Carbon STEEL

LOW-C MED –C HIGH - C

0.01-0.3 0.3-0.6 0.6-1.4
Alloy steels

Low alloy (cs+ below 7% alloy) high alloy (cs+ above 7% alloy)

Alloy elements : chromium,nickel,molybdenum,niobium,vanadium,manghaneese

Effect of adding element

Aluminium- deoxidize agent

Carbon-increase hardness
Chromium-resist to oxidation
Mn-to control solidification crack
Sulpher- to control solidification crack, for machinability
Ni-corrosion resistant
Copper-weathering steel(corten) producing protective layer and no need paint

CEV:%c + %mn + % cr+mo+v + ni cu

6 5 15
Deoxidized steel
Deoxidized agent ad to molten metal to remove oxide content to decrease pore generation.
Deoxidized agent: Aluminium,Silica, Mn
- Killed steel - fully deoxidized steel, denoted by letter “K” ,pipe shrinkage ,for low
tem.service(A516)
- Semi killed steel A333
- Rimmed steel
- Capped steel
 Stainless STEEL

Martensitic Ferritic Austinic ( 12% cr) 18cr 8 ni Duplex above

20 % cr

P6 P7 P8 10H

 Weld decay- (reason-chromium carbide on weld grain Boundaries, pre- use low carbon materials
like 304L,314L,316L)
 Marker using on SS- low Halegon,Sulpher > 200 PPM
Chlorine > 50 PPM and lead free
 DUPLX(2205) - 22% CR , 5 %NI SUPER DUPLEX(2507) -25%CR,7%NI
 In DSS-use point count method to determine ferrite (30%-60%),hardness test, impact test(60J)
 DSS-high energy absorption, good weld ability,low thermal expansion ,good fatigue resistance
 Austenic only magnetic

MECHANICAL TEST AND PROPERTY

1. TOUGHNESS TEST OR IMPACT TEST(doing in subzero)
2. TENSILE TEST OR TENSION TEST (transvers tensile for procedure qualification and all weld
tensile for consumable strength)
3. HARDNESS TEST (VICKERS ROCKWELL BRINESS)
4. FRACTURE TEST (FILLET FRACTURE-FILLET NICK BRAKE - BUTT)
5. MACRO- for weld defects
6. MICRO – for grain size

MECHANICAL PROPERTIES
 tensile strength
 yield strength
 hardness
 % of elongation
 reduction area

FIT UP and WELD

VT
 24 inch minimum distance 500 lux light, HI-LO 1.5 mm,under cut-0.8mm,capping height-
3mm(1+0.25xbead width)
 Fillet size Z= 1.4 x A , A= 0.7 x Z
 6 mm base metal – 3mm size
6-12 - 5 mm
12-20 - 6 mm
Above20 - 8 mm
 Minimum distance between two weld is 3T or 20 mm
 Minimum25 mm needed to clean paint and all from the joint prior to welding
 Minimum 75 mm needed to preheat

JOINT PREPARATION
1. OPER SQUARE BUTT
2. SINGLE V ( 25 dig – 30 )
3. DOUBLE V
4. SINGLE U
5. DOUBLE U
6. SINGLE J
7. DOUBLE J
8. COMPOUND BUTT (for different thick)
TYPE OF WELD
1. BUTT WELD
2. FILLET WELD
3. SPOT WELD
4. PLUG WELD
5. EDGE WELD
TYPE OF JOINT
1. T JOINT
2. BUTT JOINT
3. LAP JOINT
4. OPER CORNER
5. CLOSED CORNER
HEATING
HEAT TREATMENT
1. ANNEALING (50 C upper critical temp. soft and ductile)
2. NORMALIZING (50 C upper critical temp. toughness and strength )
3. HARDENING (50 C upper critical temp. hardness and strength )
 4. TEMPERORING (after hardening )
PWHT
 Controlled tem. At 300 digree
 Soaking time 1 hr for 25mm , 2.5 x t = soaking time
 After50 mm ,add 15 minute extra .ex. 50 mm job- 2.15 hr
 Minimum Soaking time for cs 1 hr and for alloy 2hr
 For cs 620 +/- 20 for ss 720 +/- 20
 Heating and cooling rate for cs 150 dig and for alloy 100
 Up to 20 inch 2 TC
 P5, 9,11, 91,92,22,15E, sour,amine caustic services doing pwht, CEV more than 0.4 also
 P3 gr3 all thick
 All sour ,amine, caustic services need PWHT
 Changes in mechanical property, more times can do
HEAT INPUT – V X A X 1000 KJ/MM
TRAVEL SPEED in MM /SEC
 Heat input increase = tensile ,yield, hardness, cooling rate – decrease
Percentage of elongation increase, grain size increase
 Maximum heat input for CS is 3 KJ /mm
 Decrease in heat input not more than 10% in sour service and not more than 20% in other
service
PREHEAT
 Preheat using for to remove moisture from parent metal, it reduce cooling rate and produce
ductile structure and will help H to escape from metal which lead to reduce crack
 Preheat minimum for cs 10 digree to 55. Above 20 mm its 80 digree or carbon above 0 .30%
 Preheat for alloy up to 20 mm thick 75-100 digree
 3T or 75 mm distance minimum needed to preheat
INTERPASS TEM.
 Max inter pass for cs and alloy 315 digree
 Max. for ss is 177 digree
POST HEAT
 post heat for homogeneous structure
 reduce crack chances
 cs no need to post heat
 post heat tem. For alloys 300 digree
CRACK
H2 CRACK or DELAYED OR COLD CRACK
H2 induced crack, lie on 45 digree on weld or HAZ
  In 48-72 hrs
 Below 100 digree
 If hardness 350 and above
 If H2 more than 15 mlg
 Sulpher saturation more
 If CEV more
HOT OR SOLDIFICATION CRACK
 By strain on weld bead
 To reduce the crack, sulpher or Mn will add
 Low melting nonferrous metal gathering in center line
 Depth is 2 times of width is a reason
SHIELDING GAS
 Pure inert gas such as argon and helium only using for nonferrous metal
 Co2 have deep penetration but chance to oxide formation so mixing with argon
 Trailing gas used to shield the weld while welding ss,duplez,titanium alloys to prevent
oxidization
 Dew point to storage the gas is must be below 60 digree
ELECTRODE
electrode +ve (reverse polarity) and electrode – ve ( straight polarity) ,current = rod dia. X 40 (+/-
20),marking 2.5” apart from end
GTAW electrode – ve(DCEN) AC using only for Aluminium and Mg alloy to help to dissolve hazardous
oxide
Storage humidity should be 50%
In + pole side,70% heat generate other side 30%
5.1-carbonsteel
5.3-Aluminium
5.4-SS
5.5-Alloy
5.9-gtaw for ss
5.11-nickal electrode
5.18-GTAW
5.20/29-FCAW( E71 T-1)
BASIC ELECTRODE
 Low H2 electrode (need to bake)
 8mg H / 100 mg weld metal
 Allowable moisture 0.6 % below
 7018(F-4,A-1)
 70000= psi tensile strength,1 =position, 8 = H2 covering(5,6,8)
  Iron powder content,Calcium carbonate covering,Co2 shielding gas,rapid cooling rate
CELLULOSE ELECTRODE
 For root welding, high penetration
 Cellulose coating
 6010
 High H2 generation, shielding is H+CO

RUCTILE ELECTRODE
 6013
 covering titanium oxide, shielding gas Co2
 good for fillet,structure
BAKING
Baking oven-350 digree / hr (for ss 120- 250 digree)
Holding oven-150 digree /15 minit( below 6mm rod)
Portable or quiver-75 digree
 only 4 hrs can use after remove from oven
 only 2 time can bake

REPAIR
 Repair can be done with separate repair procedure
 Repair can be done by arc gouging and grinding for ferrous and machining and grinding for
nonferrous
 After repair 50 mm need to inspect
 Partial penetration repair not to exceed 30% of weld length and full penetration repair not to
exceed 20% of weld length
 Percentage of repair= total length weld repaired in a week / total length radiographed x 100
PREWELDING DOCUMENTS
1. Quality plan
2. ITP
3. Weld map
4. Approved WPS,PQR,preheat procedure,PWHT procedure,repair procedure,consumable
handling procedure
5. Welder qualification register,id card
6. List of NDT tech,certificates,caliberation cetificates,batch certificates
7. Consumable test certificate, batch certificates
8. Mill certificate
9. Equipment calibration certificates
 MATERIALS

P METAL FORM ELEMENTS PROPERTIES ELECTRODE

NUNBE
R
P-1 ASTM 36 CS plate 7018,6010 70-
S-6
P-1 ASTM 53 CS pipe low tem., impact test 7018,6010 70-
at -45 , utility S-6
services
P-1 ASTM CS pipe high pres. tem. 7018,6010 70-
106 Services, seamless S-6
pipe
API 5L CS pipe 7018,6010 70-
GrB S-6
P-1 ASTM CS pipe Low tem.
333
Gr1/6
P-11 ASTM Nickal alloy 9 Ni E-Nicrfe-3
333 pipe
Gr3/8
P-43 INCONEL Nickal alloy Ni more than 50% E-Nicrfe-3
625 structure
P-11 ASTM alloy 1 ¼ cr High temp E-8018
335 1/2 mol
P-91 ASTM alloy 9cr 1 mol High temp. up to 600 E-9018 ER-
335 preheat-200-250 90-
,pwht-750 -2 hr , S-B3
150/hr,ss wire
brush,wide joint
angle
P-9 ASTM alloy 9cr 1 mol High temp E-505 ER-
335 505
275 JR CS structure E-71-T-1
P-10 H 2205 DSS Fer+Aust(50/50) E-2205
P-10 H 2507 SDSS E-2507
A515 Plate(LTCS)
A516 Plate killed
steel
 P8 304 SS pipe 308

MATERIAL INSPECTION
1. MTO (material take off-quantity,type,grade,weight)
2. Drawing
3. Check list
4. Mill certificate
5. Color code
6. Delivery note
7. Purchase order
RT
2 2
UG= Fd/D were F = focal sizes (sqr root of A + B ) , d = dia of pipe ,D = distance from source to
material
UG= up to 50 mm thick 0.51 and 50-76 mm ug is 0.76
Density
Darkness of image ,for gamma =2 %, ‘X ‘ray 1.8% max -4
Sensitivity
Ability show smallest discontinuity. Visible wire/ job thick x 100
Job thick= wall thick + reinforcement , for double wall, both thick needed to add
Film contrast
Density different of 2 adjacent areas .combination of film contrast and subject contrast.subject
contrast means factor which affect contrast from pipe.film contrast which effect contrast from film.
Film
D7(AA400) ,D4(MX125)
LPT
 After cleaning,need to allow the surface minimum5 minit to get dry
 Surface temp. 5-52
 Dwell time for penetrant 5 mint and for developing 10 monit
 Light minimum need 1000 lux
 Rounded indication 5mm,all linier indication rejected, relevant indication 1.6
 Length is 3 times of width called linier indication
 Length is below 3 times of width called rounded indication
MPI
 DC and permanent yoke can pull 18 kg and AC yoke can pull 4.5 kg
 To check sensitivity Burmacastro strips are using and for to check field, field indicators are using
 Up to 4 mm depth
 AC surface and DC for subsurface
  Pole spacing 3-8 inch
 Ferrous,ni,cobalt can do MPI
PMI
 Only alloy element not carbon
 PMI for CS not possible
HARDNESS
Materials resistance to penetration.an indenter is pressed on surface by specific load with in time
interval. that value is hardness.
 Maximum 325HV
 250 for sour service and low tem steels

VALVES
 Valves are classified as 4. Isolation,regulation,nonreturn,special purpose
 Up to 6 inch dia ,valves are covered with UV plastic cover and above 6 inch ,covered with
plywood
 Spectacle flange using to blind the pipe line.
WQT & PQR Sec IX
MECHANICAL TEST
Less than 10 mm - VT+FB+RB
10-19 - VT+2SB or FB+RB
19-…. - VT+2SB or FB+RB
PIPE DIA
Less that 1” - size welded to above all
1” - 2.5 - 1” to above all
2.5” above - 2.5” to above all
THICKNESS
T-2T
13 mm - to maximum welded
FILLET
Below 5 mm - T -2T - fracture and macro
Above 5 mm - maximum thick - fracture and macro
 Minimum 150 mm length need to qualify
 VT+Mechanical or VT+ NDT
 Thickness of weld metal means weld deposited by welder exclusive reinforcement
 Tack welder need to qualify by same as welder test or 6 mm size 50 mm length with fracture
and VT
 Plate test piece will be qualified to pipe 24 inch and above
 Expiry of qualification is 6 month
  Essential variables-deletion of backing,pipe dia,P ,F number,thickness of weld,position
 In GTAW ,above all and delition in backing gas,current and polarity
PQR

Below 1.5 mm T-2T TENSION 2 2FB 2 RB

1.5-10mm 1.5-2T TENSION 2 2FB 2 RB
10-19 mm 5-2T TENSION 2 4 SB or 2FB 2 RB
 Qualification of fillet welding can achieve by groove test coupon also
 WPS foe dissimilar base metal thick ,shall be consider thinner member’s thick for range
calculation
 Essential variables-which effect mechanical property and need re-qualify to make changes in
WPS
 Nonessential variables –which not effect mechanical property and no need to re-qualify for
changes
 Supplementary variables-which effect impact property and if impact tect not required,it will
classed as nonessential
 Essential-base metal thick,P,F,A number.filler wire below 6 mm dia,preheat decresing below 55
digree,changes in PWHT
 Supplementary-base metal group number,preheat increase above 55 digree.fillerwire dia
above 6 mm ,tem. And time range changes in PWHT,heat input,current polarity .from any
position to vertical uphill
 Nonessential-joint design,root gap,filler classification,current and polarity.
WQT AWS D1.1
PIPE
Below 4 “ any thick ¾”-4” 3-20 mm
Above 4” up to 10 mm half of test coupon or 4” - unlimited 3-20mm
Above 4” above 10 mm half of test coupon or 4” - unlimited 5-unlimited
PLATE
Up to 10 mm 3-20mm
10- 25 3-2T
25 above 3-unlimited

PRESSURE TEST
TIGHTNESS TEST-to ensure tightness of piping system
SHELL TEST - by exceeding pressure than CWP
SERVICE TEST - testing by working pressure and fluid
CLOSSURE TEST-valve test by closure mechanism
HYDRO TEST - by rising 1.5 x system pressure
PNEMATICTEST – by rising 1.1 x system pressure
 CWP means pressure rate in ambient temperature
 Allowed chlorine content for hydro test 250 ppm for cs and alloy 50 ppm for SS
 Water needed ƛ/4 D2x L
 Punch list for hydro test include unfinished items according to drawing before test. category A-
before hydro test ,B- after hydro test
 PSV(pre.safety valve ) set above 5% of test pre.
 Range 30-80 % above test pre.
 One gauge at manifold and second one in system line .manifold 100% RT

STANDARDS
ASME SEC I-construction of power boiler
ASME SEC II-A-ferrous
B-nonferrous
C-filler
D-property
ASME SECIII –construction of nuclear components and facilities
ASME SEC IV – construction of heating boiler
ASME SEC V- NDT
ASME SEC VI- operation and maintenance of heating boiler
ASME SEC VII- operation and maintenance of power boiler
ASME SEC VIII- rules for construction of pressure vessel

DIV -1 appendix 4 – rounded indication

DIV -1 appendix 6- MPT
DIV -1 appendix 8- LPT
DIV -1 appendix 12-UT
ASME SEC IX – qualifications
ASME SEC X – plastic reinforced pressure vessel
ASME SEC XI – in service inspection of nuclear components and facilities
ASME SEC XII – construction of transportation tank

ASME B 31.1 – power piping

ASME B 31.2 – fuel and gas piping
ASME B 31.3 – process piping
ASME B31.4 –transportation of liquid and hydro carbon
ASME B 31.5-refrigerent piping
ASME B 31.8- transportation of gas
ASME B 31.9- building service piping
ASME B 31.11 slurry transportation

ASME B 16.1 cast iron flange

ASME B16.5 below 24 “ cs flange
ASME B16.47 above 24” cs flange

ASME B 16.10 face to face end to end valve

ASME B16.34 cs valve

ASME B 36.10 – cs pipe

ASME B -36.19 SS pipe

AWS D1.1- structure welding

AWS B2.1 -material grouping
AWS A2.4- weld symbol

API 1104-welding of pipe line and related facility

API 598 – valve inspection
API 6D – valve inspection
API 650-tank
API 570 – piping

BS 7570- qualification and calibration of welding equipment

B1.20.1 –threading
PFI-22 - pipe color code

RUST
Grade A- surface covered with mill scale
Grade B-mill scale and begun to flake
Grade C- slight pitting visible
Grade D- heavy pitting
QC DATA
 Width of weld bead SMAW = 3 x dia of electrode
 GTAW = 10 mm
 Number of passes = 3 or 1/3 of thick
 Up to 12” nominal dia means ID and above 12 “ is OD
 Weight of CS = volume x density ,density of steel = 7.8 g/cm3 or 8k kg/ m3
 Ohms law states that current is directly proportional to voltage and inversely proportional to
resistance
 CS welder can weld ss but not vise versa
 Wind allowed at site is 5 miles per hr
 AC TIG welding using for aluminium alloy because to dissolve harmful oxides
 Tungsten extension too high –tung. Inclusion and too low – unstable arc
 Electrode extension should be 2-3 times of electrode dia
 For TIG welding DCEN and SMAW DCEP
 Hard facing using to deposit thick metal coating to prevent wear
 Buttering using to make up or adding metal to achieve correct dimension before start welding
 Spectacle flange using to blind the pipe line for shut down or pressure test
 Failure in piping systems are fatigue and catastrophic failure
 Minimum tack weld up to 4” dia is 3 nos and above 4” dia is 4 nos
 Back purging will reduce O2 level up to 1% in alloy and for SS 0.05 %
 Schedule Q means company’s contractors minimum quality syatem
 Welding point of steel is 2780 F
 Chromium is SS is 12% and for Duplex above 20%
 Category D fluid –line carrying nonflammable and toxic ,pre. Up to 150 psi,tem.180 digree
 Category M fluid – line carrying highly flammable and toxic by a single exposure
 Cryogenic service means low temperature services
 Sour services means line under presents of H2s .H2s will act with low ph liquid and water and
allow to H to escape which leads to H2 crack.
 Minimum distance between two welding is 20 mm or 3T
 Up to 425 digree cs using and above 425 alloy using
 For WPS parameter range calculation is by 10 % +/- of average parameter value
 Yield strength is defined that material’s maximum strength before deforming permanently to
plastic stage
 Yield point is the value where a metal transforming from elastic to plastic
 Tensile strength means material’s maximum strength before it failure
 P number implemented for to reduce number of welding and brazing procedure by numbering
same chemical, mechanical and weld ability characteristics
 F number assigned for grouping of filler wires which have same chemical composition and
characteristics
 For purging,argon can use with 12-15 LPM
 Heat input for CS and alloy 3 KJ/mm
 SFA is universal classification for filler metal
 Group number used only for impact test requirements of ferrous metal
 Grade A,B,C . C have high carbon ,high hardness and tension but low ductility.
 Above 6 mm thick metal only do punching
UNITS
 1K lux = 92 foot candles (candle place 1 ft apart)
 1 micro meter = 1mm/1k
 1 micrometer = 0.04 mils
 Least count of vernier is 0.1
 Least count of micrometer or screw gauge is 0.01
 1 bar = 14.5 psi or 1 kg/cm2
 F to C = (F-32)x.5 0.5 means 5/9
 PPM= 1 X 106
 Tie joint-where new line connect to exist line(instead of hydro test , can do RT)