Professional Documents
Culture Documents
DOCUMENT TITLE :
REV.
XXX-P-PR-002
EFFECTIVE DATE
Table of Contents
1.
2.
3.
4.
4.1
4.2
4.3
4.4
5.
6.
6.1
6.2
6.3
6.4
7.
7.1
7.2
7.3
7.4
8.
SCOPE
DEFINITIONS
REFERENCES
WELDING PROCEDURE AND PROCEDURE QUALIFICATION
General
Documentation of WPSs and PQRs
General Welding Requirements for Piping
Welding Requirements for Specific Materials
WELDING RODS AND ELECTRODES
WELDER PERFORMANCE QUALIFICATION TEST
General
Classification of Welders
Required Test and Acceptance Criteria
Records of Tests.
QUALITY CONTROL
General
Quality Control Procedures
Supporting Procedures
Inspection and Test
APPENDIXES.
REVISION RECORDS
REV.
DATE
DESCRIPTION
Ars
DISTRIBUTION
1.
2.
Contractor/Owner
Project Managers
3.
Site Managers
4.
File ( DCC )
ORIGINATOR REVIEWED
BY
REMARKS
APPROVED
BY
SCOPE
This specification covers the requirements for welding procedures, welding procedure and
welder.
Performance qualifications and the minimum quality control/inspection requirements for piping
welding.
This specification applies to piping welding work at the jobsite, as well as any prefabrication
shop(s), on-site or off-site, including piping welding as part of packaged equipment.
2.1.1.1.1.1.1.1.1.
DEFINIT
IONS
Contractor
Owner
Migas
:
:
:
2.1.1.1.1.1.1.1.2.
REFERE
NCES
The requirements contained in the latest edition as of March 2009 of the following publications
shall form a part of this specification, unless a different edition is specified in the individual
datasheets, drawing or specification
-
ASME Sec. IX
ASME B31.1
: Power Piping
ASME B31.3
: Process Piping
ASME B31.9
: Building Piping
arsil
Aaa
11/12/16 lh\
2.1.1.1.1.1.1.1.3.
WELDIN
G
PROCED
URE
AND
PROCED
URE
QUALIFI
CATION
4.1 General.
(1) In principle, welding procedures for piping using manual welding process (GTAW and/or SMAW
process) shall comply with Appendix-1 Outline of Recommended Welding Procedures for
Piping herein.
Detailed Welding Procedure Specifications (WPSs) and supporting Procedure
Qualification
Records
(PQRs) for piping shall be prepared by Supplier in accordance with the
requirements of local
Regulation applicable Code and this specification
Contractor shall submit WPSs and PQRs to Owner for review and approval prior
to commencing of any production welding.
(2) If Contractor intends to use manual welding procedures other than those specified in Appendix-1
herein or welding procedures for other piping materials not listen in Appendix-1 herein, Supplier
shall submit such welding procedures to Owner for review and approval. Supporting technical
data and/or evidence of previous satisfactory application shall also be submitted to Owner when
so requested.
(3) The use of semi-automatic or automatic FCAW/GTAW/GMAW/SAW process for piping welding
are acceptable at piping fabrication shop only within the limitation imposed in XXX-P-PR-001
and the provision of the specific approval of Owner. Contractor shall submit satisfactory previous
experience, limitation on material, pipe size, thickness, welding position, etc. and quality control
method for Owner satisfaction.
(4) PQRs for previous jobs are acceptable provided that the contents of WPSs/PQRs satisfy all the
requirements of this specification except that the following WPSs shall require new qualification
at the jobsite or Contractor fabrication shop.
a) When an impact test is required, e.g., WPSs for low temperature carbon steels and austenitic
stainless steels in cryogenic service. Welding procedure qualification test shall be carried out
using exactly the same manufacturer and trade name of welding consumables to be used for
production welds. And the welding parameters shall be monitored by using proper equipment
such as electronic portable monitoring equipment.
arsil
Aaa
11/12/16 lh\
The required weld size for branch connections, sockets, flanged connections and other
pressure- retaining welds shall comply with the requirements of applicable piping code. The
fillet weld size for support welds, etc., shall comply with the applicable piping standard
drawings approved by Owner
(3) The edge preparation and root gap for girth butt welds and branch connection welds shall
comply with the requirements/recommendations of applicable piping code and the approved
WPS.
(4) For butt welding of pipe sizes 2 inch NPS and smaller, the GTAW process shall be used for all
passes of the complete weld.
(5) All pressure-retaining welds shall be made by multilayer welding (at least two layers)
regardless of pipe size, thickness and joint/weld type (butt, branch, socket or fillet). If it is not
practical for small bore piping, the GTAW process with a minimum two layers shall be used.
(6) All welding shall be uphill for the vertical position unless otherwise approved by Owner for
pipeline welding.
arsil
Aaa
11/12/16 lh\
(7)
Impact test requirements shall comply with the applicable piping code. In addition,
manufacturer and trade names of welding consumables shall be the essential variable for
procedure qualification when an impact test is required .
(8)
PWHT requirements for carbon and low alloy steels shall comply Subsection 4.4 and
Appendix-1 herein.
(9)
Hardness test requirements for welding procedure qualification and production weld shall
comply with Subsection 4.4 herein.
(10)
Front weld of slip-on flange shall be carefully done so that the flange face is not
damaged.
(11)
If a threaded joint need seal welding, it shall be made up without compound or seal tape,
from outside, back-gouge or back-grind from inside and back weld from inside, is acceptable
provided that all weld slag is removed and pipe internal is thoroughly cleaned .
(4) Electrodes for the SMAW process shall be low-hydrogen types for all pressure-retaining parts of
piping except for the root pass of girth butt welds and branch connection welds described in (2)
above.
(5) The GTAW process (minimum of 2 layers) shall be used for socket welds unless otherwise
approved by Owner.
(6) Welding of carbon steel and low-temperature carbon steel piping shall required preheating at a
minimum 10C or as per Manufactures recommendation and it with a wall thickness 25.4mm or
greater shall require preheating at a minimum 80C.
(7) PWHT shall be applied either when required by applicable piping code or when required for
process reason, such as for piping in wet H2S (sour), amine or caustic service, as specified in the
applicable Project Specification and the piping service class. PWHT condition shall be those
specified in piping code and Appendix-1 herein, with a minimum holding time of one hour.
arsil
Aaa
11/12/16 lh\
When PWHT is required for process reason, PWHT shall be required for not only pressure
retaining welds but also for attachment welds to the pressure parts.
(8) Each PQR for carbon steel piping in wet H2S (sour including lean and rich amine) service shall
include a hardness survey as per requirement of XXX-P-PR-001. The maximum Brinell hardness
of production welds (on the deposited weld metal) in these shall be 200BHN.
4.4.2 Welding of C-1/2Mo and Cr-Mo Low-Alloy Steels (P. No. 3, 4 5A & 5B)
(1) Root pass of girth butt welds and branch connection weld shall be made the GTAW process. For
Cr-Mo low-alloy steels, the root and second layers shall be made by GTAW process.
(2) Internal gas purging with an inert gas shall be required for the GTAW root run of a butt/ branch
connection weld of 2-1/4Cr-1Mo and higher grade alloys. The gas purging shall be maintained
and monitored until the second weld layer is completed.
(3) Electrodes for the SMAW process shall be the low-hydrogen types for all pressure-retaining
welds and attachment welds to the pressure-retaining parts of piping.
(4) The GTAW process (minimum of 2 layers) shall be used for socket weld.
(5) Preheating shall be as bellow:
a) P No.3: minimum 100 C regardless of thickness
b) P No.4: minimum 150 C regardless of thickness
c) P No.5A and 5B : minimum 200 C regardless of thickness
Only for root and/or second layer made by the GTAW process, the preheat temperature may be
lowered to a minimum 100 C for P No.4 and 5A (up to 2-1/4Cr-1Mo) materials and to a
minimum 150 C for P No.5B (5Cr-1/2Mo, 9Cr-1Mo) materials.
The required preheat temperature shall be maintained until the weld is completed.
(6) In principle, all welding shall be completed without interruption. And immediately after
completion of Cr-Mo (P No.4, 5A & 5B) welding, de-hydrogenation post-heating by using
resistance heaters shall be applied as per requirements XXX-P-PR-001. This post-heating shall
be also be applied immediately after interruption of the welding when the welding is unavoidably
interrupted.
(7) Appropriate preheating and post-heating methods shall be employed to maintain the required
temperature. Oxy-acetylene cutting torches shall not be used for preheating and post-heating.
Preheating and Post-heating temperature shall be checked by temperature indicating crayons,
thermocouples, or other suitable means.
(8) PWHT of low alloy welds shall comply with the code requirement except as follows:
a) For P No. 3 and P No. 4 welds in sour or hydrogen service and all P No.5A/5B welds, PWHT
shall be required regardless of thickness.
arsil
Aaa
11/12/16 lh\
b) Exemption of PWHT for ferritic materials based on the use of austenitic stainless steel or
nickel-based filler materials is not permitted unless specifically approved by Owner.
The PWHT conditions shall be as specified in piping code and Appendix-1 herein
(9) The production weld hardness on the deposited weld metal and HAZ after PWHT shall satisfy
the maximum value of 225BHN for P No. 3 and 4, and 235BHN for P No.5A/5B respectively.
4.4.4 The Welding of High-Nickel Alloys (such as Incoloy 800, 825, Inconel 600, 625,
Monel, etc)
The same requirement for austenitic stainless steels shall apply to the welding of highnickel alloys. In addition:
(1) To avoid hot cracking, the weld area and adjacent area within 30mm of each side of the weld
shall be cleaned prior to welding. Acetone or an equivalent cleaning solvent should be used for
cleaning.
(2) Maximum inter pass temperature shall be 150 C or as per Manufacturers recommendation.
(3) All weld craters shall be ground off to eliminate possible crater cracks or pinholes .
Aaa
11/12/16 lh\
arsil
Aaa
11/12/16 lh\
(1) All welders engaged in the welding work shall be qualified in accordance with ASME Sec. IX
and the requirements herein and shall be approved by Owner prior to commencing any welding
work.
(2) All welders shall be newly qualified except when welders hold a valid welder certificate and it
is specifically reviewed and approved by Owner.
(3) Standard welder test procedure and each qualified range shall be prepared by Contractor and
agreed by Owner prior to commencement of welder qualification test.
(4) The requirements in Subsection 5.2 and 5.3 are for manual welders using GTAW or SMAW or
combination thereof. For semi-automatic welding operator qualification, Contractor shall
propose the detailed test procedure and approved by Owner.
Separate qualification tests shall be conducted for Carbon Steel piping welders, Cr-Mo Low Alloy
Steel piping welders and Stainless Steel piping welders. These qualifications are not
interchangeable, even if the F. No. of ASME Section IX is the same. The qualification test for
Special Alloy piping welders shall comply with ASME Section IX.
Conspicuous identification is required for each class of welders for the purpose of avoiding weld
by a wrong class welder.
arsil
Aaa
11/12/16 lh\
During and after welding, each welders skill, technique and appearance of their weld beads
shall be checked carefully. External weld reinforcement and internal protrusion shall be fused
with and shall be merged smoothly into the component surfaces. Cracks, incomplete
penetration, surface porosity, exposed slag inclusion and undercutting (over 0.5mm dept) are
unacceptable.
(2) Radiographic Examination
Radiographic examination shall comply with QW-302.2 of ASME Sec. IX and acceptance
criteria per QW-191.
7. QUALITY CONTROL
7.1 General
Contractor is wholly responsible for the quality of welding. To achieve and maintain the required
quality level as specified by the contract throughout the construction period, Contractor shall
establish an adequate quality control system, including the necessary quality control procedure(s)
and supporting procedure(s). Such system and procedures shall be subject to review and approval
by Owner before Contractor commences any piping work.
arsil
Aaa
11/12/16 lh\
(4) Specified quality control and inspection records or reports shall be prepared, approved,
Welding consumables control during storage, at fabrication shop and at site including
identification method of consumables, especially that have close chemistry.
Weld joint numbering system on each ISO Drawing. or spool Drawing for recording of welder
identities and all the welding inspection results, including visual inspection/NDE/PMI/PWHT.
Marking each production weld with the joint number, welder identity and indication that visual
inspection is complete. (Note that hard die-stamping shall not be used on low temperature
service piping.)
Procedure for instructing welders of the correct WPS to be used for a specific weld joint.
(Especially for piping other than carbon steel piping).
Weld QC monitoring before, during and after welding, covering such precautions as protecting
welds from detrimental weather conditions such as wind or rain (including at the time of weld
interruption), condition of welding machines and cables, scaffolding, baking/handling and
correct usage of weld consumables, fit-up check including root gap/miss-alignment,
preheating, post heating, etc.
Procedure for release to pressure test of a piping system including documentation of a test
package, i.e., :
Checking satisfactory completion of all welding work and required welding inspections/
PWHT. (Summary/check sheet for the welding inspection results for each weld is
required.)
Aaa
11/12/16 lh\
Defects that are outside the limits of the codes, project specifications or other requirements shall be
cause rejection and Contractor shall take such remedial action as is necessary to secure acceptance
and shall be at sole expense of Contractor.
arsil
Aaa
11/12/16 lh\
8. APPENDIX
Appendix-1
Appendix 2
WELD TYPE
GW: Groove Weld (for butt & branch connection welds)
SW: Socket Weld
FW: Fillet Weld
(2)
arsil
Aaa
11/12/16 lh\
(3)
WELDING PROCESS
SMAW: Shielded Metal Arc Welding
GTAW: Gas Tungsten Arc Welding
(4)
When the ambient temperature is below 100 C, preheat to at least hand-warm (min.10 C) or
the specified preheat temperature, whichever is higher.
(5)
(6)
(A)
Groove weld (butt and branch connection welds) for pressure parts
(B)
(C)
Fillet welds between pressure parts and non-pressure parts, such as attachment welds for pad
plates, supports, and pipe shoes attached to run pipe.
(7)
Trade name TGS-50 (AWS A5.18, ER70S-G, KOBE STEEL LTD.) is also acceptable for
GTAW of carbon steel.
(8)
GTAW process is mandatory for butt welds in 2 inch NPS or smaller piping.
(9)
Trade name TGS-1N (KOBE STEEL LTD.) is also acceptable for GTAW of low-temperature
carbon steel piping down to 50 C. AWS ER70S-6 with certified impact test result of 27J at
46 C per each heat by manufacturer and with a maximum limitation of 1.40% on Mn may be
used. Other Ni containing low-temperature carbon steel GTAW wire (Ni content to
approximate max.1%) may be used subject to approval.
(10)
Trade name LB52NS (AWS A5.5, E7016-G, KOBE STEEL LTD.) is also acceptable and
recommended for SMAW of low-temperature carbon steel piping down to 50 C.
Other Ni containing low-temperature carbon steel SMAW electrode (Ni content to approximate
max.1%) may be used subject to approval.
(11)
When low-temperature and wet H2S (sour) service is specified for the same piping, the
maximum nickel content of the filler metal shall be 1%.
(12)
When AWS EXX16-XX is specified, EXX15-XX or EXX18-XX (low hydrogen type) is also
acceptable.
arsil
Aaa
11/12/16 lh\
(13)
Preheat temperature may be lowered to minimum 100 C for GTAW root and second passes.
(14)
(15)
(16)
Welding consumable shall be selected for each type of austenitic stainless steel as follows:
BASE METAL
Type 304 a), b)
304L
304H
316 b)
316L
321
GTAW
SMAW
(AWS Class)
ER308 c)
ER308L
ER308H c)
ER316 c)
ER316
ER347 c)
(AWS Class)
E308-15,16 c)
E308-15,16 d)
E308H-15,16 c)
E316-15,16 c)
E316L-15,16 d)
E347-15,16 c)
When a minimum carbon content of 0.04% is specified for Type 304 SS piping for high
temperature service, the minimum carbon content of E/ER308 weld consumables shall be
0.04% or alternatively E/ER308H may be used.
b)
When Type 304 or Type 316 SS piping is used in cryogenic service, low carbon grade E/ER
308L or E/ER 316L shall be used. See also Note d) below.
c)
When PWHT is specified or the design temperature is above 550 C, ferrite content of weld
consumables shall be 3-10% (3FN-10FN). The ferrite content shall be checked for each
heat/lot of welding consumables by chemical analysis using Delong or WRC Delta Ferrite
Diagram.
arsil
Aaa
11/12/16 lh\
d)
For cryogenic service temperature of below 101 C down to 196 C, each heat/lot of SMAW
electrodes (except for GTAW rods) shall be impact tested and shall satisfy the impact test
requirements of ASME B31.3 at 196 C.
(17)
(18)
Contractor shall select the welding consumables to be overmatching weld metal tensile
properties with base material.
1
Carbon Steel
Non-Low
Low
Temperature Temperature
Service
Service
(down to
-46C)
A
B+D
A
B+D
A
C+E
A
C+E
C+E
C+E
4, 5A, 5B
Cr-Mo Low
Alloy
1Cr-0.5Mo to
9Cr-1Mo
C+F
C+F
C+F
C+F
C+F
8
Austenitic Stainless Steel
NonCryogenic
Service
Cryogenic
Service (-46C
to -196C)
B+D
B+D
B+D
C+E
C+E
B+F
C+F
C+F
C+F
C+F
Legend
arsil
Aaa
11/12/16 lh\
A: 5% Random RT, i.e. Entire circumference of one weld out of every twenty welds shall be examined.
(Applicable to circumferential butt and miter welds.)
B: 10% Random RT, i.e. Entire circumference of one weld out of every ten welds shall be examined.
(Applicable to circumferential butt and miter welds.)
C: 100% RT for all circumferential butt and miter welds.
D: 10% MT or PT for pressure retaining welds except circumferential butt and miter welds, i.e., branch
connection, socket and other fillet welds.
E: 100% MT or PT for all pressure retaining welds except circumferential butt and miter welds, i.e., all
branch connection, socket and other fillet welds
F: 100% MT or PT for all pressure retaining welds including all circumferential butt and miter welds, all
branch connection, socket and other fillet welds. In addition, for Cr-Mo Low Alloy piping, all attachment
welds to pressure parts shall also be 100% MT examined.
arsil
Aaa
11/12/16 lh\
arsil
Aaa
11/12/16 lh\