GENERAL REQUIREMENTS FOR

PIPEWORK FABRICATION

SCOPE

This standard specifies the requirements for welded

fabrication, inspection and testing of pressure and process
containing piping and all welded attachments to that piping.

MATERIALS

Carbon and Carbon Manganese Steels (C & C Mn )

Low Alloy Steels
Austenitic Stainless Steels (18 Cr 8 Ni)
Ferritic Stainless Steels
Cu Ni Alloys
Duplex Stainless Steels.

CODES AND STANDARDS

ASME B31.1 (Power Piping)

ASME B31.3 (Process Piping)
IBR Standard (Steam Service)
API RP 582 (Welding Guidelines for the Chemical, Oil, and Gas Industries)
ASME Section IX (Welding and Brazing Qualifications)
NACE MR 0103 & NACE RP 0472 (Sour Service)
API 941 (Hydrogen Service)
ES 24 (Pipe Fabrication Institute Standard)
ASME B16.25 (For Pipe length and butt weld fittings)

PROJECT SPECIFICATION:

PDRP 8230 SP 0001 (Pipe Class Index)

PDRP 8440 SP 0009 (Submission of welding and manufacturing
procedures)

WELD DESIGN
BUTT WELDS:

Spool pieces shall have excess 100 mm plain end length on one
component of the joint.

RADIAL MISALIGNMENT:

Thickness up to 15 mm - 1.5 mm is allowed.

Thickness greater than 15 mm - 2.5 mm is allowed.
Excess internal misalignment shall be corrected by machining pipe ends (It
should not reduce the required wall thickness)

FLANGES:

The distance from the flange face to the pipe end = the pipe wall thickness
+ 3 mm

DIMENSIONAL TOLERANCES:
Up to and
including(mm)

Nom pipe
size(inches)

(+/-)
Tolerances(mm)

250

10

3.2

900

36

4.8

1200

48

5.6

1500

60

6.4

1800

72

CUTTING AND WELD PREPARATION:

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:

Heat affected base metal shall be removed by grinding or

machining back the cut edge by at least 1.5 mm.
All thermally cut edges of low alloy steels shall be examined by
the magnetic particle method to demonstrate freedom from
cracks.

CLEANING PRIOR TO WELDING:

Minimum of 25 mm of adjacent material shall be thoroughly

cleaned of contaminants which could adversely affect weld
quality.
For Copper/Nickel and Nickel based alloys, the joint area shall
be scratch brushed using stainless steel wire brush.

WELDING
WELDING PROCEDURE SPECIFICATION (WPS):

All WPS shall be submitted for review by IOCL in accordance with PDRP
8840 SP 0009

WELDING PROCESSES:
Acceptable Welding Processes

SMAW or MMA (Shielded Metal Arc Welding or Manual Metal Arc)

GTAW or TIG (Gas Tungsten Arc Welding or Tungsten Inert Gas)
SAW (Submerged Arc Welding)
FCAW (Flux Cored Arc Welding)
GMAW (Gas Metal Arc Welding)

PROHIBITIONS:

In GTAW Arc ignition by touch start is prohibited. HF to be used

In FCAW self shielded is prohibited.
T 2 & T 5 type wires shall not be used for vertical up welding.
FCAW shall be limited to carbon steel and austenitic stainless steels.

JOINT DETAILS:
FULL PENETRATION WELDS:

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:

Backing Strips and EB type inserts are prohibited.

Vertical down welding is prohibited.
Peening is prohibited in all passes.

WELDING CONSUMABLES:

Welding consumables with the designation EXXT G or ERXXS G shall

not be used.

SHIELDING/ PURGE GASES:

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.

INTER PASS TEMPERATURES:

Low alloy and Ferritic Stainless steels 315C

Carbon steels 315C
Austenitic Stainless steel 175C
Nickel and Cu Ni alloys 175C
Duplex Stainless Steel 150C

Inter pass temperature should not fall below the specified preheat temperature
until the completion of not less than 30% of final weld depth.
Piping shall not be moved until at least 50% of final weld depth is complete.

PWHT:

No welding shall be performed after PWHT

Austenitic stainless steel shall not be Post Weld heat treated.

WELDING PROCEDURE QUALIFICATION

ESSENTIAL AND SUPPLEMENTARY ESSENTIAL VARIABLES:

An increase in the specified current range.

An increase in the maximum electrode diameter.
An increase in the width of weave or a change from string to weave bead
technique.
An increase in maximum interpass temperature above 250 C.
A change of SMAW electrode manufacturer or brand.
A change in consumable manufacturer and brand designation.

POST WELD HEAT TREATMENT(PWHT)

Material Type

Carbon Steel

Thickness
(mm)

Min Holding
Temperature
(C)

Time at Holding
Temperatures(Min)
Per mm

Minimum

Up to 19(a)
Over 19(a)

595
595

2.5
2.5

60
60

1 Cr 0.5 Mo
Or
1.25 Cr 0.5 Mo

All (b)

704

2.5

120

2.25 Cr Mo

All (b)

704

2.5

120

5 Cr 0.5 Mo
Or
9 Cr 1 Mo

All (b)

730

2.5

120

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.
NON DESTRUCTIVE EXAMINATION (NDE) AND TESTING
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

requirements of ASME B31.3
Notes:
a) This table is for information
only .
b) Non hazardous duties only
(below 400C)
c) Pipe in the following services
Shall be treated as Class I
Disregarding the pressure
Rating
) Sulphuric acid
) SS pipe in cryogenic service
) Hydrogen service
) Chlorine service
) HS(Both wet and High
Temperature service)
) Cyclic and Amine service

Materials

Examination Class(ASME Rating)

Class I(c)

Class II

Class III

Class IV

Carbon
Steel

900
2500

150
600

150 (b)

Low alloy
steel

150
2500

Cement
lined C.S

All

Austenitic
S.S

900
2500

150
600

Cupro
Nickel

150
2500

Titanium

150
2500

Duplex
S.S

150
2500

Nickel
alloy

150
2500

EXTEND OF NDE
Examination
Class

Examination
methods

Visual
Radiography
(note a)
Mag Particle
Dye
Penetrant

II

Visual
Radiography
(note a)
Mag particle
Dye
Penetrant

Applicable Butt
materials welds

Branch
welds

Fillet/Sock
et welds

Attachment
welds

All
All

100
100

100
-

100
(note b)

100
NR

CS,LAS
Aus S.S
Duplex S.S
& Non
ferrous

100(h
)
100

100(g, h)
100(g)

100
100

100
100

All
All

100
10

100
-

100
10(note b)

100
NR

CS,Aus
S.S
S.S & Non
ferrous

10
10

10(g)
10(g)

10
10

10
10

III(note c)

Visual
Mag particle

CS
CS

100
NA

100
NA

100
100

100
100

IV (note d)

Visual
Mag particle

All
All (note e)

100

100

100

100

NA: Not Applicable

NR: Not Required

NOTES:
a)As per 11.4.2 ultrasonic examination may be utilized when radiography is
inappropriate.
b)Radiography may be used to verify correct gap for socket welding.
c)Examination Class III is applicable to carbon steel concrete lined pipe.
d)Examination Class IV will not normally be used on pressure containing pipe work.
e)Fire water Services: 10% Radiography
Amine Services: 100% Radiography
Concrete lined site joints: Random radiography
f)Including seal welds of threaded joints
g)For branch welds, the required DPI/MPI shall apply to the root pass and final
pass.
h)For butt welds in carbon steel and any low alloy steel piping classes designated
for NACE MR 0103 duty, the MPI shall be:
a.The DC prod method permitted only for non-impact tested carbon steel piping
that is not subject to PWHT. Any arc strikes resulting from this method shall be dressed out.
b.All other material/service combinations shall use the electormagnetic AC yoke method.
c.MPI of welds shall include a minimum of 25 mm of base material either side of the weld
centerline.
If the extent indicated is 10%, this is defined as 100% examination of 1 in 10 of
)those welds indicated
)The first five production welds by each welder should be examined shall cover
)each pipe size

PRODUCTION HARDNESS TESTING:

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
50C

PRODUCTION ALLOY CHECK ANALYSIS:

Austenitic stainless steel weld subject to stress relief or service over 500 C,
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#

CS > 300#

KCS

Low alloy steel

Austenitic S.S

3.5 % Ni steel

Others

RECORDS

The contractor shall maintain accurate and up to date records of piping

fabrication for each isometric or contractors piping spool drawing.

TABLES

WELDING CONSUMABLES FOR SPECIFIC MATERIALS

Base material

Consumable classification per ASME II Part C

SMAW Electrode

Carbon steel

Low alloy steels:(c)

1.25 Cr 0.5 Mo
2.25 Cr 1 Mo
5 Cr 0.5 Mo
9 Cr 1 Mo

SFA 5.1 or 5.5 E7015/16 or 18(or SFA - 5.18 ER70S 3 or 6

SFA 5.1 E6010/11/12 or 13 up to
13 mm weld thickness, with out
notch toughness requirement)

SFA-5.5 E8016 or 18-B2

SFA-5.5 E9015/16 or 18-B2
SFA-5.4 E502-15 or 16
SFA-5.4 E505-15 or 16

Austenitic S.S:
Type 304(a)
Type 306(a)
Type 321 or 347(a)

GTAW or GMAW wire

SFA-5.28 ER80S-B2
SFA-5.28 ER90S-B3
SFA-5.9 ER502
SFA-5.9 ER505
(wires also for SAW)

SFA-5.4 E308-15 or 16(a)

SFA-5.4 E316-15 or 16(a)
SFA-5.4 E347-15 or 16(a)

SFA-5.9 ER308(a)
SFA-5.9 ER316(a)
SFA-5.9 ER347(a)

WELDING CONSUMABLES FOR SPECIFIC MATERIALS continue..

Nickel alloys:
N02200(Nickel 200) (b)
N04400(Monel 400) (b)
N06 6 00(Inconel 6 00) (b)
N06 6 25(Inconel 6 25) (b)
N08810(up to 900C)
(Incoloy 800H) (b)
N08810(Over 900C)
(Incoloy 800H) (b)
N08825(Incoloy 825) (b)
Cupro-Nickel:
C7 0 6 00(90/10)
C71500(7 0/30)
Duplex S.S:
SFA 2205
Ferralium

SFA-5.11 ENi-1
SFA-5.11 ENiCu-7
SFA-5.11 ENiCrFe-1 or 3
SFA-5.11 ENiCrMo-3
SFA-5.11 ENiCrMo-2

(wires also for SAW)

SFA-5.14 ERNi-1
SFA-5.14 ERNiCu-7
SFA- ERNiCr-3
SFA-5.14 ERNiCrMo-3
SFA-5.14 ERNiCr -3

SFA-5.11 ENiCrMo-3

SFA-5.14 ERNiCrMo-3

Incoloy 135 (b)

SFA-5.14 ErNiFeCr-1

SFA-5.6 ECuNi or 90/10

CuNi
SFA-5.6 ECuNi

SFA-5.7 ERCuNi or 90/10

CuNi

Sandvick 22.9 3LR

Soudochrom 544 6 2
Metrode 2.9.3LR
Ferralium 225HB
Metrode 25.6.2 CuR

Sandvik 22.8.3L
Metrode ER329N
Metrode ER225Cu

Notes:
a.

Where L or H grades, or other limits on composition are specified for 304,316,321 or

347 then the appropriate limits shall also apply to the welding consumables

b.

Trade name of the INCO group of companies

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
material

Consumable per ASME Part C

SMAW electrode

GTAW or
GMAW wire

Carbon
Or
low alloy
or
Ferritic S.S

Ferritic S.S
or
Austenitic S.S(e)
Or
Nickel alloys(e)

SFA-5.9 E309 (a)(b)

Or
SFA-5.11 ENiCrFe-2 (c)
Or
SFA-5.11 ENiCrFe-3(c)

SFA-5.9
ER309 (a) (b)
Or
SFA-5.14
ERNiCr-3(c)

Carbon steel

Nickel alloy N04400

SFA-5.11 ENiCu-7
Or
SFA-5.11 ENiCrFe-2
Or
SFA-5.11 ENiCrFe-3

SFA-5.11
ERNiCu-7
Or
SFA-5.14
ERNiCr-3

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

S.S

90/10 Cupro-Nickel

SFA-5.11
ENiCrFe-2
Or
SFA-5.11
ENiCrFe-3

SFA-5.14
ERNiCr-3

NOTES:
a)Type E310 or ER310 consumables are specifically prohibited.
b)Type E309 or ER309 consumables shall not be used on nickel alloys, neither shall they be used
for design temperatures exceeding 315 oC where the second base material is ferritic stainless steel.
c)When welds can be exposed to high temperature, sulphur bearing, reducing process conditions
these high nickel alloys shall not be used
d) Where dissimilar base materials have dissimilar PWHT requirements, the detail design, welding and
PWHT sequence shall be subject to agreement with IOCL. Specific requirements apply per (e) and
(f)below.
e) Welding austenitic stainless steels or nickel alloys to low alloy or carbon steels requiring
PWHT:"Butter low alloy or carbon steel with nominal 3mm weld metal before PWHT of low alloy or
carbon steel part(s).Complete weld to austenitic stainless steel or nickel alloy without further PWHT.
f) Welding carbon steels to low alloy steels:- "Butter" low alloy with nominal 3mm weld metal before
PWHT of low alloy part(s). Complete weld to carbon steel without further PWHT unless required for
carbon
steel.

MINIMUM PREHEAT AND MAXIMUM INTER PASS TEMPERATURE

P.No Material type

Nominal
thickness at
weld(mm)

Minimum
preheat
temperature(
C)

T 13
13 < T 25
25 < T 50
T >50

10
75
100
150

C-Mo,Mn-Mo,Mn-Mo-Ni,
Mn-Mo-V

T 13
13 < T 25
25 < T 50
T>5

10
75
100
150

1Cr-Mo, 1 Cr- Mo

All

150

315

5A
5B

2 Cr-1 Mo, 3Cr-1Mo

5Cr-Mo, 9Cr-1Mo

All

200

315

6&7

Ferritic and Martensitic S.S

All

Per code

Austenitic S.S

All

10

175

9A

2Ni, 3Ni

All

125

250

Carbon steel

Maximum
interpass
temperature(
C)

315

315

MINIMUM PREHEAT AND MAXIMUM INTER PASS TEMPERATURE continue..

P.No

Material type

Nominal
thickness at
weld(mm)

Minimum
preheat
temperature
(C)

Maximum inter
pass
temperature(
C)

11A
&
11B

Ni-Cr-Mo,Mn-Mo-Ni,
Ni-Cr-Mo-V

T 13
13 < T 25
T > 25

125
150
175

315

3435

Cu-base alloys

All

10

175

4145

Ni-base alloys

All

10

175

Notes:
1. Preheat temperatures are based on 8ml H2/100g weld metal hydrogen levels. Alternative preheat
temperatures may be calculated in accordance with EN 1011-2, in which case, the WPS and PQR shall show
all limiting factors such as combined thickness, CE value, weld metal hydrogen content and heat input or
run-out-length, upon which the preheat level is based.
2. Preheat requirements are based on conventional carbon steel with CE 0.45 and S > 0.01%.
Low sulphur steels (S 0.01%) may be at higher risk of HAZ hydrogen cold cracking than conventional
carbon steels and fabricator shall review the necessity of increasing the preheat temperature or lowering the
specified CE value for these steels based on fabricators experience.
3. Not required other than to remove moisture prior to welding.
4. Preheat temperature for martensitic type steels shall be 200C minimum but shall not exceed the martensite
finish (Mf) temperature to ensure no untransformed austenite is present during PWHT. The maximum
interpass temperature shall not exceed the preheat temperature by more than 100C.

HYDROGEN DIFFUSION HEAT TREATMENT LOW ALLOY STEELS

Thickness
(mm)

Holding time in hours

150C

200C

250C

300C

Up to 10

See note 1

Up to 20

Up to 30

Over 30

10

NOTES:
1.For thicknesses below 10mm the cooling from preheating to
ambient temperature shall be under an insulated cover.

POST BENDING HEAT TREATMENT FOR CARBON STEELS

Heat treatment
Material and service

Calculated elongation of outer fibre (e) Note (a)

e < 5%

5% < e <
10%

10% < e
<20%

e > 20%

Non- impact
tested(Sour service not
specified)

No heat treatment
required

No heat
treatment
required

SR

Non-impact tested
(Sour service not
specified)

No heat treatment
required

SR

SR

Impact tested(All
services)

No heat treatment
required

SR

Notes:
SR Stress relieve in accordance with Table 5 of this Standard.
N Normalize.
NOTE: a. 'e' shall be calculated by: e=t/2r : r=bend radius t=pipe O.D.

APPENDIX

APPENDIX A - FABRICATION
SPECIFICATION FOR DUPLEX STAINLESS
STEEL
GENERAL:

Fabrication of these materials shall be carried out in an area separate from

that used for carbon/low alloy steels and copper alloys.
Saws, grinders and other tools used on duplex stainless steel shall not be used on
other materials.
Bare carbon steel material is not acceptable.

WELDING:
PREPARATION:

Cutting shall be by cold sawing or plasma arc process.

All low melting point materials including copper, lead and zinc compounds shall be
removed from the fabrication
Due care and attention should be taken during installation and particularly
hook up where overspray of zinc containing coating must be avoided.

ESSENTIAL VARIABLES:

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

CORROSION TEST/ IMPACT TEST:

An impact test is the preferred option over the corrosion test.

INSPECTION AND TESTING:

All welds in duplex stainless steel shall additionally be 100% examined by dye
penetrant method

ACCEPTANCE CRITERIA:
The following features are unacceptable
Any cracks
Any lack of fusion or lack of penetration at the bore surface
Surface breaking porosity.

REPAIR:
One repair per weld is permitted.
If the repair contains unacceptable defects the complete weld shall be cut out
PIPE SUPPORTS:
Internal gas purging shall be required to prevent oxidation/discolouration while
welding directly on to the pressure retaining components of thin wall

APPENDIX B FABRICATION SPECIFICATION FOR

NICKEL ALLOYS
GENERAL:

Forming and bending of nickel alloys during fabrication shall be carried out at
or below 190C.
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 20 C before
commencement of welding
The inter pass temperature shall be 150C maximum(except NO8825 120 C)
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 H/100g
Electrodes shall only be issued for use in portable electrode ovens capable
of maintaining a temperature of 70C 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 200C
Maximum interpass temperature 300C
For 9 Cr 1 Mo V :
On completion the welds shall be maintained at 200 C 400 C for 2 hrs
after welding.
Joint shall be allowed to cool below 100C 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 0 C 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 150 C maximum.
PWHT shall not be used.
INSPECTION:
Welded joints shall be 100% visually examined and 100% liquid penetrant
inspected.