4439-XH-SW-000000001

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL-BENZENE <> A SKIKDA ALGERIE

CT-EPC/017/SH/EPM/RPC-X/2023

TCM IDENTIFICATION CODE

SHEET 1 / 73

ISSUE 1

PIPING WELDING GENERAL SPECIFICATION

23/10/2024

25/06/2024

IFD - Issued for Design

G. Mancuso

F. Barsanti

F. Laurenzi

IFA - Issued for Approval

G. Mancuso

F. Scazzosi

F. Laurenzi

Issue

Date

Reason for Issue - Revision Description

Prepared

Checked

Approved

This document is property of Tecnimont S.p.A. and cannot be used by others for any purpose, without prior written consent.

PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

CONTENTS

TCM IDENTIFICATION CODE

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ISSUE 1

PURPOSE … 4

2 REFERENCE DOCUMENTS … 7

2.1

2.2

2.3

2.4

LICENSOR DOCUMENTS … 7

PROJECT DOCUMENTS … 7

INTERNATIONAL STANDARDS … 7

ORDER OF PRECEDENCE … 8

ACRONYMS AND DEFINITIONS … 8

4 WELDING DOCUMENTS … 11

4.1

GENERAL REQUIREMENTS … 11

4.2 WELDING PROCEDURE SPECIFICATION (WPS) … 13

4.3

4.4

4.4.1

4.4.2

PROCEDURE QUALIFICATION RECORD (PQR) … 14

PERFORMANCE QUALIFICATION (WPQ AND WOPQ) … 14

GENERAL QUALIFICATION REQUIREMENTS… 14

JOB ADMISSION REQUIREMENTS … 15

4.4.2.1 NEW WELDER / WELDING OPERATOR … 15

4.4.2.2 PRE-QUALIFIED WELDER / WELDING OPERATOR… 15

4.4.3

INITIAL PRODUCTION CONFIRMATION TESTS … 15

5 WELDING PROCESS(ES) … 16

5.1

GENERAL REQUIREMENTS … 16

5.2 ADDITIONAL REQUIREMENTS FOR GAS TUNGSTEN ARC WELDING (GTAW) AND PULSED (GTAW-P) … 16

5.3

5.4

5.5

5.6

ADDITIONAL REQUIREMENTS FOR SHIELDED METAL ARC WELDING (SMAW) … 16

ADDITIONAL REQUIREMENTS FOR SUBMERGED ARC WELDING (SAW) … 16

ADDITIONAL REQUIREMENTS FOR FLUX CORED ARC WELDING (FCAW) … 17

ADDITIONAL REQUIREMENTS FOR GAS METAL ARC WELDING (GMAW) … 17

5.6.1 TRANSFER MODE (GMAW-S) … 17

SPECIFIC REQUIREMENTS FOR GAS METAL ARC WELDING - SHORT CIRCUITING

6 WELDING CONSUMABLES … 17

6.1

GENERAL REQUIREMENTS … 17

6.2 MATERIAL TEST CERTIFICATES … 18

6.3

IDENTIFICATION, PACKING, STORAGE AND HANDLING … 19

7 WELD PREPARATION … 20

7.1

7.2

7.3

CUTTING AND EDGE PREPARATION GENERAL REQUIREMENTS … 20

CLEANING … 21

ALIGNMENT AND TEMPORARY WELDS … 22

This document is property of Tecnimont S.p.A. and cannot be used by others for any purpose, without prior written consent

PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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ISSUE 1

EXECUTION WELDING REQUIREMENTS … 23

8.1

8.2

8.3

8.4

JOINT EXECUTION … 23

BACKING GAS … 26

PREHEATING … 26

HEAT INPUT AND INTERPASS TEMPERATURE … 27

8.5 WELDING INTERRUPTION … 27

8.6

PROXIMITY OF WELDS … 28

8.7 WELD CONTOUR AND FINISH … 28

PWHT REQUIREMENTS … 29

9.1

GENERAL REQUIREMENTS … 29

WELD INSPECTION REQUIREMENTS … 31

10.1 NON-DESTRUCTIVE EXAMINATION (VT, MT, PT, RT AND UT) … 31

10.2 PRODUCTION HARDNESS TEST … 33

10.3 PRODUCTION FERRITE TEST … 34

10.4 PMI TEST … 34

REJECTION AND WELD REPAIRS … 34

APPENDIX-A - MINIMUM CONTENT FOR WPS … 36

APPENDIX-B - ADDITIONAL ESSENTIAL VARIABLES … 38

APPENDIX-C - INITIAL PRODUCTION CONFIRMATION TESTS … 40

APPENDIX-D - FABRICATION OF PIPING SUPPORTS … 41

APPENDIX-E - WELD CLASS(ES) - NDE REQUIREMENTS FOR PIPING … 42

APPENDIX-F - RECORDABLE UT EXAMINATION TECHNIQUE … 43

APPENDIX-G - HARDNESS REQUIREMENTS FOR PQR (METHOD, LOCATION AND NUMBER OF MEASUREMENTS) … 51

APPENDIX-H - ADDITIONAL AND SPECIFIC REQUIREMENTS FOR CARBON STEEL (CS/KCS/LTCS) … 52

APPENDIX-I - ADDITIONAL AND SPECIFIC REQUIREMENTS FOR LOW ALLOY STEEL GRADE 1 ¼ CR ½ MO … 56

APPENDIX-L - ADDITIONAL AND SPECIFIC REQUIREMENTS FOR AUSTENITIC STAINLESS STEEL (304 AND 316 GRADES) … 59

APPENDIX-K - ADDITIONAL AND SPECIFIC REQUIREMENTS FOR NICKEL ALLOY 825 (UNS N08825) … 62

APPENDIX-M - ADDITIONAL AND SPECIFIC REQUIREMENTS FOR NICKEL ALLOY 20 (UNS N08020) … 64

APPENDIX-N - DISSIMILAR WELDING … 71

APPENDIX-O - FORM 140 … 73

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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PURPOSE

The purpose of this welding specification is to cover minimum requirements for welding, heat treatment and non-destructive examination of pressure containing piping girth, socket and branch joints, and where applicable also for longitudinal joints of jacket piping components to be installed on the new Linear Alkyl Benzene (LAB) plant located in the industrial zone of Skikda - Algeria. These requirements also apply to welds attaching non-pressure parts to such piping. Requirements herein contained shall be complied with for works on fabrication sites such as construction sites or fabrication yards, and in all Sub-Contractor’s workshops. Piping serving buildings and areas other than plant or process areas are not in the scope of this specification and they shall conform to applicable plumbing, heating and ventilating or refrigeration codes. Joining requirements for piping in non-metallic materials, such as Glass Reinforced Plastic (GRP), High Density Poly-Ethylene (HDPE), Chlorinated Poly Vinyl Chloride (CPVC) or Fiber Reinforced Plastic (FRP), are outside the scope of this specification. Requirements specified by relevant Vendor shall be followed in case of field joint(s). High Pressure Fluid Service (Chapter IX of ASME B31.3) is not applicable to piping classes in the scope of this specification since their pressure rating doesn’t exceed class 2500#. High Purity Piping (Chapter X of ASME B31.3) is not applicable to piping classes in the scope of this specification. All Appendixes of this specification are mandatory and relevant additional/specific requirements shall be applied in conjunction with the general requirements of this specification. This specification covers the following base materials as specified in Piping Material Specifications Index 4439-XH-SL-Z0000001 and listed in the reference piping classes for the project, as shown in the Table 1 below:

➢ Carbon steel (CS) / Killed Carbon steel (KCS) - P-No. 1 ➢ Carbon steel (CS) / Killed Carbon steel (KCS) - P-No. 1 in High Temperature Hydrogen Attack

(HTHA1) service

➢ Carbon steel (CS) / Killed Carbon steel (KCS) - P-No. 1 in Sour Service ➢ Low temperature carbon steel (LTCS) - P-No. 1 ➢ Low Alloy steel (LAS) grade 1 ¼ Cr ½ Mo - P-No. 4 ➢ Low Alloy steel (LAS) grade 1 ¼ Cr ½ Mo - P-No. 4 in Hydrogen service and High Temperature

Hydrogen Attack (HTHA) service

➢ Low Alloy steel (LAS) grade 1 ¼ Cr ½ Mo - P-No. 4 in Sour Service ➢ Austenitic Stainless steel (ASS) grade 304/304L/304H - P-No. 8 ➢ Austenitic Stainless steel (ASS) grade 316/316L/316H - P-No. 8 ➢ Super Duplex Stainless steel alloy 2507 UNS S32750 (SDSS) - P-No. 10H ➢ Nickel alloy 825 UNS N08825 (NA) - P-No. 45 ➢ Nickel alloy 20 UNS N08020 (NA) - P-No. 45

This specification shall also be applied for base material other than those listed above, when so required by Supply Specifications or Purchase order; in such cases, Sub-Contractor shall ask Contactor for specific requirements to be applied.

1 Carbon steel in H2 service (7kg/cm2 partial pressure or 90% H2 concentration irrespective of pressure), with operating temperature above 200°C

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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ISSUE 1

When recalled in the Material Requisition and Supply Specification, this specification applies also to pressure retaining piping included in the purchase order of packages and skids assembly supplied by Vendor and Sub-Vendor (in those cases, the requirements for Sub-Contractor refer to Vendor and Sub-Vendor). In such cases, this specification shall also be applied for metallic base material, pressure rating and service other than those listed above, and Vendor shall ask to Contractor for specific requirements to be applied. This specification is based on API RP 582 (fourth Edition, May 2023), therefore, if not covered and/or supplemented/modified by this Specification or the Licensor’s documents, welding processes, materials, and procedures shall comply with the requirements of API RP 582 (including documents referenced inside itself) and any recommendation within API RP 582 shall be considered mandatory (term “should” has to be replaced by “shall”). This specification supplements and does not replace the requirements of the applicable Licensor’s documents, codes and standards, listed in relevant Material Requisition, Supply Specification, Data sheet, drawing or others contractual documents. In case of conflict between the requirements of this specification and codes, standards or others project specifications, the most stringent apply, except that local codes or those of any statutory agency regulation shall be adhered to. However, Contactor and Company shall be consulted and a ruling in writing shall be obtained by Sub-Contractor before to proceed.

Table 1 - Applicable project specific base materials: Note: For any additional piping classes, welding requirements other than below listed shall be agreed with Company and Contractor before proceeding.

Point no.

Material

P-No. & G-No. (ASME IX)

Piping classes

Design code

Impact test

PWHT Requirements

Special service conditions (if any)

1.2

Killed carbon steel, Galvanized killed carbon steel

1.1 & 1.2

B1A1NN B1A1HY B1A1BZ B1A2NN B1A2BZ B2A1NN B2A1BZ B2A1HY B2A2NN B2A2BZ B4A1NN B4A1BZ B4A1HY B4A2BZ B4A2NN MS1NN MS11NN MS12NN MS13NN MS14NN * MS16NN MS16NNU MS17NN * MS21NN MS22NN MS29NNS MS31NN MS32NN MS41NN PA5HY

ASME B31.3

As per code

No for process reason / Code exemption allowed on materials thicker than 25 mm if a minimum preheat of 95°C is applied

None

Threaded joint for size 3” and below

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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ISSUE 1

Point no.

Material

P-No. & G-No. (ASME IX)

Piping classes

Design code

Impact test

PWHT Requirements

1.3

Killed carbon steel

1.1 & 1.2

B1A1HYS

ASME B31.3

As per code

Yes for process reason

(Code exemption is not allowed)

Special service conditions (if any)

HTHA

1.4

Killed carbon steel NACE MR0103

1.1 & 1.2

B1A2NA B1A2BN B1A4NS B1A4NSM B1A4BNS B2A4NS B2A2NA B4A2NA B4A2HN B4A4HN

ASME B31.3

As per code

Yes for process reason

(Code exemption is not allowed)

Wet H2S

Cr-Mo low alloy steel (P11)

4.1

E2A1NN

ASME B31.3

Cr-Mo low alloy steel (P11)

4.1

E2A1HY E4A1HY E4A2HY E4A3HY PA2HY

ASME B31.3

4.1

E4A1HN

ASME B31.3

Yes (Code exemption is not allowed)

Yes for process reason

(Code exemption is not allowed)

Yes for process reason

(Code exemption is not allowed)

None

HTHA

Wet H2S

8.1

K1A0NN K2A0NN MS8NN MS51NN PA3NN

ASME B31.3

Not required

None

K2A1HY

ASME B31.3

Not required

M1A1NN M2A1NN MS9NN MS15NN

M1A1NA M1A1NAM

ASME B31.3

Not required

None

ASME B31.3

Not required

Wet H2S

10H

MS61NN

ASME B31.3

Not required

None

U1A0NAM

ASME B31.3

Not required

Wet H2S

MS10NN

ASME B31.3

Not required

None

1.5

1.6

1.7

1.8

1.9

1.10

1.11

1.12

1.13

1.14

Cr-Mo low alloy steel (P11) NACE MR0103

Austenitic stainless steel dual grade (304/304L)

Austenitic stainless steel dual grade (316/316L)

Super Duplex UNS S32750

Nickel alloy 825 (UNS N08825)

Nickel alloy 20 (UNS N08020)

This document is property of Tecnimont S.p.A. and cannot be used by others for any purpose, without prior written consent

PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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ISSUE 1

REFERENCE DOCUMENTS

2.1

LICENSOR DOCUMENTS

Number

Title

UOP 8-11-19

Piping

UOP 8-12-11

Fabrication of piping

2.2 PROJECT DOCUMENTS

Number

Title

4439-XZ-SG-000000002 PMI General Specification

4439-XH-SL-Z0000001

Piping Material Specifications Index

4439-LQ-PC-000000008 Management of Site Metallic Welding Activities

2.3

INTERNATIONAL STANDARDS

Number

Title

ASME Section IX

ASME Boiler and Pressure Vessel Code - ed. 2023 - Welding and Brazing Qualifications

ASME B31.3

Process Piping - ed. 2022

ASME Section V

ASME Section II Part C

API RP 582

API RP 941

NACE MR0103

NACE SP0472

ASME Boiler and Pressure Vessel Code - ed. 2023 - Non-destructive Examination ASME Boiler and Pressure Vessel Code - ed. 2023 - Specifications for Welding Rods, Electrodes, and Filler Metals Welding Guidelines for the Chemical, Oil, and Gas Industries - ed. 4th (2023) Steels for Hydrogen Service at Elevated Temperatures and Pressures in Petroleum Refineries and Petrochemical Plants - ed. 8th (2016) Standard Material Requirements - Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum Refining Environments - ed. 2015

Methods and Controls to Prevent In-Service Environmental Cracking of Carbon Steel Weldments in Corrosive Petroleum Refining Environments - ed. 2020

AWS A2.4

Standard Symbols for Welding, Brazing, and Nondestructive Examination

AWS A3.0

Standard Welding Terms and Definitions

AWS A4.2M

Standard Procedures for Calibrating Magnetic Instruments to Measure the Delta Ferrite Content of Austenitic and Duplex Ferritic-Austenitic Stainless Steel Weld Metal

AWS A4.3

Standard Method for Determination of the Diffusible Hydrogen Content of Martensitic, Bainitic and Ferritic Steel Weld Metal Produced by Arc Welding

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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AWS A4.4

Standard Procedures for Determination of Moisture Content of Welding Fluxes and Welding Electrode Flux Coverings

AWS A5.32/A5.32M

Specification for Welding Shielding Gases

AWS D10.10

Recomm. Practices for Local Heating of Welds in Piping & Tubing - ed. 3rd

AWS D18.2

BS EN ISO 17781

Guide to Weld Discoloration Levels on Inside of Austenitic Stainless Steel Tube - ed. 2000 Petroleum, petrochemical and natural gas industries - Test methods for quality control of microstructure of ferritic/austenitic (duplex) stainless steels - ed. 2017

2.4

LOCAL REGULATION

Number

Title

ARH-P-CTE-2

Regulatory Auth. for Hydrocarbons - Procedure for processing welding files

2.5 ORDER OF PRECEDENCE

Requirements due to local authority regulations (if any) shall be also complies with and will prevail on this specification.

ACRONYMS AND DEFINITIONS

The following terms used in this document have the meaning defined below:

COMPANY/OWNER

SONATRACH

ARH

Agency for Regulation of Hydrocarbons (L’Agence Nationale de Contrôle et de Régulation des Activités dans le domaine des Hydrocarbures)

CONTRACTOR

Tecnimont S.p.A, part of the Maire Tecnimont Group

CONTRACT

means the agreement signed between OWNER and CONTRACTOR

PROJECT

means Linear Alkyl Benzene (LAB)

LICENSOR

means the technology providers who entered in License Agreements with COMPANY, to grant COMPANY access to technical information and intellectual property rights related to the technology processes.

SUB-CONTRACTOR

The company appointed for plant erection

VENDOR

means the component/item supplier

SITE

means the plant located in the industrial zone of Skikda - Algeria

INSPECTOR

Company’s Inspector, Contractor’s Inspector or Statutory Agency Inspector (if any)

EXAMINATION

Quality control functions performed either in shop and in site

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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Minimum Heat Treated Condition

means subjected to the fewest heat treatment cycles and/or time-at- temperature anticipated for the component. Minimum permitted temperature for the shortest permitted duration for each thermal exposure above 482°C shall be considered. It does not include allowances for shop or field repairs

Maximum Heat Treated Condition

Shop Welds

Field Welds

means subjected to the maximum number of heat treatment cycles and/or time at temperature anticipated during fabrication (including intermediate stress relief and multiple heat treatment exposures) plus minimum two additional heat treatment to simulate future repairs. Maximum permitted temperature for the longest permitted duration for each thermal exposure above 482°C shall be considered.

The joints identified by initial suffix “S” (or “SM”), as specified in Weld Numbering System defined by Project Specification Management of Site Metallic Welding Activities (refer to sub-clause 2.2).

The joints identified by initial suffix “F” (or “FM”), as specified in Weld Numbering System defined by Project Specification Management of Site Metallic Welding Activities (refer to sub-clause 2.2).

Rejection Rate (KPI)

It is defined as the percentage ratio of repairs/cut-outs welds per number of examined welds (not measured length of defects).

Design Lot

It is defined as follow:

➢

for shop welds (suffix S or SM), a lot is specific to one welder, one weld type (e.g. BW, SW, Branch, etc.), one WPS and one RT percentage (weld class); for field welds (suffix F or FM), a lot is specific to one welder, one weld type (e.g. BW, SW, Branch, etc.), one WPS, and one RT percentage (weld class);

Each lot is comprised of 20 welds maximum. Each lot size is determined by dividing 100 by the RT percentage (100 ÷ 5% RT = 20 weld lots), as follow:

Examination Specified (%) 5%

10% 20% 25% 50%

Designed Lot Size 20 sequential welds

10 sequential welds 5 sequential welds 4 sequential welds 2 sequential welds

Note: Tracking method that clearly documents welds in each designated lot shall be established by Sub-Contractor.

100% Examination

means complete examination of all weld joints in a designated lot.

Random Examination

means complete examination of a percentage (as per specified Weld Class) of involved type of weld joints in a designated lot. The joints to be examined, shall be selected/approved by Contractor or Owner Inspector, in compliance with requirements of sub-clause 10.1.

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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ISSUE 1

Spot Examination

Weld Class

means a specified partial examination of a percentage of involved type of weld joints in a designated lot. For girth welds the minimum required partial examination is:

➢

for pipe sizes 2” ½ and below, a single elliptical exposure encompassing the entire weld circumference; for pipe sizes above 2” ½ the lesser of 25% of the inside circumference or 152 mm (6”). The joint and the point, at which it shall be spot examined, shall be selected/approved by Contractor or Owner Inspector, in compliance with requirements of sub- clause 10.1;

It defines, according to Appendix-E, the NDE examinations percentage for weld joints, to be considered by Sub-Contractor. It has specified for each line listed in the Line-list and reported also on isometric drawings.

METWE

It is the Metallurgy and Welding Engineer department of Tecnimont.

MTC

WPS

PQR

WPQ

WOPQ

PWHT

DHT

NDE

PREN

CRA

TPIA

CRS

SSC

HIC

HTHA

Material Test Certificate

Welding Procedure Specifications

Procedure Qualification Records

Welder Performance Qualifications

Welding Operator Performance Qualifications

Post Weld Heat Treatment

Dehydrogenation heat treatment

Non-Destructive Examination

Pitting Resistance Equivalent Number

Corrosion Resistant Alloy

Third Party Inspection Agency

Comment Resolution Sheet

Sulfide Stress Cracking

Hydrogen Induced Cracking

High Temperature Hydrogen Attack

Carbon Equivalent

Ferrite Number

Butt Weld - Pipe-to-pipe including any combination of BW ends between pipe/fitting/flange. Includes branch butt welds per ASME B31.3.

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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ISSUE 1

PFW

SBR

THRD

TSW

HAZ

Fillet weld - Non pressure attachments (e.g. re-pads, guides, supports, etc.)

Pressure Fillet Weld - Slip-on flanges (where allowed)

Socket Weld - Pipe to socket connections

Branch Weld - Branch connection weld (pipe-to-header). Includes both set-in and set-on types

O’let - Branch connection weld, pipe-to-self reinforced component (weld-O’let, socket-O’let) by set-on type

Threaded connection not seal welded

Threaded connection seal welded

Weld Metal

Heat Affected Zone

WELDING DOCUMENTS

4.1 GENERAL REQUIREMENTS

All the documentation provided (WPS, PQR with all test records and test reports, Weld Map etc.) shall be clearly legible, scanned and/or illegible copies will not be accepted. The applicable Form-140 to be used by Sub-Contractor is included in the “Inspection and Test Plan for Steel Piping Works” for the project (see Appendix-P of this specification for easy reference). Sub-Contractor shall prepare a complete index of all applicable WPS and PQR, which clearly identify the application of each WPS, indicating where and how these WPS will be used. It shall contain, as minimum, all the following information:

➢ WPS number (signed by Sub-Contractor/Vendor) and relevant PQR (signed by competent third

party)

➢ Welding process(es) ➢ Type of joint (e.g. BW, FW, Branch connection, SW, SOF, etc.) ➢ Material type(s) and grade(s) ➢ Actual thickness and diameter range, where each WPS is to be used ➢ AWS and brand name of filler metal classification ➢ Pre-heating temperature ➢ PWHT requirements and other heat treatments if required (e.g. ISR, DHT, etc.) ➢ Applicable piping class and fluid service ➢ Maximum design temperature ➢ Minimum Design Metal Temperature (MDMT) and whether impact tested WPS is/are required

Before fabrication, the index of WPS and PQR (as per above list) along with all WPS shall be collected by Sub-Contractor in the welding book for submission to Contractor for review by METWE Department.

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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ISSUE 1

In addition to above, Sub-Contactor shall also submit to Contractor for review by METWE Department the following documents, as separate and dedicated documents, at the same time (or after) of the submission of the welding book:

➢ Each supporting PQR ➢ Material Acceptance Request (MAR) signed by Sub-Contractor for each proposed filler materials, composed of applicable DS and example(s) of MTC, which shall demonstrate compliance with the requirements of clause 6

For piping under ARH regulation: ➢ Before starting any welding operation, after approval of the Contractor and the Company, WPS

(including WPS for repairs) shall be also submitted to ARH for his approval.

➢ Once the WPS have been approved by ARH, they shall be qualified in the presence of ARH in a

laboratory accredited ISO 17025.

➢ The Sub-Contractor shall send to Contractor the schedule for the performance of PQR qualification tests at the various laboratories selected at least 15 days before the testing date, to enable the Company to invite ARH to attend. The schedule shall be accompanied by a detailed list of the normative tests to be carried out during PQR qualification with the applicable standards and acceptance criteria for each test.

➢ Welding shall not start until the PQR have been validated by ARH.

For joints subjected to PWHT, a dedicated heat treatment procedure (according to clause 9) shall be prepared and submitted by Sub-Contractor for Contractor review by METWE Department, prior to heat treatment. At the receipt from Contractor of the reviewed/commented welding book, PQR and PWHT procedure, Sub-Contractor shall implement all comments done. Any question and/or query to Contractor comments shall be communicated by Sub-Contractor to Contractor METWE Department through a dedicated written communication. When deemed necessary by Contactor’s METWE department a dedicated meeting shall arrange in site to clarify and solve all the comments for final acceptance of welding documents. Contractor reserves the right to reject documents not complete. If a document is returned to Sub-Contractor as “NOT ACCEPTED” (code NA), Sub-Contractor shall revise and resubmit to Contractor the document for review. Welding activities can proceed based on both applicable WPS and PQR (plus the heat treatment procedure where applicable) “APPROVED WITH COMMENT” (code AC) provided that comments are fully implemented by Sub-Contractor, or “ACCEPTED” (code A) from Contractor, CA and ARH/TPIA. Sub-Contractor/Vendor shall highlight changes in each subsequent revision of the document and submit along the CRS. Contactor reserves the right to reject welding book if submitted details are incomplete. Review and acceptance of Sub-Contractor’s welding documents by Contractor does not relieve the Sub-Contractor of responsibility for meeting all the requirements of the applicable code(s), Local Regulation(s), the purchase order and this specification. Contractor’s acceptance of Sub-Contractor’s welding book shall not be construed as authority for deviation from the requirements of the applicable code(s), the purchase order, or the project specification. Deviations may only be guaranteed in response to formal written request submitted to Contractor.

On isometric drawings (or another dedicated documentation if accepted by Contractor), all welds shall be clearly identified by separate letter or number, according to Project Specification “Management of Site Metallic Welding Activities”.

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PIPING WELDING GENERAL SPECIFICATION

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TCM IDENTIFICATION CODE

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ISSUE 1

AWS A3.0 “Standard Welding Terms and Definitions” shall be used for all specifications and documents. A system of welding data base (to be defined in agreement with Quality Department of Contractor) shall be held and maintained updated during whole fabrication by Sub-Contractor, and it shall clearly indicate for each weld joint the minimum information described by Project Specification “Management of Site Metallic Welding Activities”. Sub-Contractor shall provide to Contractor, on weekly basis, the Rejection Rate (KPI) as defined in clause 3 per welding procedure (WPS), per joint type and per welder/welding operator (ID number). Since KPI is based on statistical approach, rejection rate has to be considered valid for a welder/welding operator after a significant number of examined joints by him (i.e. 20 examined joints as minimum, according to sub-clause 4.4.3), under this limit the evaluation is up to the Contractor welding Inspector. Before start of welding and fabrication, welder qualifications (WPQ/WOPQ), welder qualification register, list of NDE operators and list of test equipment’s and calibration dates shall be submitted to Contractor and Owner for review. Before start of welding and fabrication, Sub-Contractor shall prepare Inspection and Test Plan and related NDE procedures to be employed. They shall be submitted to Contractor and Owner for review. For piping subject to ARH regulation, welding documents shall be provided in accordance with local regulation ARH procedure P-CTE-2.

4.2 WELDING PROCEDURE SPECIFICATION (WPS)

Welding Procedure Specifications (WPS) shall be prepared and issued by Sub-Contractor, for each type of joint and all welding situations, including weld repairs. Specific service requirements (such as process conditions, environment, and equipment type) shall be properly addressed by Sub-Contractor when preparing and qualifying the WPS. WPS shall be representative and dedicated for the weld which it refers, a single WPS cannot be used to identify more than one type of joint configuration (e.g. girth butt weld joint, socket joint, groove branch connection, fillet joint, etc.), moreover, the use of more than one WPS to represent one joint and/or weld is not allowed. All WPS’s shall be identified by univocal number. All WPS’s shall be issued by Sub-Contractor on a form, complying with Form QW-482 of ASME Code Sec. IX (see Appendix-B of ASME IX), or an equivalent form, which shall indicate all required production welding data and variable (both essential, supplementary, additional essential as per this specification and nonessential variables), required to perform the job. Appendix-A of this specification also provides the minimum contents to be included in the WPS. Orbital welding and similar fully automated welding processes require separate programming weld schedules for the specific joint geometry, diameter, wall thickness, and welding position. These weld schedules shall report all the essential and nonessential variables that are needed to accurately describe all motion (e.g. travel and oscillation), timing and electrical functions of the welding system. The specific weld schedules relevant to each welding procedure shall be noted on the WPS or as a supplementary table attached to the WPS. WPS shall be issued directly to the welder or posted on a notice board adjacent to the welding area. Where necessary WPS shall be translated to a language understood by the welder or welding operator, in addition to English (these need not be part of the welding book but should be available at shop or field).

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4.3 PROCEDURE QUALIFICATION RECORD (PQR)

Any pressure boundary welds or welds to the pressure boundary (including tack and weld repair) shall be qualified by Sub-Contractor in accordance with ASME B31.3 and applicable API and/or NACE Standard. All PQR’s shall be issued by Sub-Contractor on a form, complying with Form QW-483 of ASME Code Sec. IX (Appendix-B of ASME IX), or an equivalent form, which shall indicate all actual qualification welding data and variables (essential, supplementary, additional variables and nonessential variables). In addition to the essential variables listed in ASME BPVC Section IX, the WPS requires requalification if the essential variables in Appendix-B of this specification are exceeded. Test laboratories for mechanical, chemical and corrosion testing shall have a certified laboratory system in compliance with ISO/IEC 17025 (or equivalent) for the test methods employed. All instruments for testing shall have valid calibration certificates, furthermore, instruments shall be calibrated periodically in accordance with the requirements of the applicable norms and standards. The list of tests performed (in terms of type, number results), along with relevant test reports and sketches shall also be included in the PQR. Material test certificated of base material and welding consumables used during welding procedure qualification shall be attached to relevant PQR and submitted along with PQR itself. PQR run sheets (parameter per weld run to be recorded including amperes, volts, travel speed, preheat and inter-pass temperatures) detailing all essential variables and non-essential variables encountered during the procedure qualification testing, shall be part of PQR file. All PQR’s shall be approved or released by competent third party recognized by Contactor (like Lloyd Register, Bureau Veritas, etc.). All PQR’s shall be identified by univocal number. Buttering of the weld end of a component, which at a later stage will become a part of a pressure containing butt weld, e.g. as a transition between a corrosion-resistant alloy and a carbon steel, shall be qualified as a butt weld. Base materials and welding consumables necessary to perform new/fresh PQR shall be procured by Sub-Contractor.

4.4 PERFORMANCE QUALIFICATION (WPQ AND WOPQ)

4.4.1 GENERAL QUALIFICATION REQUIREMENTS

All welding including tack and repair welding shall be performed by welders and welding operators qualified in accordance with the applicable ASME B31.3 and Section IX, including API and/or NACE Standard. For each welder/welding operator, a Welder Performance Qualification (WPQ) or Welding Operator Performance Qualification (WOPQ) shall be issued by Sub-Contractor (or recognized competent third party when so released by him) on a form, complying with Form QW-484 A/B of ASME Sec. IX, or an equivalent form, which shall indicate all actual demonstration welding data, essential variables and test results. Materials and welding consumables necessary for WPQ’s execution shall be procured by Sub- Contractor. Contractor shall only accept welder qualification certificates issued by the welder’s current employer, at time of submission. Qualified welders shall be identified by means of an exclusively assigned ID Number. Sub-Contractor shall maintain a report of welders including name, photograph and welder ID number.

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4.4.2 JOB ADMISSION REQUIREMENTS

4.4.2.1 NEW WELDER / WELDING OPERATOR

Any new welder / welding operator (including welder / welding operator working with Sub-Contractor for less than 6 months) shall be subject to new/fresh project qualification, performing a welding test coupon using an approved WPS. In addition to the above, new/fresh project qualification shall be required for: a) any welders that have not practice on the tasks for which they were approved for a period of more

than 3 months;

b) in case of poor appearance of welds, final decision on the need for re-approval must be agreed

with Contractor and Owner;

The welder / welding operator final acceptance in production shall be subject to the follow chart described in Appendix-C (see sub-clause 4.4.3).

4.4.2.2 PRE-QUALIFIED WELDER / WELDING OPERATOR

Welder / welding operator pre-qualification working with Sub-Contractor since more than 6 months may be admitted directly to project, without any additional skill-test. Performance records and previous WPQ shall be submitted to Contractor and Company for acceptance prior to start the weld production. For each P-No. material, the first two production joints shall be subject to visual and radiographic test to confirm welder / welding operator pre-qualification acceptance according to sub-clause 4.4.3.

4.4.3 INITIAL PRODUCTION CONFIRMATION TESTS

After job admission, to verify the welders / welding operator ability at site and/or prefabrication shop the first two production welded joints shall be 100% examined by VT and RT methods for each P-No. material. The welder / welding operator final acceptance in production shall be subject to the follow chart described in Appendix-C. The above “first two production joints” examined and the two additional progressive joints (when required) shall be in addition to the NDE examination required according to sub-clause 10.1, and they shall be at Sub-Contractor’s charge.

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PIPING WELDING GENERAL SPECIFICATION

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WELDING PROCESS(ES)

5.1 GENERAL REQUIREMENTS

Sub-Contractor shall consider the following acceptable welding process (es):

Welding Process 1

Shielded metal arc welding (SMAW)

Root pass 2

Second pass

Fill/cap and fillet

Gas tungsten arc welding (GTAW/GTAW-P)

Gas metal arc welding spray (GMAW-Sp)

Gas metal arc welding short circuiting (GMAW-S)

X 5

Gas metal arc welding pulsed (GMAW-P)

Submerged arc welding (SAW)

Gas shielded flux cored arc welding (FCAW)

X 3

X 4

Note 1: This table is a list of welding processes that are commonly used and are deemed to be acceptable. Other welding processes and applications may be acceptable subject to purchaser’s approval

Note 2: Single side weld, where the root pass is not removed

Note 3: Only for welds on piping of NPS 2” and above (see also sub-clause 8.1)

Note 4: Only for welds on piping of NPS 4” and above (see also sub-clauses 5.4 and 5.5)

Note 5: With prior approval

5.2 ADDITIONAL REQUIREMENTS FOR GAS TUNGSTEN ARC WELDING (GTAW)

AND PULSED (GTAW-P)

Autogenous welding (without filler metal) is not allowed, no deviations are permitted. All GTAW/GTAW-P machines shall be equipped with arc starting devices (e.g. high frequency starting unit), crater-elimination, slope-in and slope-out control, and pre-gas and post-gas flow. Use of flux-cored GTAW rod (Kobelco TGX) or flux coated GTAW rod (Taseto TGF) for root pass of single-sided groove welds shall be subject to Contractor’s approval.

5.3 ADDITIONAL REQUIREMENTS FOR SHIELDED METAL ARC WELDING (SMAW)

Unless otherwise prior approved in writing by Contractor, maximum allowed electrode diameter is 4 mm.

5.4 ADDITIONAL REQUIREMENTS FOR SUBMERGED ARC WELDING (SAW)

Only automatic or fully mechanized SAW systems are permitted. SAW might be used for butt joints with rotating horizontal axis, having an outside diameter equal to or higher than 150 mm and a thickness exceeding 5 mm.

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Individual bead run deposited by single wire SAW processes shall not exceed 13 mm. Using of multi wire/tandem SAW process require specific approval from Contactor in advance. SAW shall not be used for repair welding without written approval from Contractor for each individual repair. SAW cannot be used for welding of high performance austenitic stainless steel materials.

5.5 ADDITIONAL REQUIREMENTS FOR FLUX CORED ARC WELDING (FCAW)

Self-shielded FCAW (FCAW-S) shall not be used. FCAW process can be used for welding of carbon steel with MDMT equal to or higher than -29°C, and for austenitic stainless steel materials only. For butt weld joints, FCAW process is allowed for pipe sizes NPS 4 and above, in 1G (rolled) position only. FCAW shall not be used for branch connections and for girth welds of pipe sizes under NPS 4. The use of short circuit transfer mode is not permitted.

5.6 ADDITIONAL REQUIREMENTS FOR GAS METAL ARC WELDING (GMAW)

GMAW process in spray transfer mode can be used for welding of carbon steel with MDMT equal to or higher than -29°C, and for austenitic stainless steel materials only. For butt weld joints, GMAW process is allowed for pipe sizes NPS 4 and above, in 1G (rolled) position only. GMAW shall not be used for branch connections and for girth welds of pipe sizes under NPS 4.

5.6.1 SPECIFIC REQUIREMENTS FOR GAS METAL ARC WELDING - SHORT

CIRCUITING TRANSFER MODE (GMAW-S)

Subject to prior Contactor approval, GMAW-S may be used for root pass of butt joints, expect for root pass of branch connections, socket welds or girth welds of pipe sizes under NPS 4. GMAW-S shall only be used with adapted/modified arc transfer mode like STT (Surface Tension Transfer), RMD (Regulated Metal Deposition), QSET (optimal short arc parameters settings) and CMT (Cold Metal Transfer), and it is allowed for carbon steel material only.

WELDING CONSUMABLES

6.1 GENERAL REQUIREMENTS

Welding filler material and fluxes shall be in accordance with ASME Section II Part C or ISO specification and classification. Welding consumables shall be supplied by a Manufacturer/Supplier accredited in accordance with ISO 9001 or an equivalent quality system approved by Contractor and Owner. Electrodes with a “G” (General) designation shall not be used. The solid bare/wire of welding consumables shall contain all the alloying elements; no alloy element shall be added via the flux or coating of welding consumables (i.e. synthetic consumables are not allowed). Only neutral and basic flux shall be used. Addition of alloying elements to the weld via the flux (other than to compensate arc losses) isn’t allowed. Active, alloy and crushed-slag fluxes shall not be used.

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Welding consumables shall be used only for the welding process applications recommended in the ASME II, Part C/AWS or ISO filler metal specification or by its manufacturer (e.g. filler metals or fluxes designed for ‘single-pass welding’ shall not be used for multiple pass applications and fluxes designated for non-PWHT applications shall not be used for PWHT applications). Consumable inserts may only be used with Contractor and Owner prior written approval. Filler metals shall be selected such that when joining similar materials, the chemical composition of the deposited weld metal shall match that of the base material and able to achieve required properties (e.g. ferrite content, corrosion test, etc.). However, this shall not preclude the use of welding materials containing alloying elements of different types or in different amounts than those in the base materials provided there is evidence that such elements are not harmful and are the only way to achieve desirable weld metal properties, such as adequate tensile strength after PWHT, adequate impact strength at low temperatures or corrosion resistance. Welding consumables shall be selected based on their mechanical properties, compatibility with the materials to be joined, their suitability for the intended service and consideration of welding process variables such as polarity, welding position and direction of welding. For FCAW procedures Sub-Contractor shall review weld metal properties with the consumable manufacturer to ensure that the original qualified properties continue to be met. Minor variations that occur over time with FCAW consumable formulations (e.g. raw material and microalloying changes) do not adversely affect the ability of these products to perform as intended. However, small changes in microalloying additions can have significant effects on properties, especially after heat treatment. All welding consumables shall have mechanical properties (strength, ductile and impact properties at required temperature) in the required heat-treated condition at least equal to the minimum required equivalent properties of the base material being welded. Welds joining materials of different strength grades within the same P-No. shall give the same strength as that specified for the lower grade of material and shall have ductility and notch toughness properties equal to the higher values specified for the grades of steel being joined. Filler metals for welds joining dissimilar materials shall be in accordance with Appendix-O, nevertheless, when attaching non-pressure parts to pressure parts, the filler metal chemical composition shall match the nominal chemical composition of the pressure part. Required consumable mechanical properties (both strength, ductile and impact properties at required temperature) in the required heat-treated condition, can be certified by: a) the filler metal manufacturer according to ASME BPVC Section II, Part C/AWS or ISO filler metal

specifications, or,

b) if approved by Contractor, can be established by the PQR if it has been qualified using the same

heat / lot of filler metals to be used for production welding.

Shielding and backing gas shall be of highest quality according to AWS 5.32.

6.2 MATERIAL TEST CERTIFICATES

Welding consumables shall be delivered in accordance with their product data sheet and shall have certification according to the following: a) Chemical analysis (including ferrite content, for Austenitic Stainless Steel and Duplex Stainless Steel), corrosion test results (if requested), maximum diffusible hydrogen content per 100g and mechanical properties (tensile and impact properties) shall be included as a minimum mandatory requirement on certification;

b) Material Test Certificates (MTC) shall be delivered

for each batch,

lot, diameter of

wire/strip/covered electrodes, wire/flux combination to be used for fabrication, as follow:

for chemical analysis according to EN 10204, Type 3.1 or AWS 5.01 sch. 3 or H
for mechanical properties according to EN 10204, Type 2.2 or AWS 5.01 sch 2 or G

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c) Fluxes for SAW/ESW processes shall be delivered with certification according to ASME BPVC Section II, Part C, SFA-5.01, paragraph 5, Schedule 2 or G, or EN 10204 Type 2.2 minimum; d) The quantity of consumables in a single lot of covered electrodes shall be in accordance with lot

classification C3 defined in ASME BPVC Section II, Part C or ISO 14344;

e) The quantity of consumables in a single lot of solid consumables shall be in accordance with lot

classification S3 defined in ASME BPVC Section II, Part C or ISO 14344;

f) The quantity of consumables in a single lot of tubular cored electrodes and rods shall be in accordance with lot classification T2 defined in ASME BPVC Section II, Part C or ISO 14344; g) The quantity of consumables in a single lot of SAW and ESW fluxes shall be in accordance with

lot classification F2 defined in ASME BPVC Section II, Part C or ISO 14344;

Gas cylinders shall be delivered in accordance with their product data sheet and shall have certification. Each Material Test Certificates (MTC) shall be provided by Sub-Contractor to Contractor along with a dedicated form according to “Project Inspection and Test Plan for Steel Piping Works”.

6.3

IDENTIFICATION, PACKING, STORAGE AND HANDLING

All material shall be visually inspected prior to welding to confirm the absence of mechanical damage/corrosion and to confirm correct marking. Consumables shall be supplied in moisture-resistant-sealed containers and stored in original and undamaged packaging. All welding consumables materials shall be stored and used in a manner that prevents exposure to the Manufacturer moisture and recommendation. In particular:

inclusion of hydrogen

the deposited weld,

following

➢ Low hydrogen filler metals shall be packaged in hermetically sealed containers, remain in sealed

packaging prior to use, and conserved in a dedicated heated storage area until to use.

➢ Alternatively, low hydrogen filler metals shall be thermally backed according to filler metals manufacturer instructions before using to ensure that they can meet a maximum hydrogen level of 8ml/100g weld metal prior to start the welding.

➢ Portable ovens (quivers), and other means as necessary, shall be used to ensure that the

electrodes remain dry.

➢ Open containers of SAW flux shall be stored in a humidity-controlled area, with a relative humidity

and temperature in accordance with the manufacturer’s recommendations.

Materials of different types shall be segregated and stored separately to avoid mix-up. Consumables shall be withdrawn from store only when required for immediate use. Unused consumables shall be returned to store at the end of welding operation. Batch numbers shall be recorded in the fabrication records on issue. Records of consumables shall be maintained to ensure an auditable trail from receipt, through pre-treatment, their issue to operators and return to warehouse so that their identity can be verified on each phase. Extra moisture resistant (EMR) consumables with a diffusible hydrogen content of less than 4-5 ml/100 g, supplied in vacuum pack, may be used without preheated storage for a period of maximum 9 hrs (after opening) or as per manufacturer instructions (if more stringent). Baking and storage of welding consumables shall be carried out in separate ovens. The ovens shall be heated by electrical means and shall have automatic temperature control. Welding consumable storage and baking ovens shall have a visible digital temperature indicator. Low hydrogen electrodes shall be issued to fabrication in portable ovens and they can be maintained at recommended temperature in such ovens for a maximum of four hours daily. After such time non- used low hydrogen electrodes shall be thermally backed according to filler metals manufacturer

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ISSUE 1

instructions before re-using. SMAW electrodes that have been re-dried shall be marked in a clear manner to indicate the number of drying cycles to which they have been subjected. SMAW electrode shall be subject to no more than three re-drying cycles or as per the consumable manufacturer’s recommendation (whichever is lower). All welding consumables shall be clearly identified with brand name, classification, and batch number. The identity must be maintained until consumed, in order that all the consumables, shall be made traceable with identification numbers to their material test certificate. Unidentifiable and/or rusty welding consumables shall not be used. Damaged filler material or filler materials exposed to moisture, grease or other substances that will induce hydrogen or oxygen into the weld deposit shall be discarded. Any welds that were made with such consumables shall be cut out and re-welded. No electrodes shall be left open in the site or workshops. All such electrodes, which are left open shall be discarded, as well as that have damaged flux coatings. Flux remaining unused (including flux remaining in the machine hoppers) shall be returned to the storage facility, re-baked, and returned to moisture-proof containers in accordance with the flux manufacturer’s recommendation. SAW fluxes exposed to moisture shall be reconditioned by baking in accordance with the flux manufacturer’s recommendations. In humid environments, the fabricator should consider the use of heated hoppers. 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. Seamed flux-cored wires shall not be left on machines out of use for more than a shift. Reuse of burned flux is prohibited. Flux using recrushed slag is not permitted. Controls shall be in place to ensure recovered flux is not contaminated in the recovery process and that the process meets the flux manufacturer’s requirements for protection from moisture. Where flux recycling is applied, the supplier’s consumable control procedure shall address new and reused recycling ratios and the number of times a flux may be recycled in accordance with the flux manufacturer’s recommendation. Gas cylinders as shall be clearly identified by identification labels with trade name, where applicable, or AWS classification, and the identity must be maintained until consumed. Gas cylinders shall be made traceable with identification numbers to their material test certificates. All bottles containing shielding gas (or gas mixture) shall be identifiable and shall be in a well- maintained condition without signs of external corrosion or rust on the body of the cylinder. Sub-Contractor shall have a documented procedure covering the storage, baking, segregation, distribution, and return of all welding consumables, complying with the above requirements. Documented records to ensure an auditable trail from receipt, through pre-treatment, issue, and return to store shall be provided by Sub-Contractor upon request.

WELD PREPARATION

7.1 CUTTING AND EDGE PREPARATION GENERAL REQUIREMENTS

Cutting and bevel preparation can be done using flame or plasma-arc process, a machine cutter, or grinding disc (or a combination therefore), as limited in below paragraphs. Edges shall normally be machined or beveled by grinding. Preparation of weld edges by flame or plasma cutting shall be done, wherever practical, with a mechanically guided torch, and followed by

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grinding/dressing to sound metal and bright surface finishing. Beveling with hand-held cutting torches is not permitted except when specifically approved by the Contactor. All cut and beveled edges shall be visually examined to ensure the absence of any defects. Any small burrs, nicks, dents or other surface irregularities on the weld bevel shall be repaired, if possible, by light grinding. Any suspected edge defects or laminations shall be reported to Contactor prior to proceeding with investigation or repairs. Unless otherwise accepted in advance by Contactor, aluminum flake weld-through primers shall not be used for weld joint surface protection. Weld bevels end preparation shall be performed according to ASME B31.3 para. 328.4.2. Weld bevel and fit-up shall assure complete joint penetration without excessive melt-through (refers also to additional requirements listed in sub-clause 8.7 for weld profile requirements). If not otherwise accepted by Contactor, the following basic bevel angles of ASME B16.25/ASME B31.3 shall be followed.

Where field welding (FW) is required to join the ends of two pieces of fabricated pipe, or a piece of pipe and a welding fitting or flange, the Sub-Contractor shall furnish both adjacent ends beveled for field welding and no extra pipe shall be added. Where field fit welding (FFW) is required, the Sub-Contractor shall allow 150 mm extra length of pipe with a plain end on one piece and furnish the adjacent piece of piping material with its end beveled for welding.

7.2 CLEANING

Prior to welding, surfaces to be welded shall be clean and free from paint, oil, dirt, scale, oxides and other foreign material detrimental to weld integrity. Organic contaminants such as oil, cutting fluids, or crayon marks shall be removed with appropriate solvents prior to welding. Oil and grease shall not be removed by heating with a torch. Each beveled edge, and internal and external surfaces over a distance of at least 50 mm back from the bevel, shall be thoroughly dried immediately prior to welding. 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.

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Welding shall not be performed when the base metal surface is wet or damp, appropriate heating shall be provided according to provisions of sub-clause 8.3 along with the applicable Appendix(es) of this project specification. Wire brushes and grinding discs shall be dedicated to one material type and shall be free from sulphur or chloride containing elements. Carbon or low-alloy steel wire brushes or other carbon or low-alloy steel tools shall not be used on stainless steel, duplex stainless steel and nonferrous materials. On small pipes, for which it is not possible to wire brush internal surface, an approved chemical cleaning material shall be used. Cleaning agents shall be compatible with the materials of construction and shall be neutralized, if required. Degreasing agents shall not leave chloride or sulfide containing residues on the surface. Parts painted with zinc rich paints or hot dip galvanized shall not be welded to any pressure equipment, unless the zinc in the area adjacent to the welding zone is completely removed by shot blasting, grinding or taping (prior to welding). Removal of the zinc rich areas by burning is not permitted. GTAW filler rods shall be checked for surface contamination prior to use and, if necessary, cleaned or degreased. For piping wrapped with coal tar enamel or other protective coating, the wrapper must be removed over a distance of at least 100 mm from the weld end.

7.3 ALIGNMENT AND TEMPORARY WELDS

Assembly, joint alignment and fit up shall be carried out to minimize any introduction of excessive loading or strains. Temporary attachments welded to the base metal shall be of the same material grade as the base metal and welded in accordance with a qualified weld procedure. Temporary attachments shall be removed by gouging or grinding only, taking care to prevent damage to the base metal (if thermal cutting is employed for remove temporary attachments), the attachment shall be cut off at a minimum distance of 5 mm from the surface of the material then ground flush. Removal by hammering shall not be allowed. The base metal shall be restored to its original condition before final heat treatment (if required), pressure testing, and final acceptance. The base metal shall be inspected with MT or PT upon removal of the attachment. Attaching thermocouples for PWHT using capacitor discharge is not considered as temporary attachment. However, after removal of thermocouple, the area is typically ground and inspected with MT or PT. Where required internal or external clamps and fixing aids may be used to assist the fit-up process:

➢ Fixing aids or temporary attachments welded directly to production material shall only be

permitted when approved by the Contractor and Owner.

➢ Where attachments are welded to materials such as stainless steel, duplex and nickel alloys

oxidation of the internal surface shall be avoided.

If line-up clamps are used without tack welding, they shall not be removed until the root pass has been fully completed. Where an internal or external line-up clamp is not used, alignment may be achieved using tack welds. Welding parameters for tack weld shall be always in accordance with approved WPS and performed by qualified welders. Tack welds shall use the same filler metal composition as the completed weld. The tacks shall be equally spaced around the circumference and in sufficient number to temporarily support the loads.

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XH-SW-000000001

SHEET 23 / 73

ISSUE 1

If tacks are applied using bars, bullets or bridges, these components shall be of the same nominal composition of the base material. Tack welds shall be removed by grinding. Tack welds intended to be an integral part of the root weld shall be ground to a taper edge to facilitate weld pick-up. Tack welds incorporated into the main weld shall be free of visible defects. Cracked, defective or badly profiled tack welds are to be completely removed and ground smooth prior to welding. Weld assembly / joint alignment shall be performed according to ASME B31.3 para. 328.4.3. Internal misalignment (due to difference in ID, lack of concentricity or their combination) in circumferential butt weld joints shall not exceed 1.5 mm. Greater misalignments than this limit may be corrected by grinding or machining, according to ASME B31.3 (refer to ASME B31.3 para. 328.4.2) provided that: ➢ ➢ Use of deposited weld metal to correct misalignment shall be subject to agreement by the Contractor. Reforming of elements, either hot or cold shall not be attempted without the acceptance of Contractor. For socket weld alignment, the axial gap between male and female component, as shown in figures 328.5.2B and 328.5.2C of ASME B31.3 code, shall be 1.6 mm minimum and 3.5 mm maximum. This gap is required prior to welding.

it shall be evenly distributed around the full circumference the wall thickness is not reduced below the minimum design thickness around the full circumference

Joint alignment for branched connections shall conform to the provisions of the figure 328.4.4 of ASME B31.3.

EXECUTION WELDING REQUIREMENTS

8.1

JOINT EXECUTION

Welding shall be carried out in conditions, which will not result in negative effect on weld quality. The weld and the area around it to a distance of at least 1 mt. shall be protected from wind, rain or other unfavorable weather conditions. Adequate wind shielding shall be ensured in the area where gas shielded welding (GTAW, FCAW or GMAW) is taking place. When field 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. Appropriate segregation control shall be employed during fabrication and necessary precautions taken to avoid contamination between different alloy types.

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XH-SW-000000001

SHEET 24 / 73

ISSUE 1

Fabrication areas for austenitic and duplex stainless steel, nickel alloys and other CRA materials shall be separate from that used for carbon and low alloy steel. Individual alloy types shall be segregated during fabrication. All jigs, fixtures, tools, cleaning and grinding equipment shall be clearly identified to avoid surface contamination between materials. In fact, tools and other equipment shall be suitable for, and dedicated to, each single type of material (not to mix between different alloy family). Iron and steel contamination of the austenitic and duplex stainless steel, nickel alloys and other CRA materials surface shall be prevented. Contamination during lifting and handling should be prevented by use of proper equipment (e.g. by use of nylon slings, rather than carbon steel chains). Do not mix tools (e.g. grinding discs) between them and carbon and low-alloy steel fabrication. Do not use the same grit blasting media as used for iron or non-stainless steel material. Rolling, forming, and other handling operations typically use carbon or alloy steel tools and machines that can embed iron and steel in the surface of these alloy steel. The embedded iron and steel cannot be reliably removed by brushing with a stainless steel wire brush, nor by light grinding, therefore pickling or electropolishing should be used to remove the embedded iron and steel. Failure to do so can result in rust blooms where the contamination occurred. Welding shall not be performed on cast iron (gray or ductile iron) parts. Components coated with low melting point materials as lead, zinc, cadmium, etc. shall not be welded, unless the relevant areas are completely removed. For no-flanged valves, the welding sequence and procedure and any heat treatment for a welding end valve shall be such as to preserve the seat tightness of the valve. Care shall be taken to minimize the amount of heat that goes into valves. Welding adjacent to inline valves shall be performed with valve in fully opened position. For piping not subjected to PWHT, welding after hydrotest is prohibited without Contractor and Owner approval. For piping subjected to PWHT, welding after PWHT is prohibited without Contractor and Owner approval. No further welding, forming or other operation detrimental to the galvanizing shall be performed after the galvanizing. Two passes shall always apply, including for socket joint welding. Single-pass welds are not allowed. All butt welds and branch connections on piping with diameters of NPS 2” and smaller shall have the root and hot passes performed with GTAW process. All socket and fillet welds (including flanges connected slip-on) on piping with diameters of NPS 2” and smaller shall be 100% GTAW. Using of vertical down welding requires prior Contactor’s approval. Weld starts and stops shall be situated in the fusion path. Starts and stops shall be staggered. The weld bead shall be ground smooth before the next weld bead is made, to avoid hot cracking especially at the stop/start positions. Thorough inter-run cleaning and slag removal shall be carried out. Peening shall not be permitted on any pass. Permanent backing strips or rings shall not be used. Fusible inserts or removable backing strips may only be used with the approval of Contactor. When accepted by Contractor, temporary backing devices may be used provided that the chemical composition is the same of base material being welded and/or that chemistry of the weld metal is not influenced by the backing strip itself. The strip shall be removed without damage to the surrounding material. The areas involved shall be ground flush and cleaned after removal. After backing strip removal, the area will be inspected for cracks by either liquid penetrant or magnetic particle testing. Under no circumstances shall the welding arc be struck outside the weld bevels. Any erroneous arc strikes shall be removed by grinding or other suitable method and the area shall be subject to surface

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XH-SW-000000001

SHEET 25 / 73

ISSUE 1

inspection (MT or PT) to ensure it is defect free. 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 it shall be reported to Contractor and Owner before any remedial action is taken and where required (e.g. to restore material thickness, a local weld repair shall be carried out in accordance with a welding procedure approved by Contractor and Owner). Sub-Contractor/Vendor 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. Earth cables shall not be welded to components being welded. Welds are to be uniquely identified. Sub-Contractor shall demonstrate to the satisfaction of Contractor that individual welds can be positively identified at all stages of construction. Weld identification numbers shall be marked adjacent to the weld (located at least 25 mm from the edge of the weld) by crayon, paint stick or similar marker prior to welding. Similarly, welder/welding operator shall mark their numbers/ identification symbol adjacent to each weld they make. Sub-Contractor shall maintain records of weld number and the welder identification for each weld for inclusion in final documentation. Welder ID number shall be stenciled by low stress stamps, upon completion of weld joint, at 25 mm from the edge of the weld. For alloy materials the ID number shall be painted in lieu of stenciled. In case of joints executed by more than one welder, each welder shall stencil his own symbol to allow a clear identification of the joint portion executed by him. Stamping, when used, shall be performed by a method that will not result in sharp discontinuities. In no case shall stamping infringe on the minimum wall thickness or result in dimpling or denting of the material being stamped. Upon completion of a weld, the welder must affix his registration number besides the welded joint. Marker pencils or paints free from sulphur, zinc, aluminum, lead, chloride, and other halogens. Each weld found without identification shall be 100% examined by RT method at the Sub-Contractor’s expense. Calibrated device for measuring the following variables/parameters shall be always available by Sub- Contractor/Vendor: ➢ welding current (amperage) ➢ arc voltage ➢ interpass temperature (digital) ➢ oxygen content of backing gas ➢ wire feed speed ➢

travel speed (a wristwatch with a second hand or second display and common ruler or tape measure may be used)

➢ shielding and backing gas flow rate Preheat and interpass temperatures shall be checked by use of thermocouples, temperature- indicating crayons, pyrometers, or other suitable methods. For austenitic stainless steels, duplex steel and nickel alloys, digital hand-held contact thermocouples are preferred over temperature-indicating crayons to avoid the potential contamination from tramp elements, such as fluorides, chlorides, and sulfides, which may be contained in the crayons. crayons shall not be used on stainless and duplex stainless steel. Thermocouples or pyrometers shall be calibrated. Preheat, interpass, and preheat maintenance temperatures shall be measured on the weld metal or on the immediately adjacent base metal. Temperature-indicating crayons are not permitted directly on weld metal or on the joint preparation. Welding and welding parameter measuring and recording equipment shall be calibrated at least every 12 months, or more often if required by the equipment manufacturer’s recommendations. In making socket and fillet welds, the weld metal shall be deposited in a way to guarantee adequate penetration into the base metal at the root of the welding.

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XH-SW-000000001

SHEET 26 / 73

ISSUE 1

Threading seal weld shall be performed when required by relevant Piping Classes, in such cases: ➢ all threaded shall be covered by weld metal; ➢

joints shall be cleaned of all foreign matter, including sealant and made up to full thread engagement before seal welding;

➢ when is necessary to weld galvanized materials, galvanizing coating shall be removed prior to welding on groove joints plus 50 mm on base material (both sides), galvanizing coating shall be replaced in accordance to painting specifications;

Precautions shall be taken throughout fabrication not to damage the gasket face on flanges.

8.2 BACKING GAS

Back purging is required to maintain internal weld surfaces and parent metal adjacent to weldment, clean and free from scale and excessive oxidation. In this concern: ➢ All single-welded groove joints of material containing more than two percent of chromium or nickel shall be welded using GTAW with inert gas back purge. The purge shall be maintained until at least 6.5 mm depth of weld metal has been deposited. Inert gas back purge shall be also applied and maintained throughout the welding operation, for socket, seal, and any other attachment welds on base materials containing more than two percent of chromium or nickel, when the relevant wall thickness is less than 6.5 mm.

➢

In the above cases, backing gas at the weld shall have no greater than 0.10% (1000 ppm) oxygen before welding. This is the criteria to be achieved. This does not mean that the fabricator needs to measure this criterion for every weld. This requirement may be achieved by established purging rules (e.g. 5X replacement volumes). The below formula should be used to achieve the required purging time: ➢ PT = (V/PGFR) X 4

where: a) PT = purging time (hr) b) V = volume of pipe section to be purged (ft³) c) PGFR = purging gas flow rate (ft³/hr)

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

8.3 PREHEATING

The Sub-Contractor is requested, under their full responsibility, to establish the minimum preheat temperatures related to:

thickness

➢ chemical analysis ➢ ➢ welding process and heat input ➢ restraint of the parts being joined

Minimum preheat requirements shall comply with the rules of ASME B31.3 (refer to para. 330.1.1, Table 330.1.1 and Table 331.1.3) and applicable API and/or NACE Standard. In addition, provisions of this specification shall be considered as a minimum mandatory requirement.

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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SHEET 27 / 73

ISSUE 1

Preheating, where required, applies to all type of welding (including welds joint for internals) and/or welding activities such as tack welding, carbon arc gouging and thermal cutting. For welding material combinations of different thicknesses, the minimum required preheat temperature shall be that for the material requiring the higher preheat. When dissimilar weld joint is accepted by Contactor, Sub-Contractor shall consult Contractor, for preheating requirements. In line of principle the temperature of the material with highest preheating temperature is governing. For welds of components such as fit-up clips, insulation rings, ladder and pipe clips, etc. proper application of preheat is essential and it shall not be less than that used for relevant main seams. The minimum preheat temperature specified in WPS shall be maintained during welding, until completion of the joint. The preheat temperature shall be applied throughout the entire thickness of the weld and at least 100 mm on each side of the weld. The preheat temperature shall be measured on the face opposite to that being heated when possible. When this is not possible, allowance shall be made for temperature equalization, (i.e. remove heat source and allow period of one minute for each 25 mm thickness of material to elapse, before measuring temperature). In case of fillet weld, the base metal must be preheated from the opposite side of the member to which the attachment weld is to be made and that the preheat temperature be measured on the side of the member to which the attachment weld is to be made. When the specified preheat is less than 100°C, the following shall be considered: ➢ Fuel gas/air burner systems, high-velocity gas/oil burners, electric resistance mats, induction

heating or infrared radiators may be employed

➢ Handheld oxy/fuel gas burners may only be used for welds with OD size less than 150 mm (6”) or

attachment welds less than 300 mm long

➢ Heating fuel shall be sulphur-free fuel ➢ Welding or cutting torches, oxyacetylene preheating and specifically designed heating nozzles

shall not be used.

When the specified preheat is 100°C or greater, or the wall thicknesses is above 20 mm, electric resistance heating mats, induction heating or infrared radiators shall be used. Anyhow where the joint configuration or dimensions make the use of electric element preheat impracticable as in the case of small diameter pipe work (DN<2”), then gas heating is permitted on carbon steel material, subject to Contractor and Owner approval with detail preheating procedure.

8.4 HEAT INPUT AND INTERPASS TEMPERATURE

Interpass temperatures shall be checked by use of thermocouples, temperature-indicating crayons, pyrometers, or other suitable methods. Thermocouples or pyrometers shall be calibrated. Interpass temperatures shall be measured on the weld metal or on the immediately adjacent base metal. Temperature-indicating crayons are not permitted directly on weld metal or on the joint preparation.

8.5 WELDING INTERRUPTION

If welding is interrupted for more than 3 minutes without maintenance of preheat before a minimum 10 mm of deposit or 25% of the total joint thickness or is completed (whichever is less), surface NDE (magnetic particle testing or penetrant testing) shall be performed before welding is restarted. Preheating shall be restored to the minimum preheat temperature specified in the WPS before welding is restarted.

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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SHEET 28 / 73

ISSUE 1

During interruption of preheat for:

Low alloy with wall thickness less than 50 mm, weldment cooling rates shall be reduced by using

insulation to allow hydrogen outgassing.

Carbon steel with wall thickness greater than 50 mm, weldment cooling rates shall be reduced by

using insulation to allow hydrogen outgassing.

Low alloy steel with wall thickness greater than 50 mm, DHT shall be performed before welds are

allowed to cool down.

8.6 PROXIMITY OF WELDS

Circumferential welds shall be separated by at least two times the wall thickness or 50 mm, whichever is greater, measured between the toe of each weld. Non-intersecting branch and non-pressure part attachment welds shall be at least two times the wall thickness or 50 mm, whichever is greater, from any weld, measured between the toe of each weld. Longitudinal weld seams shall be staggered by minimum 50 mm. Branch and non-pressure part attachment welds should not cross main seam welds if possible. If intersections are unavoidable, the length of the main seam weld covered by the attachment, including a projection at least 50 mm beyond each side of the attachment, shall be ground flush and RT examined and then the intersecting joint shall be inspected by minimum MT or PT, after welding.

8.7 WELD CONTOUR AND FINISH

All welds must be finished with a smooth profile, and they shall blend smoothly with the base material. All welds shall be contoured to permit proper interpretation of any required NDE. Welds shall be left as welded (except surfaces requiring machining or grinding to meet requirements stipulated in the applicable Weld Class) 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. Special care shall be taken by Sub-Contractor to eliminate or prevent stress risers which might causes low impact strength due to notch effect or abrupt change in section. On completion of fabrication, Sub-Contractor shall thoroughly clean the inside and outside of all fabricated assemblies of all loose material, scale, dropping, debris, slag, weld spatter, burrs, flux and other carbonized material or other imperfections, which could interfere with radiographic or ultrasonic inspection. All heat tinting on internal surface, defined as unacceptable by applicable Appendix(es), shall be removed by mechanical polishing, glass bead blasting or by chemical cleaning. AWS D18.2 chart shall be used as reference for heat tint color acceptance criteria, however, it shall be considered that AWS D18.2 chart is for austenitic stainless steels only. AWS D18.2 is not to be used for other alloy materials such as aluminum, titanium, or nickel, moreover, Sub-Contractor is cautioned that oxygen levels in the purge gas specified in AWS D18.2 chart coupled with different welding heat inputs may result in different visual oxidation results compared to the AWS D18.2 chart. All heat tinting on external surfaces shall be removed by pickling and passivation. Pressure retaining butt welds shall be full penetration. Weld metal penetration shall comply with the limits given in ASME B31.3 para. 341.3.2 and Table 341.3.2, with the following additional requirements, whichever is the more stringent: a) Internal welds at the joint of orifice flange to pipe shall be ground smooth, as requested by

Instrument dept.

b) Unless otherwise permitted by Contactor concavity on the root side is not permitted.

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XH-SW-000000001

SHEET 29 / 73

ISSUE 1

The welds of any type of branch connection (both SBR and OL) shall be finished with cover fillets, which shall fill and smoothly transition to the attachment weld and pipe/fitting. Branch connection joint type shall be carried out according to ASME B31.3 para. 328.5.4 and Figures from 328.5.4A to F. If no more stringent requirements are specified by other project documents, weld profile reinforcement shall comply with the limits given in para. 341.3.2 and Table 341.3.2 of ASME B31.3. Socket and fillet welds shall be ground to a smooth concave contour, for socket weld joints the corner of the edge where the bead rests shall not have melted. Socket and fillet welds sizes shall be according to ASME B31.3 para. 328.5.2 and Fig. 328.5.2A.

PWHT REQUIREMENTS

9.1 GENERAL REQUIREMENTS

PWHT shall comply with the requirements of para. 331 of ASME B31.3, construction drawing(s) and Licensor’s documents, together with the additional requirements specified in this paragraph and on relevant Appendixes. The lower PWHT temperature permitted by code(s) by increasing holding time is not acceptable. Exemption of code required PWHT for ferritic steel base materials based solely on the use of austenitic or nickel-based filler materials is not permitted. Temper bead technique shall not be allowed to be used in place of PWHT. When joining parts of different thickness, holding time shall be that for the thicker material. PWHT shall be performed in fuel-fired or electrical enclosed furnaces, during heat treatment the spool(s) shall be supported and stiffened to prevent distortions. Fuel-powered furnaces shall have adequate flame controls to avoid an oxidizing furnace atmosphere. Direct flame impingement is always prohibited. Exothermic kits shall not be used for PWHT. When local PWHT is necessary, the following shall apply:

a) Full circumferential band around joint shall be uniformly heated by electric resistance and cooled, according to AWS D10.10 (any recommendations shall be considered mandatory) and NACE SP 0472 para. 3.7 for piping in sour, amine, caustic and HTHA service

b) Local spot PWHT (called a “bull’s eye”) on piping is not allowed. c) The weld joining sections shall be positioned away from local discontinuities such as branch,

changes in section and major attachments.

PWHT hold time shall be set according to wall thickness in compliance with applicable code(s) and project specifications, in any case 1 hour minimum shall apply (unless a stringent requirement is specified in the applicable Appendix). PWHT temperature shall be strictly controlled, measuring both the piping skin and furnace temperatures using thermocouples. All thermocouple attachments shall be adequately insulated to avoid temperature misreading caused by the effect of radiation. Thermocouple attachments shall be capacitor discharge connection, or nut and bolt construction (as shown in the figure below).

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PIPING WELDING GENERAL SPECIFICATION

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TCM IDENTIFICATION CODE

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SHEET 30 / 73

ISSUE 1

➢

if nut and bolt construction method is used, the materials shall be of a compatible composition and treated as a temporary attachment per sub-clause 7.3 If low energy capacitor discharge welding method is used, the following shall apply: • • a dedicated WPS describing the low energy capacitor discharge equipment and technique

the materials should be of a compatible composition;

shall be included in the reference PWHT procedure; the energy output of the welding process shall not exceed 125 W/sec;

•

The weld metal shall be removed by careful dressing followed by MT or PT examination after PWHT to confirm absence of linear indications. Continuous time-temperature chart shall be provided to record the metal temperatures of the part or components being heat treated and to control heating and cooling rates and holding times. The temperature measured by each thermocouple shall be recorded by means of a multi-channel chart recorder. Each chart shall be marked with the date of the PWHT. Prior to commencement of PWHT the Sub-Contractor’s competent Inspector or nominee will inspect the set up and sign the heat treatment chart which shall have as a minimum the following information: ➢ ➢ channel identification and signature(s) of Sub-Contractor’s responsible personnel, confirming

information to ensure traceability of the joint(s) under treatment;

compliance with the approved procedure;

Copy of these charts along with relevant PWHT report shall be furnished to Contractor Welding Inspector for review and they shall be included in the fabrication dossier. All temperature measuring devices will have valid calibration certificates. All machined surfaces shall be protected against oxidation during heat treatment. When dissimilar weld joint is accepted by Contactor between ferritic to stainless steel, Sub-Contractor shall consult Contractor for PWHT requirements (if applicable). A PWHT procedure shall be developed by Sub-Contractor prior to heat treating and submitted to Contractor and Company for review and approval. As a minimum it shall include the following information:

a) Description of the pipe weldment

b) The method and type of heating process

c) Location and type of heating elements

d) The number and locations of thermocouples (with a single line sketch)

e) Supporting details (including a sketch)

f) Heating and cooling rates

g) Maximum allowable temperature differentials

h) Gradient control information

i) PWHT temperature range and holding time

j) Soak, heating and gradient control band dimensions for local PWHT applications (including a

sketch)

k) Insulation type and dimensions for local PWHT applications (including a sketch)

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PIPING WELDING GENERAL SPECIFICATION

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TCM IDENTIFICATION CODE

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ISSUE 1

10 WELD INSPECTION REQUIREMENTS

10.1 NON-DESTRUCTIVE EXAMINATION (VT, MT, PT, RT AND UT)

NDE examinations (both in terms of extension, personnel, procedure and acceptance criteria) shall comply, as a minimum, with the requirements of ASME B31.3 para. 341, together with the additional requirements specified in this specification. All finished welds shall be subject to VT examination by Sub-Contractor, and it shall precede all other NDE to be performed. It shall be noted that VT examination may be conducted, as necessary, during the fabrication and erection of piping components to provide verification that the design and WPS requirements are being met; but in any case, VT examination shall be performed by Sub-Contractors to verify that all completed welds in pipes comply with the requirements of sub-clause 8.6 along with the acceptance standards specified in this specification. Non-destructive examination of welds shall be carried out after final heat treatment. For girth welds, the required RT examination may be performed before or after PWHT, if examination is performed before PWHT the following shall be considered: ➢ RT examination performed before PWHT shall be at Sub-Contractor’s charge; ➢ An additional RT examination shall be performed after PWHT; Appendix-E of this specification shows (for each type of joint) the followings: ➢ applicable NDE method(s) ➢ NDE extension for the different Weld class(es) When spot or random examination is specified, a “progressive sampling for examination” as below described shall be applied by Sub-Contractor: a) If a weld is rejected (repaired / cut-out), other two welds of the same designed lot made by the welder (who made the defective weld) shall be examined by Sub-Contractor, at his charge. If these other two welds examined are acceptable progressive sampling is concluded;

b) If any of the welds examined as required by point-a above reveals a defect, then two further welds (for each defective joint found) of the same designed lot made by the involved welder shall be examined, at Sub-Contractor’s charge. If all these further welds examined are acceptable progressive sampling is concluded;

c) If any of the welds examined as required by point-b above reveals a defect, then all the welds of the same designed lot made by the involved welder shall be examined, at Sub-Contractor’s charge;

Should spot or random examination reveal the systematic presence of defects in welds or of defects imputable to mis-assembly and/or mis-removal of assembling brackets, examination shall be extended to 100% of the welds. The extension of the test shall be at Sub-Contractor’s charge. Random and Spot examination of welds is an effective quality control tool when properly implemented, therefore the following shall be considered and applied by Sub-Contractor: ➢ Examination shall provide feedback to the welder showing that the work is satisfactory or not. If the work is not satisfactory, the welder and/or the welding supervisor has to take corrective steps to improve the welding’s quality in subsequent work. Such steps can include the full range of changes through increased attention, from initial fit-up to replacement of the welder; It is critical that examinations shall be made (and timely feedback provided to the welder), contemporaneously with the work being done. The sooner the welder learns that his weld requires repair, the sooner he can take corrective action;

➢

Weld class is specified on isometrics and line list of the project, and NDE examinations shall be performed based on the designed lot as defined in clause 3.

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XH-SW-000000001

SHEET 32 / 73

ISSUE 1

Regardless Wels Class, the followings shall apply:

In jacketed lines, all welds covered by jacket shall be RT examined;
All longitudinal welds carried out by Sub-Contractor shall be subject to 100% RT examination, where radiography is not feasible (e.g. split collar, two halves tee and cross pieces of jacket lines), 100% recordable UT examination shall be performed;
For dissimilar materials (different P-No.), unless otherwise required by Contactor, 100% of both

superficial and volumetric examination shall apply;

All reinforcing and attachment pads to be leak tested after welding and before hydro test by using vent hole. Leak test shall be done by air or other approved test media at 1.00barg. The vent hole shall be packed with heavy grease after hydro test (do not close by NPT plug);

Note: Drill and tap 6 mm Dia NPT through reinforcing pad before weld on pipe. Vent hole shall be provided at the side (not in the crotch). If reinforcing pad is made of several pieces, provide vent hole to each piece. For full pad, longitudinal weld seam shall be flushed and PT (or MT) before install pad plates (see last paragraph of sub-clause 8.6).

Branch connection weld shall be subjected to the required NDE examination prior to install reinforcing pads. When a circumferential weld with an intersecting longitudinal weld(s) is examined, at least the adjacent 38 mm of each intersecting weld shall be examined. Only the method with A.C. yoke shall be used for MT examination. Permanent magnet or D.C. yoke shall not be used. Liquid penetrant materials shall be free of heavy metals (e.g., zinc, lead), sulfur, and other materials detrimental to high nickel nonferrous materials. Penetrant, Cleaner and Developer solutions shall not have a combined residual Sulphur and halogen content more than 1%. The penetrant and the developer must be from the same manufacturer and the same generic type. Both the PT and MT examinations shall always be carried out from the outside and, if accessible, also from the inside. Examination shall include a base metal portion at least 25 mm wide on each side of the joint. For ferritic material (CS, LTCS and LAS only), Sub-Contractor may propose the use of recordable UT examination technique method (Phased Array Technique) as examination system in lieu of radiographic examination, ensuring that all results are permanently recorded and can be archived. Recordable UT examination technique shall comply with Appendix-F. Any examination shall be performed in accordance with a written procedure that conforms to the requirements of this document. All NDE examination to be performed by Sub-Contractor, including VT examination, shall be carried out by personnel qualified (as a minimum) in according with the requirements of SNT-TC-1A level 2 (or equivalent), for the examination method. An updated record shall be maintained for NDE personnel. Personnel qualified level 2 shall be supervised by a level 3 certified specialist. Level 2 and 3 certificates shall also be issued by authorized, independent third-party bodies in accordance with current regulations and standards. At the start of the project, the subcontractor shall submit copies of the NDT inspectors’ level 2 certificates for approval by the contractor and the company. Contactor Inspector, the Authorized Inspection Agency, the Owner (or his Agent) and ARH shall have access to the Sub-Contractor’s facilities and equipment for the purpose of inspection and audit of work and materials. They shall have free entry, always while work is being performed, to all parts of the Sub-Contractor’s works that concern the fabrication, assembly and/or installation. The Sub-Contractor shall afford the above Inspectors all reasonable facilities to satisfy him that the work is being furnished in accordance with the Contract. All inspections shall be conducted so as not to interfere unnecessarily with the operation of the works.

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XH-SW-000000001

SHEET 33 / 73

ISSUE 1

All non-destructive examinations shall be certified by testing reports issued by Sub-Contractor and signed also by Contractor and Company Inspector(s).

10.2 PRODUCTION HARDNESS TEST

When production hardness test is required by relevant Appendix(es), test shall be carried out by Sub-Contractor on weld joints (including repair if applicable) to verify the compliance with the required maximum hardness values. For each hardness tested welds: ➢ a minimum of three test points per joint shall be taken, 120° a part each other’s ➢ each test point shall include three measurements:

• one in the weld metal •

two adjacent to the fusion line (HAZ) at each side of weld

Areas to be checked shall be located by Contractor Inspector. Hardness test report, issued by Sub-Contractor, shall record all the test results and locations. Acceptable portable hardness testing equipment are the followings:

Portable Brinell hardness testers (e.g. Telebrineller, Poldi, Calibrated Pin Tester, or other

approved equivalent device) shall comply with the followings:

➢ portable Brinell type hardness testing shall be performed in accordance with ASTM A833 and the

➢ ➢ ➢

equipment manufacturer’s recommendations; the hardness of the reference bar shall be within ±10% of the maximum specified hardness; the diameter of the indention ball shall not be smaller than 7 mm and not larger than 10 mm; the area under test shall be ground or machined flat and shall have a surface finish (Ra) of 3μm max (grit size approx 120), in order to remove the decarburized surface (~0.3 - 0.5 mm) and to get the surface to be hardness tested sufficiently ground to ensure that the edge of the impression will be clearly defined to permit measurement of the diameter to within +/- 0.02 mm;

➢ grinding shall be conducted in such a manner that overheating of the material is prevented; ➢ one hardness test measurement shall consist of minimum three hardness readings for each

location. The average of these readings shall be reported as the test result;

➢ adjacent readings shall be at least 6.4 mm apart, edge to edge; ➢ according to manufacturer, the minimum wall thickness for hammer impact testers that depend on a reference bar comparison is about 5 mm. However, if any test piece deflection results from the test, such a comparison would be invalid; the identification of the manufacturer’s equipment and the diameters of the impressions in the test piece and comparative test bar shall also pointed-out in the test procedure;

➢

UCI (ultrasonic contact impedance e.g. MIC 10/20, etc.) hardness testers are also permitted if the

procedure is approved by TCM Inspector; and provided that:

➢ portable UCI Vickers hardness testing shall be performed in accordance with ASTM A1038 and

➢

the equipment manufacturer’s recommendations; the area under test shall be ground or machined flat and shall have a surface finish (Ra) of 2,5μm max (grit size approx 180) where the decarburized surface (~0.3 - 0.5 mm) has been removed;

➢ grinding shall be conducted in such a manner that overheating of the material is prevented; ➢ one hardness test measurement shall consist of minimum five hardness readings for each

➢

location. The average of these readings shall be reported as the test result; if the difference between the maximum and minimum valid values exceeds 30 UCI hardness number; the test shall be repeated in an adjacent area and testing with a Brinell type hardness tester is required for verification;

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XH-SW-000000001

SHEET 34 / 73

ISSUE 1

➢ material thickness is 5 mm or greater; Leeb type (rebound) hardness testers (e.g. Equotip, or similar device), according to ASTM A956, are not permitted. The hardness test report shall indicate the following minimum information’s: a) Type of hardness tester and its most recent calibration date b) Personnel conducting hardness tests c) Test surface preparation (method and tool) d) Type of material e) Test location f) Reading of each point tested Personnel performing hardness testing shall demonstrate their capabilities to the satisfaction of Inspector. Qualification of the hardness testing personnel, including training and experience, shall be made available to Inspector. Hardness acceptance criteria for each material are specified in relevant Appendix(es).

10.3 PRODUCTION FERRITE TEST

When production ferrite test is required by applicable Appendix(es), welds shall have ferrite measurements made by using a ferrite scope calibrated in accordance with AWS A4.2M. A valid calibration certification shall be available for the Inspector(s) verification. A total of five readings for each measurement shall be taken in the center of each weld cap surface and on the root pass (where accessible). The weld cap and root pass shall be prepared as recommended by the testing equipment manufacturer. For chemical analysis a physical sample is required. Alternatively, an optical emission spectrometer may be used to check all required elements, including carbon and nitrogen. The number and location of tests to be performed are specified in applicable Appendix(es). In any case welds made from each weld procedure, welder, and heat/lot of filler metal shall be tested. Ferrite measurements shall be taken before PWHT. Sub-Contractor shall consult Contractor about requirements to be applied to welds joining dissimilar materials (different P-No.). Ferrite measurement techniques and procedure shall be subject to Contractor Quality Dept. and Owner acceptance.

10.4 PMI TEST

Low-alloy and alloy material weld joint shall require PMI test according to project specification no. 4439-XZ-SG-000000002 - PMI General Specification.

REJECTION AND WELD REPAIRS

Weld repairs shall comply with the requirements of the applicable code(s), including preheat requirements (or recommendations), PWHT requirements and NDE. Unacceptable defects in ferritic steels shall be excavated by mechanical means or by carbon arc gouging to a depth agreed with Contactor followed by grinding. Unacceptable defects in nonferrous materials shall be excavated by mechanical means only. The excavation shall be contoured to permit proper access for welding.

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XH-SW-000000001

SHEET 35 / 73

ISSUE 1

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. When a defect is removed but welding repair is unnecessary, thickness shall not be reduced below the minimum requirement and the surface shall be contoured to eliminate any sharp notches or corners, otherwise the excavation shall be contoured to permit proper access for welding. If back purging was required for the original weld, then back purge shall be re-established if the repair excavation encroaches closer than 6.5 mm to the inside surface. All repair welds are to be 100% re-inspected by the methods specified for the original examination, and a progressive sampling for examination shall be applied by Sub-Contractor according to sub- clause 10.1, at Sub-Contractor’s charge. All repair preparation, remedial grinding and repair welding shall not begin before informing Contractor and Company about the Sub-Contactor’s proposed actions. The Contractor and Company Inspectors shall have the right to witness all repair works. Welds containing repairs that were made after PWHT shall be subject to repeat PWHT in accordance with this document. When repair of a weld is done by a weld cut-out, the original weld and HAZ shall be removed. Repair welding shall be qualified by the original PQR if it is within the essential variables, or by a separate PQR qualified for the specific repair scenario. Impact testing of repair weld procedure qualification shall sample the weld metal and both the adjacent HAZ (i.e. the HAZ in the original weld metal and the HAZ in the parent material). A second attempt to repair the same weld area is not allowed. Welds indicating irremediable or injurious defects, improper fabrication and/or excessive repairs, shall be subject to rejection at any time, at Contactor and Owner discretion. Crack repair is not allowed. When cracks are observed the cause shall be investigated.

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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SHEET 36 / 73

ISSUE 1

APPENDIX-A - MINIMUM CONTENT FOR WPS

The following minimum data shall be specified on WPS:

Welding process/combination of welding processes and grade or type of automatization (i.e.

Manual, Semiautomatic, Machine, etc.)

Equipment type and model when a power source employing pulsed modes is used (without

waveform control)

Equipment type, model and waveform control mode, when a power source with waveform control is allowed to be used (e.g. Lincoln STT, Fronius CMT, ESAB Superpulse, Kemppi WISEROOT etc)
Base material data:

a) P-No. and G-No. assigned by the ASME Code section IX committee or applicable material

specification and grade

b) Detailed base material properties/condition and/or chemical composition, when such data are

considered additional essential variables (e.g. maximum Carbon Equivalent, etc.)

Applicable production diameter and wall thickness range
Joint design sketch (including all the welding passes foreseen):

a) Type of bevel b) Angle of bevel c) Root gap d) Root face e) Weld pass(es) sequence representation

Where metallic backing material is permitted, the P-No. or its nominal chemical composition
Filler metal data:

a) Size b) ASME II, Part C/AWS specification and classification (including flux-wire designation) c) A-number and F-number d) Manufacturer and trade/brand name (always) 9) Flux type, grade and manufacturer trade/brand name 10) Infusible Tungsten electrode:

a) Size b) Type c) AWS classification 11) Electrical characteristics:

a) Current type (ac or dc) and Polarity b) Arc voltage (V) with appropriate ranges c) Current (A) with appropriate ranges d) Transfer mode (for each run) in case of GMAW and FCAW processes e) The pulse frequency, waveform and background current, for pulsed welding process (with or

without waveform control)

f) Background current, Pinch current, Peak current and Tail-out speed for STT (Surface Tension

Transfer) welding mode or other short arc mode with wave control form

g) Heat Input range (kJ/mm)

NOTE: For waveform-controlled welding the heat input shall be measured according to QW-409.1(c) of ASME Code sect. IX, along with the applicable appendixes (when required).

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XH-SW-000000001

SHEET 37 / 73

ISSUE 1

Travel speed (mm/min)
Wire feed speed and electrode stick-out for partial-mechanized, mechanized and automatic

welding processes (e.g. SAW or when allowed for GMAW, FCAW)

Oscillation width when weave bead technique is applied
Frequency width and dwell time on side wall for each pass, when oscillation technique is applied

using mechanized or automatic welding processes

In case of multi-arc is used, number of arcs per head (or number of heads) and separation

between arcs.

Welding position and direction of welding
When interruption in welding is allowed, minimum number of runs completed before to cooling to

ambient temperature.

Cleaning method (for both base metal surfaces to be welded, inter-run and final surface cleaning)
Interpass data:

a) Maximum temperature b) Method of measuring temperature

Pre-heating data:

a) Minimum temperature, b) Method of applying heat c) Method of measuring temperature

Shielding gas composition, purity and flow rate
Internal gas purging data (when applicable):

a) Composition, purity and flow rate b) Number of passes before removal of internal gas purging c) Details of the method and equipment to be used for monitoring oxygen content.

Arc starting aids or devices in case of using GTAW welding process
Post-heating data (when applicable):

a) Temperature range, b) Minimum holding time c) Method of applying heat d) Method of measuring temperature

NOTE: for maximum (and minimum) heating and cooling rates, details of the method and equipment to be used, the reference to applicable PWHT procedure shall be included in WPS

Post weld heat treatment data (where applicable):

a) Holding temperature range b) Holding time range c) Heating rate d) Cooling rate

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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SHEET 38 / 73

ISSUE 1

APPENDIX-B - ADDITIONAL ESSENTIAL VARIABLES

In addition to the essential variables required by applicable Code and ASME BPVC Section IX, the WPS requires requalification if the essential variables listed in this Appendix are exceeded.

Essential variable

Description

Joints

A change from double sided welding to single sided welding (1)

When impact testing or corrosion testing is required, a decrease in the included angle or more than 10° where this results in an included angle that is less than 50°

A deviation from qualified included angle of more than 2.5° if the qualified included angle is less than 30° (except for portions of compound bevels)

Any change in nominal root gap tolerance +/- 1 mm (0.04 in.) for single sided welding

For P-No. 1 in sour service:

a) an increase in CE content of more than 0.03%

respect of the PQR coupon

Base material

b) any increase (respect of the PQR coupon) for:

Nb(Cb) > 0.01wt%
V > 0.01wt%
Ti > 0.01wt%
B > 0.0005wt%

x(2)

Base material

A change in the material grade or in the UNS number

Base material

A change heat treatment condition (N, Q+T, N+T, etc.)

Material thickness

Any change exceeding what is specified in clause B.1

x(2)(3)

Consumable

A change in brand name

x(2)(3)(5)

x(5)

Consumable

Same AWS classification

Consumable

A change in the flux-wire combination

x(5)

Consumable

Any change in the filler material size or width and thickness in case of strip

x(2)(3)

Wire diameter

Any change in the diameter for FCAW and GMAW processes

Welding position A change from vertical downhill welding and vice versa

Welding position

For mechanized and automated welding processes, a change in position exceeding ASME sect. IX, QW-461.9

Welding position

For manual and semi-automatic welding processes a change in position exceeding ASME sect. IX, QW-461.9

Gas

Removal of backing gas

x(3)

x(7)

x(8)

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Girth welds

LAS

ASS

NA N08020 N08825

SDSS S32750

Buttering

x(2)

x(5)

PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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SHEET 39 / 73

ISSUE 1

Description

Girth welds

Buttering

Essential variable

Gas

A change in shielding or backing gas composition or decrease in purity level, e.g. a change from high purity to industrial purity argon

Preheating

Any decrease on minimum temperature

Post-heating

Any decrease in holding temperature or holding time

Post-heating

Deletion of post-heating

Interpass Temperature

Heat Input

Any increase on maximum temperature

Any increase of the minimum heat input for a weld zone used during procedure qualification welding

Any reduction of the minimum heat input for a weld zone used during procedure qualification welding

PWHT

Any decrease in holding temperature or holding time

x(2)(4)

Transfer mode

A change in transfer mode

Welding equipment

Weaving

A change in make, model and program settings for GTAW-P or GMAW-P and any type of wave control mode

A change from stringer bead to weaving technique or vice versa

x(3)

Welding process

A change between single wire to multiple/tandem configuration

Welding process

A change between manual, semi-automatic, mechanized and automatic welding

Welding process

A change in the welding processes combination used during the qualification (including the order of application)

x(2)

x(3)

x(2)

x(7)

x(6)

NOTE 1 - single sided welding with backing strip is equivalent to double sided welding. NOTE 2 - when Sour Service is applicable. NOTE 3 - when impact test is applicable. NOTE 4 - when HTHA service is applicable. NOTE 5 - for SAW and FCAW processes only. NOTE 6 - for materials and material combinations of P-No. 3 and greater (except P-No. 8). A process used only for root passes can be qualified separately. NOTE 7 - for nickel alloy 20 base material only (UNS N08020) NOTE 8 - WPS shall be qualified in the vertical-up position (3G), if the welding is to be performed only in the flat (1G) position, then only qualification in the 1G position is required

B.1 - DUPLEX STAINLESS STEEL - THICKNESS QUALIFIED

The minimum and maximum qualified weld thickness (t) shall be as follows: a) For t ≤ 16 mm the minimum qualified thickness shall be the thickness of the qualification test coupon

(T) and the maximum qualified thickness shall be 2T, up to a maximum of 16 mm

b) For t > 16 mm but < 29 mm both the minimum and maximum thicknesses may be qualified by

qualification test coupons within this range

c) For t ≥ 29 mm the minimum qualified thickness is T, and the maximum qualified thickness shall be

1.2T

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XH-SW-000000001

SHEET 40 / 73

ISSUE 1

APPENDIX-C - INITIAL PRODUCTION CONFIRMATION TESTS

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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ISSUE 1

APPENDIX-D - FABRICATION OF PIPING SUPPORTS

Piping supports shall be fabricated in accordance with the requirements of “Project Specification Piping Support”. Welders, welding operators and WPS shall be qualified in accordance with the requirements of the ASME Code Section IX. If not otherwise accepted by Contractor, requirements specified in both the clauses 5 and 6 shall be followed. In addition to VT examination of all welds, random PT or MT examination on 5% of whole welds shall be performed by Sub-Contractor. Full traceability shall be carried out by Sub-Contractor for all support materials and weld joints.

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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ISSUE 1

APPENDIX-E - WELD CLASS(ES) - NDE REQUIREMENTS FOR PIPING

TYPE OF JOINT

WELD CLASS

Girth welds

10% MT/PT

100% RT

TBA

5% RT random and 100% UT

5% RT random

Socket welds

None

100% MT/PT

TBA

Not applicable

10% MT/PT

Pressure containing Tee welds such as pipe to pipe branch connections (including reinforcing pads) and branches made with “O-let” fittings

Fillet weld (including seal welds, slip-on flanges, reinforcements, supports)

None

100% MT/PT

TBA

100% MT/PT

10% MT/PT

None

100% MT/PT

TBA

100% MT/PT

10% MT/PT

➢ Note 1: 100% ferrite test of welds shall be performed where weld class with digit -1 is specified ➢ Note 2: Hardness test shall be performed according to appendix(es) (weld class is not specified)

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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ISSUE 1

APPENDIX-F - RECORDABLE UT EXAMINATION TECHNIQUE

F.1 - REQUIREMENTS FOR CONCESSION REQUEST

Radiographic examination can be replaced by automated or semi-automated recordable UT examination (AUT) provided that prior written approval to be obtained from Contractor METWE Department, Company and ARH. The written concession request to be prepared by Sub-Contractor shall clearly define the scope of production welds to be inspected by AUT in lieu of RT, providing all the following information: a) reason for using of UT method in place of RT method b) applicable base material c) size and wall thickness d) weld bevel configuration e) weld geometry including weld cap condition (as weld, ground smooth, or ground flush) f) single or double side accessibility g) number of the joint expected to be examined by AUT for each combination of above parameters h) proposed techniques of inspection, specifying methods of inspection for each of the following type

of flaws: ➢ ➢ ➢

in longitudinal direction in transverse direction, and in base metal lamination

All the conditions listed in below paragraphs shall be applied by Sub-Contractor, in addition to the ASME B31.3 para 344.6 requirements.

F.2 - SCOPE

The AUT in substitution of the RT can be proposed only under the following conditions: a) for carbon steel material grade (P-No. 1) with a minimum specified tensile strength not greater

than 70 ksi b) butt weld joints:

of size not lower than 6”
with wall thickness not lower than 12 mm

Commentary Note: Phased Array S-scan (PAUT) technique could be applied for size 2” and above and wall thickness 6 mm and above, provided that:

dedicated probe (e.g. cobra type) are considered
the distance between the probe and the weld center line shall be constant with a maximum allowable variation of ±1 mm.
the scan increment along the weld shall be no more than 0.5 mm

c) not apply to butt weld joints of unequal thickness, or in general aligned within the dimensional

limits of the WPS by tapering (inside or outside) or by trimming

d) not apply to narrow gap bevel joints e) not apply to welds executed with high strength welding consumables (type E80xx/ER80 or higher

grades)

f) using of Phased Array S-scan (PAUT) technique with minimum 2 scans

Commentary Note: In cases where scanning is performed from one face, half and full skip shall be used as minimum; if scanning is performed

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

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ISSUE 1

from both faces, half skip could be sufficient. g) each scan from external surface and parallel to the weld axis shall be done for both sides. h) if accepted by CONTCTOR and OWNER and properly qualified and demonstrated, PAUT could

be applied on one side for the pipe-to-fitting and/or pipe-to-flange joints.

i) perpendicularity tolerances between fusion lines and beams remains within ± 6° in order to

generate an optimum beam/discontinuity interaction. the examination area shall include the volume of the weld, plus the lesser of 25 mm or nominal wall thickness Tw of adjacent base metal on each side of the weld

Commentary Note: Alternatively, the examination volume may be reduced to include the actual heat-affected zone (HAZ) plus 6 mm (0.25 in.) of base material beyond the heat-affected zone on each side of the weld, provided: (1) the extent of the weld HAZ is measured and documented. (2) the ultrasonic transducer positioning and scanning device is controlled using a reference mark (paint or low stress stamp adjacent to the weld) to ensure that the actual HAZ plus an additional 6 mm (0.25 in.) of base metal is examined.

k) all activity shall be performed by an experienced Third party appointed by Sub-Contractor.

F.3 - GENERAL EXAMINATION REQUIREMENTS

The proposed automated or semi-automated recordable ultrasonic examination (AUT) system shall be Phased Array S-scan technique (PAUT), utilizing computer-based data acquisition and analysis abilities. A mechanical guided scanner capable of maintaining a fixed and consistent search unit position relative to the weld centerline shall be used.

Commentary Note: Guide mechanisms such as probe holding frames or magnetic strips shall be used to ensure that the probe moves at a fixed distance from the weld centerline.

The devices and accessories (magnetic strips and magnetic wheel, optical target, carriage, cradle…) shall ensure an accuracy of transducer positioning equal to the greater of 2 mm or 5% of the distance from the transducer to the weld centerline and ensure also that the ultrasonic beams are perpendicular to the theoretical axis of the flaws to be detected. Multiple passes with minimum 2 scans with an encoder are required. Each scan shall be from external surface and parallel to the weld axis, maintained at a fixed distance by mechanical means, with the beam oriented perpendicular to the weld axis. Scanning speed shall be such that data drop-out is less than 2 data lines/in. (25 mm) of the linear scan length and that there are no adjacent data line skips. For S-scan techniques, the angular sweep incremental change shall be a maximum of 1 deg or sufficient to assure 50% beam overlap. When multiple linear scans are required to cover the required volume of weld and base material, overlap between adjacent linear scans shall be a minimum of 10% of the effective beam width for S- scans. A-scan data shall be recorded for the area of interest at a minimum digitization rate of five times the examination frequency and recording increments of a maximum of 1 mm. The scan increment setting perpendicular to the weld, when applicable, shall be chosen in order to ensure the coverage of the examination testing volume. If the length of a weld is scanned in more than one section, an overlap of at least 20 mm between the adjacent scans is required. When scanning circumferential welds, the same overlap is required for the end of the scan with the start of the scan. Data shall be recorded in unprocessed form. A complete data set with no gating, filtering, or thresholding for response from examination of the required volume above specified shall be saved

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PIPING WELDING GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

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electronically (e.g., magnetic, optical, flash memory, etc.). Missing scan lines shall not be compensated (by use of software artifices such as pixel size increase) and the instrument shall be able to clearly display those missing scan lines. Missing lines in the display shall not exceed 5% of the scan lines to be collected, and no adjacent lines shall be missed A data viewer shall be permanently made available to Contactor and Owner, during the inspection phase as well as for future data investigations. The data viewer shall be included with the data package. Appendix-P of ASME V art. 4 shall be considered for interpretation of PAUT scans. The proposed AUT shall be always supplemented by manual ultrasonic technique (MUT), or other complementary AUT technique: a) for examination of laminar reflectors in the base material on both weld side for a distance of at

least 50 mm (straight beam) according to ASME V art.5;

b) for examination of reflectors transverse to the weld seam (angle beam) according to ASME V art.4

clause T-472.1.3, utilizing at least two different angle beam shear wave probes;

Commentary Note: This supplementary technique shall be used that directs the beam parallel or essentially parallel to the weld centerline. The technique used shall depend on whether or not the weld reinforcement has been ground flush or not.

c) provisions of ASTM E164 related to the MUT examination techniques, shall be taken in account

with the following considerations: ➢

fusion lines shall be interrogated by beams being, within ± 6° tolerances, perpendicular to their surfaces.

➢ all points of the weld metal volume shall be interrogated by two angle beams minimum, those

angles differing by more than 10°, whatever is the component thickness

F.4 - ACCEPTANCE CRITERIA

Welds that are shown by ultrasonic examination to have discontinuities that produce an indication greater than 20% of the reference level shall be investigated to the extent that ultrasonic examination personnel can determine their shape, identity, and location so that they may evaluate each discontinuity for acceptance in accordance with (1) and (2) below:

Discontinuities evaluated as being cracks, lack of fusion, or incomplete penetration are

unacceptable regardless of length;

For other discontinuities, the acceptance criteria for the thickness to be examined specified in

ASME B31.3 para. 344.6.2 applies.

F.5 - PROCEDURE

F.5.1 GENERAL

The AUT shall be executed following a written procedure prepared by a level-Ill UT, in compliance with the requirements of ASME V art.4, including Mandatory Appendixes V, VII and IX, along with the recommended practices provided in ASTM E2700 / ASME BPVC Section V ARTICLE 23 SE 2700. The same Level III person shall control and supervise procedure qualification demonstration. The supervising Level III shall prepare and approve the written procedure before conducting the demonstration. The written procedure shall be subject to the review by Contactor and Owner prior to procedure demonstration.

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The procedure shall identify which software, and associated release, is used for: ➢ Ray tracing (scan plan) ➢ Focal law calculation (if not computed by the instrument itself) ➢ Data collection ➢ Data analysis The procedure shall specify which technique is used for length sizing, height sizing and/or defect indication nature evaluation. In case of supplemental Manual UT is performed for nature or height evaluation, it shall also be explained in the scan interpretation Section of the procedure. Any use of data post processing shall be mentioned. This procedure shall contain scan plans dedicated to each combination diameter/thickness subject to AUT. Each scan plan shall contain, as minimum, the following: ➢ Weld thickness ➢ Weld cross-section geometry ➢ Extent of clad (if present) ➢ Weld joint preparation, configuration, and dimensions ➢ Extent of the HAZ and additional coverage ➢ Weld crown width and profile ➢ Beam plots for all refracted angles used, including focal law setting ➢ Extent of coverage (on a sketch showing the actual weld Section and the extent of the scanning

coverage by each probe)

➢ Calibration reflectors ➢ Probe index spacing (from weld centerline) ➢ Zonal coverage overlap Marking of lines corresponding to probe index location, as well as the use of a mechanical device (e.g. magnetic strip for small encoders fixed to the probes) are mandatory. The encoder resolution shall be at least 0.2 mm. The nominal frequency shall be the same as used in the qualification. The rate of search unit movement shall not exceed that qualified. The scanning sensitivity level shall not be less than that qualified. Instrument calibration within its validity period (12 months maximum). The wedge shall not be damaged (no strips, cracks, wearing which produce spurious wedge reflections) and shall be checked as follows: No wedge echoes, located in the area of interest, and with amplitude > 20% reference level shall be observed.

F.5.2 - COUPLING REQUIREMENTS

Coupling shall be monitored. In this concern a control function for coupling efficiency is required. The way to monitor the coupling shall be described in the procedure. A suitable coupling shall be used to ensure a proper transmission of the ultrasonic signals between the probe and the wedge. A suitable coupling shall be used to acoustically couple the wedge to the inspected component, not being detrimental to the material being examined. Typically, injected water shall be used in case of semi-automated or automated inspections: a thin film of water shall be produced between scanning surface and search unit contact surface. The characteristics of the coupling medium shall remain constant throughout the verification, calibration operations and the examination. It shall be suitable for the temperature range in which it

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will be used. After the examination is completed, the coupling shall be removed. The same coupling shall be used for calibration and examination operations.

F.5.3 - SURFACE REQUIREMENTS

Weld intersection between circumferential and longitudinal welds shall be ground flushed in order to ensure a proper scanning (coupling and guiding of probes). Scanning surfaces shall be clean in an area wide enough to permit the testing volume to be fully covered. Scanning surfaces shall be even and free from foreign matter likely to interfere with probe coupling (e.g. rust, loose scale, weld spatter, notches, grooves). Waviness of the test surface shall not result in a gap between a probe and the test surface greater than 0.5 mm. These requirements shall be ensured by dressing the scanning surface, as soon as judged necessary by the inspector. The temperature difference between the reference block and examination surface shall be within 14°C (25°F). When not using special high temperature probes and coupling, the surface temperature of the object under testing shall be in the range +5°C to 50°C. For temperatures outside this range, the suitability of the equipment and coupling shall be verified. To ensure repeatability of the scanning, a permanent reference system shall be applied by permanent marking using hard stamps to indicate the origin and direction of each scanning. This reference system shall also be indicated on the associated material drawing in final report.

F.6 - CALIBRATION REQUIREMENTS

IIW or Phased Array calibration block type A shall be considered

For time base/sweep range setting (velocity, wedge delay, exit points etc.) and sensitivity balancing: ➢ For sensitivity settings (DAC/ACG/TCG): ➢ provisions of T434 of ASME Section V article 4 and VII-434 of mandatory Appendix-VII shall apply In particular, a scanner block shall be fabricated meeting the requirements of ASME V article 4 para. VII-434.1(a), to verify the scan plan and examination calibration. The scanner block is in addition to the calibration block required per ASME V article 4 unless the scanner block has all the specified reference reflectors required per figure T-434.3-1 or T-434.3-2 (as applicable).

Commentary Note: For piping diameter > 6’’ and t > 20 mm, T-434.3-2 shall be used.

As built dimensional reports of the blocks used for sensitivity calibration shall be provided. Scanner block shall be of sufficient length (or number) to ensure that the examination technique is demonstrated, and the flaws are captured at full production scanning speed. For calibration confirmation, the scanner block shall be scanned, and the reference reflector indications recorded prior to and at the completion of each examination or series of similar examinations, when examination personnel (except for automated equipment) are changed (i.e. each shift) or equipment shutdown, and anyhow, every 4 working hours. Calibration and scanner blocks shall be in “as welded” (or in PWHT conditions for joint subject to PWHT, otherwise transfer methods in compliance with ASME B31.3 para 344.6.1 shall apply). For encoder calibration confirmation, a calibration check shall be performed at intervals not to exceed one month or prior to first use, thereafter, made by moving the encoder along a minimum distance of 20 in. (500 mm) and the displayed distance being ±1% of the actual distance moved.

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F.7 - QUALIFICATION REQUIREMENTS

Considering a tolerance of +/-25% on the thickness, the testing procedure shall be validated and qualified in accordance with ASME V art. 4 Appendix IX and ASME V art. 1 para. T-150 requirements, witnessed by Contactor and Owner. The requirements of ASME V article 4 Table T-421 and Table V-421 shall also apply. Procedure qualification shall take place before the first examination. Qualification blocks shall be made from the same material grade (P-No. according to ASME IX) as the test object (e.g. with regard to sound velocity, grain structure, and surface condition). Qualification blocks shall contain a weld according to the same welding procedure, made from the same material and having a similar surface and (weld) geometry as the test object.

Commentary Note: the weld caps/root conditions shall be the same as those encountered for production weld testing.

When the production joints will be scanned from both sides of the weld axis, the qualification blocks shall be prepared by welding and shall contain one set of flaws as below described. When approved by Contactor and Owner, the production joints will be scanned from one side of the weld axis, then the qualification blocks shall contain two sets of flaws: one set on each side of the weld axis. One set of flaws consist of minimum four flaws artificial discontinuities, as follow: a) three actual planar flaws (or three EDM notches) oriented to simulate flaw parallel to the production weld’s axis and major groove faces. The flaws shall be located at or adjacent to the block’s groove faces: i. One surface flaw on the side of the block representing the component O.D. surface ii. One surface flaw on the side of the block representing the component I.D. surface iii. One subsurface flaw

b) on actual planar flaws (or EDM notch) oriented to simulate flaw-oriented transverse to the

direction of welding: i. One surface flaw on the side of the block representing the component O.D. surface

Commentary Note:

When the scan plan to be utilized subdivides a weld into multiple examination zones, a minimum of one flaw per zone is required.
Width of EDM notches shall be 0.2 mm.

For nominal wall thickness (Tw) greater than or equal to 6 mm but less than 25 mm, flaws size shall be no larger than the flaw sizes in Table below:

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For nominal wall thickness (Tw) greater than or equal to 25 mm, flaws size shall be no larger than the flaw sizes in Table R308.1 and R308.2 of ASME B31.3, considering an aspect ratio of 0.25 for surface flaws and of 0.50 for subsurface flaws. The block design drawing shall be subject to the review of Contactor and Owner before procedure demonstration. “As built” dimensional reports of the qualification blocks shall be provided. Acceptable performance is defined as follow:

all reflectors shall be detected and their amplitude exceeding 20% of the reference level
transverse flaws shall be correctly detected and located
the flaws nature (Planar, threadlike, volumetric, slag, etc.) shall be correctly assessed
the flaws length shall be sized as being equal to or greater than their actual length Demonstration block flaws may be sized and categorized by a supplemental manual technique(s) outlined in the procedure, only if the automated or semiautomated flaw recorded responses meet the requirements of (1) above. The examiner performing the procedure demonstration shall be a Level II or Level III examiner (other than the supervising Level III). The information of the flaws in the procedure demonstration block shall not be disclosed to the examiner(s) demonstrating the procedure. The AUT examiner shall be qualified to use the procedure when their performance demonstration test is determined to be successful. The following shall be also verified according to the written procedure during the witness: ➢ Personnel qualification ➢ ➢ Calibration process ➢ All essential variables and non-essential variables in the written procedure ➢ Process of scanning according to scan plan ➢ Process of data evaluation and analysis ➢ The range of which the procedure is qualified for shall be documented on the procedure demonstration record (PDR). The Sub-Contactor shall maintain procedure demonstration records (PDR’s) including the following: ➢ Written procedure ➢ Number including revision number ➢ Name of the examiner ➢ Person witnessing the qualification ➢ Date and location of the demonstration ➢ Demonstration block ➢ Scan plan used for demonstration ➢ The range of the procedure qualification based on each demonstration The test records shall be available to Contractor and Owner, for review.

Instrument Manufacture’s/Supplier’s calibration

Inspection report on the demonstration block

F.8 - PERSONNEL REQUIREMENTS

AUT personnel shall be qualified according to ASME Section V, T-120 (e) or (f) as UT Level II or UT Level III. AUT personnel using PAUT techniques shall meet the requirement of ASME Section V, T- 120 (g) as Level II in PAUT.

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All the operators executing the AUT and its evaluation, shall successfully participate in the above- described qualification. The final data package shall be reviewed and approved by different level-Ill UT (other than the Level II or Level III, performing the examination). His review shall include the ultrasonic data records, the data interpretations and the flaw evaluations / classifications reports performed by all the qualified AUT Level 2 or 3 teams involved on project. Assessment of the quality of AUT image is part of the UT Level 3 final verification work. The signing of the final report as checker means having assessed this quality, classification of indication and acceptance criteria.

F.9 - REPAIRS

Considering that weld repairs shall be inspected with the same AUT procedure and criteria, one or more complementary offset scan (offset corresponding to extra-width of weld induced by repairs) shall be developed and qualified. The entire thickness of repaired joint shall be scanned. In this concern, a specific setting shall be necessary due to the position of repair, as well as a specific calibration is required in that case. Qualification for weld repair shall be performed scanning the qualification block with a probe index variation corresponding to the maximum weld width considering the weld repair. Re-examination after repair shall cover at least 150 mm (6 in) beyond each end of the repair.

F.10 - RECORDS

All the PAUT raw data shall be daily stored on a media accepted by Contactor and Owner and transmitted to Contactor and Owner with the final report. A clear directory structure shall explain the correspondence between the electronic files and the inspected welds. Those files shall be readable by anybody using the appropriate software provided by the Sub-Contractor to Contactor and Owner and shall not be protected. Written AUT reports, together with their unprocessed scan files (and data viewer software), previously also checked by Sub-Contactor personnel, shall be delivered to Contactor and Owner for their review. In fact, the Sub-Contactor shall be the sole responsible for the review, interpretation, evaluation, and acceptance of the completed scan data to assure compliance with the requirements of this Appendix, and the referencing ASME B31.3 Code. Sub-Contactor acceptance shall be completed prior to presentation of the scan data and accompanying documentation to Contactor and Owner. All reportable indications (i.e. responses above 20% of reference level for PAUT) shall have the following included in the report: ➢ Location ➢ Size ➢ Characterization ➢ Categorization ➢ Reject/accept ➢ Additional comments (e.g. reason for rejection) At least one scan image (B-scan, D-scan or C-scan) showing the entire volume of the weld/HAZ shall be included in the report for each weld section examined. Every rejectable indication shall be marked on the image showing its presence and have additional image(s) showing its sizing measurement. Welds that do not have any reportable indications shall have at least one scan image for the entire volume of each section examined to show the absence of reportable indications.

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APPENDIX-G - HARDNESS REQUIREMENTS FOR PQR (METHOD, LOCATION AND

NUMBER OF MEASUREMENTS)

In all cases, hardness tests shall be performed after PWHT when PWHT is required. Vickers hardness testing method, in accordance with ASTM E384, with a load of HV10 shall be used. The following criteria shall be full filled for both groove and fillet joints: a) for weld thicknesses less than or equal to 5 mm, only one row of indentations shall be made at a

depth of 1.5 mm below the upper surface of the welded joint;

b) for weld thicknesses over 5 mm, one row of indentation from each side shall be made at a depth

of 1.5 mm from the surface;

c) for double sided welds, one additional row of indentations shall be made through the root area; d) where more than one welding process is used, each welding process shall be tested by at least

one row of indentation;

e) for each row of indentation at least three individual indentations shall be made in each of the

following areas:

the weld
both HAZ
both parent metals for the HAZ, the first indentation shall be placed as close to the fusion line as possible (approximately 0.2 mm);

g) The minimum distance between the centers of any two hardness indentations, shall be 1 mm; therefore, it is acceptable that hardness measurement location in HAZ is off-the line in order to satisfy the minimum spacing requirements;

Individual HAZ hardness readings exceeding the value permitted by this specification are considered acceptable if the average of three hardness readings taken in the equivalent HAZ profile location adjacent to the hard HAZ reading (by repolishing the existing procedure qualification specimens or extracting additional procedure qualification specimens) does not exceed the values permitted by this specification and no individual hardness reading is greater than 10HV10 units above the acceptable value.

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APPENDIX-H - ADDITIONAL AND SPECIFIC REQUIREMENTS FOR CARBON STEEL

(CS/KCS/LTCS)

H.1 - PQR TESTING REQUIREMENTS

H.1.1 - TENSILE TEST AND BEND TEST

For all PWHT’ed items tensile strength tests and bend tests for each butt weld procedure qualification shall be carried out on coupon heat treated simulating maximum heat treated condition of relevant item, and shall comply with the requirements of the subject material specification.

H.1.2 - IMPACT TEST

Impact test shall be performed for LTCS material welding at -46°C, as follows: a) For PWHT’ed joints, impact test on weld metal and HAZ for each butt weld procedure qualification shall be performed on both two coupons, one heat treated simulating minimum heat treated condition and one heat treated simulating maximum heat treated condition of relevant item;

b) Impact test shall comply with the requirements of applicable code(s) but not lower than 27J (avg) /

20J (sing) for full size specimen (10x10 mm);

For FCAW process (when allowed) PQR testing shall be always qualified with impact testing in weld metal. Charpy V notch toughness (CVN) shall be equal to or greater than 27J (avg) / 20J (sing) at either -18°C or the MDMT whichever is lower. In welds that join two different base materials (e.g. P-No.1 gr.1 and P-No.1 gr.2), both sides of the weld shall be tested. Impact test is not required when the maximum obtainable Charpy specimen has a width along the notch of less than 2.5 mm. When more than one welding process is included in a test coupon, the following shall apply for impact test:

The specimens shall be full-sized or the largest subsize specimen that can be obtained based on

the thickness of the test coupon;

The weld metal test specimens shall contain as much of the weld metal from each process as is

practical;

When the test coupon contains more than two welding processes, and it is not possible to locate specimens within 1.5 mm of a surface, additional weld metal impact specimens shall be taken at the thickness where those processes are located;
Heat-affected zone specimens shall be prepared from material that was removed at the thickness plane associated with weld metal from each process. These specimens may contain material that was affected by the heat from more than one welding process;

H.1.3 - MACRO AND HARDNESS TEST

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Vickers hardness traverses for each welding procedure qualification shall be carried out in as welded conditions (for no-PWHT items) and after PWHT (for PWHT’ed items, considering the minimum heat- treated condition) and it shall comply with the following: a) For non-sour service item(s), method, location and number of measurements specified in

Appendix-G shall be complied with. The maximum hardness value shall be 248HV10

b) For sour service item(s), method, location and number of measurements specified in NACE MR0103 Appendix-C shall be complied with. No individual reading shall exceed 248HV10 and in weld metal the average shall also not exceed 210HV10

H.2 - WELDING CONSUMABLES

C-0.5Mo (A-2 number) welding consumables shall not be used. For carbon steel pressure-retaining welds, if base metal is exempt from impact testing, weld metal shall have a Charpy-V notch toughness (CVN) equal to or greater than 27J (avg) / 20J (sing) at either -18°C or the MDMT whichever is lower. For carbon steel with sour service requirements, welding consumables shall produce a deposit containing less than 1% Ni. Except for components in sour service and subject to prior Contractor written approval for MDMT lower than -30°C, filler material with Ni alloy element (e.g. ER80S-Ni1, E7018-C3L, etc.) with a maximum of 1% nominal nickel content, could be proposed by Vendor to consistently achieve impact test properties, provided that the required hardness values specified in sub-clause H.1.3 are complied with.

H.2.1 - GTAW AND GMAW

The following requirements shall apply: a) Rod/wire designation SFA-5.18 ER70S-2 and ER70S-3 shall be used b) Rod/Wire designation SFA-5.18 ER70S-6 may be used, provided that hardness requirements of

this specification are complied with

c) For Sour Service, SFA-5.18 ER70S-6 shall be restricted as follows:

➢ Carbon (C) 0.10 wt% max, Manganese (Mn) 1.60 wt% max, Silicon (Si) 1.00 wt% max

d) Where impact test is required, the following requirements shall be considered:

➢ For MDMT not lower than -20°C: SFA-5.18 ER70S-2, ER70S-3 and ER70S-6 ➢ For MDMT not lower than -30°C: SFA-5.18 ER70S-2 and ER70S-6 ➢ For MDMT not lower than -46°C: welding rod/wire EN classified W 42/46 5 xx (e.g. Bohler

EML 5, Lincoln LNT-25, etc.)

Only hydrogen free gas (with dew point ≤ -40°C) shall be used, to avoid possible cracking and embrittlement of the weld.

H.2.2 - SMAW

The following low hydrogen electrode shall be used: SFA-5.1 E7018, E7015 and E7016, only. The diffusible hydrogen limit (per SFA-5.1) shall not exceed H8 for base materials with a specified minimum yield strength (SMYS) less or equal to 60 ksi (415 MPa), and H5 for base materials with a specified minimum yield strength (SMYS) greater than 60 ksi (415 MPa). Where impact test is required, the following requirements shall be considered: a) For MDMT not lower than -30°C: SFA-5.1 E7018-1, E7016-1 and E7015-1 b) For MDMT not lower than -46°C: SFA-5.1 E7018-1 and E7016-1

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H.2.3 - SAW

Wire classified according to SFA-5.17 shall be used, including EH (high manganese) provided that hardness requirements of this specification are complied with (see clause H.7). Electrodes specified in ASME SFA 5.17 and electrode classification EM12K specified in ASME SFA 5.23, shall not be used for SAW on carbon steels having a minimum specified tensile strength of 482 N/mm2 or higher, where P.W.H.T. is specified, unless a PQR with same PWHT (or higher temperature/time) as production demonstrates that filler metal has sufficient strength. The diffusible hydrogen limit (per SFA-5.17) shall not exceed H8 for base materials with a specified minimum yield strength (SMYS) less or equal to 60 ksi (415 MPa), and H5 for base materials with a specified minimum yield strength (SMYS) greater than 60 ksi (415 MPa).

H.2.4 - FCAW

The diffusible hydrogen limit (per SFA-5.20) shall not exceed H8 for base materials with a specified minimum tensile strength less or equal to 70 ksi (483 MPa), and H4 for base materials with a specified minimum tensile strength greater than 70 ksi (483 MPa). Only hydrogen free gas (with dew point ≤ -40°C) shall be used, to avoid possible cracking and embrittlement of the weld.

H.3 - WELD PREPARATION

For wall thickness greater than 50 mm, magnetic-particle examination shall be performed on all pressure-containing plate edges and openings before welding. Examined area shall involve the weld bevel area, and a minimum of 50 mm of neighboring surfaces.

H.4 - PREHEATING

For carbon steel any moisture shall be removed by wiping and subsequent heating. If the ambient temperature is below 10°C, preheat temperature of 50°C min. shall be applied; however, the material to be welded shall be always at a temperature not lower than the ambient dew point temperature. Non-sour service carbon steel items with wall thickness 25 mm and above shall be preheated to 95°C minimum. Sour service carbon steel items, a minimum of 95°C preheat shall be used for all welding (regardless wall thickness). When welding high CE forgings and fittings, such as high strength low-alloy steels, special welding procedures, including preheat and cooling rate control for hardness management, shall be developed to reduce the risk of hydrogen assisted cracking.

H.5 - HEAT INPUT AND INTERPASS

For carbon steel material interpass temperature shall not exceed 315°C.

H.6 - POST-HEATING AND PWHT REQUIREMENTS

When PWHT is required by applicable code(s) due to thickness, stress relieving shall be performed in the temperature range 595-650°C, as follows: a) If PWHT “T” is indicated for a piping line in Line List and/or isometric drawing(s), exemption to PWHT may be applied by Sub-Contractor according to ASME B31.3 Table 331.1.3, except for thickness greater than 38 mm. For thickness up to 38 mm PWHT exemption specified by ASME B31.3 shall be confirmed by ARH as part of his WPS approval.

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b) If PWHT “Y” (“YES”) is indicated for a piping line in Line List and/or isometric drawing(s), all relevant welds, including branch, socket, seal and attachment welds, shall be subject to PWHT, code exemption is not permitted in such cases.

c) PWHT shall be performed at 635ºC +/- 14ºC, due to the following environmental cracking

services: ➢ Wet H2S ➢ Hydrogen (in the form of HTHA - refer to API RP 941) ➢ Amine ➢ Caustic

d) For quenched/normalized 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 30°C below the tempering temperature used during the manufacture of the base metal component and recorded on the material certificate.

e) PWHT holding time shall be set according to wall thickness in compliance with para. 331 of ASME

Code B31.3, in any case 1 hour minimum shall apply.

f) PWHT for TMCP pipe is strictly forbidden.

H.6.1 - ADDITIONAL REQUIREMENTS FOR UOP PIPING CLASS(ES)

Welded joints greater than 38 mm in thickness that require PWHT shall be heat treated immediately upon completion of welding. The joint shall not be allowed to cool below 150ºC prior to PWHT. Alternately, the weld and adjacent metal may be heated to 315ºC, wrapped with insulation, and allowed to cool. PWHT may then be performed later. Welded joints less than or equal to 38 mm in thickness that require PWHT, alternatively, may be permitted to cool prior to PWHT if the joint is 100% radiographed after completion of PWHT. If 100% radiography cannot be performed, the provisions of UOP 8-12-10 para. 2.4b are required.

H.7 - PRODUCTION HARDNESS TEST

The hardness for production welds is required as per sub-clause 10.2. Hardness test shall be performed as a minimum on 10% of butt joints, except where 100% hardness test is required. 100% of hardness test for production welds is required in any of the following cases: a) Using of FCAW welding process with any type of filler metal (hardness only in weld metal); b) Using of SAW welding process with AWS A5.17 EH (high manganese) wire (hardness only in

weld metal);

c) Using of GMAW welding process with ER70-S6 wire (hardness only in weld metal); d) Joints subjected to PWHT, as follows:

➢ ➢

If local PWHT apply, then the hardness test shall be performed for all butt joints; If furnace PWHT apply, then on 10% of butt joints;

Hardness shall not exceed 225 HBW, except for sour service items where 200 HBW max shall be considered.

H.8 - WELD REPAIRS

For carbon steel in sour service, a specific repair welding procedure test shall be carried out and as a minimum subjected to macro-hardness examination testing in accordance with NACE MR0103 Appendix-C.

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APPENDIX-I - ADDITIONAL AND SPECIFIC REQUIREMENTS FOR LOW ALLOY STEEL

GRADE 1 ¼ CR ½ MO

I.1 - PQR TESTING REQUIREMENTS

I.1.1 - TENSILE TEST AND BEND TEST

Tensile strength tests and bend tests for each butt weld procedure qualification shall be carried out on coupon heat treated simulating the maximum heat treatment condition of relevant item, tensile properties at room temperature shall meet the requirements of the applicable design code(s).

I.1.2 - IMPACT TEST

Impact test shall be performed for LAS material welding at -18°C, as follows: a) Impact test on weld metal and HAZ for each butt weld procedure qualification shall be performed on both two coupons, one heat treated simulating minimum heat treated condition and one heat treated simulating maximum heat treated condition of relevant item;

b) Impact test shall comply with the requirements of applicable code(s) but not lower than 27J (avg) /

20J (sing) for full size specimen (10x10 mm);

Impact test is not required when the maximum obtainable Charpy specimen has a width along the notch of less than 2.5 mm. When more than one welding process is included in a test coupon, the following shall apply for impact test:

The specimens shall be full-sized or the largest subsize specimen that can be obtained based on

the thickness of the test coupon;

The weld metal test specimens shall contain as much of the weld metal from each process as is

practical;

When the test coupon contains more than two welding processes, and it is not possible to locate specimens within 1.5 mm of a surface, additional weld metal impact specimens shall be taken at the thickness where those processes are located;
Heat-affected zone specimens shall be prepared from material that was removed at the thickness plane associated with weld metal from each process. These specimens may contain material that was affected by the heat from more than one welding process;

I.1.3 - MACRO AND HARDNESS TEST

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 shall be etched to reveal individual passes and the full extent of the HAZ. Macro sections shall be examined at a magnification of 5x. PQR 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. Vickers transverse hardness test for each welding procedure qualification shall be carried out after the minimum heat treatment condition and it shall comply with the following: a) Method, location and number of measurements specified in Appendix-G shall be complied with b) Maximum hardness value measured shall be 248HV10

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I.2 - WELDING CONSUMABLES

I.2.1 - GTAW

The following requirements shall apply: a) the following rod shall be used: AWS-5.28 ER80S-B2 b) the chemical composition shall also meet the following limits to improve resistance to

embrittlement (these limits apply to the heat analysis): ➢ X-bar = (10P+5Sb+4Sn+As) / 100≤15 ppm (where P, Sb, Sn, and As are in ppm) ➢ C is 0.15 wt% max ➢ Cu is 0.20 wt% max ➢ Ni is 0.30 wt% max ➢ Sn is 0.015 wt% max ➢ P is 0.012 wt% max

c) only hydrogen free gas (with dew point ≤ -40°C) shall be used, to avoid possible cracking and

embrittlement of the weld.

I.2.2 - SMAW

The following requirements shall apply: a) the following low hydrogen electrode shall be used: SFA-5.5 E8018-B2 or E8016-B2 b) the diffusible hydrogen limit shall be H8 minimum (as per SFA-5.5) c) the chemical composition shall also meet the following limits to improve resistance to

embrittlement (these limits apply to the heat analysis): ➢ X-bar = (10P+5Sb+4Sn+As) / 100≤15 ppm (where P, Sb, Sn, and As are in ppm) ➢ C is 0.15 wt% max ➢ Cu is 0.20wt % max ➢ Ni is 0.30 wt% max ➢ Sn is 0.015 wt% max ➢ P is 0.012 wt% max

I.2.3 - SAW

The following requirements shall apply: a) wire classified B2 according to SFA-5.23 shall be used b) the diffusible hydrogen limit for flux/wire combination shall be H8 minimum (as per AWS A5.23) c) the chemical composition shall also meet the following limits to improve resistance to

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I.3 - WELD PREPARATION

MT examination shall be performed on all bevel ends before welding. Examined area shall involve the weld bevel area, and a minimum of 50 mm of neighboring surfaces.

I.4 - PREHEATING

All base metals shall be pre-heated to a minimum of 150°C during all welding, rolling, thermal cutting, and gouging operations. For wall thickness equal to or greater than 12 mm, the preheat temperature shall be maintained until PWHT or DHT if performed (see below clause I.6).

I.5 - HEAT INPUT / INTERPASS

Interpass temperature shall not exceed 315°C.

I.6 - POST-HEATING AND PWHT

Letter “Y” (“YES”) is always indicated in Line List and/or isometric drawing(s), then all relevant welds, including branch, socket, seal and attachment welds, shall be subject to PWHT. Code exemption to PWHT is not permitted. PWHT shall comply with the followings: ➢ Stress relieving shall be performed in the temperature range 690°C +/-10; ➢ For quenched/normalized 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 30°C 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 30°C of the tempering temperature, the mechanical properties shall be approved by Contactor and demonstrated with mechanical testing at the proposed temperature;

➢ PWHT hold time shall be set according to wall thickness in compliance with applicable code(s), in

any case 2 hours minimum shall apply;

For wall thickness equal to or greater than 12 mm, welded joints shall be heat treated immediately upon completion of welding. The joint shall not be allowed to cool below 150ºC prior to heat treatment. Otherwise, the weld and the base material portion adjacent (at least 75 mm as a minimum) may be heated to a minimum temperature of 300°C for a minimum duration of one hour, wrapped with insulation, and allowed to cool (in this case heat treatment may be performed later).

I.6.1 - ADDITIONAL REQUIREMENTS FOR UOP PIPING CLASS(ES)

All weld joints (including wall thickness less than 12 mm) in LAS that require PWHT shall be heat treated immediately upon completion of welding. The joint shall not be allowed to cool below 150ºC prior to PWHT. Alternately, the weld and adjacent metal may be heated to 315ºC, wrapped with insulation, and allowed to cool. PWHT may then be performed later.

I.7 - PRODUCTION HARDNESS TEST

The hardness for production welds is required as per sub-clause 10.2. The hardness for production welds is required for all items, and values shall not exceed 225 HB. Hardness test extension shall comply with the following: ➢ ➢

If local PWHT apply, then the hardness test shall be performed for all butt joints; If furnace PWHT apply, then on 10% of butt joints;

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APPENDIX-L - ADDITIONAL AND SPECIFIC REQUIREMENTS FOR AUSTENITIC

STAINLESS STEEL (304 AND 316 GRADES)

L.1 - PQR TESTING REQUIREMENTS

L.1.1 - FERRITE TEST

For all items, ferrite test for each welding procedure qualification shall be carried out on weld metal using ferrite scope calibrated in accordance with AWS A4.2M. Measured values shall be in the range 3FN-8FN (extension to max 10FN requests a prior Contractor’s approval in writing).

L.2 - WELDING CONSUMABLES

The following table shows the applicable filler metal for combination stainless steel grades:

304H

304

304L

304/304L (dual grade)

316

316L

316/316L (dual grade)

316H

304H

304

304L

304/304L (dual grade)

316

316L

316/316L (dual grade)

316H

308H

308

308L

308

308L

308

308L

308L (note a)

308

308L

308L (note a)

316

316L

316

316L

316L (note a)

316H

Note a: mechanical properties shall be equal to or greater than the 304 or 316 materials being welded, as shown in relevant material test certificate (MTC) for the specific heat/batch number of filler material used in production welding.

Ferrite content to be reported on material test certificate may be estimated by filler material manufacturer considering the actual chemical composition using WRC 1992 (FN) diagram. Austenitic stainless steel FCAW weld filler materials shall also comply with the followings: ➢ Filler materials shall not intentionally contain bismuth ➢ Bismuth in the deposited weld metal shall not exceed 0.002% Welding consumables, intended for use at design temperatures in excess of 540ºC shall be a minimum of 0.04 weight percent on the certified mill test report. Subject to prior Contactor and Licensor approval in writing, as alternative to E304H, E16-8-2 (with C>0.04% and ferrite in the range 1-5 FN) may be used to minimize ferrite when the weld deposit will be exposed to high temperatures and high creep strains where sigma phase may affect performance. Argon or helium gases shall be used as shielding and backing gas during welding. Nitrogen shall not be used neither as shielding nor purging gas.

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Use of hydrogen gas is not permitted unless previously accepted in writing by Contactor.

L.3 - WELD PREPARATION

Machining, plasma cutting or grinding shall be used, flame-cutting and carbon-arc shall not be used. Wire brushes shall be stainless steel and all grinding/cutting discs shall be iron and carbon free. In the beveling process, HAZ(s) formed during plasma-arc cutting shall be removed. During machining operations, only a cutting fluid compatible with stainless steel (i.e. sulfur and chloride free) shall be used.

L.4 - CLEANING

Carbon and alloy steel wire brushes or other tools shall not be used on austenitic stainless steel. Wire brushes and other tools to be used for austenitic stainless steel shall be stainless steel. Also, stainless brushes or tools that have been previously used on carbon or low-alloy steel shall not be used on austenitic stainless steel. When found or present, low melting point metallic contaminants, such as copper, lead, and zinc, shall be removed before welding. Grinding is not generally recommended since heat from grinding can drive low melting point contaminants further into the stainless steel. Low melting point contaminants can be liquified by welding heat, then can penetrate into the grain boundaries, and embrittle the austenitic stainless steel. Other techniques, such as chemical removal or abrasive flapper discs, have been used successfully to remove these low melting point contaminants. Surfaces shall be protected from chlorides and other halides. Marking, painting, coating, or inspection materials should contain as few halides as possible. Commentary Note: MIL-STD-2041D and DOE RDT-F-7-3T have adopted the following for limits in markers and paints: < 200 ppm halogens; < 250 ppm each, low melting point metals; < 300 ppm total low melting point metals; < 200 ppm sulfur; Welds cleaned with power tools shall be free from work-hardening. Surfaces of stainless steels contaminated with iron during fabrication shall be pickled and passivated in accordance with procedure to be approved by Contractor.

L.5 - PREHEATING

For austenitic stainless steel no specific preheating is required, but any moisture shall be removed by wiping and subsequent hot air blowing prior to welding and fit-up activity.

L.6 - HEAT INPUT / INTERPASS

For austenitic stainless steel interpass temperature shall not exceed 175°C.

L.7 - PWHT

PWHT is not required, and shall not be performed, except when otherwise specified.

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L.8 - WELD CONTOUR AND FINISH

Discoloration on welds, HAZ(s), or areas adjacent to the HAZ (on internal surface), shall never exceed level 7 of the AWS D18.2 chart. The definition of a stringer requirement shall be determined by the corrosion engineer, based on the specific service corrosivity (e.g. aqueous chlorides, acids, etc.).

L.9 - FERRITE TEST IN PRODUCTION

Ferrite control on production welds shall be performed (i.e. weld class with digit -1) and the measured values shall be in the ranges specified by sub-clause L.1.1, in the following cases: a) for operating temperature exceeds 350°C b) where the weld will be subject to PWHT c) cryogenic service A complete (100%) testing of welds shall be performed and the number of tests for circumferential welds shall be as follows: ➢ ➢ ➢ The ferrite measurement shall be done on the root side of the weld where accessible.

for NPS up to 24, two (2) ferrite tests for NPS 26 through NPS 36, three (3) ferrite tests for NPS 38 and larger, four (4) ferrite tests

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APPENDIX-K - ADDITIONAL AND SPECIFIC REQUIREMENTS FOR NICKEL ALLOY 825

(UNS N08825)

K.1 - PQR TESTING REQUIREMENTS

Paragraph not used.

K.2 - WELDING CONSUMABLES

The following table shows the applicable filler material to be used for Nickel alloy 825:

Welding Process

Specification

Classification

GTAW

SMAW

SFA-5.14

SFA-5.11

ER-NiCrMo3

E-NiCrMo3

Argon or helium gases shall be used as shielding and backing gas during welding. Nitrogen shall not be used neither as shielding nor purging gas. Use of hydrogen gas is not permitted unless previously accepted in writing by Contactor.

K.3 - WELD PREPARATION

Machining, plasma cutting or grinding shall be used, flame-cutting and carbon-arc shall not be used. In the beveling process, HAZ(s) formed during plasma-arc cutting shall be removed. During machining operations, only a cutting fluid compatible with nickel alloys (i.e. sulfur and chloride free) shall be used.

K.4 - CLEANING

Carbon and alloy steel wire brushes or other tools shall not be used on nickel alloy. Wire brushes and other tools to be used for nickel alloy shall be stainless steel. Also, stainless brushes or tools that have been previously used on carbon or low-alloy steel shall not be used on nickel alloy. When found or present, low melting point metallic contaminants, such as copper, lead, and zinc, shall be removed before welding. Grinding is not generally recommended since heat from grinding can drive low melting point contaminants further into the nickel alloy. Low melting point contaminants can be liquified by welding heat, then can penetrate into the grain boundaries, and embrittle the nickel alloy. Other techniques, such as chemical removal or abrasive flapper discs, have been used successfully to remove these low melting point contaminants. Surfaces shall be protected from chlorides and other halides. Marking, painting, coating, or inspection materials should contain as few halides as possible. Commentary Note: MIL-STD-2041D and DOE RDT-F-7-3T have adopted the following for limits in markers and paints: < 200 ppm halogens; < 250 ppm each, low melting point metals; < 300 ppm total low melting point metals; < 200 ppm sulfur;

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Welds cleaned with power tools shall be free from work-hardening. Surfaces contaminated with iron during fabrication shall be pickled and passivated in accordance with procedure to be approved by Contractor.

K.5 - PREHEATING

For nickel alloy no specific preheating is required, but any moisture shall be removed by wiping and subsequent hot air blowing prior to welding and fit-up activity.

K.6 - HEAT INPUT / INTERPASS

Interpass temperature shall not exceed 175°C.

K.7 - PWHT

PWHT is not required, and shall not be performed, except when otherwise specified.

K.8 - WELD CONTOUR AND FINISH

Evaluation of surface oxidation of completed nickel and nickel alloy weldments shall fulfil the criteria specified in the following table:

Weld Colour

Shielding

Light brown (tan) to brown

Acceptable shielding

Narrow band of dark brown color and intermittent spots of blue color

Acceptable shielding

Darker or more extensive oxidation colors

Unacceptable shielding

Comment

No action

Oxidized surfaces shall be removed by mechanical tools, pickling

Nickel and nickel alloy welds cleaned prior to inspection shall be rejected.

K.9 - WELD INSPECTION REQUIREMENTS

Paragraph not used

K.10 - PRODUCTION HARDNESS TEST

Paragraph not used

K.11 - WELD REPAIRS

Paragraph not used

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APPENDIX-M - ADDITIONAL AND SPECIFIC REQUIREMENTS FOR NICKEL ALLOY 20

(UNS N08020)

M.1 - PQR TESTING REQUIREMENTS

Paragraph not used.

M.2 - WELDING CONSUMABLES

The following table shows the applicable filler material to be used for Nickel alloy 20:

Welding Process

Specification

Classification

GTAW

SMAW

SFA-5.14

SFA-5.11

ER-NiCrMo3

E-NiCrMo3

M.3 - WELD PREPARATION

M.4 - CLEANING

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M.5 - PREHEATING

For nickel alloy no specific preheating is required, but any moisture shall be removed by wiping and subsequent hot air blowing prior to welding and fit-up activity.

M.6 - HEAT INPUT / INTERPASS

Interpass temperature shall not exceed 150°C.

M.7 - PWHT

PWHT is not required, and shall not be performed, except when otherwise specified.

M.8 - WELD CONTOUR AND FINISH

Evaluation of surface oxidation of completed nickel and nickel alloy weldments shall fulfil the criteria specified in the following table:

Weld Colour

Shielding

Light brown (tan) to brown

Acceptable shielding

Narrow band of dark brown color and intermittent spots of blue color

Acceptable shielding

Darker or more extensive oxidation colors

Unacceptable shielding

Comment

No action

Oxidized surfaces shall be removed by mechanical tools, pickling

Nickel and nickel alloy welds cleaned prior to inspection shall be rejected.

M.9 - WELD INSPECTION REQUIREMENTS

Paragraph not used

M.10 - PRODUCTION HARDNESS TEST

Paragraph not used

M.11 - WELD REPAIRS

Paragraph not used

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APPENDIX-N - ADDITIONAL AND SPECIFIC REQUIREMENTS FOR SUPER DUPLEX

STAINLESS STEEL (UNS S32750)

N.1 - PQR TESTING REQUIREMENTS

N.1.1 - Impact test

Impact testing shall comply with para. 4.3 and 5.4 of ISO 17781 (type 25Cr duplex), and acceptance shall comply with para. 5.4 Level QLI.

Test conditions and acceptance criteria for each set of three tests in the HAZ shall be as per the base metal values for the alloy (type 25Cr duplex) in table 2 of ISO 17781.

N.1.2 - Macro and Hardness test

PQR 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.

Vickers transverse hardness test for each welding procedure qualification shall be carried out and it shall comply with the following:

➢ Vickers hardness testing method shall be according to ASTM E384, a load of HV10 shall be used

➢ Location and number of measurements specified in Appendix-G shall be complied with

➢ The maximum hardness value shall be 350HV10

N.1.3 - Microstructural examination and Ferrite test

Microstructural examination shall be carried out according to para. 4.3 and 5.2 of ISO 17781.

Ferrite test shall be carried out according to para. 4.3 and 5.3 of ISO 17781.

Ferrite test for each welding procedure qualification (including for fillet joint PQR and cap repair PQR) shall be carried out on WM and in HAZ, test shall comply with the following:

Measurement of the ferrite to austenite content in the deposited weld metal and HAZ shall be performed according to ASTM E562 and at a magnification of 400X-500X. The number of fields and points per sampled area shall agree with the guidance displayed in the 10% relative accuracy column in ASTM E562 Table 3. A 100-point grid mapped over 10 fields in a target area (weld/HAZ) may be considered sufficient for material with 30% or greater ferrite content
Test shall be reported on PQR and evaluated for ferrite to austenite content on the following weld

zones:

➢ Root pass

➢ Cover pass (this is to be used as a reference for the test required on production welds)

In addition to limits on ferrite content in base metals and weld deposits specified by ISO 17781, the

HAZ ferrite content limit shall be 40% to 65%

Measurements in each above location shall be performed using the point count method (as per ASTM E562), but also using a ferrite scope calibrated in accordance with AWS A4.2M. The ferrite scope testing at each location shall consist of 5 readings averaged. The ferrite scope FN readings

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are to be used as a reference during ferrite testing of production welds

N.1.4 - Corrosion test

Corrosion test examination (type 25Cr duplex) shall comply with para. 4.3 and 5.5 of ISO 17781.

N.2 - WELDING CONSUMABLES

The following table shows the applicable filler material to be used for Super Duplex alloy 2507:

Welding Process

Specification

GTAW

SMAW

SFA-5.9

SFA-5.4

Classification 1

ER-2594

E-2594, E-2595

Note 1: The minimum %Mo and PREN of the selected filler metal shall be compatible with the base metal;

Shielding and back purging gases shall be argon or an argon/nitrogen mixture (typically argon plus a minimum of 2% nitrogen). 100% nitrogen back purging gas may be used, when approved by Contactor.

Only hydrogen free gas (with dew point ≤ -40°C) shall be used, to avoid possible cracking and embrittlement of the weld.

N.3 - WELD PREPARATION

Machining, plasma cutting or grinding shall be used, flame-cutting and carbon-arc shall not be used.

In the beveling process, HAZs formed during plasma-arc cutting shall be removed.

During machining operations, only a cutting fluid compatible with stainless steel (i.e. sulfur and chloride free) shall be used.

All grinding and cutting discs shall be iron and carbon free.

Grinding wheels shall be resin bonded alumina or silicon carbide.

The final surface preparation and configuration shall be obtained by machining.

Weld repairs to bevel shall not be permitted, unless approved by Contactor.

N.4. - CLEANING

Carbon and alloy steel wire brushes or other tools shall not be used on duplex stainless steel. Wire brushes and other tools to be used for duplex stainless steel shall be stainless steel. Also, stainless brushes or tools that have been previously used on carbon or low-alloy steel shall not be used on duplex stainless steel.

When found or present, low melting point metallic contaminants, such as copper, lead, and zinc, shall be removed before welding.

To avoid hot cracking, the area adjacent to the weld preparation shall be duly cleaned. Contaminants like to S, Pb, Sb, Cd and Zn are detrimental impurities, which may be present in grease or paint. Acetone (or other solvents approved by Contractor) shall be used for cleaning, to avoid porosity. The oxide layer shall be removed by grinding to a bright metal surface appearance just prior to welding.

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Grinding is not generally recommended since heat from grinding can drive low melting point contaminants further into the duplex stainless steel. Low melting point contaminants can be liquified by welding heat, then can penetrate into the grain boundaries, and embrittle the duplex stainless steel. Other techniques, such as chemical removal or abrasive flapper discs, have been used successfully to remove these low melting point contaminants.

Surfaces shall be protected from chlorides and other halides. Marking, painting, coating, or inspection materials should contain as few halides as possible.

Commentary Note

MIL-STD-2041D and DOE RDT-F-7-3T have adopted the following for limits in markers and paints:

< 200 ppm halogens;

< 250 ppm each, low melting point metals;

< 300 ppm total low melting point metals;

< 200 ppm sulfur.

Welds cleaned with power tools shall be free from work-hardening.

Surfaces contaminated with iron during fabrication shall be pickled and passivated in accordance with procedure to be approved by Contractor.

Post fabrication cleaning shall include removal of heat tint on the process side by pickling and passivation as specified by relevant Supply specification.

N.5 - PREHEATING

Preheat temperature shall not exceed 50°C (120°F).

Any moisture shall be removed by wiping and subsequent hot air blowing prior to welding and fit-up activity.

N.6 - HEAT INPUT/INTERPASS

Interpass temperature shall comply with the following table:

Joint thickness

Super Duplex (alloy 2507)

<3 mm

<6 mm

<9.5 mm

9.5 mm

50°C maximum

70°C maximum

100°C maximum

120°C maximum

For SDSS the heat input shall be within the following range: 0.5 kJ/mm - 1.5 kJ/mm.

This range is a starting point. Heat input selection should be based on actual parameters recorded during welding procedure qualification according to Appendix-B.

Moreover, the followings shall be considered:

To maintain acceptable corrosion resistance in SDSS (i.e. in order to avoid the formation of secondary austenite. Secondary austenite reduces the corrosion resistance), open root passes shall be GTAW for single sided welds with filler metal addition, with the next pass using a lower heat input than the root pass. The second pass shall aim to be about 75% of the heat input of the root pass to

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avoid overheating of the root pass (this lower heat input second pass is often called a “cold pass”). The cold pass shall be a single bead.

For SMAW, weaving beyond three times the electrode diameter shall be avoided to prevent

excessive exposure to elevated temperature.

N.7 - PWHT

PWHT is not required and shall not be performed, except when otherwise specified.

N.8 - WELD CONTOUR AND FINISH

All heat tinting, defined as unacceptable by above point, shall be removed by mechanical polishing or glass bead blasting or by chemical cleaning.

N.9 - WELD INSPECTION REQUIREMENTS

N.9.1 - Ferrite Test in production

Pressure-retaining welds shall be tested in according with the sub-clause 10.3, as follows:

100% of testing of welds shall be performed and the number of tests for each circumferential weld

shall be as follows:

a) for NPS up to 24”, two (2) ferrite tests (oriented at 180° from each other)

b) for NPS 26” through NPS 36”, three (3) ferrite tests (oriented at 120° from each other)

c) for NPS 38” and larger, four (4) ferrite tests (oriented at 90° from each other)

Acceptance criteria shall be as per ISO 17781
The ferrite measurement shall be done on the root side of the weld where accessible

N.9.2 - Production Hardness Test

The hardness for production welds is required as per sub-clause 10.2.

The hardness for production welds is required for all items, and values shall not exceed 350HV10.

Hardness test shall be performed on 1/3 (i.e. 33%) of butt weld joints.

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N.10 - WELD REPAIRS

Full penetration repairs are not allowed, and the remaining ligament for partial penetration repairs shall be minimum 3 mm for Zone A.

Partial penetration repairs deeper than within 6 mm for Zone B of the inner surface, a specific repair welding procedure test shall be carried out on the minimum required ligament.

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APPENDIX-O - DISSIMILAR WELDING

O.1 - DISSIMILAR WELDING BETWEEN CARBON OR LOW ALLOY STEEL AND AUSTENITIC

STAINLESS STEEL

type 309 and type 309L may be used for design temperatures not exceeding 315°C

When joining ferritic steels (P-No. 1 or P-No. 4) to austenitic stainless steels (P-No. 8), the filler metal shall be selected based on the following criteria: ➢ ➢ nickel-base alloy filler materials shall be selected for temperatures above 315°C (due to high differential thermal expansion of austenitic stainless steel) or in presence of PWHT, using design conditions shown in following table:

ASME/AWS FM classification (note 1)

Maximum Design T° (note 2) (non-sulfidation environment)

Maximum Design T° (note 3) (sulfidation environment)

ENiCrFe-3

1000°F (540°C)

ERNiCr-3, ENiCrFe-2

1400°F (760°C)

ERNiCrMo-3, ENiCrMo-3

1100°F (590°C)

700°F (370°C)

750°F (400°C)

900°F (480°C)

ERNiCrCoMo-1

1800°F (982°C)

1700°F (927°C)

note 1: Comparable FCAW consumables may be applied for, provided they are approved by the purchaser note 2: Refer to API 939-C for the definition of sulfidation note 3: Nickel alloy temperature limits are for through-wall and fillet boundary welds. For weld overlay and clad restoration, these limits may not apply, depending on the user’s experience

➢

for service conditions exceeding the limits stated in above table, filler metal selection shall be reviewed with the Contactor

➢ ASME/AWS classification ER310/E310-XX and ASME/AWS classification ERNiCrFe-6 shall not

be used

Dissimilar metal welds joining carbon or alloy steels to stainless or nickel-base alloys shall be avoided in severe thermal cycling service, in the immediate vicinity of a high-restraint location, and in hydrogen, caustic and sour services. In fact, the use of dissimilar metal welds (carbon or alloy steels to stainless or nickel alloys) in services corrosive shall be carefully evaluated. Failures have been reported due to hydrogen charging of zones exhibiting high hardness adjacent to the fusion line. It is unclear whether the charging is due to corrosion of the carbon steel / low alloy steel alone or accelerated due to the presence of a galvanic couple. The dissimilar metal weld may be acceptable if the interface with the ferritic steel is not exposed to the service fluid. Dissimilar weld joint is prohibited also where galvanic corrosion is a concern. In addition, carbon to austenitic stainless steel welds might be susceptible to brittle fracture at service temperatures below -29°C.

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O.2 - DISSIMILAR WELDING BETWEEN CARBON STEEL AND LOW ALLOY STEEL GRADE 1 ¼

CR ½ MO

When joining dissimilar ferritic steels (P-No. 1 through P-No. 4), filler metal shall conform to the nominal chemical composition of either base metal or an intermediate composition. Wherever piping welds between CS and LAS materials are accepted by Contractor, a welding procedure with buttering shall be used in order to avoid exposure of CS base material to high temperatures (temperature higher than 650°C). Before PWHT, buttering on the LAS base material side shall be carried out using the filler metal according to below table:

Welding Process

GTAW

SMAW

PWHT

Yes

Classification

ER70S-2 / ER70S-3 / ER70S-61

E70XX-1

Note 1: ER70S-6 may be used provided that hardness requirements of this specification are complied with;

After buttering execution, PWHT shall be performed according to Appendix-I clause I.6 (unless otherwise accepted by Contractor). After execution of PWHT, weld bevel and fit-up shall be executed according to clause 7 and the final joint with CS base material shall be performed with the filler metal selected according to the above table.

O.3 - DISSIMILAR WELDING BETWEEN CARBON STEEL OR AUSTENITIC STAINLESS STEEL

AND SUPER DUPLEX STAINLESS STEEL

A duplex filler is generally used for welding DSS (duplex stainless steel) to carbon steel or austenitic stainless steel, but austenitic stainless steel filler metals have also been satisfactory. Ni-based filler metals are sometimes used, but they may promote a fully ferritic zone adjacent to the fusion line in DSS, which can reduce the toughness properties along the fusion line.

Base Materials to be welded

S32750

P-No. 1

E(R)2209 E(R)309L E(R)309LMo

P-No. 8 (type 304/304L)

P-No. 8 (type 316/316L)

E(R)2209 E(R)309L E(R)309LMo

E(R)2209 E(R)309LMo

When welding DSS to carbon steel, there can be detrimental effects due to the preheating or PWHT required by the carbon steel. Preheating may slow the cooling of the HAZ on DSS material in sufficient way to reach the forming of intermetallic phases. Preheating should not be used unless approved by the purchaser. Most PWHT temperatures for steel will lead to formation of intermetallic phases in DSS which reduce toughness and corrosion resistance. One solution is to butter carbon steel weld bevels with austenitic filler metal (e.g. E309L), PWHT shall be carried out, and then the welding to the DSS may be performed using a DSS filler metal without PWHT. When welding DSS alloyed with nitrogen (e.g. 22Cr Duplex, 25Cr Duplex), welding consumables shall not contain deliberate additions of niobium (columbium) such as ENiCrMo-3. This is due to precipitation of niobium nitrides and other intermetallic that have resulted in low weld metal toughness and solidification cracking. In addition, niobium-containing filler metals may degrade the ductility and corrosion properties of the weldment due to changing the ferrite/austenite balance in the DSS fusion line and HAZ. Note that other nickel-based filler metals with Nb less than 0.5 wt.% (e.g. ENiCrMo-10, ENiCrMo-13, and ENiCrMo-14) have been used successfully.

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APPENDIX-P - FORM 140

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