H-331 E WPS

< Security Level 2 > Sheet 1 of 31

ENGINEERING SPECIFICATION MINIMUM REQUIREMENTS FOR WELDING PROCEDURE SPECIFICATION FOR CIVIL WORKS FOR HINDUSTAN PETROLEUM CORPORATION LTD. VISAKH REFINERY

DHT PROJECT TEIL JOB NO. : 6261 DOCUMENT NO. : H – 331

A

29.12.2008

For Bid Enquiry

Rev. no.

Issue Date

Description

UCM

PRK

Prepared by Checked by Approved by

TOYO ENGINEERING INDIA LIMITED MUMBAI

SSV

INDIA

< Security Level 2 > Sheet 2 of 31

Revision History Rev.

Date

A

29.12.2008

Description For Bid Enquiry

< Security Level 2 >

HPCL, Visakh ISSUED : 29.12.2008 DOC.No. H – 331

MINIMUM REQUIREMENTS FOR WELDING PROCEDURE SPECIFICATION

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261 DHT PROJECT

Sheet 3 of 31

CONTENTS Section 1

Topic

Page No.

GENERAL

1.1

Scope

4

1.2

Conflicts

4

1.3

Codes and Standards

4

1.4

Related Engineering Specifications

4

2

WELDING PROCEDURE SPECIFICATIONS (WPS)

2.1

Applicable Codes and Standards

5

2.2

Responsible Organizations

5

2.3

Preparation of WPS and PQR

6

2.4

Minimum Requirements for WPS

6

2.5

Procedure Qualification Test Requirements

7

3


3.1

Welding Processes

7

3.2

Base Metals

8

3.3

Electrodes and Welding Rods

9

3.4

Dissimilar Joint

11

3.5

Low Temperature Service

13

3.6

Preheat and Interpass Temperature

13

3.7

Post weld Heat Treatment (PWHT)

14

ATTACHMENT – 1 Table-1 List of Items for Welding Procedure Qualification (QW-451.1) Table-2 Applicable Base Material Specification Table-3 Selection of Electrodes and Welding Rods ATTACHMENT – 2 Attached Figure of Joint Sketch ATTACHMENT – 3 Appendix – 1 Welding Specification for Pressure Piping

16 17 18 20 23 24 27



1.

GENERAL

1.1

Scope

MINIMUM REQUIREMENTS FOR WELDING PROCEDURE SPECIFICATION JOB NO. : 6261 DHT PROJECT


Sheet 4 of 31

This specification covers minimum requirements for welding procedure specification (WPS) which shall be established for the piping construction work. 1.2

Conflicts Any conflict between the requirements of this specification and the provisions of any applicable codes, standards and Customer’s requirements shall be referred to PMC for resolution prior to the work.

1.3

Codes and Standards The following codes and standards shall be referred to the latest edition unless otherwise specified: ASME Sec.II Part C

Specifications for Welding Rods, Electrodes, and Filler Metals.

ASME Sec. IX

Qualification

Standard

for

Welding

and

Brazing

Procedures, Welders, Brazers, and Welding and Brazing Operators.

1.4

ANSI/ ASME B31.1

Power Piping

ANSI/ ASME B31.3

Chemical Plant and Petroleum Refinery Piping

AWS D1.1

Structural Welding Code - Steel.

Related Engineering Specification H-103

Piping Materials or Enclosures

H-109E

Piping Support

H-301E

Piping Construction Works

H-321E

Welders Qualification Test






2.

WELDING PROCEDURE SPECIFICATIONS (WPS)

2.1

Applicable Codes and Standards

Sheet 5 of 31

This specification shall be used in conjunction with the piping code ANSI/ASME B31.3. For the piping support and shoe welding except the joints to pressure containing parts, prequalified welding procedures only for SMAW meeting AWS D1.1 may be applied for P-No.1 base metals without procedure qualification tests and WPS shall be submitted to PMC for approval. When the non-pressure containing or load bearing parts are joined to pressure containing piping, this specification shall be applied. 2.2

Responsible Organizations The construction LSTK contractor shall list the parameters applicable to welding that he performs in construction of weldments build in accordance with this specification. These parameters shall be listed in documents known as a Welding Procedure Specification (WPS).

Each construction LSTK contractor shall qualify WPS by

welding test specimens, and recording the welding data and test results in documents known as Procedure Qualification Records (PQR). The welders or welding operators used to produce weldments to be tested for qualification of procedures shall be under the full supervision and control of the LSTK contractor during the production of these test weldments. It is not permissible permissible for the construction LSTK contractor to have the welding of test weldments performed by another organization. organization.

This specification specification recognizes recognizes a construction construction

LSTK contractor as the organization, which has the responsible operation control of the production of the weldments to be made in accordance with the requirements of this specification. If in an organization effective operational control of welding procedure qualification for two or more companies of different names exits, the company involved shall describe in their Quality Control System/ Quality Assurance






Sheet 6 of 31

Program the operational operational control of procedure qualifications. In this case, separate welding procedure qualifications are not required, provided all other requirements of this specification are met. Prior to production welding, the corresponding WPS and supporting PQR shall be submitted to PMC for approval.

2.3

Preparation of WPS and PQR

2.3.1 Applicable WPS for the specific job shall shall be selected selected and prepared in accordance accordance with “ASME B-31.3 and ASME SECTION IX“, Engineering Specification H-103 and H-301. WPS shall be identified by a unique number and shall contain complete data including all the Essential, Supplementary Essential and Non Essential Variables with maximum and minimum values qualified. 2.3.2 PQR to support related for the specific specific job shall be prepared prepared in accordance with with Attached Table 1 “List of Items I tems for Welding Procedure Qualification”. All test results to be recorded into PQR shall be from specimens representative of the final condition including all heat treatments of the weldment. 2.3.3 Joint designs referred to in each WPS shall be referred to Attached Figure Figure “Joint Sketch”. 2.3.4 The WPS and PQR shall be recorded and documented in the following forms: APPENDIX -2 WELDING PROCEDURE SPECIFICATION (1/2 and 2/2). APPENDIX -3 PROCEDURE QUALIFICATION RECORDS (1/3, 2/3 and 3/3).

2.4

Minimum Requirements for WPS This

specification

and

APPENDIX-

1

“WELDING

SPECIFICATION

FOR

PRESSURE PIPING” shall give the minimum requirements and guidelines for the establishment of WPS and supporting PQR for the most used manual welding processes, Gas Tungsten Arc Welding (GTAW), Shielded Metal Arc Welding (SMAW) process or a combination for the piping or a combination for the piping systems based upon the piping code ANSI/ ASME B31.3 and B31.3.






Sheet 7 of 31

Any deviation from Minimum Requirements for WPS and related requirements on this specification, including the application of other welding process than GTAW or SMAW shall be informed to PMC for approval.

2.5

Procedure Qualification Test Requirements

2.5.1 Impact Test Impact test for procedure qualification test shall be performed in accordance with Table 323.2.2 REQUIREMENTS FOR LOW TEMPERATURE TOUGHNESS TESTS FOR METALS in ANSI/ ASME B31.3. The test temperature of impact tests shall not be higher than the design minimum temperature.

If the sub-size specimens are used, a suitable reduction of

temperature must be done. (See Par. 323.3.4 Test Temperatures in ANSI/ ASME B31.3). 2.5.2 Hardness Test The welding procedure qualification test shall include hardness test when required by the applicable codes, standards, or specifications for such process designs as wet hydrogen sulfide, amine etc.

3.


3.1

Welding Processes

3.1.1 General (1)

Welds shall be made by gas tungsten are welding (GTAW), shielded metal are welding (SMAW) process or a combination thereof. Any other welding process requires PMC approval.

(2)

The applications of backing rings and consumable inserts are prohibited.

(3)

All passes shall be uphill unless specifically approved by PMC.

(4)

Argon gas with purity of not less than 99.995% shall be used as shielding gas.



(5)




Sheet 8 of 31

Argon gas backing with purity of not less than 99.995% shall be performed for P-No.9B metals, 5Cr-1/ 2 Mo and higher low alloy metals, stainless steels, and nonferrous metals.

3.1.2 Gas Tungsten Arc Welding (GTAW) (1)

GTAW process shall be applied to root pass welding for all groove joints except for specified in Par. 3.3.1.

(2)

Gas composition and flow rate of the shielding gas and backing gas shall be recorded in the PQR and specified in the WPS, where applicable.

3.1.3 Shielded Metal Arc Welding (SMAW) (1)

AWS classification classification E6010 may be used for root pass and filler passes of carbon steel, except Al-killed carbon steel, provided all of the following conditions are met: -

nominal pipe size of 2.1/2 inches and over.

-

the specified minimum strength of less than 70 ksi (483 Mpa).

(2)

In all cases, AWS classification E6012/ E6013 shall not be used.

(3)

All the SMAW electrodes for carbon and low alloy steels shall be low hydrogen types except E6010/E6011.

3.2

Base Metals

3.2.1 P-Numbers 1, 4, 5A, 8 are covered in this specification, and examples of base metals are listed in Attached Table 2. Other metals shall be qualified in accordance accordance with QW-424.1 in ASME Sec.IX. Sec.IX.

3.2.2 Where the AWS AW S D1.1 is applied for piping support and / or shoe shoe welding, the specification or designation of base metals shall meet those specified in H-109 “Piping Support”.



3.3



Sheet 9 of 31

Electrodes and Welding Rods

3.3.1 Electrodes and welding welding rods shall be selected from Attached Table 3 “Selection of Electrodes and Welding Rods”. (1)

Attached Tables 3 shows ASME specifications and AWS Classifications of the applicable electrodes and welding rods.

(2)

The manufacturers of electrodes and welding rods shall be chosen by the construction LSTK contractor in his responsibility and approved approved by PMC.

(3)

Prior to using Non-listed electrodes and welding rods, a written proposal accompanied by physical and mechanical properties, and chemical analysis shall be submitted to PMC for approval.

(4)

Electrodes and welding rods shall be specified and identified in WPS and PQR by ASME specification and AWS classification.

Brand name of

electrodes and welding rods shall also be specified in WPS. (5)

When non pressure containing parts are welded to pressure containing piping, the chemical and mechanical properties of deposited weld metal shall be met the pressure containing base metal.

3.3.2 All electrodes and welding rods rods shall be used used within the limits recommended recommended by manufacturers.

Batch test certificates of electrodes and and welding welding rods shall be

obtained and verified by TEIL prior to commencement of welding work.

3.3.3 When “H Grade” is specified for type 304, 316, 321 and 347 stainless steels, the filler metal shall have 0.04% of carbon content or more.

3.3.4 WPS shall be re-qualified whenever: (1)

A filler metal in “G” classification is changed to any other manufacturer or manufacturer’s designation.



(2)




Sheet 10 of 31

The chemical composition of the weld deposit is changed from A-No. 1 to ANo.2 and vice versa.

3.3.5 Carbon Steel (1)

For GTAW, the filler metals shall meet the chemical and mechanical requirements of SFA5.18 classification ER70S-3, ER70S-6, TGS-50 (ER70SG: Kobe Steel Ltd) is acceptable for using.

(2)

For SMAW, the electrodes designated AWS classification E7016 or E7018 shall be used.

3.3.6 Al-killed Carbon Steel (1)

For GTAW, the certificates of filler metals shall include impact test which have 0

been conducted at - 46 C or minimum design temperature and the results shall conform to the absorbed energy requirement. (2)

For SMAW, the electrodes designated AWS classification E7016-1 or E70181 shall be used. It is acceptable to use a trade designations of LB-52NS (SFA 5.5 E7016G:Kobe Steel, Ltd.) NB-1 NB-1 SFA 5.5 E8016-G: Kobe Steel Ltd) provided that the certificates of filler metals shall include impact test which have been 0

conducted at -46 C or minimum design temperature and the results conform to the absorbed energy requirement. (3)

For sour service application (NACE MR0175), nickel content in the filler metal shall not exceed exceed 1.0%. NB-1 shall not be used for sour service service because of exceeding 1.0% of Ni content.

3.3.7 3.5 Ni steel (1)

The certificates of filler metals shall include impact test which have been 0

conducted at -101 C or minimum design temperature and the results conform to the absorbed energy requirement.




(2)



Sheet 11 of 31

For GTAW, the welding rods designated AWS classification ER80S-Ni3 shall be used. The trade designation of TGS-3N (Kobe Steel, Ltd) can be used provided that the certificates of filler metals include impact test which have been conducted 0

at -101 C or minimum design temperature and the results conform to the absorbed energy requirement. (3)

For SMAW the electrodes designated AWS classification E7016-C2L or E7018-C2L shall be used The trade designation of NB-3N (Kobe Steel Ltd) or N-16 (Nippon Steel Welding Products & Engineering Co. Ltd) for SMAW can be used provided that the certificates of filler metals include impact test which have been 0

conducted at -101 C or minimum design temperature and the results conform to the absorbed energy requirement. (4)

0

NB-3N shall be used where the design temperature is -60 C or higher in case of as-welded condition. If the design temperature falls within the range from 0

0

60 C to -101 C, PWHT is required regardless of base metal thickness. 3.3.8

C-1/2Mo ERXXS-G is specified for GTAW, the deposited weld metal shall have the same chemical composition and mechanical properties as the base metal.

3.4

Dissimilar Joint

3.4.1 For dissimilar joint made of ferritic steel and austenitic stainless steel at the design 0

temperature above 450 C, nickel - chromium -iron filler metal (Inconel-type) shall be used in order to minimize the carbon migration and thermal fracture during service.

3.4.2 Inconel - type welding rods and electrodes shall not be used, where the joints are 0

exposed to a sulfidation environment at the design temperature above 537 C.





Sheet 12 of 31

3.4.3 For dissimilar joint which which includes P-No.8 metal, preheat, interpass and postweld heat treatment conditions shall be confirmed from PMC.

3.4.4 The following following guidance for special DISIMILAR WELDS and ELECTRODES are as follows: Whenever possible, dissimilar welds between stainless steel and carbon or low alloy steel should be avoided in wet H 2S and other services where hydrogen embrittlement is possible. This is because of hard zone that occurs at the fusion line of austenitic metal and the carbon or low alloy steel base metal. This hard zone can not be completely removed with PWHT. When dissimilar welds between carbon steel and UNS NO8825 or UNS S32205 are specified in the drawings. The following guidance is offered.

a.

Carbon Steel to Alloy 825 (UNS N08825)

For weld metal, use nickel-based filler metal type ER-NiCrMo-3(INCO 625) wire and E-NiCrMo-3 rod (INCO 112). b.

Carbon Steel to Duplex 2205 (UNS S32205)

There is not an industry consensus on how to make a dissimilar weld between carbon steel and Duplex Duplex 2205, suggests suggests that the carbon steel side of the joint be overlaid(“buttered”) with a first pass of low carbon steel (AWSR45 or equal). The thickness of the “butter”should be 1/16-1/8 inch {1.5-3} max. This will avoid the problem of a hard zone in the AWS E2209 (UNS W39209) weld metal due to dilution from the carbon in carbon steel. The low Carbon “butter” pass should be as close to 1/16 in (1.5mm) minimum as possible so that the strength of the joint is adequate.After the “butter”pass of low carbon weld metal is deposited on the carbon steel, weld the Duplex 2205 to the ‘buttered” carbon steel with E2209 electrodes. This procedure must be qualified to make sure that the tensile strength of the joint is adequate. As part of the welding procedure qualification a microhardness






Sheet 13 of 31

survey should be run across the weld to make sure that there is no hardness that exceeds those recommended by NACE MRO103. In addition, because the yield strength of the Duplex 2205 is so much higher than that of carbon steel, the welding procedure should be qualified using longitudinal bends rather than transverse bends as permitted by the code. This will avoid failure in the carbon steel before the Duplex 2005 begin to bend. Some refiners weld carbon steel directly to Duplex 2205 using filler metal type ERNiCrMo-3 (INCO 625) wire and E-NiCrMo-3 rod (INCO 112). As part of the welding procedure qualification a micro hardness survey should be run across the weld to make sure that there is no hardness that exceeds those recommended by NACE MRO103. 3.5

Low Temperature Service Delta ferrite content of austenitic stainless steel filler metals shall be controlled as follows: 0

Where the design temperature is at -101 C or lower, the electrodes (SMAW) and welding rods (GTAW) shall be low carbon type. In addition, the ferric content of electrodes (SMAW) shall be in the range range of 2 to 5 percent (FN2 to FN5). Using low ferrite content electrodes (SMAW) such as NC-38LT (Kobe Steel Ltd), WEL308LA (Nippon Welding Rod Co, Ltd) is recommended.

3.6

Preheat and Interpass Temperature

3.6.1 Preheat temperature for procedure procedure qualification test must be measured just before start of welding and temperature shall be recorded in PQR.

3.6.2 The maximum interpass temperature for austenitic stainless steels shall not exceed exceed 0

180 C.



3.7




Sheet 14 of 31

Postweld Heat Treatment (PWHT)

3.7.1 PWHT for dissimilar joint between ferritic materials shall be at higher of the temperature range for the materials in the joint.

3.7.2 PWHT cycles used for procedure qualification test shall be recorded in a chart and attached to PQR for PMC approval.

3.7.3 PWHT cycles including

heating rate, the maximum and minimum holding

temperatures, holding time and cooling rate shall be specified in WPS.

3.7.4 PWHT shall be performed when it is stipulated in H-103 for certain services regardless of base metal thickness.

3.7.5 When joining austenitic material to ferritic material of the thickness thickness being required PWHT by applicable code, code, the welding procedure and PWHT applications shall be confirmed from PMC.

3.7.6 The requirements for PWHT of fillet weld weld joints and branch connections shall be referred to the requirements on H-301 “Piping Construction Works”. 0

0

3.7.7 All 18-8 cold bends should be heat treated at 1500-1650 F (843-899 C) , 1 hour per inch of thickness, 1 hour minimum for resistance to chloride stress corrosion cracking (CISCC).

3.7.8

Drain lines and lower points in austenitic austenit ic stainless steel lines are particularly prone to to chloride stress corrosion cracking (CISCC) shall be PWHT. PWHT lowers the






Sheet 15 of 31

incidence of CISCC of drain lines. It does not eliminate it. Therefore, it is recommends drains and low points be made of Alloy 625, Alloy 825 or Alloy 20Cb3. 3.7.9 Carbon steel piping joints , for thick walled piping in hydrogen hydrogen or hydrogenhydrogenhydrocarbon services, the wall thickness of pipe greater than ¾” (19 mm) should be post weld heat treated.

3.7.10 All weld of 18-8 stainless steel for thick walled piping in hydrogen or hydrogenhydrocarbon services should be post weld heat treatment.

3.7.11 All weld of Cr-Mo steel piping for thick walled piping in hydrogen or hydrogenhydrocarbon services should be post weld heat treatment.





Sheet 16 of 31

ATTACHMENT – 1 TABLE –1

LIST OF ITEMS FOR WELDING PROCEDURE QUALIFICATION QUALIFICATION (QW-451.1)

TABLE – 2

APPLICABLE BASE MATERIAL SPECIFICATION SPECIFI CATION

TABLE – 3

SELECTION OF ELECTRODES AND WELDING RODS






Sheet 17 of 31

TABLE - 1 List of Items for Welding Procedure Qualification (QW-451.1)

Test piece Material Classificat ion

Classificat ion of PNumber

Note *

Thickness t of test coupon welded Less than 1.6 mm (1/16 in.) 1.6 mm (1/16 in.) to 9.5 mm (3/8 in.) Over 9.5 mm (3/8 in.), less than 19 mm (3/4 in.) 19 mm (3/4 in.) to less than 38 mm (1 1/2 in.) 38 mm (1 1/2 in.) and over

Applicable Thickness in actual work

Items of examination and number of test specimen Tension

Face bend

Root bend

Side bend

Impact

t - 2t

2

2

2

-

-

1.6 - 2t

2

2

2

-

4.8 - 2t

2

2

2

-

4.8 - 2t

2

-

-

4

4.8 - 203 (8 in.)

2

-

-

4

* 2 sets (3 pcs/set ) * 2 sets (3 pcs/set ) * 2 sets (3 pcs/set ) * 2 sets (3 pcs/set )

For both sides of all test specimen

Notch toughness test shall be made at the weld metal, base metal, and heat affected zone when impact test is required.

Remark

Appearance

t = Thickness of Base Metal.






Sheet 18 of 31

TABLE - 2 Applicable Base Material Specifications PNo. 1

Base Metal No. 1

2

Pipes A106Gr B

Material Specification Fittings Flanges A105

API 5L Gr B A53 Gr A/B A672 Gr.A55 CL.13 A672 Gr.A55 CL.22 A672 Gr.A60 CL.13 A672 Gr.B60 CL.12 A672 Gr.B60 CL.22 A333 Gr.1

A350 Gr. LF2

A671 Gr.CC60 CL.13

A420 Gr.WPL6

Others

A105

A216 WCB

Gr.

A350 Gr. LF2

A350 LF2 A352 LCB

Gr.

A234 Gr WPB A515 Gr. 55 A283 Gr. D

Gr.

A516 Gr.60 4

4

A335 Gr P11

A691 Gr.11/4Cr A335 Gr P12

A691 Gr.1Cr CL.22 A691 Gr.1 1/4Cr CL.42 5A

5

A335 Gr P22

A182 Gr F11

A182Gr. CL.1

A234 Gr WP11 A387 Gr.11 CL.1 A182 Gr F12

A182 CL.1

F11 A217 WC6

Gr.

Gr.F12

A234 Gr WP12 A387 Gr.12 CL.1

A182 Gr. F22 CL.1 A234 CL.1

Gr.

A182 CL.1

Gr.

F22 A217 WC9

Gr.

WP22

A691 Gr.2 1/4 Cr 8

9

A312 TP304 A358 Gr. 304 CL.2

A182 F304 A403 WP 304

A182 F304

A182 F304 A351 Gr.CFB





Sheet 19 of 31

A240 Type 304 11

A312 TP304H

A182 F304H A403 WP 304H

12

A312 TP316

A182 F316

A358 Gr. 316 CL.2 13

A312 TP316L A358 Gr.316L CL.2

A182 F304H

A351 Gr.CF8M

A403 WP 316 A182 F316L A403 WP 316 L

A351 CF8M

Gr.


MINIMUM REQUIREMENTS FOR WELDING PROCEDURE SPECIFICATION TOYO ENGINEERING INDIA LTD.

HPCL, Visakh

ISSUED : 29.12.2008 DOC.No. H – 331


Sheet 20 of 31

TABLE - 3 Selection of Electrodes and Welding Rods Base Metal SL. No. (P-No.)

Nominal Type of Base Metals

1

(P-No.1)

Carbon Steel

2

(P-No.1)

Al-Killed Carbon Steel

3

(P-No.3)

C-1/2Mo

4

(P-No.4)

1Cr1/2Mo,11/4 Cr-1/2Mo

9 10 11 12 13

(PNo.5A) (PNo.5B) (PNo.5B) (PNo.9B) (P-No.8) (P-No.8) (P-No.8) (P-No.8) (P-No.8)

14

(P-No.8)

5 6 7 8

Base Metal SL. No. 1 (1)

A

2 (2)

A

B

3

4

(2)

5

(2)

(2)

6

7

8

9

10 (4)

R/T

(4)

(3)

R/S

(4)

-

R/T

(4)

-

R/T

(4)

-

R/T

(4)

-

R/T

(4)

-

A

A

A

D

E

A/B

R/T

-

-

-

-

-

A/B

R/S

C

C

C

D

E

-

R/T

D

D

D

E

-

R/T

E

E

E

-

R/T

F

F

-

R/T

G

-

R/T

H

R/S

21/4 Cr-1Mo 5 Cr - 1/2 Mo 9 Cr-1Mo 3-5Ni Type 304 Type 304L Type 304H Type 316 Type 316L Type 321 and Type 347

11

(3)

R/T

(3)

(4)

-

12 (4)

R/T

(3)

R/S

R/T

R/S (4)

R/T

(4)

R/T

(4)

R/T

(4)

R/T

R/T

(4)

R/S J K

(3)

J

13 (4)

14 (4)

R/T

(3)

-

(4)

-

R/T

(4)

(4)

-

R/T

(4)

-

R/T

(4)

-

R/T

R/T

(4)

-

R/T

-

-

-

-

J L

J M

M N

-

(4)

(4)

(4)

(4)

P


HPCL, Visakh


ISSUED : 29.12.2008 DOC.No. H – 331



Sheet 21 of 31

Nomenclature:

A B C

Spec. (SFA) 5.18 5.1 5.18 5.1 5.28 5.5

D

5.28 5.5

E

5.28

AWS (Class) (5)

ER7OS-G E7016/ E7018 (6) ER70S-G E7016-1/E7018-1 (7) ERXXS-G E7016-A1/E7018 A1 ER 80SB2 E8016-B2/ E8018-B2 ER90S-B3

Spec. (SFA) 5.9 5.4 5.9 5.4 5.9 5.4

ER308L E308L-16 ER308H E308H-16 ER316 E316 - 16

N

5.9 5.4

ER316L E316L-16

P

5.9

ER347

K L M

AWS (Class)


HPCL, Visakh


ISSUED : 29.12.2008 DOC.No. H – 331



Sheet 21 of 31

Nomenclature:

A B C

Spec. (SFA) 5.18 5.1 5.18 5.1 5.28 5.5

D

5.28 5.5

E

5.28 5.5

F

5.9 5.4 5.9 5.4 5.28 5.5

G H

J

5.9 5.4

AWS (Class) (5)

ER7OS-G E7016/ E7018 (6) ER70S-G E7016-1/E7018-1 (7) ERXXS-G E7016-A1/E7018 A1 ER 80SB2 E8016-B2/ E8018-B2 ER90S-B3 E9016-B3/ E9018-B3 ER502 E502-16 ER505 E505-16 ER80S-Ni3 E7016C2L/E7018-C2L ER308 E308-16

Spec. (SFA) 5.9 5.4 5.9 5.4 5.9 5.4

ER308L E308L-16 ER308H E308H-16 ER316 E316 - 16

N

5.9 5.4

ER316L E316L-16

P

5.9 5.4

ER347 E347-16

R

5.9 5.4 5.9 5.4 5.14 5.11

ER309 E309-16 ER309L E309L-16 ERNiCr-3 ENiCrFe-2

K L M

S T

AWS (Class)

ENiCrFe-3

DISSIMILAR ELECTRODES AND WELDING ROD: ROD: a. Carbon Steel to Alloy 825 ( UNS NO8825) For weld metal, use nickel-based filler metal type ER-NiCrMo-3 ( INCO 625 ) wire and E-NiCrMo-3 rod (INCO 112) b.

Carbon Steel to Duplex 2205 ( UNS S32205) For weld metal, follow as per para 3.4.4 strictly.


HPCL, Visakh

ISSUED : 29.12.2008 DOC.No. H – 331



Sheet 22 of 31

Notes: (1) Application of AWS classification E6010 (DC only) for root pass shall be subject to PMC approval (see par. 3.3.1). (2) Do not use E6010 (DC only) for root pass. (3) When the applicable code requires PWHT for the ferritic base metal, the application of welding procedure and PWHT shall be confirmed to PMC. (4) When the applicable code requires PWHT for the ferritic base metal, the application of welding procedure and PWHT shall be confirmed to PMC. Type 309 welding materials shall not be used where the design temperature exceeds 0 450 C. Inconel can not be used for the sulfidation environment at the design temperature 0 above 537 C. (5) The filler metal shall meet the chemical and mechanical test requirements of SFA 5.18, classification ER70S-2, ER70S-3 or ER70S-6. (6) Filler metals for welds shall meet the same minimum impact test requirements as those of the base metal. (7) Chemical composition and mechanical properties of the deposited weld metal shall be same as the base metal.


HPCL, Visakh

ISSUED : 29.12.2008 DOC.No. H – 331


ATTACHMENT – 2 ATTACHED ATTACHED FIGURE OF JOINT SKETCH


Sheet 23 of 31


HPCL, Visakh


ISSUED : 29.12.2008 DOC.No. H – 331



Sheet 24 of 31

ATTACHMENT – 3 APPENDIX – 1 WELDING SPECIFICATION FOR PRESSURE PIPING



HPCL, Visakh

ISSUED : 29.12.2008 DOC.No. H – 331



Sheet 25 of 31

1.

A sheet of WELDING SPECIFICATION FOR PRESSURE PIPING is not effective as a WPS.

2.

Either the ASME Code B31.1 or B31.3 is referred in a sheet.

3.

Identification B3

5

7

SR PWHT (2) Base Metal No. (2) Base Metal No. (1) (3) Code

(1)

4.

The last part “-SR” indicates “PWHT YES”.

(2)

A Base Metal Number is correspondence correspondence to the numbers in TABLE 1. But for dissimilar joints, P-No. 8 materials are designed as “P8”.

(3)

B3 means ANSI/ ASME B31.3 and B1 does ANSI / ASME B31.1.

The differences of the listed base metals between “PWHT YES” and “PWHT NO” sheet are subjected to code requirements for : (a)

a thickness of thicker component at the joint (B31.3) a nominal base metal thickness (B31.3)

(b)

a specified carbon content

(c)

a specified minimum tensile strength (σ)

(d)

a specified chromium content


HPCL, Visakh

ISSUED : 29.12.2008 DOC.No. H – 331


APPENDIX – 1

WELDING SPECIFICATION FOR PRESSURE PIPING Sheet No. for Piping System based on ANSI / ASME B 31.1

B3-1.1 B3-1.8 B3-8.8 B3-4.4 B3-4.4 SR


Sheet 26 of 31



HPCL, Visakh

ISSUED : 29.12.2008 DOC.No. H – 331



Sheet 27 of 31

APPLICABLE CODE THICKNESS RANGE ASME B31.3 Groove Weld : Nominal Thickness T ( mm) : T< 19 ASME SEC. IX Fillet Weld : See Par. 3.9.3 in H – 301. BASE METALS (QW-403) P-No. 1 Material Spec. (P-No./ Group No.)

Pipes

Fittings

A106 Gr B API 5L Gr B A53 Gr A/B A672 Gr. A55 CL.13 A672 Gr. B60 CL.13 A672 Gr. B60 CL.13 IS 1239 Part I IS 3589

(1/1) (1/-) (1/1) (1/1) (1/1) (1/1) (1/-) (1/-)

A105 A234 Gr. WPB A515 Gr. 55 A283 Gr. D

WELDING PROCESS 1) Groove weld : GTAW (Root Pass)

Flanges

(1/2) (1/1) (1/1) (1/1)

PREHEAT (QW-406) (QW- 406) 0 Preheat Temp. ( C) 0 Interpass Temp. ( C) Preheat Maintenance

: : :

Min 10. -

(1/2)

A216 Gr. WCB A 105

FILLER METALS (QW-404) Spec. (SFA) AWS GTAW :

SMAW (Filler Pass)

A105

Others

5.18 5.1 5.1

(Class) ER70S-G

(1/2) (1/2)

GAS (QW-4089) (QW- 4089) Shielding gas : 2)

Argon 99.9% vol. or over

E7016 E7018

Gas Backing : Not Applicable

POSTWELD POSTW ELD HEAT TREATMENT (QW-407) (QW- 407) Required : No. 0 Metal Temp. Range ( C) : Min Holding Time (hr / 25mm)

TECHNICAL NOTES : 0 1) A Minimum preheat of 95 C is applied when the nominal material thickness of either of the base metals exceed 25.0 mm. 2) Application of AWS classification E6010 (DC only) for root pass shall be subjected to PMC approval. 3) Filler metals shall meet the chemical and mechanical test requirements of SFA 5.18, AWS class. ER70S-2, ER70S-3, or ER70S-6. TGS-50 (ER70S-G: Kobe Steel) is acceptable for using. 4) Process conditions such as caustic, amine and wet hydrogen sulfide may require PWHT regardless of thickness. 5) A1A, A2S, A6S Class H 103



HPCL, Visakh

ISSUED : 29.12.2008 DOC.No. H – 331



Sheet 28 of 31

APPLICABLE CODE THICKNESS RANGE ASME B31.3 Groove Weld : Nominal Thickness T ( mm) : T< 19 ASME SEC. IX Fillet Weld : See Par. 3.9.3 in H – 301. BASE METALS (QW-403) P No. 1 To P. No.8 Material Spec. (P-No./ Group No.)

Pipes

Fittings

A106 Gr B API 5L Gr. B A53 Gr A/B A 312 TP 304 A 358 TP 304

(1/1) (1/-) (1/1) (8/1) (8/1)

Flanges

A105 A234 Gr. WPB

(1/2) (1/1)

A182 F 304 A403 WP 304

(8/1) (8/1)

WELDING PROCESS Groove weld : GTAW (Root Pass)

(1/2) (8/1)


SMAW (Filler Pass)

A105 A182 F 304

Others

5.9

(Class) ER309

5.4

E309-16

A216 Gr. WCB A105

(1/2) (1/2)

A182 F 304

(8/1)

GAS (QW-4089) (QW- 4089) Shielding gas : Argon 99.9% vol. or over Gas Backing : Argon 99.9% vol. or over


: : :

Min 10. O 180 C -


TECHNICAL NOTES : 1) Filler metals shall shall meet the chemical and mechanical test requirements of SFA 5.9, ER 309 and SFA 5.4 AWS E 308-16



HPCL, Visakh

ISSUED : 29.12.2008 DOC.No. H – 331



Sheet 29 of 31

APPLICABLE CODE THICKNESS RANGE ASME B31.3 Groove Weld : Nominal Thickness T ( mm) : T< 19 ASME SEC. IX Fillet Weld : See Par. 3.9.3 in H – 301. BASE METALS (QW-403) P. No.8 Material Spec. (P-No./ Group No.)

Pipes

Fittings

A 312 TP 304 A 358 TP 304

(8/1) (8/1)

A182 F 304 A403 NP 304


Flanges

(8/1) (8/1)

(8/1) (8/1)


SMAW (Filler Pass)

A182 F 304 F 316

Others

5.9

(Class) ER308

5.4

E308-16

A182 F 304

(8/1)



: : :

Min 10. O 180 C -


TECHNICAL NOTES : 1) Filler metals shall shall meet the chemical and mechanical test requirements of SFA 5.9, AWS class. ER 308 and SFA 5.4 AWS E 308-16 2) A1K, A1L, B3K, B1L Class of H 103



HPCL, Visakh

ISSUED : 29.12.2008 DOC.No. H – 331



Sheet 30 of 31

APPLICABLE CODE THICKNESS RANGE ASME B31.3 Groove Weld : Nominal Thickness T ( mm) : T< 12.7 ASME SEC. IX Fillet Weld : See Par. 3.9.3 in H – 301. BASE METALS (QW-403) P. No.4 Material Spec. (P-No./ Group No.)

Pipes

Fittings

A 335 Gr. P11 A 335 Gr. P12 A 691 Gr. 1 ¼ Cr. A 691 Gr. 1 Cr CL-22 CL-22

(4/1) (4/1) (4/1) (4/1)

A 234 WP 11 A 234 WP 12 A 182 F 11 A 182 F 12 A 387 Gr. 11 A 387 Gr. 12


Flanges

(4/1) (4/1) (4/1) (4/1) (4/1) (4/1)

A182Gr.F 11 A182Gr.F 12

Others

(4/1) (4/1)


SMAW (Filler Pass)

5.28

(Class) ER80S-B2

5.5

E8018-B2

A 217Gr. WC 6

(4/1)



: : :

o

Min 180 C O 300 C Max Yes

POSTWELD POSTW ELD HEAT TREATMENT (QW-407) (QW- 407) Required : No. 0 Metal Temp. Range ( C) : NA Min Holding Time (hr / 25mm) NA

TECHNICAL NOTES : 1) Filler metals shall meet the chemical and mechanical test requirements of SFA 5.28, AWS class. ER 80S-B2 and SFA 5.5 AWS Class E 8018-B2

LEGEND :- NA – Not Applicable



HPCL, Visakh

ISSUED : 29.12.2008 DOC.No. H – 331



Sheet 31 of 31

APPLICABLE CODE THICKNESS RANGE ASME B31.3 Groove Weld : Nominal Thickness T ( mm) : T > 12.7 ASME SEC. IX Fillet Weld : See Par. 3.9.3 in H – 301. BASE METALS (QW-403) P. No.4 Material Spec. (P-No./ Group No.)

Pipes

Fittings

A 335 Gr. P11 A 335 Gr. P12 A 691 Gr. 1 ¼ Cr. A 691 Gr. 1 Cr CL-22 CL-22

(4/1) (4/1) (4/1) (4/1)

A 234 WP 11 A 234 WP 12 A 182 F 11 A 182 F 12 A 387 Gr. 11 CL 1 A 387 Gr. 12 CL 1


Flanges

(4/1) (4/1) (4/1) (4/1) (4/1)

A182Gr.F 11 A182Gr.F 12

Others

(4/1) (4/1)

(4/1) (4/1) (4/1)

(4/1)


SMAW (Filler Pass)

A 182 Gr. F 11 A 182 Gr. F 12 A 217Gr. WC 6

5.28

(Class) ER80S-B2

5.5

E8018-B2


PREHEAT (QW-406) (QW- 406) 0 Preheat Temp. ( C) 0

Interpass Temp. ( C) Preheat Maintenance

o

:

Min 180 C

: :

300 C Max Yes

O

POSTWELD POSTW ELD HEAT TREATMENT (QW-407) Required : Yes, above 12.7 mm . 0 Metal Temp. Range ( C) : 703 – 740 Min Holding Time (hr / 25mm) 2 Hrs. min.

TECHNICAL NOTES : 1) Filler metals shall meet the chemical and mechanical test requirements of SFA 5.28, AWS class. ER 80S-B2 and SFA 5.5 AWS Class E 8018-B2

LEGEND :- NA – Not Applicable

H-331 E WPS

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