Shell DEP 30.10.60.18

DEP SPECIFICATION

Copyright Shell Group of Companies. No reproduction or networking permitted without license from Shell. Not for resale

WELDING OF METALS (AMENDMENTS/SUPPLEMENTS TO API RP 582)

DEP 30.10.60.18-Gen. February 2012 (Amendment A01 has been incorporated – February 2013) ECCN EAR99

DESIGN AND ENGINEERING PRACTICE

© 2012 Shell Group of companies All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior written permission of the copyright owner or Shell Global Solutions International BV. This document contains information that is classified as EAR99 and, as a consequence, can neither be exported nor re-exported to any country which is under an embargo of the U.S. government pursuant to Part 746 of the Export Administration Regulations (15 C F.R. Part 746) nor can be made available to any national of such country. In addition, the information in this document cannot be exported nor re-exported to an end-user or for an end-use that is prohibited by Part 744 of the Export Administration Regulations (15 C.F R. Part 744)..

This document has been supplied under license by Shell to: Abu Dhabi Gas Industries Ltd. [email protected] 26/03/2017 10:23:46

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DEP 30.10.60.18-Gen. February 2012 Page 2

PREFACE DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions International B.V. (Shell GSI) and, in some cases, of other Shell Companies. These views are based on the experience acquired during involvement with the design, construction, operation and maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international, regional, national and industry standards. The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help achieve maximum technical and economic benefit from standardization. The information set forth in these publications is provided to Shell companies for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the information set forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the quality of their work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will typically expect them to follow those design and engineering practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own respons bility, consult the Principal. The right to obtain and to use DEPs is restricted, and is typically granted by Shell GSI (and in some cases by other Shell Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three categories of users of DEPs can be distinguished: 1)

Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.

2)

Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of a Service Agreement or otherwise).

3)

Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these companies, that may issue DEPs or advise or require the use of DEPs. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement. All administrative queries should be directed to the DEP Administrator in Shell GSI.


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DEP 30.10.60.18-Gen. February 2012 Page 3 TABLE OF CONTENTS

PART I 1.1 1.2 1.3 1.4 1.5 1.6 1.7

INTRODUCTION ........................................................................................................ 5 SCOPE ....................................................................................................................... 5 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 5 DEFINITIONS............................................................................................................. 6 CROSS-REFERENCES ............................................................................................. 6 SUMMARY OF MAIN CHANGES .............................................................................. 6 COMMENTS ON THIS DEP ...................................................................................... 7 DUAL UNITS .............................................................................................................. 7

PART II 2.1 2.2 2.3 2.4 2.5 2.6

GENERAL .................................................................................................................. 8 GENERAL .................................................................................................................. 8 DEVIATIONS.............................................................................................................. 8 METHODS AND EXTENT OF NON-DESTRUCTIVE EXAMINATION...................... 8 TESTING QUALIFICATIONS ..................................................................................... 8 EQUIPMENT .............................................................................................................. 9 SPECIAL REQUIREMENTS ...................................................................................... 9

PART III

AMENDMENTS/SUPPLEMENTS TO API RP 582 ................................................. 10

1

Scope ....................................................................................................................... 10

2

Normative References ........................................................................................... 10

4 4.7 4.8 4.9

General Welding Requirements ............................................................................ 10 Before Welding ......................................................................................................... 11 During Welding ......................................................................................................... 17 After Welding ............................................................................................................ 19

5 5.1 5.2

Welding Processes ................................................................................................ 20 Acceptable Welding Processes................................................................................ 21 Limitations of Fusion Welding Processes ................................................................ 21

6 6.1 6.4 6.5 6.6 6.7 6.8 6.10 6.11 6.12 6.13 6.14 6.15 6.16

Welding Consumables (Filler Metal and Flux) .................................................... 24 General ..................................................................................................................... 24 Stainless Steel Welding (P-6, P-7, and P-8) ............................................................ 25 Duplex Stainless Steel Welding ............................................................................... 26 SAW ......................................................................................................................... 27 Electroslag Welding (for Corrosion Resistant Weld Overlay) .................................. 28 Consumable Storage and Handling ......................................................................... 28 Carbon steel ............................................................................................................. 29 Nickel Alloys ............................................................................................................. 30 Copper Alloys ........................................................................................................... 30 Titanium Alloys ......................................................................................................... 30 Nickel Steels............................................................................................................. 31 6 % Mo Superaustenitic Stainless Steels ................................................................ 31 P91 ........................................................................................................................... 31

7

Shielding and Purging Gases ............................................................................... 32

8

Preheating and Interpass Temperature ............................................................... 32

9

Post Weld Heat Treatment (PWHT)....................................................................... 33

10 10.13

Cleaning and Surface Preparation ....................................................................... 37 9 % Nickel Steel ....................................................................................................... 37

11 11.1

Special Procedure Qualification Requirements/Testing .................................... 37 General ..................................................................................................................... 37

12 12.1 12.4 12.5 12.6

Other Items ............................................................................................................. 38 Backing Materials ..................................................................................................... 38 Temporary Attachments ........................................................................................... 38 Stud Welding ............................................................................................................ 39 Hardness Testing—Weld Procedure Qualification and Production Testing ............ 39


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12.7 12.8

Single-pass Welds.................................................................................................... 40 Tube Skin Thermocouple Welding ........................................................................... 40

13

Environment ........................................................................................................... 41

Annex A

(informative) Welding Consumables for Shielded Metal Arc Welding (SMAW) .................................................................................................................... 41

Annex B

(normative) Weld Overlay and Clad Restoration (Back Cladding) .................... 41

Annex C

(normative) Carbon steel Welding ........................................................................ 51

Annex D

(normative) Low Alloy Steel Welding ................................................................... 51

Annex E

(normative) Stainless Steels Welding .................................................................. 54

Annex F

(normative) Ni steels .............................................................................................. 64

Annex G

(normative) High Ni Alloys Welding ..................................................................... 66

Annex H

(normative) Copper Alloys Welding ..................................................................... 67

Annex I

(normative) Aluminum alloys Welding ................................................................. 68

Annex J

(normative) Titanium alloys Welding ................................................................... 69

Annex K

(normative) Dissimilar Welding ............................................................................ 70

PART IV

REFERENCES ......................................................................................................... 73


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PART I INTRODUCTION 1.1

SCOPE This DEP specifies requirements and give recommendations for welding of metals. It is based on API RP 582 (second edition, December 2009). Part III of this DEP amends, supplements and deletes various clauses of API RP 582, and follows the clause numbering of API RP 582 for easy reference. The annexes primarily cover details that are material specific and other welding information not covered in API RP 582. All clauses of API RP 582 not modified by this DEP remain valid as written. This DEP essentially lists basic and expected good manufacturing practices. Most of these quality assurance requirements or technology items would be normally expected to be in place in good quality welding shops or other welding organizations and can be found in different forms in most user’s specifications. They should not be viewed as extraordinary or unusual requirements unless so identified. This DEP also includes experience-based requirements and warnings to prevent defects and rework. Some of the specific technical requirements may not be commonly used in industrial standards or well known but they are important to be identified as they would have an impact on weld performance. This DEP is also intended to be used as a yardstick of fabrication quality assessment. It can be easily measured by the number of exceptions a fabrication shop will require to be able to comply with the basic good fabrication practices. There is an emphasis on proper work procedures, record keeping and traceability. These are concepts, which should be well developed in quality fabrication organizations. It is important to review this DEP with the fabrication organization prior to fabrication to ensure that all questions and issues are settled. It is possible that in some cases the fabricator can offer an alternate approach leading essentially to the same result. In such cases the Principal may accept such alternate solutions and record them in using the project standard management of change (MOC) procedures prior to commencement of fabrication. Additional technical aspects of welding relevant to the job and not specifically listed by this DEP should be covered individually via review of proposed welding procedures and/or other agreements made between the Manufacturer and Contractor or Principal representatives during prefabrication meetings. The scope of this DEP does not include pipelines and civil structural welding. DEP 61.40.20.30-Gen., DEP 37.81.40.31-Gen. and DEP 30.10.60.30-Gen. cover pipeline welding, and DEP 37.81.10.34-Gen. covers civil structural welding. This is a revision of the DEP of the same number dated May 2004; see (1.5) regarding the changes.

1.2

DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated by them. Any authorised access to DEPs does not for that reason constitute an authorisation to any documents, data or information to which the DEPs may refer. This DEP is intended for use in facilities related to oil and gas production, gas handling, oil refining, chemical processing, gasification, distribution and supply/marketing. This DEP may also be applied in other similar facilities. When DEPs are applied, a Management of Change (MOC) process shall be implemented; this is of particular importance when existing facilities are to be modified. If national and/or local regulations exist in which some of the requirements could be more stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable with regards to the safety, environmental, economic and legal aspects. In all cases, the Contractor shall inform the Principal of any deviation from the requirements of this DEP which is considered to be necessary in order to comply with national and/or local


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regulations. The Principal may then negotiate with the Authorities concerned, the objective being to obtain agreement to follow this DEP as closely as possible. 1.3

DEFINITIONS

1.3.1

General definitions The Contractor is the party that carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party that manufactures or supplies equipment and services to perform the duties specified by the Contractor or Principal. NOTE:

For the purposes of this DEP, Vendor is the supplier of the equipment, not necessarily the Manufacturer.

The Principal is the party that initiates the project and ultimately pays for it. The Principal may also include an agent or consultant authorised to act for, and on behalf of, the Principal. The word shall indicates a requirement. The word should indicates a recommendation. The word may indicates a permissible option. 1.3.2

1.4

Specific definitions Term

Definition

Subcontractor

a company awarded a contract by a Contractor to do part of the work awarded to the Contractor by the Principal. The work of the Subcontractor is carried out under the direction and control of the Contractor. Under its model contracts the Principal maintains the right to review all proposed Subcontractors, and subcontracts.

Welding Technical Authority (TA)

person identified by the Principal as the authority for welding technology. In Shell, the TA assignment will follow the structure established by the DCAF (Discipline Controls and Assurance Framework) process used in major projects. For work that is performed for small projects or maintenance activities, a welding focal point will normally be identified as the TA.

CROSS-REFERENCES Where cross-references to other parts of this DEP are made, the referenced section number is shown in brackets ( ). Other documents referenced by this DEP are listed in (Part IV).

1.5

SUMMARY OF MAIN CHANGES This DEP is a revision of the DEP of the same number dated May 2004 (with DEP Circulars 01/06, 44/07 and 16/08 incorporated). This DEP has undergone a complete re-write. In addition, it has been harmonized with the following local and project welding specifications: a) Previous DEP 30.10.60.18-Gen. (2002). b) Prior DEP 30.10.60.18-Gen. (October 1995). c) 2EG-50 Welding (Including Heat Treatment, NDT & Other Testing Requirements). d) 2 GS-50 Welding, Post weld Heat Treatment, and Weld Testing for Pressure Equipment. e) 2GS-51 PS MZR Crude Tank Replacement Project. f)

2GS-57 Welding, PWHT, and Inspection of Pipe with Internal Overlay.

g) S-21 Construction Specification Section 21: Welding (SPDC-Nigeria). h) SES 46-3 Welding Austenitic/Ferritic (Duplex and Super Duplex) stainless Steel.


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i)

BSP-12-Standard-601 – The Welding of Metals.

j)

API 577 Welding Processes, Inspection, and Metallurgy.

k) DEP 31.38.01.31-UIE Welding and Inspection of Process and Utility Pipework, Vessels and Equipment at Land and Offshore Facilities. January 2011. l)

DISSIMILAR WELDS AMENDMENTS AND SUPPLEMENTS TO STANDARDS Draft proposal, Dec 8, 2010 Frank J.Vacha.

m) STD 57-2-01 Welding of pressure Equipment and Piping Project Specification for Scotford Expansion 1 Downstream. n) 118-57-11 ASME/ANSI Registered Welding Procedures. o) MZR – Welding & Materials Supplement to API 650. p) Filler Metal Procurement Guidelines. Amendment A01

1.6

Section

Change

PART I, 1.6

Updated DEP feedback process.

PART IV

Reference to pressure vessel DEPs have been updated.

PART IV

Added DEP feedback form - DEP 00.00.05.80-Gen.

COMMENTS ON THIS DEP

Amendment A01

Comments on this DEP may be submitted to the Administrator using one of the following options: Shell DEPs Online (Users with access to Shell DEPs Online)

Enter the Shell DEPs Online system at https://www.shelldeps.com Select a DEP and then go to the details screen for that DEP. Click on the “Give feedback” link, fill in the online form and submit.

DEP Feedback System (Users with access to Shell Wide Web)

Enter comments directly in the DEP Feedback System which is accessible from the Technical Standards Portal http://sww.shell.com/standards. Select “Submit DEP Feedback”, fill in the online form and submit.

DEP Standard Form (Other users)

Use DEP Standard Form 00.00.05.80-Gen. to record feedback and email the form to the Administrator at [email protected].

Feedback that has been registered in the DEP Feedback System by using one of the above options will be reviewed by the DEP Custodian for potential improvements to the DEP. 1.7

DUAL UNITS This DEP contains both the International System (SI) units, as well as the corresponding US Customary (USC) units, which are given following the SI units in brackets. When agreed by the Principal, the indicated USC values/units may be used.


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PART II GENERAL 2.1

GENERAL Part III of this DEP is written as amendments and supplements to API RP 582. Wherever reference is made to API RP 582, it shall be understood to mean API RP 582 as amended/supplemented by this DEP. For ease of reference, the clause numbering of API RP 582 has been used throughout Part III of this DEP. Clauses in API RP 582, which are not mentioned in this DEP shall remain valid as written. The Principal shall identify a welding Technical Authority (TA) whenever this DEP is applied. For work that is performed for small projects or maintenance activities, a welding focal point will normally be identified as the TA. This person shall be responsible for any special requirements clauses in this DEP identified by the statement, “If required by the Principal…”

2.2

DEVIATIONS All conflicts between the requirements of this DEP and other relevant documents shall be referred to the Principal’s welding TA for resolution.

2.3

METHODS AND EXTENT OF NON-DESTRUCTIVE EXAMINATION This DEP does not include a complete specification for testing and the non-destructive examination (NDE) requirements for all production welds. Only the NDE or testing which may be specific to or resulting from the use of a particular welding process (e.g., GMAW, FCAW) or to assure in service weld performance (e.g., ferrite tests) are included. The methods and extent of NDE for pressure vessels or piping are covered by other applicable DEPs, the respective design code, and relevant design/purchasing documents.

2.4

•

The extent of piping inspection is covered by DEP-31.38.01.31-Gen.

•

The extent of pressure vessel inspection is contained in the DEP associated with the applicable pressure vessel design code.

TESTING QUALIFICATIONS Mechanical, chemical and electrical testing shall be performed with equipment calibrated in accordance with applicable ASME, ASTM or ISO standards or by a recognised local Regulatory Agency or third-party agency (e.g., TŰV, Lloyds, DNV, EN, CSA). Inspection Personnel The inspection personnel to be used by the Contractor are to be individually approved by the Principal. The Principal reserves the option to interview operatives and, when necessary, to require a practical skills test. The minimum qualification requirements are as follows: Visual

ASNT, CGSB or EN 473 or ISO 9712, Level 2

MT


PT


Radiography


Interpretation only


Ultrasonic


Additionally, supervisors responsible for overseeing and controlling NDE activities shall be Level 3 qualified.


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Alternative qualifications shall be accepted only by specific approval of the Principal. Approval shall be subject to satisfactory demonstration of independence and control of the qualification specifications and reviewed by an NDE Specialist. 2.5

EQUIPMENT All welding equipment shall be in accordance with the relevant sections of either EN 60974-1 or equivalent AWS standard. Welding sets shall be calibrated or verified at intervals not exceeding 12 months. Welding generators, cables, electrode holders, earth return clamps and all other ancillary equipment shall be supplied by the Contractor or Manufacturer and shall conform to a standard acceptable to the Principal that ensures acceptable welds and continuity of operations. All welding equipment and cutting equipment shall be maintained in good condition and working order throughout the Contract to ensure the safety of the personnel. All gas cutting equipment shall comply with ISO 5172 or equivalent AWS standard. The continuous rated capacity of all equipment shall be at least 30 % greater than the duty requirement for any welding or cutting procedure used in the Contract. All welding equipment and associated metres shall be verified as calibrated immediately prior to the commencement of production welding and thereafter at regular intervals according to the Contractor’s or Manufacturer’s calibration procedure. This procedure shall be agreed with the Principal before the start of production. In the case of critical equipment where heat input and interpass temperature will have impact on metal toughness, such measurements shall be done either continuously or if agreed by the Principal, for a minimum of three times per shift. Ammeters and voltmeters shall be fitted to welding equipment for the GMAW, FCAW and SAW welding processes. Separate voltmeters and ammeters (‘tong tester’ or Hall effect type tester) shall be provided for all other arc-welding processes by the Contractor or Manufacturer. The equipment shall be operated within the current and voltage ranges given in the qualified welding procedure; and, any equipment which does not meet these requirements shall be repaired or replaced at the Contractor’s or Manufacturer’s expense. If clamps are welded to the pipe during fit up and welding, these attachment welds shall be treated as temporary welds per API RP 582, section 12.4. The Contractor or Manufacturer shall supply, as required, ovens for drying and storage of electrodes. The ovens shall be capable of accurate temperature control and be of sufficient size to facilitate uniform drying of the electrodes. The Contractor shall ensure that all welding operators are provided with full protective clothing, helmets, suitable welding glasses and visors.

2.6

SPECIAL REQUIREMENTS Requirements introduced by a statement: “If required by the Principal…” are special requirements, which shall be confirmed by the Principal. It is intended that this confirmation be performed either at the beginning of a project (as a whole), or for individual equipment purchases, during a pre-award or prefabrication meeting.


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PART III AMENDMENTS/SUPPLEMENTS TO API RP 582 1

Scope

Add new 1.4: 1.4

Throughout API RP 582, all instances of the word "should" shall be read as "shall" unless otherwise approved by the Principal.

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 Nondestructive 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, Recommended Practices for Root Pass Welding without Backing; CSA Welded Steel Construction (AWS D1.1 for US based companies); CSA W59.2, Welded Aluminium construction (AWS D1.2 for US based companies); European Pressure Equipment Directive (PED) 97/23 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 DEP 30.10.02.31-Gen.-Shell Design and Engineering Practice: Metallic Materials – Prevention of Brittle Fracture EN 473, Non-destructive Testing. Qualification and Certification of NDE Personnel – General Principles 4

General Welding Requirements Add the following to 4.1: Structural welding may alternatively require compliance with the local jurisdictional code (e.g., CSA W59 in Canada). When welding is performed onto the pressure boundary, it shall be qualified and executed in accordance with ASME/BPVC Sec IX or applicable pressure vessel code. Add the following to 4.2: Procedures prequalified in accordance with other local jurisdictional codes will also be accepted, provided they comply with requirements of this DEP.


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Add new 4.5: 4.5

Special Conditions When the equipment or piping is identified as “sour” or “wet H2S” service, fabrication shall be in accordance with DEP-30.10.02.15-Gen. or DEP 30.10.02.17-Gen. as applicable. Special root pass quality - Note: Whenever special root quality or profile is required, it should be specified in other purchasing specifications, such as drawings or manufacturing specifications.

Add new 4.6: 4.6

During new piping fabrication, deposition of weld metal, or weld build up to restore the wall thickness of the base metal for strength consideration or for meeting minimum design wall thickness requirement is prohibited.

Add new 4.7: 4.7

Before Welding

4.7.1

Welding procedure Specifications (WPS) No fabrication welding shall be carried out before the WPS and the PQR are completed and approved by the Principal and the welders have been qualified. When required by the Principal, a detailed WPS shall be prepared by the Contractor and submitted to the Principal for review and approval before procedure qualification welding is started. For piping fabrication, applicable WPS shall refer to the relevant piping classes and shall indicate the diameter and the thickness range, as appropriate. The WPS submitted shall also indicate repair-welding procedures separately. Only WPS approved by the Principal shall be used for procedure test welding.

4.7.1.1

Approval WPS shall meet the local jurisdictional code requirements. In addition to the local requirements, the WPS shall meet the ASME/BPVC Sec IX or the relevant part of ISO 15614, and the requirements of this specification. WPS approval may be withdrawn during production welding when excessive repair rates that cannot be attributed to bad workmanship are encountered.

4.7.1.2

Previously Qualified Procedures WPSs previously qualified by the Contractor may be submitted for approval as long as requirements of this specification are met. If required by the Principal, they shall be supported by a WPQR witnessed by an acceptable Independent Third Party. When required by the Principal, the Contractor shall furnish evidence of the successful application of the proposed procedures from previous work.

4.7.1.3

Procedures to be Qualified Specification of welding essential variables for heat input/arc energy determination and all measurement records shall relate to unfactored arc energy. Designated testing laboratories shall have a quality system in compliance with ISO 17025 or equivalent. The Principal may require laboratory to be pre-approved.

4.7.2

Welding Procedure Qualifications Procedure and documentation – Unless local Codes/regulations require otherwise welding procedures shall be prepared and qualified according to ASME/BPVC Sec IX or ISO 15614. If required by the Principal, the PQR shall include test reports that demonstrate that the test welds meet chemical, mechanical and hardness requirements as specified by the Purchaser. PQR review - Procedure qualifications records (PQR) shall always be attached to WPS for the review by the Purchaser, unless otherwise approved by the Purchaser.


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Mock-up coupons – For designated thickness ranges or where required by purchasing specifications, all “highly restrained” joints or tube sheets with strength welded tube joints will require full size mock-ups. Other methods of demonstration of sufficient weldment ductility in restrained weld cases can be proposed for acceptance by the Principal. When welding production coupons for ASME/BPVC Sec VIII Div 2 vessels, the coupons shall be welded on production machines whenever possible. If this is agreed by the Principal as being impractical, a comparative review of the production and laboratory welding machines shall be made to ensure that the welding parameters used on the laboratory machines are indeed identical to those of the production welding machines. Weld and NDE maps – Use of welding procedures (WPS) and NDE coverage shall be identified on general arrangement and/or detail drawings as applicable in a manner allowing identification of welding procedure and NDE coverage used on each particular weld. Field weld identification – Field welds shall be identified on drawings using the identifier described in AWS D2.4 or ISO 2553. Unless otherwise identified, multi-pass fillet welds may be qualified by groove welds in accordance with ISO 15614, although separate WPS's shall be submitted. Single pass fillet welds for pressure retention shall be separately qualified in accordance with ISO 15614. Combination of WPQRs with other Contractor procedures, even if a combined operational control exists, is not permitted unless specific approval is given by the Principal. 4.7.2.1

If required by the Principal or Jurisdiction: •

All welding procedures proposed for welding on registered pressure equipment and piping shall be approved by the Jurisdiction of the state or province in which the equipment shall be registered, or if fabricated outside of the state or province in which it is registered, by a certified/authorised third party entity (i.e., ASME, TSSA).

•

The WPQR/PQR documentation shall include the material certificates for the base and filler materials applied in the weld qualification test.

•

Separate WPSs for fillet and groove should be submitted even in the case the procedure was qualified using groove welds.

•

And if not required by the code, all welders and welding operators’ performance test coupons shall be visually examined, radiographed and mechanically tested, which include bend test and subjected to corrosion testing when applicable. The mechanical test pieces shall be as per ASME/BPVC Sec IX.

•

Prior to removal of test specimens, the test weld shall be subjected to the NDT defined below in the presence of the Principal or approved third party certifying authority. The NDT shall consist of the following: visual examination liquid penetrant or magnetic particle testing; Radiographic testing; and Ultrasonic testing (for welds made by GMAW, GTAW and/or FCAW only).

•

The acceptance criteria shall be as stated in chapter VI of ASME B31.3 and the corresponding sections of this specification. The Principal will select the service condition to be used along with ASME B31.3 Table 341.3.2. Any weld, which fails to meet the acceptance criteria, shall not be offered for destructive testing. Visual examination of all butt welds shall include the pipe bore surfaces. For austenitic and duplex stainless steel and high Nickel austenitic alloys welds the degree of oxidation present on these surfaces following welding shall be within the visual acceptance criteria of DEP 30.10.60.31-Gen.

•

After successful completion of NDT and destructive testing, the Contractor shall submit the original WPS/PQR to be used for production welding along with supporting test results for review and approval by the Principal. Production welding shall not commence until the WPS/PQR has been endorsed ‘Approved for


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DEP 30.10.60.18-Gen. February 2012 Page 13 Fabrication’ with the date and contract number and signed by the Principal. Only those WPS/PQR shown on the approved WPS register shall be used in production.

4.7.2.2

•

Charpy tests beyond code requirements may be specified.

•

Mechanical testing shall be delayed to account for delayed hydrogen cracks.

Materials Specific requirements for each material group are shown in the relevant section for material types included in this specification. Other non-specified materials shall comply with usual industrial standards plus any specific design requirements as advised by purchase order.

4.7.3

Welder Qualification

4.7.3.1

All welders shall be qualified to meet the local jurisdictional code requirements. Additionally, all welders and welding operators shall be qualified in accordance with ASME/BPVC Sec IX, EN 287-1, ISO 9606-3 to ISO 9606-5 or EN 1418 as applicable or equivalent codes. If the applicable code does not specify the welder qualification validity period, it should be set to a maximum of 6 months, with possibility of extension upon review of welders’ performance records. If the Principal requires, welder qualification tests shall be witnessed by the Principal. While on site, the welders and welding operators shall be easily identifiable. This may be by: 1. A badge bearing name, photograph and identification number 2. The welder carrying a works ID pass including a photograph 3. By the Contractor maintaining a report of welder IDs including name, photograph, and welder ID number. In the event that a welder leaves the Contractor, his welder number shall not be assigned to another welder employed on the work.

4.7.3.2

If required by the Principal, and if not required by the code, all welders and welding operators’ performance test coupons shall be visually examined, radiographed and mechanically tested, which include bend test and subjected to corrosion testing when applicable. The mechanical test pieces shall be as per ASME/BPVC Sec IX.

4.7.3.3

In order to confirm the qualification by validation, a welder performance register shall be kept up-to-date by the Manufacturer. This register shall at least contain the following data: 1. Welder's name and stamp; 2. Welding position and X-ray number; 3. Data of welding inspection and the result; 4. Materials (base and consumable); 5. Geometrical data (diameter, wall thickness, etc.); 6. Reference to welding procedure specification applied.

4.7.3.4

If required by the Principal, for pressure retaining welds, for all positions only welders qualified in 6G position shall be acceptable.

4.7.4

Weld Preparation Before start of welding, all of the materials, consumables, shielding gas shall be made traceable with identification numbers to their material test certificates. All material shall be visually inspected prior to welding to confirm freedom from mechanical damage/corrosion and confirm correct marking. Any deviations shall be reported in writing to the Principal. Weld preparations shall be in accordance with ASME B16.25 or as-qualified in the PQR. Square butt ends are permissible below 2 mm (0.080 in) wall thickness. Care shall be taken to avoid contamination of prepared bevel surface and surrounding area with low melting point metals such as copper, zinc or paint and markers containing zinc or chloride.


ECCN EAR99


If required by the Principal, prior to preparation/fabrication/cutting of vessel wall or process piping for branch connection shall be UT tested to confirm freedom from non-acceptable discontinuities. The weld foot print and 75 mm (3 in) minimum about the weld shall be examined. 4.7.4.1

Cutting and Bevelling The equipment used for edge preparation and cleaning (e.g., plasma cutting, grinding, brushing, etc.) shall cause no detrimental metallurgical effects upon the edges to be welded. Edges shall normally be machined or bevelled by grinding. Preparation of weld edges by plasma cutting shall be done, wherever practical, with a mechanically guided torch. Bevelling with hand-held cutting torches is not permitted except when specifically approved by the Principal. Flame cutting may be used for un-alloyed and low-alloy steels. Carbon and low-alloy steels shall be ground to bright metal approximately 3 mm (1/8 in). Cold-sheared plates of 10 mm (0.4 in) and less need not be dressed back. For Ni-steels (> 0.5 % Ni) used for low temperature application, the edge preparation shall be done by machining or grinding. Flame cutting may be used, followed by 3 mm (1/8 in) grinding or machining. Cold shearing shall not be used. After grinding, the weld edges shall be visually examined to ensure freedom from defects. Deep gouges and dents on the preparation surface shall be cause for rejection. Any bevelled edge that has been damaged shall be restored within the tolerances required by the welding procedure to be applied. Weld bevel restoration involving welding shall be accompanied by a qualified procedure in case of major build-up over 6 mm (1/4 in), and in case of alloy equipment shall only be permitted by approval of the Principal. Laminations identified on the bevel surface by visual examination shall be investigated by MT or PT prior to removal. Plasma cutting should be used for high-alloy steels and clad steels followed by grinding to bright metal to a minimum of 3 mm (1/8 in). In all cases, grinding depth could be reduced if testing shows that microstructure changes have been removed.

4.7.4.2

Spacing Pipe or vessel containing longitudinal seams shall be separated by at least 45 ° of rotation or 150 mm (6 in), whichever is the less. Additionally, any longitudinal welds in horizontal pipes shall also be so positioned that the weld is at the upper segment of 120 ° of the pipeline. Circumferential welds shall be separated by at least 4 times the nominal wall thickness (toe to toe). Attachments shall be at least 2 times the nominal thickness or 40 mm (1.5 in) (toe to toe) from any weld, whichever is the smaller.

4.7.4.3

Permitted Weld Detail All vessels, process piping and other equipment main pressure retaining joint welds shall be fabricated with full penetration butt welds unless otherwise specified. Two-sided welding shall be applied whenever practical. Permanent backing strips or rings shall not be used unless approved. Temporary backing devices (e.g., ceramics, fluxes, copper backing strips, etc.) may be used provided that the chemical composition of the weld metal is not influenced by the backing strip. The strip shall be removed without damage to the surrounding material. The areas involved shall be ground flush and cleaned after removal. Welds of low-alloy ferritic steels shall be inspected by MT after the removal of the metallic backing strips or other temporary weldments, with acceptance criteria in accordance with the design code. Fusible inserts or removable backing strips may only be used with the approval of the Principal.


ECCN EAR99

4.7.4.4


Tack Welding and Clamping Tack welding is to be carried out following the root parameters of the qualified WPS and be performed by qualified welders. If tacks are applied using bars, bullets or bridges, these components shall be of the same nominal composition of the base material. The tacks shall be equally spaced around the circumference and in sufficient number to temporarily support the loads from the process piping, equipment or fitting. Tack welds intended to be an integral part of the root weld shall be ground to a taper edge to facilitate weld pick-up. Cracked or badly profiled tack welds are to be completely removed prior to welding. If line-up clamps are used without tack welding, they shall not be removed until after the root pass has been fully completed. Permanent tack welds shall be made in accordance with all parameters of welding procedures requirements (e.g., including preheat) by qualified welders. All tack welds shall be examined in accordance with design specification. VT inspection is mandatory in all cases. On pressure vessels with skirts, no tack welds are permitted on the inside of the skirt between the head and the skirt.

4.7.4.5

Alignment When not specified in the piping code or purchasing specification, the permitted maximum misalignment for butt welds shall be: Internal Pipe Diameter

Misalignment

= 100 mm (4 in)

1.0 mm (0.04 in)

> 100 mm(4 in)

1.6 mm (1/16 in)

External Pipe Diameter

Misalignment

≤ 12 mm (0.5 in)

Pipe thickness/4

> 12 mm(0.5 in)

3.0 mm (1/8 in)

For vessels and other equipment, misalignment shall be in accordance with the design standards. Misalignments greater than these limits may be corrected by grinding or machining to a taper of 1:4 provided the wall thickness is not reduced below the minimum tolerance. Reforming of process piping vessel walls or other equipment, either hot or cold shall not be attempted without the approval of the Principal. 4.7.4.6

Identification Welds are to be uniquely identified. The Contractor shall demonstrate to the satisfaction of the Principal that individual welds can be positively identified at all stages of construction. Weld identification numbers shall be marked adjacent to the weld by crayon, paint stick or similar marker prior to welding. The Contractor shall maintain records of weld number and the welder identification for each weld for inclusion in documentation package. Particular attention shall be given to maintaining identification during grit-blasting and painting. Similarly, welders shall mark their numbers adjacent to each weld they make.


ECCN EAR99

4.7.5


Quality Assurance The Contractor shall have an established, active and documented quality assurance system in accordance with the applicable ISO 9000 series standards as defined elsewhere in the order. These requirements shall be applied in full to the Subcontractor. The Principal may make any investigation necessary to assure compliance by the Contractor and may reject any material or work processes that do not comply with the specification. Full compliance with this specification does not relieve the Contractor from the obligation to carry out additional tests at the discretion of the inspector representing the Principal in the case that serious doubt has arisen about certain quality aspects of the Work. If required by the Principal, the Contractor is required to issue a signed statement of compliance confirming that the product has been fabricated in accordance with the requirements detailed in the purchase order.

4.7.6

Quality Conformance Prior to commencement of work, the Contractor shall submit for the Principal’s review and approval, a Quality Plan and procedural specifications, which shall be in accordance with the relevant clauses from ISO 3834 or equivalent. Fabrications shall be accepted after the Contractors submits satisfactory reporting on production welding and inspection activities. Review of the Quality Plan by the Principal shall only indicate a general acceptance and does not relieve the Contractor of obligations to comply with the requirements of the Contract.

4.7.7

Alloy segregation Prior to welding, the Contractor shall submit with the Quality Plan, a procedure for the segregation of all materials in the work scope and control of the tools to be used with them. The shop fabrication of stainless steel and other non-ferrous process piping and equipment work shall be carried out in a separate area from that of Carbon-Manganese and low alloy steels. Alternatively, fabricators might submit to the Principal for approval a procedure to avoid surface contamination. Titanium welding shall be carried out in a fully enclosed quarantined area dedicated to Titanium fabrication.

4.7.8

Inspection and Testing Plan (ITP) Before start of welding and fabrication, the Contractor shall prepare a test package containing Inspection and Test plan and procedures to be employed in the project and shall be submitted to the Principal QCS Engineer through the project group for review and approval. The Contractor shall maintain records showing the weld defect rates per welding procedure and per welder. For piping, rejection rates are based on the number of completed pipe welds. A rejection is considered to be any weld that requires a repair. The rejection rate will be defined as the number of repairs per number of completed welds. For equipment, the rejection rate is based on the total linear weld distance on a per-metre (or per-foot) basis. A rejection is considered to be any weld that requires a repair within a one-metre segment. The rejection rate will be defined as the number of repair segments per total number of one-metre segments.

4.7.9

Records Pre-Welding Documentation shall include the following: 1. Quality plan, ITP and QA/QC procedures 2. Weld plan/map 3. Approved WPS/PQR repair procedures 4. Preheating and PWHT Procedures per Section 3.9 5. Welder qualification register and identification cards copy


ECCN EAR99


6. List of NDE operators and their qualification certificates 7. Copies of the Principal approved deviations 8. List of material certificates 9. List of consumable batch certificates 10. List of test equipments and calibration certificates 11. Approved Consumable handling procedure 12. If required by the Principal, Original copy of the WPS proposal, endorsed ‘Approved for Qualification’ Add new 4.8 4.8

During Welding

4.8.1

Shop and Site Conditions / Weld protection Field welding shall be carried out in conditions, which will not result in negative effect on weld quality. The Contractor shall propose and the Principal review the methods and precautions (e.g., heating and shelters), which shall be used to ensure good quality of welds. Such precautions shall be applied in case of rain or snow. When the base metal temperature is below 5 °C (40 °F), both sides of the weld preparation shall be preheated to a temperature of approximately 50 °C (120 °F) or the preheat temperature prescribed in the WPS, whichever is higher. When fabrication is to be carried out in the vicinity of plant or equipment, which may be damaged or otherwise compromised by such planned construction work, i.e., weld spatter, cutting droplets, fumes, grinding dust, etc., then adequate protection shall be provided for this ancillary plant and equipment. The use of tent type enclosures shall be subject to approval by the Principal but such approval may be withdrawn at any time that the enclosures become inadequate or ineffective.

4.8.2

Weld Integrity and Quality

4.8.2.1

The backside of double-welded joints shall be cleaned to sound metal and examined 100 % visually, and by PT or MT as specified in the design documents or corresponding to joint efficiency.

4.8.2.2

Starts and stops - Weld starts and stops shall be situated in the fusion path, i.e., no start and stops to be located on the base metal during the final weld layer. However, finishing weld on the bevel of the base metal is acceptable. When welding is interrupted (i.e., after a power failure), the welder shall ensure full fusion and penetration into the previously deposited weld metal. Starts and stops should be staggered.

4.8.2.3

Weld surface and finish - When a smooth surface is specified in the design documentation, the fabricator shall submit a sample of a smooth weld surface, for the Purchaser's acceptance prior to the start of welding. The accepted sample shall be used as a reference for visual examination of welds that require a "smooth weld surface". Undercut is not acceptable. All welds must be finished with a smooth profile, abrupt ridges or valleys, and they shall blend smoothly with the base material. If fillet welds are concave, or not equal, the minimum throat size shall not be less than 0.7 x the specified leg length. For “olet” branch fittings, the root profile shall be as specified for full penetration butt welds. The contour of completed welds shall be as shown in Figure 1 of this specification, unless the Principal advises or approves that the design requirement can be met with a smaller weld.


ECCN EAR99


If restricted by the Principal, toe profile grinding or cosmetic grinding shall only be carried out when directed by the design drawings or by the Principal. B A

A

B

PWHT if t 4B t 38mm

Sec ion 'A-A'

Section 'B-B'

(illu5580480)

Figure 1—Weld Profile - Weldolets 4.8.2.4

Fillet welds in vibrating service, as specified in the design documents, the initial pass shall have a convex profile whereas the final weld shall have a concave profile. The minimum throat-size shall not be less than the value specified on the design documents and maximum effective weld size should be used for vibrating service. If necessary, this requirement shall be achieved by blend grinding.

4.8.3

Stray Arc Strikes Arcs shall be struck only on fusion faces (in the fusion path) or previously deposited weld metal. Any erroneous arc strikes shall be removed by grinding or other suitable method and the area shall be subject to surface inspection (MT or PT) to ensure continued freedom from defects. The thickness of material remaining after the removal of such defects shall be measured. If this measurement reveals loss of wall thickness below the minimum required thickness, then the item shall: 1) be replaced or 2) weld repair only if permitted with agreement of the Principal. Weld repair of such areas shall not be permitted. The Contractor shall ensure a good earth connection and periodically examine the condition of the earth cables and attachments. Any arcing from a poor connection shall be treated as a stray arc strike. Connections shall be made to the work by stainless steel clamps. Earth cables shall not be welded to piping components.

4.8.4

Records A daily record of all cutouts, repairable defects and repairs shall be maintained by the Contractor and copies shall be available to the Principal’s representative upon request. Detailed records of all weld numbers and pipe numbers, including weld repairs, shall be maintained by the Contractor for each and every weld as it is completed. The records shall include identification serial numbers; the position of the weld; date; qualified procedure reference number; welders’ names and reference numbers and include cross references to all inspection sheets and test records. The format of the records, the information to be included and the frequency at which they shall be submitted for Principal approval shall be agreed between the Contractor and the Principal beforehand.


ECCN EAR99

4.8.5


Calibrated Equipment For Measuring the Following Variables Shall Be Available At All Times: 1. welding current (amperage); 2. arc voltage; 3. interpass temperatures (digital); 4. oxygen content of backing gas; 5. wire feed speed; 6. travel speed (A wrist watch with a second hand or seconds display and common ruler or tape measure may be used); and, 7. shielding and backing gas flow rate.

Add new 4.9: 4.9

After Welding

4.9.1

Weld Inspection Inspection of welds shall be carried out after final heat treatment. Inspection before final PWHT is considered a good practice but will not be enforced unless the Principal requires it. Inspection shall be done in accordance with the ITP (Inspection and Test Plan).

4.9.2

Repair of Welding Defects If required by the Principal, repair preparation, remedial grinding and repair welding shall not commence before informing the Principal of the Contractor’s proposed remedial actions. A second attempt to repair the same weld area shall only be made by permission of the Principal. Where permission for a second repair is not given, the whole weld is to be removed. If back purging was required for the original weld, then back purge shall be re-established if the repair excavation encroaches closer than 5 mm (0.2 in) to the inside surface of the vessel, process piping or equipment. Welds containing repairs that were made after PWHT shall be subject to repeat PWHT in accordance with this Specification, unless otherwise approved by the Principal. If required by the Principal a separate PQR shall be prepared to demonstrate acceptable mechanical properties with extended PWHT time.

4.9.2.1

Defect Removal Unacceptable defects in steels shall be excavated by mechanical means or carbon arc gouging to a depth agreed with the Principal followed by grinding. Unacceptable defects in non-ferrous materials shall be excavated by mechanical means only. The excavation shall be contoured to permit proper access for welding. For planar or other defects not detectable by visual inspection or dimensional checks, MT or PT surface inspection techniques shall be used to confirm removal of welds defects. Materials that require preheat for welding will require adequate preheat for defect removal.

4.9.2.2

Root Repairs Where access permits and if approved by the Principal, weld repairs to the root of a single sided weld may be permitted from the inside.

4.9.2.3

Complete Weld Metal Removal and Subsequent Re-welding When complete removal of the defective weld metal is required in impact-tested materials or as required by the Principal, it shall also include the removal of at least 5 mm (0.2 in) of HAZ/parent metal on each side of weld. For non-impact-tested materials, cutout and re-preparation is allowed once.


ECCN EAR99

4.9.2.4


Non-Destructive Testing All repair welds are to be 100 % re-inspected by the methods specified for the original weld and shall extend a minimum of 50 mm (2 in) beyond either side of the repair.

4.9.2.5

Repair Procedure The Contractor shall submit to the Principal for approval a general repair procedure detailing: 1. The method of defect excavation; 2. The shape and size of excavation prior to re-welding; •

Cap repair

•

Mid thickness repair

•

Through thickness repair

1. All inspections prior to re-welding; 2. The WPS and WPQR, if different from original weld. The repair WPS shall be qualified in accordance with this specification. When required by the Principal, the Qualification shall require the reproduction of a typical production repair. When required by the Principal, full penetration and partial penetration excavations shall be qualified separately. The acceptance criteria for mechanical testing of repair welds shall be the same as the original weld. The repair WPS shall be supported by appropriate PQR. The repair PQR shall be qualified by carrying out mechanical and NDT tests – same as specified for the original PQR. Separate WPS’s might need to be prepared for the weld repair of each defect found after NDT inspection of shop or field welds as required by the applicable repair code. 4.9.2.6

Repair Limitations When cracks are observed, the cause shall be investigated. Based on the result of the investigation, a crack repair procedure shall be developed and approved by the Principal prior the crack repair. For partial penetration repairs, the total length of excavation shall not exceed 30 % of the weld length. For full penetration repairs, the total length of excavation shall not exceed 20 % of the weld length. A repair with dimensions greater than described above shall be considered and addressed as a highly restrained weld per 4.7.2. For partial wall excavations, the remaining ligament adopted for the test weld shall be the smallest allowed in production.

4.9.3

Records Post-Production Documentation 1. Certificate of Compliance 2. List of as build drawings with weld map 3. Copies of Principal approved deviations 4. NDE reports 5. Repairs carried out 6. Hydrostatic test reports 7. Any other documents as per contract requirements.

5

Welding Processes


ECCN EAR99

5.1


Acceptable Welding Processes Add the following to 5.1: b): GTAW-HW (Hot wire) Add new: j) EBW k) LBW

5.2

Limitations of Fusion Welding Processes

5.2.1

General Add the following to 5.2.1: Use of autogenous root pass (without addition of filler metal) requires a specific acceptance by the Principal. If welding without backing gas is planned on steels having over 2¼ % Cr content, examination of the root pass for signs of excessive oxidation should be part of all acceptance tests.

5.2.2

GTAW-P Add the following to GTAW-P: General - All GTAW machines shall be equipped with arc starting devices (high frequency, lift arc, crater eliminating slope out control, etc.). If legislative bodies do not permit these, alternative proposals shall be submitted to the Principal for approval. Scratch starting is strictly prohibited. Unless otherwise approved by the Principal for welding of small-bore pipe work (DN 75 (NPS 3) and smaller, GTAW shall be used for the root pass. If required by the Principal, DN 75 (NPS 3) and smaller diameters shall be welded with GTAW throughout. As a minimum, all pipe 40 mm (1.5 in) or lower shall be welded with GTAW.

5.2.3

GMAW-S Add the following to 5.2.3(e): Adaptive GMAW such as STT (Surface Tension Transfer), RMD (Regulated Metal Deposition) , ESAB QSET (optimal short arc parameters settings) and CMT (Cold Metal Transfer), if used without a backing gas, should be avoided on the following equipment and piping: 1) Materials other than CS, 304 SS and 316 SS. 2) Equipment with normal operating temperatures over 450 °C (850 °F). 3) Services with high corrosion or pitting potential such as oxygen, chloride containing low pH water. 4) Services that require special quality root finish (e.g., no oxides). These restrictions might be waived if the welding procedure qualification (mechanical and corrosion tests) shows required properties can be achieved without the use of a backing gas.

5.2.5

FCAW Add the following to 5.2.5: Shops that will perform FCAW shall be approved individually, based on merits, experience and track record with FCAW.


ECCN EAR99


Add the following to 5.2.5.1: Additionally, FCAW-S shall not be used for welding structural items to a pressure/containment boundary. It is not permitted for lifting lugs or similar lifting devices, or tank floor plates. Add the following to 5.2.5.1(b): The electrode specified minimum impact requirements must be demonstrated by testing in the PQR. Add new 5.2.5.6 a) Production welding consumables shall be limited to the same manufacturer brand/trade name as used in the procedure qualification record. The fabricator QC process shall demonstrate how welding consumables are controlled. •

Electrode types identified by the consumable Manufacturer for multi-pass application should be used.

•

Electrodes of type T-12 or T-5 are preferred. T-1 electrodes are acceptable, but only if required impact properties can be demonstrated. A maximum niobium (Nb) content of 0.02 % shall be specified (and reported) in consumable purchases when a T-1 type electrode is selected to avoid low toughness properties.

•

Type EXXT-XX-J electrodes should be specified if the application specifies a toughness requirement 27 J (20 ft-lbs) at -40 °C (-40 °F).

b) For ferritic steels, all WPS/PQRs shall be qualified with impact testing. Impact testing of a minimum of three Charpy V-notch specimens will be performed at -18 °C (0 °F) or lower or code required temperature for testing, whichever is lower, and must demonstrate an average impact energy of 40 J (30 ft-lb), with no single specimen less than 27 J (20 ft-lb). c) For ferritic steels in non-sour service, in addition to code requirements the WPS/PQRs shall be qualified with a hardness traverse per API RP 582, paragraph 12.6 using Vickers hardness testing equipment (ASTM E92). The maximum permissible hardness for procedure qualification of P-1 steels will be 275 HV10. For sour service, NACE MR0103 or ISO 15156 hardness requirements will apply. Other traverses may be submitted for consideration by the Principal. d) Welder qualification – Each welder is to be qualified by mechanical testing. Mechanical testing shall also include Brinell hardness testing on each side of the welded coupon (root and cap surface) with an acceptance value of 200 HBW. Hardness results will not be accounted to pass/fail a welder but only to add data points on FCAW hardness. The Principal shall be informed if any hardness reading is greater than 200 HBW. Radiographic testing of welder coupons or production welds shall not be used in lieu of mechanical bending tests of coupons. e) Production welding – Required hardness testing: For the FCAW process, the hardness limit for the carbon steel welds is 200 HBW. Weld metal hardness testing (HBW with Telebrineller) will be performed on the 0.5 m (1.5 ft) of the first five welds made by each welder. Welders with (excessive hardness) rejection rates higher than 2 welds should have additional training before continuing production welding. Also, the quality of the electrode and shielding gas should be reviewed. After satisfying this first testing requirement, random hardness readings will be taken on the remaining welds (measurements are done at least on 20 % of girth welds on piping or one measurement per seam on pressure vessels category A and B welds, spaced no more than 6 m (20 ft) apart). Welders with (excessive hardness) rejection rates higher than 10 % based on 20 readings (minimum) should have additional training before continuing production welding. Only one welder per section of weld seam may be tested. Production hardness testing of P-8 base metal welds is not required.


ECCN EAR99

f)

DEP 30.10.60.18-Gen. February 2012 Page 23 The work area shall be shielded from excessive crosswind ventilation.

g) No vertical down progression is allowed. h) FCAW is not permitted on root pass, except when root weld is back-gouged. i)

The use of short circuit transfer mode is not permitted.

j)

FCAW wire shall be stored in a dry location while still in the original package according to the following table: Ambient Temperature °C (°F)

Maximum relative humidity (%)

15-21 (60-70)

80

21-27 (70-80)

60

27-32 (80-90)

45

32-38 (90-100)

30

Only new FCAW coils in the original, undamaged packaging can be used for pressure retaining weld welding. The electrodes should be used within a shift after opening the package. Upon opening the spool, it should be marked with the date by when it should be spent or discarded. All wires having diffusible hydrogen “H” rating shall be treated in strict conformance with the Manufacturer’s instructions. Opened electrode mounted on wire feeders should be protected against condensation. Oxidised electrodes shall be discarded. k) FCAW wire shall be clearly identified. The identification shall be in compliance with the relevant consumable standard. Unidentified or rusty wire shall not be used. l)

FCAW welds shall be subjected to NDE examination in accordance with the P.O. specifications/Construction Class rating of a given equipment. Absolute minimum NDE coverage of FCAW-G pressure retaining welds shall correspond to the ASME/BPVC Sec VIII “spot RT” rules unless higher/more intensive examination is specified in the P.O. documents in which case such a specification shall govern.

m) When FCAW-G is proposed for welding P1 through P5 and P15 materials on equipment with design temperatures over 350 °C (650 °F) or below -29 °C (-20 °F), and when required by the Principal, special submission of evidence demonstrating prior experience and documented performance is required prior to acceptance by the Purchaser. This experience should include a list of past projects and number of completed welds and corresponding rejection rates. n) Seamed flux-cored wires shall not be left on machines out of use for more than a shift. 5.2.6

EGW Add new: (d) Unless otherwise more strictly specified, all PQRs for the EGW process shall be qualified with impact testing at a temperature of -18 °C (0 °F). (e) If multiple-pass vertical welding butt joints are made by the electrogas process, the impact specimens shall be taken from the final weld pass except when the heat input of the first pass exceeds the second pass by more than 25 %. In such cases, impact specimens from the first and final pass will be required. In either case, the HAZ specimens shall be oriented with the base of the notch parallel to the fusion line.

5.2.7

SAW

Add new 5.2.7.4: 5.2.7.4

Only fully mechanised SAW systems are permitted.


ECCN EAR99


Add new 5.2.7.5: 5.2.7.5

SAW shall not be used for repair welding of pressure vessels, storage tanks or pipelines without written approval from the Purchaser for each individual repair.

Add new 5.2.7.6: 5.2.7.6

Run-on/off pads – Run-on and run-off pads shall have the same P- Number as the base material.

Add new 5.2.7.7: 5.2.7.7

When SAW is used for weld overlay the targeted dilution in the weld deposit is 14 % - 19 % (strip electrode).

Add new 5.2.8: 5.2.8

SMAW

5.2.8.1

Where it is desirable for a tank fabricator to use E7024 and where E7024 electrodes are permitted by API 650, E7024-1 shall be used. E7024 shall only be used for flat and horizontal fillet.

Add new 5.2.9: 5.2.9

ESW ESW welding is permissible for overlay applications only. All ESW welding shall be fully qualified to ASME/BPVC Sec IX or other equivalent jurisdictional code using the same brand consumables as those proposed for production welding. Single layer overlay is acceptable when approved by the Principal. Target dilution of this overlay process is 9 % - 14 %. Thickness of deposited pass should not exceed 5 mm (0.2 in).

6

Welding Consumables (Filler Metal and Flux)

6.1

General Add the following to General: AWS A5.01 or equivalent ISO document should be used for filler metal procurement. All welding consumables shall have specified or actual mechanical properties equal to or greater than the material being welded and chemical analyses values under their various international classifications, unless otherwise specified. Synthetic consumables - The Manufacturer shall be aware as to whether proposed filler metals/electrodes contain principal alloying elements in the metal or in the flux or electrode coating. If “synthetic” filler materials are proposed, i.e., consumables which rely on principal alloying elements transfer from flux, metal powder core or coating to develop the required weld deposit chemistry, the Manufacturer shall specifically identify all proposed “synthetic” filler materials as such. In cases where closely controlled weld deposit chemistry has been specified, such as X-bar or similar chemistry restrictions, the Manufacturer shall indicate the alloying elements being transferred from the flux and sensitivity to welding parameters/probable weld metal composition variation which may develop when welding with such consumables. Use of synthetic consumables shall be reviewed and accepted by the Principal. Compliance with PQRs - For the processes, materials and/or conditions listed below, production welding shall be performed using the same welding consumable Manufacturer brand names and classifications as were used for developing the supporting PQRs. The use of different consumables, regardless of equivalency based on SFA specification, requires additional retesting or re-qualification as specified below: a) For all welding processes, when the normal operating temperature of P4 through P7 material exceeds 350 °C (650 °F) and weld metal chemistry controls have been


ECCN EAR99

DEP 30.10.60.18-Gen. February 2012 Page 25 imposed; or

b) when impact tests below -46 °C (-50 °F) have been imposed by code or design documents. Consumables shall be supplied by a Manufacturer accredited to ISO 9002 or an equivalent quality. When alternative consumables are required, e.g., when improved corrosion resistance is necessary, then these will be specified by the Principal prior to procedure qualification. Filler metals proposed for use in dissimilar base metal combinations shall be agreed upon with the Principal for each specific design case if the combination is not covered in API RP 582. Add the following to 6.1.1: Consumable Certification As a minimum, welding consumables shall be delivered in accordance with their product data sheet and shall have certification including chemical analysis according to EN 10204, Type 3.1 or AWS 5.01. Each consumable, or consumable batch, shall have individual marking relative to its certification. Batch testing of the welding consumables is also acceptable. In such case, welding and testing shall be carried out in accordance with a typical welding procedure specification and certification presented in the format of a WPQR. Production material or an equivalent parent metal specification shall be used for such product certification. Fluxes for submerged arc welding processes shall be delivered with certification according to EN 10204, Type 2.2, or AWS A5.01. Other options may be approved by the Principal. If required by the Principal, Welding consumables shall be purchased from Manufacturers who are currently acknowledged by bodies, which independently test consumables, e.g., Controlas, Lloyd's Register of Shipping, American Bureau of Shipping and Det Norske Veritas. Welding consumables DEP 30.10.02.31-Gen.

for

low

temperature

service

shall

also

comply

with

All consumables shall be identified on the WPS by their AWS classification or EN / ISO designation, depending on the design code. Welding fluxes shall also be specified including the Manufacturer and type. 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

For general service (those not defined below), the minimum FN (Ferrite Number) for deposited weld metal should be 3 FN except for the following (FN shall be measured prior to PWHT). a) The minimum FN for Type 347 weld deposits shall be 5 FN. The minimum FN may be reduced to 3 FN provided the fabricator submits data verifying that hot cracking will not occur using the lower FN consumable to be used in production and this is approved by the purchaser. b) When joining stainless steels for cryogenic service, non-magnetic applications, or special corrosive service, weld deposits with a lower FN down to zero may be required to obtain the specified material properties. When FN is below 3 %, additional precautions should be implemented to prevent solidification cracks. The fabricator should prepare a written procedure for Principal approval. c) The FN for 16Cr-8Ni-2Mo weld deposits shall be 1-5 FN.


ECCN EAR99


d) Some filler metals such as E/ER320 or E/ER310 may not have measureable ferrite. These cases shall be submitted for approval by the Principal. Add the following to 6.4.2.4: For normal operating temperatures over 450 °C (840 °F) or if PWHT of the weldment is specified such as stress relief, stabilisation heat treatment or solution annealing heat treatment filler metal selection shall be specifically reviewed and accepted by the Purchaser. In hot service - In case of welding with E347- xx or ER347 filler or other Nb stabilised filler metal. The minimum Nb content shall be % Nb = 0.093 %+ 7.7(% C-0.013) + 6.6(% N-0.022) or Nb/C = 13.5 whichever is higher for applications above 500 °C (932 °F) and wall thickness above 14 mm (0.55 in). Nb/C = 12.6 for applications below 500 °C (932 °F) and lower thickness. Liquation Number Ln <30 for FN>8 Liquation Number 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 measurements - The Manufacturer shall submit a ferrite measuring procedure for Purchaser review and acceptance. The procedure should consider the following: •

List of welding procedures

•

Intended services

•

Ferrite control on filler metals (MTRs, weld test pads+wet chemistry or OES analysis) and weld production predictions based WRC-1992 diagram.

•

Ferrite control on production weld deposits. Only ferritoscope and wet or OES chemistry analysis on production welds are acceptable methods.

Add new 6.4.2.6: 6.4.2.6

For stabilised stainless steel weld metal, and for any A-8 weld metal with a design temperature less than -29 °C (-20 °F) or higher than 450 °C (840 °F), 100 % ferrite checking, one per weld or one per each metre (3 feet) whichever is higher, of all accessible welds (butt and fillet) shall be required. The Principal might approve other options, whenever ferrite cannot be measured due to accessibility problems.

6.5

Duplex Stainless Steel Welding Add the following to 6.5.1: Ferrite measurements - The Manufacturer shall submit a ferrite measuring procedure for the Principal’s review and acceptance. The procedure should consider the following: •

List of welding procedures

•

Intended services

•

Ferrite control on filler metals (MTRs, weld test pads+wet chemistry or OES analysis) and weld production predictions based in constitutional diagram and cooling rates.

•

Ferrite control on production weld deposits. Only ferritescope and wet or OES chemistry analysis on production welds are acceptable methods. In case of single side welded joints with GMAW and GTAW the ferrite measurement shall be done on the root side of the weld where accessible.


ECCN EAR99


Add new 6.5.4: 6.5.4

When welding duplex stainless steel, consumables shall meet the requirements listed below. In addition, consumables for grade UNS S32205 shall meet the chemical composition requirements shown in the table below. 1) SAW flux shall be a basic flux. 2) Filler metal(s) and flux used for the procedure qualification shall be of the same type and brand as used in production. Element

Minimum Chemical Composition

Nitrogen

0.14 %

Nickel

8.0 %

Molybdenum

3.0 %

Add new 6.5.5: 6.5.5

Welding consumables for super duplex stainless steel shall have chromium content at least 25 % and the nickel content shall be minimum 9 % and the nitrogen content shall be at least 0.15 % - 0.2 %. The PREN (PRE = %Cr + 3.3.MO + 16 %N) of the filler material shall be higher than minimum specified for the base material. For welding of SDSS material, welding consumable of SDSS shall be used. All welding consumables shall be a low hydrogen type, i.e., 10 ml/100 g of weld metal.

Add new 6.5.6: 6.5.6

Inspection documents for the welding consumable materials shall be in accordance with ISO 10474, Type 3.1 or AWS A5.01. All welding consumables shall be identifiable to batch certificate. Unidentifiable welding consumables shall not be used.

Add new 6.5.7: 6.5.7

SMAW consumables shall be handled as low-hydrogen consumables to avoid hydrogen cracking in the ferritic phase of DSS. Use -H10 or lower (<10mg/100l).

Add new 6.5.8: 6.5.8

If the Principal approves, Ni based alloy filler metals might be used.

6.6

SAW Add the following to 6.6: For 2¼Cr-1Mo-V and P91 steels requiring use of the same brand of consumable, appropriate re-testing to demonstrate the controlled quality or performance parameter is required whenever the consumable Supplier has changed the formulation of the filler metal or the flux or if the Supplier has changed sources of raw materials or if the qualification is more than 10 months old. Flux from re-crushed slag shall not be used. Submerged arc flux may be recycled but it shall be free from fused slag, mill scale, dirt or other foreign matter. Recycled flux shall be treated in accordance with the flux Manufacturer recommendations. SAW fluxes shall not be left in machine hoppers for extended periods, when welding is not being carried out, e.g., overnight or during non-productive shifts. Recycling of flux shall only be allowed if the procedure is endorsed by the consumable Manufacturer and by the Principal. Submerged arc flux shall be supplied clearly identified in moisture-proof containers and shall be stored in a dry location per the Manufacturer instructions. The identification shall be in compliance with the relevant consumable standard.


ECCN EAR99


Unless otherwise stipulated by the Manufacturer of the flux, submerged arc flux may be recycled but shall be free from fused flux, slag particles, mill scale, dirt or other foreign matter. Before re-use, the flux shall be re-baked in accordance with the Manufacturer's instructions. 6.7

Electroslag Welding (for Corrosion Resistant Weld Overlay) Add the following to 6.7: Single layer overlay with austenitic stainless steel consumables is acceptable (refer to para 5.2.9 above) when the Manufacturer can demonstrate experience with successful applications and is approved by the Principal. WPS shall indicate the thickness of the non-diluted chemistry of the overly. Overlay thickness should not exceed 5 mm (0.2 in). Parameters controlling magnetic field/control of the process shall be included in the WPS and be monitored during welding. Multi-layer systems are most of the time better if absolute protection of the substrate is required.

6.8

Consumable Storage and Handling

Add new 6.8.4: 6.8.4

Extra moisture resistant (EMR) consumables with a diffusible hydrogen content of less than 4-5 ml/100 g may be used without preheated storage for a period of maximum 9 hrs. No electrodes shall be left lying about the site or in workshops. Electrodes so left shall be scrapped, as shall electrodes, which have damaged flux coatings. Submerged arc, gas metal arc and flux-cored wire shall be clearly identified and shall be stored in a dry location following the Manufacturer recommendations. The identification shall be in compliance with the relevant consumable standard. Unidentifiable and/or rusty wire shall not be used. Submerged arc, gas metal arc and flux-cored arc consumables shall be withdrawn from store only when required for immediate use. Unused consumables shall be returned to store on completion of the welding operation. Batch numbers shall be recorded in the fabrication records on issue. After issue from storage, fluxes shall be held in a heated silo following the Manufacturer recommendations. Low hydrogen welding consumables shall be stored upon opening, in heated storage areas under controlled temperature conditions recommended by the Manufacturer. The amount of low hydrogen consumables required for immediate use shall be placed in heated quivers. Non-EMR low hydrogen consumables, which have been out of the heated quiver for more than four hours shall not be used. Damaged electrodes or electrodes exposed to moisture, grease or other substances that will induce hydrogen or oxygen into the weld deposit shall be discarded. When consumables with AWS 5.20 hydrogen content rating of H4 or lower/better or vacpacs are specified, special QC procedure shall be prepared and certified to assure and demonstrate compliance with the Manufacturer handling requirements. Storage and baking of welding consumables shall be carried out in different ovens. Ovens shall be heated by electrical means and shall have automatic heat controls and visible temperature indication. The storage, baking, issue and return of welding consumables shall be controlled by procedures with documented records. The storage room shall have a maximum relative humidity of 50 %. Stored items shall be clearly identified with brand name, classification and batch number. Each batch of flux and wire shall be labelled with the information from the supply container. All bottles containing shielding gases shall have clear identification labels.


ECCN EAR99


Consumable handling shall be controlled by a procedure approved by the Principal. Storage shall be in accordance with the Manufacturer’s recommendations for the consumable type. Electrodes and fluxes shall be supplied in moisture-resistant-sealed containers and stored in controlled environment as recommended by the Supplier. Wire spools for automatic and semi-automatic processes shall be stored in original packaging preferably in cabinets. Flux shall be supplied and stored in accordance with the Manufacturer’s instructions. All non-identified, damaged, wet, partially used, rusty or otherwise contaminated consumables are to be discarded. Low hydrogen electrodes shall not be stored in heated cabinets containing electrodes of other types, such as rutile or organic type electrodes. Records of consumables shall be maintained to ensure an auditable trail from receipt, through pre-treatment, their issue to operators and return to stores so that their identity can be verified at any stage. For welding of heavy wall vessels (100 mm (4 in) and thicker), complete welding flux traceability to individual welds and their segments, shall be developed and maintained. Bare wire for automatic or semi-automatic welding, remaining from a partly used coil or spool, may be reused as new wire if it is promptly repackaged after use in new sealed containers and stored as a new consumable. Bare filler wire in coils or spools that have not been kept in sealed containers after use or have been contaminated with rust, grease or other debris, shall not be used. All wire that cannot be cleaned without damage to the surface, change in size or other damage that would adversely affect its use should be discarded. Consumables that cannot be identified to the satisfaction of the Principal shall be removed from the work site and any welds made with such consumables may be cut out and re-welded at the option of the Principal. Add new 6.10: 6.10

Carbon steel

6.10.1

Restriction of F1 and F2 filler – Welding electrodes classified as "F1" and "F2" in ASME/BPVC Sec IX shall not be used on pressure-retaining welds unless the Principal approves.

6.10.2

Restriction on “G” filler – Use of filler metals with “G” classification or any other filler with containing additional elements for de-oxidation (e.g., triple de-oxidised fillers) or which could cause hardening require specific review and acceptance by the Principal. PQRs qualified with this type of filler material will be always submitted with hardness tests done as specified in Section 12 of this Standard. Such consumables shall not be used for wet H2S or sour service designated equipment.

6.10.3

Using Low Hydrogen Welding Consumables When required by the Principal, low hydrogen welding consumables (H4 or better) shall be used on P1 materials when the thickness of a butt weld or the throat of a fillet weld exceeds 13 mm (0.51 in), or when welding on steels with tensile strength of 490 N/mm² (70 ksi) or higher or if equipment is designated for use in wet H2S/sour service. In case of SMAW process, E-6010 cellulose-type coated electrodes may be used for the root passes only on piping not intended for wet H2S/sour service.

6.10.4

E6010 Electrodes When permitted by the Principal, E-6010 electrodes may be used for root passes on mild and moderate wet H2S (sour) service. For severe wet H2S (sour) service, root passes


ECCN EAR99


should be deposited with GTAW process due to supplementary root bead quality requirements. GMAW is also acceptable provided these same root quality requirements are met. If E-6010 electrodes are used for applications requiring impact properties, the consumable must be demonstrated to show that it can achieve the required impact properties on its own. Cellulosic electrodes shall not be used for repair welding. 6.10.5

SAW Procedures for Carbon Steels (P1) SAW procedures for carbon steels shall utilise the wire and flux combinations recommended by the Manufacturer. The combination should not result in manganese and silicon build-up in the weld in excess of 1.65 % Mn and 0.80 % Si.

6.10.6

Basic Low-hydrogen Electrodes and Fluxes Basic low-hydrogen electrodes and fluxes shall give a weld metal deposit with a diffusible hydrogen content which shall not exceed 10 ml/100 g weld metal.

6.10.7

Testing Hydrogen Level The level of hydrogen shall be tested using the procedure in ISO 3690 if there is any doubt as to the welding consumable control level or if extra moisture resistance needs to be confirmed.

6.10.8

Shielded Metal Arc Welding (SMAW) Utilising Low Hydrogen Electrodes For P-No. 1 base materials having a specified minimum tensile strength ≤ 416 N/mm² (60 ksi), the root pass may be made using E-6010 or E-6011, whenever the SMAW process is permitted for the root.

6.10.9

Preferential Weld Corrosion If the Principal requires it for hydrocarbon service, consumables selected for internal root run (or internal capping run of a two sided weld), for butt joints, shall nominally match the chemistry of the parent metal. Deliberate alloying addition of up to 0.5 % molybdenum is permissible. Nickel (>0.3 %) or silicon (>0.5 %) additions shall not be permitted.

Add new 6.11: 6.11

Nickel Alloys SAW and SMAW consumables shall not be used where the main alloy additions are added through the flux. However, final alloy compositions may be achieved through supplementary additions in the flux to compensate for element losses during welding or to trim an appropriate alloy core wire analysis to that required. The shielding gas for GTAW shall be high purity Argon per AWS 5.32.

Add new 6.12: 6.12

Copper Alloys For GTAW welding of Grade CN102 (90/10), AWS 5.7 ERCuNi or BS 2901 Pt 3, C18 consumables shall be used. For other copper alloys, the consumables not listed in API RP 582 shall be agreed with the Principal. SAW and SMAW consumables shall not be used where the main alloy additions are added through the flux. However, final alloy compositions may be achieved through supplementary additions in the flux to compensate for element losses during welding or to trim an appropriate alloy core wire analysis to that required. The shielding gas for GTAW shall be high purity Argon per AWS 5.32.

Add new 6.13: 6.13

Titanium Alloys The composition of the minor constituent of the shielding or backing gas in a gas mixture shall not be changed by more than 10 %.


ECCN EAR99


Add new 6.14: 6.14

Nickel Steels

6.14.1

3.5 % Ni The following restrictions shall apply unless otherwise agreed with the Principal. a. SMAW consumables shall comply with class 7016C2L, 7018C2L, 8016C2 or 8018C2. b. The GTAW root pass of welds completed using SMAW fill shall use wires complying with AWS A5.28, ER 80S-Ni 2. c.

For welds to be completed using the GTAW process a Nickel wire complying with AWS A5.14, ER NiCr-3 shall be used.

d. For the more demanding applications alternative, nickel based filler metals such as AWS ENiCrFe-2 or EniCrFe-3 may be considered e. The brand name of the consumable shall not be changed. f.

Austenitic stainless steel consumables shall not be used.

g. ENiCrMO-4 or other nickel base alloys as approved by the Principle. Add new 6.15: 6.15

6 % Mo Superaustenitic Stainless Steels The brand name or country of origin of consumables shall not be changed unless approved by the Principal.

Add new 6.16: 6.16

P91 •

The following 9Cr-1Mo-V (B9) welding consumables specified in AWS and ASME specifications should be used: o o o o

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

•

E9015-B9-H4 electrodes are preferred for SMAW of grade 91. These electrodes have no extra iron in the coating and this eliminates a potential source of contaminants and potential increase in hardenability. Use of E9018 shall require prior approval from the Principal

•

Filler material requirements: o o o o

o o o o

Nb: 0.05 wt % max N: 0.04 wt % max Si: 0.2 - 0.3 wt % max Ni +Mn <1.5 wt % (For weld repair of forgings, the ASTM A182 specifies that the sum of the Ni+Mn content of all welding consumables shall not exceed 1.0 %) X bar <15 P : 0.01 wt % max S : 0.01 wt % max V : 0.20 wt % max


ECCN EAR99

7


Shielding and Purging Gases

Add new 7.7: 7.7

The use of soluble dams for minimising back purge requirement during piping fabrication shall be approved by the Principal. When dams are to be used on site, working procedures shall ensure removal after welding. Their application shall be in accordance with the Manufacturer’s recommendations.

Add new 7.8: 7.8

Titanium welds shall use a back purge of high purity argon per AWS 5.32, helium or argon/helium mix, as qualified during welding procedure qualification trials. The purge shall be maintained until the metal temperature drops below 500 °C (932 °F) after the completion of welding. Welds made in austenitic, nickel and copper-nickel alloys should have back purge maintained for a minimum of the root and second pass. Other options can be considered for approval by the Principal if the contractor provides sufficient technical basis. Welding 6Mo stainless steel requires that the purge be maintained for the first 3 passes.

Add new 7.9: 7.9

Prior to welding of austenitic stainless steels, nickel alloys and copper-nickel welds, the back purging shall be applied for a period long enough for the oxygen content of the exit gas to fall below 1.0 %. This shall be demonstrated during weld procedure qualification and production by means of a suitable oxygen metre. For other materials, unless otherwise advised in this specification, the oxygen content shall not exceed 0.5 % immediately prior to welding.

Add new 7.10: 7.10

Except when required for carbon steel, whenever argon is used as purging or backing gas during welding, it shall be of highest quality per AWS 5.32 with oxygen level less than 50 ppm.

Add new 7.11: 7.11

All bottles containing shielding gas shall be identifiable and shall be in a well-maintained condition without signs of external corrosion or rust on the body of the cylinder.

8

Preheating and Interpass Temperature Add the following to 8.3: Temperature indicating crayons shall be certified free of lead and sulphur (less than 1 ppm) or any other low melting point constituent. Residue from crayons shall be removed from the weld surface before proceeding with the weld. Thermocouple devices shall be regularly calibrated according to a procedure agreed with the Principal. Contact calibrated pyrometers may be used. Add the following to 8.3: Preheat temperature of CRA materials shall be read within the weld preparation or immediately adjacent. Add the following to 8.5 Table 4: Material Group

Maximum Interpass Temperature

P11A Group 1

175 °C (350 °F)

The maximum interpass temperature, unless otherwise established by procedure qualification, shall be 150 °C (300 °F) for 3½ % Nickel steel and 175 °C (350 °F) for Monel®.


ECCN EAR99


Add new 8.6 8.6

If required by the Principal, preheat requirements should follow EN 1011-2 guidance. For carbon-manganese steel, preheating is generally not required, unless condensation of moisture on the weld area is possible. In wet H2S services, preheat shall be in accordance with DEP 30.10.02.15-Gen. or DEP 30.10.02.17-Gen., as applicable. For all other materials, preheat temperatures shall be applied as specified in the applicable code. For 3½ % nickel steels, a minimum preheat of 100 °C (212 °F) shall be used for welding all thicknesses. Where reinforced branch fittings such as “olets” are to be welded, the minimum preheat is to be 50 °C (120 °F) above that indicated by the applicable code.

Add new 8.7 8.7

The guidance of WRC-452 for pressure vessels and AWS D10.10 for piping shall be followed. Preheat Application – For preheating temperatures below 200 °C (400 °F), fuel gas/air burner systems, high-velocity gas/oil burners or infrared radiators may be employed (either locally or in a furnace), or electric resistance, induction heating or infrared radiators may be employed. For preheating temperatures > 200 °C (400 °F), electric resistance, induction heating or infrared radiators may be used. Welding or cutting torches shall not be used. For wall thicknesses up to and including 19 mm (3/4 in), preheating shall be applied by burners or electrical resistance heaters. Above 19 mm (3/4 in), electric resistance heating mats, induction heating or infrared radiators should be used unless it is agreed with the Principal that access or location makes it impractical. Handheld oxy/fuel gas burners may only be used for welds less than 150 mm (6 in) OD or attachment welds less than 300 mm (12 in) long. Thermocouples shall be installed under resistance heater mats unless test trials prove the process will not expose the component to temperatures above the lower critical transformation temperature of the base metal alloy.

Add new 8.8 8.8

Interruption of Welding – Normally, the weld shall be completed before the preheat temperature is lowered. Lowering of preheat temperature is permitted for unalloyed steels (P1) with UTS of 450 N/mm² (65 ksi) or lower, or for steels with UTS of 490 N/mm² (70 ksi) when welded with low hydrogen consumables and with a welded thickness of less than 28 mm (1.1 in). At least 30 % of the weld joint thickness shall have been completed. The joint shall be slow cooled under insulation. Preheating shall be restored to the specified temperature before welding is recommenced. Other materials may allow for interruption of welding, but only as permitted by the applicable code and relevant industry standards, and as a minimum, the root and second pass shall be completed before it is permissible to interrupt welding progress and allow the joint to cool. If cooling has occurred and the completed weld ligament depth is less than 25 % of the total joint thickness, then the appropriate surface inspection (e.g., MT or PT) shall be performed to ensure freedom from deleterious defects.

9

Post Weld Heat Treatment (PWHT) Add the following to 9.1: Procedure Requirements As a minimum, the procedure shall include the following information: 1. name of (sub) Contractor; 2. ruling specification; 3. material and item type;


ECCN EAR99


4. method of heating (gas, electrical resistance, induction, furnace, etc.); 5. fuel gas and method of atmosphere control (if gas-fired furnace); 6. size and type of electrical element (if electrical resistance) and size and type of coils (if induction); 7. type, location and number of thermocouples; 8. method of thermocouple attachment; 9. details of loading and supporting arrangements to avoid distortion; 10. provisions to avoid flame impingement (if flame heated); 11. holding time and temperature; 12. heating and cooling rates; 13. type of recording equipment including number of channels; 14. chart speed. Add the following to 9.12: Wherever possible, PWHT shall be performed in a fully enclosing furnace. Fuel-powered furnaces shall have adequate flame controls to avoid an oxidising furnace atmosphere. Flame impingement onto PWHT items is not permitted. Unless specified by the applicable code, during heating and cooling, the temperature shall not vary by more than 150 °C (300 °F) in any 4.5 m (15 ft) length. The number of thermocouples shall be sufficient to ensure that the temperature and thermal gradients of the whole work are within the required range. One thermocouple shall be attached directly to each assembly at the point of greatest wall thickness. If a large number of small spools are to be heat treated in one batch, thermocouples may be attached to a representative number (no less than one in four) of the spools. Add the following to 9.12, Table 5 notes: Add New Note (d) (d)

For 9 % Ni, the entire vessel, assembly or plate must be at PWHT temperature at the same time. The cooling rate from the PWHT shall not be less than 167 °C (300 °F) per hour down to a temperature of 315 °C (600 °F). A local or partial PWHT cannot be used; because, it results in portions of the structure being in the embrittlement temperature range of 315 °C to 540 °C (600 °F to 1000 °F) for extended periods, which impairs the toughness of the material.

Add the following to 9.13: Local PWHT may be allowed where size or installation restrictions prevent furnace treatment. The guidance of WRC-452 for pressure vessels and AWS D10.10 for piping shall be followed. The full PHWT procedure must be submitted for review and approval by the Principal. Add new 9.15: 9.15

Recording and Reporting – As a minimum heating rate, holding time, temperature and cooling rate data shall be recorded. The temperature measured by each thermocouple should be recorded by means of a multi-channel chart recorder.


ECCN EAR99


Each PWHT cycle shall be verified by heat-treatment chart. Each chart shall be marked with the date of the PWHT, the weld or spool number(s), channel identification and signature(s) of Subcontractor personnel. A heat treatment report shall contain sufficient information to ensure traceability to the item(s) under treatment and confirm compliance with the approved procedure, including: 1. Identification of the component being PWHT. 2. Actual heating and soaking rates as recorded on the temperature chart. 3. Actual soak and withdrawal temperatures as recorded on the temperature chart. 4. Material dimensions and specification. 5. Applicable welding procedure specification number. 6. Project description/code. The report shall also contain an authorised signature confirming completion of works in accordance with design requirements. Completed charts shall be available for Principal review, together with the heat treatment report(s). All temperature measuring devices will have valid calibration certificates. Add new 9.16: 9.16

Thermocouple attachments – Thermocouple attachments should be: •

Capacitor discharge connection, or

•

Nut and bolt construction (as shown in Figure 2).

Figure 2—Thermocouple attachment If the latter method is used, the materials should be of a compatible composition and treated as a temporary attachment per Section 12.4. Other types of thermocouple attachments may be used with approval of the Principal. All thermocouple attachments shall be adequately insulated to avoid temperature misreading caused by the effect of radiation. The number and positions of the thermocouples shall be in accordance with the design code; and as a minimum at least 3 thermocouples shall be directly welded on the work piece, as indicated in Figure 3. Additionally, for a hollow configuration, there shall be one additional thermocouple on the inside.


ECCN EAR99

DEP 30.10.60.18-Gen. February 2012 Page 36 Figure 3—Thermocouple placement for full body heat treatment

Add new 9.17: 9.17

Service (Environmental) PWHT Requirements – In addition to any code requirements, the following process conditions are examples of environments that shall require PWHT for all carbon and low alloy steel welds of all thicknesses and shall be so indicated on the applicable equipment data sheet or piping/line designation table. 1. Caustic and ammonia service 2. HF service 3. Rich amine service irrespective of service temperature 4. Lean amine with operating temperatures above 60 °C (140 °F) or, if required by the Principal, lean amine irrespective of service temperature. 5. ANSI/NACE MR0175/ ISO 15156 specified severe sour service conditions 6. High pressure, high temperature hydrogen service (lethal hydrogen service) 7. Alkaline sour waters containing carbonates Holding times at designated heat-treating temperatures shall be a minimum of one hour per 25 mm (1 in) of thickness. When heat treatments are imposed because of environmental cracking concerns, combinations of longer-than-designated holding times at lower-than-designated heat-treating temperatures are not permitted.

Add new 9.18: 9.18

For quenched/normalised and tempered steels, the PWHT temperature shall be such to avoid an unacceptable decrease of mechanical properties of the parent material. PWHT temperature shall be at least 25 °C (50 °F) below the tempering temperature used during the manufacture of the base metal component and recorded on the material certificate. If the heat treatment needs to be performed within 25 °C (50 °F) of the tempering temperature, the mechanical properties shall be approved by the Principal and demonstrated with mechanical testing at the proposed temperature.

Add new 9.19: 9.19

Unless otherwise agreed, the PWHT cycle shall be designed in such a way as to allow for minimum two additional PWHT cycles in case weld repairs are required. Where conflict between this requirement and the base material temper develops, it shall be brought to the attention of the Principal for resolution. Note:

The Manufacturer is cautioned to purchase materials, which will allow the additional tempering cycles.

If additional PWHT cycles need to be applied on the material, additional production test coupons exposed to the same heat cycle are required to verify the mechanical properties stated in the PQR are maintained. Add new 9.20: 9.20

Procedures for PWHT of dissimilar metal welds shall be approved by the Principal.

Add new 9.21: 9.21

No welding or heating shall be carried out after final PWHT.

Add new 9.22: 9.22

If there is no subsequent machining operation, all threads and gasket surfaces shall be protected from oxidation while equipment is subject to heat treatment.

Add new 9.23: 9.23

Unless otherwise agreed with the Principal, all welds in AISI 4130 material shall be subject to PWHT.


ECCN EAR99

10


Cleaning and Surface Preparation Add the following to 10.6: If approved for use, the specific weld-through primer is considered to be an essential variable and shall be recorded on the PQR by type and brand. Add the following to 10.7: Wire brushes and grinding discs shall be dedicated to one material type and shall be free of sulphur or chloride containing elements.

Add new 10.9: 10.9

All surfaces to be welded shall be clean and free from paint, oil, dirt, scale, oxides and other foreign material detrimental to weld integrity. Cleaned zone shall extend for a minimum of 50 mm (2 in) on either side of weld.

Add new 10.10: 10.10

Welding of austenitic stainless steels and the high nickel alloys in contact with or in close proximity to zinc from paint or zinc-coated, copper or galvanised steels is to be avoided during fabrication and heat treatment. Protection from zinc droplets shall be provided to these alloys, if flame cutting or welding of galvanised parts must occur nearby.

Add new 10.11: 10.11

If required by the Principal, filler wires shall be cleaned with stainless steel wool and solvent. Cleaned filler wires shall only be handled by welders using clean gloves that have been used for handling only one material type. On completion of fabrication, the Contractor shall clean the inside and outside of all fabricated assemblies of all loose material, scale, slag and weld spatter. Where applicable, wooden or plastic covers shall be provided to protect weld bevels from mechanical damage and prevent ingress of foreign material into the vessel, piping or other process equipment.

Add new 10.12: 10.12

All finished welds shall be visually examined. For stainless steel welds, the weld acceptance shall be as per applicable code or standard such as AWS D18.1 and DEP 30.10.60.31-Gen. Unless waived by the Principal, welds showing oxidation in excess of specified limits shall be acid pickled and passivated; and if severe oxidation is noticed, the weld shall be cut out and re-welded.

Add new 10.13: 10.13

9 % Nickel Steel

10.13.1

Machine or grind thermally cut edges of material to remove dross and burn serration.

10.13.2

Sandblasting or other adequate means must be used to remove mill scale from all surfaces of material that are to be in contact with a refrigerated liquid or vapour before welding. Sandblasting or other adequate means is required to remove slag from the first welding pass if coated electrodes are used.

11

Special Procedure Qualification Requirements/Testing

11.1

General

Add new 11.1.4: 11.1.4

WPQR Non-Destructive Testing When required by the Principal, the following requirements apply:


ECCN EAR99

o

DEP 30.10.60.18-Gen. February 2012 Page 38 NDE shall be performed. Visual Butt Welds

MT ferrous materials or PT for non-ferrous materials Radiography Ultrasonic

Fillet Welds

Visual MT ferrous materials or PT for non-ferrous materials

o

Visual examination of the completed weld shall be conducted by both the Contractor and the Principal. Cutting of the test piece for mechanical testing should not take place until it has been visually examined and accepted by the Principal.

o

Should the completed test piece diameter be too small to allow proper examination of the weld root, the test piece shall be cut longitudinally to facilitate examination.

o

If alternative or additional NDE methods are proposed for production welding, the test weld shall also be subjected to these methods.

Add new 11.1.5: 11.1.5

Macro Examination When required by the Principal, macro sections shall be prepared so that the whole cross section of the weld, inclusive of HAZ, and adjacent parent material may be examined. These should be etched to reveal individual passes and the full extent of the HAZ. Macro sections shall be examined at a magnification of 5x. WPQR documentation shall include macro-photograph(s) of the section. Any hardness survey indentations shall remain visible on these macro-photographs. Macro-photographs shall be marked to identify magnification. Only original photographs or good-quality digital images shall be accepted as part of the weld procedure qualification documentation.

12

Other Items

12.1

Backing Materials Add the following to 12.1: Permanent backing strips are not allowed unless specifically permitted by the Principal. After backing strip removal, the area will be inspected for cracks by either liquid penetrant or magnetic particle testing. Use/Non-Use of temporary ceramic backing strips should be considered an essential variable when impact testing is required.

12.4

Temporary Attachments Add the following to 12.4: If thermal cutting is employed, the attachment shall be cut off at a minimum distance of 5 mm (0.2 in) from the surface of the material then ground flush. Removal by hammering shall not be allowed.


ECCN EAR99

12.5


Stud Welding

Add new 12.5.4: 12.5.4

Arc and resistance stud welding on pressure retaining parts, shall be qualified on material with the same P number and group number and with the same thickness or greater, as the material used for production welding.

Add new 12.5.5: 12.5.5

Stud test welds shall be made in the orientation described in ASME/BPVC Sec IX, QW-121 for plate and QW-122 for pipe (excluding QW-122.1). In all cases, the stud shall be perpendicular to the surface of the plate or pipe.

Add new 12.5.6: 12.5.6

In order to qualify the procedure, stud testing - Destructive tests of at least ten consecutively welded studs in each position shall be used to measure the suitability of the procedure, including the specified percent fusion.

12.6

Hardness Testing—Weld Procedure Qualification and Production Testing Delete 12.6.1.3 and Replace with:

12.6.1.3 Unless the design code specifies lower values, the following general hardness requirements for base material, heat-affected-zone and weld metal shall apply: 1. For wet H2S environments where DEP 30.10.02.15-Gen. is applicable (for oil and gas production), all hardness testing and acceptance values shall meet the requirements of that DEP. 2. For wet H2S environments where DEP 30.10.02.17-Gen. is applicable (for petroleum refining and related processing environments), all hardness testing and acceptance values shall meet the requirements of that DEP. 3. 248 HV10 maximum for ferritic metals in process services, including H2 and sour service conditions. 4. 300 HV10 maximum for ferritic materials in utility service (steam, air, water, non-sour service). 5. 350 HV10 maximum for 9 % Ni steels in the as-welded condition. 6. 290 HV10 maximum for 9Cr-1Mo-V steel (P91, T91) in the PWHT condition. 7. 325 HV10 maximum for structural steels. 8. 250 HV10 maximum for 3.5 % Ni steel ≤ 9.5 mm (3/8 in). However for joint thickness > 9.5mm (3/8 in), 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) 300 HBW in maximum in ferritic steel in utility services. g) For P91, follow API TR 938-B guidance. h) For super duplex stainless steels, follow API TR 938-C guidance. Add new 12.6.2.7: 12.6.7

Acceptable portable hardness testing equipment is limited to the MIC-10, MIC-20 and the Telebrinell hardness testers. The Telebrinell may only be used for weld or base metal hardness. HAZ testing is not acceptable by Telebrinell. Other testing instruments may be accepted by the Principal.

Add new 12.6.2.8: 12.6.2.8 Existing PQRs that were qualified prior to the issue of this DEP publication using other hardness test methods may be accepted by the Principal.


ECCN EAR99


Add new 12.6.2.9: 12.6.2.9 A minimum of two production hardness tests shall be performed utilising the agreed test method on each major circumferential weld and each major longitudinal weld. Austenitic stainless steels and nickel alloys are excluded. If hardness values are exceeded, the material should be rejected unless acceptable remediation action is approved by the Principal. If only one hardness result exceeds the specified maximum, then a minimum of three further indentations shall be made in close proximity to that which failed such that they do not mutually interfere. If all the further tests are below the maximum specified hardness, the retest shall be accepted. 12.7

Single-pass Welds Add the following to 12.7: Single pass attachment welds on valve bonnets shall be approved by the Principal. No single pass welding is acceptable on pressure components. Stops and starts shall be acceptable.

Add new 12.8: 12.8

Tube Skin Thermocouple Welding

12.8.1

TC Pad Welding Guidelines Welding shall be performed using a qualified welding procedure (WPS) with the GTAW (gas tungsten arc welding) process. The WPS shall match the base metal of the pad and sheath with the applicable heater tube base metal (e.g., P8 to P5B for welding a 310 stainless steel pad to 9Cr-1Mo steel tubes). The metal surfaces at the weld joint should be cleaned to bright metal. Preheat will be applied as applicable to the heater tube base metal. The WPS requires approval from the Principal prior to welding. Penetrant testing (PT) or magnetic particle testing (MT) shall be performed on each completed weldment after 24 hours for possible “delayed cracking” as a result of hydrogen introduced by the welding process. The sheath or cover (when applicable) shall not be attached until satisfactory NDE has been completed on the T/C pad.

12.8.2

PWHT Requirement Guidelines for TC Pad Welding For general hydrocarbon service service, PWHT is not needed. For tubes made of ferritic steels (such as carbon steel, carbon-½Mo, Cr-Mo, and 12 % Cr steels) in hydrogen charging service, Principal authorisation to waive PWHT is required. The Principal will consider the following: 1. The delayed hydrogen cracking that could occur due to the welding process risk is being mitigated by the inspection of the weld before starting up the heater. 2. The risk for wet H2S environmental cracking for processing sulphur-bearing fuels is very low and no failures reported in tube heaters associated to this mechanism. 3. The risk for thermal fatigue failure is being mitigated by the inspection in the first T/A. 4. In most heaters, these welds will be tempered and stress relieved in service.

12.8.3

Welding Consumables for TC Pads For ferritic steel heater tubes, the welding consumables are given in Table 1. Table 1—Environment

Temperature °C (°F)

Non-Sulfidizing

Sulfidizing (non-reducing)

Sulfidizing (Reducing) / Metal Dusting

Up to 590 (1100)

ERNiCrMo-3

ERNiCrMo-3

ERNiCr-4 and ERNiCrFe-7A

591 to 760

ERNiCr-3 or ENiCrFe-2

ERNiCr-3 (ERNiCrFe-11 for very high S environment)

ERNiCr-3 (ERNiCrFe-11 for very high S environment)


ECCN EAR99

DEP 30.10.60.18-Gen. February 2012 Page 41 Table 1—Environment

Temperature °C (°F)

Non-Sulfidizing

(1101 to 1400)

761 to 1150 (1401 to 2100)

ENiCrCoMo-1 and ERNiCrCoMo-1

Sulfidizing (non-reducing)

Sulfidizing (Reducing) / Metal Dusting

ERNiCr-3 for strength with weld capped with ERNiCr-4 or ERNiCr-7 (for maximum sulfidation resistance)

ERNiCr-3 for strength with weld capped with ERNiCr-4 or ERNiCr-7 (for maximum sulfidation resistance)



Sulfidizing environment means sulphur bearing furnace gases or products containing more than 50 grains (3.24 g) of sulphur per 100 standard cubic foot.

For austenitic stainless steel tubes, filler metal should be selected based on Table A.2 in API RP 582. For carbon steel and the Cr-Mo steels, the use of the high nickel filler metal as specified in the Table above is preferred due to the similarity of the coefficient of thermal expansion between these two materials. Add new section 13: 13

Environment Any local rules regarding fumes, environment, waste, etc. in direct relation to welding shall be followed.

Annex A

(informative) Welding Consumables for Shielded Metal Arc Welding (SMAW) Add new to Annex A: Note 1:

Table A.1 should be modified as follows: Annex A.1 refers to coated electrodes. For bare and flux cored wire welding (SAW, GMAW, FCAW, GTAW), 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).

Add in Table A.3: For CD4MCu, AWS A5.9 Class ER2553 shall be the filler metal.

Annex B

(normative) Weld Overlay and Clad Restoration (Back Cladding) Add new to Annex B: These additional requirements to Annex B shall apply to pressure equipment and piping fabricated with corrosion-resistant overlay, clad or strip lining. The base material shall be welded in accordance with the procedure for the base metal involved. Single and double layered overlay - For equipment with normal operating temperature below 425 °C (800 °F). The Manufacturer can propose procedures with single overlay layer. •

It shall demonstrate satisfactory test data showing acceptable fusion and dilution results, acceptable hardness in dilution zone, acceptable hydrogen disbonding test (if applicable) and consistent capability to maintain required overlay chemistry 3 mm (1/8 in) below the overlay surface.

•

It has an experience with application of such overlays and portion of the data are supported by actual production work done.

Unless otherwise agreed, PQR and production welds chemistry tests shall be taken between 2.5 mm – 3 mm (0.1 in – 0.125 in) below finished surface. The production test location shall be restored after the test.


ECCN EAR99


In the case of using ERCrNiMo-3 filler metal to meet Alloy 825 clad chemistry requirements, the as-deposited Cr & Mo weld metal content shall meet or exceed 18.5 % and 3.0 %, respectively. NDE - For normal operating temperatures above 425 °C (800 °F), all weld overlay shall be 100 % UT examined for disbonding from base metal after final shop hydrotest, in accordance with applicable NDE specification. Single-sided welds - Single-sided welding from the non-clad side (e.g., Method 1 or 2 in Figure B-1) shall only be done with the written acceptance of the Purchaser. Strip lining The proposal for and/or use of strip-type lining requires prior written approval of the Purchaser. Strip lining shall be welded circumferentially using three passes of weld. Each side of the strip shall be individually welded to the shell and then a third pass shall be deposited to provide a continuous weld flush with the strips. Overlay chemistry 1. When weld overlay is applied to restore the clad area of weld joints between clad components at least one deposit analysis per welding procedure per each Class A and B seams in the vessel. 2. When weld overlay is applied to the surface of equipment shells: 2

2

•

at least two deposit analyses per 10 m (100 ft ) of overlay or fraction thereof; and,

•

an analysis shall be taken from each end of the shell at locations that are diametrically opposed.

3. When weld overlay is applied to the surface of equipment components for each welding procedure used and for each piece of equipment manufactured: •

at least one deposit analysis representing the smallest component welded with each procedure; and,

•

one deposit analysis representing the largest component welded.

4. When weld overlay is applied for surface repair of clad components or restoration of surfaces where cladding has been removed (other than weld seams at least one deposit analysis shall be provided for each welding procedure used. Sleeve liner - The use of sleeve liner instead of clad materials requires written approval of the Principal. Welding from two sides General procedure First, the cladding material shall be removed next to the weld area to ensure that no contamination can occur from the cladding material into the weld of the base material. Clad removal shall be checked with a saturated copper sulphate solution. ASTM A380 provides some guidelines and limitations of the solutions to use. Cladding material inclusions in the weld of the base material may cause cracking owing to high hardness caused by martensite formation. Next, the base material is welded from one or two sides as required for the thickness and material. After completion of the base material weld, the cladding layer is welded. For the first pass, a buffer consumable shall be used. This buffer consumable shall have acceptable mechanical and chemical properties after dilution with the base material. Weld preparation


ECCN EAR99


The cladding material shall be removed from both sides of the weld preparation. The total amount removed depends on the welding process selected and the clad thickness but shall have a minimum width of 5 mm (0.2 in) on each side of the weld preparation. The depth of the layer to be removed shall be the thickness of the cladding layer increased by 1 mm ± 0.5 mm (0.04 in ± 0.02 in). The edges of the groove in the cladding shall be rounded off to prevent entrapment of slag. Welding procedure for the base materials The base material shall be welded in accordance with the procedure for the base material involved. Welding procedure for the cladding materials If arc gouging is applied to the inside surface of a vessel, it shall be sandblasted in accordance with SSPC SP-6 before weld overlay application. Martensitic/ferritic or ferritic stainless steel cladding, e.g., AISI 410/405: The procedure is to weld the first pass with a buffer electrode type E/ER 309 and the subsequent passes also with an AISI 309 electrode. For temperatures > 315 °C (600 °F), Ni based electrodes should be used. Additional Requirements for Welding, PWHT, and Inspection of Pipe with Internal Overlay For PMI extension, refer to DEP 31.10.00.10-Gen. Unless otherwise approved in writing, minimum schedule/wall thickness of pipe to be internally overlaid shall be:

Table B-1—High Pressure (≥ Class 600) Pipe size mm (in)

Schedule/Wall Thickness

38 – 150 (1 1/2 - 6)

Schedule 160

> 150 (6)

18 mm (0.718 in) nominal wall

Low Pressure (< Class 600) Pipe Size

Schedule/Wall Thickness

38 – 150 (1 1/2 - 6)

Schedule 80

> 150 (6)

Schedule 40

Test Samples If specified by the purchaser, for overlay welding a 300 mm x 300 mm (12 in x 12 in) test sample representing each combination of pipe base material/overlay material and WPS/PQR shall be submitted to the purchaser for evaluation by the purchaser prior to start of welding. Welding Processes for Weld Overlay The following welding processes may be used subject to the requirements listed below each one: Gas Tungsten Arc Welding (GTAW) Shield Metal Arc Welding (SMAW) Submerged Arc Welding (SAW) SAW flux/wire combination used for production welds shall be of the same brand as that used for qualification of procedure. Alloying elements shall be in the wire, not the flux, if possible.


ECCN EAR99


Gas Metal Arc Welding (GMAW) Other Welding Process Unless otherwise approved in writing by the Purchaser, other welding processes shall not be used. Welding Consumables 1. Tubular alloy-filled electrodes may be used for welding alloys, if these electrodes have been used for qualification of the welding procedures. 2. Fabricator shall review and document the chemical analysis of each heat of filler material prior to production welding to verify that the filler material meets the chemistry and ferrite requirements in this DEP. Preparations for Welding General 1. Surfaces to be welded shall be clean and free from paint, oil, dirt, scale, oxides and other foreign material detrimental to weld integrity. 2. Surfaces to be overlaid shall be blasted in accordance with SSPC SP-5, machined or ground to clean, bright metal prior to application of overlay. 3. Cleaned zone shall be a minimum of 25 mm (1 in) on each side of weld. Production Welding General 1. Overlay materials shall conform to Table B-2. The Principal will indicate how many layers are required and might indicate if tighter requirements are needed. Use of other materials, including the required chemical analysis for procedure qualification and production testing, requires prior written approval by the Purchaser. 2. Unless otherwise specified, nominal thickness of overlay shall be 3 mm to 6 mm (1/8 in to ¼ in). 3. Required inspections and tests of overlaid (such as liquid penetrant) pipe shall be completed prior to further assembly fabrication of the pipe. 4. For parts assembled prior to overlay welding, the weld metal joining the parts shall have the same nominal chemical composition as the base metal. Field End Preps Unless otherwise specified, end preps for field joints for piping as detailed below shall be buttered in accordance with Figure B-3 and then subjected to PWHT. 1. Piping made from 2¼Cr-1Mo and 1¼Cr-½Mo in all thickness. 2. Carbon steel piping > 19 mm (3/4 in) thickness. Single Sided Butt Welds 1. Thickness of root and first hot pass shall be approximately the same as that of the overlay. Refer to Figure B-1. 2. Remainder of the weld may be completed using any of the processes specified in this standard. 3. Unless otherwise specified, analysis of filler metal used to complete the weld shall conform to Table B-3. Two Sided Butt Welds For butt welds, which are made prior to internal overlay, the welds shall be made with filler material of the same nominal composition as the base metal. Internal protrusion shall be smooth and a maximum of 1/16” to allow for the internal overlay.


ECCN EAR99


PWHT 1. When PWHT of the base metal without overlay is required by Code, it shall also be subject to PWHT when provided with overlay. Chemical Analysis 1. Weld overlay shall be chemically analysed in accordance with DEP 31.10.00.10-Gen., covering PMI. 2. Tests may be performed on actual items or on run-off tabs from the production pieces. Run-off tabs shall be properly identified with S/N, heat number, etc., and shall be kept by the fabricator for a minimum of six months after completion of work. 3. Unless otherwise specified by purchaser, ferrite content for austenitic stainless steels shall be 4.0 % to 9.0 %. Ferrite content for operating temperatures below 425 °C (800 °F) may be 3.0 % to 12.0 %. Impact Tests 1. Impact testing of procedure qualification welds shall be carried out if impact testing of the base material is required. 2. Acceptance criteria of test results shall conform to ASME B31.3 or applicable piping code or class specification. NDE General 1. The extent of NDE shall conform to Shell specifications covering pressure vessels or piping. Liquid Penetrant Examination Penetrant testing (PT) shall be performed on 100 % of weld overlay surfaces. Penetrant materials shall conform to paragraph T-644 of Article 6, Section V of ASME Code, for sulphur and halogen content regardless of the type of material to be examined.


ECCN EAR99

DEP 30.10.60.18-Gen. February 2012 Page 46 Table B-2—Overlay Materials and Required Overlay Analysis REQUIRED ANALYSIS (Note 1)

Overlay Type

C Max.

No. of layers

Cr

Ni

Mo

Fe Max

Cb

PQR

Std. (13)

PQR

Std. (13)

PQR

Std. (13)

PQR

Std. (13)

PQ R

Std. (13)

PQR

Std. (13)

Notes

308L

2

0.04

0.03

17.5-21.5

18-20

8.5-11.5

8-12

-

-

-

-

-

-

2, 3

309L

1

0.08

0.03

15.0-18.5

22-24

8.0-12.5

12-15

-

-

-

-

-

-

4

309L

2

0.04

0.03

16.5-21.5

22-24

10.5-14.5

12-15

-

2-3

-

-

-

-

2

309MoL

2

0.04

0.03

16.5-21.5

22-24

10.5-14.5

12-15

2.0-3.0

2-3

-

-

-

-

2

316L (ESW)

1

0.04

0.03

16.0-21.5

16-18

8.0-12.0

10-14

2.0-3.0

2-3

-

-

-

-

4, 11

316L

2

0.04

0.03

16.0-21.5

16-18

10.0-14.0

10-14

2.0-3.0

2-3

-

-

-

-

2

317L (ESW)

1

0.04

0.03

16.0-21.5

18-20

8.0-12.0

11-15

3.0-4.0

3-4

-

-

-

-

4, 11

317L

2

0.04

0.03

17.5-21.5

18-20

11-14.5

11-15

3.0-4.0

3-4

-

-

-

-

2

347 (ESW)

1

0.08

0.08

16.0-20.0

17-19

8.0 – 12.0

9-13

-

-

-

-

8 xC min

10 xC min

4, 11

347

2

0.08

0.08

17.5-21.5

17-19

8.5-11.5

9-13

-

-

-

-

8 xC min

10 xC min

2

904L

2

0.04

0.02

16.0-20.0

19-23

18-25

23-28

3.0-4.0

4-5

-

-

Cu>1.0

Alloy 825

2

0.05

0.05

19.0-23.0

19.5-23.5

38-46

38-46

2.5-3.5

2.5-3.5

22 min

3

Alloy 625

1

0.10

0.10

16.0-23.5

20-23

50-55

58 min

6.0-10.0

8-10

20

5

2.5-4.0

3.15-4.15

4, 5, 7

Alloy 625(ESW)

1

0.10

0.10

18.0-23.5

20-23

50-65

58 min

7.0-10.0

8-10

15

5

2.5-4.0

3.15-4.15

4, 6, 7, 11

Alloy 625

2

0.10

0.10

18.0-23.5

20-23

55-65

58 min

7.0-10.0

8-10

10

5

2.5-4.0

3.15-4.15

6, 7

Alloy 600(ESW)

1

0.15

0.15

14.0-17.5

14-17

50-70

72 min

-

-

15

6-10

4, 8, 11

Alloy 600

2

0.15

0.15

14.0-17.5

14-17

50-70

72 min

-

-

15

6-10

7

Alloy 400(ESW)

1

0.3

0.3

-

-

60 - 69

63-70

-

5

2.5

-

-

4, 9, 10, 11

Alloy 400

2

0.3

0.3

-

-

55 - 69

63-70

-

15

2.5

-

-

9, 10

Alloy 400

3

0.3

0.3

-

-

55 - 69

63-70

-

10

2.5

-

-

9, 10

Nickel 200

2

0.15

0.15

-

-

90 - 95

99 min

-

-

5

0.4

-

-

-

Alloy 276

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

Other

7 12


ECCN EAR99


NOTES : 1.

Surface analysis shall be performed at a depth of one-half the minimum specified thickness as qualified in the welding procedure.

2.

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.

3.

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.

4.

Optional 1 layer overlay only if specified by the purchaser in writing. ESW has shown to e adequate in some applications.

5.

Minimum Pitting Resistance Equivalent Coefficient: 30

6.

Minimum Pitting Resistance Equivalent Coefficient: 40

7.

ASTM G48, Pitting and Crevice Corrosion Coefficient: Max 5 mpy

8.

For GTAW, GMAW, and SAW overlay process use ERNiCr-3 filler for SMAW use ENiCrFe-3 (minimum 50 % nickel); or ENiCrFe-2 (minimum 13 % Chromium)

9.

Also for Alloy 400: Mn - 4.0 max., Si - 1.25 max., Al - 1.25 max., Ti - 1.0 max., Cu - balance.

10.

A ferricyanide test (ASTM A380, paragraph 7.3.4) must be passed, no free iron is allowed.

11.

If required by the Principal, PQR must include a hydrogen-disbonding test.

12.

Other types of overlay shall conform to the Project Specific Annex or the Purchase Order.

13.

Chemistry for wrought equivalent in ASME/BPVC Sec II.


ECCN EAR99

DEP 30.10.60.18-Gen. February 2012 Page 48 Table B-3—Single Sided Butt Weld in Overlaid Pipe (per Figure B-1)

Overlay Type

Root and Hot Pass

Fill Passes

Notes

308L

309L

ERNiCrMo-3 (Alloy 625)

1,2,4

309MoL

309MoL

ERNiCr-Mo-3 (Alloy 625)

1,2,4

316L

309MoL


1,2,4

317L

309MoL


1,2,4

347

309MoL


1,2,4

625



1,2

600

ERNiCr-3 (Alloy 600)


1,2

400

ERNiCu-7 (Alloy 400)

ERNiCu-7

3

NOTES: 1.

Or ENiCrMo-3 for SMAW.

2.

Alloy 625 for design temperature up to 538 °C (1000 °F). Materials for higher temperatures require prior Shell approval.

3.

Or ENiCu-7 for SMAW.

4.

If specified by purchaser, 309L/309MoL may be allowed for fill passes of butt welds.


ECCN EAR99


Figure B-1—SINGLE SIDED BUTT WELDS


ECCN EAR99


Figure B-2—FIELD JOINTS FOR BASE MATERIAL REQUIRING PWHT


ECCN EAR99


Add new annex: Annex C C.1

(normative) Carbon steel Welding Wet H2S or Sour Service Applicable documents:

C.2

•

DEP 30.10.02.17-Gen., SPECIFICATION WET H2S REQUIREMENTS FOR DOWNSTREAM PRESSURE VESSELS AND 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 Weldments Chemistry checks The Manufacturer shall verify chemistry of the base material intended for welding, such as carbon equivalent and check for presence of unspecified or micro alloying elements such as Nb, V, B, Ti. Exceeding combined concentration of 0.03 % or B alone in excess of 50 ppmw, to ensure that weldment behaviour will correspond to that of the test plates. The Purchaser shall be responsible for MTRs of Purchaser-supplied materials. The Manufacturer shall be responsible for MTRs of Manufacturer-supplied materials. When the concentration of elements required for Ceq calculation is not available on MTRs of Manufacturer-supplied materials, the Manufacturer shall: •

Determine the concentration, calculate the Ceq, validate compliance with requirements, and report results; or

•

Supply alternate conforming material and certification.

Add new annex: Annex D D.1

(normative) Low Alloy Steel Welding 1.25 and 2.25Cr – API 934s and DEP 30.10.02.32-Gen., should be followed whenever applicable. For piping services not covered by API 934s, ANSI/AWS D10.8-96 Recommended Practices for Welding of Chromium-Molybdenum Steel Piping and Tubing should be observed. For alloy materials P-3 through P-9, the root pass shall be made using GTAW or GMAW. As specified in 6.1 regarding “synthetic consumables”, in case of 1.25Cr-0.5Mo weld applications in hot hydrogen service, the chemistry of the deposits produced by synthetic consumbles needs to be carefully verified, as marginal composition will cause the hot hydrogen attack resistance to be reduced.

D.2

P91 9Cr-1Mo-V API TR 938-B should be observed unless deviation is approved by the Principal. Unless specified in the applicable code or specification, 9Cr-1Mo-V (Grade P91) welding procedures shall be qualified with impact tests. Impact tests shall be performed on the thickest pipe section used and shall include testing on the base metal, weld metal and HAZ at 1/2t.


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Consumables used to provide PQR test specimens shall be the same (trade name) used in the fabrication of P91 spools unless otherwise permitted by the Principal. Heat input shall be controlled and monitored during production welding. Specific inspection records showing compliance with actual WPS parameters during welding (shop records) and PWHT procedures (including complete temperature cycles and PWHT initial temperatures) shall be submitted to QA/QC for each weld made on 9Cr-1Mo-V (Grade P91) materials. Chemical Composition In addition to the specifications in the ASTM standards, the following shall apply: 1. Neither the phosphorus nor the sulphur content shall exceed 0.010 wt percentage. 2. X-bar shall be below 15. X-bar shall be calculated with the following formula: X-bar =

10P + 5Sb + 4Sn + As 100

in which P, Sb, Sn, and As are expressed in ppm 3. Creq < 10 to minimise the formation of delta ferrite Creq = Cr + 6Si + 4Mo + 1.5W + 11V + 5Nb + 9Ti + 12Al - 40C - 30N - 4Ni - 2Mn - 1Cu

4. N/Al 4:1 minimum ratio Material Manufacture •

Base material shall be procured in normalised and tempered condition.

•

Tempering shall be done at a minimum of 760 °C (1400 °F). Care shall be taken to prevent heating above Ac1 temperature.

•

Mechanical Requirements o

For seamless P91 piping, hardness shall be between 190-250 HBW.

o

For ASTM A387 grade 91 plate, maximum hardness shall be 241 HB (it also applies for welded pipe, i.e., ASTM A691 P91).

o

For welded pipe (ASTM A691), hydrotest shall be done after PWHT.

o

For welded pipe (ASTM A691) supplementary requirement S3 (hardness), S7 (MT of weld metal) and S10 (UT) shall apply. Acceptable hardness range shall be 190-241 HB.

o

For fittings, acceptable hardness range shall be 190-250 HB. Hardness shall be checked on minimum of one sample per charge and one sample per size.

o

For forgings (ASTM A182 F91), maximum acceptable hardness shall be 248 HBW.

o

For castings, no hardness values are specified in the standard.

o

Further, supplementary requirement S14, i.e., tension test from each heat and heat treatment charge (as per ASTM A703) shall apply.

o

Transverse charpy impact test at 20 °C (70 °F). Acceptance criterion is a minimum of 40 J (30 ft-lb) impact energy value

o

Photomicrographs shall be produced to ensure 100 % tempered martensite structure.

o

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 same as for the other mechanical tests in the relevant standard.


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DEP 30.10.60.18-Gen. February 2012 Page 53 o

•

When impact toughness is specified, the close control of heat input and PWHT cycle is required. Preproduction test samples should be prepared on coupons having thickness no less than the one being welded (up to 25 mm (1 in)).

Welding Requirements o

A preheat temperature of 200 °C (392 °F) shall be maintained and a maximum interpass temperature of 300 °C (572 °F) shall be maintained.

o

The weld shall be allowed to cool to at least 93 °C (200 °F) before PWHT is commenced. This is to ensure complete transformation of austenite to martensite.

o

The non-post weld heat-treated weldment shall always be post heated before PWHT. Post heat temperature range shall be between 310 °C – 320 °C (590 °F – 608 °F) for minimum 15 minutes.

o

Further, the temperature shall not be high enough to prevent NDE (such as RT) of the weld.

o

PWHT shall be carried out at a minimum of 732 °C (1350 °F) and at least 15 °C (30 °F) below the tempering temperature. The Principal might approve deviations proposed by the Manufacturer.

o

All butt welds shall be 100 % RT examined.

o

All fillet welds and branch welds shall be 100 % MT examined.

o

To avoid over-tempering by PWHT, hardness measurement after PWHT shall be done at the weld, HAZ and base metal. Acceptance criterion shall be a 190 HB minimum.

o

Maximum acceptable hardness shall be in line with what is specified for different forms in the corresponding ASTM specs or what is mentioned in the section on mechanical requirements.

o

PQR and WPS shall be submitted to the Principal for review. PQR shall cover the following: §

Base metals, HAZ, and weld shall adhere to the following requirements: •

Transverse charpy impact test at 20 °C (70 °F). Acceptance criterion is a minimum of 40 J (30 ft-lb) impact energy value

•

Hot yield test at design temperature

•

Photomicrographs shall be produced to ensure 100 % tempered martensite structure.

Extent of testing shall be same as that for other mechanical tests in the relevant standard. o

Heat input used during production welding shall not be higher than 115 % of the value recorded during PQR welding.

o

Repair welding shall not start until the Principal or its representative has inspected the defect and has approved the repair procedure.

o

For castings, the aforementioned requirements shall apply for weld repair. Further, supplementary requirement S51 (mandatory PWHT after weld repair) as per ASTM A703 shall apply. PWHT shall be done as mentioned above.

NDE •

All butt welds shall be 100 % RT examined.


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•

All fillet welds and branch welds shall be 100 % MT examined.

•

Fittings and Forgings shall be ordered with 100 % PT (as per ASTM E165) for 10 % of the fittings. Acceptance criterion as per ASME/BPVC Sec VIII Div 1.

•

If weld repair is required for castings, supplementary requirement S10 (examination of weld preparation) shall apply.

QA/QC •

Unless specified otherwise, all inspection and test certificates shall be supplied to the Principal.

•

Each pipe/fitting/casting shall be checked with PMI. Acceptance of the method and the equipment shall be at the discretion of the Principal. The alloy analyser chosen must be able to differentiate between grade 9 and grade 91.

•

For castings, supplements requirement S21 (HT furnace record) shall apply.

Misc •

For all the hardness measurements, Brinell hardness tester is preferred as the surface preparation is relatively easier. In case Vickers hardness testing is used, then at least 10 % of the weld joints (weld/HAZ/base metal) shall be inspected by Brinell hardness tester for verification.

•

Local re-normalisation and tempering shall not be permitted to avoid the formation of a broad zone of material on either side of the heated area that has been intercritically heated. Thus, if any component fabricated from Grade 91 is “locally” heated above Ac1 temperature, then either the entire component shall be re-normalised and tempered or the section to be heated shall be removed from the component in its entirety, re-normalised and tempered, and then re-inserted into the component by appropriate means.

Add new annex: Annex E

(normative) Stainless Steels Welding

E.1

General

E.2

Austenitic Stainless steels shall not come in contact with unalloyed or low alloy steels. Fabrication of stainless steels shall be done separately in a work area and with tools only to be used for the fabrication of stainless steels. Materials Typically, this section is applicable to: AISI 300 Series, Grades 304L, 304, 316L, 316, 321, 347, etc., their corresponding H-grades, and any other austenitic stainless steels agreed with the Principal. WPQR Controls Arc volts, welding current, travel speed and arc energy shall be recorded for each weld run, preferably with automated monitoring equipment, although hand-held metres and stopwatch may also be used. For other processes, the range of bead widths shall be recorded for each weld run. Weld Procedure Test Requirements Testing shall have the following additions and clarifications. Radiographic examination shall be used for volumetric NDE wherever the geometry allows. Surface crack detection will be by PT.


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If production NDE will utilise a different inspection method to the above, the production NDE method shall also be applied. The macro sections of the weld shall be polished to 1-micron finish and etched to reveal the weld microstructure. Essential Variables The following essential variables apply in addition to those of ISO 15614-1 Welding Process The welding process, combination of processes or order of welding processes shall not be changed. Welding Parameters The polarity, or electrical characteristics (AC/DC), shall not be changed for any weld pass. The welding current for GTAW shall not be changed by more than +10 % nor shall the characteristics change from normal to pulsed current or vice versa. For pulsed GTAW, the pulse frequency, waveform or background current shall not be changed unless approved by the Principal. The stick-out length for SAW or FCAW shall not be changed beyond the range specified in the WPS or approved Specification parameters. Production Welding Controls All plasma spatter and other debris shall be removed from the vessel, process pipe work or other equipment surface by disc grinder or emery disc. PWHT - Austenitic stainless steels weldments shall receive post weld heat treatment such as stress relief, stabilisation heat treatment or solution annealing only when specified in design/purchasing documents. Detailed PWHT procedures shall be submitted for purchaser review and acceptance for every case when PWHT is planned. When stabilisation post weld heat treatment is specified the Manufacturer should provide charpy impact values of the heat-treated weld metal. Minimum values shall be not less than 32 J (24 ft-lb) at 20 °C (70 °F). The Manufacturer should consult with the filler metal Supplier and get advice on effect of post weld heat treatment cycle on material toughness. 6Mo Superaustenitic Stainless Steels Materials Typically, this section is applicable to: UNS S31254, UNS N08367, UNS N08925, UNS N08926, etc., and any other super austenitic stainless steels agreed with the Principal. Permitted Processes The welding heat input shall be restricted to 1 kJ/mm maximum. WPQR Controls The maximum inter-pass temperature recorded during the qualification test shall be the highest inter-pass recorded at the start of any weld pass. During weld procedure qualification, each welding pass shall be monitored using equipment that records the arc time, volts and welding current. The inter-pass temperature shall be recorded at the start of each pass. Travel speed and arc energy shall be recorded for each pass. Weld Procedure Test Requirements Testing shall have the following additions and clarifications: 1. Radiographic examination shall be used for volumetric NDE wherever the geometry allows.


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2. Surface crack detection will be by PT. 3. If production NDE will utilise a different inspection method to the above, the production NDE method shall also be applied. 4. For 5G and 6G (PF & HL045) welding positions, three macro sections shall be used for macro and hardness examination, representing 12, 3 and 6 o’clock positions. 5. A weld metal analysis shall be taken from material sampling the root area. The method of sample extraction shall be agreed with the Principal. The analysis shall include all deliberately added elements with the following elements as a minimum: C, Si, Mn, S, P, Cr, Fe, Mo, Ni, Cu, Nb, and N. 6. Ferric chloride testing shall be carried out. Any deviation to this that is due to the specimen size or configuration shall be approved by the Principal. The test temperature shall be 30 °C (86 °F). 7. Metallographic examination is required. Two micro sections shall be prepared to a procedure approved by the Principal and the microstructure of the weldment shall be assessed by a qualified metallurgist at a magnification of at least x 400, and reported in the PQR. The microstructure shall be free of any fissuring and any feature considered deleterious or unusual shall be reported. 8. Original copies of photomicrographs, taken at a magnification of x 250, of the HAZ at the fusion line and the weld metal shall be included in the PQR package. Essential Variables The following essential variables apply in addition to those listed in the applicable code. Composition A new procedure qualification shall be required if the UNS number is changed. Joint Type Joint bevel angle shall not be decreased by more than 5 ° or increased by more than 10 °. The root gap for 6Mo shall not be less than 2 mm (0.08 in). The root gap tolerance shall be -0 / +2 mm (-0 / +0.08 in). Single-sided and double-sided preparations require separate qualification. 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. Removable backing strips or inserts (if permitted) require separate qualification. Butt welds do not qualify as fillet welds, and multi-pass and single-pass fillets require separate qualification. Welding Process Combination of processes or order of welding processes shall not be changed unless approved by the Principal. Welding Parameters The polarity, or electrical characteristics (AC/DC), shall not be changed for any weld pass. The welding current for GTAW shall not be changed by more than +10 % nor shall the characteristics change from normal to pulsed current or vice versa. For pulsed GTAW the pulse frequency, waveform or background current shall not be changed unless approved by the Principal. The calculated arc energy shall not be changed by more than 10 %. The stick-out length for SAW or FCAW shall not be changed beyond the range specified in the WPS or approved Specification parameters.


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Production Welding Controls The shop fabrication of stainless steel vessels, process piping and other equipment shall be carried out in a separate area (preferably a separate shop) from that of Carbon-Manganese and low alloy steels. All plasma spatter and other debris shall be removed by disc grinder or emery disc. Production welding parameter monitoring is required. Minimum frequency of testing shall be one record per process per shift and schedule shall ensure that each welder is tested at least once per calendar month. Material Segregation 6Mo stainless materials and welding consumables will be protected from coming into contact with CMn steels or their residual fabrication products (dust, etc.). Special care shall be taken to ensure that consumables for welding 6Mo and components are not confused with other materials. Workbenches shall normally be restricted to use for one type of material at a time. Repair Welding A separate WPS shall be prepared for all repair welding. For repair welding in 6Mo stainless materials using the same procedure as the original weld, a separate procedure qualification is required. This qualification should include reproduction of a typical production repair. For part wall excavations, the remaining ligament adopted for the test weld shall be the smallest allowed in production. Full penetration excavations shall be qualified separately. Mechanical testing of this repair welding procedure should include macro examinations, hardness tests, weld metal analysis, ASTM G48 ferric chloride testing (at process exposed weld surface, whether new or original) and metallographic examinations (x 400 magnification). Where a different welding procedure/process is to be used for repair welding, this procedure shall be fully re-qualified in accordance with this Specification. Such repair WPQR testing should be identical to that for the original weld. When 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. Testing temperature shall be the same as that for the original weld. E.3

Martensitic Refer to BP&G MAT-10.

E.4

Duplex Stainless Steels Additional Procedure Qualification Requirements for Duplex Stainless Steels: Procedure qualification shall be done on duplex stainless steel base metal of the same UNS number as used in production and per the following requirements: 1. Thickness and Heat Input: In addition to the requirements of ASME/BPVC Sec IX, a new PQR is required when: a. The maximum qualified production wall thickness shall not exceed 120 % (1.2T) of the thickness of the test coupon used during qualification. The minimum qualified production wall thickness is the test coupon thickness (T).


ECCN EAR99

DEP 30.10.60.18-Gen. February 2012 Page 58 b. The maximum heat input qualified on the WPS shall be the maximum achieved on the supporting PQR. The minimum heat input qualified shall be the higher 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.

2. Weld Position: All vertical weld progression shall be uphill. 3. Ferrite to Austenite Ratio: a. Per ASTM E562, the ferrite-to-austenite ratio in the deposited weld metal and heat-affected zone (HAZ) shall be determined on a polished and etched cross section of the weld coupon at a magnification of 500 x. The number of fields and points per field shall be in agreement with the guidance provided in the 10 % Relative Accuracy column found in Table 3 of ASTM E562. b. The following three areas shall be evaluated and reported in the PQR: i. Root pass ii. Mid-thickness iii. Cover pass c.

Ferrite content shall be within 30 % - 65 %. Base metal 40 % to 60 %.

4. Hardness testing: Hardness testing requirements per API TR 938-C Section 4.4. a. For UNS S31803 and S32205, the measured hardness shall not be above 310 HV average, with no reading over 320 HV. b. For all other grades of duplex stainless steel, the measured hardness shall not be above 350 HV average, with no reading over 360 HV. 5. Corrosion and Impact Testing: Either the corrosion or impact test as described below shall be performed to the PQR sample: a. Corrosion Test: i. One test specimen that includes the weld, HAZ, and base metal shall be removed from each procedure qualification test coupon and tested in accordance with ASTM A923 Method C. Acceptance criteria shall be per ASTM A923 except that no pitting is allowed. The Rapid Screening Test method per ASTM A923 is not permitted. ii. As part of procedure, qualification a pitting corrosion test shall be carried out in accordance with ASTM G48 Method A using Ferric Chloride solution. The test shall be carried out for 24 hrs immersion at 25±1 °C (77±1 °F) for Duplex steel and 40±1 °C (104±1 °F) for super duplex steel. The test specimen shall be machined perpendicular to the weld axis. The specimen dimensions shall be full wall thickness by 10 mm (0.4 in) along the weld and 50 mm (2 in) across the weld. The test shall expose the external and internal surface and a cross-section surface including the weld zone in full wall thickness. No flattening of the coupon material shall be carried out. Before the start of the testing, the specimen shall be degreased, dried, weighed to three decimal places and the weight recorded. On completion of the test period, the specimen shall be rinsed, cleaned dried and re-weighed using the procedures specified in ASTM G48A. The test acceptance criteria shall be: - No evidence of pitting examined at a magnification of X 20. 2

- Weight loss shall not exceed 4g/m [~0.04 mm/yr] (1.6 mpy) All samples shall be photographed and made available with PQR submitted for Principal approval.


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DEP 30.10.60.18-Gen. February 2012 Page 59 iii. Third-party laboratories used for the testing shall have prior experience with duplex iv. Stainless steel testing using ASTM G48A or ASTM A923 C methods. Vendor shall submit to the Owner the laboratory name and qualifications, to be used for qualification and production testing. v. If the specimen does not meet the acceptance criteria, then a new specimen may be taken and retested. The Owner must be notified before proceeding with retesting. b. Impact Test: i. For Charpy V notch impact tests of the weld metal and HAZ, three specimens for each location are required. The following values are required for full-size specimens: o

o

For 22Cr grade §

Weld Metal: 34 J (25 ft-lbs) average and 27 J (20 ft-lbs) minimum at -40 °C (-40 °F)

§

HAZ: 54 J (40 ft-lbs) average and 43 J (32 ft-lbs) minimum at −40 °C (−40 °F)

For 25Cr grade §

Weld Metal: 70 J (52 ft-lbs) average and 65 J (48 ft-lbs) minimum at -50 °C (-46 °F)

§

HAZ: 70 J (52 ft-lbs) average and 65 J (48 ft-lbs) minimum at -50 °C (−46 °F)

ii. The orientation of standard size specimens shall be per ASME/BPVC Sec VIII DIV1, UG84. In addition, the weld metal impact specimen shall be removed from the T/2 (mid-wall) position. Furthermore, the HAZ impact specimen location may need to be adjusted to ensure the notch is completely in the HAZ but should be as close as feasible to the T/2 position. iii. The lateral expansion shall be 0.38 mm (0.015 in) minimum. For 25CrDSS this value should be obtained at 0. 6. Heavy Wall Equipment: a. For duplex weldments with a wall thickness over 25 mm (1 in), the impact test using full-size specimens and the corrosion test are required. b. For duplex weldments with a wall thickness over 50 mm (2 in), full-size impact specimens shall be removed for testing at the location of the first weld pass and at the 1/4T position. Additional Requirements for Welding Duplex Stainless Steel: 1) Welder and Welding Operator Qualifications: a. Welder and welding operator performance 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. The ferrite-to-austenite ratio shall be determined as required in Section 11.3, Item (3) of API RP 582 for all performance qualification tests. c.

In addition to the applicable code requirements, impact testing for butt weld and hardness tests for branch and fillet welds as required in this annex shall be done for all performance qualification tests. Also, macro and visual examination is required in all cases.

2) Production Test Plates: Each heat of plate used to fabricate shell and head


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DEP 30.10.60.18-Gen. February 2012 Page 60 segments shall be subjected to production testing. Test plates shall be made from the same heat as the base material and installed as run-off tabs at the end of longitudinal weld seams. The test plate shall be of sufficient size to equal the cooling gradient of the component. The samples shall be subjected to ferrite-to-austenite ratio testing and impact testing as required in this annex.

Inspection and Testing of Duplex Stainless Steel Welds: 1) Pressure boundary welds shall have ferrite measurements made by using a Fischer Feritscope® calibrated in accordance with AWS A4.2M. Welds made from each weld procedure, welder, and heat/lot of filler metal shall be tested. A total of three measurements shall be taken in the centre line of a weld cap bead and if accessible, the root pass. The weld cap and root pass shall be prepared suitably flat to take the ferrite reading, so as not to alter the microstructure of the specimen. 2) Complete welds shall be 100 % visually examined for heat tinting, i.e., oxide discolouration of the surface. When deemed necessary by the Owner, all heat tinting shall be removed and thoroughly cleaned by pickling or glass bead blasting. If any oxidation is noticed, the vessel shall be acid pickled and passivated in accordance with DEP 30.10.60.31-Gen., both internally and externally. Detail for pickling and passivation to be agreed with the Principal. Shielding gass Should lead to achieving satisfactory G48 test results. The oxygen content in the shielding (and backing) gas shall be less than 50 ppm. JOINT PREPARATION DSS may be cut using the plasma-arc process, a machine cutter, or grinding disc dedicated solely for the use on DSS. Carbon-arc shall not be used for cutting or back gouging. If plasma-arc cutting is used, the inside surface must be thoroughly cleaned of all spatter. Sufficient metal shall be removed in the bevelling process to remove any heat-affected zone (HAZ) that occurred as a result of the plasma-arc cutting. Once used for cutting DSS, grinding discs shall be used exclusively for that purpose. The final surface preparation and configuration shall be obtained by machining. During machining operations, only a cutting fluid compatible with stainless steel shall be used. Any small burrs, nicks, or other irregularities on the weld bevel shall be repaired, if possible, by light grinding. Any suspected edge defects or laminations shall be reported to the Purchaser before proceeding with investigation or repairs. Repairs by welding shall not proceed without prior approval of the Purchaser. Each bevelled edge and internal and external surface over a distance of at least 50 mm (2 in) back from the bevel shall immediately, prior to welding, be thoroughly dried, and shall be cleaned with a stainless steel wire brush. The bevelled edge shall then be wiped clean with acetone, or other Purchaser-approved solvent. HEAT INPUT LIMITS 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)


ECCN EAR99


Heat input for tube-to-tubesheet welding may be as high as 3.0 kJ/mm (76 kJ/in), assuming that when the ferrite is checked during the procedure qualification, it is found to be within the acceptable ferrite range in this DEP in the as-welded condition. WPQR Controls During weld procedure qualification, each welding pass shall be monitored using equipment that automatically records the arc time, volts and welding current. The inter-pass temperature shall be recorded at the start of each pass. Travel speed and arc energy shall be recorded for each pass. Upon request, the fabricator shall provide specific inspection records showing compliance with actual WPS parameters during welding for each weld made. If the crayons are used, certificates from the crayon Manufacturer shall be available for review by the Purchaser’s representative, which certify that the halogen content of the crayon does not exceed 250 ppm. All single-sided welds shall be made with a GTAW root pass and back purged until at least 6 mm (1/4 in) of weld metal thickness has been deposited. Backing gas and shielding gas 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 vendor shall submit details of the method and equipment to be used for monitoring oxygen content as part of the welding procedure specification. Other options shall be approved by the Principal. High level of care shall be exercised to ensure proper application of backing gas. For field welding where access to the weld is limited to one side only (back welding not possible), GTAW shall be used with a hydrogen free shielding gas to avoid possible cracking and embrittlement of the weld. The WPQR test weld root passes should be assessed visually using DEP 30.10.60.31-Gen. Under no circumstances shall the welding arc be struck outside the weld bevels. If this occurs, the arc strike shall be removed by grinding. The ground area shall be examined with liquid penetrant, and any relevant indications will require repairs. The contractor shall ensure a good earth connection and periodically examine the condition of the earth cables and attachments. Any arcing from a poor connection shall be treated as a tray arc strike. Connections shall be made to the work by stainless steel clamps. Earth cables shall not be welded to piping components. Welds, which are for welding on the opposite side, shall have liquid penetrant examination after cleaning for the back weld. Unless approved by the Principal, all back grinding shall be accomplished with approved procedures, ensuring complete removal of oxides from plasma-cut surfaces. Carbon arc gouging shall not be used, unless agreed by the Purchaser. All welds with access to the process side shall be cleaned after welding by hand wire brushing of the as-welded surfaces. All welds made, including tack and fit-up, shall be done with approved weld procedures, materials and certified welders. 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. For manual and machine welding: filler metal type: Any change in the Manufacturer filler metal size: Any change in diameter of the filler metal. shielding gas flow rate: Any change in flow rate beyond -20/+10 %. backing gas composition: Any change in the gas composition. electrical characteristics: Any change in type of current, polarity, or pulse range. interpass temperature: Any change in the maximum interpass temperature. heat input: Any change greater than ± 10 %.


ECCN EAR99


For machine welding only: welding equipment - 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. The minimum number of mechanical test specimens required for a welding procedure qualification test weld shall be in accordance with API 938-C Annex B, Table B.1 In addition to the acceptable criteria given in ASTM A923, the specimens shall also show no pitting, except for obvious “end grain attack” or one slag inclusion per specimen. photo-micrographs and macro-examination - Photo-micrographs at approximately x 500 shall be provided to the Purchaser for each of the locations where a phase balance assessment is performed. - Photo-micrographs shall show a typical austenite/ferrite microstructure. The macro-examination shall provide evidence that the weld is sound and free from cracks and other defects with full penetration and fusion between weld passes and parent metal. Dissimilar metal welds, i.e., carbon steel to DSS or austenitic stainless steel to DSS, shall require qualification and testing to the requirements of this DEP except that the non-duplex HAZ need not be subject to Charpy or corrosion testing (3.4.1). Third party laboratories used for testing (for both procedure qualifications and production) shall be experienced in the methods used for DSS testing. When requested, the Vendor shall submit the laboratory name and qualifications to the Purchaser. For tube to tubesheet welding the requirements of API 938-C annexes C.3 and B.9 should be met. E.5

Additional requirements for piping Butt welding procedures, branch welding procedures, fillet welding procedures and repairwelding procedures shall be qualified separately. Test welding shall be performed under simulated site conditions. WELDING METHOD Prior to commencement of test welding, the Contractor shall have available at the test site the written procedure to remove oxygen before welding of DSS pipes. Chemical Analysis Chemical analysis shall be conducted on the root run of the weld metal. The elements required for calculation of the PRE shall be determined. The PRE value shall exceed the minimum specified for the base material to be welded. Retests General If the results of destructive testing are unsatisfactory owing to defective specimen preparation or a localised weld defect, the Contractor shall inform the Principal and obtain agreement to proceed with retests. Corrosion tests Retesting shall be permitted only if failure can be reasonably attributed to test conditions or sample preparation. When testing is agreed, two further specimens shall be prepared and tested. Both the retest specimens shall meet the acceptance criteria.


ECCN EAR99


QUALIFICATION OF REPAIR WELD PROCEDURE Each type of repair shall be separately qualified, including, partial penetration and cap repair. Through-thickness repairs are not permitted. In addition to the items required for normal PQR, the WPS for repair shall show the following: -

the method of excavation

-

the NDE techniques applied to ensure removal of defects.

PRODUCTION WELDING Preparation for Welding The open ends of the pipe shall be capped when interruptions to work occur, which are expected to last two or more hours. All open ends of pipe strings shall be capped off and sealed when welding is completed. USE OF LINE-UP CLAMP FOR BUTT WELDS Internal line-up clamps shall be used wherever possible and their design shall be such as to allow the introduction and containment of purging gases. These clamps shall have stainless steel inserts or shall be clad with a suitable material to prevent contact between the DSS pipe and CS clamp. External line-up clamps may be used for line pipe 150 mm (6 in) NPS and below, for tie-in welds, and for special welds, such as connections to valves, flanges and fittings. Pipe shall not be moved or lowered off until the second pass has been completed. Where an internal or external line-up clamp cannot be used, alignment may be achieved using tack welds. Tack welds shall be temporary bar tacks using suitable duplex stainless steel material. Welding parameters shall be in accordance with the appropriate fill pass. Tack welding shall be performed only by welders qualified to weld with the WPS. The tack welds shall be removed by grinding as welding progresses around the joint. Fully penetrating root tacks shall not be allowed. Welding Before start of welding, pipes shall be flushed with backing gas. The oxygen content of the exit gas shall be monitored using suitable oxygen measuring equipment and welding shall not commence until a level of 50 ppm (0.005 %) is attained. During welding of the root run, 50 ppm oxygen level in backing gas shall be ensured. For subsequent runs, an oxygen level may be increased to 500 ppm and maintained. If the oxygen level reaches above 500 ppm, welding must be stopped. The level of less than 50 ppm must then be re-established before further welding takes place, and slowly increased to 500 ppm max as welding progress. Interruption of welding should be avoided. If interruption is unavoidable, a minimum of three passes or one-third of the joint thickness, whichever is greater, shall have been deposited. On resumption of welding any preheat requirements specified in the approved WPS shall be applied. Welds shall be left as welded and shall not be treated with a flame torch or other mechanical means to change their appearance other than cleaning and dressing operations specified in the WPS. Welds shall not be peened. A circular tight cap, of a design, which will not damage pipe ends, shall be used to cover the open ends of the pipe and shall be placed on the line at the end of each day’s work to prevent entry of foreign material. Caps shall not be removed until commencement of the following day’s work. When fabrication is completed, all surfaces adjacent to the welds shall be cleaned of spatter, burrs and other imperfections, which could interfere with radiographic or ultrasonic inspection.


ECCN EAR99

E.5.2


Additional requirements for pressure vessels Production Welding General Along with actual production welding, the fabricator shall prepare a production test coupon, which comprises of one long seam, one circ seam and one nozzle welding. The material for production coupon shall be the actual used for fabrication of the vessel. These production coupons shall be tested for all the weld qualification tests. If any hot forming or cold forming is involved with PWHT/solution annealing, the same shall be included in the production coupon production sequence. Post weld heat treatment (PWHT) shall normally not be carried out. When required, the PWHT shall be in accordance with the code and the steel Manufacturer’s recommendations. After heat treatment, the internal surfaces shall be cleaned free of scale and oxides. On the completion of the welding, the adjacent surfaces shall be cleaned free of all spatter, slag, flux and other carbonised material.

Add new annex: Annex F (normative) Ni steels Alternating current shall be used with SMAW, since direct current may cause magnetic arc blow problems and consequent lack of fusion. 3.5 % Nickel Steels 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 Principal. A back purge with high purity Argon shall be required for GTAW of 3½ % Nickel steels unless otherwise approved by the Principal. A minimum preheat of 100 °C (200 °F) shall be used for welding all thicknesses. WPQR Controls The minimum qualified preheat temperature on a procedure qualification test is defined as either the minimum temperature for the root run or the minimum temperature at the start of the first capping pass deposited on the parent material with the highest carbon equivalent, whichever is higher. During weld procedure qualification, each welding pass shall be monitored and record the arc time, volts, and welding current. The inter-pass temperature shall be recorded at the start of each pass. Travel speed and arc energy shall be recorded for each pass. Weld Procedure Test Requirements Additions and clarifications. •

Radiographic examination shall be used for volumetric NDE wherever the geometry allows.

•

Surface crack detection will be by magnetic particle inspection.

•

If production NDE will utilise a different inspection method to the above, the production NDE method shall also be applied.

Essential Variables


ECCN EAR99


The following essential variables apply in addition to those of ASME/BPVC Sec IX or ISO 15614-1. Chemical Composition Qualifications carried out on 3½ % Nickel steels shall only qualify that material. For welding 3½ % Nickel steels to other material where impact properties are required, specific procedures shall be qualified using the particular combination of dissimilar materials. Thickness The maximum thickness for as-welded applications at a service temperature of -80 °C (-112 °F) is 12.5 mm (0.5 in). For service below -80 °C (-112 °F), all thicknesses shall be PWHT. Position A change from 5G vertical up welding (PF) to vertical down (PG) requires re-qualification. For site erection and offshore hook-up, qualification in 6G (HL045) may be permitted if agreed with the Principal Joint Type Joint bevel angle shall not be decreased by more than 5 °. Single-sided and double-sided preparations require separate qualification. 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. However, changes between single and compound angle V-preparations may be permitted without re-qualification if approved by the Principal. Removable backing strips or inserts (if permitted) require separate qualification. Multi-pass fillet welds are qualified by butt weld qualifications but single-pass fillets require separate qualification. Welding Process The welding process, combination of processes or order of welding processes shall not be changed. Welding Parameters The polarity, or electrical characteristics (AC/DC), shall not be changed for any weld pass. The welding current for FCAW, SMAW or GTAW shall not be changed by more than +10 %. The calculated arc energy shall not be increased by more than 20 % or decreased by more than 10 %. The electrode extension length for FCAW shall not be changed beyond the range specified in the WPS or approved Specification parameters. The minimum preheat specified shall not be less than minimum qualified preheat temperature (MQPT). The specified maximum inter-pass temperature shall not exceed the PQR maximum by more than 25 °C (77 °F). Production Welding Controls Production welding parameter monitoring is required. Minimum frequency of testing shall be one record per process per shift and schedule shall ensure that each welder is tested at least once per calendar month. Welding sets shall be calibrated or verified at intervals not exceeding 12 months. Tack welding requires preheating to the minimum level specified on the WPS or 100 °C (212 °F) whichever is higher.


ECCN EAR99


Add new annex: Annex G

(normative) High Ni Alloys Welding Materials Typically, this section is applicable to: UNS N08825 (825) UNS N06625 (625) UNS N04400 (Monel®) and any other nickel alloys agreed with the Principal To avoid hot cracking, the area adjacent to the weld preparation shall be clean. S, Pb, Sb, Cd and Zn are detrimental impurities, which may be present in grease or paint. Acetone and equivalent solvents are used for cleaning, to avoid porosity. The oxide layer shall be removed by grinding to a bright metal surface appearance just prior to welding. The weld bead shall be ground smooth before the next weld bead is made, to minimise hot cracking especially at the stop/start positions. WPQR Controls Arc volts, welding current, travel speed and arc energy shall be recorded for each weld run, preferably with automated monitoring equipment, although hand-held metres and stopwatch may also be used. For other processes, the range of bead widths shall be recorded for each weld run. WPQR shall be carried out in accordance with ISO 15614-1. Weld Procedure Test Requirements Additions and clarifications. Radiographic examination shall be used for volumetric NDE wherever the geometry allows. Surface crack detection will be by PT. If production NDE will utilise a different inspection method to the above, the production NDE method shall also be applied. Essential Variables The following essential variables apply in addition to those of ASME/BPVC Sec IX or ISO 15614-1 Welding Process The welding process, combination of processes or order of welding processes shall not be changed. Welding Parameters The polarity, or electrical characteristics (AC/DC), shall not be changed for any weld pass. The welding current for GTAW shall not be changed by more than +10 % nor shall the characteristics change from normal to pulsed current or vice versa. For pulsed GTAW the pulse frequency, waveform or background current shall not be changed unless approved by the Principal. The stick-out length for SAW or FCAW shall not be changed beyond the range specified in the WPS or approved Specification parameters. Maximum inter-pass temperature shall not exceed that used on the PQR or 200 °C (392 °F), whichever is less.


ECCN EAR99


Production Welding Controls The shop fabrication of nickel alloy vessels, process piping and other equipment shall be carried out in a separate area (preferably a separate shop) from that of Carbon-Manganese and low alloy steels. Nickel and its alloys may only be cut mechanically or by plasma arc cutting. All plasma spatter and other debris shall be removed from the vessel, process pipe work or other equipment surface by disc grinder or emery disc. Material Segregation Nickel alloys will generally be welded in isolation or where other non-ferrous materials are being fabricated. Hand tools, including their consumables, should be colour-coded, or other controls implemented to ensure that they are only used for nickel alloys. Add new annex: Annex H

(normative) Copper Alloys Welding Materials Typically, this section is applicable to: BS 2870/2871/2875 grade CN102, DIN 17664 No. 2.0872 CU NI 10 FE and any other copper alloys agreed with the Principal Permitted Processes Autogenous welding of grade CN102 material is not permitted. WPQR Controls Arc volts, welding current, travel speed and arc energy shall be recorded for each weld run, preferably with automated monitoring equipment, although hand-held metres and stopwatch may also be used. For other processes, the range of bead widths shall be recorded for each weld run. WPQR shall be carried out in accordance with ISO 15614-6. Weld Procedure Test Requirements Additions and clarifications. Radiographic examination shall be used for volumetric NDE wherever the geometry allows. Surface crack detection will be by PT. If production NDE will utilise a different inspection method to the above, the production NDE method shall also be applied. Essential Variables The following essential variables apply in addition to those of ISO 15614-6. Welding Process The welding process, combination of processes or order of welding processes shall not be changed. Welding Parameters The polarity, or electrical characteristics (AC/DC), shall not be changed for any weld pass.


ECCN EAR99


The welding current for GTAW shall not be changed by more than +10 % nor shall the characteristics change from normal to pulsed current or vice versa. For pulsed GTAW the pulse frequency, waveform or background current shall not be changed unless approved by the Principal. The electrode extension length for SAW or FCAW shall not be changed beyond the range specified in the WPS or approved Specification parameters. Maximum inter-pass temperature shall not exceed that used on the PQR. Production Welding Controls The shop fabrication of copper, and its alloys vessels, process piping and other equipment shall be carried out in a separate area (preferably a separate shop) from that of Carbon-Manganese and low alloy steels. Copper and its alloys may only be cut mechanically or by plasma arc cutting. Immediately prior to welding the weld preparation and an area 50 mm (2 in) 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. All plasma spatter and other debris shall be removed from the vessel, process pipe work or other equipment surface by disc grinder or emery disc. Material Segregation Copper alloys will generally be welded in isolation or where other non-ferrous materials are being fabricated. Hand tools, and their consumables, should be colour-coded or other controls implemented to ensure that they are only used for copper alloys. Add new annex: Annex I (normative) Aluminum alloys Welding GENERAL This Appendix annex covers the mandatory requirements for welding pressure retaining equipment fabricated from aluminium and aluminium alloys. Welding procedures shall be prepared and qualified in accordance with the welding requirements of this Standard, using the same base material and filler wire to be used in fabrication. Only GMAW and GTAW processes shall be used to weld aluminium fabrications. The shielding gas shall be pure argon (99.998 per cent vol.) for both processes. Pure argon shall be applied as a backing gas when welding from one side only. Where back-welding is feasible, the root pass shall be ground away and re-welded. WPQR shall be carried out in accordance with ISO 15614-2. WELD PREPARATION The basic weld preparations used for welding steel are acceptable for welding aluminium. When dissimilar metal backing bars are used, care shall be taken during welding to avoid melting the backing bar and contaminating the aluminium weld metal. Permanent aluminium backing bars, when allowed by the Principal, shall be of the same material as the fabrication.


ECCN EAR99


CLEANING The surfaces to be joined shall be free of moisture, greases, oils, paints or any other substances. Degreasing shall be done by wiping, spraying, dipping in a suitable solvent or by steam cleaning. Surface oxides shall be removed with a chemical solution that has been approved by the Principal. Cleaning by mechanical means is preferred. PREHEATING A minimum preheat temperature of 50 °C (120 °F) shall be applied when the base metal is thicker than 6 mm (1/4 in). WELDING Tack welds shall be removed as welding progresses and shall not be part of the finished weld. Filler metal shall be dry, free of grease and other foreign matter. If the filler metal becomes damp, heat for a minimum of two hours at 120 °C (250 °F) before using. Add new annex: Annex J (normative) Titanium alloys Welding Fabrication Facilities: The shop fabrication of titanium vessels, process piping and other equipment shall be carried out in fully contained and quarantined area dedicated only to titanium fabrication. Periodic checks for iron contamination shall be made by a chemical method (e.g., ferroxyl) on surfaces to be welded. Materials Typically this section is applicable to: ASTM B337 Gr2 (Pipe) ASTM B363 Gr.WPT2 (Fittings) ASTM B381 Gr.F2 (Flanges) and any other titanium grades advised by the Principal Permitted Processes ASME

EN/ISO

Process Description

Application

GTAW

141

Gas Tungsten Arc Welding

Root, Fill, and Cap

WPQR shall be carried out in accordance with ISO 15614-5. Use of alternative welding processes may be permitted if the Contractor can demonstrate that they have good working experience with the proposed process, their process controls are satisfactory and the ongoing competence of their welders is proven by acceptable inspection results. GTAW torches shall be fitted with gas lenses. A secondary inert gas shield shall be established over the solidified and cooling weld metal and HAZ and maintained until the metal temperature falls below 500 °C (932 °F). The shielding will be provided by use of a glove-box chamber, trailing shield, or incorporated into the head of orbital GTAW welding equipment.


ECCN EAR99


Essential Variables The following essential variables apply in addition to those of ASME/BVPC Sec IX or ISO 15614-5 Thickness The thickness tested is the maximum qualified Joint Type Joint bevel angle shall not be decreased by more than 5 ° or increased by more than 10 °. The root gap tolerance shall be -0 +2 mm (-0 +0.08 in). Single-sided and double-sided preparations require separate qualification. 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 Parameters The polarity, or electrical characteristics (AC/DC), shall not be changed for any weld pass. The welding current for GTAW shall not be changed by more than +10 % nor shall the characteristics change from normal to pulsed current or vice versa. For pulsed GTAW the pulse frequency, waveform or background current shall not be changed unless approved by the Principal. The calculated arc energy shall not be changed by more than 10 %. Maximum inter-pass temperature shall not exceed that used on the PQR. Production Welding Controls For titanium, only machining or grinding is permitted for weld preparation. Immediately prior to welding the weld preparation and an area 50 mm (2 in) 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. The colour of the weld beads is an important method of assessing the integrity of a Ti weld. If the weld bead remains bright and silver in colour, then no inter-run cleaning is necessary. Straw or light blue weld discolouration should be removed by stainless wire brushing. Dark blue, grey or white powdery discolouration of the weld beads indicate contamination and the affected weld must be completely removed by grinding. Add new annex: Annex K

(normative) Dissimilar Welding Hardness - When welding materials in 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 designed to achieve sufficient tempering of more hardenable material and to prevent excessive weakening of the softer material or loss of toughness. Welding procedures qualification tests shall demonstrate the results. Hardness tests and results meeting requirements of API RP 582, sub-section 12.6 or NACE RP0472 are mandatory for all dissimilar weld PQRs. Limitations for sour and hot hydrogen service - Dissimilar welds between ferritic and austenitic materials shall be avoided for application in wet H2S/sour service or other services where acid corrosion can occur or in services over 450 °C (842 °F) in presence of hydrogen. If dissimilar welds appear to have to be used in such services the Purchaser’s Materials Specialist shall be consulted. To retain control over the dissimilar welds, some sort of list/record needs to be kept from the beginning of the project and updated as it progresses.


ECCN EAR99


Problems with dissimilar welds are varied depending on the type and service. Additional care and weld design approvals may be required. Suitability of a dissimilar weld design has to be decided after considering the service, weldment and the weld design together. Their use shall be limited to applications where other solutions are not practical or tend to be very costly. Use of dissimilar pressure retaining or other dissimilar weld critical to integrity of the equipment require an approval of the Purchaser/Principal

Classes of dissimilar welds and suggestions for their design CLASS (1) P1 to P4/P5/P9/P91 (CS to low ferritic low alloy) These welds need to be post weld heat treated. Focus on selection of the PWHT temperature and the overall tempering parameter to ensure the harder structures of the alloy welds are properly tempered without weakening the CS. Hardness traverse on PQR is required. Consider properties of the weld in the fusion boundary. Use welding parameters minimising width and continuity of the diluted zone. If the weld is identified as being in NACE, then sour, wet H2S or other electrochemical corrosive service generating significant hydrogen, wetted parts of the weld and its fusion zones shall be overlaid by the same Ni alloy that the weld is made from and extended on the CS side of the weld for a safe distance from the fusion line. 12 mm (0.5 in) minimum has been used on similar welds. This distance may be increased at the advice of a corrosion engineer. When using austenitic (A8) or event Ni-based filler metals, PWHT alone is not considered adequate protection against dissimilar weld cracking when exposed to corrosive environment causing hydrogen embrittlement. CLASS (2) P1 to P8 (CS to austenitic stainless steel) For high criticality welds with thickness over 19 mm (3/4 in), carefully consider the design of the weldment including number and severity (rate of temperature change) of the temperature cycles that the weldment shall be exposed to during its design life. In case the number of full temperature cycles exceeds approximately 500 °C (932 °F) and/or if rate of process temperature change is in excess of 25 °C/hr (45 °F/hr) consult Engineer experienced in thermal fatigue design prior selecting the dissimilar weld design. Dissimilar welds requiring post weld heat treatment shall be made using the buttered overlay design described in CL (3) weld below. The weld dissimilar fusion line should not run normal to the maximum applied load. Minimum angle of the weld bevel should be more than 18 ° off the plane normal to the axis of the pipe unless stress assessment indicates otherwise. If such weld is identified as being in NACE, sour, wet H2S or other electrochemical corrosive service, wetted parts of the weld and fusion zones shall be overlaid by the same Ni alloy that the weld is made from on the CS side of the weld for a safe distance from the fusion line. 12 mm (0.5 in) has been used on similar welds. This distance may be increased at the advice of a corrosion engineer. When using austenitic (A8) or Ni-based filler metals on CS or low alloy steels, PWHT alone is not considered adequate protection against dissimilar weld cracking when exposed to corrosive environment causing hydrogen embrittlement. CLASS (3): P4/P5/P9/P91 to P8 (ferritic low alloy steel to austenitic stainless steel) These welds should not be used without protective overlay on “wetted side(s)”. These welds shall be used only in post weld heat-treated condition. Post weld heat treatment shall be done prior final assembly of the weld on “the buttered” section of the low alloy pipe.


ECCN EAR99


Minimum thickness of the “buttered” layers shall be 7 mm (¼ in) after final machining. The thickness of the finished buttered layer shall be measured and reported. The “buttered” overlay shall be made using Ni based fillers, which will not be injuriously sensitised during the PWHT cycle. CLASS (4) Dissimilar welds other than CL (1), (2) and (3) These welds shall be designed with the input of Purchaser/Principal. Applicable Design concepts used for the above classes can be utilised on Cl (4) welds where applicable. Note:

For design temperatures over 454 °C (850 °F), C welds amongst different grades of austenitic stainless steel (P8) should be considered to be “CL 4 dissimilar welds”.

Design for NDE The weak link of dissimilar welds is the fusion boundary between a base metal and weld made from the different material. NDE coverage of dissimilar welds should reflect their design and criticality and may require NDE coverage different from that of the piping class or standard project NDE schedules. They should be designed to allow volumetric examination and should be examined by at least one such suitable method. NDE coverage shall be developed/assigned by the Project Material Specialist. Critical dissimilar welds or pressure retaining weld designs not suitable for volumetric examination and their NDE shall be approved by the Principal/TA2. Dissimilar Weld Register All dissimilar welds shall be recorded in Dissimilar Weld Register prepared by the Manufacturer and included in the welding plan/map. As a minimum, such register shall contain the following information: Weld identifier Relevant drawing identifier (P&ID/MEFD/isometric or equipment fabrication drawings) P numbers of the alloys to be welded and brief description of the weld Criticality rating of the weld (as per Project criticality-rating procedures - pressure-retaining welds should be considered critical) Applicable welding procedure identifier (includes the name of the organisation, which welded such weld.) Identification of the officer/function who decided approved the location of the dissimilar weld. Identification of the officer/function that ultimately approved the Dissimilar Weld Register. Each EPC/Contractor stationary equipment department shall assemble the Manufacturer’s weld register and keep it current, available for Principal/TA2 review and audit. The Responsible Engineer (RE) shall certify such register prior final approvals by the Principal/TA2. Final Approvals Use, design of pressure retaining and all other dissimilar welds listed on certified Dissimilar Weld Register and critical to integrity of the equipment shall be reviewed and accepted by the Purchaser/Principal/TA2.


ECCN EAR99


PART IV REFERENCES In this DEP Specification, reference is made to the following publications: NOTES:

1. Unless specifically designated by date, the latest edition of each publication shall be used, together with any amendments/supplements/revisions thereto. 2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell Wide Web) at http://sww.shell.com/standards/.

SHELL STANDARDS Amendment A01

DEP feedback form

DEP 00.00.05.80-Gen.

Materials for Use in H2S-Containing Environments in Oil and Gas Production (Amendments and Supplements to ISO 15156:2009)

DEP 30.10.02.15-Gen.

Wet H2S Requirements for Downstream Pressure Vessels and Piping

DEP 30.10.02.17-Gen.

Metallic Materials - Prevention of Brittle Fracture in New Assets

DEP 30.10.02.31-Gen.

Materials and fabrication requirements for 2¼Cr-1Mo, 2¼Cr-1Mo¼V, 3Cr-1Mo & 3Cr-1Mo-¼V heavy wall pressure vessels (amendments/supplements to API RP 934-A)

DEP 30.10.02.32-Gen.

Welding on Pressurized Pipes (Amendments/Supplements to API Standard 1104)

DEP 30.10.60.30-Gen.

Oxidation of Stainless Steel Weldments

DEP 30.10.60.31-Gen.

Positive Material Identification (PMI) Program

DEP 31.10.00.10-Gen.

Amendment A01

Shop and Field Fabrication of Piping

DEP 31.38.01.31-Gen.

Structural Fabrication of Deepwater Floating Production Systems (Based on API RP 2FPS)

DEP 37.81.10.34-Gen.

Welding of Deepwater Pipelines, Flowlines and Steel Catenary Risers (Amendments and Supplements to API 1104)

DEP 37.81.40.31-Gen.

Welding of Pipelines and Related Facilities (Amendments/Supplements to ISO 13847:2000)

DEP 61.40.20.30-Gen.

AMERICAN STANDARDS Recommended Practices for Welding of Chromium-Molybdenum Steel Piping and Tubing

ANSI/AWS D10.8-96

Petroleum and natural gas industries — Materials for use in H2Scontaining environments in oil and gas

ANSI/NACE MR0175/ ISO 15156

Welding Guidelines for the Chemical, Oil, and Gas Industries Second Edition

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

Welded Tanks for Oil Storage

API 650

Section II A Ferrous Material Specifications Materials

ASME/BPVC Sec II

Section V Nondestructive Examination

ASME/BPVC Sec V

Section VIII Division 1 Rules for Construction of Pressure Vessels

ASME/BPVC Sec VIII


ECCN EAR99


Qualification Standard For Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operators Welding and Brazing Qualifications

ASME/BPVC Sec IX

Buttwelding Ends

ASME B16.25

Process Piping - Includes Interpretation 22

ASME B31.3

Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High-Temperature Service

ASTM A182

Standard Specification for Pressure Vessel Plates, Alloy Steel, Nickel

ASTM A203

Standard Specification for Seamless and Welded Steel Pipe for Low-Temperature 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 Pressure-Vessel-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 Test Method for Vickers Hardness of Metallic Materials

ASTM E92

Standard Practice for Liquid Penetrant Examination for General Industry

ASTM E165

Standard Test Method for Determining Volume Fraction by Systematic Manual Point Count

ASTM E562

Standard Test Methods for Pitting and Crevice Corrosion Resistance of Stainless Steels and Related Alloys by Use of Ferric Chloride Solution

ASTM G48

Recommended Practices for Local Heating of Welds in Piping and Tubing

AWS 10.10/D10.10M


ECCN EAR99


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 Bare Stainless Steel Welding Electrodes and Rods

AWS A5.9

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

Structural Welding Code - Steel

AWS D1.1

Structural Welding Code— Aluminum

AWS D1.2

Standard Welding Symbols

AWS D2.4

Recommended Practices for Root Pass Welding without Backing

AWS D10.11

Specification for Welding of Austenitic Stainless Steel Tube and Pipe Systems in Sanitary (Hygienic) Applications

AWS D18.1

White Metal Blast Cleaning

SSPC-SP 5/NACE No. 1

Commercial Blast Cleaning

SSPC SP-6

Petroleum and natural gas industries—Materials for use in H2Scontaining environments in oil and gas production (see ISO 15156-1)

ANSI/NACE MR0175/ ISO 15156

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

Welding Type 347 Stainless Steel – An Interpretative Report

WRC Bulletin 421

Recommended Practices for Local Heating of welds in Pressure Vessels

WRC Bulletin 452

INTERNATIONAL STANDARDS European Pressure Equipment Directive (PED) 97/23

Directive 97/23

Textile Machinery and Accessories - Pirn Winders and Cross Winders - Definition of Left and Right Sides

EN 141

Non-destructive Testing – Qualification and Certification of NDT Personnel - General Principles

EN 473

Quality Requirements for Fusion Welding

EN 729

Welding - Recommendations for Welding of Metallic Materials Part 2: Arc Welding of Ferritic Steels

EN 1011-2

Welding Personnel - Approval Testing of Welding Operators for Fusion Welding and Resistance Weld Setters for Fully Mechanized and Automatic Welding of Metallic Materials

EN 1418

Quality Requirements for Fusion Welding of Metallic Materials

EN ISO 3834

Quality Management Systems - Fundamentals and Vocabulary

EN ISO 9000


ECCN EAR99


Metallic Products - Types of Inspection Documents

EN 10204

Arc Welding Equipment – Part 1: Welding Power Sources

EN 60974-1

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

Steel and Steel Products - Inspection Documents

ISO 10474

Petroleum and natural gas industries — Materials for use in H2Scontaining environments in oil and gas production — Part 1: General principles for selection of cracking-resistant materials (see ANSI/NACE MR0175/ISO 15156)

ISO 15156-1

Specification and Qualification of Welding Procedures for Metallic Materials — Welding Procedure Test

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


Shell DEP 30.10.60.18

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