T-MCE-STD-001 Rev 0 - Welding and Inspection of Process and Utility Pipework Vessels and Equipment

TECHNICAL SPECIFICATION
WELDING AND INSPECTION OF PROCESS AND UTILITY PIPEWORK, VESSELS AND EQUIPMENT AT LAND AND OFFSHORE FACILITIES
Issue Date By Eng. By: UIE/P/SDD Location: UIE
I,) Cfieckea
Approved
Revised from DEP 31.38.01.31-UIE Description
I I
Sheet: 1 of 59 Doc No.: T-MCE-STD-001 Rev
Shell Upstream International Europe
TABLE OF CONTENTS 1. INTRODUCTION 1.1. SCOPE 1.2. PRECEDENCE OF DOCUMENTS 1.3. DEFINITIONS 1.4. ABBREVIATIONS/ACRONYM 1.5. REFERENCE DOCUMENTS 1.6. QUALITY CONFORMANCE 1.7. DEVIATIONS 2. GENERAL 2.1. MATERIALS 2.2. PROCESSES 2.3. WELDING CONSUMABLES 2.3.1. General 2.3.2. Consumable Certification 2.3.3. Consumable Handling/Storage 3. GENERAL REQUIREMENTS 3.1. WELDING PROCEDURES 3.1.1. Qualified Procedures 3.1.2. Procedures to be Qualified 3.1.3. Essential Variables 3.1.4. Welding Procedure Qualification Testing 3.1.5. Repair Welding Procedures 3.2. WELDER QUALIFICATION 3.2.1. General 3.2.2. Pre-Qualification 3.2.3. Documentation 3.2.4. Time Limitations 3.2.5. Tube-to-tubesheet welding 3.3. WELDING - GENERAL REQUIREMENTS 3.3.1. Shop/Site Conditions 3.3.2. Equipment 3.3.3. Preparation for Welding 3.3.4. Weld Execution 3.3.5. Preheat Temperature Requirements 3.3.6. Interruption of Welding 3.3.7. Arc Strikes 3.3.8. Weld Finish 3.3.9. Post-Weld Heat Treatment 3.4. WELD INSPECTION 3.4.1. General Requirements 3.4.2. Visual Inspection 3.4.3. Magnetic Particle Inspection 3.4.4. Liquid Penetrant Testing 3.4.5. Radiographic Examination 3.4.6. Ultrasonic Examination 3.4.7. Inspection Personnel 3.4.8. Extent of Inspection of Process Piping Production Welding 3.4.9. Acceptance Specifications 3.4.10. Reporting 3.5. REPAIRS 3.5.1. General 3.5.2. Defect Removal 3.5.3. Root Repairs 3.5.4. Re-welding 3.5.5. Non-Destructive Testing 4. MATERIAL-SPECIFIC ADDITIONAL REQUIREMENTS 4.0.1. General Requirements Eng. By: UIE/P/SDD Location: UIE Shell Upstream International Europe Sheet: 2 of 59 Doc No.: T-MCE-STD-001
4 4 4 4 5 6 8 8 9 9 9 10 10 10 10 12 12 12 12 12 13 15 16 16 16 16 17 17 17 17 18 18 20 21 22 22 22 22 25 25 25 25 26 26 26 26 27 27 27 27 27 28 28 28 28 29 29
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4.0.2. PQR Requirements 4.0.3. PQR Testing Requirements 4.0.4. Essential Variables 4.0.5. Production Controls 4.1. NON-IMPACT TESTED CMN STEELS 4.2. IMPACT TESTED CMN STEELS (LTCS) 4.3. 3.5% NICKEL STEELS 4.4. LOW ALLOY STEELS 4.5. AUSTENITIC STAINLESS STEELS 4.6. 6% MO AND OTHER SUPERAUSTENITIC STAINLESS STEELS 4.7. DUPLEX STAINLESS STEELS 4.8. NICKEL ALLOYS 4.9. COPPER ALLOYS 4.10. TITANIUM FIGURES TABLES 46 APPENDICES APPENDIX A APPENDIX B APPENDIX C
29 29 29 29 31 32 33 34 35 36 37 39 40 41 42
APPENDIX D
REPORTING REQUIREMENTS FOR WPQR 52 MINIMUM NDE REPORTING REQUIREMENTS 54 RECOMMENDED PRACTICE FOR DETERMINING VOLUME FRACTION OF FERRITE IN DUPLEX STAINLESS STEEL WELDMENTS BY SYSTEMATIC POINT COUNT S 55 WPQR/WPS COMPLIANCE WITH NORSOK M-601 59
Eng. By: UIE/P/SDD Location: UIE Shell Upstream International Europe Sheet: 3 of 59 Doc No.: T-MCE-STD-001 Rev 0
1. INTRODUCTION 1.1. SCOPE This document specifies the minimum requirements for the Welding and Weld Inspection of Process and Utility Vessels, Piping and associated Equipment for all facilities in UIE. It replaces DEP 31.38.01.31-UIE (March 2011). Existing procedures qualified to DEP 31.38.01.31-UIE, or its predecessor ES/124 Part 1 may be accepted, subject to review by the Principal. Note that, whenever reference is made to or compliance required with an international industry standard, a DEP or a technical specification, then the corresponding international industry standard, DEP and technical specification shall also apply. It is written in recognition of the latest regulations in force within the European Union including the European Pressure Equipment Directive (PED) 97/23/EC and refers to a list of harmonised Standards covering all aspects of the design and fabrication of pressure equipment. This Standard is based on these harmonised Standards, but recognises and builds on the expertise and good practice developed in previous Shell Specifications. References are also made to ASME B31.3, in conjunction with Shell DEP.30.10.02.31-Gen, with regard to PWHT requirements. For each welding procedure specification the Contractor is responsible for selection of welding consumables, welding processes, and welding operators, and obtaining approval for their use from the Principal. Responsibility for compliance with local/regional legislative requirements, e.g. NORSOK M-601 or Stoomwezen Rules for Pressure Vessels, and required approvals remain with the Contractor, though guidance on compliance with NORSOK M-601 is given in appendix D. When referenced standards are revised or superseded, then it should be assumed that the latest revision or superseding standard applies unless a specific revision is referenced. Final acceptance of fabrications is dependent upon acceptance of Contractors reporting and recording of production welding and its monitoring and welding inspection activities. The following work scopes are not included: Equipment within pipeline design scope, i.e. Risers, pipelines, and associated topsides pipe fabrication, and subsea manifold pipework and tie-ins Large bore low pressure ducting, less than 0.5 bar gauge. Domestic pipework. 1.2. PRECEDENCE OF DOCUMENTS In the case of conflict between documents the following hierarchy of documents shall apply: First level Second level Third level Fourth level Statutory laws and regulations This Technical Specification Cross-referenced documents International codes and standards
Any apparent conflict between the requirements of this Technical Specification and any other relevant document shall be notified to the Principal for clarification purposes. 1.3. DEFINITIONS Within this Standard, the following terms shall be applicable: Principal The Principal is the party that initiates the project and ultimately pays for it. The Principal may also include an agent or consultant authorised to act for, and on behalf of, the Principal.
Contractor
The Contractor is the party that carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor. A company awarded a contract by a Contractor to do part of the work awarded to the Contractor by the Principal. The work of the Sub-Contractor is carried out under the direction and control of the Contractor. Under its model contracts the Principal maintains the right to review all proposed SubContractors, and sub-contracts. The Manufacturer/Supplier is the party that manufactures or supplies equipment and services to perform the duties specified by the Contractor. The word shall indicates a requirement. The word should indicates a recommendation.
Sub-Contractor
Manufacturer / Supplier Shall Should
1.4. ABBREVIATIONS/ACRONYM The following abbreviations or acronym shall denote: WPS WPQR SMAW GTAW GMAW SAW FCAW T OD ID B HAZ PWHT C CMn CTOD ECA AWS ANSI ASME ASTM NDE MT PT RT UT VT DWDI DWSI FSH IQI SDH FBH SENT SWSI CSWIP PCN SNT Welding Procedure Specification Welding Procedure Qualification Record Shielded metal arc welding Gas Tungsten Arc Welding Gas Metal Arc Welding Submerged arc welding Flux Cored Arc welding Nominal pipe wall thickness Outside Diameter Internal Diameter Maximum nominal pipe wall thickness for As-Welded application Heat Affected Zone Post weld heat treatment The chemical element Carbon carbon manganese Crack Tip Opening Displacement Engineering Critical Assessment American Welding Society American National Specifications Institute American Society of Mechanical Engineers American Society for Testing and Materials Non-destructive examination Magnetic particle inspection Liquid Penetrant Examination Radiographic Testing Ultrasonic Testing Visual Testing Double Wall, Double Image Double Wall, Single Image Full Screen Height Image Quality Indicator Side Drilled Hole Flat Bottom Hole Single Edge Notch Test Single Wall, Single Image Certification Scheme for Weld Inspection Personnel Personnel Certification in Non-Destructive Testing Society for Non-Destructive Testing
1.5.
REFERENCE DOCUMENTS Section II - Materials Part C Specifications for Welding Rods, Electrodes and Filler Metals. Section V - Non-destructive Examination. Section VIII-Rules for Construction of Pressure Vessels Division 1. Section IX-Welding and Brazing Qualifications. Process Piping. Specification Test Methods and Definitions for Mechanical Testing of Steel Products of Steel Products. Standard Test Methods for Detecting Detrimental Intermetallic Phase in Duplex Austenitic/Ferritic Stainless Steels Standard Test Method for Determining Volume Fraction by Systematic Manual Point Count Guide on Methods for Assessing the Acceptability of Flaws in Fusion Welded Structures. Requirements for the Certification of Welding Inspectors and Senior Welding Inspectors Shell Design and Engineering Practice: Metallic Materials Prevention of Brittle Fracture Shop and Field Fabrication of Piping Selection of materials for life cycle performance (Upstream facilities) Materials selection process Metallic materials Tensile testing Part 1: Method of test at ambient temperature Metallic materials Tensile testing Part 2: Method of test at elevated temperature Metallic materials - Charpy pendulum impact test Part 1: Test method Welding. Recommendations for welding of metallic materials. General guidance for arc welding. Welding. Recommendations for welding of metallic materials. Arc welding of ferritic steels. Metallic products Types of inspection documents. Destructive tests on welds in metallic materials macroscopic and microscopic examination of welds. Welding personnel Approval testing of welding operators for fusion welding and resistance weld setters for fully mechanised and automatic welding of metallic materials Non-destructive examination of welds. Radiographic examination of welded joints Qualification test of welders Fusion welding Part 1: Steels Welding consumables shielding gases for arc welding and cutting. Non-destructive testing. Qualification and certification of NDE personnel. General principles Welding consumables fluxes for submerged arc welding. Validation of arc welding equipment Welding and allied processes. Determination of hydrogen content in ferritic steel arc weld metal. Quality requirements for fusion welding of metallic materials Part 2: Comprehensive quality requirements Gas welding equipment Blowpipes for gas welding, heating and cutting. Metallic materials. Vickers hardness test. Test method.
ASME B&PV Code ASME B&PV Code ASME B&PV Code ASME B&PV Code ASME B31.3 ASTM A370 ASTM A923 ASTM E562 BS 7910 CSWIP-WI-6-92 DEP 30.10.02.31-Gen DEP 31.38.01.31-Gen DEP 39.01.10.11-Gen EN ISO 6892-1 EN ISO 6892-2 EN ISO 148-1 EN 1011-1 EN 1011-2 EN 10204 EN 1321 EN 1418 EN 1435 EN 287-1 EN 439 EN 473 EN 760 EN 50504 ISO 3690:2001 ISO 3834-2 ISO 5172 ISO 6507-1 Eng. By: UIE/P/SDD Location: UIE
Shell Upstream International Europe
Sheet: 6 of 59 Doc No.: T-MCE-STD-001
Rev 0
ISO 6508-1 ISO 6520-1 ISO 9000 ISO 9606-1 ISO 9606-3 ISO 9606-4 ISO 9606-5 ISO 14731 ISO 15609 ISO 15614-1 ISO 15614-2 ISO 15614-3 ISO 15614-4 ISO 15614-5 ISO 15614-6 ISO 15614-7 ISO 15156 ISO 17020 ISO 17025 NORSOK M-601
Metallic materials. Rockwell hardness test. Test method (scales A, B, C, D, E, F, G, H, K, N, T) Welding and allied processes Classification of geometric imperfections in metallic materials Part 1: Fusion welding Quality management systems - Fundamentals and vocabulary. Approval testing of welders Fusion welding Part 1: Steels Approval testing of welders Fusion welding Part 3: Copper and copper alloys Approval testing of welders Fusion welding Part 4: Nickel and nickel alloys Approval testing of welders Fusion welding Part 5: Titanium and titanium alloys, zirconium and zirconium alloys Welding coordination Tasks and responsibilities Specification and qualification of welding procedures for metallic materials Specification and qualification of welding procedures for metallic materials Welding procedure test Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys Specification and qualification of welding procedures for metallic materials - Welding procedure test - Part 2 : arc welding of aluminium and its alloys Specification and qualification of welding procedures for metallic materials - Welding procedure test - Part 3 : fusion welding of nonalloyed and low alloyed cast irons Specification and qualification of welding procedures for metallic materials - Welding procedure test - Part 4 : finishing welding of aluminium castings Specification and qualification of welding procedures for metallic materials Welding procedure test Part 5: Arc welding of titanium, zirconium and their alloys Specification and qualification of welding procedures for metallic materials - Welding procedure test - Part 6 : arc and gas welding of copper and its alloys Specification and qualification of welding procedures for metallic materials - Welding procedure test - Part 7: Overlay welding Materials for Use in H2S-containing Environments in Oil and Gas Production - Parts 1, 2 and 3 General criteria for the operation of various types of bodies performing inspection General requirements for the competence of testing and calibrating laboratories Welding and inspection of piping
1.6. QUALITY CONFORMANCE The Contractor shall demonstrate to the satisfaction of the Principal that his activities within the scope of this document are in accordance with the relevant clauses from ISO 3834-2 and EN ISO 9000. The Contractor shall submit to the Principal for review and approval, a Quality Plan and procedural Specifications prior to commencement of work. Review of this documentation by the Principal shall only indicate a general acceptance and shall not relieve the Contractor of his obligations to comply with the requirements of the Contract. 1.7. DEVIATIONS There shall be no deviation from or addition to this Standard and pertaining documents without a specific written approval from the Principal. All conflicts between the requirements of this Standard and other relevant documents shall be referred to the Principal for resolution.
2. GENERAL 2.1. MATERIALS All materials used for qualification of welding procedure specification, as defined by this Standard, shall be representative of materials to be used in production. They shall be supplied to a recognised national manufacturing specification and certified in accordance with EN10204, inspection certificate 3.1. as a minimum This certification shall verify that all appropriate inspections have been carried out, materials can be traceable to specific chemical analysis/mechanical properties and that material is technically consistent with the design requirements of this Standard. Specific requirements for each material group are shown in the relevant section for material types included in this Standard. Other non-specified materials shall comply with industry standards plus any bespoke design requirements as advised by purchase order. 2.2. PROCESSES All welding shall be performed with one of the following processes within the restrictions of this Standard unless an alternative is approved by the Principal. Process Description Gas Tungsten Arc Welding
(a)
ASME GTAW SMAW

(a)
EN/ISO 141 111 136 114 121 125 15 135 138
Shielded Metal Arc Welding Gas Shielded Flux Cored Arc Welding Self-Shielded Flux Cored Arc Welding Submerged Arc Welding - Solid Wire Plasma Arc Welding
(a) (a) ,(c) (a) ,(c) (b) (b)
(GS)FCAW (SS)FCAW SAW SAW PAW GMAW MCAW
Submerged Arc Welding - Cored Wire Gas Metal Arc Welding (active gas)
Metal-Cored Arc Welding (active gas)

(a)
Gas shielded processes (GTAW, GSFCAW, GMAW, MCAW, PAW) shall only be used on site with adequate weather shielding, as approved by the Principal. (b) Only fully mechanised SAW systems are permitted. (c) GMAW or MCAW welding may be allowed if the Contractor can demonstrate to the Principals satisfaction, experience and control over the process and the continued competence of his welders.
Unless otherwise approved by the Principal, the root and second pass of all single-sided welds shall be made using GTAW (or PAW in the case of austenitic stainless steel). All GTAW machines shall be equipped with arc starting devices, e.g. high frequency starting unit, cratereliminating slope out control, etc. If local regulations or interference considerations do not permit these, alternative proposals shall be submitted to the Principal for approval. Whilst it is generally undesirable to change the type of tungsten electrode used for GTAW from that qualified, this change shall not be considered an essential variable when made for health and safety reasons (eg. a move away from thoriated tungstens) provided that there are no other significant process changes. Where thoriated tungsten electrodes continue to be used, automated sharpeners with dust removal facilities shall be used, along with an approved removal procedure. The permitted application of these processes is detailed in the relevant material section of this Standard.
2.3. WELDING CONSUMABLES 2.3.1. General Consumables shall be supplied by a manufacturer accredited to ISO 9002 or an equivalent quality Specification approved by the Principal. Additionally, welding consumables shall be approved by one of the following organisations: Controlas Lloyds Register of Shipping American Bureau of Shipping Det Norske Veritas Bureau Veritas Their selection shall be approved by the Principal prior to procedure qualification. Their use shall be supported by manufacturer recommendation and verified performance data. As a minimum all welding consumables used in fabrication shall be selected to produce welds with mechanical properties fulfilling those specified for the base metal and this Standard. When alternative consumables are required, e.g. when improved corrosion resistance is necessary, then these will be specified by the Principal prior to procedure qualification. Filler metals proposed for use in dissimilar base metal combinations shall be agreed upon with the Principal for each specific design case. All consumables shall be identified on the WPS by their AWS or ISO classification along with the manufacturers name and designation. Reference by AWS or ISO classification alone may be acceptable to the Principal for certain types of solid wire consumables (eg. GTAW 316L wire). 2.3.2. Consumable Certification Welding consumables shall be delivered in accordance with their product data sheet and shall have certification (including chemical analysis) according to EN 10204, Type 3.1, as a minimum. Each consumable, or consumable batch, shall have individual marking relative to its certification. Batch testing of the welding consumables is also acceptable. In such case welding and testing shall be carried out in accordance with a typical welding procedure specification and certification presented in the format of a WPQR. Production material or an equivalent parent metal specification shall be used for such product certification. Fluxes for submerged arc welding processes shall be delivered with certification according to EN 10204, Type 2.2 as a minimum. 2.3.3. Consumable Handling/Storage Stored items shall be clearly identified with brand name, classification and batch number. Each batch of flux and wire shall be labelled with the information from the supply container. All bottles containing shielding gases shall have clear identification labels. Consumable handling shall be controlled by a procedure approved by the Principal. Storage shall be in accordance with the manufacturers recommendations for the consumable type. Electrodes and fluxes shall be supplied in moisture resistant sealed containers and stored in controlled environment as recommended by the supplier. Wire spools for automatic and semi-automatic processes shall be stored in original packaging preferably in cabinets. Flux shall be supplied and stored in accordance with manufacturers instructions. Eng. By: UIE/P/SDD Location: UIE Shell Upstream International Europe Sheet: 10 of 59 Doc No.: T-MCE-STD-001 Rev 0
All non-identified, damaged, wet, partially used, rusty or otherwise contaminated consumables shall be discarded. Low hydrogen electrodes shall not be stored in heated cabinets containing electrodes of other types, such as rutile or organic type electrodes. Records of consumables shall be maintained to ensure an auditable trail from receipt, through pretreatment, their issue to operators and return to stores so that their identity can be verified at any stage. SAW fluxes shall not be left in machine hoppers for extended periods, when welding is not being carried out, e.g. overnight or during non-productive shifts. Recycling of flux shall only be allowed if the procedure is endorsed by the consumable manufacturer and by the Principal. GTAW wires shall be cleaned with a solvent immediately prior to their use. 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. GSFCAW wires shall be returned to a controlled storage area at the end of each shift. This requirement may be waived for seamless copper-coated wires that are fully enclosed in the wire feeder. Bare filler wire in coils or spools that has not been kept in sealed containers after use or has been contaminated with rust, grease or other debris, shall not be re-used without cleaning in accordance with the wire manufacturers advice. All wire that cannot be cleaned without damage to the surface, change in size or other damage that would adversely affect its use shall be discarded. Consumables that cannot be identified to the satisfaction of the Principal shall be removed from the work site and any welds made with such consumables shall be cut out and re-welded.
3. GENERAL REQUIREMENTS 3.1. WELDING PROCEDURES Welding Procedure Specifications (WPS) shall be qualified for all welded joints in accordance with the relevant part of ISO 15614, and as amended by this Standard. Each individual Contractor shall prepare and qualify their own WPSs. These shall contain information as listed in either ISO 15609 or ASME IX, and this Standard. Production welding shall not proceed until WPSs have been approved by the Principal. Combination of WPQRs with other companys procedures, even if a combined operational control exists, is not permitted unless specific approval is given by the Principal. Prior to submittal to the Principal the Contractor shall ensure that all WPS and WPQR documentation is accurate and fully in compliance with contract design requirements. The testing results for WPQR shall be laid down in a precise and detailed format. Unless otherwise identified, multi-pass fillet welds may be qualified by groove welds in accordance with ISO 15614, although separate WPS's shall be submitted. Single pass fillet welds shall be separately qualified in accordance with ISO 15614. The approval of WPS by the Principal is subject to acceptable performance in subsequent production. Approval may be withdrawn where excessive repair rates are encountered that cannot be attributed to bad workmanship. 3.1.1. Qualified Procedures WPSs previously qualified by the Contractor may be submitted for approval provided they meet the requirements of this Standard and they are supported by WPQR witnessed by an acceptable Independent Third Party. The Contractor shall be able to furnish evidence of the successful application of the proposed procedures from previous work. 3.1.2. Procedures to be Qualified The Contractor shall prepare, for Principal approval, a preliminary WPS for each welding procedure proposed, or a welder instruction card containing Specification parameters for the nominated process and consumable combination. If acceptable it shall be approved for qualification only. Procedure qualification shall then be performed according to these instructions. Procedure documentation, including the final WPS, (which may be modified from the original submission according to the parameters actually used during qualification), and welder instruction card (if adopted), shall be submitted to the Principal or his designated representative for final approval. As a minimum the WPQR documentation shall include the information specified in Appendix A of this Standard. 3.1.3. Essential Variables Any change to the welding procedure outside the allowances of the essential variables in ISO 15614, or the variables shown in this Standard shall require re-qualification. Where the thickness range of a weld procedure extends past a threshold where additional or more severe testing would be required, the qualification range shall be limited to that threshold unless the additional testing is performed. Unless otherwise specified the qualified diameter range for process piping shall be 0.5xOD to 2xOD.
In preparing qualification records and weld procedure specifications, care should be taken to distinguish between factored heat inputs and unfactored arc energy. Arc energy is the preferred method for welding documentation, but heat input can be used if this is the normal methodology applied on site. Factored arc energy, i.e. heat input, should be used when applying process limits and calculating preheat levels. 3.1.4. Welding Procedure Qualification Testing WPQR testing shall not commence without the presence of a representative of the Principal unless permission has been given to the contrary. The Contractor shall record all the information required for WPQR as defined in Appendix A of this Standard. The Contractor should supply all instrumentation necessary to record the applicable welding essential variables as required by this Standard, Appendix A, i.e. portable arc monitoring systems, current meters, temperature measurement devices, etc. All such equipment shall have a current and valid certificate of calibration. The WPQR, inclusive of all recorded data, shall be signed as witnessed by the Contractor and submitted to the Principal. Mechanical testing shall be performed as per ISO 15614 and the additional requirements in this Standard. Designated testing laboratories shall have a quality system in compliance with ISO 17025 or equivalent. When specified PWHT shall be carried out in accordance with section 3.3.9. of this Standard. 3.1.4.1. WPQR Non-Destructive Testing The following NDE shall be performed. Butt Welds Visual (section 3.4.2.) MT ferrous materials or PT for non-ferrous materials (sections 3.4.3. or 3.4.4.) Radiography (section 3.4.5.) Ultrasonic (3.4.6.), if specified for the material. Fillet Welds Visual (section 3.4.2.) MT ferrous materials or PT for non-ferrous materials (sections 3.4.3.or 3.4.4.) Visual examination of the completed weld shall be conducted by both the Contractor and the Principal. Cutting of the test piece for mechanical testing should not take place until it has been visually examined and accepted by a representative of the Principal. Should the completed test piece diameter be too small to allow proper examination of the weld root, the test piece shall be cut longitudinally to facilitate examination. Radiographic examination for WPQR shall be by X-radiography. If alternative or additional NDE methods are proposed for production welding, the test weld shall also be subjected to these methods.
3.1.4.2. Macro Examination Macro sections shall be prepared so that the whole cross section of the weld, inclusive of HAZ, and adjacent parent material may be examined. These should be etched to reveal individual passes and the full extent of the HAZ. Macro sections shall be examined at a magnification of x5. WPQR documentation shall include macro-photograph(s) of the sections. Any hardness survey indentations shall remain visible on these macro-photographs. Macro-photographs shall be marked to indicate the magnification. Only original photographs or good-quality digital images shall be accepted as part of the welding procedure qualification documentation. For acceptance the macro examination shall be free from cracks, lack of fusion (root, sidewall or interrun) or volumetric defects (slag, porosity, etc) outside the limits set by Tables 6 & 7 of this Standard. At the request of the Principal volumetric defects may be further investigated by grinding and/or resectioning to define their extent. Fillet welds shall meet the following, additional requirements: Fillet welds shall show full fusion to the root of the fillet. The length of each leg shall be equal to or greater than the specified weld size and there shall be no more than 3mm difference between the two. The throat thickness shall be at least 0.7 x the specified leg length. Convexity or concavity shall be no greater than 1.5mm. 3.1.4.3. Hardness Testing Hardness surveys, as described in ISO 15614, shall be carried out using Vickers hardness at 10Kg load on a macro section prepared as above. Testing shall be in accordance with ISO 6507-1. 3.1.4.4. Charpy Impact Testing As a minimum Charpy impact testing is required to demonstrate compliance with the European Pressure Equipment Directive (97/23/EC). Therefore for WPQRs to support fabrication of usually non-Charpy tested materials, i.e. ASTM A105 or A106 grade B, these shall be subject to Charpy testing at a minimum temperature of 0C, or the minimum design temperature, whichever is lower, and display a minimum average Charpy impact resistance of 27J. For all other materials Charpy Impact testing shall fully comply with the testing requirements of this Standard. Testing temperature and acceptance criteria shall be in accordance with Table 3 of this Standard. Charpy V-notch specimens shall be prepared and tested in accordance with EN ISO 148-1 (2mm radius striker - KV2). For welds made with a maximum heat input of 2kJ/mm, a set of three Charpy impact specimens shall be taken with notches at the weld centre line, fusion line and fusion line + 2mm as shown in Figure 2. Where heat inputs greater than 2kJ/mm have been used during WPQR an additional set of three specimens is to be taken at fusion line + 5mm. For single sided welds, the specimens shall be taken with the lower surface no more than 2mm above the inner surface. Additionally, for material thicknesses of greater than 20mm, a set of three specimens shall be taken with their notches at the weld centre line and with their upper surfaces within 2mm of the outer surface. Each specimen shall be etched prior to notching and the location of the notch relative to the fusion or weld centre line individually marked. The notch shall be placed in the square face of single bevel welds. If the WPQR uses two different materials, fusion line and HAZ specimens shall be taken from both sides. The notch positions for 2-sided welds shall be agreed with the Principal.
Full size (10mm x 10mm) impact test specimens shall be used wherever possible. Where this is not possible, the larger of three quarter size (7.5mm x 10mm), half size (5mm x 10mm), or quarter size (2.5mm x 10mm) specimens shall be used. Reduced acceptance values for reduced size samples are given in Table 3, note 1. No result shall be less than the specified minimum individual value and not more than one result shall be less than the minimum average value specified. If the above requirements are not met, three further specimens shall be tested. The average of the six specimens shall be not less than the minimum specified average. Only 2 values may be below the specified minimum average value and only one of those may be below the specified minimum individual value. 3.1.4.5. Corrosion Testing Welds in superaustenitic and duplex stainless steels shall be corrosion tested according to ASTM G 48, Method A. Two test specimens are required for 5G or 6G positions. One specimen is sufficient for other welding positions. The test temperature shall be as shown below, and the exposure time shall be 24 hour minimum. The test specimens shall have a dimension of full wall thickness by 25 mm along the weld and 50 mm across the weld. The test shall expose the external and internal surface and a cross section surface including the weld zone in full wall thickness. Cut edges shall be prepared according to ASTM G48 but the internal and outside surfaces shall be left in the as-welded condition. Pickling prior to the test is not permitted unless the test is conducted in accordance with NORSOK M-601 at its higher temperatures (or 25C in the case of 22% duplex). Material 22% Duplex 25% Duplex 6%Mo This Specification Test Temperatures (no pickling permitted) 22C 35C 35C NORSOK M-601 Test Temperatures 25C 40C 40C
Note: Previously accepted PQRs on 6%Mo with corrosion testing at 30C do not require retesting at 35C.
The weight loss shall not exceed 4.0 g/m2 and there shall be no pitting visible on the internal or external surfaces at 20X magnification. 3.1.4.6. Metallography / Ferrite Determination
Where micro-examination and/or ferrite testing are required, these shall normally be carried out on macro specimens after hardness surveys and photomacrographs have been completed. Ferrite determination of duplex stainless steels shall be in accordance with Appendix C. If the WPQR uses two different components, both HAZs shall be tested. Ferrite check on the weld of 300-series austenitic steels may be carried out using a magnetic ferrite meter, or by point counting in accordance with ASTM E562 using a 100 point grid minimum. 3.1.5. Repair Welding Procedures Separate WPSs shall be prepared for repair welding. Repair welding shall normally be carried out to the same procedure as the original welding. Therefore unless otherwise noted in this Standard (see section 3.5. and section 4.) for non-sour service, repair WPQR shall not be required. The Contractor shall submit to the Principal for approval a general repair procedure detailing: The method of defect excavation; The shape and size of excavation prior to re-welding; All inspections prior to re-welding; Eng. By: UIE/P/SDD Location: UIE Shell Upstream International Europe Sheet: 15 of 59 Doc No.: T-MCE-STD-001 Rev 0
The WPS and WPQR, if different from original weld. Where a different welding procedure (ie. a change of process or other essential variable) is to be used for repair welding, or sour-service hardness criteria apply to the material, the repair WPS shall be qualified in accordance with this Standard. Qualification shall require the reproduction of a typical production repair. Full penetration and partial penetration excavations shall be qualified separately. For part wall excavations the remaining ligament adopted for the test weld shall be the smallest allowed in production. Repair welds shall generally be tested in accordance with the requirement for the original weld. Where impact testing had been specified for the original weld, impact testing of the repair weld metal and the adjacent HAZs, both in the parent material and the original weld metal, shall be carried out at the test temperature of the original weld. Where repair welding is performed using the same procedure as the original weld, tensile and bend tests are not required for the repair WPQR. 3.2. WELDER QUALIFICATION 3.2.1. General All welders and welding operators shall be qualified in accordance with this Standard and ASME Section IX, EN 287-1, ISO 9606 or EN 1418 as applicable or equivalent codes. Fillet welds may be qualified by groove weld performance tests, where the national codes permit this.
(NB. The 2012 draft of ISO 9606-1 does not permit fillet welds to be qualified by butt welds.)
For site erection and offshore hook-up qualification testing shall be in the 6G position. Whilst on site the welders and welding operators shall be easily identifiable. This may be by: A badge bearing name, photograph and identification number, The welder carrying a works ID pass including a photograph By the Contractor maintaining a report of welder IDs including name, photograph, and welder ID number. In the event that a welder leaves the work his welder number shall not be assigned to another welder employed on the work. 3.2.2. Pre-Qualification Welders qualified on work other than for the Principal shall be accepted provided: Their qualification has been carried out in accordance with ASME Section IX, EN 287-1, ISO 9606 or EN 1418 as applicable, and the requirements of this Standard. Their qualification testing has been witnessed by a Certifying Authority or independent third party acceptable to the Principal, and the certificate of qualification is endorsed as acceptable by the Authority; The Contractor can give proof that the welder has been continuously employed by him for the previous six months and has been welding with reasonable continuity during that time, to the same, or similar, procedures with satisfactory results. 3.2.3. Documentation Prior to commencement of work, the Contractor shall submit: A register of the welders to be used on the work, giving the procedures, positions and thickness ranges in which they are qualified, together with the identity number for each welder; All welding performance qualification certificates, including relevant back-up documentation, such as NDE and mechanical test certificates.
3.2.4. Time Limitations Welder and Operator performance qualification is valid for a six-month period from the date of approval. Qualification certificates may be re-approved for further periods of six months provided the welder has been employed with reasonable continuity on welding covered by the performance certificate. The essential variables in EN 287 applicable to performance qualification apply to the time limitation and continuity criteria. If there are reasonable grounds to question that welders ability to weld to the specified procedure the Principal may demand the re-qualification of any welder, at any time. 3.2.5. Tube-to-tubesheet welding When a welded tube-to-tubesheet joint is specified on the equipment data sheet, it shall be a full strength-welded joint. Autogeneous seal welds are not permitted. Unless otherwise stated the qualification of the strength-welded tube-to-tubesheet joints shall be in accordance with the requirements of ASME Section IX, paragraph QW-193 or the applicable pressure design code. The following additional requirements shall apply if a strength-welded tube-to-tubesheet joint is specified: The degree of expansion shall be agreed between the Supplier and the Contractor, with consideration of the tube and tubesheet materials, hardness, and potential for work hardening during the expansion process. All mechanical testing shall take place after expansion. A minimum of two (2) weld passes shall be applied using the GTAW technique. The length of the combined weld legs measured parallel to the longitudinal axis of the tube at its outside diameter shall be at least 1.4 times the nominal thickness of the tube. A tensile pull-test shall be performed on the qualification test coupon. A minimum of three tests shall be performed. Where the material is too thin to allow HV5 hardness surveys to be performed, Contractor shall propose an alternative (eg. low load Vickers or Micro-Hardness survey) for approval by the Principal. Results shall satisfy the HV5 acceptance criteria. 3.3. WELDING - GENERAL REQUIREMENTS 3.3.1. Shop/Site Conditions The Contractor shall submit to the Principal a list of all welded joint types to be encountered in terms of size, material and position, and the welding procedures by which they shall be made. The welding environment should be such that all welding is adequately screened from draughts and inclement weather. Particular care shall be taken where gas shielded methods are employed. If in the opinion of the Principal adequate protection is not provided, work shall be halted until the situation has been rectified to the satisfaction of the Principal. When fabrication is to be carried out in the vicinity of plant or equipment which may be damaged or otherwise compromised by such planned construction work, i.e. weld spatter, cutting droplets, fumes, grinding dust, etc., then adequate protection shall be provided for this ancillary plant and equipment. Prior to welding the Contractor shall submit, for approval by the Principal, a procedure for the segregation of all materials in the work scope and control of the tools to be used with them.
The shop fabrication of stainless steel and other non-ferrous process piping and equipment work shall be carried out in a separate area from that of Carbon-Manganese and low alloy steels. Titanium welding shall be carried out in a fully enclosed quarantined area dedicated to Titanium fabrication. Care shall be taken to avoid overstressing or other mechanical damage to any process equipment or piping fabrication at all stages of the work. 3.3.2. Equipment All equipment shall be in good condition and properly maintained with records to support its ongoing safe operation. 3.3.2.1. Gas Cutting Equipment All gas cutting equipment shall comply with ISO 5172. 3.3.2.2. Welding Equipment All welding equipment shall be in accordance with the relevant sections of EN60974-1. Ammeters and voltmeters shall be fitted to welding equipment for the GMAW, FCAW and SAW welding processes. Separate voltmeters and ammeters (tong tester or Hall effect type) shall be provided for all other welding processes. All welding equipment and associated meters shall be verified as calibrated immediately prior to the commencement of production welding and thereafter at regular intervals according to the Contractors calibration procedure. This procedure shall be agreed with the Principal before the start of production. 3.3.2.3. Grinding and Cleaning Equipment Wire brushes and grinding discs shall be dedicated to one material type. Only stainless steel wire brushes shall be used for non-ferrous materials. Precautions shall be established to ensure that grinding wheels, files, wire brushes and similar tools that have been used on Carbon-Manganese and low alloy steels are not used for fabrication of any other material. 3.3.3. Preparation for Welding 3.3.3.1. Permitted Weld Detail All vessel, process piping and other equipment main pressure retaining joint welds shall be fabricated with full penetration butt welds unless otherwise specified. Permanent backing strips shall not be used. Fusible inserts or removable backing strips may only be used with the approval of the Principal. Where fillet welds are used in piping design, the requirements of ASME B31.3 shall be applied. Socket welded fittings shall not be permitted unless approved by the Principal. 3.3.3.2. Weld Preparation All material shall be visually inspected prior to welding to confirm freedom from mechanical damage/ corrosion and confirm correct marking. Any anomalies shall be reported in writing to the Principal Deep gouges and dents on the preparation surface shall be cause for rejection. Weld repair of such defects shall only be permitted by approval of the Principal. Laminations identified on the bevel surface by visual examination shall be investigated by MT or PT) prior to removal. Weld preparations shall be in general accordance with ASME B16.25. Square butt ends are permissible below 2mm wall thickness. Weld preparations and a distance 50mm either side shall be free from rust, scale and other contaminants. Prior to preparation/fabrication/cutting of vessel wall or process piping for branch connection i.e. flange or weldolet attachment, UT examination shall be performed to confirm freedom from injurious defects. Eng. By: UIE/P/SDD Location: UIE Shell Upstream International Europe Sheet: 18 of 59 Doc No.: T-MCE-STD-001 Rev 0
Where applicable, wooden or plastic covers shall be provided to protect weld bevels from mechanical damage and prevent ingress of foreign material into the vessel, piping or other process equipment. 3.3.3.3. Cutting and Bevelling Ferritic steel items may be cut mechanically or by oxy-fuel gas cutting. Weld bevels shall be prepared by machining or by mechanically guided flame cutting. Bevelling with hand-held cutting torches is not permitted except when specifically approved by the Principal. Flame cut bevel surfaces shall be ground to bright metal unless the welding procedure was qualified with surfaces in the same condition. 3.3.3.4. Alignment Equipment used to hold and support process equipment, vessels, piping, etc., shall be capable of bearing the load in a safe manner whilst maintaining the stability required for working in both the vertical and horizontal planes. The permitted maximum misalignment for piping butt welds shall be: Internal Pipe Diameter <= 100mm > 100mm External Pipe Diameter 12mm > 12mm Misalignment Pipe thickness/4 3.0mm Misalignment 1.0mm 1.6mm (3.0mm when welding is carried out from both sides)
For vessels and other equipment misalignment shall be in accordance with the design standards. Misalignments greater than these limits may be corrected by grinding or machining to a taper of 1:4 provided the wall thickness is not reduced below the minimum tolerance. Reforming of process piping vessel walls or other equipment, either hot or cold shall not be attempted without the approval of the Principal. For general tolerances, refer to DEP 31.38.01.31-Gen 3.3.3.5. Spacing Pipe or vessel longitudinal seams shall be separated by at least 45 degrees of rotation or 150mm, whichever is the less. Circumferential welds shall be separated (toe to toe) by at least 4 times the nominal wall thickness or 50mm, whichever is greater. Attachments shall be separated by at least 2 times the nominal thickness or 50mm (toe to toe) from any weld, whichever is the smaller. 3.3.3.6. Tack Welding and Clamping Tack welding shall be carried out following the root parameters of the qualified WPS and shall be performed by qualified welders. Tack welds shall be at least 25mm in length and shall be equally spaced around the circumference in sufficient number to support the process piping, equipment or fitting. The preferred method of tack welding for single sided welds shall be by the temporary welding of a short length of round bar along the bevel faces of the preparation. The bar material shall be specified by the Contractor and approved by the Principal. Tack welds intended to be an integral part of the root weld shall be ground to a taper edge to facilitate weld pick-up. Eng. By: UIE/P/SDD Location: UIE Shell Upstream International Europe Sheet: 19 of 59 Doc No.: T-MCE-STD-001 Rev 0
Cracked or badly profiled tack welds shall be completely removed prior to welding. If line-up clamps are used without tack welding they shall not be removed until after the root and hot pass have been fully completed.
3.3.4. Weld Execution 3.3.4.1. Identification Welds shall be uniquely identified. The Contractor shall demonstrate to the satisfaction of the Principal that individual welds can be positively identified at all stages of construction.
Particular attention shall be given to maintaining identification during grit-blasting and painting. Weld identification numbers shall be marked adjacent to the weld by crayon, paint stick or similar marker prior to welding. Similarly, welders shall mark their numbers adjacent to each weld they make. 3.3.4.2. Cleaning Weld preparations and a distance 50mm either side shall be cleaned to remove rust, scale, oil, grease and other contaminants. Filler wires shall be cleaned with stainless steel wool and solvent. Cleaned filler wires shall only be handled by welders using clean gloves that have been used for handling only one material type. On completion of fabrication the Contractor shall clean the inside and outside of all fabricated assemblies of all loose material, scale, slag and weld spatter. 3.3.4.3. Back purging Back purging is required to maintain internal weld surfaces, and parent metal adjacent to weldments, clean and free from scale and excessive oxidation (slight bluing is permitted for nickel alloys and stainless steels ). The method of application for back purging welds shall be detailed either in the relevant WPS or in a separate document referred to by the WPS. This shall be approved as part of welding procedure qualification documentation endorsement. The use of soluble dams for minimising back purge requirement during piping fabrication should be approved by the Principal. Their application shall be in accordance with the Manufacturers recommendations. When dams are to be used on site, working procedures shall ensure their removal after welding. For fabrication of carbon and low alloy steels, when using solely gas shielded welding processes, unless demonstrated to the contrary during welding procedure qualification trials, back purging with high purity Argon is required. This back purge shall be maintained for a minimum of the root pass. The use of another gas or gas mixture may be proposed for consideration by the Principal. For GTAW of 3% Nickel steels, back purging is mandatory. Welds made in austenitic, Nickel alloys and Copper-Nickel shall have a back purge which shall be maintained for a minimum of the root and second pass. Welding 6 Mo stainless steel requires that the purge be maintained for the first three layers. 22% Duplex stainless steel welds shall use a back purge of high purity Argon containing 2-3% Nitrogen. However, if the root is carried out with a 25% duplex consumable then high purity Argon may be used. The purge shall be maintained for a minimum of the first three layers. Eng. By: UIE/P/SDD Location: UIE Shell Upstream International Europe Sheet: 20 of 59 Doc No.: T-MCE-STD-001 Rev 0
25% Duplex stainless steel welds shall use a back-purge of high purity Argon with, or without nitrogen addition. The purge shall be maintained for a minimum of the first three layers. Titanium welds shall use a back purge of high purity Argon, Helium or Argon/Helium mix, as qualified during welding procedure qualification trials. The purge shall be maintained continuously until the metal temperature drops below 500C after the completion of welding. For all corrosion-resistant materials requiring back-purging, the purge shall be applied for a period long enough for the oxygen content of the exit gas to fall at least below 0.5% and preferably 0.1%. This shall be demonstrated during weld procedure qualification and production by means of a suitable oxygen meter. The acceptance criteria for oxidation of stainless steel weldments shall be in accordance with NORSOK M-601 Annex B or DEP 30.10.60.31-Gen. As-deposited weld beads and HAZs of titanium welds should be inspected after each pass for the degree of oxidation. Light and dark straw coloured oxides are permissible, but dark blue, light blue, grey, and white deposits indicate progressively unacceptable contamination that leads to embrittlement. Removing these oxide deposits will not improve the underlying damage to the material properties, so welds exhibiting these undesirable oxide colours shall be rejected. The cause of the contamination shall be rectified before production continues. 3.3.5. Preheat Temperature Requirements For Carbon-Manganese and low alloy steels, the minimum preheat shall be as calculated in accordance with EN 1011-2 using the maximum Carbon equivalent allowed for the material to be welded and the weld metal hydrogen level guaranteed by an approved consumable control procedure. For WPS preheat determination the heat input used in the calculation should be the lowest single pass value recorded during WPQR. If higher preheats are found to be necessary to meet the hardness values required by this Standard, particularly for sour service conditions, the temperature margin above the minimum required by EN 10112 shall be preserved for all thicknesses to be welded. For 3% Nickel steels, a minimum preheat of 100C shall be used for welding all thicknesses. Where reinforced branch fittings such as olets that are to be welded, the minimum preheat shall be 50C above that indicated by EN 1011-2. When preheat is not explicitly required by this Standard and ambient temperature is below zero, or condensation/moisture is apparent on work surfaces, then sufficient preheat should be applied to ensure work surfaces are dry and remain warm to touch. 3.3.5.1. Preheat Application For up to and including 19 mm wall thickness, preheating shall be by gas torch or electrical resistance heaters. Above 19 mm, electric resistance heating mats should be used unless it is agreed with Principal that access or location makes it impractical. Electric resistance elements shall be controlled by thermocouples attached on or adjacent to the weld preparation. Thermocouple devices shall be regularly calibrated according to a procedure agreed with the Principal. Preheating with oxy/fuel gas should only be by soft flame burners designed for the purpose. Hand held oxy/fuel gas burners may only be used for welds less than 150mm OD or attachment welds less than 300mm long. Non-electrical preheat temperature should be measured using contact pyrometers, temperature indicating crayons or thermocouples. Where access permits measurement shall be from the opposite Eng. By: UIE/P/SDD Location: UIE Shell Upstream International Europe Sheet: 21 of 59 Doc No.: T-MCE-STD-001 Rev 0
surface of the work being heated and shall be at a location displaced from the source of heat by a minimum of 25mm in a direction parallel to the vessel, process piping or other equipment axis. Measurement shall be after removal of the heat source. If access is not possible to the opposite surface temperature measurement shall be taken 75mm from both weld toes / edges and delayed for a period not less than 2 seconds per mm of thickness after removal of the heat source. Temperature indicating crayons shall be certified free of lead and sulphur. Residue from crayons shall be removed from the weld surface before proceeding with the weld. 3.3.5.2. Interpass Temperature In general the maximum interpass temperature shall not exceed that measured during PQR by more than 50C, though there may be additional limitations in the relevant material-specific section. 3.3.6. Interruption of Welding For CMn, LTCS, low-alloy, and 3.5% nickel steels, the root and second pass shall be completed as a minimum before it is permissible to interrupt welding progress and allow the joint to cool below the minimum preheat temperature. If cooling has occurred and the completed weld ligament depth is less than 25% of the total joint thickness then surface inspection (MPI or DPI) shall be performed to ensure freedom from deleterious defects. When interruption of welding ferritic steels is unavoidable then slow cooling is mandatory and shall be achieved by wrapping the joint in a suitable insulation material. 3.3.7. Arc Strikes The welding arc shall only be struck on the prepared welding surface or previously deposited weld metal. Any erroneous arc strikes shall be removed by grinding or other suitable method and the area shall be subject to surface inspection (MT or PT) to ensure continued freedom from defects. The thickness of material remaining after the removal of such defects shall be measured. If this measurement reveals loss of wall thickness below the minimum required thickness then the item shall be replaced. Weld repair of such areas shall not be permitted. 3.3.8. Weld Finish All welds shall be finished with a smooth profile, without overlap, abrupt ridges or valleys, and shall blend smoothly with the base material. Toe profile grinding or cosmetic grinding shall only to be carried out when directed by the design drawings or with the approved of the Principal. If fillet welds are concave, or not equal, the minimum throat size shall not be less than 0.7 x the specified leg length. For olet branch fittings the root profile shall be as specified for full penetration butt welds. The contour of completed welds shall be as shown in Figure 3 of this Standard, unless the Principal advises that the design requirement can be met with a smaller weld. 3.3.9. Post-Weld Heat Treatment For Vessels, pumps, instruments and any other ancillary process or utility equipment PWHT shall be in accordance with the ruling design codes and as detailed in the relevant standards included in the purchase order. 3.3.9.1. Piping PWHT requirements Fabrication of NON IMPACT tested CMn steel piping and fittings (i.e. ASTM A105, A106 grade B, etc.), shall be subject PWHT if the wall thickness exceeds 19mm unless advised otherwise on the design drawings or by the Principal. Eng. By: UIE/P/SDD Location: UIE Shell Upstream International Europe Sheet: 22 of 59 Doc No.: T-MCE-STD-001 Rev 0
For branch connections in NON IMPACT tested steels the wall thickness, t, shall be taken as the governing thickness as defined in ASME B31.3 Section 331.1.3. Fabrication of IMPACT tested CMn piping and fittings, for process piping service (i.e. ASTM A333 gr6, A350 LF2, etc.), shall be subject to PWHT if the wall thickness exceeds the thickness B as defined in Table 1. NB. For branch connections in impact tested steel, PWHT is required where the wall thickness of the fitting exceeds thickness B, as defined in Table 1, or where, for olet branch fittings, the maximum thickness of the fitting exceeds 4B, or the weld thickness exceeds 38 mm (refer to Figure 3). All welds in AISI 4130 material shall be subject to PWHT. If there is no subsequent machining operation all threads and gasket surfaces shall be protected from oxidation whilst equipment is subject to heat treatment. Non-ferrous materials do not normally require PWHT. However, if approval is granted or if directed by the Principal, e.g. where austenitic steel shall be welded to CMn steel, PWHT shall be carried out generally in accordance with this section. Additional restrictions as deemed necessary for the materials involved will be advised by the Principal. 3.3.9.2. Procedures All PWHT shall be carried out in accordance with a procedure approved by the Principal prior to commencement of heat treatment. As a minimum the procedure shall include the following information: name of (sub) Contractor; ruling Specification; material and item type; method of heating; fuel gas and method of atmosphere control (if gas-fired furnace); size and type of electrical element (if electrical resistance); type, location and number of thermocouples; method of thermocouple attachment; details of loading and supporting arrangements to avoid distortion; provisions to avoid flame impingement (if flame heated) holding time and temperature; heating and cooling rates; type of recording equipment including number of channels; chart speed. 3.3.9.3. Conditions Holding temperature CMn steels 3% Nickel steel CrMo steel (AISI 4130) 580C - 620C 590C - 630C 660C - 700C
Alternative holding temperature may be submitted for Principal consideration providing this application is supported by appropriate data. In the case of quench and tempered steels the actual holding temperature shall be at least 25C below the finishing temperature recorded on the material certificate. Holding time Maximum heating rate above 300C t <= 25 t > 25mm t <= 25mm t > 25mm Eng. By: UIE/P/SDD Location: UIE Shell Upstream International Europe Sheet: 23 of 59 Doc No.: T-MCE-STD-001 Rev 0 1 hour t/25 hours 220C/hour 220 x 25/t C/hour
Maximum cooling rate above 300C
t <= 25mm t > 25mm
275C/hour 275 x 25/t C/hour
(Cooling in still air is permitted below 300C.) 3.3.9.4. Furnace PWHT Wherever possible PWHT shall be performed in a fully enclosed furnace. Fuel powered furnaces shall have adequate flame controls to avoid an oxidising furnace atmosphere. Flame impingement onto PWHT items is not permitted. During heating and cooling the temperature shall not vary by more than 150C in any 4500mm length. The number of thermocouples shall be sufficient to ensure that the temperature and thermal gradients of the whole of the work are within the required range. One thermocouple shall be attached directly to each spool or assembly at the point of greatest wall thickness. If a large number of small spools/assemblies are to be treated in one batch, thermocouples may be attached to a representative number (no less than one in four) of the spools. 3.3.9.5. Local PWHT Local PWHT shall be allowed where size or installation restrictions prevent furnace treatment. In this case heating shall normally be by electrical resistance heating elements. Other heating methods may be considered. These should be submitted for review and approval by the Principal. For local PWHT the soak temperature shall be achieved and maintained in a band 2.5 x weld thickness (e) either side of the weld centre line. The width of the thermal insulation shall be 7.5e either side of the weld centre line. Circulation of air in the bore of the process piping or equipment work shall be prevented. The minimum number and position of thermocouples shall be as follows: No. of Thermocouples Clock Position per Weld 100 1 12 >100 to 300 2 6, 12 >300 4 3, 6, 9, 12 Thermocouples shall be located on the weld centre line and shall either be held in direct contact with the surface of the weld mechanically or be attached by capacitance discharge welding. The attachment points of capacitance discharge welded thermocouples shall be dressed by grinding after removal. 3.3.9.6. Calibration The Contractor shall approve calibration procedures for all equipment measuring and recording temperature. As a minimum temperature recorders shall be calibrated every three months. 3.3.9.7. Recording and Reporting As a minimum heating rate, holding time, temperature and cooling rate data shall be recorded. The temperature measured by each thermocouple should be recorded by means of a multi-channel chart recorder. Each chart shall be marked with the date of the PWHT, the weld or spool/assembly number(s), channel identification and signature(s) of sub-Contractor personnel. A heat treatment report shall contain sufficient information to ensure traceability to the item(s) under treatment and confirm compliance with the approved procedure. Eng. By: UIE/P/SDD Location: UIE Shell Upstream International Europe Sheet: 24 of 59 Doc No.: T-MCE-STD-001 Rev 0 External Dia. mm
It shall also contain an authorised signature confirming completion of works in accordance with design requirements. Completed charts shall be available for Principal review, together with the heat treatment report(s). 3.4. WELD INSPECTION 3.4.1. General Requirements Weld inspection, as detailed below, shall be the responsibility of the Contractor. Unless otherwise approved by the Principal, the NDE Company responsible for the final inspection of welds shall have a quality system in compliance with ISO/IEC 17020, or equivalent, and be accredited by a nationally recognised body. The Contractor shall submit NDE procedures to the Principal for review and approval prior to the work commencing. These procedures shall clearly illustrate how visual, surface and volumetric inspection techniques will establish that all welded joints meet the quality requirements of this Standard. The Contractor shall implement a system for uniquely identifying each weld, for the control and recording of inspections (VT, MT, PT, UT and RT). It is recommended that isometric drawings, marked with the individual weld numbers, be maintained for this purpose. Prior to fabrication start-up, the Contractor shall submit his process for approval by the Principal. The causes for each defect shall be immediately investigated and corrective action shall be taken to prevent further occurrence. The defects shall be reported with reference to the numbering system according with ISO 6520-1. The Contractor shall implement a system for recording of weld defect rates. The defect rates shall be recorded on a weekly basis for each production area and shall be reported together with the accumulated defect rate. Individual welders shall be identified in the defect rate recording system. When required by this Standard the Contractor shall submit to the Principal a procedure for production welding parameter monitoring. This procedure shall include details of the method(s) used, reporting process and the frequency of tests related to the number of welders, processes, and shift patterns. Where PWHT is required, final non-destructive acceptance testing shall not take place until final PWHT has been completed. 3.4.2. Visual Inspection Personnel performing visual testing of welded joints shall be qualified in accordance with EN 473, VT level 2, or equivalent. Visual inspection shall be carried out on all prepared joints prior to welding, during welding (welder self checks) and upon completed welds. Pre-weld checks shall include compliance with clause 4.3 and the tolerances of the WPS. Verification checks shall include the internal surface of the weld wherever possible. The visual acceptance of each weld shall be recorded by the Contractor. 3.4.3. Magnetic Particle Inspection Magnetic particle inspection shall be used as the surface inspection technique applied to nonimpact/impact tested CMn steels, low alloy steels, 3.5 nickel steels, ferritic/martensitic stainless steels and any other ferritic alloy. This inspection shall be carried out in accordance with ASME V, Article 7. Eng. By: UIE/P/SDD Location: UIE Shell Upstream International Europe Sheet: 25 of 59 Doc No.: T-MCE-STD-001 Rev 0
Examination areas shall be cleaned prior to inspection and shall be free from surface irregularities, such as weld spatter. Magnetisation shall normally be by electromagnetic yoke using alternating current. Coil or parallel conductor methods shall only be used if approved by the Principal. Only the wet method shall be employed, using either black ink on white background or ultra-violet fluorescent ink. The total coating thickness allowable, including contrast paint, shall be 20m. 3.4.4. Liquid Penetrant Testing Liquid penetrant testing shall be used as the surface inspection technique applied to 6% Mo stainless steels, duplex stainless steels, nickel alloys, copper alloys, titanium and any other non-ferritic alloys. This inspection shall be carried out in accordance with ASME V, Article 6. Examination areas shall be cleaned prior to inspection and shall be free from surface irregularities, such as weld spatter. Colour contrast, solvent removable penetrant shall normally be used. 3.4.5. Radiographic Examination Radiography shall be in accordance with EN 1435, class B improved techniques. The permitted penetrated thickness ranges for gamma ray sources and X-ray equipment above 1 Me V shall comply with EN 1435 table 1. Alternative techniques may be used providing it can be demonstrated that the required sensitivity can be achieved for each procedure proposed. For general radiography, only lead intensifying screens shall be used. Fluorometallic screens may be used in particular cases, if approved by the Principal, where the purpose is to extend the practicable range of radiography. The radiographs shall be positively located relative to a marked datum point on the weld. For radiographs other than those taken with the DWDI technique this shall be affected by means of a number tape with lead numbers at a maximum of 100mm spacing. For DWDI radiographs shall be identified as A, B C, etc., by means of lead letters. The centre line of these three exposures shall be marked on the weld. 3.4.6. Ultrasonic Examination Ultrasonic examination of welds shall be carried out where the material properties allow in accordance with ASME V, Article 5. On branches, O-lets and similar geometrys, scanning from the internal surface shall be carried out if practicable. 3.4.7. Inspection Personnel The inspection personnel to be used by the Contractor shall be individually approved by the Principal. The Principal reserves the option to interview operatives and, when necessary, to require a practical skill test. The minimum personnel qualification requirements are EN 473 Level 2 Additionally, supervisors responsible for overseeing and controlling NDE activities shall be Level 3 qualified.
Alternative qualifications (e.g. SNT) will be accepted only by specific approval of the Principal. Approval will be subject to satisfactory demonstration of independence and control of the qualification Specifications. 3.4.8. Extent of Inspection of Process Piping Production Welding Table 4 provides guidance for process and utility piping inspection class definition, in terms of piping service and pressure rating. More specific inspection requirements may be included in the purchase order in the form of specific equipment design standard(s) and/or construction drawings. The required extent of inspection for piping fabrication for each class is listed in Table 5. For non-impact/impact tested CMn steels, low alloy steels, 3.5 nickel steels, ferritic/martensitic stainless steels and any other ferritic alloy ultrasonic examination shall be carried out for wall thickness in excess of 19mm, unless otherwise specified by the Principal. For 6% Mo stainless steels, duplex stainless steels, nickel alloys, copper alloys, titanium and any other non-ferritic alloys of wall thicknesses over 19mm radiography is the preferred inspection technique for volumetric examination. Percentage radiography refers to the number of whole welds to be 100% inspected by the radiographic technique. Welds shall be selected so that the maximum number of welders will be evaluated. Should an Inspection Class 1 or 2 weld contain unacceptable defects, two further welds made by that welder shall be inspected by radiography. If either of these proves unacceptable, all welds produced by that welder shall be considered unacceptable unless proved otherwise to the satisfaction of the Principal. All welds found to be unacceptable shall be removed or repaired. 3.4.9. Acceptance Specifications Visual Examination prior to welding Parameter Monitoring Visual examination of finished welds MT PT Radiography Ultrasonic Examination
Verify compliance with dimensional control requirements of this Standard. Within the limits of the approved WPS In accordance with Table 6 of this Standard ASME VIII, Appendix 6-4 ASME VIII, Appendix 8-4 In accordance with Table 7 of this Standard ASME VIII, Appendix 12-3 or as agreed with the Principal for non-ferritic materials
3.4.10. Reporting All inspection reports should be signed by the approved operative who did the inspection and contain sufficient information to ensure traceability to the weld inspected and the procedure used. It shall record all equipment identification and settings to enable the inspection to be repeated to the same procedure. All defects shall be identified and located relative to a clear reference. Details of the minimum information to be recorded are included in Appendix B. 3.5. REPAIRS 3.5.1. General Repair preparation, remedial grinding and repair welding shall not commence before informing the Principal of the Contractors proposed remedial actions. Second attempts at repairing the same weld area shall only be made by permission of the Principal. Where permission for a second repair is not given the whole weld shall be removed. Welds containing repairs that were made after PWHT shall be heat treated a second time in accordance with this Standard, unless approved otherwise by the Principal. Eng. By: UIE/P/SDD Location: UIE Shell Upstream International Europe Sheet: 27 of 59 Doc No.: T-MCE-STD-001 Rev 0
3.5.2. Defect Removal Surface profile defects or surface porosity on the cap, or root if accessible, may be removed by disc grinding or burr grinding to a smooth profile subject to the minimum material thickness being maintained. Unacceptable defects in ferritic steels shall be excavated by mechanical means or Carbon arc gouging to a depth agreed with the Principal followed by grinding. Carbon arc gouging operatives shall be approved by the Principal. Unacceptable defects in non-ferrous materials shall be excavated by mechanical means only. The excavation shall be ground to a smooth boat shape with no sharp edges and have sufficient slope on the sides to permit proper access for welding. Weld repair excavation depth shall be controlled by gauges to ensure the minimum amount of material necessary is excavated to completely remove the defect. MT or PT surface inspection techniques shall be used to confirm removal of weld defects. 3.5.3. Root Repairs Where access permits and if approved by the Principal, weld repairs to the root of a single sided weld may be permitted from the inside. This shall be subject to the availability of a suitably qualified repair WPS. Where access does not permit internal rectification, special attention shall be necessary to locate the defect prior to excavation from the outside and to controlling the root gap of the excavation. If the component remains under external loading during defect excavation, the permitted size of the excavation shall be calculated and agreed with the Principal. When necessary assemblies shall be supported whist repair excavations and welding is performed. 3.5.4. Re-welding Repair welding shall be in accordance with section 3.1.5. of this Standard. If, after excavation, the root gap geometry is outside the allowable tolerances of the relevant procedure, a new repair welding procedure shall be qualified unless alternative proposals are accepted by the Principal. If back purging was required for the original weld, the back purge shall be re-established if the repair excavation encroaches closer than 5mm to the inside surface of the vessel, process piping or equipment. 3.5.5. Non-Destructive Testing All repair welds shall be 100% re-inspected by the methods specified for the original weld.
4.
MATERIAL-SPECIFIC ADDITIONAL REQUIREMENTS
4.0.1. General Requirements Requirements vary according to the specific material as shown on the following pages. Common requirements are shown below. It should be noted that the numbering in sections 4.1-4.10 contain deliberate gaps so that the minor sections are similar across all materials (eg. 4.#.4.16 always relates to preheat). Material-specific requirements include lists of approved welding processes. Alternative processes may be permitted by the Principal, subject to a detailed technical justification including documented previous experience. 4.0.2. PQR Requirements PQR Monitoring PQR Monitoring PQR Monitoring SMAW : record runout lengths (ROL) and stub lengths Other : record minimum and maximum bead widths for each weld area Record interpass temperature at start of each pass.
4.0.3. PQR Testing Requirements PQR requirements are generally in accordance with the relevant part of EN ISO 15614, with clarifications changes as indicated for the specific material. Hardness test maxima have been set to allow approved weld procedures to cover all types of process application. These may be relaxed for certain applications where hardness is less critical, by written agreement of the Principal. 4.0.4. Essential Variables Direction of Welding Single/Double Sided Bevel / V Backing Shielding / Backing Gases Arc Voltage Current / Wire Feed Travel Speed Arc Energy or Heat Input Arc Type PWHT
A change from vertical up to vertical down or vice versa requires requalification. Single-sided and double-sided welds require separate qualification. Bevels qualify Vees but not vice versa. Addition or removal of backing strips or gas requires qualification. Minor constituents of gases may not be changed by more than 10% +/- 10% of the average measured for the specified weld region +/- 15% of the average measured for the specified weld region +/- 20% of the average measured for the specified weld region +/- 25% of the average measured for the specified weld region A change in arc characteristics (eg. dip, globular, spray) requires requalification. Increase in total PWHT time exceeding 25% requires requalification
Voltage, current, wire feed, speed, arc-energy, and heat input parameter ranges may need to be modified for certain applications. The above ranges apply unless alternatives are advised by the Principal. Where 2G+5G procedures are required for full coverage, the Principal may accept existing 6G procedures as covering all-positional welding, particularly in the case of manual GTAW and SMAW welding. 4.0.5. Production Controls Requirements for parameter monitoring reflect the sensitivity of the material mechanical and/or corrosion resistance properties. Welding sets shall be validated at intervals not exceeding 12 months in accordance with EN 50504. For some sites, where the problems identified in EN 50504 Annex F apply, documented in-house verification of welding equipment under actual welding conditions may be accepted, Testing equipment used for this Eng. By: UIE/P/SDD Location: UIE Shell Upstream International Europe Sheet: 29 of 59 Doc No.: T-MCE-STD-001 Rev 0
type of verification shall have a current certificate of calibration which is traceable to national standards, and a detailed procedure, including acceptance criteria, shall be submitted to the Principal for approval.
4.1. NON-IMPACT TESTED CMN STEELS

4.1.1 4.1.1.1 4.1.1.2 4.1.1.3 4.1.1.4 4.1.1.6 4.1.1.7 4.1.2 4.1.2.1 4.1.2.2 4.1.3 4.1.3.1 4.1.3.2 4.1.3.3 4.1.3.4 General Requirements - Non-Impact Tested CMn Steels Typical Materials ASTM A285C, A515, A106B, A105, A234-WPB, API 5L Gr B, A516, A216 Approved Root Processes GTAW (141) Approved Fill & Cap GTAW (141), SMAW (111), FCAW (136,114), GMAW (135), MCAW Processes (138), SAW (121,125) Consumable Restrictions SMAW electrodes : Shall be type EXX16 or EXX18 Consumable Chemistry Root & 2nd pass limited to max 0.3% Ni, 0.6% Si, 0.5% Mo for hydrocarbon service. For water service, 0.8-1.0% Ni consumables are recommended. Hydrogen Control <= 5ml/100g to EN ISO 3690 PQR Requirements - Non-Impact Tested CMn Steels PQR Monitoring Automatic monitoring equipment preferred PQR Preheat Level Higher of initial preheat and initial capping temperature PQR Testing Requirements - Non-Impact Tested CMn Steels PQR NDT Radiography + MPI (plus other, if used for production) Charpy Impacts, T > 5mm See section 3.1.4.4. re. PED requirements Charpy Impacts, T > 20mm See section 3.1.4.4. re. PED requirements Macro + Hardness Survey 1 Required as per EN ISO 15614. Photomacrographs to be included with indicated magnification not less than 1 and clearly showing all hardness indentations. 250HV10 in root up to 8mm from inner surface, 275HV10 above 8mm from inside surface Essential Variables - Non-Impact Tested CMn Steels Carbon Equivalent Production CEq max = PQR CEq +0.03, or 0.38, whichever is higher Thickness Limits (other) As-welded: <=19mm unless otherwise defined. Joint Type Multipass fillets may be qualified by butt weld fill and cap parameters. Bevel Angle Total included angle shall not be decreased by more than 10 from PQR Electrode / Filler Rod Size Root electrode or filler wire size shall not be changed. Polarity / Current Type Any change in polarity or current type requires requalification. Preheat Decrease from that qualified is not permitted. Interpass may be raised by 50C above PQR maximum Interpass Limit 300C maximum Repair Welding Repair WPS to be issued. Separate PQR not required unless essential variables change, or where sour service is specified. Production Controls - Non-Impact Tested CMn Steels Parameter Monitoring Random ROL or bead width checks are sufficient Other Tack welding requires preheating to the minimum level specified on the WPS or 50C whichever is higher. Maximum Hardness
4.1.3.5 4.1.4 4.1.4.1 4.1.4.5 4.1.4.7 4.1.4.11 4.1.4.14 4.1.4.15 4.1.4.16 4.1.4.17 4.1.4.18 4.1.4.20 4.1.5 4.1.5.1 4.1.5.3
4.2. IMPACT TESTED CMN STEELS (LTCS)

4.2.1 4.2.1.1 4.2.1.2 4.2.1.3 4.2.1.4 4.2.1.6 4.2.1.7 4.2.2 4.2.2.1 4.2.2.2 4.2.3 4.2.3.1 4.2.3.2 4.2.3.3 4.2.3.4 General Requirements - Impact Tested CMn Steels (LTCS) Typical Materials ASTM A537, A352, A333 Gr6, A350 LF2, A420 Gr WPL6, API 5L X##, A694 F## Approved Root Processes GTAW (141) Approved Fill & Cap GTAW (141), SMAW (111), FCAW (136), SAW (121,125) Processes Consumable Restrictions SMAW electrodes : Shall be type EXX16 or EXX18 Consumable Chemistry Root & 2nd pass limited to max 0.3% Ni, 0.6% Si, 0.5% Mo for hydrocarbon service. For water service, 0.8-1.0% Ni consumables are recommended. Hydrogen Control <= 5ml/100g to EN ISO 3690 PQR Requirements - Impact Tested CMn Steels (LTCS) PQR Monitoring Automatic monitoring equipment required. PQR Preheat Level Higher of initial preheat and initial capping temperature PQR Testing Requirements - Impact Tested CMn Steels (LTCS) PQR NDT Radiography + MPI (plus other, if used for production) Charpy Impacts, T > 5mm Root : Weld, Fusion Line, FL+2mm (and FL+5mm when heat input > 2.0kJ/mm) Charpy Impacts, T > 20mm Root impacts above plus Cap Weld Centreline Macro + Hardness Survey 5G or 6G : 3 off - 3 or 9 oc, 6 o'c, 12 o'c positions. Other welding positions: 1 off. Photomacrographs to be included with indicated magnification not less than 1 and clearly showing all hardness indentations. Maximum Hardness 250HV10 in root up to 8mm from inner surface, 275HV10 above 8mm from inside surface Essential Variables - Impact Tested CMn Steels (LTCS) Carbon Equivalent Production CEq max = PQR CEq +0.03, or 0.38, whichever is higher Material Supply Condition Charpy impact and hardness acceptability for Normalised, TMCR, Q&T materials shall be qualified or demonstrated separately. Thickness For PQRs with T < 5mm, impact tests are not required unless the WPS is to be used on material with thickness greater than 5mm Thickness Limits (other) See Table 1 Position 2G + 5G qualification required for all positional coverage (see 4.0.4). Joint Type Multipass fillets may be qualified by butt weld fill and cap parameters, unless intended for sour service. Simple / Compound Change to/from compound bevel requires approval by the Principal. Bevel Angle Total included angle shall not be decreased by more than 10 from PQR Process Combination The welding process, combination of processes or order of welding processes shall not be changed unless approved by the Principal. Consumable The consumable brand name is an essential variable, though the Principal may agree to changes for solid wires. Electrode / Filler Rod Size Electrode or filler wire size shall not be changed at any stage of welding from that used in procedure qualification Polarity / Current Type Any change in polarity or current type requires requalification. Preheat Decrease from that qualified is not permitted. Interpass may be raised by 50C above PQR maximum Interpass Limit 250C maximum Repair Welding Repair WPS to be issued. Separate PQR not required unless essential variables change, or where sour service is specified. Production Controls - Impact Tested CMn Steels (LTCS) Parameter Monitoring Scheduled, minimum 1 test per process per shift Other Tack welding requires preheating to the minimum level specified on the WPS or 50C whichever is higher.
4.2.3.5 4.2.4 4.2.4.1 4.2.4.2 4.2.4.4 4.2.4.5 4.2.4.6 4.2.4.7 4.2.4.8 4.2.4.11 4.2.4.12 4.2.4.13 4.2.4.14 4.2.4.15 4.2.4.16 4.2.4.17 4.2.4.18 4.2.4.20 4.2.5 4.2.5.1 4.2.5.3
4.3. 3.5% NICKEL STEELS

4.3.1 4.3.1.1 4.3.1.2 4.3.1.3 4.3.1.4 General Requirements - 3.5% Nickel Steels Typical Materials ASTM A333 Gr3, A350 LF3, A420 Gr WPL3, A765 Gr III, A352 LC3, A203 D Approved Root Processes GTAW (141) Approved Fill & Cap GTAW (141), SMAW (111), FCAW (136), SAW (121,125) Processes Consumable Restrictions Matching : GTAW : ER80S-Ni2 / SMAW electrodes : Shall be 7016C2L, 7018C2L, 8016C2 or 8018C2 Consumable Restrictions Non-Matching : GTAW : ERNiCr-3 / SMAW : ENiCrFe-2 or ENiCrFe-3
4.3.1.5 4.3.1.6 4.3.1.7 4.3.2 4.3.2.1 4.3.2.2 4.3.3 4.3.3.1 4.3.3.2 4.3.3.3 4.3.3.4
4.3.3.5 4.3.4 4.3.4.1 4.3.4.2 4.3.4.4 4.3.4.5 4.3.4.6 4.3.4.7 4.3.4.8 4.3.4.11 4.3.4.12 4.3.4.13 4.3.4.14 4.3.4.15 4.3.4.16 4.3.4.17 4.3.4.18 4.3.4.20 4.3.5 4.3.5.1 4.3.5.3
Consumable Chemistry See restrictions above. Hydrogen Control <= 5ml/100g to EN ISO 3690 PQR Requirements - 3.5% Nickel Steels PQR Monitoring Automatic monitoring equipment required. PQR Preheat Level Higher of initial preheat and initial capping temperature PQR Testing Requirements - 3.5% Nickel Steels PQR NDT Radiography + MPI (plus other, if used for production) Charpy Impacts, T > 5mm Root : Weld, Fusion Line, FL+2mm (and FL+5mm when heat input > 2.0kJ/mm) Charpy Impacts, T > 20mm Root impacts above plus Cap Weld Centreline Macro + Hardness Survey 5G or 6G : 3 off - 3 or 9 oc, 6 o'c, 12 o'c positions. Other welding positions: 1 off. Photomacrographs to be included with indicated magnification not less than 1 and clearly showing all hardness indentations. Maximum Hardness 250HV10 in root up to 8mm from inner surface, 275HV10 above 8mm from inside surface Essential Variables - 3.5% Nickel Steels Carbon Equivalent Production CEq max = PQR CEq +0.03, or 0.38, whichever is higher Material Supply Condition Charpy impact and hardness acceptability for Normalised, TMCR, Q&T materials shall be qualified or demonstrated separately. Thickness For PQRs with T < 5mm, impact tests are not required unless the WPS is to be used on material with thickness greater than 5mm Thickness Limits (other) As-welded : 12.5mm for service down to -80C Position 2G + 5G qualification required for all positional coverage (see 4.0.4). Joint Type Multipass fillets may be qualified by butt weld fill and cap parameters. Simple / Compound Change to/from compound bevel requires approval by the Principal. Bevel Angle Total included angle shall not be decreased by more than 10 from PQR Process Combination The welding process, combination of processes or order of welding processes shall not be changed unless approved by the Principal. Consumable The consumable brand name is an essential variable, though the Principal may agree to changes for solid wires. Electrode / Filler Rod Size Electrode or filler wire size shall not be changed at any stage of welding from that used in procedure qualification Polarity / Current Type Any change in polarity or current type requires requalification. Preheat Decrease from that qualified is not permitted. Interpass may be raised by 25C above PQR maximum Interpass Limit 250C maximum Repair Welding Repair WPS to be issued. Separate PQR not required unless essential variables change, or where sour service is specified. Production Controls - 3.5% Nickel Steels Parameter Monitoring Scheduled, minimum 1 test per process per shift Other Tack welding requires preheating to the minimum level specified on the WPS or 100C whichever is higher.
4.4. LOW ALLOY STEELS

4.4.1 4.4.1.1 4.4.1.2 4.4.1.3 4.4.1.7 4.4.2 4.4.2.1 4.4.2.2 4.4.3 4.4.3.1 4.4.3.2 4.4.3.3 4.4.3.4 General Requirements - Low Alloy Steels Typical Materials ASTM A 387 types 0.5 Mo, 1 Cr-0.5 Mo, 1.25 Cr- 0.5 Mo, 2.25 Cr-1 Mo steels, AISI 4130 Approved Root Processes GTAW (141) Approved Fill & Cap GTAW (141), SMAW (111), FCAW (136), SAW (121,125) Processes Hydrogen Control <= 5ml/100g to EN ISO 3690 PQR Requirements - Low Alloy Steels PQR Monitoring Automatic monitoring equipment preferred PQR Preheat Level Higher of initial preheat and initial capping temperature PQR Testing Requirements - Low Alloy Steels PQR NDT Radiography + MPI (plus other, if used for production) Charpy Impacts, T > 5mm See section 3.1.4.4. re. PED requirements Charpy Impacts, T > 20mm See section 3.1.4.4. re. PED requirements Macro + Hardness Survey 1 Required as per EN ISO 15614. Photomacrographs to be included with indicated magnification not less than 1 and clearly showing all hardness indentations. 250HV10 in root up to 8mm from inner surface, 275HV10 above 8mm from inside surface. NB. PWHT is invariably essential on these materials to achieve acceptable hardness. Essential Variables - Low Alloy Steels Material Supply Condition Any change shall be requalified Joint Type Multipass fillets may be qualified by butt weld fill and cap parameters. Simple / Compound Change to/from compound bevel requires approval by the Principal. Bevel Angle Total included angle shall not be decreased by more than 10 from PQR Process Combination The welding process, combination of processes or order of welding processes shall not be changed unless approved by the Principal. Consumable The consumable brand name is an essential variable, though the Principal may agree to changes for solid wires. Electrode / Filler Rod Size Electrode or filler wire size shall not be changed at any stage of welding from that used in procedure qualification Polarity / Current Type Any change in polarity or current type requires requalification. Preheat Decrease from that qualified is not permitted. Interpass may be raised by 25C above PQR maximum Interpass Limit 250C maximum Repair Welding Repair WPS to be issued. Separate PQR not required unless essential variables change, or where sour service is specified. Production Controls - Low Alloy Steels Parameter Monitoring Random ROL or bead width checks are sufficient Other Tack welding requires preheating to the minimum level specified on the WPS or 100C whichever is higher. Maximum Hardness
4.4.3.5
4.4.4 4.4.4.2 4.4.4.7 4.4.4.8 4.4.4.11 4.4.4.12 4.4.4.13 4.4.4.14 4.4.4.15 4.4.4.16 4.4.4.17 4.4.4.18 4.4.4.20 4.4.6 4.4.6.1 4.4.6.3
4.5. AUSTENITIC STAINLESS STEELS

4.5.1 4.5.1.1 4.5.1.2 4.5.1.3 4.5.1.4 General Requirements - Austenitic Stainless Steels Typical Materials AISI 300 Series, Grades 304L, 304, 316L, 316, 321, 347 Approved Root Processes GTAW (141), PAW (15) Approved Fill & Cap GTAW (141), PAW (15), SMAW (111), FCAW (136), GMAW (135), Processes SAW (121,125) Consumable Restrictions 304, 304L : ER308L, ER347 (GTAW), E308, E347 (SMAW) 321, 347 : ER347 (GTAW), E347 (SMAW) 316, 316L :ER316L (GTAW), E316L (SMAW) Consumable Chemistry Principal alloying additions should not be made through flux additions. PQR Requirements - Austenitic Stainless Steels PQR Monitoring Automatic monitoring equipment preferred PQR Testing Requirements - Austenitic Stainless Steels PQR NDT Radiography + DPI (plus other, if used for production) Macro + Hardness Survey 1 Required as per EN ISO 15614. Photomacrographs to be included with indicated magnification not less than 1 and clearly showing all hardness indentations. Maximum Hardness Micro Examination 250HV10 5G or 6G : 2 off representing min and max heat input, 1 off for other positions. Microstructure of weld and HAZ shall show appropriate phase distribution and absence of microphases considered deleterious to mechanical or corrosion properties. Photomicrographs shall be provided of each region (typically 250X) with the PQR.
4.5.1.6 4.5.2 4.5.2.1 4.5.3 4.5.3.1 4.5.3.4
4.5.3.5 4.5.3.8
4.5.3.9 4.5.4 4.5.4.7 4.5.4.11 4.5.4.12 4.5.4.14 4.5.4.15 4.5.4.17 4.5.4.18 4.5.4.20 4.5.5 4.5.5.1 4.5.5.2 4.5.5.3
Ferrite Test Shall be 3-7% in the weld root by point counting or ferrite meter Essential Variables - Austenitic Stainless Steels Joint Type Multipass fillets may be qualified by butt weld fill and cap parameters. Bevel Angle Total included angle shall not be decreased by more than 10 from PQR Process Combination The welding process, combination of processes or order of welding processes shall not be changed unless approved by the Principal. Electrode / Filler Rod Size Electrode or filler wire size shall not be changed at any stage of welding from that used in procedure qualification Polarity / Current Type Any change in polarity or current type (including pulse characteristics) requires requalification. Interpass may be raised by 0C above PQR maximum Interpass Limit 150C maximum Repair Welding Repair WPS to be issued. Separate PQR not required unless essential variables change. Production Controls - Austenitic Stainless Steels Parameter Monitoring Random ROL or bead width checks are sufficient Material Segregation Required Other Austenitic stainless steels may only be cut mechanically or by plasma arc cutting. All plasma spatter and other debris shall be removed from the vessel, process pipework or other equipment surface by disc grinder or emery disc.
4.6. 6% MO AND OTHER SUPERAUSTENITIC STAINLESS STEELS

4.6.1 4.6.1.1 4.6.1.2 4.6.1.3 4.6.1.4 4.6.1.6 4.6.1.8 4.6.2 4.6.2.1 4.6.3 4.6.3.1 4.6.3.4 General Requirements - 6%Mo and Other Superaustenitic Stainless Steels Typical Materials UNS S31254, UNS N08367, UNS N08925, UNS N08926 Approved Root Processes GTAW (141) Approved Fill & Cap GTAW (141), SMAW (111), FCAW (136), SAW (121,125) Processes Consumable Restrictions Type ERNiCrMo-3 Consumable Chemistry Principal alloying additions should not be made through flux additions. Autogenous Welding Not permitted PQR Requirements - 6%Mo and Other Superaustenitic Stainless Steels PQR Monitoring Automatic monitoring equipment required. PQR Testing Requirements - 6%Mo and Other Superaustenitic Stainless Steels PQR NDT Radiography + DPI (plus other, if used for production) Macro + Hardness Survey 5G or 6G : 3 off - 3 or 9 oc, 6 o'c, 12 o'c positions. Other welding positions: 1 off. Photomacrographs to be included with indicated magnification not less than 1 and clearly showing all hardness indentations. Maximum Hardness 35HRC (335 HV10) Root Chemical Analysis All principal alloying additions : minimum C, Si, Mn, P, S, Cr, Mo, Ni, Cu, Nb, and Fe Corrosion Test ASTM G48 Method A @ 35C for 24 hours to achieve <= 4g/sq.m loss. (see section 3.1.4.5. for NORSOK requirements) Micro Examination 5G or 6G : 2 off representing min and max heat input, 1 off for other positions. Microstructure of weld and HAZ shall show appropriate phase distribution and absence of microphases considered deleterious to mechanical or corrosion properties. Photomicrographs shall be provided of each region (typically 250) with the PQR. Essential Variables - 6%Mo and Other Superaustenitic Stainless Steels Chemistry Limitations A change in UNS number requires requalification Position 2G + 5G qualification required for all positional coverage (see 4.0.4). Joint Type Single and multipass fillets require separate qualification Root Gap Tolerance: -0 / +2mm of the PQR and not less than 2mm Bevel Angle Total included angle shall not be changed by more than +/-10 from PQR Process Combination The welding process, combination of processes or order of welding processes shall not be changed unless approved by the Principal. Consumable The consumable brand name is an essential variable, though the Principal may agree to changes for solid wires. Electrode / Filler Rod Size Electrode or filler wire size shall not be changed at any stage of welding from that used in procedure qualification Polarity / Current Type Any change in polarity or current type (including pulse characteristics) requires requalification. Interpass may be raised by 0C above PQR maximum Interpass Limit 100C maximum Heat Input Limits 1 kJ/mm maximum Repair Welding Separate procedure to be qualified Production Controls - 6%Mo and Other Superaustenitic Stainless Steels Parameter Monitoring Scheduled, minimum 1 test per process per shift Material Segregation Required Other 6 Mo stainless steels may only be cut mechanically or by plasma arc cutting. All plasma spatter and other debris shall be removed by disc grinder or emery disc.
4.6.3.5 4.6.3.6 4.6.3.7 4.6.3.8
4.6.4 4.6.4.3 4.6.4.6 4.6.4.7 4.6.4.9 4.6.4.11 4.6.4.12 4.6.4.13 4.6.4.14 4.6.4.15 4.6.4.17 4.6.4.18 4.6.4.19 4.6.4.20 4.6.5 4.6.5.1 4.6.5.2 4.6.5.3
4.7. DUPLEX STAINLESS STEELS

4.7.1 4.7.1.1 4.7.1.2 4.7.1.3 4.7.1.4 General Requirements - Duplex Stainless Steels Typical Materials UNS S31803, UNS32205 (22% Cr) and UNS S32550, UNS S32750, UNS S32760 (25% Cr) Approved Root Processes GTAW (141) Approved Fill & Cap GTAW (141), PAW (15), SMAW (111), FCAW (136), SAW (121,125) Processes Consumable Restrictions Root & 2nd pass of 22% duplex shall be made with 25% duplex consumable unless nitrogen containing shield gas and purge are used. Consumable Chemistry Shall overmatch nickel content (typically 2209 type for 22% duplex and 2509 type for 25% duplex). Principal alloying additions should not be made through flux additions.
4.7.1.6
4.7.1.7 4.7.1.8 4.7.2 4.7.2.1 4.7.3 4.7.3.1 4.7.3.2 4.7.3.3 4.7.3.4
Hydrogen Control <= 5ml/100g to EN ISO 3690 Autogenous Welding Not permitted PQR Requirements - Duplex Stainless Steels PQR Monitoring Automatic monitoring equipment required. PQR Testing Requirements - Duplex Stainless Steels PQR NDT Radiography + DPI (plus other, if used for production) Charpy Impacts, T > 5mm Root : Weld, Fusion Line, FL+2mm (and FL+5mm when heat input > 1.75kJ/mm) Lateral expansion shall be >= 0.38mm Charpy Impacts, T > 20mm Root & Cap : Weld, Fusion Line, FL+2mm (and FL+5mm when heat input > 1.75kJ/mm) Lateral expansion shall be >= 0.38mm Macro + Hardness Survey 1 Required as per EN ISO 15614. Photomacrographs to be included with indicated magnification not less than 1 and clearly showing all hardness indentations. Maximum Hardness Root Chemical Analysis Corrosion Test Micro Examination 28HRC (335 HV10) for 22% duplex and 34HRC (378 HV10) for 25% duplex All principal alloying additions : minimum C, Si, Mn, P, S, Cr, Ni, Mo, Cu, Al, (W) and N ASTM G48 Method A for 24 hours to achieve <= 4g/sq.m loss. Test temperature 22C for 22% duplex and 35C for 25% duplex (see section 3.1.4.5. for NORSOK requirements) 5G or 6G : 2 off representing min and max heat input, 1 off for other positions. Microstructure of weld and HAZ shall show appropriate phase distribution and shall have grain boundary with no continuous precipitations and the inter-metallic phases, nitrides and carbides shall not in total exceed 0,5 %.. Photomicrographs shall be provided of each region (typically 250) with the PQR. Shall be 40-60% in parent and 30-70% in weld/HAZ according to method in appendix C. Measurements to be made 1mm from root and cap in weld, HAZ, and parent metal.
4.7.3.5 4.7.3.6 4.7.3.7 4.7.3.8
4.7.3.9
Ferrite Test
4.7.4 4.7.4.3 4.7.4.4
Essential Variables - Duplex Stainless Steels Chemistry Limitations A change in UNS number requires requalification Thickness Welding procedure tests conducted on impact-tested materials less than 5mm thick need not be impact tested. However, such procedure tests shall not qualify for thicknesses greater than 5mm. For 22 Cr duplex, the thickness ranges qualified shall be in accordance with ISO 15614-1 For 25 Cr duplex, the thickness ranges qualified shall be based on the PQR thickness (t) as follows: t < 5 mm : t - 1.5t (limit 5mm if not impact tested) t >= 5 mm : 0.75t - 1.5t Thickness Limits (other) Position Joint Type 30mm for MMT >= -50C, 50mm for MMT >= -30C, and subject to design code 2G + 5G qualification required for all positional coverage (see 4.0.4). Single and multipass fillets require separate qualification.
4.7.4.5 4.7.4.6 4.7.4.7
4.7.4.8 4.7.4.11 4.7.4.12 4.7.4.13
Simple / Compound Bevel Angle Process Combination Consumable
Change to/from compound bevel requires approval by the Principal. Total included angle shall not be decreased by more than 10 from PQR The welding process, combination of processes or order of welding processes shall not be changed unless approved by the Principal. The consumable brand name is an essential variable, though the Principal may agree to changes for solid wires. PREN of production consumables should not be more than 0.5 below those used for the PQR
4.7.4.14 4.7.4.15 4.7.4.17 4.7.4.18 4.7.4.19
4.7.4.20 4.7.5 4.7.5.1 4.7.5.2 4.7.5.3
Electrode or filler wire size shall not be changed at any stage of welding from that used in procedure qualification Polarity / Current Type Any change in polarity or current type (including pulse characteristics) requires requalification. Interpass may be raised by 25C above PQR maximum Interpass Limit 150C maximum for 22% duplex 125C maximum for 25% duplex Heat Input Limits The arc energy and interpass temperature shall be controlled to ensure an optimum cooling rate of the weld with respect to the thickness. Typical arc energies are in the range 0.5 to 1.75 kJ/mm. The second pass is normally deposited at a lower arc energy than that of the root pass. Repair Welding Separate procedure to be qualified. Only one production repair is permitted to 25% duplex stainless steel. Production Controls - Duplex Stainless Steels Parameter Monitoring Scheduled, minimum 1 test per process per shift Material Segregation Required Other Duplex stainless steels may only be cut mechanically or by plasma arc cutting. All plasma spatter and other debris shall be removed from the vessel, process pipework or other equipment surface by disc grinder or emery disc.
Electrode / Filler Rod Size
4.8. NICKEL ALLOYS

4.8.1 4.8.1.1 4.8.1.2 4.8.1.3 4.8.1.4 General Requirements - Nickel Alloys Typical Materials UNS N08825 (Alloy 825), UNS N06625 (Alloy 625), UNS N04400 (Monel) Approved Root Processes GTAW (141) Approved Fill & Cap GTAW (141), SMAW (111), FCAW (136), SAW (121,125) Processes Consumable Restrictions UNS N08825 : SMAW AWS 5.11 ENiCr-3 or AWS 5.11 ENiCrMo-3 / GTAW AWS 5.14 ERNiCr-3 or AWS 5.14 ERNiCrMo-3 UNS N06625 : SMAW AWS 5.11 ENiCrMo-3 / GTAW AWS 5.14 ERNiCrMo-3 UNS N0440 (Monel) : GTAW AWS 5.14 ERNiCu-7 or AWS 5.14 ERNiCrMo-3 Consumable Chemistry Principal alloying additions should not be made through flux additions. PQR Requirements - Nickel Alloys PQR Monitoring Automatic monitoring equipment preferred PQR Testing Requirements - Nickel Alloys PQR NDT Radiography + DPI (plus other, if used for production) Macro + Hardness Survey 1 Required as per EN ISO 15614. Photomacrographs to be included with indicated magnification not less than 1 and clearly showing all hardness indentations. Maximum Hardness For Information Essential Variables - Nickel Alloys Chemistry Limitations A change in UNS number requires requalification Joint Type Multipass fillets may be qualified by butt weld fill and cap parameters. Bevel Angle Total included angle shall not be decreased by more than 10 from PQR Process Combination The welding process, combination of processes or order of welding processes shall not be changed unless approved by the Principal. Electrode / Filler Rod Size Electrode or filler wire size shall not be changed at any stage of welding from that used in procedure qualification Polarity / Current Type Any change in polarity or current type (including pulse characteristics) requires requalification. Interpass may be raised by 25C above PQR maximum Interpass Limit 150C maximum Repair Welding Repair WPS to be issued. Separate PQR not required unless essential variables change, or where sour service is specified. Production Controls - Nickel Alloys Parameter Monitoring Random ROL or bead width checks are sufficient Material Segregation Required Other Nickel and its alloys may only be cut mechanically or by plasma arc cutting. All plasma spatter and other debris shall be removed from the vessel, process pipework or other equipment surface by disc grinder or emery disc.
4.8.1.6 4.8.2 4.8.2.1 4.8.3 4.8.3.1 4.8.3.4
4.8.3.5 4.8.4 4.8.4.3 4.8.4.7 4.8.4.11 4.8.4.12 4.8.4.14 4.8.4.15 4.8.4.17 4.8.4.18 4.8.4.20 4.8.5 4.8.5.1 4.8.5.2 4.8.5.3
4.9. COPPER ALLOYS

4.9.1 4.9.1.1 4.9.1.2 4.9.1.3 4.9.1.4 4.9.1.5 4.9.1.6 4.9.1.8 4.9.2 4.9.2.1 4.9.3 4.9.3.1 4.9.3.4 General Requirements - Copper Alloys Typical Materials BS 2870/2871/2875 grade CN102, DIN 17664 No. 2.0872 CU NI 10 FE Approved Root Processes Approved Fill & Cap Processes Consumable Restrictions GTAW (141) GTAW (141), SMAW (111), FCAW (136), SAW (121,125)
GTAW welding of grade CN102 (90/10) : AWS 5.7 ERCuNi or BS 2901 Pt 3, C18 Consumable Restrictions Other : 70/30 composition, to be agreed with the Principal Consumable Chemistry Principal alloying additions should not be made through flux additions. Autogenous Welding Not permitted PQR Requirements - Copper Alloys PQR Monitoring Automatic monitoring equipment preferred PQR Testing Requirements - Copper Alloys PQR NDT Radiography + DPI (plus other, if used for production) Macro + Hardness Survey 1 Required as per EN ISO 15614. Photomacrographs to be included with indicated magnification not less than 1 and clearly showing all hardness indentations. Maximum Hardness For Information Essential Variables - Copper Alloys Joint Type Multipass fillets may be qualified by butt weld fill and cap parameters. Bevel Angle Total included angle shall not be decreased by more than 10 from PQR Process Combination The welding process, combination of processes or order of welding processes shall not be changed unless approved by the Principal. Electrode / Filler Rod Size Electrode or filler wire size shall not be changed at any stage of welding from that used in procedure qualification Polarity / Current Type Any change in polarity or current type (including pulse characteristics) requires requalification. Interpass may be raised by 0C above PQR maximum Interpass Limit 175C maximum Repair Welding Repair WPS to be issued. Separate PQR not required unless essential variables change. Production Controls - Copper Alloys Parameter Monitoring Random ROL or bead width checks are sufficient Material Segregation Required Other Copper and its alloys may only be cut mechanically or by plasma arc cutting. Immediately prior to welding the weld preparation and an area 50mm on each side shall be abraded with a stainless steel brush or stainless wire wool and degreased with a non-toxic, non-inflammable solvent on both external and internal surfaces. All plasma spatter and other debris shall be removed from the vessel, process pipework or other equipment surface by disc grinder or emery disc. Brazing Brazing of copper based alloys shall be qualified according to ASME Section IX. The qualification is primarily valid for the workshop performing the welding tests, and other workshops under the same technical and quality management. It may also be transferred to and used by a subcontractor, provided the principles of ISO 3834-2 and ISO 14731 are implemented and documented. The WPQR/PQR documentation shall include the material certificates for the base and filler materials applied in the weld qualification test.
4.9.3.5 4.9.4 4.9.4.7 4.9.4.11 4.9.4.12 4.9.4.14 4.9.4.15 4.9.4.17 4.9.4.18 4.9.4.20 4.9.5 4.9.5.1 4.9.5.2 4.9.5.3
4.9.5.4
4.10. TITANIUM
4.10.1 4.10.1.1 4.10.1.2 4.10.1.3 4.10.1.6 4.10.1.8 4.10.1.9 General Requirements - Titanium Typical Materials ASTM B337 Gr2 (Pipe), ASTM B363 Gr.WPT2 (Fittings), ASTM B381 Gr.F2 (Flanges) Approved Root Processes GTAW (141) Approved Fill & Cap GTAW (141) Processes Consumable Chemistry Same nominal composition as parent metal Autogenous Welding Not permitted Secondary Shielding Maintained until metal temperature falls below 500C and provided by: glove-box chamber, trailing shield, or incorporated into the head of orbital welding equipment PQR Requirements - Titanium PQR Monitoring Automatic monitoring equipment required. PQR Testing Requirements - Titanium PQR NDT Radiography + DPI (plus other, if used for production) Macro + Hardness Survey 5G or 6G : 3 off - 3 or 9 oc, 6 o'c, 12 o'c positions. Other welding positions: 1 off. Photomacrographs to be included with indicated magnification not less than 1 and clearly showing all hardness indentations. Maximum Hardness 200 HV5 Essential Variables - Titanium Thickness The thickness tested is the maximum thickness qualified. Minimum thickness qualified is in accordance with EN ISO 15614 Position 2G + 5G qualification required for all positional coverage (see 4.0.4). Joint Type Multipass fillets may be qualified by butt weld fill and cap parameters. Simple / Compound Change to/from compound bevel requires approval by the Principal. Root Gap Tolerance: -0 / +2mm of the PQR Bevel Angle Total included angle shall not be changed by more than +/-10 from PQR Process Combination The welding process, combination of processes or order of welding processes shall not be changed unless approved by the Principal. Consumable The consumable brand name is an essential variable, though the Principal may agree to changes for solid wires. Electrode / Filler Rod Size Electrode or filler wire size shall not be changed at any stage of welding from that used in procedure qualification Polarity / Current Type Any change in polarity or current type (including pulse characteristics) requires requalification. Interpass may be raised by 0C above PQR maximum 175C maximum Repair WPS to be issued. Separate PQR not required unless essential variables change. Production Controls - Titanium Parameter Monitoring Scheduled, minimum 1 test per process per shift Material Segregation Required Other For titanium only machining or grinding is permitted for weld preparation. Immediately prior to welding the weld preparation and an area 50mm on each side shall be abraded with a stainless steel brush or stainless wire wool and degreased with a non-toxic, non-inflammable solvent on both external and internal surfaces. Periodic checks for iron contamination shall be made by a chemical method (e.g. ferroxyl) on surfaces to be welded. Any inter-run tarnishing observed shall be removed by wire brushing. Interpass Limit Repair Welding
4.10.2 4.10.2.1 4.10.3 4.10.3.1 4.10.3.4
4.10.3.5 4.10.4 4.10.4.4 4.10.4.6 4.10.4.7 4.10.4.8 4.10.4.9 4.10.4.11 4.10.4.12 4.10.4.13 4.10.4.14 4.10.4.15 4.10.4.17 4.10.4.18 4.10.4.20 4.10.5 4.10.5.1 4.10.5.2 4.10.5.3
FIGURES Figure 1 Figure 2 Figure 3 Position of Test Specimens Location of Impact Specimens Weld Profile Weldolets
Figure 1
Approximate Position of Test Specimens
Location 1 2 3 4 5 1-2 4-5
Alternative n/a 2 3 4 n/a 2-1 5-4
Specimens 12 oc macro hardness (if required for 5G/6G) 1 Tensile and 2 bend tests Charpy Impacts and 3 or 9 oc macro hardness (if required for 5G/6G) 1 Tensile and 2 bend tests 6 oc macro hardness Corrosion test specimen A (Duplex and 6%Mo) Corrosion test specimen B (Duplex and 6%Mo)
Notes: (1) Locations are based on EN ISO 15614-# st nd rd th th (2) Specimen location priority : 1 Macros, 2 Impacts, 3 Tensiles, 4 Corrosion Coupons, 5 Bends. (3) Sampling position is non-essential for joints that are not in fixed 5G or 6G positions but care should be taken to ensure that two tensile specimens or two pairs of bend specimens are not adjacent to each other. (4) Where no other guidance is given, the 3 or 9 oc position shall be assumed to be the high heat input position, and the 6 oclock position shall be assumed to be the low heat input position. For large diameter pipes, where different welding parameters are used in primary positions, the contractor should seek guidance from the Principal if this assumption would be incorrect.
(1) RW = Notch at root weld

2mm
(2) RF = Notch at root fusion line

2mm
(3) R2 = Notch at 2mm from fusion line (and R5 = at 5mm for heat inputs over 2kJ/mm)
2mm 2mm 2 or 5mm
(4) CW = Notch at cap weld centreline

2mm
(5) CF = Notch at cap fusion line
2mm
(6) C2 = Notch at 2mm from fusion line (and C5 = at 5mm for heat inputs over 2kJ/mm)
2 or 5mm
NOTE: (1), (2) and (3) - All welds (4) - Additional for ferritic steels with wall thicknesses over 20mm. (4), (5) and (6) - Additional for duplex stainless steels with wall thickness over 20mm.
Figure 2 Location of Impact Specimens
Note: C5 heat input limits are 1.75kJ/mm for duplex stainless steels.
PWHT if t 4B t 38mm
Section 'A-A'
Figure 3
Section 'B-B'
(illu5580480)
Weld Profile Weldolets Note : B is the PWHT threshold thickness, as defined in Table 1
TABLES Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Thickness Limits for Application in the As-Welded Condition Procedure Qualification - Qualified Positions Charpy Impact Testing Temperatures and Acceptance Criteria Inspection Classes Extent of Inspection Visual Acceptance Criteria Radiographic Acceptance Criteria
Table 1 Process Piping Thickness Limits for Application in the As-Welded Condition (Reference DEP.30.10.02.31-Gen 1987 Graph 1). Material A333 Gr A420 Gr WPL6 A 350 LF2 A333 Gr3 A350 LF3 A420 WPL3 Designation LT30 LT50 LT80 Max. thickness for as-welded application, B (mm) for Min. Service Temp. -50C -55C -60C 14 19 Refer note (3) 12 17 9 14
NOTES: (1) The thicknesses listed above should be adopted unless otherwise advised in the relevant Principal Piping Class or Approved Drawing. For service temperatures not listed the thicknesses may be interpolated. Reference should be made to the latest version of DEP 30.10.02.31-Gen for any other conditions. (2) All thicknesses assume Charpy impact toughness in compliance with Table 3. (3) The maximum thickness for as-welded applications at a service temperature of -80C is 12.5 mm. For service below -80C all thicknesses shall be PWHT. (4) The designations LT30, LT50, and LT80 relate to DEP 39.01.10.11-Gen table E.1. These terms are no longer in common use but it is necessary to retain the concept to handle existing low temperature carbon steel procedures/materials that have been impact tested at -46C instead of the -50C required by current MESC purchase specifications.
Table 2 Procedure Qualification - Qualified Positions MATERIAL C-Mn steel (non-sour), Austenitic steels, Nickel alloys, Copper-Nickel and Titanium PROCEDURE TEST WELD POSITION 1G 2G 5G 6G or 2G+5G 1G 2G 5G 2G+5G 1F 2F 2F+3F 2F+3F+4F POSITION QUALIFIED BUTT WELD 1G 1G+2G 1G+5G All 1G 1G+2G 1G+5G All FILLET WELD Multipass fillets may be qualified by butt welds. See ISO 15614 plus relevant section 4.#.4.7 Butt welds do not qualify
C-Mn steel (sour), 6 Mo and duplex stainless steels
All Materials
1F 1F,2F 1F,2F,3F All
NOTE:
For site erection and offshore hook-up qualification in 6G or 2G and 5G, as appropriate, will normally be required
Table 3 Charpy Impact Testing Temperatures and Acceptance Criteria Material (1) LT30 (Deprecated: see note 3) A333 Gr 6, A350 LF2 & A420 WPL6 LT50 A333 Gr 6 A350 LF2 & A420 WPL6 UNS S31803 (4) UNS S32550 (4) UNS S32750 (4) UNS S32760 (4) LT80 A333 Gr 3, A350 LF3, A420 WPL3 Charpy Test Temp. C -46 -50 -50 -50 -50 -50 -50 -80 (5) Charpy Energy J (2) Average 27 27 27 50 50 50 50 27 Individual 19 19 19 40 40 40 40 19
NOTES: (1) The designations LT30, LT50, and LT80 relate to DEP 39.01.10.11-Gen table E.1 (2) The acceptance criteria for subsize specimens shall be reduced to: 7.5mm x 10mm 0.83 x full size values 5mm x 10mm 0.67 x full size values 2.5mm x 10mm 0.5 x full size values (3) Predecessors of this document (ES/124 and DEP 31.38.01.31-UIE) accepted 20J av./16J ind. for LT30 materials, but this is not PED-compliant. New weld procedures shall be charpy impact tested at -50C. The LT30 band is retained for compatibility with existing weld procedure qualifications within the thickness limits of table 1. (4) The application of duplex stainless steels is limited to -50 C for thicknesses up to 30 mm and -30 C for thicknesses up to 50 mm. (see DEP.30.10.02.31-Gen) (5) If the design temperature is lower than -80C, the test temperature shall be the same as the minimum design temperature.
Table 4 Inspection Classes / Definition of NDE Groups Table 4 Inspection Classes / Definition of NDE Groups SERVICE Utility Pressure Rating 150 300 >300 150 >150 All 150 >150 INSPECTION CLASS / NDE Group 1 2 3 2 3 3 2 3
Fire Fighting
Process Low temperature service All other Process services
Table 5 Extent of Inspection INSPECTION CLASS /NDE Group 1 2 METHOD Visual Radiography Visual MT/PT. Radiography Visual MT/PT Radiography Ultrasonic Testing Ultrasonic Testing EXTENT OF TESTING (1) BUTT WELDS BRANCH WELDS (2) 100% 100% 5% 5% (where possible) 100% NR 10% 100% t 19mm - NR t > 19mm - 100% t 19mm - 100% t > 19mm - 100% (3) t > 10mm - 100% (4), (6) t > 19mm - 100% (5), (6) 100% 10% 10% (where possible) 100% 100% 100% NR t 10mm - 100% t 10mm - 100%
NR = Not required NOTES: (1) The specific percentage shall be calculated from the length of welds per WPS. The inspection shall be planned to represent each diameter/size, welder, and fabrication location/shop. Minimum one off weld of each size shall be examined (2) Angular branch welds shall be examined to the same extent as butt welds. All socket, branch connections, O-lets and attachment welds shall be surface examined to the same extent as stated for butt welds. (3) RT is the applicable volumetric inspection test method for CRA materials of all wall thicknesses, unless specified by the Principal. (4) Additional ultrasonic testing shall be carried out when fabrication is by gas metal arc welding (131 MIG/135 MAG). Testing shall verify freedom from planar (lack of fusion) type defects. (5) Applicable for C-Mn and low alloy steels only unless otherwise directed by the Principal. (6) Ultrasonic Testing means manual ultrasonic examination and/or automatic (AUT) depending on application.
Table 6 Visual Acceptance Criteria TYPE OF DEFECT/FEATURE Cap Reinforcement (mm) PERMITTED MAXIMUM T < 6.4 6.4 t 12.7 12.7 < t 25.4 t > 25.4 Dia 200 mm Dia > 200 mm Depth 1.5mm Depth 0.5mm Not Permitted Not Permitted Not Permitted
1.6 3.2 4.0 4.8 1.5 3.0
Root Penetration (mm) (where visible) Root Concavity (mm) (where visible) Undercut (mm) Arc strikes Surface Breaking Porosity and Slag Inclusions Cracks
NB. In the case of different thicknesses, the lower will be taken as T.
Table 7 Radiographic Acceptance Criteria Planar Defects DEFECT TYPE Cracks and lamellar tears Lack of root fusion Lack of side fusion Lack of inter-run fusion Lack of root penetration Isolated pores (or individual pores in a group) Uniformly distributed or localised porosity Wormholes, crater pipes Linear Porosity PERMITTED MAXIMUM Not Permitted Maximum dimension t/3 and no greater than 3mm 2% by area (area to be considered should be the length of weld containing the porosity multiplied by the width of the image of the weld) Length 6 mm Width 1.5 mm Shall be investigated in case this indicates lack of fusion that is not permitted. Otherwise as for individual pores in a group. Length t/3 Width t/3 and no greater than 2.4 mm Inclusions shall be separated by a minimum distance of t/3 and shall not exceed a total length of t in any weld length of 12t As isolated pores As localised porosity Not permitted Radiographic density of indication is not to exceed that of parent material
Cavities
Solid Inclusions
Slag Inclusions
Profile Defects
NOTE:
Tungsten Inclusions (1) Isolated (2) Grouped Copper Inclusions Root Concavity
In the case of different wall thicknesses, the lower will be taken as t.
APPENDICES Appendix A Reporting Requirements for WPQR Appendix B Minimum NDE Reporting Requirements Appendix C Recommended Practice for Determining Volume Fraction of Ferrite in Duplex Stainless Steel Weldments by Systematic Point Count Appendix D Acceptance Criteria for Oxidation of Stainless Steel Weldments
APPENDIX A REPORTING REQUIREMENTS FOR WPQR A1 Welding Procedure Documentation The following documentation shall be presented for approval for each welding procedure qualified: Weld Procedure Specification (final version); Weld Procedure Qualification Record; parent material certification; consumable batch certification; NDE reports on test weld (including visual examination); post-weld heat treatment record charts (if applicable); mechanical test reports: A1.1 Weld Procedure Specification
The Weld Procedure Specification shall be on a clean and clear format and shall include the following information. Alternatively the required information may be submitted clearly and concisely on a welder instruction card: a unique procedure number; the applicable welding Specification; the welding process(es); the parent material(s) Specification(s); the thickness and diameter range qualified; the weld preparation or preparations (including sketch with dimensions and tolerances); method of clamping or tack welding; weld position, and direction if vertical; minimum preheat level; the maximum interpass temperature; welding consumables (AWS classification and trade name); electrode size for each pass or group of passes (e.g. for root, second pass, fill and cap); the electrical conditions, i.e.; polarity (or if ac), current and voltage ranges for each weld pass or group of passes; travel speed for each pass or group of passes bead width or run out length (for SMAW) range for each pass or group of passes the arc energy in kJ/mm (NB. If factored to take account of process thermal efficiency, i.e. a true heat input figure, this shall be clearly indicated) shielding and backing gases, type and flow rate; electrode stick-out for SAW, GMAW and FCAW; electrode material and size for GTAW; gas shroud diameter for GMAW, FCAW (gas shielded) and GTAW; post-weld heat treatment, including heating rate, soak time and temperature, and cooling rate; Weld Procedure Qualification Record
A1.2
The weld procedure qualification record shall include the following information: weld procedure number and test weld number; date and time of test; parent material(s) (including dimensions), Specification(s) and certification number(s); welding consumables, AWS classification, trade names, batch numbers; welders names and identification number(s); welding positions(s); drawing showing actual weld preparation; drawing showing actual run location; method of alignment/tacking; method of preheating and preheat temperature at start of welding; reference to PWHT procedures and record charts if applicable; Eng. By: UIE/P/SDD Location: UIE Shell Upstream International Europe Sheet: 52 of 59 Doc No.: T-MCE-STD-001 Rev 0
welding machine(s), type and make. range of bead widths In addition, the following information shall be recorded for each, individual weld run: electrode size and type; polarity (or if ac); current; voltage; average run out length of electrodes and remaining stub length (for SMAW); welding speed; calculated arc energy; interpass temperature immediately prior to commencement of run; electrode stick-out length (FCAW, GMAW, MCAW, or SAW).
The weld procedure qualification record shall be endorsed by the Contractor and by the witnessing inspector(s) as a true record of the weld.
APPENDIX B
MINIMUM NDE REPORTING REQUIREMENTS
B1 All Methods. work location; description and identity of weld tested; date of test; stage of test (e.g. before or after PWHT repair etc); NDE procedure used; statement of compliance or non-compliance with the acceptance criteria; name of NDE Company; name and signature of the person performing the tests. The position and description of all reportable indications shall be recorded. The position of such indications shall be uniquely defined, with if necessary, a drawing. Any deviation from the approved NDE procedure due to access, surface condition or other factors shall be reported. In addition to the above general information, each report shall contain the information specific to the process, as detailed below. B1.1 MT method of surface preparation and resulting surface condition; method of inducing magnetic field; current and waveform details; pole spacing or coil/conductor arrangement; type of field strength indicator used and frequency of calibration; thickness of background paint, (where used); method and frequency of mixing magnetic inks. B1.2 PT surface condition; dye used; developer used; development time. B1.3 Radiography source type, size, strength (isotope if used); type of x-ray equipment and focal spot size (if used); source to film distance; exposure details; for gamma radiography - source strength and exposure time; for x-radiography - tube current, voltage and exposure time; IQI type, location and sensitivity; film density over weld. B1.4 Ultrasonic Examination surface condition; instrument used (including serial number); probe angles and frequencies used; primary reference level sensitivity; sensitivity level for examination; surface correction factor; response level of reportable defects as percentage of the DAC curve.
APPENDIX C
RECOMMENDED PRACTICE FOR DETERMINING VOLUME FRACTION OF FERRITE IN DUPLEX STAINLESS STEEL WELDMENTS BY SYSTEMATIC POINT COUNT S
C.1 Scope This procedure describes a method for estimating the volume fraction of delta ferrite in duplex stainless steel by systematic point counting on transverse metallographic sections. C.2 Basis of Method The method involves the superimposition of a test grid over an image, produced by an optical light microscope, of the appropriate microstructural area. The number of grid points falling within delta ferrite are counted and divided by the total number of grid points, to yield a point fraction which represents an estimate of the volume fraction of delta ferrite present within the field of view. The average point fraction taken over a number of appropriately selected fields gives an estimate of the volume fraction within the region sampled. C.3 Terminology a. Point count - the number of grid points which lie within areas of a specific phase (in this case delta ferrite). b. Point fraction (Pp) - the point count divided by the total number of points in the test grid. c. Volume fraction (Vv) - the volume of a specific phase per unit volume, expressed as a fraction. C.4 Sample Preparation C.4.1 Planar sections shall be taken through parent material or the weldment, transverse to the welding direction and perpendicular to the material surface. Each sample shall section the whole of the weldment and HAZ and an area of parent material on either side of the weld. Preparation of these specimens shall be in accordance with Specification metallographic techniques, such as described in Reference 1. It is recommended that the last grinding stage should be with 600 grit, or finer, abrasive and the final polish should be with 1 m, or finer, abrasive (e.g. diamond paste). C.4.2 The specimen shall be etched electrolytically in 40% KOH solution (i.e. 400g KOH in 1000 ml of solution made with distilled water). Etching shall be carried out in a container of sufficient size to allow immersion of the specimen in the etch at a distance of 100mm from the platinum cathode. Electrical contact between the specimen and power source may be made by means of a suitably shaped conducting probe. Acceptable contrast can generally be obtained at an anode/cathode voltage of 7-8V for 2-5 seconds, but trials may be necessary to determine the most appropriate conditions for a particular specimen. It may be noted that the contrast between the delta ferrite and austenite phases will probably vary through the weldment. C.5 Area Selection Measurements shall be made 1mm below root and cap surfaces (excluding weld reinforcement) in weld, HAZ, and parent metal. The weld pass shall be stated (e.g. root, cap, fill - preferably with a number) as shall the area which has been measured (i.e. weld metal, HAZ or parent material). Where possible it should be indicated whether the area has been re-heated or is as-deposited. Any uncertainty shall be noted. The location of measurements shall be recorded on a sketch or photograph of the section. C.6 Apparatus C.6.1 An optical light microscope that projects an image of the magnified micro-structure onto a viewing screen shall be used, preferably with graduated x and y translation controls. The magnification shall be selected such that the ferrite particles have an average dimension approximately one half of the grid point spacing. This should be judged visually in more than one field of view, before measurements are made. For many weldment microstructures, particularly in re-heated areas, a magnification in the range x500 x1000 is suitable, and is preferred.
C.6.2 The test grid shall be marked on a transparent sheet that shall be superimposed on the magnified image of the microstructure. The grid shall consist of a square array of equally spaced points, produced by the intersection of fine parallel lines (maximum width 0.3mm), and shall have 16 or 25 points. It is recommended that the spacing of the points should be 10mm along both directions parallel to the edges of the square grid, e.g. as in Figure C.6.2. At a magnification of 1000x this corresponds to a point spacing on the actual microstructure of 10 m. C.7 Procedure C.7.1 Superimpose the test grid on the magnified image of the microstructure in the chosen area of the parent material or weldment. C.7.2 Count the number of points that lie within the delta ferrite phase; any points that cannot be assigned positively to either phase shall be counted as one half. Delta ferrite is the phase that is stained dark by the etch, although its colour may vary significantly throughout the weldment. The austenite phase remains light coloured in all areas after etching. C.7.3 The specimen shall then be moved by a small amount in x and/or y so that another field is chosen. A second point count shall be performed in the new field, provided that this field of view still falls within the specified region of the parent material or weldment. If the field of view falls outside the area of interest the specimen shall be moved back, without rotating, to an appropriate position within the specified area. Where possible the specimen should be moved without looking at the micro-structure in order to avoid bias in the choice of fields. It is recommended that the use of overlapping fields be avoided. This process shall be continued until a minimum of 400 points have been counted. C.7.4 When measurements are being made within the coarse grained HAZ, the operator shall first assess whether the test grid can be superimposed over an area that is entirely within the coarse grained HAZ. This can be done simply by attempting to fit the grid within a single coarse grain. If the grid size is less than the grain size, then the technique described in C.7.1 - C.7.3 shall be used. If the whole grid is too large, a smaller area of the grid shall be used, by ignoring one or more whole rows of grid points. The area chosen may be either square or rectangular. If a rectangular grid is used, the specimen shall be rotated so that the long axis of the rectangle is kept parallel to the fusion boundary. Measurements in the coarse grained HAZ shall be made within approximately two grain diameters of the fusion line. C.7.5 The volume fraction of delta ferrite shall be estimated by taking an average of the point fractions counted in each of the n fields as follows:
where i is the field number. C.7.6 The 95% confidence interval (CI) shall be calculated as follows:
where
The accuracy of the technique shall comply with the allowable errors specified in Table C.7.6. Eng. By: UIE/P/SDD Location: UIE Shell Upstream International Europe Sheet: 56 of 59 Doc No.: T-MCE-STD-001 Rev 0
C.8 Reporting The following details shall be included in the point counting report. i. The number of sections taken from the weld. ii. The locations of sections taken along the weld. iii. The polishing procedure and etching conditions. iv. The magnification used. v. The number of points and shape of the grid. vi. Whether the fields were chosen randomly or at regular intervals. If regular intervals were employed, report the spacings used. vii. The location of the areas in which measurements were made, preferably on sketch or photograph and in words, specifying parent metal or the weld pass, the region of the weld pass (i.e. weld metal or HAZ) and, where practical, whether the area was re-heated or not. Any uncertainty should be indicated. viii. A list of the point fractions of delta ferrite in each field. ix. An estimate of the volume fraction of delta ferrite, calculated as the average of the point fractions. x. The calculated value of the 95% CI. xi. Stage of manufacture, i.e. procedure qualification, production test, etc. xii. Location of sample and cast number. xiii. Statement of conformance with specified ferrite content. xiv. Signature of operator responsible for ferrite determination. C.9 Acceptance Criteria In the event that the ferrite determinations do not conform with the specified requirement, then the product represented by the sample shall be rejected at the discretion of the Principal. C.10 Safety This recommended practice involves materials, equipment and procedures that may represent a health hazard. This document does not attempt to address the safety issues associated with the described practice. It is the responsibility of the testing establishment to ensure that the appropriate health and safety precautions are taken. C.11 References 1) ASTM E3-80 (Reapproved 1986) Methods of Preparation of Metallographic Specimens. 2) Gladman T and Woodhead JH: The Accuracy of Point Counting in Metallographic Investigations, JISI 1960, 194, 189-193.
(illu5580481)
Figure C.6.2
Two Grid Types Suitable for Systematic Manual Point Counting of Delta Ferrite in Duplex Stainless Steel.
Table C.7.6 Volume % 45-50 40-45 35-40 0-35
Allowable Error in Ferritic/Austenite Determination Error 10% 11% 12% 14%
APPENDIX D
WPQR/WPS COMPLIANCE WITH NORSOK M-601
Weld procedures qualified and specified in accordance with this standard will be compliant with NORSOK M-601, subject to the following gaps being addressed: T-MCE-STD-001 Table 3 4.10.3.5 NORSOK M-601 4.3.2 Table 1 4.3.4 Comment or Additional Requirement in NORSOK M-601 M-601 has higher acceptance criteria for 360LT and > 360MPa YS carbon manganese steels. 3.5% Nickel steels are impact tested at -101C T-MCE-STD-001 assumes sour service by default, since this can change during service lifetime. Titanium hardness test load and acceptance criteria differs but 10kg test load survey is acceptable to Shell with a maximum of 200HV10. M-601 tests are acceptable, but additional testing required for 22% duplex to satisfy T-MCE-STD-001 Ferrite test location in the cap differs between T-MCE-STD-001 and M-601. Tests conducted in accordance with M-601 will be accepted as substitutes for the weld cap and weld root tests in T-MCE-STD-001 to avoid additional costs in complying to both specifications. Care should be taken in the applied thickness range for 25% duplex when the PQR thickness is >5mm, <=7mm When applying T-MCE-STD-001 arc energy/heat input ranges, care needs to be taken that the ranges do not exceed the min and max limits of the PQR by more than 15% on stainless steels and nickel alloys. NB. This is unlikely to be an issue for manual and semiautomatic processes unless there are few measurements on the PQR, but may be significant for automatic processes or joints with only a few passes. Interpass limit for all carbon steels is 250C
3.1.4.5 Appendix C
4.3.5 4.3.6
4.7.4.4 4.0.4
4.4.2 4.4.4
4.1.4.18
5.8

T-MCE-STD-001 Rev 0 - Welding and Inspection of Process and Utility Pipework Vessels and Equipment

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TECHNICAL SPECIFICATION

Issue Date By Eng. By: UIE/P/SDD Location: UIE

Revised from DEP 31.38.01.31-UIE Description

Shell Upstream International Europe

Manufacturer / Supplier Shall Should

Shell Upstream International Europe

Sheet: 6 of 59 Doc No.: T-MCE-STD-001

ASME GTAW SMAW

EN/ISO 141 111 136 114 121 125 15 135 138

(GS)FCAW (SS)FCAW SAW SAW PAW GMAW MCAW

Metal-Cored Arc Welding (active gas)

Maximum cooling rate above 300C

t <= 25mm t > 25mm

275C/hour 275 x 25/t C/hour

MATERIAL-SPECIFIC ADDITIONAL REQUIREMENTS

4.1. NON-IMPACT TESTED CMN STEELS

4.2. IMPACT TESTED CMN STEELS (LTCS)

4.3. 3.5% NICKEL STEELS

4.4. LOW ALLOY STEELS

4.5. AUSTENITIC STAINLESS STEELS

4.5.1.6 4.5.2 4.5.2.1 4.5.3 4.5.3.1 4.5.3.4

4.6. 6% MO AND OTHER SUPERAUSTENITIC STAINLESS STEELS

4.6.3.5 4.6.3.6 4.6.3.7 4.6.3.8

4.7. DUPLEX STAINLESS STEELS

4.7.1.7 4.7.1.8 4.7.2 4.7.2.1 4.7.3 4.7.3.1 4.7.3.2 4.7.3.3 4.7.3.4

4.7.3.5 4.7.3.6 4.7.3.7 4.7.3.8

4.7.4 4.7.4.3 4.7.4.4

4.7.4.5 4.7.4.6 4.7.4.7

4.7.4.8 4.7.4.11 4.7.4.12 4.7.4.13

Simple / Compound Bevel Angle Process Combination Consumable

4.7.4.14 4.7.4.15 4.7.4.17 4.7.4.18 4.7.4.19

4.7.4.20 4.7.5 4.7.5.1 4.7.5.2 4.7.5.3

Electrode / Filler Rod Size

4.8. NICKEL ALLOYS

4.8.1.6 4.8.2 4.8.2.1 4.8.3 4.8.3.1 4.8.3.4

4.9. COPPER ALLOYS

4.10.2 4.10.2.1 4.10.3 4.10.3.1 4.10.3.4

Approximate Position of Test Specimens

Location 1 2 3 4 5 1-2 4-5

Alternative n/a 2 3 4 n/a 2-1 5-4

(1) RW = Notch at root weld

(2) RF = Notch at root fusion line

(4) CW = Notch at cap weld centreline

(5) CF = Notch at cap fusion line

C-Mn steel (sour), 6 Mo and duplex stainless steels

1F 1F,2F 1F,2F,3F All

Process Low temperature service All other Process services

1.6 3.2 4.0 4.8 1.5 3.0

In the case of different wall thicknesses, the lower will be taken as t.

MINIMUM NDE REPORTING REQUIREMENTS

Table C.7.6 Volume % 45-50 40-45 35-40 0-35

Allowable Error in Ferritic/Austenite Determination Error 10% 11% 12% 14%

WPQR/WPS COMPLIANCE WITH NORSOK M-601

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