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

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

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EQUIPMENT WELDING GENERAL SPECIFICATION

3

2

1

0

25/11/2024

23/10/2024

05/09/2024

17/05/2024

IFD - Issued for Design

G. Mancuso

F. Barsanti

F. Laurenzi

IFD - Issued for Design

G. Mancuso

F. Barsanti

F. Laurenzi

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

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CONTENTS

1

2

2.1 2.2 2.3 2.4

3

4

PURPOSE … 4

REFERENCE DOCUMENTS … 5

LICENSOR DOCUMENTS … 5 PROJECT DOCUMENTS … 5 INTERNATIONAL STANDARD … 5 ORDER OF PRECEDENCE … 6

ACRONYMS AND DEFINITIONS … 7

WELDING DOCUMENTS … 8

4.1 GENERAL REQUIREMENTS … 8 4.2 WELDING PROCEDURE SPECIFICATION (WPS) … 10 PROCEDURE QUALIFICATION RECORD (PQR) … 10 4.3 4.3.1 General Requirements … 10 4.3.2 Specific requirements for Air Cooler Heat Exchanger (API 661) … 11 PERFORMANCE QUALIFICATION (WPQ AND WOPQ) … 11 4.4

5

WELDING PROCESS … 12

GENERAL REQUIREMENTS … 12 5.1 ADDITIONAL REQUIREMENTS FOR GAS TUNGSTEN ARC WELDING (GTAW) AND PULSED (GTAW-P) . 12 5.2 ADDITIONAL REQUIREMENTS FOR SHIELDED METAL ARC WELDING (SMAW) … 12 5.3 ADDITIONAL REQUIREMENTS FOR SUBMERGED ARC WELDING (SAW) … 12 5.4 ADDITIONAL REQUIREMENTS FOR FLUX CORED ARC WELDING (FCAW) … 13 5.5 ADDITIONAL REQUIREMENTS FOR GAS METAL ARC WELDING (GMAW) … 13 5.6 5.6.1 Specific requirements for Gas Metal Arc Welding with short circuiting transfer mode (GMAW-S)13 ADDITIONAL REQUIREMENTS FOR PLASMA ARC WELDING (PAW) … 13 5.7

6

WELDING CONSUMABLES … 13

6.1 GENERAL REQUIREMENTS … 13 6.1.1 Material Test Certificates … 14 Identification, packing, storage and handling … 15 6.1.2

7

7.1 7.2 7.3

8

WELD PREPARATION … 16

CUTTING AND EDGE PREPARATION GENERAL REQUIREMENTS … 16 CLEANING … 17 ALIGNMENT AND TEMPORARY WELDS… 17

EXECUTION WELDING REQUIREMENTS … 18

8.1 JOINT EXECUTION … 18 JOINT CONFIGURATION … 20 8.2 8.2.1 Specific requirements for shell and tube heat exchanger (API 660) … 21 8.2.2 Specific requirements for air cooler heat exchanger (API 661) … 21 BACKING GAS… 21 8.3 PREHEATING … 22 8.4 8.5 HEAT INPUT AND INTERPASS TEMPERATURE … 23 8.6 WELDING INTERRUPTION … 23 PROXIMITY OF WELDS … 23 8.7

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8.8 WELD CONTOUR AND FINISH … 23 8.8.1 Specific requirements for shell and tube heat exchanger (API 660) … 24

9

PWHT REQUIREMENTS … 24

9.1 GENERAL REQUIREMENTS … 24 9.1.1 Specific requirements for shell and tube heat exchanger (API 660) … 26 9.1.2 Specific requirements for air cooler heat exchanger (API 661) … 26

10 WELD INSPECTION REQUIREMENTS … 27

10.1 NON-DESTRUCTIVE EXAMINATION (VT, MT, PT, RT AND UT) … 27 10.2 PRODUCTION HARDNESS TEST … 28 10.3 PRODUCTION FERRITE TEST AND CHEMICAL ANALYSIS… 29 10.4 POSITIVE MATERIAL IDENTIFICATION … 30

11 WELD REPAIRS … 30

11.1 GENERAL REQUIREMENTS … 30 11.1.1 Major repair … 31 Appendix A MINIMUM CONTENT FOR WPS … 32 Appendix B ADDITIONAL ESSENTIAL VARIABLES … 35 Appendix C TUBE TO TUBESHEET JOINT SPECIFIC WELDING REQUIREMENTS … 38

Appendix D HARDNESS REQUIREMENTS FOR PQR (Method, location and number of measurements) … 45 Appendix E ADDITIONAL AND SPECIFIC REQUIREMENTS FOR CARBON STEEL (CS/KCS/LTCS) 47

Appendix F ADDITIONAL AND SPECIFIC REQUIREMENTS FOR AUSTENITIC STAINLESS STEEL (304 and 316 GRADES) … 51 Appendix G ADDITIONAL AND SPECIFIC REQUIREMENTS FOR DUPLEX STAINLESS STEEL … 54

Appendix H ADDITIONAL AND SPECIFIC REQUIREMENTS FOR AUSTENITIC STAINLESS STEEL (304L/308L OR 316L) OR NICKEL ALLOY TYPE 625 (UNS N06625) OR 825 (UNS N08825) CLAD/WELD OVERLAY ON CARBON STEEL … 58 Appendix I ADDITIONAL AND SPECIFIC REQUIREMENTS FOR LOW ALLOY STEEL GRADE 1 ¼ CR 0.5 MO … 65 Appendix J DISSIMILAR WELDING… 68 Appendix K PRODUCTION TEST COUPON (PTC) … 70

Appendix L ADDITIONAL AND SPECIFIC REQUIREMENTS FOR NICKEL ALLOY TYPE 825 (UNS N08825) … 71

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1

PURPOSE

This specification provides minimum requirements for welding and welding related topics for fabrication and repair of equipment, for both shop and site, to be installed on the new Linear Alkyl Benzene (LAB) plant located in the industrial zone of Skikda - Algeria. All appendices 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 material requisitions: a) Pressure-containing equipment such as pressure vessels, reactors, filters, heat exchangers, air-coolers

and pressure boundaries of rotating equipment and attachments welded thereto;

b) Tanks and attachments welded thereto; c) Non-removable welded internals for process equipment; d) Structural items attached and related to process equipment; e) Packages and other equipment or component items when referenced by an applicable purchase

document;

Fired equipment’s are excluded from this specification and Vendor shall refers to applicable Licensor specifications. This specification covers the following base materials:

➢ Carbon steel (CS) / Killed Carbon steel (KCS) - P-No. 1

➢ Carbon steel (CS) / Killed Carbon steel (KCS) - P-No. 1 in Sour Service, Hydrogen service, High Temperature Hydrogen Attack (HTHA) service and in Caustic Service (including tank in Sour Service)

➢ Low temperature carbon steel (LTCS) - P-No. 1

➢ CS/KCS/LTCS with austenitic stainless steel gr. 304L/308L or 316L clad/wo - P-No. 8 on P-No. 1

➢ CS/KCS/LTCS with nickel alloy type 625 (UNS N06625) or 825 (UNS N08825) clad/wo P-No. 43 or 45 on

P-No. 1

➢ 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

➢ Duplex Stainless steel (DSS) UNS S31803 and UNS S32205 (both know as alloy 2205) - P-No. 10H

➢ Duplex Stainless steel (DSS) UNS S31803 and UNS S32205 (both know as alloy 2205) - P-No. 10H in

Sour Service

➢ Nickel alloy (NA) type 825 (UNS N08825) - 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, Vendor shall ask Contactor for specific requirements to be applied.

This specification is based on API RP 582 (fourth Edition, May 2023), therefore, if not 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.

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Requirements due to local authority regulations (if any) shall be also complies with and will prevail on this specification. In case of conflict between the requirements of this specification and codes, standards or others project specifications, the most stringent apply. However, Contactor shall be consulted and a ruling in writing shall be obtained by Vendor before any work is done.

2

REFERENCE DOCUMENTS

2.1

Licensor Documents

Number

Title

UOP 3-11-11

Pressure Vessel Carbon Steel

UOP 3-12-11

Pressure Vessels Low Alloy Steel

UOP 3-15-9

Pressure Vessels Austenitic Steel

UOP 3-16-10

Storage Tanks Atmospheric

UOP 3-17-10

Pressure Vessels ASME Section VIII Division 2

UOP 3-26-9

Vessel Internals Low Chrome and Stainless Steel

UOP 3-28-9

Storage Tanks Low Pressure

UOP 4-11-13

Tubular Exchangers Shell and Tube Type

UOP 4-12-12

Tubular Exchangers Hair Pin Type

UOP 4-13-12

Air Cooled Exchangers

2.2 Project Documents

Number

Title

4439-XZ-SG-000000003 Additional requirements for materials in wet H2S service

4439-XZ-SG-000000002 PMI General Specification

4439-CZ-SG-000000001

General Specification for Supply of Pressure and Non-Pressure Equipment

4439-CZ-SG-000000004 Pressure Vessels Specification

4439-CZ-SG-000000005 Columns Internals and Trays Specification

4439-CZ-SG-000000006 Tubular Heat Exchangers Specification

4439-CZ-SG-000000007 Air Cooler Specification

4439-SZ-PM-0000005

ARH Dossiers Requirements for Suppliers

2.3

International Standard

Number

Title

ASME Section IX

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

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ASME Section VIII

ASME Section V

ASME Section II Part C

API RP 582

API STD 620

ASME Boiler and Pressure Vessel Code - ed. 2023 - Rules for Construction of Pressure Vessels 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) Design and Construction of Large, Welded, Low Pressure Storage Tanks - ed. 12th (2013) with addendum 1 - 2014, addendum 2 - 2018 and addendum 3 - 2021

API STD 650

Welded Steel Tanks for Oil Storage - ed. 13th (2015) with errata 1 - 2021

API STD 660

Shell and Tube Heat Exchangers - ed. 9th (2015) with addendum 1 - 2020

API STD 661

Air cooled Heat Exchangers - ed. 7th (2013)

API STD 662 Part 1

Plate Heat Exchangers for General Refinery Services - ed. 1st (R2011)

API STD 663

Hairpin Type Heat Exchangers - ed. 2nd (2022)

API RP 934-C

API RP 934-E

API RP 941

NACE MR0103

NACE SP0472

Materials and Fabrication of 1 ¼ Cr ½ Mo Steel Heavy Wall Pressure Vessels for High-pressure Hydrogen Service Operating at or below 825°F (440°C) - ed. 2nd (2019) Materials and Fabrication of 1 ¼ Cr ½ Mo Steel Pressure Vessels for Service above 825°F (440°C) - ed. 2nd (2018) 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

BS EN ISO 17781

WRC Bulletin 452

Executive Decree no. 21-261 of 13 June 21

Petroleum, petrochemical and natural gas industries - Test methods for quality control of microstructure of ferritic/austenitic (duplex) stainless steels - ed. 2017 Recommended Practices for Local Heating of Welds in Pressure Vessels - ed. 2000 Regulating pressure equipment (ESP) and electrical equipment intended to be integrated into facilities in the hydrocarbon sector

ARH-P-CTE-2

Regulatory Auth. for Hydrocarbons - Procedure for processing welding files

2.4 Order of Precedence

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

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3

ACRONYMS AND DEFINITIONS

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

COMPANY/OWNER

SONATRACH

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.

VENDOR

means the equipment/component/item supplier

Minimum Heat Treated Condition

Maximum Heat Treated Condition

Minimum Total Overlay Thickness

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

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.

It is the distance from base material interface and the final surface (after grinding and surface preparation) of the overlay, which satisfies the required thickness of undiluted weld overlay. It shall be:

• Equal to or greater than sum of Minimum Qualified Overlay Thickness plus Thickness of Undiluted Weld Overlay, or

• 3 mm (whichever is greater)

Thickness of Undiluted Weld Overlay

It is the thickness (typically 3 mm) of undiluted chemistry of weld- overlay specified in the applicable data sheet or supply specification (minimum 1.5 mm). It is the depth measured from the finished deposit surface, after grinding and surface preparation.

Minimum Qualified Overlay Thickness

As defined in figure QW-462.5 (a) of ASME section IX, it is the minimum distance from base material interface surface and the weld overlay depth at which the required undiluted chemistry has been measured in PQR.

MTC

WPS

PQR

Material Test Certificate

Welding Procedure Specifications

Procedure Qualification Records

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WPQ

WOPQ

PWHT

DHT

PREN

CRA

TPIA

CRS

MR

MDS

SS

SSC

HIC

HTHA

CE

FN

Welder Performance Qualifications

Welding Operator Performance Qualifications

Post Weld Heat Treatment

Dehydrogenation heat treatment

Pitting Resistance Equivalent Number

Corrosion Resistant Alloy

Third Party Inspection Agency

Comment Resolution Sheet

Material Requisition

Mechanical Data Sheet

Supply Specification

Sulfide Stress Cracking

Hydrogen Induced Cracking

High Temperature Hydrogen Attack

Carbon Equivalent

Ferrite Number

4

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. Before fabrication, all the following welding documents shall be collected by Vendor, in an appropriate welding book for each item (welding book for multi-items is not acceptable) for submission to Contractor and Owner for review, according to time schedule specified in applicable MR/SS or Purchase Order:

➢ An index of all applicable WPS/PQR

➢ Weld Map/Weld Plan with the following information (as minimum):

− Line sketch of the equipment item

− Special Service of the equipment, if any (e.g. sour, caustic, hydrogen, etc.)

− Material type(s), grade(s) and thickness for each part/component

− Type of joint (BW, FW, Branch connection, SW, SOF, etc.)

− Welding process(es)

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− WPS to be used for each type of joint of same design and similar thickness (i.e., longitudinal and circumferential seam, closing seam, typical large nozzle connection, typical small nozzle connection, fillet weld attachments and any back cladding, if applicable), for pressure parts and non-pressure parts (e.g. saddle, skirt, pads, etc.)

− Minimum Design Metal Temperature (MDMT) and whether impact tested WPS is/are required

− Actual thickness where each WPS is to be used

− PWHT requirements (process, specifications or code) and other heat treatments if required (e.g.

ISR, DHT, etc.)

➢ Welding Procedure Specifications (WPS) signed by Vendor

➢ Welding Procedure Qualification Records (PQR) signed by Vendor and competent third party

For tube-to-tubesheet strength welds a complete fabrication plan (including assembly, cleaning, weld preparation, rolling and testing) shall be also submitted.

For each field assembled items (including internals) to be installed at site by welding, Vendor shall submit:

➢ Two separate Welding Books one for shop and one for field welding

➢ Erection procedure to include detailed technical instructions for handling, welding, heat treatment,

inspection, etc.

➢ Before starting any welding operation, for items under ARH regulation, Vendor shall submit the WPS to ARH for approval. Once the WPS have been approved by ARH, they shall be qualified in the presence of ARH in a laboratory accredited ISO 17025. Welding shall not start until the PQR have been validated by ARH.

The unacceptability (code “NA” or “CR”) of welding book after the 2nd review by Contactor and Company will require the presence of Vendor in Contactor’s office for due clarifications. For equipment subject to ARH regulations, Vendor shall not start with welding activities until the preliminary dossier has been approved by ARH for equipment fabricated in shop. For equipment assembled in field, welding shall not start until the PQR have been validated by ARH after qualification of WPS. For equipment subject to ARH regulation, welding dossier shall be provided in accordance with local regulation ARH procedure P-CTE-2. Any welding performed prior to review and acceptance of welding documents is subject to rejection, at sole Contactor and Owner option. For item(s) subject to heat treatments as PWHT, hot forming, tube(s) bending and heat treatment after forming or bending, a dedicated procedure shall be prepared and submitted by Vendor as a dedicated document for Contactor and Owner review, prior to heat treatment. Review and acceptance of Vendor’s welding documents by Contactor and/or Owner does not relieve the Vendor of responsibility for meeting all the requirements of the applicable code(s), contractual requirements, purchase order and this specification. 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. Owner/Contactor’s acceptance of Vendor’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 requests submitted to Contactor and Company. For item to be ASME code stamped, approval of welding book and welder/welding operator qualification by Authorized Inspector (AI) shall be available by Vendor to Contactor/Owner.

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AWS A2.4 ” Standard Symbols for Welding, Brazing, and Nondestructive Examination ” shall be used for all welding details on all drawings. AWS A3.0 “Standard Welding Terms and Definitions” shall be used for all specifications and documents. Before start of welding and fabrication, Vendor shall prepare Inspection and Test Plan and related NDE procedures to be employed. They shall be submitted to Contractor and Owner for review. Prior to commencing fabrication work, welder qualifications (WPQ’s), welder qualification register, list of NDE operators shall be submitted by Vendor to Contractor and Owner for review.

4.2 Welding Procedure Specification (WPS)

Welding Procedure Specifications (WPS) shall be prepared and issued by Vendor, 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 Vendor when preparing and qualifying the WPS. All WPS’s shall be identified by univocal number. WPS shall be representative and dedicated for the weld which it refers, a single WPS cannot be used to identify more than one joint configuration, moreover, the use of more than one WPS to represent one joint and/or weld is not allowed. All WPS’s shall be issued by Vendor on a form, complying with Form QW-482 of ASME 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. In case of field welding, for welding processes employing shielding and/or backing gas, WPS also shall specify the precautions that will be taken to prevent wind or drafts from interfering with the gas protection. 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. WPSs shall be issued directly to the welder or posted on a notice board adjacent to the welding area. Where necessary WPSs 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 filed).

4.3 Procedure Qualification Record (PQR)

4.3.1 General Requirements

Any pressure boundary welds or welds to the pressure boundary (including tack, repair and stud welding) shall be qualified in accordance with the applicable design code(s), including ASME Section IX and the applicable API and/or NACE standard(s). All PQR’s shall be issued by Vendor on a form, complying with Form QW-483 of ASME Sec. IX (Appendix-B), 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 are exceeded.

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For tube-to-tubesheet joints the WPS shall be qualified and tested through mock-up in accordance with Appendix C. 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. 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. All PQR’s shall be approved or released by competent third party recognized by Contractor (like Lloyd Register, Bureau Veritas, etc); this requirement is not mandatory in case of equipment with ASME code stamping. Material test certificate of base materials and welding consumables used during welding procedure qualification shall be attached to relevant PQR and submitted along with PQR itself. 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. Stud welding used to secure refractory material shall be qualified in accordance with ASME IX QW- 192 and QW-261. If not otherwise specified by relevant design code(s), for structural (non-pressure boundary) weld joints, welding procedures shall be qualified per ASME BPVC Section IX. When impact test is required for base material, by applicable code/standard or by this specification, the welding procedures shall be qualified for impact properties using the Charpy V-notch test (in weld metal and HAZ). Test temperature and acceptance criteria shall be as requested by applicable code/standard or by this specification, in any case the MDMT of the project shall be respected. When PWHT is required all the applicable PQR shall be qualified also with simulated heat treatments (the sum of holding time in one cycle is not permitted). Parameters for simulated heat treatment shall be equivalent to production PWHT plus two additional post weld heat treatment for future weld repair. 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. For items (including internals) to be installed at site by other than relevant Vendor, test coupons and necessary filler materials for PQR execution (including necessary spare material in case of re-testing) shall be included by Vendor in his scope of supply.

4.3.2 Specific requirements for Air Cooler Heat Exchanger (API 661)

For air cooler heat exchanger (ACHE) covered by API 661 standard, subject prior to Company approval, if tubes with circumferential welds are allowed by Contactor the Vendor shall demonstrate by means of a macro examination in qualification procedure that weld-root penetration on the tube inside diameter does not exceed 1.5 mm.

4.4 Performance Qualification (WPQ and WOPQ)

All welding including tack, repair and stud welding shall be performed by welders and welding operators qualified in accordance with the applicable ASME and/or API Code, including Section IX and the applicable API and/or NACE standard(s). For each welder/welding operator, a Welder Performance Qualification (WPQ) or Welding Operator Performance Qualification (WOPQ) shall be issued by Vendor (or recognized by 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. For items (including internals) to be installed at site by other than relevant Vendor, test coupons for WPQ execution (quantity to be agreed with Contractor) shall be included by Vendor in the scope of

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supply, if not otherwise required by applicable Material Requisition/Supply Specification or Purchase Order.

5

WELDING PROCESS

5.1 General Requirements

Vendor shall consider the following acceptable welding process(es):

Welding Process (1)

Root pass (2)

Second pass

Fill/cap and fillet

Weld overlay

Buttering

Shielded metal arc welding (SMAW)

Gas tungsten arc welding (GTAW/GTAW-P)

Gas metal arc welding spray (GMAW-Sp)

Gas metal arc welding short circuiting (GMAW-S)

Gas metal arc welding pulsed (GMAW-P)

X

X3

Submerged arc welding (SAW)

Electroslag welding (ESW)

Gas shielded flux cored arc welding (FCAW)

Plasma arc welding (PAW)

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X4

X

X

X

X

X

X

X

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: With prior approval

Note 4: Limited to WO on P-No. 1 through P-No. 5 and P-No. 15E base materials

5.2 Additional requirements for Gas Tungsten Arc Welding (GTAW) and Pulsed

(GTAW-P)

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.

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. For all longitudinal seams, run-on and run-off pads shall have the same P-No. as the base material.

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

5.5 Additional requirements for Flux Cored Arc Welding (FCAW)

Self-shielding FCAW (FCAW-S) shall not be used. FCAW can be used for welding of carbon steel with MDMT > -29°C and austenitic stainless steel materials only The use of short circuit transfer mode is not allowed.

5.6 Additional requirements for Gas Metal Arc Welding (GMAW)

GMAW in spray mode can be used for welding of carbon steel with MDMT > -29°C and austenitic stainless steel materials only.

5.6.1 Specific requirements for Gas Metal Arc Welding with short circuiting transfer mode

(GMAW-S)

It is allowed for carbon steel material only. GMAW-S shall not be used for branch connections, nozzle-to-shell welds, socket welds or girth weld on pipe of any sizes. For remaining type of joints, GMAW-S shall only be used for root pass with wave control arc transfer mode.

5.7 Additional requirements for Plasma Arc Welding (PAW)

PAW can be used for welding of carbon steel and austenitic stainless steel materials only.

6

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 unless specifically accepted by Contractor and Owner in writing. In such case, a PQR shall be performed for each batch and lot used for production welds. MTC & data sheet of the respective G classification electrode shall be shared as part of relevant WPS/PQR. 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) is not allowed. Active, alloy and crushed-slag fluxes shall not be used. 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

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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. When attaching non-pressure parts to pressure parts, the filler metal chemical composition shall match the nominal chemical composition of the pressure part. 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 Vendor 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-number 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. 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. For items (including internals) to be installed at site by Other than relevant Vendor, necessary welding filler metals for field assembly execution (including necessary surplus, typically 8-10% of surplus on the theoretical estimated quantities) shall be included by Vendor in the scope of supply, if not otherwise required by applicable Material requisition / Supply Specification or Purchase Order.

6.1.1 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

lot, diameter of wire/strip/covered electrodes, wire/flux combination to be used for fabrication, according to EN 10204 Type 3.1 as per AWS 5.01 sch. 3 or H

for each batch,

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

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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.

6.1.2

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 moisture and the Manufacturer recommendation. In particular:

inclusion of hydrogen

the deposited weld,

following

in

➢ 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 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).

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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. Vendor 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 Vendor upon request.

7

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 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

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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.

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 25 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. 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 8.4 along with the applicable Appendix(es) of this procedure. 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.

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.

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➢ 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. 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. On pressure vessels with skirts, no tack welds are permitted on the inside of the skirt between the head and the skirt. For storage tanks, tack welds used during the assembly of vertical joints of tank shells shall be removed and shall not remain in the finished joints when the joints are welded manually. When such joints are welded by the submerged-arc process, the tack welds shall be thoroughly cleaned of all welding slag but need not be removed if they are sound and are thoroughly fused into the subsequently applied weld beads. Tacks on clad/weld-overlay surfaces shall not be allowed. Misalignment shall be in accordance with the applicable design code(s), and it shall be evenly distributed around the full circumference. The minimum design thickness shall be achieved around the full circumference.

8

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-G, GMAW or PAW) 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. 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

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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-PWHTed items, welding after hydrotest is prohibited without Contractor and Owner approval. For PWHTed items, welding after PWHT (except as permitted by Appendix H) is prohibited without Contractor and Owner approval. No further welding, forming or other operation detrimental to the galvanizing shall be performed after the galvanizing. All production welds, including tack welds and tube-to-tubesheet welds, shall be made with filler metal. Autogenous welding (without filler metal) is not permitted. Two passes shall be considered as minimum. Single-pass welds are not permitted, unless approved by Contactor. 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 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). Except for longitudinal weld where run-on and run-off pads of same material, as base material, shall be used, weld starts and stops shall be situated in the fusion path and starts and stops shall be staggered. 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. Temper bead technique is not allowed for new welding(s), except for site assembled storage tanks and for weld repair(s) where local PWHT cannot be applied (see clause 11 for details).

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For site assembled storage tanks, all the prefabricated nozzles and accessories shall be stress relieved prior to installation wherever required by API 650 standard. Welds are to be uniquely identified. Vendor 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. Vendor shall maintain records of weld number and the welder identification for each weld for inclusion in final documentation. Marker pencils or paints free from sulphur, zinc, aluminum, lead, chloride, and other halogens. Calibrated device for measuring the following variables/parameters shall be always available by 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. Use of subcontractors for any operations required for the execution of this project by the Vendor is prohibited without prior permission and acceptance by EPC Contractor. Subcontractors include other plant locations than the main or identified plant of the Vendor. All the requirements of this document, including all the herein referenced documents, codes, specifications, procedures, etc. are applicable to the subcontractor and are to be included in Vendor’s purchase orders to subcontractors.

8.2

Joint configuration

All pressure retaining joints (including nozzles, manways and their reinforcements where welded to vessel shell and/or heads), shall be fabricated with full penetration welds unless otherwise specified in approved construction drawings. Two-sided welding shall be applied whenever practical. Double-welded groove joints shall have their root passes back gouged to sound metal on the reverse side and examined by PT or MT before proceeding with welding on that side. Where double welding is impractical (e.g., the groove joint backside is not accessible for chipping or gouging and welding) the root pass shall be made by GTAW or (if approved) by GMAW-S with wave control arc transfer

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mode welding processes. It also includes the root pass of skirt-to-head joint. Use of set-on nozzle connections is not permitted, except a) for connections at air-cooler header box b) for nozzles attached to flat heads/ blind flanges complying with the followings:

1. The ratio of the blind flange (or flat component) and nozzle thickness is bigger than 4;

2. The blind flange (or flat component) shall be 100% inspected by ultrasonic and magnetic particle (liquid penetrant for austenitic material) over a surface of 150 mm around the opening before and after welding, to ensure that it is defect free;

c) When permitted by applicable Licensor specifications; Lifting lugs and trunnions shall be attached with a full penetration weld. Unless otherwise specified in approved construction drawings, all internal and external attachments shall be continuously welded to the pressure part at all points of contact. For items in Sour, Amine, Caustic and HTHA Service, internal and external attachments joint type shall be in accordance with applicable Licensor specifications.

8.2.1 Specific requirements for shell and tube heat exchanger (API 660)

Pass-partition plates for forged or welded channels and floating heads shall be welded full length, either from both sides or with full-penetration welds. If welded from both sides, the first 50 mm from the gasket face shall be full-penetration welds.

8.2.2 Specific requirements for air cooler heat exchanger (API 661)

All pressure-containing header welds and nozzle welds shall have full penetration and full fusion. For plug header, partition plates shall be seal-welded to abutting tubesheet and plugsheet plates and shall be welded from both sides; a full-penetration weld joint preparation shall be used. Seal welds on the ends of internal pass partitions plates are excluded from this requirement. For plug header, if pass partition plates are also used as stiffeners, a full-penetration configuration shall be used and weld joint efficiencies shall be in accordance with the pressure design code. All removable cover plate design shall have flanges installed with full penetration welding regardless of design temperature. Partition plates and stiffeners shall be welded from both sides, along the full length of the three edges Corner weld joints in box headers shall be preferably designed with double side welds (except end plate and nozzle welds). In case the exchanger manufacturer will select single side welds, it shall follow the design code and ASME Code sect. VIII Division 1 para. UW-13.

8.3 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,

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e.g. 5X replacement volumes.

8.4 Preheating

The Vendor is requested, under their full responsibility, to establish the minimum preheat temperatures related to: ➢ chemical analysis ➢ ➢ welding process and heat input ➢ restraint of the parts being joined (such as shell welds and nozzles to vessel or nozzles to header

thickness

welds, etc.)

Any recommendations or requirements for preheat listed in the relevant code and recommended practice (such as Appendix R of ASME Code Section VIII Division 1, Table 6.7 of ASME BPVC Section VIII Division 2, etc., as applicable) and in this specification shall be considered as minimum mandatory requirement. 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, Vendor 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 e.g. 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.

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8.5 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.

8.6 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. During interruption of preheat for:

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

using insulation to allow hydrogen outgassing.

2. Carbon steel with wall thickness greater than 50 mm, DHT shall be performed before welds are

allowed to cool down.

8.7 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. The minimum distance between two longitudinal seams in one shell course shall be 200 mm or five times the wall thickness, whichever is the larger, as 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. 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.

8.8 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 SS/MR) 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 Vendor 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, Vendor 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.

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8.8.1 Specific requirements for shell and tube heat exchanger (API 660)

Unless otherwise specified in applicable construction drawings, all welds shall be ground smooth on the inside of the shell to facilitate assembly/removal of the bundle.

9

PWHT REQUIREMENTS

9.1 General requirements

PWHT shall comply with the requirements of the applicable code(s), datasheet, construction drawing(s) and Licensor’s documents, together with the additional requirements specified in this specification. The rates of heating and cooling shall not be less than 56°C/h (100°F/hr). 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. Code exemption of PWHT for alloy steels in nonutility services with nominal chromium content of 1% or greater shall be approved by the Contractor and Company. Unless otherwise accepted by Contractor, temper bead technique shall not be allowed to be used in place of PWHT. Final PWHT modifies the microstructure of the weld metal and of the HAZ. It gives the best metallurgical asset of the weldment. For this reason, PWHT parameters shall be optimized and defined by Vendor taking into account the anticipated number of heat treatment cycles (in accordance with steel Manufacturer) so as to guaranty, at one and the same time, mechanical and toughness characteristics on the delivered equipment. 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. Special heat-treating methods, such as induction and internally fired, shall be approved by the Contractor and Owner, prior to production. Exothermic kits shall not be used for PWHT. Vessel shall be subjected to PWHT in one piece fully fabricated. In case of any furnace size limitation or limitation due to transportation, Vendor shall obtain specific derogation from Contractor and Company to perform local PWHT, at the closing seams of shell. Only this type of weld will be allowed for local PWHT. When local PWHT is necessary, the following shall apply:

a) Full circumferential band around vessels shall be uniformly heated by electric resistance and cooled, according to WRC Bulletin 452 (any recommendations shall be considered mandatory) and NACE SP 0472 para. 3.7 for items in sour, amine, caustic and HTHA service

b) Local spot PWHT (called a “bull’s eye”) on vessels is not allowed.

c) The number of sections shall be minimized.

d) The weld joining sections shall be positioned away from local discontinuities such as nozzles,

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. The PWHT temperature shall be strictly controlled, measuring both the vessel skin and furnace temperatures using thermocouples (minimum two thermocouples each to the outside and inside surfaces of the equipment).

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Thermocouples shall be located on the inside and outside of the vessel surface and placed to ensure that that all portions of the vessel are properly and uniformly heat treated, without the presence of detrimental thermal gradients. Locations thermocouple shall include the thinnest component, the thickest member, the top of the component (as oriented during PWHT) and the bottom of the component (as oriented during PWHT). In any case, the number of thermocouples shall be sufficient to ensure that the temperature and thermal gradients of the whole work are within the required range. 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 figure below)

➢

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 capacitor discharge method is used, the materials should be of a compatible composition

The weld metal shall be removed by careful dressing followed by MT or PT examination after PWHT to confirm absence of linear indications. For all temperatures above 300°C, 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. Prior to commencement of PWHT the fabricator’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: All temperature measuring devices shall have valid calibration certificates, furthermore, instruments used for checks and measurements shall be calibrated periodically by an accredited laboratory, in accordance with the requirements of the applicable norms and standards. During heat treatment the vessel shall be supported and stiffened to prevent distortions. All machined surfaces shall be protected against oxidation during heat treatment. Fuel-powered furnaces shall have adequate flame controls to avoid an oxidizing furnace atmosphere. Direct flame impingement is always prohibited. Except as specified in Appendix H sub-clause H.7, for carbon steel with austenitic stainless steel 304L/308L or 316L clad/weld overlay, welding after PWHT is prohibited without Contractor and Owner approval. Production welding test plates (when applicable) shall be heat treated in furnace together with the vessel. When dissimilar weld joint is accepted by Contactor between ferritic to stainless steel, Vendor shall consult Contractor, for PWHT requirements (if applicable). A PWHT procedure shall be developed by Vendor prior to heat treating and submitted to Contractor for review and approval. As a minimum it shall include the following information:

a) Description of the equipment

b) The method and type of heating process

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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) Precautions taken to prevent distortion, collapse, or other damage as appropriate

g) Heating and cooling rates

h) Maximum allowable temperature differentials

i) Gradient control information

j) Holding time

k) PWHT temperature range

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

sketch)

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

n) Chart speed and type of recording

9.1.1 Specific requirements for shell and tube heat exchanger (API 660)

According to API 660 para. 9.6.9 the PWHT of fabricated carbon steel channels and bonnets shall be performed for the following:

1. channels and bonnets with six or more tube passes;

2. channels and bonnets whose nozzle-to-cylinder internal diameter ratios are 0.5 or greater, except

where a conical reducer is used in place of the channel or bonnet;

According to API 660 para. 9.6.11 the PWHT shall be performed for all carbon steel and low-alloy steel floating-head covers that are fabricated by welding a dished-only head into a ring flange. When PWHT is required for process reasons:

3. shell side:

➢ PWHT shall be performed for the shell and the floating head cover

➢

the requested PWHT for tubes-to-tubesheet welds shall be indicated on the individual DS or SS

4. tube side:

➢ PWHT shall be performed for the channel and the floating head cover

➢ Tubes-to-tubesheet welds shall be PWHTed, as well (NOTE: the above requirements apply in

case of both strength and seal welds)

For welded and expanded tube-to-tubesheet joints requiring PWHT, the tubes shall be expanded after PWHT execution.

9.1.2 Specific requirements for air cooler heat exchanger (API 661)

According to API 661 para 9.2.1 all carbon steel and low-alloy chromium steel headers shall be subjected to PWHT. The headers shall be post weld heat treated prior to insertion of the tubes, therefore welded tube-to- tubesheet joints shall be excluded unless required by the pressure design code or specified by the reference DS or SS.

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10 WELD INSPECTION REQUIREMENTS

10.1 Non-Destructive Examination (VT, MT, PT, RT and UT)

NDE examinations (both in terms of extension, procedure and acceptance criteria) shall comply with the requirements of the applicable code(s), DS, construction drawing(s) and Licensor’s documents, together with the additional requirements specified in this specification. Minimum NDE examination of weld joints shall be the “Spot examination”, as defined by applicable code(s). In addition to the requirements of applicable code(s) the following shall be complied with:

➢ All finished welds shall be subject to visual examination.

➢ Expansion joints made of thin-walled bellows shall have the longitudinal weld 100% examined by

RT method before forming.

➢ All pressure containing equipment designed with 100% radiography of joints, shall have all nozzle and reinforcing pad attachment welds examined by MT or PT. Inspection shall be performed on all accessible weld surfaces (inside and outside).

➢ Where nozzle pipe or pipe transitions are fabricated from plate, the relevant longitudinal welds

shall be subject to 100% radiography.

➢ Butt welds and vessel support attachment welds of items having 50 mm and greater in thickness

shall be ultrasonically examined after hydrotest.

➢ Requirements indicated in applicable Licensor specifications

Unless more stringent requirement in applicable design code(s), when forming occurs after completion of welding, the radiography examination shall be after welding but prior to forming. If so, an additional liquid penetrant or magnetic particle examination of all surfaces is required after forming. When radiographic inspection is required, the welds that cannot be examined by RT shall be subjected to ultrasonic examination, under Contractor, Company and ARH written agreement. Vendor shall consult Contractor about NDE requirements to be applied to welds joining dissimilar materials (different P-No.). Unless otherwise required, 100% of both surface and volumetric examination shall apply. The work of all welders employed on the job shall be included in the required NDE examination in general, and in particular, in RT examination. Only the wet method with A.C. yoke shall be used for MT examination. Permanent magnet or D.C. yoke shall not be used. Coil or parallel conductor methods shall only be used if approved by Contractor. 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. Wherever UT examination is required, a calibration block for ultrasonic examination shall be provided. The block shall be in accordance with ASME Code section V, Article 5 (it shall include a lining identical with the vessel cladding/weld-overlay, where it is applicable to relevant production examined joint under examination) Inspection of welds shall be carried out after final heat treatment. For ferritic material (carbon steel and low alloy steels), Vendor may propose the use of recordable UT examination technique method (TOFD/phased array technique) as examination system in lieu of radiographic examination. Recordable UT shall be performed in accordance with applicable design code(s). The proposal of using recordable UT examination method is subjected to Contractor written

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acceptance. NDE personnel shall be qualified to the requirements of the applicable code. As a minimum, the qualification shall be to the requirements of SNT-TC-1A level 2 (or equivalent) for the examination method. An updated record shall be maintained for NDE personnel. Certification of NDE personnel shall be issued by an independent and accredited third-party body authorized in the manufacturer’s country. Contactor Inspector, TPIA, the Owner (or his Agent) and ARH shall have access to the Vendor’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 Vendor’s works that concern the fabrication, assembly and/or installation. The Vendor 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.

10.2 Production Hardness Test

When production hardness test is required by Appendixes, it shall be performed:

➢ on the weld metal and both base metals adjacent to the fusion line,

➢ after PWHT (for heat treated item),

➢ on the side contacted by the process whenever possible, if access to the process side is

impractical or weld is internally overlayed, hardness test shall be done on the opposite side.

Vendor shall check the weld joint hardness of the initial production weld for each welding process and filler metal used. Once the initial weld hardness is checked, subsequent production hardness testing shall be conducted as follow:

➢ minimum one hardness test shall be made for each 3 mt. of weld seam

➢ minimum one hardness test shall be made on each nozzle flange-to-neck and nozzle neck-to-

shell/head weld.

➢ Each unique welding procedure used shall be hardness tested.

Acceptable portable hardness testing equipment are the followings:

1. 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.

➢ a hardness test shall consist of three hardness readings for each location. The average of these

three 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

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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

2. 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.

➢ a minimum of five (5) measurements the mean shall reported.

➢

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.

➢ 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:

➢ Type of hardness tester and its most recent calibration date

➢ Personnel conducting hardness tests

➢ Test surface preparation (method and tool)

➢ Type of material

➢ Test location

➢ 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.

10.3 Production Ferrite Test and Chemical Analysis

When production ferrite test is requested by applicable Appendix(es), pressure boundary 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 (5) 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

➢ Ferrite measurements shall be taken before PWHT When chemical analysis is requested by applicable Appendix(es), a physical sample is required. Alternatively, an optical emission spectrometer may be used to check all required elements, including carbon and nitrogen.

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10.4 Positive Material Identification

Low-alloy and alloy components, welds and overlay/clad-restoring shall require PMI (Positive Material Identification) according to project specification no. 4439-XZ-SG-000000002 PMI General Specification.

11 WELD REPAIRS

11.1 General requirements

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. 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. 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 weld and shall extend a minimum of 50 mm beyond either side of the repair. Welds containing repairs that were made after PWHT shall be subject to repeat PWHT in accordance with this Specification, unless otherwise approved by Contractor. When repairs are made to cladding or overlay welds on low alloy steels without subsequent PWHT, a minimum remaining clad or overlay thickness of 5 mm is required unless it can be demonstrated that no new HAZ is formed in the base metal with thinner overlay. When repair of a weld is done by a weld cut-out, the original weld and HAZ shall be completely 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 weld metal and both adjacent HAZs (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. In-process repairs (i.e., repairs performed prior to completion of the joint using the same welding procedure as for the original fabrication) during production do not require a separate repair procedure except for major repair. Welds indicating irremediable or injurious defects, improper fabrication and/or excessive repairs, shall be subject to rejection at any time, at Contactor discretion. Crack repair is not allowed. When cracks are observed the cause shall be investigated. For major repair (as defined in sub-clause 11.1.1), the following shall be applied:

a) remedial grinding and repair welding shall not commence before informing Contactor and Company of the Vendor’s proposed remedial actions. The Contractor inspector shall have the right to witness all repair works.

b) Weld repair shall be carried out in accordance with a written procedure.

Weld repair procedures shall include:

➢ method of defect removal;

➢ method for verification of defect removal;

➢ shape and size of excavation prior to re-welding;

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EQUIPMENT WELDING GENERAL SPECIFICATION

➢ repair WPS;

➢ PQR;

➢ PWHT procedure (if applicable);

➢

type and extent of NDE after repair;

➢ approval requirements;

11.1.1 Major repair

Major repairs can be performed only when a dedicated Non-Conformity Report (NCR) is approved by Contractor and Company. The following shall be considered major repair:

BASE METAL

WELD METAL

Repair cavity greater than 6450 mm2

Repair cavity greater than 6450 mm2

Repair cavity deeper than 50% of thickness or 13 mm, whichever is less

Repair cavity deeper than 50% of thickness or 13 mm, whichever is less

Weld build-up to correct manufacturing error. All weld build-up or buttering shall be 100% examined by radiographic or ultrasonic testing.

Edge defects greater than 25 mm deep or thickness of base metal, whichever is less

Edge defects greater than 20% of edge length

Lack of fusion and or penetration

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APPENDIX A MINIMUM CONTENT FOR WPS

The following minimum data shall be specified on WPS:

1. Welding process/combination of welding processes and grade or type of automatization (i.e. Manual, Semiautomatic, Machine, etc.)

2. Equipment type and model when a power source employing pulsed modes is used (without waveform control)

3. 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)

4. 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 CE)

5. Applicable production diameter and wall thickness range

6. The required chemical composition for weld overlay/clad restoring application

7. The minimum total overlay thickness (see clause 3 for definition), for weld overlay/clad restoring application

8. 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

9. Where metallic backing material is permitted, the P-No., or its nominal chemical composition

10. 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)

e) Filler material heat/batch number, when such data are considered additional essential variables

(e.g. in case of using of “G” classified welding consumable where permitted)

11. Flux type, grade and manufacturer trade/brand name

12. Infusible Tungsten electrode

a) Size

b) Type

c) AWS classification

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13. Minimum number of passes to be applied

14. Electrical characteristics

a) Current type (ac or dc) and Polarity

b) Arc voltage (V) with appropriate ranges

c) Current (A) with appropriate ranges

d) Mode of transfer for each run, in case of GMAW and FCAW

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 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).

15. Travel speed (mm/min)

16. Wire feed speed and electrode stick-out for partial-mechanized, mechanized and automatic welding processes (e.g. SAW or when allowed for GMAW, FCAW)

17. Oscillation width when weave bead technique is applied

18. Frequency width and dwell time on side wall for each pass, when oscillation technique is applied using mechanized or automatic welding processes

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

20. Parameters controlling magnetic field for ESW and SAW strip weld-overlay

21. Welding position and direction of welding

22. When interruption in welding is allowed, minimum number of runs completed before to cooling to ambient temperature.

23. Overlap between adjacent passes, for weld overlay/clad restoring application

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

25. Interpass data:

a) Maximum temperature

b) Method of measuring temperature

26. Pre-heating data:

a) Minimum temperature,

b) Method of applying heat

c) Method of measuring temperature

27. Shielding gas composition, purity and flow rate

28. 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.

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29. Arc starting aids or devices in case of using GTAW (and when allowed for PAW and ESW) welding process

30. 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

31. 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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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

Joints

Joints

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

CS

x

x

x

Girth welds

LAS

ASS/NA

DSS

WO

Buttering

x

x

x

x

x

x

x(7)

x

x

x

x

Base material

or

x(2)

x(2)

x(2)

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

1. Nb(Cb) > 0.01wt%
2. V > 0.01wt%
3. Ti > 0.01wt%
4. B > 0.0005wt%

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.)

Coupon configuration

Material thickness

Any change exceeding what is specified in clause B.1.1

Any change exceeding what is specified in clause B.1.2

x(2)(3)

x(2)(3)

x

x

x(7)

x(7)

x(6)

Consumable

A change in brand name

x(2)(3)(5)

x

x(5)

Consumable

Same AWS classification

Consumable

A change in the flux-wire combination

x

x(5)

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

x

x

x

x

x

x

x

x

x

x

x(5)

x

x(5)

x(7)

x

x

x

x(5)

x(5)

x

x

x

x

x

x

x(5)

x

x(5)

x

x

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Essential variable

Description

Girth welds

WO

Buttering

Welding position

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

Gas

Gas

Removal of backing 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

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

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

x

x(3)

x

x

x(2)

x

x(3)

x(3)

x(2)

x(2)(4)

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x(7)

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x(8)

x(7)(8)

x(8)

x

x

x

x

x

x

x

x

x

x

x

x

x

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 Caustic, HTHA or Amine service are applicable. NOTE 5 - for SAW, FCAW and ESW processes only. NOTE 6 - except that UNS S31803 and UNS S32205 are interchangeable. NOTE 7 - for nickel alloys only. NOTE 8 - 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.

B.1

ESSENTIAL VARIABLES FOR COUPON CONFIGURATION

B.1.1 Weld Overlay

a) Qualification of overlays on nozzles shall be made on same materials of the smallest size

intended to be qualified and in the same welding position.

b) Overlap of adjacent weld beads shall be the same in production as that used to qualify the weld

overlay procedure.

c) The total overlay thickness shall not be less than minimum total overlay thickness applicable to

the relevant PQR.

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d) The number of layers in production shall not be less than the number of layers in the procedure

qualification test.

e) Single-sided welding of clad or weld overlaid material shall be qualified using clad or overlaid

materias

B.1.2 Duplex Stainless Steel - Thickness qualified

The minimum and maximum qualified weld thickness (t) shall be as follows:

a) For t ≤ 16 mm (5/8 in.) 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 (5/8 in.)

b) For t > 16 mm (5/8 in.) but < 29 mm (11/8 in.), both the minimum and maximum thicknesses

may be qualified by qualification test coupons within this range

c) For t ≥ 29 mm (11/8 in.) the minimum qualified thickness is T, and the maximum qualified

thickness shall be 1.2T

B.1.3 UOP Additional Requirements

The weld deposit overlay procedure shall be qualified on base metal of the same composition as the vessel and thickness of at least one-half of the vessel thickness or 50 mm, whichever is less.

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APPENDIX C

TUBE TO TUBESHEET JOINT SPECIFIC WELDING REQUIREMENTS

C.1 DEFINITIONS

Seal weld: Tube to tubesheet joint weld of unspecified strength applied between the tubes and tubesheet for the sole purpose of reducing the potential leakage.

Full strength weld: tube to tubesheet joint welded so that the design complies with ASME VIII div.1 UW- 20 with a joint efficiency (fr) value equal to 1,00.

Minimum leak path (MLP) is the distance from the root of the weld to the surface nearest to the root.

C.2 WELDING FABRICATION REQUIREMENTS

A fabrication procedure shall be submitted for Contactor review with the following minimum information, in the following sequence of execution:

a) Cleaning method

b) Visual inspection of machined tube-sheet (i.e. checks for hole finish, hole dimension tolerance,

groove depth and dimensions)

c) Method to fix the tube before welding

d) Applicable WPS/PQR

e) PWHT (where applicable)

f) Applicable NDE

g) Leak test (where requested)

h) Tube light expansion strength (where groove strength expansion is not applicable)

i) Final hydraulic test

Welding shall be carried out by manual GTAW or orbital GTAW automatic machine. The use of other welding process requires the acceptance of Contractor.

All tubes shall be welded individually.

No second run shall be deposited until the first run has been completed, cleaned as necessary and the first weld is VT examined (and PT tested, when requested).

Strength welded tube-to-tubesheet welds shall have a minimum of two weld passes, with start/stop points offset by at least 30°. For seal welds one welding pass minimum can be applied.

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Each pass shall be carried out without interruption and the finish point of the bead shall cover the start point of the bead.

Autogenous welding is not permitted unless agreed in writing with Contactor; in their proposal, Vendor shall specify additional tests to be carried out during qualification to ensure suitable corrosion and mechanical properties are maintained.

When welding with the tube-plate in the vertical position, particular care should be taken to ensure a uniform weld profile. Any over-run or spillage of weld metal into the bores of the tubes which is considered detrimental shall be cleaned out and spatter removed.

The tube joints shall be welded in such a manner as to minimize distortion of the tube-plate.

The method used to position a tube in advance of tube-end welding shall be done in such a way as to prevent the trapping of gases during the welding process.

Commentary Note:

For expansion into ring groove(s), coupled with seal-welding may be utilized. This method introduces risks if the tube is fully expanded prior to welding as gases evolved/released during welding will not be able to escape from the root side of the joint. Therefore, partial expansion to secure the tube, followed by welding and final expansion is recommended.

Tubes can be located by means of GTAW tack welds. The tack welds shall form part of the procedure qualification. All such tacks shall be completely fused during subsequent tube end welding. The start of the root pass shall not be on the tack weld.

C.3 QUALIFICATION OF WELDING PROCEDURE

C.3.1 General

The tubes shall be welded to the tube-plate using the approved procedure.

WPSs for seal welding of tube-to-tubesheets shall be qualified in accordance with ASME BPVC Section IX, QW-202.6 a, b, or c.

For tube-to-tubesheet design where strength welds are specified, WPSs shall be qualified and tested by mock-up, in accordance with ASME BPVC Section IX, QW-193 and QW-288, and the following requirements.

The assembly of the mock-up is required to simulate all steps of the production joint, including both welding and rolling, and in particular:

1. For base material:

a) the tubes used for mockup shall have the same:

i) diameter, thickness, material P-No. and Group No. of production tubes.

ii) geometry lay out and tube projection of production.

b) The tube sheet material used for mockup shall have the same:

i) material P-No. and G-No. used in production.

ii) supply condition (including heat treatment)

iii) thickness (50 mm thickness can be used to qualify thicknesses greater than 50 mm, if not

otherwise required in the contract).

iv) overlay nominal composition of production, in case of overlayed tubesheets

2. The following shall be considered essential variables, in addition to QW-288:

a) Weld Joint dimensions (including tube-sheet hole size and tube protrusion dimensions)

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b) Number of weld passes

c) Welding process

d) Filler Metal classification

e) The addition or deletion of filler metal

f) Shielding gas composition

g) Preheat and PWHT

The mockup shall be welded in the same position as the production weld (vertical or horizontal). The welding configuration and sequence shall be the same to be applied in production.

Tube expansion shall be performed after welding.

Where the tube to tube-sheet weld will be carried out through the plug holes, the mockup shall be welded simulating the same condition, including the thickness of the plate, the separation between plates and the diameter of the holes.

C.3.2 Testing requirements

The tests and inspections to be carried out on test coupon and applicable acceptance criteria are included in the Table 1:

Table 1 - Tests and acceptance criteria

Type of test

Test position/extension

Acceptance criteria

Visual test

100% welded joint

The welds shall show complete fusion, be free from visual cracks or porosity indications and have no evidence of burning through the tube wall. Welds shall show uniform contour without excessive reinforcement with the bores of the tubes, free from any spatter, obstruction, weld spillage or overfill, which shall be considered detrimental.

Liquid Penetrant test

100% welded joint

The welds surfaces shall meet the requirements of ASME IX QW-195.2

Macrographic examination

4 macros for each mockup weld (total 40 examinations)

1. weld joint dimensions according to sub-clause C3.2.1
2. no cracking
3. complete fusion and penetration of the weld deposit into the tube-sheet and tube wall face

Microstructural examination with ferrite measurement

Applicable to duplex and super duplex stainless steel

Two faces 90° apart shall be polished to a one-micron finish and suitably etched. The specimen shall be examined for any deleterious third phases and ferrite content shall be determined using point counting to ASTM E562. The acceptance criterion shall be 35% - 65% ferrite in the weld and HAZ. Note: For tube-plates in the vertical position, the ferrite determination shall be carried out at 3 and 12 o’clock positions. For tube-plates in the flat position, two diametrically opposed tests are required.

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Type of test

Test position/extension

Acceptance criteria

A corrosion test shall be carried out in accordance with ASTM G48. Care should be taken to grind away or seal crevices on the root side, depending on weld geometry. The minimum test parameters and acceptance criteria shall be as follows:

Corrosion test

Applicable to duplex, super duplex and super austenitic stainless steel

22% Cr duplex 24hrs @ 22°C minimum 25% Cr duplex 24hrs @ 35°C minimum 27% Cr duplex 24hrs @ 40°C minimum 6% Mo 24hrs @ 35°C minimum

The acceptance criteria shall be a weight loss < 4g/m² and no pitting on the test face. If the weight loss is >4g/m² and it can be positively identified that this is only due to corrosion at the cut faces, the test shall be invalid. In this case re- testing shall be carried out on replacement specimens.

Transversal section: BM/HAZ/WM One specimen at the first tube end which was welded.

Hardness test

Unless otherwise requested, the acceptance criteria shall be as follow:

• P-No. 1, 4 and 5A: 248HV10 max
• P-No. 10H: 310HV10 max

Hardness shall be performed after tube expansion.

Location of indentation shall be equivalent to the one specified for fillet welds by ISO 9015-1 or NACE MR0175 (fig.3) or NACE MR0103 (fig. C.6).

Pull-out test

when required by sub-clause C.3.2.2

ASME VIII div.1 UW-20.4.3, in accordance with below sub- clause C.3.2.2

C.3.2.1 Details about macro-examination - Minimum leak path (MLP) verification

As part of macrographic examination the Minimum leak path (MLP) dimensions shall be verified.

MLP shall be greater than 1.0 t (where t is the nominal wall thickness of the tube).

For weld joint complying with ASME Code sect. VIII div. 1 para. UW-20.3, as alternative of above MLP verification, the following examination or test can be performed:

• Alternative 1: Dimensions of af, ag, ac with respect to figure UW-20.1 shall be measured, reported

and compared against the value specified in approved construction drawing.

• Alternative 2: Three (3) pull-out tests according to ASME Code sect. VIII div. 1, para. UW-20.4.3.10

can be performed (fr determined shall not be less than 1,00).

C.3.2.2 Details about pull-out test

For weld joint not complying with ASME Code sect. VIII div. 1 para. UW-20.3, nine (9) pull-out tests according to ASME Code sect. VIII div. 1 para. UW-20.4.3.11 can be performed (fr determined shall not be less than 1,00).

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C.4 QUALIFICATIONS OF WELDERS AND WELDING OPERATORS

Every welder or welding operator shall be required to produce evidence of his ability by making a test sample similar to that prescribed for welding procedure qualification in clause C3.

The purpose of this qualification test is to demonstrate that both the welders and welding equipment are capable of producing satisfactory joints in accordance with the approved weld procedure.

A minimum of 3 tubes shall be welded by the welder/operator.

One of these tubes shall be used to obtain two macro-sections 90° apart (12 and 3 o’clock if tube-plate vertical).

Macro-examination examination shall comply with the followings:

1. weld joint dimensions according to above sub-clause C3.2.1

2. no cracking

3. complete fusion of the weld deposit into the tube-sheet and tube wall face

When pull-out test is requested by sub-clause C3.2.2, the two remaining tubes shall be subjected to pull-out test in accordance with ASME VIII div. 1 para. 20.4.3 (fr determined shall not be less than 1,00).

C.5

PREPARATION OF TUBES AND TUBES-PLATES

The ends of the tubes which are to be welded shall be cleaned and degreased with a suitable non- residue forming solvent, both inside and out, for a length equal to the tube-plate thickness but not less than 25 mm.

It is recommended that the solvent used for degreasing materials should be chloride free, e.g. acetone.

For welding with the GTAW process, the outside ends of the tubes for a minimum distance of 13 mm shall be finished to bright metal, e.g. by linishing or power brushing.

Tubes with score marks or any other surface irregularities at the ends shall not be used if considered to be detrimental to the production of sound welds.

The tube-plates shall be machined and the tube holes bored or drilled as required by the design. The holes so formed shall be normal to the tubeplate surface, parallel, circular and shall have smooth internal surfaces. They shall be free from burrs. Holes shall be free from radial or longitudinal scratches or imperfections.

Immediately prior to assembly, the plates shall be thoroughly cleaned and degreased using a nonresidue forming solvent. It is recommended that the solvent used should be chloride free, e.g. acetone.

The face of the tube-plate, the holes and the tubes shall be free from dirt, grease, scale and other foreign matter when they are assembled. To avoid possible damage during assembly or entrapment of contaminants, baffle and support plate holes should be free from burrs and effectively cleaned prior to the commencement of tube insertion.

C.6

PREHEATING AND INTERPASS

Preheating and interpass temperatures shall be in accordance with prescriptions included in EEMUA- 143, see below table:

Tube-plate

Preheat temperature

Interpass temperature

Carbon (< 0.26%) steel

No preheat (*)

Carbon (> 0.26%) steel

50°C min

250°C max

250°C max

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Tube-plate

1 ¼ Cr ½ Mo

Austenitic Stainless Steel

22% Cr Duplex Stainless Steel

Preheat temperature

Interpass temperature

100°C min

None (*)

None (*)

250°C max

150°C max

150°C max

(*) No welding is permitted if the plate temperature is below 5°C

In addition to the above, for carbon steel material with hardness requirements specified due to crack- inducing environments or nominal thickness exceed 32 mm, a minimum preheating of 95°C shall be considered.

Different temperatures shall be agreed with Contractor with a written technical request.

C.7

PWHT

Considering that the post-weld heat treatment of complex assemblies such as welded tube end connections may present difficulties, post-weld heat treatment should be only performed when it is essential to reduce the hazard of stress corrosion cracking associated or when it is mandatory requested by applicable design code.

For air cooler heat exchanger (ACHE), PWHT of the tube ends welds should be avoided, due to exposure of the aluminum fins to high temperatures during the PWHT process.

Where PWHT is required, a detailed description of heat treatment procedure must be submitted to Contractor for review and acceptance prior to use.

The rate of cooling and heating during PWHT shall be controlled to avoid the possibility of weld fracture and tube distortion. The difference in temperature between tubes and shell shall be controlled to avoid excessive difference, number and location of thermocouples shall be indicated in PWHT procedure.

Adequate tube support during PWHT activities to avoid distortion shall be implemented and included in the PWHT procedure.

In case of PWHT, the tube expansion shall be performed after PWHT.

C.8

TUBE LIGHT EXPANSION

Where possible crevice corrosion or vibration fretting susceptibilities must be minimized, it may be necessary to provide for intimate contact between the OD of the tubes and the bores of the tube-plate holes. This may be accomplished by light expansion after both welding and successful leak testing (where required) but before pressure testing.

For tube light expansion, the following requirements shall be fulfilled:

the equipment used for tube expansion shall be of the mandrel and parallel roller type incorporating limiting controls to give a predetermined amount of tube wall thinning, e.g. controlled torque equipment.

If the tubes are to be expanded after welding, the bores shall be inspected for evidence of distortion and/or weld spillage. It is permissible to lightly dress the bores to avoid jamming of the rollers during subsequent expansion, but care must be exercised to ensure the minimum removal of metal from the bores of the tubes.

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• The percentage of the original tube wall thickness and the machine settings to achieve this thinning shall be determined checked during procedure testing by micrometer measurements, according to the formula provided by EEMUA-143 clause 14.4.

Commentary Note:

Where work hardening of the tube material during rolling could result in the potential for environmental cracking, a strength- welded tube-to-tubesheet joint should be applied, and a light expansion (1 % to 3 % wall reduction) should be applied.

• Special care should be taken to ensure that tube expansion equipment is clean and free of any contamination prior to use. If the equipment is used on more than one material type, Manufacturer shall provide a procedure for Purchaser approval detailing how cross contamination is avoided.

• After expansion, the tube internal shall be visual inspected to ensure no damages of tubes.

C.9

INSPECTION AND TESTING OF TUBE TO TUBESHEET WELDS IN PRODUCTION

The following tests shall be performed:

• 100% VT examination

• 100% PT examination

• Leak test (where applicable, see sub-clause C.9.1)

• Whenever specified in the SS or other contractual documents, the final hydraulic test shall be preceded by a low-pressure pneumatic test or gas leak test and must be witnessed by Contractor or its representative. Before the gas leak test no liquid must be applied on the shell side of the tubesheet

• Hydraulic test

Commentary Note:

Radiographic examination shall be performed when it is required by Client/Licensor.

C.9.1 Leak Test

Whenever specified in the SS or other contractual documents, the final hydraulic test shall be preceded by a low-pressure air test or (preferably) gas leak test.

For both types of tests, the tube bundle shall be placed in the shell and welded or bolted as designed and all openings blanked off. No liquid shall be applied to the shell side of the tube-plate prior to any gas leak test.

Air test:

A pressure test at 0.5 bar(g) is performed on the weld joint between the tubes and the tube sheet for leak detection. Soapy water shall be used to detect any leak while the shell is pressurized.

Gas leak test:

Where greater sensitivity to leaks is required, a tracer gas leak test is preferred to an air test. The use of helium, hydrogen or argon as the tracer gas is permissible, but for reasons of economy, argon is preferred. The sniffer gun or detector, which is sensitive to any gas having a thermal conductivity different from that of air, usually has several ranges of sensitivity and the sensitivity is generally progressively reduced so as to pin-point precise leak sites.

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APPENDIX D 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:

f)

the weld;

g) both heat affected zones;

h) both parent metals.

i)

for the HAZ, the first indentation shall be placed as close to the fusion line as possible (approximately 0.2 mm).

j) 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.

For qualification of procedures utilizing temper bead techniques:

➢

➢

➢

the hardness surveys shall be performed as defined in ASME Code sect. IX para. QW-290.5 (c) and figure QW-462.12, except the Vickers testing may be performed using a 49 N (5 kgf) load, and instrumented indentation testing shall not be allowed.

the production procedure shall require that the cap pass be applied so that the edges of the weld beads come within 3.0 mm of the base metal, but do not touch the base metal.

if this results in an unacceptable profile, the excess weld deposit should be removed by grinding, machining, or other low-heat input processes.

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Weld overlay hardness test shall be done on three vertical survey lines distant each other 13 mm, involving weld deposit, HAZ and base metal. Indentations in the weld deposit shall be done on each layer. Indentation in the HAZ shall be 0.2 mm away from fusion line.

For hardness survey of tube-to-tubesheet joints, in addition to the macro-examination required by ASME Section IX, QW-193, macro hardnesses of one randomly selected weld section shall be analyzed (both in the weld and HAZs).

Location of indentation shall be equivalent to the following picture:

When the production tube-to-tubesheet joints are to be expanded after welding, the hardness survey shall be performed on a test coupon which simulates all fabrication steps including the tube expansion.

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 E ADDITIONAL AND SPECIFIC REQUIREMENTS FOR CARBON STEEL

(CS/KCS/LTCS)

E.1

PQR TESTING REQUIREMENTS

E.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.

E.1.2

Impact test

For PWHT’ed items, when impact testing is required for a component or weld that will be heat treated, 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.

Impact test shall be performed at MDMT and shall comply with the applicable MDS plus codes and standards listed on clause 2.

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.

E.1.3 Hardness test

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:

• For non-sour service item(s), method, location and number of measurements specified in Appendix-

D shall be complied with. The maximum hardness value shall be 248HV10

• 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

E.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,

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provided that the required hardness values specified in sub-clause E.1.3 are complied with.

E.2.1 GTAW and GMAW

The following requirements shall apply:

1. Rod/wire designation SFA-5.18 ER70S-2 and ER70S-3 shall be used

2. Rod/Wire designation SFA-5.18 ER70S-6 may be used, provided that hardness requirements of this

specification are complied with

3. For Sour Service, SFA-5.18 ER70S-6 shall be restricted as follows:

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

4. Where impact test is required, the following requirements shall be considered:

i.

ii.

iii.

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.

E.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:

1. For MDMT not lower than -30°C: SFA-5.1 E7018-1, E7016-1 and E7015-1

2. For MDMT not lower than -46°C: SFA-5.1 E7018-1 and E7016-1

E.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 E.8).

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).

E.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.

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E.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.

E.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 32 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.

E.5 HEAT INPUT AND INTERPASS

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

E.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;

PWHT shall be performed at 635ºC (1175ºF) +/- 14ºC (25ºF), when PWHT is specified in applicable DS or SS, due to the following environmental cracking services:

➢ Wet H2S

➢ Hydrogen (in the form of HTHA - refer to API RP 941)

➢ Amine

➢ Caustic

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.6.1 UOP additional requirements

Welded joints greater than 1 ½ inches (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 300ºF (150ºC) prior to PWHT. Alternately, the weld and adjacent metal may be heated to 600ºF (315ºC), wrapped with insulation, and allowed to cool. PWHT may then be performed later.

For welded joints less than or equal to 1 ½ inches (38 mm) in thickness that require PWHT, the requirements of above paragraph are preferred. Alternatively, the joint 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 3-11-10 para. 5.3c are required.

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E.6.2 Additional requirements for Tank in wet H2S service

For tag-item 920-S-004 in wet H2S service, considering that according to relevant DS compliance with NACE SP0472 is specified and PWHT is not considered as mandatory, in addition to base material chemistry control and pre-production weld procedure hardness (HAZ) survey, either “temper bead” or “cooling time control (t8/5)” welding technique shall be applied according to NACE SP0472.

E.7 WELD INSPECTION REQUIREMENTS

For Sour or Caustic service items, all accessible surfaces of welds of pressure retaining parts in contact with the process fluid shall be 100% inspected by wet magnetic fluorescent particle test after PWHT.

E.8

PRODUCTION HARDNESS TEST

The hardness for production welds is required in any of the following cases:

➢ Using of FCAW welding process with any type of filler metal (hardness only in weld metal)

➢ Using of SAW welding process with AWS A5.17 EH (high manganese) wire (hardness only in weld

metal)

➢ Using of GMAW welding process with ER70-S6 wire (hardness only in weld metal)

➢

Items subjected to PWHT

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

E.9 WELD REPAIRS

For item(s) 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 F ADDITIONAL AND SPECIFIC REQUIREMENTS FOR AUSTENITIC STAINLESS

STEEL (304 AND 316 GRADES)

F.1

PQR TESTING REQUIREMENTS

F.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).

F.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

308H

308H

308H

308

308L

308

308

308L

308

308L

308L

308L

308L

308L

308L (note a)

308

308L

308L (note a)

316

316L

316

316L

316L

316L (note a)

316H

Note a: mechanical properties shall be equal to or greater than the 304 or 316 material 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 (1000ºF) 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.

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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.

F.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 stainless steel (i.e. sulfur and chloride free) shall be used.

F.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, including cladding, 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 (including cladding).

F.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.

F.6

HEAT INPUT / INTERPASS

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

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F.7

PWHT

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

F.8 WELD INSPECTION REQUIREMENTS

F.8.1 Ferrite Test in production

Where the service application exceeds 350°C, or where the weld will be subject to PWHT, ferrite control on production welds shall be performed and the measured values shall be in the ranges specified by sub-clause F1.1.

Main pressure-retaining welds shall be tested at least once in every 3 mt. (10 ft.) of linear weld.

Nozzle connection welds shall have one test per weld.

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APPENDIX G ADDITIONAL AND SPECIFIC REQUIREMENTS FOR DUPLEX STAINLESS

STEEL

G.1 PQR TESTING REQUIREMENTS

G.1.1 Impact test

Impact testing shall comply with para. 4.3 and 5.4 of ISO 17781 (type 22Cr 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 22Cr duplex) in table 2 of ISO 17781.

G.1.2 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 10X.

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:

➢ For non-sour service item(s) Vickers hardness testing method shall be according to ASTM E384, a

load of HV10 shall be used

➢ For non-sour service item(s), location and number of measurements specified in Appendix-D shall

be complied with

➢ The maximum hardness value shall be 320HV10

➢ 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 320HV10 and the average hardness shall also not exceed 310HV10

G.1.3 Microstructural examination

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

G.1.4 Ferrite test

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.

For sour service item(s), metallographic ferrite measurements shall be performed in accordance with ASTM E562. The average ferrite content in weld deposit and HAZ shall be within the range of 35% to 65%, with a relative accuracy of 10% or lower.

For non-sour service item(s), test shall be performed according to para. 4.3 and 5.3 of ISO 17781 and shall also comply with the followings:

1. 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 400-500X. The number of fields and points per sampled area shall agree with the guidance displayed in the 10% relative accuracy column

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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

2. 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)

3. 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%

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

G.1.5 Corrosion test

Corrosion test examination (type 22Cr duplex) shall comply with para. 4.3 and 5.5 of ISO 17781.

G.2 WELDING CONSUMABLES

The following filler material shall be used: SFA-5.9 ER2209 and SFA-5.4 E2209

Basicity index (BI) of SAW flux shall be greater than 1.2. Experience suggests that as much as 1.8 BI may be necessary to effectively reduce oxygen content to ensure code-required elongation.

Shielding and back purging gases shall be argon or an argon/nitrogen mixture (typically argon plus 2% nitrogen for butt-welds or argon plus 3% nitrogen for tube-to-tubesheet joints). 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.

G.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.

G.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.

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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.

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, including cladding, 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, (including cladding).

G.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.

G.6 HEAT INPUT/INTERPASS

For duplex stainless steel, interpass temperature shall comply with the following table:

Joint thickness

Duplex (alloy 2205)

<3 mm

<6 mm

<9.5 mm

9.5 mm

50°C maximum

70°C maximum

100°C maximum

150°C maximum

For duplex stainless steel, heat input shall be within the following range: 0.5 kJ/mm - 2.5 kJ/mm.

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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, for duplex material the followings shall be considered:

1. To maintain acceptable corrosion resistance in DSS (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 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.

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

excessive exposure to elevated temperature.

G.7 PWHT

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

G.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.).

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

G.9 WELD INSPECTION REQUIREMENTS

G.9.1 Ferrite Test in production

Main pressure-retaining welds shall be tested at least once in every 3 mt. (10 ft.) of linear weld. Nozzle connection welds shall have one test per weld.

Measured values shall be in the range 30% to 70%.

G.10 WELD REPAIRS

For duplex stainless steel, full penetration repairs are not allowed, and the remaining ligament for partial penetration repairs shall be minimum 3 mm for Zone A.

For duplex stainless steel, 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 H ADDITIONAL AND SPECIFIC REQUIREMENTS FOR AUSTENITIC STAINLESS STEEL (304L/308L OR 316L) OR NICKEL ALLOY TYPE 625 (UNS N06625) OR 825 (UNS N08825) CLAD/WELD OVERLAY ON CARBON STEEL

H.1

PQR TESTING REQUIREMENTS

H.1.1 Macro examination

On PQR coupon, liquid penetrant test (PT) shall be performed on both first and last passes.

Macro examination of overlay cross sections shall be carried out to verify that the overlay penetrated into the base metal with no lack of fusion present.

When ESW or SAW strip processes are allowed to be used by Contactor, the PQR metallographic examination, carried out in accordance with ASME Code section IX, QW-382.1(b), indicates that at least 5% penetration (based on the overlay thickness) has been achieved.

Commentary Note:

Even though QW-382.1(b) addresses hard facing, it is being used to evaluate corrosion resistant overlays by this specification.

When second layer (or subsequent layers), are applied after PWHT, Vendor shall demonstrate in PQR that the thickness of the first layer and the heat input of the second pass welding procedure shall be such that the base metal is not affected by the heat of welding after PWHT and in particular that it shall be demonstrated on macro-examination that no new HAZ is formed in the base metal during welding after PWHT.

Commentary Note:

It is typically achievable when overlay thickness, before applying second layer (or subsequent layers), is 4.8 mm or greater.

H.1.2 Hardness test

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- treatment condition) and it shall comply with the following:

1. The maximum hardness shall be 248 HV10

2. The hardness shall be checked in base material and HAZ on three different vertical line, distant 13 mm each other, the indentations in the HAZ shall be 0,5 mm (maximum) away from the fusion line

3. The indentations in the base material shall be 13 mm away from the fusion line

4. The hardness survey shall ensure that each layer of weld metal is included in the survey

H.1.3 Chemical analysis

The chemical analysis of weld overlay shall report all elements for which specific values are given for the applied consumable in ASME Code Section II, Part C/AWS filler metal specifications, and in particular for austenitic stainless steel types 304L and 316L clad/weld overlay, the following table (from table B.2 of API 582 Annex-B) shall be complied with.

Overlay type 308L (for clad in 304L)

316L NiCrMo-3

%Fe (max) %C (max) %Cr (min) %Ni (min)

---

---

5.0/10.0

0.04

0.04 0.10

18.0

16.0 20.0 to 23.0

8.0

10.0 balance

%Mo

%Nb (max)

2.0 to 3.0 8.0 to 10.0

---

3.15 to 4.15

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Specimens for chemical analysis shall be taken on a depth, measured from the finished deposit surface not less than thickness of undiluted weld overlay (see clause 3 for definition) required by DS or SS.

The PQR shall point-out the content (%) of each element measured and the minimum qualified overlay thickness (see clause 3 for definition).

H.1.4 Ferrite test

Ferrite test for each welding procedure qualification shall be carried out, and shall comply with the following:

1. Ferrite measurement shall be performed at the same location required for chemical analysis (i.e. at a

depth from the finished deposit surface not less than thickness of undiluted weld overlay)

2. Ferrite measurement shall be taken before PWHT

3. Maximum ferrite measurement shall not exceed 8 FN (extension to max 10 FN requests a prior

Contractor’s approval in writing)

4. Minimum ferrite measurement shall be 3 FN

Ferrite test is not required in case of weld overlay in nickel alloy type 625/825.

H.1.5 Corrosion Test

When PWHT is required for base materials with austenitic stainless steel weld overlay, corrosion testing of samples for weld procedure qualifications shall be performed per the ASTM A262 Practice E.

Test shall be carried out on coupon heat treated simulating maximum heat treatment condition foreseen on the relevant item.

H.1.5.1 UOP additional requirements

When austenitic stainless steel weld deposit overlay is used in hydrogen service at elevated operating temperature over 700ºF (370ºC), the manufacturer shall demonstrate that their procedures and materials provide immunity to lining disbonding. Testing shall be as per ASTM G146. As a minimum, the tests shall be representative of the actual operating conditions (e.g., hydrogen partial pressure, materials and material thicknesses, temperatures, and heating/cooling rates).

H.2 WELDING CONSUMABLES

The following table 1 shows the filler metal grade to be considered:

Overlay Materiala) 304L 316L

Alloy 625 (UNS N06625) Alloy 825 (UNS N08825)

Note:

Table 1:

First layer 309L 309LMo NiCrMo-3 b) c) NiCrMo-3 b) d)

Top layer(s) 308L 316L NiCrMo-3 b) c) NiCrMo-3 b) d)

a) Weld overlays shall be deposited with a minimum of two layers. Machine or automated single-layer

overlays are permitted when approved by Contactor b) Filler material shall have a maximum Fe content of 1% c) For items with alloy 625 WO/clad: undiluted chemistry measured in PQR shall have Fe<5% d) For items with alloy 825 WO/clad: undiluted chemistry measured in PQR shall have Fe<10%

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Single side welding carried out from the non-clad side shall only be done with the written approval by Contractor and CA, in compliance with the following table 2:

Overlay Material 304L 316L

Alloy 625 (UNS N06625) Alloy 825 (UNS N08825)

General note:

Table 2:

Root and hot passes 309L a) 309LMo a) NiCrMo-3

NiCrMo-3

Fill passes NiCrMo-3 b) NiCrMo-3 b) NiCrMo-3

NiCrMo-3

Thickness of root and hot passes shall be approximately the same as that of the overlay

a): subject to prior Contactor approval NiCrMo-3 may also be used b): subject to prior Contactor approval 309L/309LMo may also be used based on the carbon steel material strength

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H.3 WELD PREPARATION

Machining, plasma cutting or by 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 stainless steel (i.e. sulfur and chloride free) shall be used.

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

When integrally clad stainless plates are being joined, the following shall comply with:

1. Strip back cladding on clad plate a minimum of 10 mm from the plate edges before welding of the

backing plate

2. The edges of the groove in the cladding shall be rounded off to prevent entrapment of slag

3. The edge of the cladding shall be rounded with a minimum radius of 1.5 mm or tapered at a minimum

angle of 30°

4. When the cladding is removed, the base material thickness shall not be reduced below the design

thickness

Commentary Note:

When the clad strip back depth impinges upon the minimum backing material design thickness, the overlay shall be qualified as a composite joint in accordance with QW-217 of ASME BPVC Section IX

5. To ensure complete removal of residual cladding from previously clad surfaces, all surfaces shall be etched with an 8% nitric acid solution or copper sulfate solution or similar solution approved by Contactor. Acid etching and grinding shall be repeated as required until clad material is completely removed prior to welding or cutting

6. Flaws on the surface of the base metal that would interfere with bonding of the overlay shall be

removed by grinding

7. The stripped area shall be also examined by magnetic-particle or liquid penetrant inspection before

weld overlay of the joint

H.4

PREHEATING

For corrosion resistant weld metal overlay, preheat to a minimum temperature of 95°C shall be applied during application of the first layer when the thickness of the backing material is 32 mm or greater.

H.5 HEAT INPUT / INTERPASS

For carbon steel material with clad or weld overlay in austenitic stainless steel the interpass temperature shall not exceed 250°C (for first layer), and 175°C for the subsequent layers.

H.6

PWHT

If PWHT applies, welding directly to the base metal (base metal joint and weld overlay/clad restoring) shall be completed prior to final PWHT.

H.7 WELD CONTOUR, FINISH AND WELD OVERLAY RESTORING

The overlay surface shall be relatively smooth (waving is permissible but without notches, undercuts, etc. that would serve as stress risers). The interface between base metal and overlay shall be prepared by grinding where necessary to eliminate pockets, sharp notches and other flaws which would prevent full bonding of the overlay material. Overlay surface shall blend with the clad/overlaid surfaces.

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The surface of weld overlay shall be left in the “as deposited” condition except for gasket surfaces or other surfaces requiring machining or grinding to meet requirements stipulated in the construction drawing(s) or SS.

In lined areas, the specified inside diameter is the inside diameter of the finished lining. Connections that receive equipment shall be checked by Vendor to ensure that the inside diameter is large enough and the flanges match.

Weld overlays shall be deposited with a minimum of two layers. Machine or automated single-layer overlays using either the ESW or strip SAW process are permitted when the fabricator demonstrates successful fusion and adherence to chemical composition limits and are approved in advance by Contractor.

Unless differently indicated in applicable construction drawing(s) or SS and except for tubesheet, maximum overlay thickness shall not exceed 10 mm.

Nozzles necks installed on internal cladded vessel/components (clad-rolled or weld overlayed), shall be fabricated from clad-rolled plates, or protected with deposited weld metal of the same alloy material as the internal cladding.

Solid construction nozzles are not acceptable, if not otherwise accepted by Contractor.

Weld deposit overlay shall be applied circumferentially to the vessel and shall be smooth with no notches or undercuts that would act as stress intensifiers. If necessary, longitudinal application in nozzles up to 8” NPS is acceptable.

Single-sided welding from the non-clad side shall only be done with the written acceptance of Contractor and Owner. Vendor shall provide all detail with applicable sketches for approval.

Internals may be attached directly to the cladding/weld-overlay, when so specified by approved construction drawings. In this case attachment may be performed after PWHT and, therefore, the following two-layer overlay technique shall be used:

1. the 1st pass of multipass austenitic stainless steel weld overlays shall be applied prior to PWHT when it is required and shall be made with an electrode complying with the requirements of clause H.2

2. the second layer shall be made with an electrode of the required lining alloy, and it shall be applied after completion of the final PWHT. When the second layer is applied after PWHT, the thickness of the first layer (typically it shall be greater 4.8 mm) and the heat input of the second pass welding procedure shall be such that the base metal is not affected by the heat and then additional heat treatment of the base metal after the second layer is not required.

When internals are not attached directly to the cladding/weld overlay, welding shall be performed before PWHT, as follow:

3. the cladding shall be cut back at least 19 mm beyond the toe of the attachment weld

4. complete removal of the cladding shall be verified before proceeding with welding to the base metal

5. attachment shall be welded directly to the base metal

6. after attachment directly to the base metal, the exposed area shall be completely covered with weld

overlay as described in clause H.2

The nozzle facing shall be made with a minimum of a two-layer weld deposit. For ring joint flanges, the second pass shall be applied after completion of PWHT. In such case, the thickness of the first pass and the heat input of the second pass welding procedure shall be such that the base metal is not affected by the heat and additional PWHT of the base metal is not required after the second pass.

Plug welded, spot welded, sleeve or loose liners are not permitted.

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H.7.1 Weld overlay restoring

In case of clad restoring welds:

1. The base material shall be welded in accordance with the procedure for the base metal involved,

except that carbon arc gouging shall not be used for back gouging

2. After the cladding material shall be removed next to the weld area to ensure that no contamination can occur from the cladding material into the weld of the base material (as per clause H.3), the base material shall be welded from two sides as required for approved WPS

3. Deposited ferritic weld metal must not contact the cladding and weld pull of backing material welding shall not be closer to clad material, since cladding material inclusions in the weld of the base material may cause cracking owing to high hardness caused by martensite formation

4. After completion of the base material weld, internal protrusion of weld shall be flush with carbon steel material internal surface (to allow for the internal overlay) and inside surface of base material shall be cleaned to remove rust, mill, scale, dirt, weld spatter, etc.

5. Then the clad-restoring layer shall be welded using minimum two passes (unless otherwise accepted

by Contractor)

6. The weld deposit overlay shall be (at least) thick as the cladding, but no greater than twice its

thickness

H.8 WELD INSPECTION REQUIREMENTS

H.8.1 NDE in production

Weld overlays shall be 100% liquid penetrant examined. If the component is PWHT, this examination shall be performed after PWHT. The acceptance criteria for weld overlay PT examination shall be zero cracks or crack-like indications and zero open defects of any size.

Back clad areas shall include cladding thickness measurements; measurements shall include one measurement for the first 850 mm of weld and one at each additional 850 mm interval.

Where ESW or strip SAW processes are used, after welding and PWHT, also spot UT shall performed on least four strips, approximately 80 mm wide, along the full length of the shell and one strip approximately 80 mm wide across each head on weld overlay.

UT shall meet the requirements of ASTM A578, Level C.

H.8.1.1 UOP additional requirements

Weld deposit overlay, whether by manual or automatic procedures, shall be 100% liquid penetrant (PT) examined prior to PWHT in accordance with the methods described in ASTM E165.

In areas where attachments will be welded directly to the overlay, the overlay within 50 mm of the attachment weld shall be 100% ultrasonically examined from the inside after PWHT. All unbonded areas at attachments shall be repaired and re-examined.

The final PT at attachments shall be performed after final PWHT and pressure testing.

When the hydrogen partial pressure exceeds 50 psia 3.5 kg/cm2(a), the design temperature exceeds 600ºF (315ºC), the overlay shall be 100% ultrasonically examined for lack of bond. The examination shall occur after the final PWHT and shall be from the outside. Examination shall be in accordance with ASME Section II, Part A, SA-578. The acceptance standard shall be Level C of ASME Section II, Part A, SA- 578 meeting a bond quality level of Class 1 in accordance with Section II, Part A, SA-264. Indications of a lack of bond shall be recorded and re-examined from the inside. Indications of an unbonded area that exceed the acceptance criteria shall be repaired by weld deposit overlay and re-examined.

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H.8.2 Chemical analysis and Ferrite test in production

Both ferrite measurement and chemical analysis are required for all weld-overlay deposit and clad restoring. They shall be taken on a depth, measured from the finished deposit surface not less than thickness of undiluted weld overlay (see clause 3 for definition), as follow:

1. For equipment/components using clad plates, where weld overlay is applied to restore the clad area of weld joints between integrally clad components, at least one deposit analysis shall be taken per welding procedure for each main longitudinal or circumferential weld seam

2. For equipment which are entirely overlaid, at least test shall be made on each shell course, channel cylinder and each head (as a minimum, two deposit analyses shall be made for every 10m2 of overlay surface, or fraction thereof, for each welding procedure applied, minimum of 5 checks per vessel)

3. The analysis shall be taken from each end of the component, at locations that are diametrically

opposed

4. When weld overlay is applied to the surface of channel covers, girth and floating head flanges and tubesheets, at least one deposit analysis shall be made for each welding procedure used and for each component manufactured

5. For tubesheets that are weld overlaid on both sides, at least one deposit analysis is required on each

side of the tubesheet

6. Flanges, nozzles and pipe/fitting which have been overlaid require that the deposited overlaid material have one test taken on weldments made for each welder, each welding process, and each lot of weld wire and/or flux. Where multiple nozzle assemblies are manufactured with the same welding procedure, the deposit analysis shall be taken from the smallest diameter nozzle manufactured for each welding procedure, with a minimum of one test for every 4 components

7. When weld overlay is applied for the surface repair of clad components or for the restoration of surfaces (other than weld seams), where the cladding has been removed, at least one deposit analysis shall be taken for each welding procedure used

8. Test area shall be taken at locations designed by Contactor or Owners Inspector. The Inspector shall consider those locations containing visual weld abnormalities or where weld process, weld wire and/or welders have been changed

9. All locations, where chemical analysis and ferrite test has been performed, shall be repaired by

Vendor using already qualified WPS and qualified welder(s)

10. Requirements indicated in applicable Licensor specifications shall govern for items belonging to

process units licensed by him

Ferrite measurements shall be in the range 3-8 FN (extension to max 10 FN requests a prior Contractor’s approval in writing). Ferrite test is not required in case of weld overlay in nickel alloy type 625/825.

Chemical analysis shall comply with range specified in sub-clause H.1.3

H.9 WELD REPAIRS

When repairs are made to cladding or overlay welds on carbon steel material subjected to PWHT, a minimum remaining clad or overlay thickness of 4.8 mm is required in order to exempt PWHT.

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APPENDIX I

ADDITIONAL AND SPECIFIC REQUIREMENTS FOR LOW ALLOY STEEL GRADE 1 ¼ CR 0.5 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 on WM and HAZ for each butt weld procedure qualification shall be carried out on both two coupons, one heat treated simulating the minimum heat treatment condition and one heat treated simulating the maximum heat treatment condition of relevant item.

The minimum CVN impact values at -18°C shall be 54 Joules (average) of three specimens and 27 Joules minimum for a single specimen. In addition, if the MDMT is lower than -18°C, ASME Code requirements for impact testing must also be met. If the impact tests performed at this MDMT (lower than -18°C) meet the required Joules criteria, retesting at -18°C is not needed.

I.1.3 Hardness test

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:

1. For non-sour service item(s), method, location and number of measurements specified in Appendix-

D shall be complied with

2. For sour service item(s), method, location and number of measurements specified in NACE MR0103

Appendix-C shall be complied with

3. the maximum hardness value measured shall be 235HV10

I.2 WELDING CONSUMABLES

I.2.1 GTAW

The following requirements shall apply:

1. the following rod shall be used: AWS-5.28 ER80S-B2

2. the chemical composition shall also meet the following limits to improve resistance to embrittlement

(these limits apply to the heat analysis)

i.

X-bar = (10P+5Sb+4Sn+As) / 100≤15 ppm (where P, Sb, Sn, and As are in ppm)

ii. C is 0.15 wt% max

iii. Cu is 0.20 wt% max

iv. Ni is 0.30 wt% max

3. the tensile properties of the deposited weld metal in the maximum heat treatment condition shall

meet requirements of sub-clause I.1.1

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4. prior to the start of fabrication activities, each heat shall be impact tested and shall meet the

requirements of sub-clause I.1.2

5. 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:

1. the following low hydrogen electrode shall be used SFA-5.5 E8018-B2 or E8016-B2

2. the diffusible hydrogen limit shall be H8 minimum (as per SFA-5.5)

3. the chemical composition shall also meet the following limits to improve resistance to embrittlement

(these limits apply to the heat analysis)

i.

X-bar = (10P+5Sb+4Sn+As) / 100≤15 ppm (where P, Sb, Sn, and As are in ppm)

ii. C is 0.15 wt% max

iii. Cu is 0.20wt % max

iv. Ni is 0.30 wt% max

4. The tensile properties of the deposited weld metal in the maximum heat treatment condition shall

meet requirements of sub-clause I.1.1

5. Prior to the start of fabrication, each lot of electrodes shall be impact tested and shall meet the

requirements of sub-clause I.1.2

I.2.3 SAW

The following requirements shall apply:

1. wire classified B2 according to SFA-5.23 shall be used

2. the diffusible hydrogen limit for flux/wire combination shall be H8 minimum (as per AWS A5.23)

3. the chemical composition shall also meet the following limits to improve resistance to embrittlement

(these limits apply to the heat analysis)

i.

X-bar = (10P+5Sb+4Sn+As) / 100≤15 ppm (where P, Sb, Sn, and As are in ppm)

ii. C is 0.15 wt% max

iii. Cu is 0.20 wt% max

iv. Ni is 0.30 wt% max

4. the tensile properties of the deposited weld metal in the maximum heat treatment condition shall

meet requirements of sub-clause I.1.1

5. prior to the start of fabrication, each combination of batch of flux and heat of wire shall be impact

tested and shall meet the requirements of sub-clause I.1.2

I.2.4 Material certificates

EN 10204 type 3.1 Certified Material Test Report (CMTR) shall be delivered for each batch, lot, diameter of wire covered electrodes and wire/flux combination to be used for both chemical, mechanical and properties.

Level of testing shall be schedule 6 or K “All tests specified by the purchaser, for each lot shipped”, and the lot size shall comply with AWS 5.01, as follow: C3, S3 or F2 (whichever is applicable)

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I.3 WELD PREPARATION

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 50mm 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.

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

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).

All pressure containing components (regardless of size, thickness, or product form) and items welded to them shall be PWHT as follow:

1. stress relieving shall be performed in the temperature range 660-690°C

2. 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

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

any case 2 hours minimum shall apply

I.6.1 UOP additional requirements

For items licensed by UOP the temperature range shall be furthermore limited to 676-690°C.

I.7 WELD INSPECTION REQUIREMENTS

MT shall be performed for all welds, including pressure-retaining base metal welds, weld build-up deposits, root passes, and attachment welds.

All pressure-retaining butt welds and vessel to support skirt welds shall be fully examined by RT. Other full penetration welds, including nozzles, shall be fully examined by UT.

I.8

PRODUCTION HARDNESS TEST

The hardness for production welds is required for all items, and values shall not exceed 225 HB.

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APPENDIX J

DISSIMILAR WELDING

If welded tube to tubesheet joints are specified for dissimilar tubes and tubesheet material, weld overlay shall be provided on the tubesheet to eliminate bimetallic welds. If not otherwise specified by Contactor, the overlay shall have the same metallurgy as the tube.

J.1

DISSIMILAR WELDING BETWEEN CARBON OR ALLOY STEEL AND AUSTENITIC STAINLESS STEEL

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:

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

2. 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

3. for service conditions exceeding the limits stated in above table, filler metal selection shall be

reviewed with the Contactor

4. 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.

In addition, carbon to austenitic stainless steel welds might be susceptible to brittle fracture at service temperatures below -29°C (-20°F).

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J.2

DISSIMILAR WELDING BETWEEN CARBON STEEL OR AUSTENITIC STAINLESS STEEL AND 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

P-No. 1

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

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

S31803 S32205

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

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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ISSUE 3

APPENDIX K PRODUCTION TEST COUPON (PTC)

Production test coupons shall be performed when so required by applicable design code(s) and Licensor specifications.

Fabrication welding activities can start only after acceptance by Contactor of PTC(s) test results

K.1 ADDITIONAL PTC REQUIREMENTS FOR LOW ALLOY STEEL GRADE 1 ¼ CR 0.5 MO

PTC as per the ASME BPVC Section VIII, Division 2, para. 3.11.8 or ASME BPVC Section VIII, Division 1, para. UG-84(i) shall be subjected to the minimum and maximum heat treatment condition and test results shall meet also the requirements stated in sub-clause I.1.2.

Welding procedures and materials shall comply with the requirements of API RP 934-A, API RP 934-C, or API RP 934–E, as applicable, with the addition that weldments representing each batch of welding consumables, covered electrodes, and wire-flux combinations for each production welding process and samples from each welding procedure and qualified welding position (per ASME Section IX) is tested. Welded samples shall use production plate.

K.2 ADDITIONAL PTC REQUIREMENTS FOR DUPLEX STAINLESS STEEL

ASME BPVC Section VIII, Division 1 required production test plates for each heat of plate used to fabricate shell and head segments shall be subjected to production testing.

Test plates shall be made from the same heat as the base material and installed as run-off tabs at the end of longitudinal weld seams.

Test plates shall be of sufficient size to provide the same temperature gradient during cooling from weld temperatures as the component being welded.

Sample coupons shall be subjected to ferrite determination and CVN impact testing as required in ISO 17781.

K.3 ADDITIONAL REQUIREMENTS FOR STUD WELDING

For stud welding, a production test sample of at least five consecutively welded studs shall be tested at the beginning of each shift and after performing maintenance operations on the stud welding equipment.

Tests shall be performed by bend or hammer in accordance with ASME BPVC Section IX, QW-192.1.2.

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APPENDIX L ADDITIONAL AND SPECIFIC REQUIREMENTS FOR NICKEL ALLOY TYPE

825 (UNS N08825)

L.1

PQR TESTING REQUIREMENTS

Paragraph not used.

L.2 WELDING CONSUMABLES

The following filler material shall be used:

➢ SFA-5.14 ER-NiCrMo-3

➢ SFA-5.11 E-NiCrMo-3

Argon or helium gases shall 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.

L.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 nickel alloys (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 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.

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

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

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ISSUE 3

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

L.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.

L.6

HEAT INPUT / INTERPASS

Interpass temperature shall not exceed 175°C.

L.7

PWHT

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

L.8 WELD CONTOUR AND FINISH

Paragraph not used.

L.9 WELD INSPECTION REQUIREMENTS

Paragraph not used.

L.10 PRODUCTION HARDNESS TEST

Paragraph not used.

L.11 WELD REPAIRS

Paragraph not used

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Project: Q-32976 - Tecnmont SKIKDA Folder: Reference Documents