note (d)
d. For 9 % Ni material, the whole vessel, assembly or plate shall be PWHT at the
same time and temperature. Cooling rate shall be a least 167 °C per hour down to
315 °C. Local or partial PWHT shall not be used because the structure is exposed
to embrittlement temperature range of 315 °C to 540 °C for prolonged periods
which may impair the toughness.
Add the following to 9.13
9.13.1 Local PWHT may be permitted if impractical (i.e. due to size or installation restrictions)
to perform furnace treatment. WRC-452 for pressure vessels and AWS D10.10 for piping
guideline shall be complied with. PWHT procedure shall be submitted to the Owner for review
and approval.
Add new 9.15
9.15
Recording and Reporting
9.15.1 Data such as heating rate, holding time, temperature and cooling rate shall be
recorded.
9.15.2 Multi-channel recorder shall be used to measure the temperature of each of the
thermocouple.
9.15.3 All PWHT activities shall have heat treatment charts. The chart shall be marked with:
(i)
(ii)
(iii)
(iv)
(v)
PWHT date;
PWHT start and end time;
Weld number, Spool number and drawing number;
Channel identification;
Signature(s) of Subcontractor personnel.
9.15.4 PWHT report shall have sufficient information to ensure traceability of the PWHT
component and verify compliance to the relevant PWHT procedure, comprising of:
(i)
(ii)
(iii)
(iv)
(v)
(vi)
Project description/code.
ID of the PWHT component.
Actual heating and soaking rates as recorded on the temperature chart.
Actual soak and withdrawal temperatures as recorded on the temperature chart.
Material dimensions and specification.
Applicable WPS number.
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The report shall be signed by the Contractor to confirm completion of the works per design
requirements.
9.15.5 PWHT report(s) and temperature charts shall be furnished for the Owner review.
9.15.6 Temperature measuring devices shall have valid calibration certificates.
Add new 9.16
9.16
Thermocouple Attachments
9.16.1 Attachment for thermocouples shall be;


Capacitor discharge connection, or
Bolt and nut construction per Figure 2
Figure 2: Thermocouple Attachment
Other type of thermocouple attachment shall require Owner approval.
9.16.2 If bolt and nut is used, the material shall have compatible composition with the base
material and shall be treated as temporary attachment per Section 12.4.
9.16.3 Adequate insulation shall be provided for all thermocouple attachments to prevent
error due to radiation or direct contact with heating element.
9.16.4 Number and position of thermocouples shall be per design code, and at least 3
thermocouples shall be welded directly to the component per Figure 3. An additional
thermocouple shall be provided in the internal of hollow equipment.
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Figure 3: Thermocouple Placement for Full Body Heat Treatment
Add new 9.17
9.17
Service (Environmental) PWHT Requirements
9.17.1 Besides the code requirements, all carbon and low alloy steel welds of all thickness
shall be PWHT when used in the following process services. PWHT requirement shall be
indicated in the equipment data sheet and piping, line designation table.
(i)
(ii)
(iii)
(iv)
Caustic and ammonia service
HF service
Rich amine service irrespective of service temperature
Lean amine with operating temperatures above 60 °C or, if required by the Owner,
lean amine irrespective of service temperature.
(v) ANSI/NACE MR0175/ ISO 15156/ NACE MR0103 specified severe sour service
conditions
(vi) High pressure, high temperature hydrogen service (lethal hydrogen service)
(vii) Alkaline sour waters containing carbonates
9.17.2 The holding time shall be at least one (1) hour per 25 mm of thickness. Longer
designated holding times at lower than designated temperature are not permitted if PWHT
are required because of environmental cracking concerns.
Add new 9.18
9.18 PWHT temperature of quenched/normalised and tempered steels shall be
determined and specified to prevent reduction in mechanical properties of base metal. PWHT
temperature shall be a minimum of 25 °C below the tempering temperature used during
manufacture of the material and stated on the material certificate. If PWHT temperature is
within 25 °C of the tempering temperature, the mechanical properties shall be approved by
the Owner and proved by performing mechanical testing at the specified temperature.
Add new 9.19
9.19 The PWHT cycle shall be developed to allow for at least two (2) additional PWHT cycles
if weld repairs are necessary. If a conflict between this requirement and the presence of
tempered embrittlement, the Contractor shall submit proposal to resolve the issue for Owner
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approval. Manufacturer is cautioned to purchase materials that have allowance for additional
tempering cycles.
To ensure and verify that the mechanical properties stated in the PQR are maintained,
additional production test coupons exposed to the same heat cycle shall be performed, if
additional PWHT cycles is required.
Add new 9.20
9.20
PWHT procedure for dissimilar metal welds shall be approved by the Owner.
Add new 9.21
9.21
No heating or welding shall be performed after final PWHT.
Add new 9.22
9.22 If no additional machining is required, all threads and gasket surfaces shall be
protected from oxidation during PWHT.
Add new 9.23
9.23
All AISI 4130 welds shall be PWHT, unless otherwise agreed by the Owner.
Add new 9.24
9.24
The requirements for PWHT for Piping shall be as specified in Table 5 below.
Revised Table 331.1.3 of ASME B 31.3-2014 for PETRONAS
PETRONAS Interpretation on Postweld Heat Treatment for P.No.1, all Group Nos.
P. No. and Group No.
(BPV Code Sec IX,
QW/420 [Note (1)]
Control thickness
in (mm) [Note
(2)]
Type
of
Weld
P. No.1, all Group Nos.
Less than or
All
equal to 25mm
P. No.1, all Group Nos.
Greater
than
25mm and less
All
than or equal to
38mm
P. No.1, all Group Nos.
Greater
38mm
PWHT requirement shall be decided based on below Notes
No PWHT is required Refer below notes
(a),
(b),
(c),
(d),
(e),
(f).
No PWHT is required - Refer below notes (b), (c), (d), (e), (f).
A preheat of 95 °C is applied prior to welding on any nominal
material
thickness>25mm.
PWHT is Mandatory. Refer below note (b), (c), (d), (e), (f).
than
All
A preheat of 95 °C is applied prior to welding on any nominal
material thickness>25mm.
NOTES: (as applicable for PETRONAS Interpretation of PWHT requirement for all P.No.1, all Group Nos.)
Note (f) below is to be applicable to all P Nos. in Table 331.1.3 ASME B 31.3-2014 (including P. No. 1).
(a) The required minimum pre-heat temperature as given in ASME B31.3-2014 Table 330.1.1, for <25mm @ 10°C shall be followed. This note is more applicable
for site locations where the metal temperature for piping during welding is below 10°C.
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(b) Welding Procedure Qualification (WPQ) thickness limits shall be as per ASME BPV Code Sec IX-2015 Table QW 451.1. The type and number of tests required
shall as a minimum follow Table QW 451.1 along with its foot notes.
(c) Wherever the fluid is SOUR and welding need to be SOUR certified - the WPQ results shall also meet the hardness requirements in NACE MR 0175 for Upstream
or NACE MR 0103 for Downstream Applications. The final hardness value of the weldment, HAZ and base metal shall be 248HV10 (22HRC) maximum. If any of
the test results exceed 248 HV10, PWHT shall be conducted to reduce the final hardness value to <248HV10. As an alternative, the weldment may be cut out and
re-welded, and the maximum hardness for the new weld shall be below 248 HV10. For further details on SOUR Service / Wet H2S requirements refer to Appendix
17,18 of PTS 12.30.02-Sept 2015 (Piping General Requirements as applicable for Upstream and Downstream Applications).
(d) In low temperature service or whenever the fluids are of low temperature, and the welding needs to meet the low temperature requirements, the WPQ shall
be impact tested to meet the minimum impact energy values stated in the piping material specification, and the design code requirements. If any of the results
does not meet the minimum impact energy requirements of the material specification and design code requirements at the test temperature, PWHT shall be
conducted during the WPQ to obtain the required minimum energy values.
(e) No exemptions are permitted for PWHTs required by the designer due to process fluid, and in that the respective Project Specification requirement shall be
followed. This is applicable for all thickness range.
(f) (Applicable to all P. Nos. including P. No. 1 of Table 331.1.3 of ASME B 31.3-2014): Multiple layer welds are used when the nominal material thickness >3mm
(1/8 in.) [Note (6)].
Table 5: Exemptions to Mandatory PWHT
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10
Cleaning and Surface Preparation
Add the following to 10.6
10.6.1 If allowed by the Owner, the specific weld through primer is considered as an essential
variable and shall be recorded in the PQR for the type and brand.
Add the following to 10.7
10.7.1 Grinding discs and wire brushes shall be free of sulphur, chloride or ferrite containing
elements and shall be dedicated to one (1) type of material.
Delete 10.8
Add new 10.9
10.9 Surfaces to be welded shall be cleaned and free of contaminants (e.g. paint, oil, dirt,
scale, oxides, etc.) that may affect the weld integrity.
10.9.1 The area adjacent to the weld shall be cleaned for at least 50 mm on either side of the
weld.
Add new 10.10
10.10 Fabrication of CRA materials shall be conducted in a separate enclosed area with
proper protection to avoid contamination from the environment. Stainless steels and high
nickel alloys shall not be in contact with or in close proximity to zinc paint or zinc-coated,
galvanised steels or copper during welding fabrication and heat treatment. If flame cutting or
welding galvanized component is performed nearby, these materials shall be protected from
zinc droplets or spatters.
Add new 10.11
10.11 Filler wire shall be cleaned with stainless steel wool and solvent. Cleaned filler wires
shall be handled by welders using clean gloves or tools that have been used for handling the
same type of material.
Add new 10.12
10.12 Completed welds shall be examined by VT. The weld acceptance criteria for stainless
steel welds shall be per applicable code or standard e.g. AWS D18.1 and PTS 15.12.03. Weld
with excessive oxidation shall be pickled and passivated, and the weld shall be cut out and
rewelded if severe oxidation is observed.
Add new 10.13
10.13 9 % Ni Steel
10.13.1 Thermally cut edges shall be machined or grind to remove dross and burn serration.
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10.13.2 Abrasive blasting or other appropriate methods shall be used to remove mill scale
from surfaces of material that has been exposed to refrigerated liquid or vapour before
welding.
10.13.3 Abrasive blasting or other appropriate methods shall be used to remove slag from the
welding passes if coated electrodes are used.
Add new 10.14
10.14 Weld bevels and flange faces shall be protected from mechanical damage. Vessel,
piping or other process equipment openings shall be covered to prevent ingress of foreign
material internally, using wooden or plastic covers.
Add new 10.15
10.15 Upon completion of fabrication, the inside and outside of all fabricated assemblies
shall be cleaned and free of loose materials, debris, scale, slag and spatter.
11
Special Procedure Qualification Requirements/Testing
11.1
General
Add new 11.1.4
11.1.4 WPQR Non-Destructive Testing
If specified by the Owner, the following requirements shall apply:
(i) Following NDT shall be performed
Joint Type
VT
Butt Welds
Fillet Welds
√
√
NDT
MT for ferrous and PT for
non-ferrous
√
√
RT
UT
√
√
(ii) VT of completed weld shall be performed by both the Contractor and the Owner.
Mechanical test pieces shall not be cut until it has been VT and accepted by the
Owner.
(iii) If the root is not accessible for proper examination, the test specimen shall be cut
longitudinally to facilitate the examination.
(iv) The test specimen shall also be subjected to alternative or additional NDT
methods as proposed for the actual production weld.
Add new 11.1.5
11.1.5 Macro Examination
If specified by the Owner, Macro section shall be cut so that the whole cross section, HAZ, and
adjacent base metal can be examined. The surface shall be etched so that the individual passes
and HAZ are revealed.
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Examination of the macro section shall be done at a magnification of 5X.
Photographs of the macro section shall be included and attached in the WPQR
documentation. The hardness survey indentations shall be visible in the photographs and shall
be marked to indicate the magnification used. Only original photographs or good quality
digital images shall be accepted and attached in the WPQR documentation.
12
Other Items
12.1
Backing Material
Add the following to 12.1
12.1.1 Permanent backing strips are not permitted unless approved by the Owner.
12.1.2 Following removal of backing strip, the area shall be examined for cracks with the aid
of PT or MT.
12.1.3 If impact testing is required, use/non-use of temporary ceramic backing strips should
be considered as an essential variables
12.4
Temporary Attachments
Add the followings to 12.4
12.4.1 Removal of attachment by hammering shall not be permitted.
12.4.2 All temporary attachment shall be cut from a good condition plates and shall be
matched to the adjoining members in term of weldability. All temporary attachments shall be
removed by thermal cutting to a minimum of 5mm from the surface. After grinding, the area
shall be checked by MT.
12.5
Stud Welding
Add new 12.5.4
12.5.4 If arc and resistance stud welding is carried out on pressure retaining components,
the WPS shall be qualified using material with the same P-No., Gr-No. and with same or
greater thickness as the material used for production welding.
Add new 12.5.5
12.5.5 Orientation of stud test welds shall be as described in ASME/BPVC Sec IX, QW-121 for
plate and QW-122 for pipe (excluding QW-122.1). The stud shall be perpendicular to the plate
or pipe surface.
Add new 12.5.6
12.5.6 To ascertain the suitability of the stud WPS and the specified percent fusion, DT of a
minimum of ten (10) consecutively welded studs in each position shall be carried out for
WPQT of stud welds.
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12.6
Hardness Testing – Welding Procedure Qualification and Production Testing
Delete 12.6.1.3 and Replace with
12.6.1.3 Unless specified otherwise by the design code, the general hardness requirements
for base metal, HAZ and weld shall be as follows:
No. Material and Services
1 Wet H2S environments where PTS
30.10.02.15-Gen. is applicable (for oil and
gas production)
2 Wet H2S environments where PTS
30.10.02.17-Gen. is applicable (for
petroleum refining and related processing
environments)
3 Ferritic metals in process services,
including H2 and sour service conditions.
4 Ferritic materials in utility service (steam,
air, water, non-sour service).
5 9 % Ni steels in the as-welded condition.
6 9Cr-1Mo-V steel (P91, T91) in the PWHT
condition
7 Structural steels.
8 (a) 3.5 % Ni steel, joint thickness ≤ 9.5
mm (3/8 in).
(b) 3.5% Ni steel, joint thickness >
9.5mm (3/8 in)
Hardness requirement
All hardness testing and acceptance values
shall meet the requirements of that PTS.
All hardness testing and acceptance values
shall meet the requirements of that PTS.
248 HV10 maximum
300 HV10 maximum
350 HV10 maximum
290 HV10 maximum
325 HV10 maximum
250 HV10 maximum
275 HV10 is permitted in the mid-thickness
and cap when the hardness impression is
located at least 8 mm (5/16 in) from the
internal surface.
Add the following to 12.6.2.5
f)
Ferritic steel in utility service – 300 HBW maximum
g) P 91 – to comply with API TR 938-B guidance
h) Super duplex stainless steel - to comply with API TR 938-B guidance
Add new 12.6.2.7
12.6.1.7 Portable hardness testing instrument shall comply with ASTM A1038 or ASTM A833
for MIC-10, MIC-20 and Telebrinell hardness testers. However, the Telebrinell may be used to
measure hardness on weld and base metal only. Telebrinell is not allowed for HAZ testing. Use
of other testing equipment is subject to Owner approval.
12.6.2.8 Existing PQRs that were qualified before this PTS using other hardness test methods
and requirements shall require Owner approval.
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Add new 12.6.2.9
12.6.2.9 At least two (2) production hardness tests shall be carried out using the agreed test
method on each major circumferential weld and each major longitudinal weld, except for
stainless steels and nickel alloys.
The material shall be rejected if the hardness values are exceeded.
If one hardness results exceed the maximum required, a minimum of three measurements
shall be taken in close proximity to the location that failed. The retest shall be accepted if all
the measurements are below the maximum hardness specified.
12.7
Single-pass Weld
Add the following to 12.7
Use of single pass attachment welds on valve bonnets shall be approved by the Owner.
Single pass welding is not acceptable on pressure components.
Welds starts and stops shall be acceptable.
Add new 12.8
12.8
Welding of Thermocouple to Tube Skin
12.8.1 Welding Guidelines of Thermocouple Pad
Welding shall be carried using qualified WPS utilising GTAW process. The WPS shall
be approved by the Owner.
The pad and sheath material shall match the heater tube base metals (e.g. P8 to P5B for
welding 310 stainless pad to 9Cr-1 Mo steel tubes).
The surfaces at the weld joint and adjacent areas shall be cleaned to bright metal and free of
scale and contaminant that may affect the integrity of the weld.
Preheat if required shall be applied to heater tube base metal.
PT or MT shall be performed after 24 hours to detect likely “delayed cracking” due to
hydrogen. The sheath or cover shall not be installed until satisfactory NDT completion and
results on the pad are acceptable.
12.8.2 PWHT Requirement for Thermocouple Pad Welding
PWHT is not required for general hydrocarbon service.
For ferritic steels tubes (e.g. carbon steel, C ½ Mo, CrMo, and 12 % Cr steels) in hydrogen
charging service, authorisation to waive PWHT shall be obtained from the Owner. Owner to
consider the following:
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(i) Delayed hydrogen cracking is mitigated by examination of the weld before heater
start-up.
(ii) Risk associated with wet H2S environment cracking for processing sulphurbearing fuels is very low and no failures related to this mechanism are reported.
(iii) Risk associated with thermal fatigue are mitigated by performing thorough
examination in the first turn around.
(iv) Welds are tempered and stress relieved in service.
12.8.3 Welding Consumables for Thermocouple Pads
Welding consumables for ferritic steel heaters tubes are per Table 6.
Service
Temperature
°C
Service Environment
Non-Sulfidizing
Up to 590
ERNiCrMo-3
ERNiCrMo-3
ERNiCr-4 and ERNiCrFe-7A
591 to 760
ERNiCr-3 or
ERNiCr-3 (ERNiCrFe-11 for
service environment very
high)
ERNiCr-3 (ERNiCrFe-11 for
service environment very high)
ENiCrFe-2
Sulfidizing (non-reducing)
ERNiCr-3 for strength with
weld capped with ERNiCr-4 or
ERNiCr-7
(for
maximum
sulfidation resistance)
761 to 1150
ENiCrCoMo-1 and
ERNiCrCoMo-1
ENiCrCoMo-1 and
ERNiCrCoMo-1
Sulfidizing (Reducing) / Metal
Dusting
ERNiCr-3 for strength with
weld capped with ERNiCr-4 or
ERNiCr-7
(for
maximum
sulfidation resistance)
ENiCrCoMo-1 and
ERNiCrCoMo-1
Sulfidizing environment means sulphur bearing furnace gases or products containing more than 50 grains (3.24
g) of sulphur per 100 standard cubic foot.
Table 6: Welding Consumables for Ferritic Steel Heater Tubes
Consumables for austenitic stainless steel tubes should be per Table A.2 of API RP 582. For
carbon steel and Cr-Mo steel, the use of high Ni consumables as tabulated in Table 6 is
preferred because of the small variance in coefficient of thermal expansion between these
two materials.
Add new section 13
13
Environment
Local code and legal requirements with regards to fumes, environment, waste, etc. related to
welding shall be complied.
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Annex A (Informative) Welding Consumables for Shielded Metal Arc Welding (SMAW)
Clause
Description
Annex A
Add New
Note 1 : Table A.1 should be changed as follows:
Annex A.1 refers to coated electrodes. Use equivalent electrode classifications (ASME/AWS SFA 5.14, SFA/A5.17, SFA/A5.18,
SFA/A5.20, SFA/A5.23, SFA/A5.28, SFA/A5.29, SFA/A5.34) for bare and flux cored wire welding (SAW, GMAW, FCAW, and GTAW).
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Annex B (normative) Weld Overlay and Clad Restoration (Back Cladding)
Clause
Description
B.1
B.2
B.3
B.4
B.5
B.6
B.7
Pressure equipment and piping made with CRA overlay, clad or strip lining shall comply with all additional requirements to Annex B).
The base metal shall be welded per the procedure for the base metal used.
Single and double layered overlay
For equipment with operating temperature below 425 °C, single layered overlay can be proposed by the manufacturer:
 Manufacturer shall proof acceptable test results showing acceptable fusion and dilution, acceptable hardness in the dilution zone,
satisfactory hydrogen disbonding test if applicable and reliable capability to attain and maintain the required overlay chemistry 3 mm below
the overlay surface.
 Manufacturer has the experience with the application of such overlays and the data provided shall also be supported by actual production
work carried out.
Weld chemistry test for PQR and production welds shall be taken between 2.5 mm – 3 mm below the finished surface or each weld overlay
layer shall be PMI prior to the next weld overlay layer, unless agreed otherwise by the Owner. The chemistry test locations of the production
weld shall be restored after the test.
If ERCrNiMo-3 filler is used to meet Alloy 825 clad chemistry requirements, the Cr and Mo content of the as-deposited weld shall be ≥ 18.5 %
and 3.0 % respectively.
NDT
For equipment with operating temperature above 425 °C, 100 % UT shall be performed on all weld overlay to check for disbonding from the
base metal after the final Hydrotest, per applicable NDT specification.
Single-side welds
Single-sided welding from the non-clad side (e.g. Method 1 or 2 in Figure B- 1) shall only be carried out if agreed by the Owner.
Strip lining
Written approval from the Owner shall be required for the proposal for and/or use of strip-type lining. The strip lining shall be welded
circumferentially using three weld passes. Each side of the strip shall be individually welded to the shell and then followed by the third pass to
provide continuous weld flush with the strips.
Overlay Chemistry
If overlay is applied to restore the clad area of weld joints between clad components,
 At least one (1) deposit analysis per WPS per each Category A and B seams in the vessels shall be carried out.
If overlay is applied to the surface of equipment shells:
 At least two(2) deposit analyses per 10 m2 of overlay or fraction thereof; and
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Clause
B.8
B.9
B.10
B.11
B.12.1
Description
 An analysis shall be performed on each end of the shell at locations that are diametrically opposed.
If overlay is applied to the equipment component surface, for each WPS used and for each piece of equipment fabricated:
 At least one(1) deposit analysis representing the smallest component welded with each WPS; and
 One (1) deposit analysis representing the largest component welded.
If overlay is applied for surface repair of clad components or restoration of surfaces where cladding has been removed (besides weld seams):
 At least one deposit analysis shall be performed for each WPS used.
Sleeve Liner
Written approval shall be requested from the Owner for the use of sleeve liner instead of clad materials.
Welding from both sides
General steps as follows:
a) Remove the cladding material next to the weld area. Check using saturated copper sulphate solution to ensure complete removal of clad
material. Refer to ASTM A380 for the guidelines and limitation of the solutions used. Contamination or inclusions of the cladding material
into the base material shall be avoided to prevent cracking due to high hardness caused by formation of martensite.
b) Weld the base material either from one or two sides depending on material thickness and type.
c) Weld the cladding layer after completion of the base metal weld.
d) Buffer consumable shall be used for the first pass. After dilution with the base metal, the buffer consumable shall have satisfactory chemical
and mechanical properties.
Weld preparation
Cladding material shall be removed from both side of the weld edge preparation. The depth of cladding material removed depends on the clad
thickness and the welding process selected. However, the width shall be at least 5 mm on each side of the weld edge preparation.
The cladding depth removed shall be the thickness of the cladding layer plus 1 mm ± 0.5 mm.
In order to avoid slag entrapment, the edges of the groove for the cladding shall be rounded.
Welding procedure for base materials
Base material shall be welded per the WPS for the base material used.
Welding procedure for the cladding materials
If the inside of vessel surface is prepared using arc gouging, it shall be abrasive blasted per SSPC SP-6 or equivalent prior to application of weld
overlay.
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Clause
Description
B.12.2
Martensitic/ferritic or ferritic stainless steel cladding e.g. AISI 410/405
The first pass shall be welded with buffer electrode type E/ER 309 and the subsequent passes shall also use the same electrode. Ni based
electrodes shall be used for equipment that will be operated a temperature > 315 °C.
Additional Requirement for Welding, PWHT, and Inspection of Pipe with Internal Overlay
Refer PTS 15.02.01 – Gen. for PMI extension.
The minimum pipe schedule/wall thickness to be internally overlaid shall be per Table B- 1, unless otherwise agreed by the Owner:
Test Samples
For overlay welding a 300 mm X 300 mm test sample for each combination of base material/overlay material and WPS/PQR shall be submitted
to the Owner prior to start of welding.
Welding Processes for Weld Overlay
Welding processes that may be used, subject to the additional requirements specified below:
 Gas Tungsten Arc Welding (GTAW)
 Shielded Metal Arc Welding (SMAW)
 Submerged Arc Welding (SAW)
(i) Flux/wire combination used for production welds shall be the same brand used during procedure qualification.
(ii) Alloying elements shall be in the wire and not the flux.
 Gas Metal Arc Welding (GMAW)
Unless otherwise approve by the Owner, other welding processes shall not be used.
Welding Consumables
Alloy filled tubular electrodes may be used if these electrodes have been used and recorded in the PQR.
The chemical analysis of each heat of filler shall be reviewed and documented by the Manufacturer prior to start of production weld. This to
ensure that the filler material comply with the chemistry and ferrite requirements of this PTS.
Preparation for welding
The weld surface shall be cleaned and free of contaminants (e.g. paint, oil, dirt, scale, oxides and foreign material) that may affect the integrity
of the weld.
Prior to the overlay, the surface shall be blasted per SSPC SP-5 or equivalent, machined or ground to clean bright metal.
A minimum width of 25 mm on both side of the weld shall be cleaned.
B.13
B.14
B.15
B.16
B.17
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Clause
Description
B.18
Production Welding
The overlay material shall conform to Table B-2. Use of other materials for procedure qualification and production testing requires prior
approval by the Owner. The Owner shall specify the number of layers required and also specify additional or tighter requirements if required.
Nominal thickness of overlay shall be 3 mm to 6 mm, unless otherwise specified.
Inspection, examination, and test (e.g. PT, Ferrite Check, and Overlay Thickness) of the overlaid shall be completed before proceeding with
further assembly/manufacturing of the component.
The weld joining the component shall have similar nominal chemical composition as the base material for components assembled prior to
overlay welding.
Preparation for Field Weld
End preparation for field joint of piping listed below shall be buttered per Figure B- 2and then subjected to PWHT, unless otherwise specified
by the Owner.
 2 ¼ Cr 1 Mo and 1 ¼ Cr ½ Mo piping of all thickness
 Carbon steel piping > 19 mm (3/4 in) thickness
Single Sided Butt Welds
Thickness of first hot pass and root shall be approximately the same thickness of the overlay. Refer Figure B- 1.
The remaining welds may be completed by using any of the processes stated in this PTS. The composition of the filler used to complete the
weld shall conform to the analysis specified in Table B- 3, unless otherwise specified by the Owner.
Two Sided Butt Welds
If butt welds are made before internal overlay, the weld shall be welded using filler material that have similar nominal composition with the
base metal. Internal protrusion shall be smoothed and not > 1.6mm to permit for internal overlay.
PWHT
If PWHT is required for the base metal, it shall also be subjected to PWHT when overlay is provided.
Chemical Analysis
Chemical analysis and PMI of weld overlay shall be per PTS 15.02.05.
Tests can be performed on run-off tabs or on the actual component. Run-off tabs shall be properly marked with a serial number, heat number,
etc. Test samples shall be kept for at least six (6) months after completion of the project.
Ferrite content of austenitic stainless steel shall be 4 % to 9 %, unless otherwise agreed. Ferrite content for equipment operating < 425 °C shall
be 3 % to 12 %.
B.19
B.20
B.21
B.22
B.23
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Clause
Description
B.24
Impact Tests
If impact testing of the base material is required, Impact testing shall be conducted in the PQR.
Acceptance criteria shall be per ASME B31.3 or applicable code.
NDT
The extent of NDT shall per the applicable PTS for pressure vessels, piping, etc.
Liquid Penetrant Examination (PT)
PT shall be carried out on 100 % of the weld overlay surfaces.
Sulphur and halogen content regardless of the material examined, in PT consumables shall comply with paragraph T-644 of Article 6, Section V
of ASME Code
B.25
B.26
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Figure B- 1: Single Sided Butt Weld
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Pipe Class
Pipe diameter mm
Pipe schedule
Low Pressure (< class 600)
38 – 150
Schedule 80
> 150
Schedule 40
38 – 150
Schedule 160,
nominal wall
High Pressure (≥ class 600)
18
mm
> 150
Table B- 1: The minimum pipe schedule/wall thickness
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No.
C Max.
Cr
Ni
Mo
Fe Max
Cb
Overlay Type
Notes
No. of
layers
PQR
Std. (13)
PQR
Std. (13)
PQR
Std. (13)
PQR
Std. (13)
PQR
Std. (13)
PQR
Std. (13)
1
308L
2,3
2
0.04
0.03
17.5-21.5
18-20
8.5-11.5
8-12
-
-
-
-
-
-
2
309L
4
1
0.08
0.03
15.0-185.
22-24
8.0-12.5
12-15
-
-
-
-
-
-
3
309L
2
2
0.04
0.03
16.5-21.5
22-24
10.5-14.5
12-15
-
2-3
-
-
-
-
4
309MoL
2
2
0.04
0.03
16.5-21.5
22-24
10.5-14.5
12-15
2.0-3.0
2-3
-
-
-
-
5
316L (ESW)
4,11
1
0.04
0.03
16.0-21.5
16-18
8.0-12.0
12-15
2.0-3.0
2-3
-
-
-
-
6
316L
2
2
0.04
0.03
16.0-21.5
16-18
10.0-14.0
10-14
2.0-3.0
2-3
-
-
-
-
7
317L (ESW)
4, 11
1
0.04
0.03
16.0-21.5
18-20
8.0-12.0
10-14
3.0-4.0
3-4
-
-
-
-
8
317L
2
2
0.04
0.03
17.5-21.5
18-20
11-14.5
11-15
3.0-4.0
3-4
-
-
-
-
9
347 (ESW)
4, 11
1
0.08
0.08
16.0-20.0
17-19
8.0-12.0
9-13
-
-
-
-
8 xC min
10 xC min
10
347
2
2
0.08
0.08
19.0-23.0
17-19
8.5-11.5
9-13
-
-
-
-
8 xC min
10 xC min
11
904L
Cu>1.0
2
0.04
0.02
16.0-23.5
19-23
18-25
23-28
3.0-4.0
4-5
-
-
12
Alloy 825
3
2
0.05
0.05
18.0-23.5
19.5-23.5
38-46
38-46
2.5-3.5
2.5-2.5
13
Alloy 625
1
0.1
0.1
18.0-23.5
20-23
50-55
58min
6.0-10.0
8-10
20
5
2.5-4.0
3.14-4.15
22min
Alloy 625(ESW)
4, 5, 7
4, 6, 7,
11
1
0.1
0.1
14.0-17.5
20-23
50-65
58min
7.0-10.0
8-10
15
5
2.5-4.0
3.15-4.15
15
Alloy 625
6, 7
2
0.1
0.1
14.0-17.5
20-23
55-65
58min
7.0-10.0
8-10
10
5
2.5-4.0
3.15-4.15
16
Alloy 600(ESW)
4, 8, 11
1
0.15
0.15
-
14-17
50-70
72min
-
-
15
6-10.
17
Alloy 600
2
0.15
0.15
-
14-17
50-70
72min
-
-
15
6-10.
Alloy 400(ESW)
7
4, 9, 10,
11
1
0.3
0.3
-
-
60-69
63-70
-
5
2.5
-
-
Alloy 400
9,10
2
0.3
0.3
-
-
55-69
63-70
-
15
2.5
-
-
20
Alloy 400
9,10
3
0.3
0.3
-
-
55-69
63-70
-
10
2.5
-
-
21
Nickel 200
-
2
0.15
0.15
-
-
90-95
99min
-
-
5
0.4
-
-
22
Alloy 276
7
2
0.04
0.01
13-15
14.5-16.5
50-55
51-63.5
14-16
15-17
15
4-7
2.5 max
2.5 max
14
18
19
Table B- 2: REQUIRED OVERLAY CHEMISTRY
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NOTE(S):
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
Surface analysis shall be performed at a depth of one-half the minimum specified thickness as qualified in the WPS
Modifications with Type 309L such as additions of Mo or Cb to help meet the analysis requirements for the final layer may be used for the first layer if they were used to qualify the procedure
Fabricator can propose a one pass overlay performed by SMAW, GTAW, GMAW, or SAW. Method of overlay, nominal thickness, and analysis from actual tests are required with the original proposal
Optional 1 layer overlay only if specified by the Owner. ESW has shown to be adequate in some applications
Minimum PREN: 30
Minimum PREN: 40
ASTM G48, Pitting and Crevice Corrosion Coefficient: Max 5 mpy
For GTAW, GMAW, and SAW overlay process use ERNiCr-3 filter for SMAW use ENiCrFe-3 (minimum 50% nickel); or ENiCrFe-2 (minimum 13& Chromium)
Also for Alloy 400: Mn - 4.0 max, Si - 1.25 max, Ti - 1.0 max, Cu - balance
A ferricyanide test (ASTM A380, paragraph 7.3.4) shall be passed. No free iron is allowed
If required by the Owner, PQR must include a hydrogen-disbonding test
Chemistry for wrought equivalent in ASME/BPVC Sec II
For IGC, please refer to Corrosion Testing in E.7
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Figure B- 2: Field Joint for Base Metal requiring PWHT
NOTE(S)
i. Buttering of weld preparation, PWHT, and machining shall be completed by
Shop fabricator.
ii. When field weld shall be completed using alloy 625, field PWHT is not
required.
Table B- 3: Single Sided Butt Weld (per Figure B-1)
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Overlay
Material
Root and Hot Weld Pass Fill Weld Passes
Notes
308L
309L
ERNiCrMo-3 (Alloy 625)
1,2,4
309MoL
309MoL
ERNiCr-Mo-3 (Alloy 625)
1,2,4
316L
309MoL
ERNiCrMo-3 (Alloy 625)
1,2,4
317L
309MoL
ERNiCrMo-3 (Alloy 625)
1,2,4
347
309MoL
ERNiCrMo-3 (Alloy 625)
1,2,4
625
ERNiCrMo-3 (Alloy 625)
ERNiCrMo-3 (Alloy 625)
1,2
600
ERNiCr-3 (Alloy 600)
ERNiCrMo-3 (Alloy 625)
1,2
400
ERNiCu-7 (Alloy 400)
ERNiCu-7
3
NOTES:
1. Alternative is ENiCrMo-3 for SMAW.
2. Alloy 625 for design temperature up to 538 °C. Materials for higher temperatures require
prior Owner approval.
3. Alternative is ENiCu-7 for SMAW.
4. 309L/309MoL may be allowed for fill passes of butt welds if specified by Owner.
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Annex C (normative) Carbon Steel Welding
Clause
Description
C.1
Wet H2S or Sour Service
Applicable documents are:
 PTS 12.20.01, Pressure Vessels refer to Appendix 6 ‘Wet H2S Requirements for Downstream Pressure Vessels’.
 PTS 12.30.02, Piping General Requirements refer to Appendix 18 ‘Wet H2S Service Requirement for Downstream Piping’.
 NACE SP0472, Methods and Controls to Prevent In-Service Environmental Cracking of Carbon Steel Weldments in Corrosive Petroleum
Refining Environments
 NACE MR0103, Materials Resistant to Sulphide Stress Cracking in Corrosive Petroleum Refining Environments
 ANSI/NACE MR0175/ ISO 15156-1, Petroleum and natural gas industries — Materials for use in H2S-containing environments
Impact Tested Carbon Steel Welds
Chemical Composition Check
(i) (The composition of the material shall be verified by the manufacturer, i.e. carbon equivalent (Ceq) and presence of unspecified or
micro alloying elements e.g Nb, V, B and Ti. The combined percentage of Nb, V, B and Ti shall not exceed 0.03 % and B shall not be
more than 50 ppmw.
(ii) The manufacturer shall be responsible for the Material Test Reports (MTRs) of manufacturer supplied material. If the concentration of
the elements required to determine Ceq is not available in the MTRs, the manufacturer shall
a) Determine the concentration and Ceq, verify compliance with requirements, and report results; or
b) Supply replacement conforming material and documentation
C.2
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Annex D (normative) Low Alloy Steel Welding
Clause
Description
D.1
1 ¼ Cr and 2 ¼ Cr low alloy
(i) API 934 and PTS 15.10.01 should be followed if applicable.
(ii) For services not covered by API 934, ANSI/AWS D10.8 Recommended Practices for Welding of Chromium-Molybdenum Steel Piping
and Tubing should be complied.
(iii) For P-3 through P-9 alloy material, the root pass shall be welded using GTAW or GMAW process.
(iv) For welding 1 ¼ Cr ½ Mo for hot hydrogen service, the composition of the deposited weld made using consumables (alloying elements
transferred from the flux, metal powder core, or electrode coating, to obtain the required weld chemistry) shall be verified. Borderline
composition may reduce resistance to HTHA.
P91 9Cr-1Mo-V
Unless approved by the Owner, API TR 938-B should be observed.
WPS for 9Cr-1Mo-V (Grade P91) shall be qualified with impact tests, unless otherwise stated in relevant code or specification. Impact tests
shall be carried out on the thickest section used and shall comprise of testing the base metal, weld metal and HAZ at half thickness.
Unless otherwise permitted by the Owner, the consumable used for production weld shall be the same trade name used and stated in PQR.
Heat input shall be controlled and monitored during production welding.
The following shall be recorded and submitted to QA/QC section for each weld made on 9Cr-1Mo-V (Grade P91) materials:
Specific shop and inspection records demonstrating compliance with actual WPS variables during welding.
Records showing compliance with PWHT procedures i.e. complete temperature cycles and initial temperature
D.2
D.3
Chemical Composition
(i)
The following shall also be complied, in addition to the requirements specified in the ASTM standards:
a.
Both phosphorus and sulphur content shall not exceed 0.010 % wt.
b.
X-bar shall be below 15. X-bar shall be calculated using the following equation, refer 6.16.
c.
Creq < 10 to minimise delta ferrite formation
Creq = Cr + 6Si + 4Mo + 1.5W + 11V + 5Nb + 9Ti + 12Al - 40C - 30N - 4Ni - 2Mn - 1Cu
d.
Ratio of N/Al minimum 4:1
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Clause
Description
D.4
Material Manufacture
(i) Base material shall be ordered in normalised and tempered condition.
(ii) Tempering shall be carried out at temperature of at least 760 °C. Care shall be taken to prevent heating above Ac1 temperature.
(iii) The following hardness requirements if applicable, shall be complied:
a) For P91 seamless piping, hardness shall be between 190-250 HBW.
b) For ASTM A387 grade 91 plate and welded pipe i.e. ASTM A691 P91, maximum hardness shall be 241 HB.
c) For welded pipe (ASTM A691), hydrotest shall be done after PWHT.
d) For welded pipe (ASTM A691) supplementary requirement S3 (hardness), S7 (MT of weld metal) and S10 (UT) shall be complied.
Acceptable hardness range shall be 190-241 HB.
e) For fittings, acceptable hardness range shall be 190-250 HB. Hardness shall be checked on at least one sample per charge and
one sample per size.
f) For forgings (ASTM A182 F91), maximum acceptable hardness shall be 248 HBW.
g) For castings, no hardness values are stated in the standard.
(iv) The following mechanical requirements if applicable, shall be complied:
a) Further, supplementary requirement S14, i.e., tension test from each heat and heat treatment charge (as per ASTM A703)
shall apply.
b) Transverse charpy impact test at 20 °C shall be carried out. Acceptance criteria is at least 40 J impact energy value
c) Photomicrographs shall be taken to confirm 100% tempered martensite structure.
d) A hot yield test shall be carried out at design temperature. For welded components, the test specimen shall include HAZ, base
metal, and the weld. Extent of testing shall be the same as for the other mechanical tests in the relevant standard.
e) If impact toughness is specified, close control of heat input and PWHT cycle is required. Preproduction test samples should be
prepared on coupons having thickness at least equal to the one being welded (up to 25 mm).
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Clause
Description
D.5
Welding Requirements for Low Alloy
(i) Preheat temperature of 200 °C shall be maintained.
(ii) Maximum interpass temperature of 300 °C shall be maintained.
(iii) To ensure complete transformation of austenite to martensite, the weld shall be allowed to cool to at least 93 °C before commencing
with the required PWHT.
(iv) The non-PWHT weld shall be post heated. Post heat temperature range shall be between 310 °C – 320 °C and held for a duration of at
least 15 minutes.
(v) Further, the temperature shall not be high enough to prevent NDT (such as RT) of the weld.
(vi) PWHT temperature shall be at least 732 °C and a minimum of 15 °C below the tempering temperature. Owner approval is required for
any deviation.
(vii) All butt welds shall be 100 % RT examined.
(viii) All fillet welds and branch welds shall be 100 % MT examined.
(ix) Hardness measurement after PWHT shall be done at the weld, HAZ and base metal. This is to check for potential over-tempering by
PWHT. Minimum acceptance criteria shall be a 190 HB.
(x) Maximum acceptable hardness shall be as specified for different forms in the relevant ASTM specification or as stated mechanical
requirements of this PTS.
(xi) WPS and supporting PQR shall be submitted to the Owner for review and approval. PQR shall include the following as a minimum:
a) Base metals, HAZ, and weld shall comply with the following requirements:
 Transverse charpy impact test at -20 °C. Acceptance criterion is at least 40 J impact energy value
 Hot yield test at design temperature
 Photomicrographs shall be made to verify and confirm 100 % tempered martensite structure.
b) Extent of testing shall be per other mechanical tests in the relevant standard
(xii) Heat input used during production welding shall not be more than 115 % of the value logged in PQR.
(xiii) Repair welding shall not commence until the Owner or its representative has inspected the defect. The repair procedure shall be
submitted to and approved by the Owner.
For castings, the above mentioned requirements shall apply for weld repair. Additional supplementary requirement S51 (mandatory PWHT
after weld repair) as per ASTM A703 shall apply. PWHT shall be carried out as stated above.
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Clause
Description
D.6
NDT
(i) 100 % RT examination shall be carried out on all butt welds.
(ii) 100 % MT examination shall be performed on all fillet welds and branch welds.
(iii) 10 % of the fittings and forgings ordered shall be 100 % PT (as per ASTM E165). Acceptance criteria in accordance with per ASME/BPVC
Sec VIII Div 1.
(iv) Supplementary requirement S10 (examination of weld preparation) shall apply, if weld repair is required for castings.
QA/QC
(i) All inspection and test certificates shall be supplied to the Owner, unless stated otherwise.
(ii) All pipe/fitting/casting shall be checked 100 % with PMI. The alloy analyser selected and used shall be able to differentiate between
grade 9 and grade 91. PMI methods and the alloy analyser selected shall be agreed by the Owner.
(iii) Supplementary requirement S21 (HT furnace record) shall apply for castings.
Miscellaneous
(i) Brinell hardness tester is preferred. If case Vickers hardness testing is selected, at least 10 % of the weld joints, inclusive of
weld/HAZ/base metal, shall be verified by using Brinell hardness tester.
(ii) Local re-normalisation and tempering shall not be permitted to prevent formation of a broad zone of material on either side of the
heated area that has been intercritically heated.
(iii) If any component fabricated from Grade 91 is “locally” heated above Ac1 temperature, the following shall be carried out:
a) The entire component shall be re-normalised and tempered or
b) The affected section shall be removed from the component in its entirety, re-normalised and tempered, and then re-inserted
into the component by appropriate means.
D.7
D.8
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Annex E (normative) Welding of Stainless Steels Material
Clause
Description
E.1
Austenitic Stainless
(i) Stainless steels shall be stored separately and segregated, and shall not come in contact with unalloyed or low alloy steels or zinc or
medium containing chloride.
(ii) Fabrication of stainless steels shall be done in dedicated work area and properly barricaded.
(iii) The tools used shall be suitable for the fabrication of stainless steels and shall not be used for fabrication of other material.
Materials
This section is applicable to the following austenitic stainless steel grades:
 AISI 300 Series, Grades 304L, 304, 316L, 316, 321, 347, etc., their corresponding H-grades, and any other austenitic stainless steels
agreed with the Owner.
Procedure Qualification Records Controls
(i) These variables shall also be recorded for each weld run, if possible with automated monitoring equipment, else hand-held metres and
stop watch may also be utilised.
 Arc volts,
 welding current,
 travel speed and
 arc energy
(ii) The range of bead widths shall be recorded for each weld run for each welding process used.
Weld Procedure Test Requirements
The following additional testing and requirements shall be carried out:
(i) For volumetric NDT wherever the geometry permit, RT shall be used.
(ii) Surface crack detection shall be examined using PT.
(iii) If different examination method compared to the above is specified for production NDT, the production NDT method shall also be
applied.
(iv) The macro sections shall be polished to 1-micron finish and etched to reveal the weld microstructure.
E.2
E.3
E.4
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Clause
Description
E.5
Welding Requirements for Low Alloy
(i) Preheat temperature of 200 °C shall be maintained.
(ii) Maximum interpass temperature of 300 °C shall be maintained.
(iii) To ensure complete transformation of austenite to martensite, the weld shall be allowed to cool to at least 93 °C before commencing
with the required PWHT.
(iv) The non-PWHT weld shall be post heated. Post heat temperature range shall be between 310 °C – 320 °C and held for a duration of at
least 15 minutes.
(v) Further, the temperature shall not be high enough to prevent NDT (such as RT) of the weld.
(vi) PWHT temperature shall be at least 732 °C and a minimum of 15 °C below the tempering temperature. Owner approval is required for
any deviation.
(vii) All butt welds shall be 100 % RT examined.
(viii)All fillet welds and branch welds shall be 100 % MT examined.
(ix) Hardness measurement after PWHT shall be done at the weld, HAZ and base metal. This is to check for potential over-tempering by
PWHT. Minimum acceptance criteria shall be a 190 HB.
(x) Maximum acceptable hardness shall be as specified for different forms in the relevant ASTM specification or as stated mechanical
requirements of this PTS.
(xi) WPS and supporting PQR shall be submitted to the Owner for review and approval. PQR shall include the following as a minimum:
a) Base metals, HAZ, and weld shall comply with the following requirements:
 Transverse charpy impact test at -20 °C. Acceptance criterion is at least 40 J impact energy value
 Hot yield test at design temperature
 Photomicrographs shall be made to verify and confirm 100 % tempered martensite structure.
b) Extent of testing shall be per other mechanical tests in the relevant standard
(xii) Heat input used during production welding shall not be more than 115 % of the value logged in PQR.
(xiii)Repair welding shall not commence until the Owner or its representative has inspected the defect. The repair procedure shall be
submitted to and approved by the Owner.
For castings, the above mentioned requirements shall apply for weld repair. Additional supplementary requirement S51 (mandatory PWHT
after weld repair) as per ASTM A703 shall apply. PWHT shall be carried out as stated above.
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Clause
Description
E.6
Essential Variables
In addition to the requirement specified in ISO 15614-1, the following essential variables shall also apply. For application of other standards
e.g. ASME IX, the essential variables shall follow the respective standards and codes unless specified by Owner.
Welding Process
The welding process and combination or order of welding processes shall not be altered.
Welding Parameters
(i) The electrical characteristics (AC/DC) or polarity shall not be changed for any weld pass.
(ii) For GTAW process, the current shall not be changed by in excess of +10 % nor shall the characteristics change from normal to pulsed
current or vice versa.
(iii) The pulse frequency, waveform or background current of pulsed GTAW shall not be changed unless permitted by the Owner.
(iv) For SAW or FCAW, the stick-out length shall not be changed beyond the range specified in the WPS or approved Specification
parameters.
Control of Production Welding
(i) Debris, contaminant, and spatter shall be removed from the surface of vessel, piping or other equipment by using disc grinder or emery
disc.
(ii) PWHT
Austenitic stainless steels weldments shall be PWHT (e.g. stress relief, stabilisation heat treatment or solution annealing) only if stated
in design/purchasing documents.
The detailed PWHT procedures for each equipment or item shall be submitted to the Owner for review and approval.
When stabilisation PWHT is specified, the Manufacturer should provide charpy impact values of the heat-treated weld metal. The
charpy impact values shall not be less than 32 J at 20 °C. The Manufacturer should consult the filler metal Supplier with regard to effect
of PWHT cycle on material toughness.
(iii) The fabrication of stainless steel equipment (e.g. vessels, process piping and other equipment shall be carried out in a separate area
or shop, from that of Carbon-Manganese and low alloy steels.
6Mo Superaustenitic Stainless Steels
The material that is applicable in this section are:
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Clause
Description

UNS S31254, UNS N08367, UNS N08925, UNS N08926, etc., and any other super austenitic stainless steels agreed with the Owner.
Permitted Processes
The welding heat input shall be limited to a maximum of 1 kJ/mm.
Welding PQR Parameters
(i) The inter-pass temperature shall be recorded at the start of each pass.
(ii) During qualification test, the maximum inter-pass temperature recorded in the PQR shall be the highest inter-pass temperature
measured at the start of any weld pass.
(iii) Each welding pass shall be monitored using instrument that records the arc time, volts and welding current.
(iv) Travel speed and arc energy shall be recorded for each pass.
Weld Procedure Test Requirements
Inspection, examination, and testing requirements shall also include followings:
(i) For volumetric NDT, if the geometry and accessibility allows, RT shall be used.
(ii) For surface crack detection, PT shall be used.
(iii) The production NDT method specified shall also be applied if production NDT specified is different inspection method stated above.
(iv) Three (3) macro sections, representing 12, 3 and 6 o’clock positions, shall be used for macro and hardness examination, for 5G and 6G
welding positions,
(v) A weld metal analysis shall be taken from material sampling extracted from the root area. Sample extraction method shall be approved
by the Owner.
(vi) The analysis shall include all element that are deliberately added, and shall include at least following elements: C, Si, Mn, S, P, Cr, Fe,
Mo, Ni, Cu, Nb, and N.
(vii) Ferric chloride testing (ASTM G48) at test temperature of 30 °C shall be carried out. Any deviation to the procedure due to the specimen
size or configuration shall be approved by the Owner.
(viii) Metallographic examination shall be carried out, and two micro sections shall be prepared.
(ix) The weldment microstructure shall be assessed at a magnification of at least x 400, and reported in the PQR.
(x) Any feature considered abnormal shall be reported. The microstructure shall be free of any fissuring.
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Clause
E.7
Description
(xi) Original copies of photomicrographs, of the HAZ at the fusion line and the weld metal at magnification of x 250 shall be included in the
PQR file.
Essential Variables
In addition to the applicable code requirements, the following essential variables shall also apply.
Joint Type
Separate qualification is required for single-sided and double-sided preparations. Single bevels and double bevel (K) preparations qualify single
vee’s and double vee (X) respectively but not vice versa. Otherwise, all preparation shapes require separate qualification.
Welding Process
Order of welding processes or combination of welding processes or shall not be changed unless permitted by the Owner.
Welding Parameters
(i) The electrical characteristics (AC/DC) or polarity of any weld pass shall not be changed.
(ii) For GTAW the welding current shall not be changed by more than +10 % and the characteristics shall not be changed from normal to
pulsed current or vice versa.
(iii) The pulse frequency, waveform or background current of pulse GTAW shall not be changed unless permitted by the Owner.
(iv) The calculated arc energy shall not be changed by more than 10 %.
(v) For SAW or FCAW the stick-out length shall not be changed beyond the range stated in the WPS or parameters required in the approved
Specification.
Production Welding Controls
(i) The fabrication of stainless steel equipment (e.g. vessels, process piping and other equipment shall be carried out in a separate area
or shop, from that of Carbon-Manganese and low alloy steels.
(ii) All plasma spatter and other debris shall be removed by iron free disc grinder or emery disc.
(iii) Monitoring of production welding parameter shall be carried out as per schedule. Testing frequency shall be at least one record per
shift, and each welder shall be tested a minimum of once per month.
Segregation of Material
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Clause
Description
(i) 6 Mo stainless materials and welding consumables must be segregated and prevented from coming into contact with CMn steels or
their residual fabrication products e.g. dust, spark or grinding particles, etc.
(ii) Workbenches shall be restricted for use for assembling and welding only one type of material at a time.
(iii) Appropriate precautions care shall be carried out to ensure that consumables for welding 6Mo and components are not mixed with
other materials.
Corrosion Testing
(i) One test specimen that include the weld, HAZ, and base metal shall be removed from each PQR test coupon for Integranular Corrosion
Testing (IGC) in accordance with ASTM A262 Practice E.
(ii) The Rapid Screening Test method per ASTM A262 Practice E is not allowed.
(iii) The test shall be carried for a minimum of 15 hours. Owner shall advice if longer test duration is required.
(iv) No flattening of the coupon material shall be carried out.
(v) Acceptance criteria shall be per ASTM A262 Practice E.
(vi) All samples shall be photographed and made available with PQR submitted for Owner approval.
(vii) Third-party laboratories used for the testing shall have prior experience with Stainless steel testing using ASTM A262 practices.
Contractor shall submit to the Owner the laboratory name and qualifications, to be used for qualification and production testing.
(viii) If the specimen does not meet the acceptance criteria, then a new specimen may be taken and retested. The Owner shall be notified
before proceeding with retesting.
Repair of Weld
(i) A separate procedure qualification, which include reproduction of a typical production repair, is required for repair welding of 6Mo
stainless steel using the same WPS as per the original weld.
(ii) For partial wall excavations, the remaining ligament used for the procedure qualification test shall be the thinnest allowed in
production.
(iii) For full penetration excavations, the procedure qualification test shall be performed and qualified separately.
(iv) The mechanical testing for the procedure qualification should include the followings:
 macro examinations,
 hardness tests,
 weld metal analysis,
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Clause
E.8
Description
 ASTM G48 ferric chloride testing (at process exposed weld surface, whether new or original) and
 Metallographic examinations (x 400 magnification).
(v) If a different WPS or process is to be used for repair welding, this WPS shall be fully re-qualified in accordance with this PTS. The weld
repair procedure qualification test should be identical to the original weld procedure.
(vi) If impact testing was specified for the original weld, repair weld WPQR should include impact testing of the repair weld metal and the
adjacent HAZs, both in the parent material and the original weld metal. Impact test temperature shall be per the original weld
requirement.
Duplex Stainless Steels
Additional requirements for Procedure Qualification of Duplex Stainless Steels (DSS):
(i) Procedure qualification shall be performed using DSS base metal of the same UNS number used in actual production.
(ii) The following requirements shall also be complied:
a) Thickness and Heat Input:
Besides the requirements of ASME/BPVC Sec IX, a new PQR is required when:
 The maximum wall thickness qualified for production weld shall not exceed 120 % (1.2T) of the test coupon thickness used
during procedure qualification. The minimum qualified production wall thickness is the test coupon thickness (T).
 The maximum heat input qualified on the WPS shall be the maximum obtained and recorded on the supporting PQR. The
minimum heat input qualified shall be the greater of 0.5 kJ/mm (12.7 kJ/in) or 50 % less than the maximum heat input
achieved on the supporting PQR. See ASME/BPVC Sec IX, QW - 409.1(C) and Annex H.
b) Weld Position:
All vertical weld progression shall be uphill.
c) Ferrite to Austenite Ratio:
 The ratio of ferrite-to-austenite in the deposited weld metal and HAZ shall be determined. The examination shall be
performed on a polished and etched cross section of the weld coupon at a magnification of 500 x, per ASTM E562.
The number of fields and points per field shall be in per the guidance provided in the 10% Relative Accuracy column found
in Table 3 of ASTM E562.
 The ferrite to austenite ratio at the following locations shall be analyzed and reported in the PQR:
o Root pass
o Mid-thickness
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Clause
Description
o
Cover pass
Ferrite content shall be within 30 % - 65 %.
 Ferrite content of Base metal shall be 40 % to 60 %.
d) Hardness testing:
Hardness testing to comply with requirements stated in API TR 938-C Section 4.4.
 For UNS S31803 and S32205, the measured hardness shall not be more than 310 HV average, with no reading exceeding
320 HV.
 For all other grades of duplex stainless steel, the measured hardness shall not be more than 350 HV average, with no
reading exceeding 360 HV.
e) Corrosion and Impact Testing:
(iii) PQR shall include result of the corrosion and impact test as described below:
a) Corrosion Test for Detrimental Intermetallic Phase and Pitting Corrosion:
 Each PQR test coupon shall be tested for Detrimental Intermetallic Phase in accordance with ASTM A923 Method C. The
test specimen shall include the weld, HAZ, and base metal. Acceptance criteria shall be per ASTM A923 except that no
pitting is allowed. The Rapid Screening Test method per ASTM A923 is not allowed.
 Each PQR test coupon shall be tested for pitting corrosion test shall be per ASTM G48
Method A using Ferric Chloride solution.
o For Duplex steel and super duplex steel, the test duration shall be 24 hours immersion at 25±1 °C and 40±1 °C
respectively.
o Test specimen dimensions shall be full wall thickness by 10 mm along the weld and 50 mm across the weld. The
test specimen shall be machined perpendicular to the weld axis. The test shall expose the external and internal
surface and a cross-section surface including the weld zone in full wall thickness.
o Flattening of the coupon material is not permitted.
o Before commencement of the test, the specimen shall be degreased, dried, weighed to three (3) decimal places,
and the weight recorded.
o Upon completion of the corrosion test interval, the test specimen shall be rinsed, cleaned, dried and re-weighed
using the procedures specified in ASTM G48A.
o The acceptance criteria of the corrosion test shall comply with the following:
- No evidence of pitting examined at a magnification of X 20.
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Clause
Description
- Weight loss shall not exceed 4g/m2 [~0.04 mm/yr] (1.6 mpy)
o All samples shall be photographed and made available with PQR. PQR shall be submitted for Owner endorsement.
 Third-party Laboratories identified to perform the tests shall have prior experience with duplex stainless steel using ASTM
A923 and ASTM G48. Vendor shall submit to the Owner the laboratory name and qualifications, to be used for qualification
and production testing.
 A new specimen may be taken and retested if the specimen does not meet the acceptance criteria. The Owner shall be
informed before proceeding with retesting.
b) Impact Test:
 Three (3) test specimens for each location are required for Charpy V notch impact tests of the weld metal and HAZ.
The following values are required for full-size specimens:
Material
Test
Impact Energy at Weld
Temperature Metal
Average
Individual
22Cr grade -40 °C
34 J
27J min
25Cr grade -50 °C
70 J
65J min
Impact Energy at HAZ
Average
54 J
70 J
Individual
43J min
65J min

For standard size specimens, the orientation of shall be in accordance with ASME/BPVC Sec VIII DIV1, UG84. Additionally,
the weld metal impact specimen shall be removed from the T/2 (mid-thickness) position. The HAZ impact specimen
location may be adjusted to ensure the notch is completely in the HAZ but should be as close as feasible to the T/2 position.
 The lateral expansion shall be at least 0.38 mm. For 25CrDSS this value should be obtained at 0.
(iv) Heavy Wall Duplex Equipment:
a) For weldments with a wall thickness exceeding 25 mm, the impact test using full-size specimens and the corrosion test shall
be carried out.
b) For weldments with a wall thickness exceeding 50 mm, full-size impact specimens shall be include the first weld pass and at
the 1/4T position.
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Clause
Description
E.9
Additional Requirements for Welding Duplex Stainless Steel:
(i) Welder and Welding Operator Qualifications:
a) Welder and welding operator qualification tests shall be made using the same welding procedure, base material UNS grade,
thickness range and brand of filler metal to be used in production.
b) For all performance qualification tests, the ferrite-to-austenite ratio shall be determined as required in E4.1.2 Item (3) of this
PTS.
c) For all performance qualification tests, in addition to the applicable code requirements the followings shall also be carried out:
 Impact testing for butt weld and hardness tests for branch and fillet welds as required in this annex.
 macro and visual examination
(ii) Production Test Plates:
Production testing, from the same heat as the base material and installed as run-off tabs at the end of longitudinal weld seams, shall
be carried out on each heat of plate used to fabricate shell and head segments.
Ferrite-to-austenite ratio testing and impact testing as required in this annex shall be conducted on the test specimen.
The test plate shall be of sufficient size to equal the cooling gradient of the component.
Inspection and Testing of Duplex Stainless Steel Welds:
(i) Ferrite measurements shall be carried out on pressure boundary welds, and the measurement shall be taken using a Fischer
Feritescope® that is calibrated per AWS A4.2M.
The ferrite check shall be made from each weld procedure, welder, and heat/lot of filler metal. Three measurements shall be taken in
the centre line of a weld cap bead and also the root pass if accessible.
The ferrite measurement on the weld cap and root pass shall be taken on a prepared/ground flat surface, so that the microstructure
of the specimen is not altered.
(ii) The welds and adjacent surface areas shall be 100 % visually examined for heat tinting (i.e., oxide discoloration).
If required by the Owner, all heat tinting shall be removed by pickling or glass bead blasting. If any oxidation is observed, the weld shall
be acid pickled and passivated as per PTS 15.12.03, both internally and externally.
Shielding gas
(i) The shielding gas selected shall ensure attaining satisfactory ASTM G48 test results.
(ii) The oxygen content in the shielding and backing gas shall not exceed 50 ppm.
E.10
E.11
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Clause
Description
E.12
Weld Joint Preparation
(i) Plasma-arc process, machine cutter, or grinding disc dedicated solely for the use on DSS shall be utilized for cutting DSS.
(ii) Carbon-arc shall not be used for cutting or back gouging.
(iii) If plasma-arc cutting is utilized, the surface (i.e. also internally if applicable) shall be thoroughly cleaned of all spatter, and the HAZ
resulted from the plasma-arc cutting shall be removed.
(iv) Grinding discs, once utilized for cutting DSS, shall be used exclusively for that purpose.
(v) The final configuration and surface preparation shall be obtained by machining.
(vi) Cutting fluid that is compatible with stainless steel shall be used during machining operations.
(vii) Any irregularities, burrs, or nicks on the bevel shall be repaired, if practical, by light grinding. Edge defects or laminations shall be
highlighted to the Owner before commencing with investigation or repairs works. Repairs by welding shall not be carried out without
prior approval of the Owner.
(viii)Prior to welding, each bevelled edge and internal and external surface over a distance of at least 50 mm from the bevel shall be
thoroughly dried and cleaned with a stainless steel wire brush. The bevelled edge shall then be wiped clean with acetone, or other
Owner-approved solvent.
HEAT INPUT IMITS
DSS Type
Heat Input
22 % Cr Duplex:
0.5 kJ/mm - 1.75 kJ/mm (12.7 kJ/in - 44.5 kJ/in)
25 % Cr Duplex:
 Root: 1.0 kJ/mm - 1.5 kJ/mm (25.4 kJ/in - 38 kJ/in)
 Passes 2 and 3: 0.5 kJ/mm - 1.2 kJ/mm (12.7 kJ/in - 30.5
kJ/in)
 Remainder: 0.5 kJ/mm - 1.75 kJ/mm (12.7 kJ/in - 44.5 kJ/in)
E.13
If the ferrite is checked, and found acceptable per this PTS in the as-welded condition, during WPQT, heat input for tube-to-tubesheet welding
may be as high as 3.0 kJ/mm.
E.14
Controls of Welding Procedure Qualification Records Controls
(i) During WPQT, all welding passes shall be monitored using equipment that automatically records the arc time, volts and welding
current.
(ii) Travel speed and arc energy shall be recorded for each pass.
(iii) The inter-pass temperature shall be recorded at the start of each pass.
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Clause
Description
(iv) The fabricator shall provide specific inspection records, if required by the Owner, proving compliance with actual WPS parameters
during welding for each weld made.
(v) Certificates from the crayon Manufacturer, certifying that the halogen content of the crayon is not more than 250 ppm, shall be
available for review if requested by the Owner’s representative .
(vi) GTAW process shall be used to weld the root pass of all single-sided welds. Back purging shall be maintained until at least 6 mm of
weld thickness has been deposited.
(vii) Backing gas and shielding gas used shall be either pure argon or argon plus 2 % maximum nitrogen. The oxygen content of the back
purge shall be less than 0.005 % (50 ppm). The contractor shall submit details of the procedure and instrument to be used for
monitoring oxygen content as part of the WPS. Adequate precautions shall be exercised to ensure proper application of backing gas.
(viii) To avoid possible cracking and embrittlement of the weld, GTAW shall be used with a hydrogen free shielding gas if field welding access
is limited to one side only and back welding is not possible. The weld root passes for the welding procedure qualification should be
assessed visually using PTS 15.12.03.
(ix) The welding arc shall not be strucked outside the weld bevels. Arc strike outside the bevels shall be removed by grinding, and the
ground area shall be examined with PT, and all relevant indications shall be repaired.
(x) Earth connection check and periodical examination of the condition of the earth cables and attachments shall be carried out regularly
by the contractor. Any arcing from improper earth connection shall be treated as a stray arc strike. Earth connections shall be made to
the work by using stainless steel clamps. The earth cables shall not be welded to the components welded.
(xi) PT examination shall be carried out on welds intended for welding on the opposite side, after cleaning for the back weld. Unless
permitted by the Owner, all back grinding shall be accomplished with approved procedures, ensuring complete removal of oxides from
plasma-cut surfaces.
(xii) Carbon arc gouging shall not be used, unless permitted by the Owner.
(xiii) All accessible welds on the process side shall be cleaned after welding by hand wire brushing of the as-welded surfaces.
(xiv) All welds made, inclusive of tack and fit-up weld, shall be made using approved weld procedures, materials and certified welders.
(xv) Essential variables for procedure qualification shall be in accordance with ASME/BPVC Sec IX, QW-250 including supplementary
essential variables for notch toughness, and those listed below. Any changes in the essential variables of an approved WPS shall require
requalification.
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Clause
Description
a) For manual and machine welding:
Variables
Filler metal type
Filler metal size
Shielding gas flow rate
Backing gas composition
Electrical characteristics
Interpass temperature
Heat input
Additional Essential Variables
Any change in the Manufacturer
Any change in diameter of the filler metal
Any change in flow rate beyond -20/+10 %
Any change in the gas composition
Any change in type of current, polarity, or pulse range.
Any change in the maximum interpass temperature
Any change greater than ± 10 %.
b) For Machine Welding only
Variables
Welding equipment
Additional Essential Variables
Any change in the Manufacturer or model of machine
welding equipment.
Joint configuration
Any change in joint configuration outside tolerances
specified in the procedure.
Weld orientation
Any change in the weld orientation (e.g., vertical to
horizontal).
Filler metal
For SAW, any change in the brand name and type of wire
and flux.
(xvi)The number of test specimens for mechanical test for procedure qualification shall be per API 938-C Annex B, Table B.1.
(xvii) On top of the acceptance criteria stated in ASTM A923, the specimens shall have no pitting, except for apparent “end grain attack” or
one (1) slag inclusion per specimen.
(xviii) Photo-micrographs at approximately x 500 shall be performed on each of the locations where a phase balance assessment is
performed. Photo-micrographs shall show a typical austenite/ferrite microstructure.
(xix) The macro-examination shall proof that the
a) weld is sound and free from cracks and other defects, and
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Clause
Description
b) have full penetration and fusion between each weld passes and parent metal.
(xx) Dissimilar metal welds (i.e., carbon steel to DSS or austenitic SS to DSS), shall be requalified and tested per this PTS.
(xxi) Third party laboratories used for PQR shall be experienced in the methods used for DSS testing.
(xxii) The requirements of API 938-C annexes C.3 and B.9 should be met for tube to tubesheet welding.
E.15
Additional requirements for piping
(i) Weld for the followings shall be qualified separately and the test shall be performed under simulated site conditions.
a) Butt welding procedures,
b) branch welding procedures,
c) fillet welding procedures and
d) repair welding procedures.
(ii) Method of Welding
Before commencement of test welding, a written procedure to remove oxygen before welding of DSS pipes, shall be available at the
test site.
(iii) Chemical Analysis
a) Chemical analysis shall be performed on the root run. The elements required for calculation of the PRE shall be ascertained.
b) The PRE value shall be more than the minimum required for the base material to be welded.
(iv) Retests
a) The Contractor shall inform the Owner and obtain permission to perform retests, if the results of DT are not acceptable due
to a localised weld defect or defective specimen preparation.
b) Retesting for Corrosion Test shall be allowed only if failure is due to test conditions or sample preparation. If retesting is agreed,
two (2) further specimens shall be prepared and tested, and all retest specimens shall comply with the acceptance criteria.
(v) Qualification of Repair Weld Procedure
a) Each type of weld repair shall be qualified separately, as well as weld cap repair and partial penetration.
b) Through-thickness repairs are not permitted.
c) On top of the variables or parameters required for normal PQR, the WPS for repair shall include the following:
 Excavation method
 NDT techniques used to examine and ensure complete removal of defects.
(vi) Protection of Piping Internal and Edge
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Clause
Description
a) Upon completion of welding, all open ends of pipe strings shall be sealed and capped off.
b) A circular tight cap of a suitable design and material shall be used to cover and protect the open ends of the pipe and shall be
placed on the pipe at the end of each day’s work to prevent entry of foreign material and protect the edge preparation. Caps
shall be in place until commencement of next welding work.
(vii) Fit-up for Butt Welds
a) If practical, internal line-up clamps shall be used and their design shall be such as to allow the introduction and containment
of purging gases.
b) To prevent contact between the DSS pipe and CS clamp, the clamps shall have stainless steel inserts or shall be clad with a
suitable material.
c) External line-up clamps may be used for the followings:
 line pipe 150 mm NPS and below,
 tie-in welds, and
 for special welds, such as connections to valves, flanges and fittings
d) Pipe shall not be moved or lifted or lowered off until after the completion of the second pass.
e) If an internal or external line-up clamp cannot be used, alignment may be achieved by using tack welds made per parameters
in approved WPS for the fill pass.
f) Tack welds shall be temporary bar tacks using suitable duplex stainless steel material.
g) Tack welding shall be performed by qualified welders.
h) Fully penetrating root tacks shall not be permitted.
i) The tack welds shall be ground out as welding progresses around the joint.
(viii) Welding
a) Pipes shall be flushed with backing gas before commencement of welding. Welding shall not begin until oxygen level of less
than 0.005 % (50 ppm) is attained.
b) The oxygen content of the exit gas shall be monitored using suitable and calibrated oxygen measuring equipment.
c) During welding of the root run, 50 ppm oxygen level in backing gas shall be ensured and maintained. For subsequent passes,
the oxygen level may be increased up to 500 ppm and maintained. However, welding shall be stopped if the oxygen level
exceed 500 ppm.
The oxygen level of less than 50 ppm shall then be re-established before further welding takes place. The oxygen level shall be
slowly increased to 500 ppm max as welding progress.
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Clause
E.16
Description
d) If interruption of welding is unavoidable, a minimum of three (3) passes or one-third (1/3) of the joint thickness, whichever is
greater, shall have been deposited before welding is stopped.
e) On resumption of welding any preheat requirements specified in the approved WPS shall be applied.
f) Other than cleaning and dressing operations as stated in the WPS, welds shall not be treated with a flame torch or other
mechanical means to change their appearance and shall be left as welded.
g) Peening of welds is not permitted.
h) Upon completion of welding, all surfaces adjacent to the welds shall be free of spatter, burrs and other imperfections, that
may interfere with RT or UT examination.
Additional requirements for pressure vessels
(i) The fabricator shall prepare a production test coupon along with the actual production welding. The production test coupon shall
comprise of one (1) long weld seam, one (1) circumferential weld seam and one (1) nozzle welding.
(ii) The material for production coupon shall be the actual used for fabrication of the vessel.
(iii) These production coupons shall be tested for all weld qualification tests.
(iv) If any hot forming or cold forming is involved with PWHT/solution annealing, the same shall be included in the production coupon
production sequence.
(v) PWHT should normally not be carried out. If carried out, the PWHT shall be per code and the steel Manufacturer’s recommendations.
After heat treatment, the internal surfaces shall be cleaned and free of scale and oxides.
(vi) Upon completion welding, the adjacent surfaces shall be cleaned and free of all spatter, slag, flux and other carbonised material.
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Annex F (normative) Ni steels (e.g. 3.5 % Nickel Steels)
Clause
Description
F.1
Materials
Typically, this section is applicable to:
ASTM A333 Gr3, ASTM A350 LF3, ASTM A420 Gr WPL3, ASTM A765 Gr III, ASTM A352 LC3, ASTM A203 D, etc., and any other 3.5 % nickel
steels agreed with the Owner.
General
(i) Alternating current shall be used with SMAW. Direct current may cause magnetic arc blow problems and resulted in lack of fusion.
(ii) For GTAW for 3½ % Nickel steels, high purity argon shall be used for back purging, unless otherwise agreed by the Owner.
(iii) A minimum preheat of 100 °C shall be carried out for welding all thicknesses of 3.5% Ni Steel.
F.2
F.3
F.4
F.5
Control of PQR
(i) The minimum qualified preheat temperature on a PQR is defined as the greater of either (i) the minimum temperature for the root
run or (ii) the minimum temperature at the start of the first capping pass deposited on the parent material with the highest Ceq.
(ii) The arc time, voltage, welding current, travel speed and arc energy of each welding pass shall be monitored and recorded during PQR.
(iii) The inter-pass temperature shall be recorded at the start of each pass.
PQR Requirements
Additions and clarifications to code or standard requirements:
 For volumetric NDT wherever the geometry allows, RT shall be used.
 Surface crack detection will be by MT.
 If production NDT state a different or additional inspection method other than method stated above, the production NDT method
shall also be carried out.
Essential Variables
In addition to the requirements of ASME/BPVC Sec IX or ISO 15614-1, the following essential variables apply:
(i) Chemical Composition
a) Qualifications performed on 3½ % Ni steels shall only qualify for that material.
b) For welding 3½ % Ni steels to other material where impact properties are required, specific procedures shall be qualified using
the particular combination of dissimilar materials.
(ii) Thickness
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Clause
Description
a) For service temperature of -80 °C or higher, the maximum thickness allowed for as-welded (i.e. without PWHT) applications
is 12.5 mm.
b) All weld regardless of thickness shall be PWHT if the service temperature is below -80 °C.
(iii) Position
Requalification is required if there is a change in weld progression from 5G vertical up welding to vertical down.
(iv) Joint Type
a) Reduction in joint bevel angle shall not be more than 5°.
b) Separate PQR is required for single-sided and double-sided weld joint.
c) Double bevel (K) and single bevel joint preparations shall qualify double vee (X) and single vee’s respectively but not vice versa.
All other joint preparation shapes shall require separate qualification. However, changes between compound angle V and
single joint preparations may be allowed without re-qualification if permitted by the Owner.
d) Separate procedure qualification is required for removable of backing strips or inserts (if use of backing is permitted by the
Owner).
e) Single-pass fillets require separate qualification. However, multi-pass fillet welds are qualified by butt weld qualifications.
(v) Welding Process
The welding process, combination of processes or order of welding processes shall not be altered.
(vi) Welding Parameters
a) The electrical characteristics (AC/DC) or polarity for any weld pass shall not be changed.
b) For FCAW, SMAW or GTAW, the welding current shall not be altered by more than +10 %.
c) The calculated arc energy shall not be decreased by more than 10 % or increased by more than 20 %.
d) For FCAW, the electrode extension length shall not be changed beyond the range specified in the approved WPS.
e) The minimum preheat specified in WPS shall not be less than the Minimum Qualified Preheat Temperature (MQPT) stated in
PQR.
f) The stated maximum inter-pass temperature in the WPS shall not exceed the PQR maximum by more than 25 °C.
(vii) Production Welding Controls
a) Monitoring of production welding parameters shall be carried out daily per welding process per shift.
b) Minimum frequency of testing for welders shall be at least once per calendar month.
c) Welding machines shall be calibrated or verified at intervals not more than 12 months.
d) Tack welding shall be preheated to the minimum level specified on the WPS or 100 °C whichever is higher.
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Annex G (normative) High Ni Alloys
Clause
Description
G.1
Materials
Typically, this section is applicable to:
 UNS N08825 (825)
 UNS N06625 (625)
 UNS N04400 (Monel®)
 and any other nickel alloys agreed with the Owner
General
The area adjacent to the weld preparation shall be clean, to avoid hot cracking.
S, Pb, Sb, Cd and Zn are detrimental impurities that may be present in grease or paint. The impurities and oxide layer shall be grind out to a
bright metal surface appearance just before commencement of welding.
To avoid porosity, acetone and equivalent solvents are used for cleaning.
To minimise hot cracking especially at the weld stop/start positions, the weld bead shall be ground smooth before the welding the next weld
bead.
PQR Controls
(i) The following shall be recorded for each weld run, preferably with automated monitoring equipment, however hand-held metres and
stopwatch may also be used:
 Arc voltage,
 welding current,
 travel speed and
 arc energy
(ii) The range of bead widths shall be measured and recorded for each weld run.
(iii) PQR shall be carried out as per ASME/BPVC Sec IX or ISO 15614-1.
G.2
G.3
G.4
PQR Requirements
Additions and clarifications to code or standard requirements:
(i) For volumetric NDT wherever the geometry allows, RT shall be used.
(ii) Surface crack detection will be by PT
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Clause
G.5
G.6
G.7
Description
(iii) If production NDT state a different or additional inspection method other than method stated above, the production NDT method shall
also be carried out.
Essential Variables
In addition to the requirements of ASME/BPVC Sec IX or ISO 15614-1, the following essential variables apply:
(i) Welding Process
The welding process, combination of welding processes or order of welding processes shall not be altered.
(ii) Welding Parameters
a) The electrical characteristics (AC/DC) or polarity shall not be altered for any weld pass.
b) For GTAW the welding current shall not be changed by more than +10 % nor shall the characteristics change from normal to
pulsed current or vice versa.
c) For pulsed GTAW the pulse frequency, waveform or background current shall not be changed unless approved by the Owner.
d) For SAW or FCAW the stick-out length shall not be changed beyond the range stated in the WPS or approved Specification
parameters.
e) Inter-pass temperature shall not exceed that recorded on the PQR or 200 °C, whichever is lower.
Production Welding Controls
(i) Fabrication of nickel alloy vessels, process piping and other equipment shall be carried out in a separate area (if possible a separate
shop) from that of Carbon-Manganese and low alloy steels.
(ii) Nickel and its alloys shall be cut either by using plasma arc cutting or mechanical cut.
The welded surface and adjacent area shall be free of all spatter and other debris. The spatter or debris shall be removed from the
surface by using disc grinder or emery disc.
Material Segregation
(i) Nickel alloys shall be fabricated in isolation, or if agreed by the Owner may be fabricated with other non-ferrous materials.
(ii) Hand tools and related consumables, shall be colour-coded, or suitable controls executed to ensure that the tools and consumables
are used solely for nickel alloys fabrication
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Annex H (normative) Copper Alloys
Clause
Description
H.1
1 Materials
This section is typically applicable to:
 BS 2870/2871/2875 grade CN102,
 DIN 17664 No. 2.0872 CU NI 10 FE
 any other copper alloys agreed with the Owner
Impact Tested Carbon Steel Welds
Chemical Composition Check
(i) The composition of the material shall be verified by the manufacturer, i.e. carbon equivalent (Ceq) and presence of unspecified or
micro alloying elements e.g Nb, V, B and Ti. The combined percentage of Nb, V, B and Ti shall not exceed 0.03 % and B shall not be
more than 50 ppmw.
(ii) The manufacturer shall be responsible for the Material Test Reports (MTRs) of manufacturer supplied material. If the concentration of
the elements required to determine Ceq is not available in the MTRs, the manufacturer shall
a) Determine the concentration and Ceq, verify compliance with requirements, and report results; or
b) Supply replacement conforming material and documentation
Permitted Welding Processes
For grade CN102 material, autogenous welding of is not allowed.
PQR Controls
(i) The following shall be recorded for each weld run, preferably with automated monitoring equipment, however hand-held metres and
stopwatch may also be used:
a) Arc voltage,
b) welding current,
c) travel speed and
d) arc energy
(ii) The range of bead widths shall be measured and recorded for each weld run.
(iii) Procedure qualification shall be qualified per ASME/BPVC Sec IX or ISO 15614-6.
H.2
H.3
H.4
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Clause
Description
H.5
Essential Variables
In addition to the requirements stated in of ASME/BPVC Sec IX and ISO 15614-6, the following essential variables are also applicable:
(i) Welding Process
The welding process, combination of processes or order of welding processes shall not be altered.
(ii) Welding Parameters
a) For any weld pass, the polarity, or electrical characteristics (AC/DC), shall not be altered.
b) For GTAW, the welding current shall not be changed by more than +10 % nor shall the characteristics be changed from normal
to pulsed current or vice versa.
c) For pulsed GTAW the pulse frequency, waveform or background current shall not be changed unless approved by the Owner.
d) For SAW or FCAW, the electrode extension length shall not be altered exceeding the range stated in the approved WPS or
stated Specification parameters.
e) The inter-pass temperature shall not be more than that recorded on the PQR.
Production Welding Controls
(i) Fabrication of copper, and its alloys vessels, process piping and other equipment shall be carried out in a separate area (if possible a
separate shop) from that of Carbon-Manganese and low alloy steels.
(ii) Copper and its alloys shall be cut either by using plasma arc cutting or mechanically.
(iii) The weld preparation and an adjacent area (i.e. 50 mm on each side) shall be abraded with a stainless steel brush or wire wool and
degreased with a non-toxic, non-inflammable solvent on both external and internal surfaces, just before start of welding.
(iv) The vessel, process pipe work or other equipment surface, shall be free of all spatter and other debris. The spatter or debris shall be
removed by using disc grinder or emery disc.
Material Segregation
(i) Copper alloys shall be fabricated in isolation, or if agreed by the Owner may be fabricated with other non-ferrous materials.
(ii) Hand tools and related consumables, shall be colour-coded, or suitable controls executed to ensure that the tools and consumables
are used solely for copper alloys.
H.6
H.7
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Annex I (normative) Aluminum alloys
Clause
Description
I.1
General
(i) This annex covers the mandatory requirements for welding pressure retaining equipment fabricated from aluminium and aluminium
alloys.
(ii) In addition to the requirements stated in of ASME/BPVC Sec IX and ISO 15614-2, WPS shall be developed and qualified, using the same
base material and filler wire that is used in fabrication, per the welding requirements of this standard,
(iii) Aluminum shall be fabricated and welded using only either GMAW or GTAW processes.
(iv) For both GMAW and GTAW, the shielding gas shall be pure argon (99.998 % vol.).
(v) When welding from one side only, pure argon shall be applied as a backing gas.
(vi) If back-welding is practical and feasible, the root pass shall be ground away and re-welded.
Weld preparation
For welding aluminium, the typical weld preparations used for welding steel are acceptable.
Permanent aluminium backing bars, if allowed by the Owner, shall be of the same material used for fabrication.
Cleaning
(i) The surfaces to be joined shall be free of moisture or substances or contaminants (e.g. greases, oils, paints, etc.) that may affect the
quality and integrity of the weld.
(ii) Degreasing shall be performed by wiping, spraying, dipping in a suitable solvent or by steam cleaning.
(iii) Cleaning to remove surface oxides by mechanical means is preferred. Chemical solution used to remove surface oxides shall be
approved by the Owner.
Preheating
If the aluminium base metal is thicker than 6 mm, a minimum preheat temperature of 50 °C shall be applied.
Welding
Tack welds shall not be part of the finished weld. The tack welds shall be removed as welding progresses.
Filler metal shall be dry, free of grease and other foreign matter.
I.2
I.3
I.4
I.5
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Annex J (normative) Titanium alloys
Clause
Description
J.1
Fabrication Facilities:
Fabrication of titanium vessels, process piping and other equipment shall be carried out in fully contained and quarantined shop area
dedicated solely to fabrication of titanium equipment.
Material surfaces to be welded shall be periodically check for iron contamination using chemical method (e.g., ferroxyl).
Materials
This section is typically applicable to the following material:
 ASTM B337 Gr2 (Pipe)
 ASTM B363 Gr.WPT2 (Fittings)
 ASTM B381 Gr.F2 (Flanges)
 and any other titanium grades advised by the Owner
Welding Process
(i) GTAW is the permitted welding process.
(ii) The use of other welding processes may be permitted if the Contractor can demonstrate:
a) good working experience with the alternate welding process,
b) satisfactory process controls and
c) competence of their welders i.e. demonstrated by acceptable inspection and examination results.
(iii) Procedure qualification shall be per ASME/BVPC Sec IX or ISO 15614-5.
(iv) Gas lenses shall be fitted to GTAW torches.
(v) A trailing or secondary inert gas shield shall be established and maintained until the metal temperature falls below 500 °C over the
solidified, cooled weld metal and HAZ.
(vi) The inert gas shielding shall be applied by using either a glove-box chamber, trailing shield, or incorporated into the head of orbital
GTAW welding equipment.
Essential Variables
In addition to the requirements specified in ASME/BVPC Sec IX or ISO 15614-5 the following essential variables shall apply:
(i) Thickness
The thickness tested during PQR is the maximum thickness qualified for the WPS.
J.2
J.3
J.4
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Clause
J.5
Description
(ii) Joint Type
a) Joint bevel angle shall not be increased by more than 10 ° or reduced by more than 5 °
b) The root gap tolerance shall be -0 mm and +2 mm.
c) Double-sided and single-sided weld preparations shall be qualified separately.
d) Single bevels and double bevel (K) preparations qualify single vee’s and double vee (X) respectively but not vice versa. All
other joint edge preparation shapes shall be qualified separately.
(iii) Welding Parameters
a) The electrical characteristics (AC/DC) or polarity of any weld pass, shall not be altered.
b) For GTAW, the welding current shall not be altered by more than +10 % nor shall the characteristics change from normal to
pulsed current or vice versa.
c) For pulsed GTAW, unless permitted by the Owner, the pulse frequency, waveform or background current shall not be altered.
d) The calculated arc energy shall not be altered exceeding than 10 %.
e) Inter-pass temperature shall not exceed that used and recorded during procedure qualification
Production Welding Controls
(i) Machining or grinding is the only permitted method for weld joint preparation for titanium.
(ii) The weld preparation and adjacent area (50 mm on each side) shall be abraded with a stainless steel brush or stainless wire wool and
degreased with a non-toxic, non-inflammable solvent on both external and internal surfaces. This preparation shall be done
immediately prior to start of welding.
(iii) The integrity of a Ti weld shall be determined by the colour of the weld beads. Any necessary action shall be carried out depending on
the color observed.
a) If the weld bead remains bright and silver in colour, then no inter-run cleaning is required.
b) Straw or light blue weld discolouration shall be removed by stainless steel wire brushing.
c) Dark blue, grey or white powdery discolouration of the weld beads indicate contamination and the affected weld shall be
completely removed by grinding.
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Annex K (normative) Dissimilar Materials
Clause
Description
K.1
General
(i) Hardness
a) If welding materials is P1 – Group 1 and 2, P3 - Group 1 and 2, P4 -Group 1 and P5 A&B Group 1, Preheat and PWHT procedures
shall be developed to:
 Achieve sufficient tempering of more hardenable material and
 Prevent excessive weakening of the softer material or loss of toughness.
b) PQR shall demonstrate the results of all the tests.
c) Hardness tests and results shall comply with the requirements of API RP 582, sub-section 12.6 or NACE RP0472 for all dissimilar
weld PQRs.
(ii) Limitations for sour and hot hydrogen service
a) Dissimilar welds between ferritic and austenitic materials shall be avoided in
 wet H2S/sour service or other services where acid corrosion can occur or
 services over 450 °C in presence of hydrogen.
b) If dissimilar welds are used in such services the Owner shall be consulted.
(iii) Records shall be kept, filed and updated to control over the dissimilar welds throughout the whole duration of the project.
(iv) Issues related to dissimilar welds are varied depending on the type and service. Extra precaution and weld design approvals from the
Owner are necessary. Suitability of a dissimilar weld design has to be determined after considering the combination of service,
weldment and the weld design. The use of dissimilar weld shall be limited to applications where other joining methods are not practical
or economical.
(v) Use of dissimilar weld or pressure retaining weld critical to the equipment integrity shall require Owner approval.
Classes of dissimilar welds and suggestions for their design
CLASS (1) P1 to P4/P5/P9/P91 (CS to low ferritic low alloy)
(i) PWHT shall be carried out on these welds. PWHT temperature and the overall tempering parameter are selected to ensure the harder
structures of the alloy welds are tempered without reducing the strength of the CS. Transverse hardness shall be conducted and
recorded during PQR.
(ii) The properties of the weld in the fusion boundary need to be considered. Consider control of the width and continuity of the diluted
zone by suitable welding parameters.
K.2
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Clause
Description
(iii) For welds identified in sour, wet H2S or other electrochemical corrosive service generating significant hydrogen, wetted parts of the
weld and its fusion zones shall be overlaid with the same Ni alloy used for the weld. The weld overlay shall be extended on the CS side
of the weld for a safe distance from the fusion line. Typically 12 mm minimum safe distance has been used on similar welds. This
distance may be increased on the advice by the Owner.
(iv) PWHT alone is not considered adequate protection against dissimilar weld cracking when using austenitic or Ni-based filler metals in
corrosive environment that may cause hydrogen embrittlement.
CLASS (2) P1 to P8 (CS to austenitic stainless steel)
(i) Design of the weldment inclusive of number and severity (rate of temperature change) of the temperature cycles that the weld will be
subjected to throughout its design life shall be considered for high criticality welds with thickness greater than 19 mm.
If the number of full temperature cycles exceeds 500 °C and/or if rate of process temperature change is more than 25 °C/hr, Owner or
Contractor may appoint external party experienced in thermal fatigue design for the selection of dissimilar weld design.
(ii) Dissimilar welds that shall be PWHT shall be made using the buttered overlay design described in K-2-3 below.
(iii) The fusion line of the dissimilar weld should not run normal to the maximum applied load. Unless stress assessment indicates
otherwise, the minimum angle of the weld bevel should be more than 18 ° off the plane normal to the axis of the pipe.
(iv) For welds identified in sour, wet H2S or other electrochemical corrosive service generating significant hydrogen, wetted parts of the
weld and its fusion zones shall be overlaid with the same Ni alloy used for the weld. The weld overlay shall be extended on the CS side
of the weld for a safe distance from the fusion line. Typically 12 mm minimum safe distance has been used on similar welds. This
distance may be increased on the advice by the Owner.
(v) PWHT alone is not considered adequate protection against dissimilar weld cracking when using austenitic or Ni-based filler metals in
corrosive environment that may cause hydrogen embrittlement.
CLASS (3): P4/P5/P9/P91 to P8 (ferritic low alloy steel to austenitic stainless steel)
(i) These welds shall only be used in PWHT condition, and should not be used without protective overlay on “wetted side(s)”. PWHT shall
be done on “the buttered” section of the low alloy pipe, prior to the final assembly of the weld.
(ii) The minimum thickness of the “buttered” layers after final machining shall be 7 mm. The thickness of the completed buttered layer
shall be measured and recorded.
(iii) The “buttered” overlay shall be welded using Ni based fillers that is not significantly sensitised during the PWHT cycle.
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Clause
K.3
K.4
Description
CLASS (4) Dissimilar welds other than CL (1), (2) and (3)
(i) These welds if required shall be designed with the input of Owner. Applicable design concepts used for the above classes can be used
on CL (4) welds where relevant.
(ii) For design temperatures greater than 454 °C, class of welds between the different grades of austenitic stainless steel should be
considered to be “CL 4 dissimilar welds”.
Design for NDT
(i) The fusion boundary between a base metal and weld made from the different material is the weak link of dissimilar welds.
(ii) The NDT coverage of dissimilar welds may be different from the piping class or standard project NDT schedules. NDT coverage of
dissimilar welds should reflect their design and criticality.
(iii) The design of the dissimilar joint should permit volumetric examination and should be examined by at least one (1) volumetric
examination method.
(iv) The Owner shall developed and assigned the relevant NDT methods/techniques and coverage.
(v) Alternate NDT of critical dissimilar welds or pressure retaining weld designs that could not be examine using volumetric examination
technique shall be approved by the Owner.
Dissimilar Weld Register
Manufacturer shall prepare and update Dissimilar Weld Register (DWR) and this shall be included in welding plan/map. All dissimilar welds
shall be recorded in this DWR. The DWR shall contain the following information:
(i) Weld identification
(ii) Relevant drawing number (P&ID/MEFD/isometric or equipment fabrication drawings)
(iii) P numbers of the alloys to be welded and brief description of the weld
(iv) Criticality rating of the weld (as per Project criticality-rating procedures-pressure-retaining welds should be considered critical)
(v) Applicable WPS number (includes the name of the organisation, which welded such weld.)
(vi) Name of Contractor Discipline Engineer who proposed the dissimilar weld.
(vii) Name of Contractor QC Manager who approved the location of the dissimilar weld.
(viii) Name of Contractor Project Manager who approved the DWR.
The DWR shall be updated and certified by the Contractor, and made available for the Owner review and audit.
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Clause
Description
K.5
Final Approvals
Use, design of pressure retaining and all other dissimilar welds listed on certified DWR and critical to integrity of the equipment shall be
reviewed and accepted by the Owner.
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Annex L (Mandatory) Welding of Subsea Facilities
Clause
L.1
L.2
L.3
Description
This Annex defines the minimum requirements for onshore fabrication of structural, pressure containing and clad welding of subsea facilities. The
Annex A to Annex K above are mandatory for the welding of subsea facilities. The design is based on sour service requirements complying with
PTS 12.30.02 Appendix 17, PTS 12.20.01 Appendix 5 and PTS 15.01.05
Contractor’s or Manufacturer’s Quality System shall consist of the management (design, control, documentation, records, etc.) of, but not limited
to:
 WPS and welder/welding operator qualification including welder/welding operator training and certification.
 Calibration of welding equipment and welding inspection equipment.
 Welding consumables from procurement, receiving inspection and storage, issuance to / return from the welders/welding operators.
 Shielding and Purging Gases
 Abrasive materials for weld preparations, work in progress and final weld surfaces.
 Welding processes and inspections in the workshop and construction site.
 Preheat and interpass temperature.
 PWHT.
Normative References:
Add the following
 ISO 10423/API 6A Petroleum and Natural Gas Industries - Drilling and Production Equipment - Wellhead and Christmas Tree Equipment
 ISO 13628-1 Petroleum and Natural Gas Industries - Design and Operation of Subsea Production Systems - Part 1: General Requirements
and Recommendations
 ISO 13628-4 Petroleum and Natural Gas Industries - Design and Operation of Subsea Production Systems - Part 4: Subsea wellhead and
tree equipment
 EN 15609-1, Specification and Qualification of Welding Procedures for Metallic Materials -- Welding Procedure specification -- Part 1:
Arc welding
 EN ISO 15614-1, Specification and Qualification of Welding Procedures for Metallic Materials - Part 1: Arc and Gas Welding of Steels and
Arc Welding of Nickel and Nickel Alloys
 EN 287-1, Qualification test of welders. Fusion welding. Steels
 EN 1418, Welding personnel. Approval testing of welding operators for fusion welding and resistance weld setters for fully mechanized
and automatic welding of metallic materials
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Clause
L.4
Description
 ASME B31.8, Gas Transmission and Distribution Piping Systems
 NORSOK M-101, Structural Steel Fabrication
 NORSOK M-601, Welding and Inspection of Piping
Welding Procedure and Welder/Welding Operator Qualification
(i) General
 Welding Procedure Qualification and Welder and Welding Operator Qualification shall be as per Clause 4.10.2 and Clause 4.10.3 of this
PTS respectively.
 The GMAW – S welding process shall only be permitted for root passes and hot passes.
 Approval of the WPS including previously qualified WPS shall be required for each part of the welding.
 The use of WPS and PQR qualified by other organizations by Contractor or Manufacturer shall require approval by Owner’s Technical
Authority.
 Contractor or Manufacturer who is assigned to the actual fabrication shall qualify the welding procedures that the Contractor or
Manufacturer intent to use.
 Prequalified WPS and PQR as defined in AWS D1.1, ASME IX and other equivalent national standards shall be subjected to approval by
Owner’s Technical Authority.
 Welding consumables (fluxes and electrode or filler metal) and proprietary shielding gas mixtures, carrying an AWS classification "G"
designator shall be specified in WPS and PQR by manufacturer and trade name.
 WPS shall record any chemistry or other property restrictions required to make welding consumables conform to code or PTS
requirements.
 Contractor or Manufacturer’s qualified for the WPS and PQR shall be certified by a competent representative of the Contractor or
Manufacturer (e.g. Welding Engineer).
 Supplementary information shall be added to the WPS as necessary to fully control the properties and quality of the production weld,
e.g.
o Passes or beads overlap (for overlay chemistry).
o Temper bead techniques (for HAZ hardness properties).
o Specific filler wire chemistries or manufacturer brand (for critical properties).
o Special preheat instructions (for avoiding cracking).
 A sketch of the weld joint showing joint design and dimensions shall be shown in the PQR. It shall also include the thickness of
deposited weld metal for each process or electrode classification for the multiple processes or different electrode classifications within
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Clause
Description
the same process. The welders and welding operators for the qualification test shall be approved by Owner and his identity shall be
shown in the PQR.
 Additional information shall be recorded in PQR for any unusual features (e.g. dual-qualification) in WPS/PQR, including the test plan
supported by an accurately-dimensioned specimen extraction drawing which shows type (purpose), orientation, and through-thickness
depth location of each specimen
(ii) Laboratory Testing
 Official laboratory reports recording test results supporting each PQR shall be referenced on the PQR and attached to each PQR. The
summary test results shall be shown in the PQR. The report shall include
o Laboratory test number, revision number, date and signature by a competent personnel of the testing laboratory.
o All elements required by the applicable codes and standards including yield strength, ultimate tensile strength, % elongation
and reduction in area.
o Photograph or a sketch to indicate the location of each hardness indentation.
o Summary of PWHT variables including hold temperatures and times for a PQR in which coupons are PWHT.
o Photograph of the macro if macro exams is required.
o The base material heat numbers and welding consumable(s) heat (or lot/batch) numbers shall be shown in the PQR. A certified
and legible Material Test Reports (MTRs) for each base material and welding consumable(s) used for the PQR shall be attached.
The heat (and lot/batch) number(s) for the material shall be readily identified. All information required including chemistry,
mechanical, and heat treatment data shall be available to ensure their compliance to the applicable codes and standards. Any
use of nonconforming materials shall be a cause for the rejection of the WPS/PQR.
 The specimens of weld for 6Mo stainless steel and super DSS shall be pickled (20% HNO3+5% HF) at 60°C for 5 minutes prior to the
corrosion test.
 The acceptance criteria of corrosion testing for super DSS shall be weight loss of < 1.0 g/m2.If NDT is performed for the qualification, the
approved NDT reports shall be attached to the PQR.
 The highest yield strength base material to be used in production shall be used to perform qualifications to achieve a specified minimum
yield strength.
 Additional PQR testing to determine yield strength (and % elongation and reduction of area (if required)) shall be required for each base
material (if PWHT‘d), butter weld material or weld joint metal; when the deposited weld metal is required to meet the minimum
specified mechanical properties of the base metal.
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Clause
Description
(iii) PWHT
 When PWHT is required by the manufacturing code, the PQR qualification coupon shall be PWHT‘d to qualify the anticipated PWHT time
and temperature including PWHT time for any anticipated repair cycles.
 A minimum of 80% the total PWHT time including multiple heat treat cycles (when applicable) shall be required for the PWHT of PQR.
 A minimum of two PQR coupons (one for minimum PWHT time and one for maximum PWHT time) are required for a procedure
qualification that is intended to address a range of PWHT times such as potential for repairs.
 PQR and WPS shall contain information of all controlled techniques or sets of variables used to meet or obtain the required PWHT
properties.
 PWHT shall not be permitted for any materials that are not intended to be PWHT‘d, including stainless steels, DSS and SDSS materials,
precipitation hardened materials subject to overaging, materials susceptible to HAZ cracking (stress relief cracking) such as A 517
grades.
 PWHT of production welds shall be conducted in accordance to the set of PWHT parameters qualified in the WPS.
 PQR and WPS shall contain information of all controlled techniques or sets of variables used to meet or obtain the required hardness
criterion including the use of temper bead techniques, minimum preheat and heat input and PWHT.
 Owner approval is required for the use of the HRC method (as per NACE MR0175/ISO 15156 Butt weld survey method for Rockwell
hardness measurements) for welding procedure qualification if the design stress does not exceed two thirds of SMYS and the welding
procedure specification includes PWHT.
(iv) Hardness Testing
 Additional Hardness Survey Locations as per NACE MR0175/ISO 15156 Butt weld survey method for Vickers hardness measurement
shall be required. Hardness Survey Locations for CRA Overlay as per following:
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Clause
Description
(v) Charpy V-Notch Impact Testing
 All pressure containing welds or others welds that being specified, Charpy v-notch impact testing (sets of 3 specimens) shall be tested in
the base metal, weld metal and HAZ at the locations for the qualification of WPS.
o Standard size impact specimens, 10mm x 10mm in cross section, shall be used.
o All specimens shall have minimum 50% shear or 15 MLE (0.015 inches lateral expansion).
o Average energy required for 3 Specimens (Alloy/Carbon Steel) is 42 joules and minimum for a single specimen is 28 joules;
except for 410SS, the average energy required is 27 joules and minimum for a single specimen is 19 joules. For all the test,
balance two specimens must be > min average.
o Test temperature shall be -46°C, except for Low Alloy Steel SMYS > 586Mpa is -30°C and 400SS is -18°C.
o Minimum energy required shall be adjusted in accordance with API 6A Table 7 for the subsize specimens.
 PQR and WPS shall contain information of all controlled techniques or sets of variables used to meet or obtain the required notch
toughness properties.
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Clause
Description
(vi) Weld Overlay
 CRA overlay welding and for applications requiring charpy v-notch properties shall have proper heat input controls, including heat input
from the GTAW hot wire (part of the equation). The essential variables shall include the duration of the peak and background currents,
and it shall be documented in both the WPS and PQR.
 Nickel Alloy 625 corrosion resistant overlay welding shall be qualified in accordance with the requirements of ASME IX, API 6A and ISO
15156 or other equivalent international standards, using the same or equivalent equipment to be used in production and filler wires
shall have 0.50% Fe maximum.
 PQR and WPS shall contain information of all controlled techniques or sets of variables used to meet or obtain the required corrosion
overlay chemistry.
 Weld metal chemical analysis shall be performed at a location of 3 mm or less from the original base metal surface in accordance with
the requirements of ASME IX. Maximum iron content of 10% in the final weld layer shall be confirmed.
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Clause
Description
 Testing shall be conducted on the weld overlay that is PWHT‘d, to confirm meeting the minimum requirements of base material tensiles
and charpies.
 The weld overlay that is PWHT‘d shall be repaired with
o Qualification of weld repairs with additional PWHT, for a weld repair contacts the original base material or is close enough to
affect the hardness, charpy values or tensile properties of base metal HAZ, with either one of the following options:
a) Supplement the original PQR with PWHT of representative base metal for a time equal to 80% of the total hours
required for the original PWHT plus additional PWHT repair cycles. Testing shall be conducted on the supplemental base
metal test coupon to confirm meeting the original requirements of base material tensiles and charpies.
b) A test coupon shall be welded and PWHT‘d for a time equal to 80% of the total hours required for the original PWHT
plus additional PWHT repair cycles. Testing shall be conducted on the repair overlay to confirm meeting the original
requirements of HAZ hardnesses and base material tensiles and charpies.
o Qualification of weld repairs without PWHT (as welded), for a weld repair based on a minimum remaining original overlay
thickness that does not affect the base metal HAZ hardness. The weld overlay deposit onto the machined surface (down to
minimum remaining original thickness to be qualified) that has an overlay and PWHT‘d in accordance with the original PQR.
Testing shall be conducted only on the repair overlay as required for the original overlay and hardness test on a portion of the
overlay that has not been repaired to confirm that base metal HAZ hardness was acceptable prior to repair of the overlay.
(ii) Butter Weld
 The qualification of butter welds and closure welds shall be in accordance with ASME IX QW-283, including additional information in
ASME Code Interpretation IX-01-03. When qualifying closure welds to carbon and low alloy steel butter welds, the actual butter weld
material shall be used. Qualification of the closure weld with substitution of plate material for the butter as stated in QW-283.4 (b) is
not permitted.
 Butter welding are permitted with GTAW process, preferable with low alloy/carbon steel filler metals on low alloy steel base materials.
Prohibition for Alloy 625 butter welds that requires PWHT temperature > 649°C.
 The control of key variables including sequence of bead/layer, direction of travel, angle of torch travel, brand and manufacturer of filler
metal, etc. shall be defined in a specific buttering techniques and approved by Owner.
 After machining, the total butter weld thickness must > 9.6 mm. In order to enable thorough volumetric NDT of the final machined
areas inside the near fields of the UT, excess butter material shall be applied to the OD, ID, and bevel face as per Owner’s drawings.
 Excess material is permitted for repairs of the butter. Waiver of 4.8mm‖ASME code minimum for a butter thickness is permitted for a
repair of closing weld with the 9.5mm final butter thickness.
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Clause
L.5
Description
 The method to verify no encroachment of the interface between the base metal and the butter by the production welds to the butter
(e.g. a reference line based on the original edge of the base metal) shall be approved by Owner.
 Minimum distance of 2.5mm between closure weld and fusion line of the base metal shall be confirmed via VT on the external surface
of completed closure welds.
 The butter welding procedure shall include the protection from errant arc strikes and weld splatter up to 300mm away from the end of
the weld preparation and visual indications to help prevent weld metal from being deposited too close to the butter fusion line.
Production Welding
(i) General
 The welder shall not be allowed to continue welding on project work without further documented training and requalification, if his
workmanship is not acceptable to the Owner.
 The use of consumable inserts, weld backing rings and re-melting of tack welding shall not be permitted.
 Bullets shall comprise of a compatible DSS and bridge tacks shall be > 25mm long; and they shall be distributed evenly around the
circumference of the pipe. All of them (and other root tacks) shall be removed during welding including HAZ.
 Details of the tack weld size and separation shall be documented if it is not recorded in the WPS.
 Only GTAW process is allowed for the butt and fillet welds in pipes of ND≤ 50mm, and a high frequency or lift start initiation unit shall
be fitted onto the GTAW equipment.
 In order to improve gas shielding, GMAW torches shall include a “gas lens”.
 No interruption shall be permitted for all root runs.
 All permanent attachments onto the pipework shall be welded as per approved WPS and inspected as per approved procedures.
 Temporary attachments to pressure pipework shall be minimized and approved by Owner. Qualified WPS shall be used and oxidation of
the internal surface of the pipework shall be avoided. 100% PT/MT and the minimum thickness verification shall be conducted after the
removal of the temporary attachment.
(ii) Spacing
 The minimum distance between the edges of two pressure-containing welds shall be four times the wall thickness of the thicker
pressure part or minimum 50 mm, whichever is higher. The same is applicable for the distance between non-pressure attachment
welds and a pressure-containing weld in order to allow NDT of the pressure-containing weld. If unavoidable, 100% surface crack
detection examination shall be conducted on the area to be welded over prior to and after welding.
 Longitudinal welds in two adjacent pipes should be 180° apart, but in any case shall be separated by at least six time the wall thickness
of the thicker pipe
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Clause
Description
 Sealing areas on all equipment, such as hubs, connectors and valves shall be carefully handled during welding, including:
o Fully open valve position prior to welding, to prevent foreign material entering the valve cavity and prevent damage on the gate
and sealing areas.
o Valves shall only be operated by Owner personnel
 Maximum root opening for fillet weld is 5 mm, or 8mm for > 75mm straightened shapes or plates which requires suitable backing with
flux, glass tape, iron powder, or similar materials, or welds using low-hydrogen process compatible with the filler metal deposited.
 The leg of the fillet weld shall be increased by the amount of the root opening for the separation > 2 mm.
 Maximum 1.6mm is allowed for the gap from the end of the tube to the base of the socket. It can be achieved with the use of gap
inserts.
(iii) Preheat
 All base metals shall be preheated > 40°C or higher preheat requirements in the related WPS. A separate approved written procedure
or WPS shall describe the method and control of the preheat > 66°C. Optical pyrometers are not permitted.
 Electrical preheat for butt welds is preferable for temperature >150 °C and mandatory for temperature > 200°C.
(iv) Welding parameters
 Key welding parameters as shown in WPS including the voltage and amperage, etc. shall be recorded once for each weld passes on the
pressure containing closure welds.
 Welding equipment with internal weld data logging capabilities to record voltage and amperage shall be calibrated every 6 months.
(iii) NDT
 PMI shall be conducted for 100% of the components (i.e. pipe, fittings and flanges) and welds as per PTS 15.02.01.
 A high definition color video camera or boroscope shall be used for pipe internal inspection of welds with limited access, e.g. root pass.
 All welds shall undergo 100% VT, 100% PT of MT and 100% UT or RT.
 UT shall not be used for thickness <10mm.
 Automated computer enhanced data acquisition for UT shall be required to obtain a permanent record of the full weld to demonstrate
the absence, or not, of linear type discontinuities with amplitudes exceeding the reference level.
 If UT is limited by the local geometry near the welds, RT using X-ray shall be used for stainless steel and DSS using fine grain film. Where
gamma RT is permitted, the ultrafine grain film shall be used.
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Clause
L.6
Description
(iv) Weld Repair
 Maximum 30% of the weld length for a partial thickness repair and 20% of the weld length for a full thickness repair are permitted,
otherwise the weld shall be completely cut out with the edge being dressed back by approximately 3mm to remove the HAZ, and rewelded. No root defect repairs are allowed.
 The removal of defects shall include the total length of defect and 50mm of sound metal beyond each end of the defect (or complete
cut out if diameter of pipe is too small) after approval by Owner.
 The same original NDT method(s) shall be conducted at areas > 50mm on each end and 25mm on each side of the repair weld.
 Single pass weld repairs and spot weld deposition to rectify damaged areas at temporary attachments is prohibited.
Weld Traceability and Documentation
 An approved weld traceability program shall be available for each welded assembly, to enable tracking of the unique joint number to
the final assembly with minimum identification of weld numbers, welder’s symbol and radiography films.
 Any welds not marked with a welder’s symbol shall be subjected to rejection.
 All welding and NDT records shall be verified by Owner and retained as permanent records.
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PTS 15.12.01
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3.0
BIBLIOGRAPHY
In this PTS, reference is made to the following Standards/Publications. Unless specifically
designated by date, the latest edition of each publication shall be used, together with any
supplements/revisions thereto:
PETRONAS TECHNICAL STANDARDS
Index to PTS
PTS 00.01.01
PTS Requirements, General Definition Of Terms, Abbreviations &
Reading Guide
PTS 00.01.03
Pressure Vessels
PTS 12.20.01
Pressure Vessel - Manufacturing Report
PTS 12.20.06
Piping General Requirements
PTS 12.30.02
Shop and Field Fabrication of Piping
PTS 12.30.05
Materials for Use in H2S-Containing Environments in Oil and Gas
Production (Amendments and Supplements to
ANSI/NACE/MR0175/ISO 15156
PTS 15.01.05
Positive Material Identification (PMI)
PTS 15.02.01
Brittle Fracture of Metallic Materials
PTS 15.10.01
PTS 15.10.14
Stainless Steel Weldments Oxidation
PTS 15.12.03
Structural Steel Fabrication
PTS 15.12.06
INTERNATIONAL STANDARDS
Recommended Practices for Welding of Chromium-Molybdenum
Steel Piping and Tubing
Petroleum and natural gas industries—Materials for use in H2S
containing environments in oil and gas production (see ISO 15156-1)
Welded Tanks for Oil Storage
Welding Guidelines for the Chemical, Oil, and Gas Industries -Second
Edition, December 2009
ANSI/AWS D10.896
ANSI/NACE
MR0175/ISO 15156
API 650
API RP 582
Use of 9Cr-1Mo-V (Grade 91) Steel in the Oil Refining Industry
API TR 938-B
Use of Duplex Stainless Steels in the Oil Refining Industry
API TR 938-C
Butt welding Ends
ASME B16.25
Process Piping - Includes Interpretation 22
ASME B31.3
Gas Transmission and Distribution Piping Systems
ASME B31.8
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Material Specifications
ASME/BPVC Sec II
Qualification Standard For Welding and Brazing Procedures, Welders,
Brazers, and Welding and Brazing Operators Welding and Brazing
Qualifications
ASME/BPVC Sec IX
Nondestructive Examination
ASME/BPVC Sec V
Rules for Construction of Pressure Vessels
ASME/BPVC Sec
VIII Div 1 and 2
Standard Specification for Forged or Rolled Alloy and Stainless Steel
Pipe Flanges, Forged Fittings, and Valves and Parts for HighTemperature Service
ASTM A182
Standard Specification for Pressure Vessel Plates, Alloy Steel, Nickel
ASTM A203
Standard Specification for Seamless and Welded Steel Pipe for LowTemperature Service
ASTM A333
Standard Specification for Carbon and Low-Alloy Steel Forgings,
Requiring Notch Toughness Testing for Piping Components
ASTM A350
Standard Specification for Steel Castings, Ferritic and Martensitic, for
Pressure-Containing Parts, Suitable for Low-Temperature Service
ASTM A352
Standard Practice for Cleaning, Descaling, and Passivation of Stainless
Steel Parts, Equipment, and Systems
ASTM A380
Standard Specification for Pressure Vessel Plates, Alloy Steel,
Chromium-Molybdenum
ASTM A387
Standard Specification for Piping Fittings of Wrought Carbon Steel
and Alloy Steel for Low-Temperature Service
ASTM A420
Standard Specification for Carbon and Alloy Steel Pipe, ElectricFusion-Welded for High-Pressure Service at High Temperatures
ASTM A691
Standard Specification for Steel Castings, General Requirements, for
Pressure - Containing Parts
ASTM A703
Standard Specification for Carbon Steel and Low-Alloy Steel PressureVessel-Component Forgings with Mandatory Toughness
Requirements
ASTM A765
Standard Test Methods for Detecting Detrimental Intermetallic Phase
in Duplex Austenitic/Ferritic Stainless Steels
ASTM A923
Standard Specification for Seamless and Welded Titanium and
Titanium Alloy Pipe
ASTM B337
Standard Specification for Seamless and Welded Unalloyed Titanium
and Titanium Alloy Welding Fittings
ASTM B363
Standard Specification for Titanium and Titanium Alloy Forgings
ASTM B381
Standard Practice for Liquid Penetrant Examination for General
Industry
ASTM E165
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Standard Test Method for Determining Volume Fraction by
Systematic Manual Point Count
ASTM E562
Standard Test Method for Vickers Hardness of Metallic Materials
ASTM E92
Standard Test Methods for Pitting and Crevice Corrosion Resistance
of Stainless Steels and Related Alloys by Use of Ferric Chloride
Solution
ASTM G48
Standard Procedures for Calibrating Magnetic Instruments to
Measure the Delta Ferrite Content of Austenitic and Duplex FerriticAustenitic Stainless Steel Weld Metal
AWS 4.2M
Welding Consumables - Procurement of Filler Metals and Fluxes
AWS 5.01
Specification for Carbon Steel Electrodes for Flux Cored Arc Welding
AWS 5.20
Welding Consumables—Gases and Gas Mixtures for Fusion Welding
and Allied Processes
AWS 5.32
Specification for Copper and Copper-Alloy Bare Welding Rods and
Electrodes
AWS 5.70
Standard Methods for Determination of the Diffusible Hydrogen
Content of Martensitic, Bainitic, and Ferritic Steel Weld Metal
Produced by Arc Welding
AWS A4.3
Procurement Guidelines for Consumables—Welding and Allied
Processes—Flux and Gas Shielded Electrical Welding Processes
AWS A5.01
Specification for Nickel and Nickel-Alloy Bare Welding Electrodes and
Rods
AWS A5.14
Specification for Low-Alloy Steel Electrodes and Rods for Gas Shielded
Arc Welding
AWS A5.28
Structural Welding Code - Steel
AWS D1.1
Structural Welding Code -Stainless Steel
AWS D1.6
Recommended Practices For Local Heating Of Welds In Piping And
Tubing
AWS D10.10
Recommended Practices for Root Pass Welding without Backing
AWS D10.11
Welding Of Chromium-Molybdenum Steel Piping And Tubing
AWS D10.8
Specification for Welding of Austenitic Stainless Steel Tube and Pipe
Systems in Sanitary (Hygienic) Applications
AWS D18.1
Standard Welding Symbols
Specification and qualification of welding procedures for metallic
materials -- Welding procedure test -- Part 1: Arc and gas welding of
steels and arc welding of nickel and nickel alloys
AWS D2.4
EN ISO 15614-1
Steel and Steel Products - Inspection Documents
ISO 10474
Petroleum and natural gas industries — Materials for use in H2S
containing environments in oil and gas production
ISO 15156
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Petroleum and natural gas industries — Materials for use in H2S
containing environments in oil and gas production — Part 1: General
principles for selection of cracking-resistant materials (see ANSI/NACE
MR0175/ISO 15156)
Specification and Qualification of Welding Procedures for Metallic
Materials — Welding Procedure Test
ISO 15156-1
ISO 15614
Specification and Qualification of Welding Procedures for Metallic
Materials — Welding Procedure Test — Part 1: Arc and Gas Welding
of Steels and Arc Welding of Nickel and Nickel Alloys
ISO 15614-1
Specification and Qualification of Welding Procedures for Metallic
Materials - Welding Procedure Test - Part 2 : Arc Welding of
Aluminium and Its Alloys
ISO 15614-2
Specification and Qualification of Welding Procedures for Metallic
Materials - Welding Procedure Tests - Part 5 : Arc Welding of
Titanium, Zirconium and Their Alloys
ISO 15614-5
Specification and Qualification of Welding Procedures for Metallic
Materials - Welding Procedure Test - Part 6 : Arc and Gas Welding of
Copper and Its Alloys
ISO 15614-6
General Requirements for the Competence of Testing and Calibration
Laboratories
ISO 17025
Welded, Brazed and Soldered Joints - Symbolic Representation on
Drawings
ISO 2553
Welding and Allied Processes - Determination of Hydrogen Content in
Ferritic Steel Arc Weld Metal
ISO 3690
Gas Welding Equipment Blowpipes for Gas Welding, Heating and
Cutting Specifications and Tests ISO 5172 Quality Systems - Model for
Quality Assurance in Production, Installation and Servicing
ISO 9002
Approval Testing of Welders - Fusion Welding - Part 3: Copper and
Copper Alloys
ISO 9606-3
Approval Testing of Welders - Fusion Welding - Part 5: Titanium and
Titanium Alloys, Zirconium and Zirconium Alloys
ISO 9606-5
Non-Destructive Testing - Qualification and Certification of Personnel
ISO 9712
Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum
Refining Environments - Item No. 21305
NACE MR0103
Methods and Controls to Prevent In-Service Environmental Cracking
of Carbon Steel Weldments in Corrosive Petroleum Refining
Environments - Item No. 21006
NACE SP0472
White Metal Blast Cleaning SSPC-SP 5/NACE No. 1 Commercial Blast
Cleaning
SSPC SP-6
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