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MATERIALS
PROJECT SPECIFICATION:
Spool pieces shall have excess 100 mm plain end length on one
component of the joint.
RADIAL MISALIGNMENT:
FLANGES:
The distance from the flange face to the pipe end = the pipe wall thickness
+ 3 mm
DIMENSIONAL TOLERANCES:
PROHIBITIONS:
For Stainless steels, thermal cutting shall be limited to plasma arc. Arc –
gouging and oxy – gas methods are specifically prohibited.
For all materials, excavation of defects and back gouging by oxy gas
method is prohibited.
DRESSING AFTER THERMAL CUTTING:
All WPS shall be submitted for review by IOCL in accordance with PDRP –
8840 – SP – 0009
WELDING PROCESSES:
JOINT DETAILS:
SMAW electrode diameter for the root pass in 3’’ NPS shall not exceed 2.5
mm.(For carbon and low alloy steels with up to 2% Cr )
GTAW shall be used for root pass in less than 3’’ NPS.
PROHIBITIONS:
Inert gas shall contain not more than 2% oxygen for GTAW or GMAW of
Austenitic stainless steel.
Shielding and purging gases for GTAW welding of Ni alloys shall be in high
purity (99.99%) argon or helium.
PWHT:
No welding shall be performed after PWHT
Notes:
Except where specifically required by the governing code, or called for in the piping class for
process or other reason, PWHT is not generally required for carbon steel up to an including 19
mm thick.
Where specifically agreed in writing with IOCL, PWHT is not required for small bore(1.5” NS
and below)
socket welds performed using SFA-5.11 ENiCrFe-2 or SFA-5.14 ERNiCr-3 consumables.
PQR TESTING REQUIREMENT:
Test welds for carbon and low alloy steels shall be subject to a 10 Kg
Vickers hardness survey of the weld.
The maximum hardness shall not exceed 248 HV10.
Where ever the extent indicated is 10% this is defined as 100% examination
of 1 in 10 of those welds indicated.
NDE shall be performed within 48 hours after completion of each weld.
Root runs may be subject to 10% MPI or DPI at the discretion of the
responsible engineers.
RT:
All shop examination up to and including 25 mm total wall thickness shall
use X rays
For above 25 mm, Gamma rays shall be used.
Sensitivity shall be 2%.
Where ever radiography is impractical, ultrasonic examination may be used
in lieu of radiography.
NON DESTRUCTIVE EXAMINATION(NDE) AND TESTING
EXAMINATION CLASS:
All NDE shall follow the
Materials Examination Class(ASME Rating)
requirements of ASME B31.3 Class I(c) Class II Class III Class IV
Notes: Carbon 900 – 150 – - 150 (b)
a) This table is for information Steel 2500 600
only . Low alloy 150 – - - -
b) Non hazardous duties only steel 2500
(below 400⁰C)
Cement - - All -
c) Pipe in the following services lined C.S
Shall be treated as Class I
Austenitic 900 – 150 – - -
Disregarding the pressure S.S 2500 600
Rating
Cupro – 150 – - - -
Sulphuric acid Nickel 2500
SS pipe in cryogenic service Titanium 150 – - - -
Hydrogen service 2500
Chlorine service Duplex 150 – - - -
H₂S(Both wet and High S.S 2500
Temperature service) Nickel 150 – - - -
Cyclic and Amine service alloy 2500
EXTEND OF NDE
Examination Examination Applicable Butt Branch Fillet/Sock Attach-
Class methods materials welds welds et welds ment
welds
I Visual All 100 100 100 100
Radiography All 100 - (note b) NR
(note a)
Mag Particle CS,LAS 100(h 100(g, h) 100 100
Dye Aus S.S ) 100(g) 100 100
Penetrant Duplex S.S 100
& Non
ferrous
II Visual All 100 100 100 100
Radiography All 10 - 10(note b) NR
(note a)
Mag particle CS,Aus 10 10(g) 10 10
Dye S.S 10 10(g) 10 10
Penetrant S.S & Non
ferrous
III(note c) Visual CS 100 100 100 100
Mag particle CS NA NA 100 100
IV (note d) Visual All 100 100 100 100
Mag particle All (note e)
NA: Not Applicable NR: Not Required
NOTES:
Production macro – hardness values shall not exceed 200 BHN for carbon
steel welds or 225 BHN for alloy steel welds.
PRESSURE TESTING:
The chloride content of the hydro test water for austenitic stainless steels
shall not exceed 30 ppm and the hydro test temperature shall not exceed
50⁰C
Austenitic stainless steel weld subject to stress relief or service over 500⁰C,
shall be subjected to a minimum of 3 ferrite checks per weld.
With minimum of 1 ferrite check per 200 mm length of manual welds.
Ferrite levels shall be in the range of 3% to 10%.
Checking shall be performed before PWHT by using ``Ferritescope” or
``Permascope”.
REPAIRS
Repairs or not permitted for use on 300 series stainless steels or non –
ferrous alloys.
Unacceptable flaws found during NDE shall be repaired in accordance with
an approved repair procedure.
Material Max no of permitted
repair attempts per weld
CS ≤ 300# 3
CS > 300# 2
KCS 2
Low alloy steel 2
Austenitic S.S 2
3.5 % Ni steel 2
Others 2
RECORDS
Cupro-Nickel:
C7 0 6 00(90/10) SFA-5.6 ECuNi or 90/10 SFA-5.7 ERCuNi or 90/10
C71500(7 0/30) CuNi CuNi
SFA-5.6 ECuNi
Duplex S.S:
SFA 2205 Sandvick 22.9 3LR Sandvik 22.8.3L
Soudochrom 544 6 2 Metrode ER329N
Metrode 2.9.3LR
Ferralium Ferralium 225HB Metrode ER225Cu
Metrode 25.6.2 CuR
Notes:
c. Where specifically agreed in writing with IOCL, small bore(1.5” NS and below)
socket/fillet
welds, which will not be subject to PWHT, may be performed using SFA-5.11
ENiCrFe-2 or 3 or SFA-5.14 ERNiCr-3 consumables.
WELDING CONSUMABLES FOR DISSIMILAR METALS(d)
First base material Second base Consumable per ASME Part C
material
SMAW electrode GTAW or
GMAW wire
Low alloy steel Other low alloy steel Consumable to be selected per table 1
for carbon steel.
WELDING CONSUMABLES FOR DISSIMILAR METALS(d) Continue…
Carbon steel (f) Low alloy steel Consumable to be selected
as per table 1 for carbon
steel
Carbon steel or Austenitic 90/10 Cupro-Nickel SFA-5.11 SFA-5.14
S.S ENiCrFe-2 ERNiCr-3
Or
SFA-5.11
ENiCrFe-3
NOTES:
3 C-½Mo,Mn-Mo,Mn-Mo-Ni, T ≤ 13 10⁽³⁾
Mn-Mo-V 13 < T ≤ 25 75 315
25 < T ≤ 50 100
T>5 150
4 1Cr-½Mo, 1¼ Cr-½ Mo All 150 315
5A 2¼ Cr-1 Mo, 3Cr-1Mo
5B 5Cr-½Mo, 9Cr-1Mo All 200 315
NOTES:
Material and service Calculated elongation of outer fibre (e) Note (a)
e < 5% 5% < e < 10% < e e > 20%
10% <20%
Notes:
WELDING:
PREPARATION:
Any increase in heat input greater than 20% of the maximum reached during the
qualification.
Any change in backing gas conditions including gas composition, flow rate,
damming method or oxygen levels in backing gas enclosure outside those reached
during the qualification test
All welds in duplex stainless steel shall additionally be 100% examined by dye
penetrant method
ACCEPTANCE CRITERIA:
GENERAL:
Forming and bending of nickel alloys during fabrication shall be carried out at
or below 190⁰C.
Grinding wheels or discs shall be iron – free and shall not be organic resin
bonded.
Nickel alloys shall be heat treated to remove the effects of any cold working in
excess of 5% fiber strain, prior to welding.
WELDING:
GTAW shall be used for root runs.
SAW shall not be used, except for welding of heavy sections with prior
approval, when heat input shall be restricted at 4 K J/mm maximum.
Brazing is not permitted.
Autogenous welding is not permitted.
HEAT CONTROL:
Preheat shall not be used
Temperature of the joint surfaces shall not be less than 20⁰C before
commencement of welding
The inter pass temperature shall be 150⁰C maximum(except NO8825 –
120⁰C)
PWHT shall not be used.
SHIELDING AND BACKING GAS:
The flow rate shall be minimum 15 liters per minute.
INSPECTION:
Welded joints shall be 100% visually examined and 100% liquid penetrant
inspected.
Lack of root penetration in excess of 1.6 mm is not permitted.
APPENDIX C – FABRICATION SPECIFICATION FOR 9Cr 1MO V
LOW ALLOY STEEL
DRESSING AFTER THERMAL CUTTING:
The heat affected base metal shall be removed by grinding or machining
back the cut edge by at least 1.5 mm
WELDING:
Acceptable welding processes:
SMAW
GTAW
WELDING CONSUMABLES:
Low hydrogen SMAW consumables shall be dried and stored in ovens prior
to issue to ensure that they are capable of meeting a maximum hydrogen
level of 10ml H₂/100g
Electrodes shall only be issued for use in portable electrode ovens capable
of maintaining a temperature of 70⁰C minimum.
Consumables for which no identification exists shall not be used.
GTAW and SMAW consumables shall be procured against schedule J class
4 of AWS A5.01.
SHIELDING/PURGING GASES:
Shielding and purge gases shall comply with EN439 with respect to mixture
tolerances, purity and dew point.
Preheat and interpass temperature:
Minimum preheat temperature – 200⁰C
Maximum interpass temperature – 300⁰C
For 9 Cr – 1 Mo – V :
On completion the welds shall be maintained at 200⁰C – 400⁰C for 2 hrs
after welding.
Joint shall be allowed to cool below 100⁰C prior to receiving PWHT.
PWHT immediately after welding without this intermediate heat treatment
cycle is not permitted.
PQR TESTING REQUIREMENTS:
Test welds shall be subject to 10Kg Vickers hardness survey of the weld.
The maximum hardness shall not exceed 270 HV10.
For impact testing the test temperature shall not exceed 0⁰C and the energy
shall be 40J average and 34J average.
APPENDIX D – FABRICATION SPECIFICATION FOR CUPRO –
NICKEL ALLOYS
WELDING:
PREPARATION:
Material shall be cut by either cold sawing with sulphur – free lubricant or
plasma.
GTAW is used for root runs and GMAW may be used for capping runs on joints
of 5 mm or greater thickness.
SMAW electrodes shall be 3.25 mm or smaller diameter core size. Bead width
shall be restricted to four times electrode core diameter maximum.
FILLER MATERIALS:
All filler materials for cupro – nickel shall be nominal 70% copper/30% nickel
composition.
HEAT CONTROL:
Preheat shall not be used.
Interpass temperature shall be 150⁰C maximum.
PWHT shall not be used.
INSPECTION:
Welded joints shall be 100% visually examined and 100% liquid penetrant
inspected.