JERES-W-010 Welding Requirements for Pressure Vessels

JERES-W-010 Welding Requirement for Pressure Vessels

Revision 2

Responsibility JER Engineering Division

11 February 2009

Jubail Export Refinery Engineering Standard


JERES-W-010 Rev 2 Welding Requirement for Pressure Vessels 11 February 2009

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

of 67

Revision Tracking

Revision Revision Date Scope of Revision

2 11 February 2009 Updated to revise paragraph: 8.6.4, and 15.1

2A 26 January 2009 Updated to revise paragraph 6.4.2.2, 8.6.4, 14.4.10, 14.4.11 and 15.1

1 14 May 2008 Updating Issued for bid package Rev. 0 to incorporate technical comments.

0 29 April 2008 Issued for bid package.

04 23 April 2008 Revised to incorporate technical audit team comments.

03 31 March 2008 Issued for bid package only for review.

02 18 February 2008 Updated as Indicated.

01 17 April 2007 The first official JERES-W-010 is issued

00 10 April 2007 First draft issued is based on Saudi Aramco SAES-W-010 “Welding Requirement for Pressure Vessels” issue date 14 November, 2005. Document was modified to incorporate amendments and modifications.





of 67

Table of Contents

Section Contents Page

1 Scope 5

2 Conflicts, Deviations and Clarifications 5

3 References 6

4 Definitions 8

5 General 9

6 Approved Welding Processes 9

7 Welding Consumables 12

8 Welding Procedures 21

9 Welder and Welding Operator Qualification 30

10 Joint Design 30

11 Corrosion Resistant Cladding, Overlays and Linings 31

12 Technique and Workmanship 31

13 Preheat 35

14 Post Weld Heat Treatment 37

15 Production weld hardness testing 41

16 Vessels Production weld test coupons 43





of 67

Section Contents Page

17 Weld Identification 44

18 Repairs 44

19 Miscellaneous Requirements 45

20 Proximity of Welds 45

Appendixes

A Strength Weld of Tube-Tube Sheet Connections 48

B Heavy Expanded Tube-Tubesheet Connections 53

C Additional Requirements for Welding the Vessels used in Wet H2S and Amine Service 56

D Additional Requirements for 5% Chromium Steel Material Fabrication and Testing 58





of 67

1 Scope

1.1 This standard specifies the welding, heat treatment, and hardness testing requirements for shop and field fabrication, repair, or modification of pressure vessels and heat exchangers to ASME SEC VIII. These requirements are in addition to the requirements of ASME SEC VIII and ASME SEC IX.

1.2 Additional requirements may be contained in Scopes of Work, Drawings, or other Instructions or Specifications pertaining to specific items of work.

1.3 Any reference to Company shall be interpreted as the Company Welding Specialist or a representative designated by Company. Any reference to "approval" shall be interpreted as written approval.

1.4 This entire standard may be attached to and made a part of purchase orders.

1.5 This standard is generally not applied retroactively to the maintenance and repair of existing facilities unless there are safety, environmental protection, health or security concerns.

2 Conflicts, Deviations and Clarifications

2.1 Any conflicts between this standard and other applicable Company Engineering Standards (JERES), Material Specifications (JERMS), Standard Drawings (JERSD), Engineering Procedures (JEREP), Company Forms or Industry standards, specifications, Codes and forms shall be brought to the attention of Company Representative by the Contractor for resolution.

Until the resolution is officially made by the Company Representative, the most stringent requirement shall govern.

2.2 Where a licensor specification is more stringent than those of this standard, the Licensor’s specific requirement shall apply.

2.3 Where applicable Codes or Standards are not called by this standard or its requirements are not clear, it shall be brought to attention of Company Representative by Contractor for resolution.

2.4 Direct all requests for deviations or clarifications in writing to the Company or its Representative who shall follow internal Company procedure and provide final resolution.





of 67

3 References

The selection of material and equipment, and the design, construction, maintenance, and repair of equipment and facilities covered by this standard shall comply with the latest edition of the references listed below as of the CUT-OFF DATE as specified in the Contract unless otherwise noted.

3.1 Company

Company Materials Specifications

JERMS-D-3204 Manufacture of Pressure Vessels

JERMS-D-3232 Manufacture of Low Alloy Vessels and Heat Exchangers in 1 ¼ Cr - ½ Mo

JERMS-D-3233 Manufacture of Low Alloy Vessels and Heat Exchangers in 2 ¼ Cr - 1 Mo and 2 ¼ Cr - 1 Mo-V

Company Engineering Standards

JERES-A-301 Materials in Wet H2S Services

JERES-W-014 Weld Overlays and Welding of Clad Materials

JERES-W-016 Welding of Special Corrosion-Resistant Materials

3.2 Industry Codes and Standards

American Society of Mechanical Engineers

ASME SEC IIC Welding Rods, Electrodes and Filler Metals

ASME SEC VIII Rules for Construction of Pressure Vessels

ASME SEC IX Welding and Brazing Qualifications

American Petroleum Institute

API RP 510 Pressure Vessel Inspection Code "Maintenance, Inspection, Rating, Repair, and Maintenance"

API RP 582 Welding Guidelines for the Chemical, Oil and Gas Industries

American Society for Testing and Materials

ASTM E92 Vickers Hardness of Metallic Materials

ASTM E140 Hardness Conversion Tables for Metals





of 67

American Welding Society, Inc.

AWS A2.4 Standard Welding Symbols

AWS A3.0 Standard Terms and Definitions

AWS A4.2 Standard Procedures for Calibrating Magnetic Instruments to Measure the Delta Ferrite Content of Austenitic and Duplex Austenitic-Ferritic Stainless Steel Weld Metal

AWS A4.3 Standard Methods for Determination of the Diffusible Hydrogen Content of Martensitic, Bainitic, and Ferritic Weld Metal Produced by Arc Welding

AWS A5.32 Specification for Welding Shielding Gases

AWS D1.1 Structural Welding Code

National Association of Corrosion Engineers

NACE RP0472 Methods of Control to Prevent In-Service Cracking of Carbon Steel Welds in P-1 Materials in Corrosive Petrochemical Refining Environments

NACE RP0590 Recommended Practice for Prevention, Detection and Correction of Deaerator Cracking

NACE 8X194 Material and Fabrication Practices for new Pressure Vessel used in wet H2S Refinery service.

NACE MR0175 Standard Material Requirements – Metals for Sulfide Stress Cracking and Stress Corrosion Cracking Resistance in Sour Oilfield Environments.

NACE MR0103 Standard Material Requirements – Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum Refining Environments.

British Standards Institution

BS 7570 Code of Practice for Validation of Arc Welding Equipment

BS EN 1043-1 Destructive tests on welds in metallic materials. Hardness testing – Hardness test on arc welded joints.

ISO Standards

ISO 9692-1 Welding and allied processes - Recommendations for joint preparation - Part 1





of 67

ISO 9692-2 Welding and allied processes. Joint preparation. Part 2

ISO 13916 Welding. Guidance on the measurement of preheating temperature, interpass temperature and preheat maintenance temperature.

ISO 3690 Welding and allied processes - Determination of hydrogen content in ferritic steel arc weld metal

ISO 14344 Welding and allied processes – Flux and gas shielded electrical welding processes – Procurement guideline for consumables

ISO 10474 Steel and steel products – inspection documents

4 Definitions

4.1 Definitions presented in this Standard and other JER documents have precedence over other definitions. Conflicts between various definitions shall be brought to the attention of Company Representative by the Contractor for resolution.

Company: Jubail Export Refinery.

Company Representative: A designated person from the Company or an assigned third party representative.

Company Inspector: A designated person or an agency responsible for conducting inspection activities on behalf of the Company.

4.2 List of Definitions

Amine Services: All amine solutions including MDEA, DEA, MEA, DGA and ADIP.

Design Engineer: The Engineering Company responsible for specifying on the data sheet the mechanical design requirements for pressure vessels.

High - Alloy Steels: Steels with a total alloying content more than 5%.

Hydrogen Service: Process streams containing relatively pure hydrogen and component streams containing hydrogen with a partial pressure of 350 kPa abs and higher.

Low - Alloy Steels: Steels with a total alloying content equal or less than 5% but more than specified for carbon steels.





of 67

MDMT: Minimum design metal temperature, determined by the Design Engineer.

Nominal Thickness: The value of the design thickness required to withstand all primary loads, and includes allowance for corrosion.

Pressure Vessel and Vessel: As defined in the ASME Boiler and Pressure Vessel Codes.

Vessel Manufacturer: The Company responsible for the manufacture of pressure vessels.

Wet Sour Service: As defined by JERES-A-301.

5 General

5.1 AWS A2.4 "Standard Welding Symbols" shall be used for all welding details on all drawings.

5.2 AWS A3.0 "Standard Terms and Definitions" shall be used for all specifications and documents.

5.3 These requirements apply to all sub-company representatives or vessel manufacturers for items within the scope of this standard.

5.4 Equipments in wet sour H2S service shall be fabricated in accordance to Appendix C “Additional Requirements for Welding Vessels used in H2S and Amine Service” and JERES-A-301.

5.5 Equipments in 5% Cr steel material shall be fabricated in accordance to Appendix D “Additional Requirements For 5%Chromium Steel Material Fabrication and Testing”

5.6 Welding of Austenitic/ferritic Stainless steel (CRA) and duplex shall be in accordance with project specification JERES-W-016 “Welding of Special Corrosion Resistant Material”

5.7 Weld Overlay and welding of clad material shall be in accordance with project specification JERES-W-014 "Weld Overlays and Welding of Clad Materials"

6 Approved Welding Processes

The following processes are approved for use with the restrictions and requirements as listed below:





of 67

6.1 Shielded Metal Arc Welding (SMAW).

6.1.1 Down hill progression shall not be allowed when using low hydrogen electrodes.

6.1.2 Coated electrodes shall be basic low hydrogen content type. (Hydrogen content shall be ≤5 ml/100g of weld metal, AWS A4.3)

6.1.3 For pressure welds parts maximum allowed diameter is 5 mm.

6.1.4 For branch connection, when nozzles diameter is ≤ 4”, maximum allowed diameter is 3,2 mm.

6.2 Gas Tungsten Arc Welding (GTAW).

6.2.1 Except for ASME P-No. 1 through P-No. 3 base materials, all manual GTAW shall use a high frequency start and post-purge gas flow for the torch. Filler metal must always be added, autogenous welding is not permitted unless specifically approved by Company.

6.2.2 The GTAW process shall be used for all passes of piping butt welds and set-in/on nozzles less than 2” Diameter (set-on nozzles are subject to approval).

6.2.3 The GTAW process shall be used for the root pass of piping butt welds and set-in / on nozzles (where the back side is not practicable).

6.2.4 The GTAW process shall be used for the root pass of single-sided groove welds without backing made with stainless steel or nickel-based consumables with minimum two passes.

6.2.5 The use of flux-cored GTAW wires for root pass of single-sided groove welds with or without backing gas is not permitted unless specifically approved by Company.

6.3 Submerged Arc Welding (SAW).

6.4 Gas Metal Arc Welding (GMAW) including Flux Cored Arc Welding (FCAW).

6.4.1 GMAW process is not accepted. The STT mode of GMAW may only be used for root pass welding if approved by Company and if double side welding is not practicable (for P1 grade only).

GMAW use, on non-pressure retaining part with external shielding gas, is subjected to COMPANY prior approval provided welds are not under critical vibration and are





of 67

inspected at least by 10% RX (butt welds) and 100% PT or MT (butt and fillet welds).

6.4.2 Flux-Cored Arc Welding (FCAW).

6.4.2.1. The FCAW Gas Shielded process shall not be used for the root pass on full penetration, groove joints that are welded from one side only without backing (backing may be used if it is removed after welding) except for the cases defined in 6.4.2.2.

6.4.2.2 Flux Cored Arc Welding (FCAW) may be acceptable by Company Representative subject to the following provisions:

a) Vessel Manufacturer must provide evidence of successful previous experience with this process.

b) The flux-cored arc welding process is protected with external shielding gas and trade mark in WPS shall be same as PQR

c) Application of FCAW process is limited to:

− Vessels in carbon steel (including P3 steel)

− Vessels in P8 stainless steel

− Vessels are not in wet sour or hydrogen service

− Design pressure is ≤ 20 bars and design temperature is greater than -29°C,

− Category A & B welds (as defined in ASME Code UW-3) efficiency factor 0.85 and below provided 100% UT are performed.

− Category C & D welds (as defined in ASME Code UW-3) above 6" in diameter, provided that 100% UT and 100% MT examination are performed.

d) All fillet welds shall be qualified by a butt weld PQR and a representative fillet PQR

e) Other application of FCAW process shall be subjected to COMPANY prior approval and shall require production test coupon and additional NDT.

f) FCAW use, on non-pressure retaining part with external shielding gas, is also subjected to Company Representative prior approval provided welds are not under critical vibration and are inspected at least by 10% RX (butt welds) and 100% PT or MT (butt and fillet welds).





of 67

g) FCAW shall use a maximum filler wire diameter of 1.2 mm

6.5 Stud Welding is permitted for attaching insulation fasteners and heat conductors. (Annex IX of AWS D1.1 and PQR according to ASME IX shall be considered).

6.6 Other processes (such as brazing, Electro-Gas, Electro-slag, Plasma, etc.) may be used only with the approval of Company. Depending upon the process and application proposed, Company may require testing in addition to that specified by the Code. Approval to use other processes shall be obtained through the welding procedure review process.

7 Welding Consumables

7.1 Electrodes, filler wires, and fluxes shall conform to ASME SEC IIC. Other consumables may be used only with the approval of COMPANY and, depending upon the process and application proposed, may require testing in addition to that specified by ASME SEC IX. Approval to use other (unlisted to ASME SEC IIC) consumables shall be obtained through the welding procedure review process. For unlisted consumables, vessel manufacturer literature, which shall include intended use and approximate chemistry and mechanical properties, shall be submitted with the procedure.

7.2 Certified Material Test Report's (CMTR) shall be supported by “Type 3.1” document according to ISO 10474 for chemical analysis and mechanical properties according to table 1 extent of testing.

7.3 GTAW filler metal shall have either the AWS/ASME identification or the manufacturer's identification marked on each individual rod by the manufacturer with tags ("flags"), stencil, or stamping.

7.4 Welding consumables shall be selected based on their mechanical properties, compatibility with the materials to be joined, their suitability for the intended service, and consideration of polarity, position, and direction of welding. Welding consumables not meeting standard industry practice using the above criteria may be rejected by the COMPANY.

7.5 Dissimilar Metal Welds (DMW) are defined as:

- Any weld joint (excluding weld overlays or strip lining) between ferritic steel and either austenitic stainless steel, duplex stainless steel, or nickel-based alloys

- Use of stainless steel or nickel-based filler metals on ferritic steels.





of 67

They shall be restricted as follows:

a) Are not permitted for pressure-containing welds in sour service (welds in clad systems are acceptable if the DMW interface with the ferritic steel is not in contact with the sour fluid).

b) Are permitted for non-sour hydrocarbon service if made with a nickel-based consumable.

c) DMW shall be performed in accordance to paragraph 7.9

7.6 Submerged Arc Welding Fluxes

7.6.1 Fluxes that the flux Manufacturer recommends for single pass welds shall not be used for multiple pass welds. Active fluxes are not permitted.

7.6.2 The brand name and grade of flux and wire used for production of submerged arc welds shall be the same as used in the relevant procedure qualification test. A change in wire or flux will require a new qualification.

7.6.3 Only neutral and basic flux shall be used. Addition of alloying elements to the weld via the flux (other than to compensate arc losses) is not permitted.

7.6.4 Flux that is not fused during welding may be re-cycled (up to P1G2 grade) providing it is seaved to remove any slag impurities, re-processed in accordance with the manufacturer’s recommendation and mixed with fresh flux (no more than 20% by volume of re-cycled flux) prior to welding. Recycle of flux for grade greater than P1G2, a written approval of the Company is required. Vessel manufacturer shall supply a specific flux re-cycle procedure for approval to the Company Representative and shall ensure that flux will not be re-cycled more by two times by controlling quantity.

7.7 Welding consumable classification

Welding consumable used for pressure vessels parts shall be supplied with the following classification and schedule as defined in ISO 14344





of 67

TABLE 1

Grade Classification Schedule

P1 C2, S2, T2, F2 6 (*)

P3, P4, P5 C3(**), S3, T3, F2 6(*)

P6, P8 and higher alloyed grade

C2, S2, T2, F2 6(*)

(*) Schedule 6 shall be understood as a schedule 5 based on the corresponding AWS standard of the welding consumables (i.e. schedule I of SFA 5.01) as defined in paragraph 6.3 of ISO 14344 plus the additional requirements of this specification if any or that vessel manufacturers may found interesting to promote. As a minimum it shall also conform to schedule 4 whichever is the most restrictive.

(**) Chemical analysis by wet mix

7.8 Filler metal selections

7.8.1 General provisions for the use of filler metals to weld number P1 steels (Asme classification, section IX)

Filler metals shall be selected on the basis of the mechanical properties of the parent metal.

The filler metal shall conform to AWS A5.1 E7018 or E7016 classification for SMAW process.

When the design temperature (MDMT) is below 0°C, the filler metal used shall have guaranteed impact test values at a temperature specified in the AWS specifications or at the design temperature if this is lower. Additionally, the brand name of welding consumables (electrodes, rods, wire, flux cored, flux) to be employed shall be the same as used in the procedure qualification test.

For bare wires used in welding processes with gas protection (GTAW) the filler metals shall conform to AWS A5.18 classification.

For SAW process wire and flux combination shall conform to ASME SFA-5.23 or SFA-5.17.

Carbon steels shall not be welded with C-½ Mo weld metal.

7.8.2 General provisions for the use of filler metals to weld number P3, P4, P5, P9, P11A steels (ASME classification, section IX)





of 67

Filler metals used to weld similar materials shall have nominal chemical analysis and mechanical properties equivalent to the basic materials, for carbon steels - molybdenum and chromium ferritic steels (from 0,5 % to 5 % of chromium).

For the welding of steels containing between 5 and 9 % of nickel, the filler metals shall be approved by COMPANY REPRESENTATIVE.

The criteria used to select filler metals are defined in table 2 (guideline): TABLE 2 (guideline)

Base metal ASME Specification

Coated electrodes

ASME specification

Welding wires

0.5 Mo SFA 5.5

E 70XXA1 SFA 5.28 ER 80SG (0.5 Mo)

0.5 Cr – 0.5 Mo 1 Cr – 0.5 Mo

SFA 5.5

E 8018 B2(L) E 8015 B2(L)

SFA 5.28 * ER 80C B2 (L) ER 80S-G

1 ¼ Cr – 0.5 Mo SFA 5.5

E 8018 B3(L) E 8015 B3(L)

SFA 5.28 * ER 80C B2 (L) ER 80S-G

2 ¼ Cr - 1 Mo SFA 5.5

E 9018 B3(L) E 9015 B3(L)

SFA 5.28 * ER 90C B3 (L) ER 90S-G

2 ¼ Cr - 1 MoV SFA 5.5 E 9015-G SFA 5.28 ER90S-G 5 Cr - 0.5 Mo SFA 5.5 E 502 15/16 SFA 5.28 ER 502

2 ¼ Ni SFA 5.5

E 8018 C1 E 8015 C1

SFA 5.28 * ER 80C Ni2

3 ½ Ni SFA 5.5

E 8018 C2 E 8015 C2 E8016-C2

SFA 5.28 SFA 5.23

ER 80C Ni3 ER80S-Ni3

ENi3 *For the welding of 0.5 % to 5 % of chromium steels, the wire-flux combination for submerged arc welding (SAW) shall conform to ASME SFA 5.23.

When JERMS-D-3232 and JERMS-D-3233 are applicable, welding consumable shall match also the requirements from these specifications.

7.8.3 General provisions for the use of filler metals to weld number P8 steels (ASME classification, section IX)

The criteria used to select filler metals are defined in table 3.





of 67

TABLE 3 (Guideline)

Base metal ASME Specification

Coated Electrodes (2)

ASME specification

Welding wires

304 L SFA 5.4 E 308 L 15/16 (1) SFA 5.9 ER 308 L (1) 316 L SFA 5.4 E 316 L 15/16 (1) SFA 5.9 ER 316 L (1) 304 SFA 5.4 E 308 15/16 *

E 308 L 15/16 (1) SFA 5.9 ER 308 *

ER 308 L (1) 316 SFA 5.4 E 316 15/16 *

E 316 L 15/16 (1) SFA 5.9 ER 316 *

ER 316 L (1) 321 SFA 5.4 E 347 15/16 SFA 5.9 * ER 347 347 SFA 5.4 E 347 15/16 SFA 5.9 ER 347 309 SFA 5.4 E 309 15/16 SFA 5.9 ER 309

304 LN SFA 5.4 E 308 L (1) SFA 5.9 ER 308L (1) 316 LN SFA 5.4 E 316 L (1) SFA 5.9 ER 316 L (1)

* This applies to high temperatures beyond 540°C. In order to avoid long term embrittlement, type 308 welding consumables shall meet the following table 4 :

TABLE 4 Carbon 0.05% - 0.07%

Mo 0.5% Max Ti 0.5% Max (a) Br 0.005% Max Bi 0.001% Max (b)

Mo+Ti+Nb 0.25% Max Ferrite 3.5% - 6%

a) Type 308H-16 SMAW electrodes are recommended. b) Applicable to SMAW and FCAW consumables

Note : 1) Filler metal recommended for cryogenic applications. Weld metals containing

Nb shall not be used. Impact tests shall be carried out per lot at design temperature (MDMT) or at a lower temperature. The test results shall include the lateral expansion and absorbed energy values.

2) EXXL-17 electrodes may be used by Vessel manufacturer if previously agreed by Company Representative

For service temperature above 315 °C filler metals shall be selected to produce weld deposits that fall within the ferrite number (FN) range of 3 to 10 as determined by the WRC (Welding Research Council) diagram which is included in AWS A-5.4. As a recommendation, FN should be limited to 8 if PWHT is required.





of 67

Welding wires or bare wires that are not listed in the ASME specifications shall not be used.

All GTAW filler wires shall be degreased prior to use and shall subsequently be handled with clean gloves. The degreasant shall leave no chloride or sulphide containing residues on the surface.

7.8.4 General provisions for the use of filler metals to weld ferritic stainless steel TABLE 5 (Guideline)

Base metal ASME specification

Coated electrodes

ASME specification

Welding wires

Type 410 SFA 5.11 ENiCrFe-3 or E309L

SFA 5.14 ERNiCr-3 or ER309L

7.8.5 General provisions for the use of filler metals to weld non ferrous metals. Selection criteria for filler metals – Ni-base alloys

TABLE 6 Base metal ASME

specification Coated Electrodes

ASME specification

Welding wires

70 Cu 30 Ni SFA 5.6 E Cu/Ni SFA 5.14 ER CuNi

Incoloy 825 SFA 5.11 E NiCrFe 2 E NiCrFe 3

SFA 5.14 ER NiCr 3

UNS N06022 (Hastelloy C22)

SFA 5.11 ENiCrMo-10 SFA 5.14 ERNiCrMo-10

UNS N06625 (Inconel 625)(**)


UNS N10276 (Hastelloy C276)


UNS (Inconel 600)(*)

SFA 5.11 ENiCr-3 SFA 5.14 ERNiCr-3

MONEL 70Ni-30Cu

SFA 5.11 ENiCu-7 SFA 5.14 ERNiCu-7

(*): shall not be used in sour service if Temperature is greater than 370°C

(**): shall not be used in sulfur service above 440°C

7.9 Dissimilar materials

7.9.1 Table 7 provides guidelines the selection of filler metal of dissimilar material.

Dissimilar welds shall be done taking into account the post weld heat treatment temperature of the more alloyed grade. The lower grade shall be able to withstand the PWHT temperature and time of the higher grade.





of 67

7.9.2 Dissimilar metal welds shall comply with the following requirements:

a) Carbon to low alloys

For dissimilar joints in base metals consisting of carbon and low alloy steels (P-No.1 through P-No.5) the filler metal shall be conform to table 7.

Testing of both parents metal shall be required in the PQR before starting welds to ensure that PWHT does not adversely affect their mechanical properties.

b) Ferritic to stainless steel

For dissimilar joints in base metals consisting of a ferritic material (P-No.1 through P-No.7) to austenitic stainless steel, the filler material selection shall be as follows:

− For service temperatures up to and including 350°C: ASME Classification E/ER 309L.

− For service temperatures above 350°C: High nickel filler metal, ASME Classification ENiCrFe-2, ENiCrFe-3, ENiCrMo3 or ERNiCr-3. API 582 can be used for filler metal selection as a guideline.

− When ferritic steel needs to be Post Weld Heat Treated the ferritic material (P-No.1 through P-No.5) may be buttered with either ASME Classification E/ER 309L or high nickel filler metal and Post Weld Heat Treated prior to welding to the austenitic stainless steel.

− Subsequent welding of the “buttered” layer to the stainless steel shall be carried out with weld metal nominally matching the stainless steel parent metal.

For services that contain sulphur compounds the use of high nickel filler metal shall be as per paragraph 8.7.5 and shall be subjected to Company agreement.





of 67

TABLE 7 FILLER METAL FOR WELDING DISSIMILAR MATERIAL

Base Nominal Analysis of Base Material Material Base Materials 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

1 Carbon steel A A A A A A A A B B B B B B B B B B B C D C2 Carbon-Molybdenum Steel A E C E E E E E B B B B B B B B B B B C D C3 2.25% Nickel & 3.5% Nickel steel A E C B B B B B B B B C C C4 9% Nickel Steel A E C C C C C C C C C C C C5 1% Cr - 0.5% Mo steel A E F F F F B B B B B B B B C D C6 1.25% Cr - 0.5% Mo steel A E F F F F B B B B B B B B C D C7 2.25% Cr - 1% Mo Steel A E F F F G B B B B B B B B C C C8 5% Cr - ½% Mo Steel A E F F H H B B B B B B B B C C C9 9% Cr - 1% Mo Steel A E F F G H J J B B B B B B B B C C C

10 Type 405 Stainless steel B B K X B B B B B B B C C C11 Type 410S Stainless steel B B J K K B B B B B B B B C C C12 Type 410 Stainless steel B B J K X B B B B B B B B C C C13 Type 304 Stainless steel B B B C B B B B B B B B L L P L L O O C C C14 Type 304L Stainless steel B B B C B B B B B B B B L M M L M O O C C C15 Type 321 Stainless steel B B B C B B B B B B B B L M N L M O O C C C16 Type 347 Stainless steel B B B C B B B B B B B B P M N P M P P C C C17 Type 316 Stainless steel B B B C B B B B B B B B L L L P Q O O C C C18 Type 316L Stainless steel B B B C B B B B B B B B L M M M Q O O C C C19 Type 309 Stainless steel B B B C B B B B B B B B O O O P O O R C C C20 Type 310 Stainless steel B B B C B B B B B B B B O O O P O O R C C C21 Alloy 800 (Incolloy 800) C C C C C C C C C C C C C C C C C C C C C C22 Monel 400 D D C C D D C C C C C C C C C C C C C C C C23 Inconel 625 C C C C C C C C C C C C C C C C C C C C C C

NOMENCLATURES:

A - AWS A5.1 classification EXX15, EXX16, EXX18. I - AWS A5.4, classification E7Cr-XX. B - AWS A5.4 and A5.11, classification E309-xx (only for service

temperature up to 350°C), ENiCrFe-3 (Inconel 182), or ENiCrFe-2, E NiCrMo3

J - AWS A5.4, classification E505-XX.

C - AWS A5.11 classification ENiCrFe-3 (Inconel 182) or ENiCrFe-2 (Inco-Weld A), E NiCrMo3

K - AWS A5.4 and A5.11, classification E410-XX, E410 Cb-XX, E309-XX, ENiCrFe-3 (Inconel 182), or ENiCrFe-2 (Inco-Weld A).

D - AWS A5.11, classification ENiCrFe-3 (Inconel 182), ENiCrFe-2 (Inco-Weld A), or ENiCr-7 (Monel 190).

L - AWS A5.4, classification E308-XX.

E - AWS A5.5, classification E7015-A1, E7016-A1, or E7018-A1. M - AWS A5.4, classification E308L-XX. F - AWS A5.5, classification E8016-B2, or E8015-B2L, E8018-B2L N - AWS A5.4, classification E347-XX. G - AWS A5.5, classification E9015-B3, E9016-B3, E9018-B3 or E9015-

B3L, E9018-B3L O - AWS A5.4, classification E309-XX or E308-XX.

H - AWS A5.5, classification E8018B6 or E8018B6L P - AWS A5.4, classification E308-XX or E347-XX. Q - AWS A5.4, classification E316-XX or E316L-XX. NOTE: R - AWS A5.4, classification E309-XX

1. Blank spaces in Table indicate combination that are considered unlikely or unsuitable

2.

Table refers to coated electrodes. For bare wire welding (SAW, GMAW, GTAW), use equivalent electrode classifications (AWS A5.9, A5.14, A5.17, A5.18, A5.20, A5.23, and A5.28).





of 67

7.10 Consumable storage

Welding consumables shall be stored with care, under dry conditions in their original unopened packing. After opening shipping containers/box of electrodes, fluxes and other welding materials, storage and handling shall be as specified in the Manufacturer's recommendation.

Electrodes, filler wires or fluxes that are damaged, damp, greasy or oxidized shall not be used.

All electrodes, which have been in direct contact with water, shall be definitely rejected.

VESSEL MANUFACTURER’s facilities shall include a temperature and humidity controlled welding consumable and flux store, including holding and drying ovens.

Low hydrogen electrodes and fluxes shall be dried at 250°C/300°C for two hours prior to use, unless otherwise recommended by the electrodes manufacturer. Welding electrodes shall then be stored in ovens at a minimum temperature of 80 °C. When used for production they shall be placed in a portable oven capable of maintaining a minimum temperature of 60 °C.

Above drying conditions do not apply to electrodes supplied in vacuum conditioning boxes unless un-properly stored and handled after opening.

Carbon steel and 0.3-0.5% Mo low hydrogen electrodes shall be used within 8 hours when stored in a portable oven. Low hydrogen Cr-Mo steel electrodes shall be used within four hours when stored in a portable oven. Electrodes stored in the portable oven, but not used within the specified time, shall be restored in the oven. No electrodes shall be left out the portable oven on shop floor or in field. Electrodes so left-out shall be scrapped.

Submerged arc flux shall be clearly identified in moisture-proof containers and shall be stored in a dry location at a temperature recommended by manufacturer.

Submerged arc, gas metal arc and flux-cored wire shall be clearly identified and shall be stored in a dry location at a temperature recommended by manufacturer. The identification shall state manufacturer, grade and batch number. Unidentifiable wire shall not be used.

Submerged arc, gas metal arc and flux-cored arc consumables shall be withdrawn from storage only when required for immediate use. Unused consumables shall be





of 67

returned to storage on completion of the welding operation. Batch numbers shall be recorded on issue.

Recycling of flux is not allowed for P N°1 Gr 3 materials and above.

The Vessel Manufacturer shall maintain recycling flux procedure as well as storage/conditioning and handling procedure for welding consumables, which shall be made available to review of COMPANY REPRESENTATIVE upon request. The procedure shall include moisture, cleanliness and identification controls.

7.11 Shielding Gases

Shielding gases shall conform to the following requirements:

7.11.1 AWS A5.32 Specification for Welding Shielding Gases.

7.11.2 The requirements for other gases and gas mixtures shall be submitted to Company for approval.

8 Welding Procedures

8.1 Documentation

8.1.1 Welding documentation shall be submitted to the Company Representative for approval before to start any welding activity.

8.1.2 All welding procedure qualification tests shall be witnessed and certified by an Independent Inspecting Authority approved by the Company, unless the Vessel manufacturer is holding a valid ASME VIII code stamp

8.1.3 All welding procedure qualification shall include a welding parameters monitoring sheet. The monitoring sheet shall monitored all welding parameters during the qualification stage by run and by process. This includes at least electrical parameters, speed, ROL (Run of length) for SMAW process, underpass temperature and heat input. For manual welding several monitoring shall be done per run.

8.1.4 Welding procedures for external structural such as platforms, walkways and stairways do not require prior COMPANY approval before start of welding and they may be qualified to AWS D1.1. But they shall be reviewed by the Company representative.

8.2 Welding Data Book





of 67

The VESSEL MANUFACTURER shall submit a detailed and complete Welding Data Book to the COMPANY REPRESENTATIVE at the time of WPS/PQR submittal. Fabrication shall not start until the Welding Data Book is returned with agreement to proceed. The Welding Data Book shall include the following documents:

− A cover sheet with title block dedicated to the Project.

− A Weld map (one-line sketch of pressure vessel locating all joints and reference to WPS).

− Welding Procedure Specifications (WPS).

− NDE Table (extent of all type of welding joint)

− Procedure Qualification Records (PQR).

Any welding prior to the approval of these welding documents is subject to rejection at the sole option of Company Inspector. Any rework required as a result of this rejection shall be at the fabricator's expense.

8.2.1 Weld map / Weld Key form

The Weld map / Weld Key form shall contain as a minimum the following information:

− Sketch of the equipment item.

− Design /Fabrication code with joint efficiency

− Material type(s), grade(s) and thickness for each type of equipment component.

− WPS to be used for each type of joint of same design and similar thickness (i.e., longitudinal and circumferential seam, closing seam, typical large nozzle connection, typical small nozzle connection, fillet weld attachments and any back cladding, if applicable).

− Calculated Minimum Design Metal Temperature (MDMT) and whether impact-tested WPS is/are required.

− Actual thickness where each WPS is to be used.

− P.W.H.T. requirements (process, specifications or code).

− Test coupon table detailing number, location and testing program according code and specification.





of 67

Each Weld Map must be completed and show the Company equipment tag number and the purchase order number. Identical equipment items may be combined on one set of forms.

8.2.2 Welding procedure specification (WPS)

Welding Procedure Specifications (WPS) and their supporting Procedure Qualification Records (PQR) shall conform to the requirements of ASME Section IX and to the requirements of this specification.

Welding Procedure Specifications together with Procedure Qualification Records shall be submitted to the COMPANY REPRESENTATIVE prior to the start of fabrication. Welding shall not proceed until these documents are returned to the VESSEL MANUFACTURER with agreement to proceed.

All Welding Procedure Specifications and Procedure Qualification Records for purchased items subcontracted by the VESSEL MANUFACTURER shall be reviewed by the VESSEL MANUFACTURER for content and contract compliance prior to submittal to the COMPANY REPRESENTATIVE.

Each WPS shall be identified by a unique number and shall be identified on the welding map.

Vessel manufacturer may be used its own WPS forms provided that complete welding data, as per ASME IX forms QW-482 and the following information are included:

a) Welding process or processes when more than one is used in making a complete joint.

b) Parent metal specification and thickness.

c) Whether shop or field welding.

d) Joint preparation (sketch).

e) Cleaning, degreasing, etc.

f) Welding position (including direction for vertical position).

g) Weaving limitation

h) Brand name, AWS classification and size (diameter) of welding consumables.

i) Pre-heating and interpass temperature, including method and control.

j) Travel speed.





of 67

k) Approximate number and arrangement of runs and weld dimensions (sketch).

l) Welding sequence.

m) Back gouging and afterwards NDE testing .

n) P.W.H.T. requirements. When welding quenched and tempered steels, low alloy steels or steel requiring impact testing and/or hardness testing, the heat input in conjunction with the minimum/maximum interpass temperatures shall be restricted to the values shown in the supporting PQR. Heat input values shall be recorded on WPS and PQR.

Heat input in Joules / cm = Amperage x Voltage x 60Travel speed in cm/min

When hardness testing is required heat input values shall not be less than minus 25% of the PQR values. This limitation does not apply if the WPS is qualified with a PWHT above the upper transformation temperature.

Each WPS shall contain, for each essential variables, minimum and maximum qualified.

8.2.3 NDE Table

For each type of joint, Vessel manufacturer shall establish a NDE table that list as a minimum:

− Type and/or weld numbering

− WPS Number

− Extent of each NDE technique (Visual, liquid penetrant, magnetic test, radiographic, UT, TOFD, …)

− For spot examination : location of test

− Schedule of test i.e. before or after : Weld overlay (if any), PWHT (if any) and hydrostatic tests

8.2.4 Approval of welding procedures shall not be construed as authority for deviation from listed specifications or requirements of the relevant codes and standards and shall not relieve the company representative, fabricator, or vessel manufacturer from correcting any deviations.

8.2.5 All WPSs, PQRs, Weld Maps, Weld Descriptions and NDE tables shall be available at the work site for verification at any time by the authorized Company Inspector.





of 67

8.2.6 All Welding Procedure Specifications and Welding Procedure Qualification Records shall be written in English language.

8.2.7 The PQRs shall include certified copies of all test records (for In-Kingdom qualification, the independent testing agency that issued the test record shall certify the copies), which may be permanently retained by the Company.

8.2.8 Originals of all test records, mill certificates, etc. including records from the independent test laboratory shall be made available for review by the Company Inspector upon request.

8.3 General Requirements

8.3.1 For any new or additional qualification tests that are required, the Company reserves the right to monitor any and all phases of the procedure qualification, including welding of the coupons and mechanical testing. The Company may assign the monitoring to an inspection agency.

8.3.2 All information shown on the PQR, such as amperage, voltage, travel speed, post weld heat treatment time and temperature, as applicable, shall be actual data as recorded using calibrated instruments.

8.3.3 For all automatic welding and any process with pulsing, the welding procedure shall include all applicable equipment and controller parameter settings.

8.4 Special Qualification Requirements

8.4.1 Tube-to-tube sheet welding, including seal welds, shall be qualified in accordance with ASME SEC VIII D2, Article F-3. For seal welds, the required weld throat thickness shall be as specified by the designer. See appendix A and B for tubes to tube sheet connections additional requirements.

8.4.2 For special applications as determined by COMPANY, such as but not limited to severe corrosion service (e.g., chlorinated seawater) or high temperature service, special qualification tests, such as stress corrosion cracking or embrittlement tests for low alloy steels, may be specified by COMPANY. These special requirements may be stated in the job specifications or purchase order, contract specifications, etc.

8.5 Procedure variables

The following additional restrictions shall be considered essential variables for procedure qualification:





of 67

8.5.1 SAW and FCAW process the brand name and type of flux or electrode shall be the same specified on both the WPS and PQR.

Additionally the trade name of all welding consumable for the welding of P1 steel shall be considered as an essential variable if the MDMT is < 0°C.

8.5.2 A change in filler metal or deposit chemistry from A-No 1 (based on ASME SEC IX) to A-No 2 and vice-versa is not permitted without approval. The approval shall be obtained through the welding procedure review process. A change from A-No. 1 to A-No. 2 is not permitted for sour service applications without requalification.

8.5.3 For ASME P-No. 1 materials, all Group 3 or 4 materials shall be qualified separately for each specific material, unless it is being used in combination with a Group 1 or 2 material and the Group 1 or 2 material strength requirements govern.

8.5.4 Aluminium flake weldable primers (e.g., "Bloxide", "Deoxaluminite", or other brand approved by COMPANY) may be used without requalification of the procedure. The welding procedure specification shall indicate the use of the type and brand of weldable primer. The maximum coating thickness shall not exceed 0.050 mm. The use of other weldable primers or coatings is not permitted unless specifically approved by COMPANY. Additional procedure qualification and/or weldability tests may be required by COMPANY. Weldable primer with Zn is not accepted and if used shall be removed prior welding for 40mm on both side of weld

8.5.5 The direction of welding for the vertical position shall be an essential variable (i.e., a change from vertical-up to vertical-down or vice-versa shall be considered an essential variable). If the procedure was not qualified in the vertical position, then the direction of welding shall be vertical-up.

8.5.6 For automatic, semi-automatic, or mechanized welding, the position limitations listed in ASME SEC IX, QW-461.9 shall be considered as an essential variable for procedure qualification.

8.5.7 Procedures using any consumable with a "G" or unlisted designation (ASME SEC IIC) shall be restricted to the brand and type of electrode used for the PQR. The nominal chemistry of the specific brand and type of electrode shall be identified on the WPS. Substitution of the "G" consumables with the "P1" requires technical evaluation by COMPANY.

8.5.8 Deletion of a backing strip in a single-sided groove weld shall be considered an essential variable and shall require prequalification.





of 67

8.5.9 For single-sided groove welds without backing, the process and electrode type used for the root pass shall be considered an essential variable. The PQR shall be performed as a single-sided groove weld without backing.

8.5.10 For full penetration, double-sided joints, the WPS shall require backgouging

8.5.11 Deletion of a backing gas purge or a change in the backing gas composition for a joint welded or brazed from one side without backing material shall require requalification.

8.5.12 Special requirements for procedures requiring impact testing

8.5.12.1 Charpy impact testing shall be required on the PQR if it is required or specified by the design code or the company specifications. The impact test acceptance criteria shall be as specified by the JERMS of the vessel or heat exchanger (e.g. JERMS-D-3204…).

8.5.12.2 The heat input to be recorded on the PQR and used as the limiting value for the WPS shall be based on the average value of welding parameters used at the location where the impact specimens are removed. If the PQR heat input varies by pass or layer, then additional impact specimens, in addition to those locations specified by the relevant Code, may be required in order to utilize the full range of heat inputs used in the PQR.

8.5.12.3 If the PQR thickness exceeds 12 mm and multiple processes or consumables are used, then separate impact test specimens shall be conducted for each process or consumable. If the impact test specimen size is larger than the deposit thickness of a specific process or consumable, then the impact test specimen shall contain the maximum possible amount of the deposit for that process or consumable (a separate set of specimens is still required for the other process or consumable).

Commentary Note:

The notch of the HAZ impact samples should be centered on the HAZ region.

8.5.13 Any other essential variables define in this specification in dedicated paragraph.

8.6 Welding Procedure Qualification Hardness Testing

8.6.1 Hardness testing is required for all PQRs for:

a) Hydrogen service vessels of any wall thickness.

b) Wet Sour service vessels of any wall thickness.





of 67

c) For vessels in any service if the shell or head is PWHT treated

Exemptions:

Hardness testing need only comply with all JERES-A-301 requirements for the following:

− The vessel is made using austenitic stainless steel or nickel-based alloys for all wetted pressure boundary materials.

− If all internal surfaces of the vessel are clad or weld overlaid with austenitic stainless steel or nickel-based alloys. Strip lining (partial or complete) or partial cladding or partial overlay are not exempt from hardness testing requirements.

8.6.2 Microexamination certificate of hardness test shall be attached to PQR

8.6.3 The hardness testing shall be in accordance with EN 1043-1 (mapping/location) and ASME IX. Prior hardness test results may be accepted as equivalent to this standard only with the approval of COMPANY and with the following conditions:

Only the Vickers test method (in accordance with ASTM E92) is acceptable, with a maximum test load of 10 kg.

Unless otherwise specified the maximum Hv10 hardness shall not exceed following values

TABLE 8

Material group according ASME IX

Material Type Without PWHT

(Units Hv10)

After PWHT

(Units Hv10)

P1 Carbon steel 350 248 (Note 1)

P3 C-1/2Mo 320 248

P4 1Cr-1/2Mo, 11/4Cr-1/2Mo

Not applicable 235 (Note 2)

P5A 21/4Cr-1Mo Not applicable 235 (Note 3)

P5B 5Cr-1/2Mo Not applicable 248

Note 1: For equipment in sour wet H2S services as defined in JERES-A-301 a maximum of 210 HV10 in the weld and 248 Hv10 in the HAZ. Refer also to attachment C and JERES-A-301.

Note 2: Particular specification JERMS-D-3232 (when applicable) shall govern

Note 3: Particular specification JERMS-D-3233 (when applicable) shall govern





of 67

8.6.4 In addition, surface Brinnel hardness test shall also be included on PQR as per method and acceptance criterias specified in §15 of this specification for Post Weld Heat Treated vessels.

8.7 Preparation of Test Coupons

For new procedures or procedures that are to be re-qualified (i.e., existing PQRs that are acceptable without any supplementary tests are exempt), the following additional requirements shall apply:

8.7.1 The qualification test shall include all of the required tests on the same coupon unless size limitations restrict the number and type of specimens that can be reasonably removed from a single coupon. If multiple coupons are required and approved by COMPANY, each of the coupons shall be of the same material and size and shall be welded with identical parameters. Use of supplementary test coupons for additional tests (e.g., Charpy impact or hardness) to be combined with existing PQRs must be approved by COMPANY. The supplementary qualification test shall comply with all of the essential and, where applicable, supplementary essential variables of the original PQR.

8.7.2 For groove welds, the test coupons shall be radiographed and shall meet the acceptance criteria of ASME SEC VIII D1, UW-51.

8.8 Fillet Welds PQR

All the following fillet welds shall be qualified at least with a butt weld PQR and an additional representative fillet weld PQR according to ASME IX:

− All fillet strength welds (fillet pressure containing welds)

− The joint is done with GMAW/FCAW previously approved process

− The joint is with reduced accessibility (e.g oblique branch connection)

Fillet welds that are penetrated through the thickness shall be qualified at least with a butt weld PQR.

If hardness test is required by code, service or specifications, tests shall also be included in fillet weld PQRs, according to paragraph 8.6.

8. 9 Dissimilar welds PQR





of 67

The qualification for welding dissimilar P number requires a PQR with the same P numbers as the original welds. For instance a PQR for welding P1 steel to P5 steel, require a qualification with a P1 steel to a P5 steel.

9 Welder and Welding Operator Qualification

9.1 All welders, welding operators, brazers, and brazing operators shall be qualified in accordance with the ASME SEC IX for all welding, including tack, temporary, and repair welds.

9.2 Performance qualification tests shall not be performed on production joints on Company work.

9.3 Manufacturer shall demonstrate that FCAW welders, if process is previously accepted, have successful experience and training at bid stage

10 Joint Details

10.1 All pressure-containing welds shall be made with multiple passes.

10.2 All shell, head and nozzle joints shall be double welded butt joints with full penetration. Double welded groove joints shall have their root passes back gouged to sound metal on the reverse side before welding on that side. In case where double welding is impractical, the root pass shall be made by the Gas Tungsten Arc Welding (GTAW) process or GMAW STT after prior approval of Company.

10.3 When air arc gouging is used, the carburized and hardened surfaces shall be removed by grinding to a bright metal finish and shall be examined by PT or MT.

10.4 For any closure welds without internal access after welding, the welding and inspection details necessary to ensure proper joint quality shall be submitted to the Company for approval.

10.5 Permanent backing rings or strips shall not be used.

10.6 Temporary backup shoes made of non-metallic, non-fusing material may be used for non containing welds.

10.7 Consumable inserts shall not be used

10.8 Full penetration groove joint included angles less than 30 degrees (except for portions of compound bevels) shall not be used without approval. The approval shall





of 67

be obtained through the welding procedure review process and the minimum included angle shall be an essential variable.

10.9 For nozzles with reinforcing pads (when permitted), the nozzle attachment weld shall be completed and inspected, as required, prior to installing the reinforcing pad.

11 Corrosion Resistant Cladding, Overlays and Linings

The following standards shall apply in addition to the requirements of this standard:

11.1 Weld overlays and welding of integral cladding shall conform to JERES-W-014.

12 Technique and Workmanship

12.1 Welding Environment

12.1.1 Wind shields or tents shall be required when the wind is strong enough to affect arc stability or shielding gas coverage or when deemed necessary by Company Inspector. GTAW, GMAW, and gas-shielded FCAW shall not be used for field or yard fabrication unless adequate wind shields are used. The wind velocity in the weld area for GTAW, GMAW, or gas shielded FCAW shall not exceed 8 kph (2.2 m/s).

12.1.2 Welding shall not be done when surfaces are wet or damp or exposed to rain or snow or when the welders are exposed to inclement conditions.

12.1.3 Contamination from the environment, such as wind-blown sand, shall be prevented by the use of adequate shielding.

12.2 Joint Preparation

As a general rules bevel preparation should be in accordance with ISO 9692-1 and ISO 9692-2.

12.2.1 Oil, moisture, rust, scale, sand, paint (except weldable primers for approved applications - refer to paragraph 8.5.3 for restrictions), metallic coatings (e.g., zinc), or other foreign matter shall be removed from the weld surface and at least 40 mm of adjacent base metal on both side of weld prior to welding, including any such coatings on temporary attachments or supports.

12.2.2 Flame cutting and arc-air gouging





of 67

12.2.2.1 Ragged and irregular edges shall be ground or machined to bright metal. Holes cut for nozzles or bosses attachment shall be ground smooth and as accurate as possible. Unless otherwise specified by ASME VIII, the actual diameter of the hole shall be ± 1.6 mm of the nominal specified diameter.

12.2.2.2 Thermally cut or gouged surfaces for all materials, including carbon steels, shall be power brushed or ground prior to welding.

12.2.2.3 A minimum of 1.5 mm depth shall be removed by grinding or machining from thermally cut or gouged surfaces of air-hardenable materials (e.g., Chrome-Moly steels) except if the vessel manufacturer can demonstrate Hv10 value below 380 after grinding to bright metal finish through representative tested coupon.

Additional nondestructive examination may be required on the cut surface, at the option of the authorized Company inspector.

12.2.2.4 Thermal cut surfaces of stainless steel and non-ferrous materials shall be ground to bright (unoxidized) material prior to welding. For P6 an d higher grade, only plasma or mechanical machining shall be used for bevel preparation.

12.2.3 All full penetration joints requiring double sided welding shall be ground or gouged to sound metal and inspected by penetrant testing (PT) or magnetic particle testing (MT) prior to welding the reverse side.

12.2.4 Buttering or weld build-up on joints

12.2.4.1 Buttering or weld build-up on the prepared surfaces shall not exceed the lesser of 3

1 of the base metal thickness or 10 mm without the approval of COMPANY. If the buttering or build-up exceeds this, then the following requirements shall apply:

a) The buttering operation shall be witnessed by the Company inspector.

b) The buttering shall be inspected by radiographic testing (RT) and PT or MT after completion of the build-up but before final welding of the joint.

12.2.4.2 Buttering of joints between dissimilar metal joints requires prior approval by Company. The approval shall be obtained through the welding procedure review process.

12.3 Cleaning

12.3.1 Each weld pass shall be thoroughly cleaned and all slag or other foreign matter removed before the next pass is deposited.





of 67

12.3.2 All slag, flux, and spatter shall be removed from the completed weld and surrounding areas.

12.3.3 Stainless steel and nonferrous materials shall be cleaned with grinding wheels or stainless steel brushes not previously used on other materials.

12.4 Tack welds

12.4.1 All tack welds shall be made by qualified welders.

12.4.2 All tacks or temporary welds shall be performed with the same care, materials, electrodes, minimum preheat, and procedures that are used for permanent welds.

12.4.3 Tack welds shall be of sufficient size to maintain joint alignment (minimum 20 mm in length)

12.4.4 Tack welds that are to be incorporated into the final weld (only for automatic welding) shall be thoroughly cleaned, prepared at each end, and inspected for cracks. Any cracked tacks shall be removed before welding the joint. Is preferable that tack weld will be carried out on the back of first pass. Manual tack welding in butt welds shall be removed.

12.4.5 If the tack welds are to be incorporated into the final root pass weld and are made with a different process or electrode than the root pass, then the tack weld process and electrode shall have been used as the root pass for an appropriate procedure qualification.

12.5 Arc strikes, gouges, and other indications of careless workmanship (such as surface porosity, uneven weld profiles, and undercut) shall be removed by grinding and then examined by Magnetic Particle Inspection.

12.6 Any temporary welded attachments or temporary tack welds shall be ground off. Attachments may be cut off no closer than 3 mm to the base metal surface, prior to the required grinding. Temporary attachment shall be of the same P nunber of the base material and shall be same chemical composition for P4 and higher.

12.7 If any grinding reduces the base metal thickness to less than the design minimum, the ground area shall be rewelded and ground flush with the original base metal surface or the component shall be replaced. Rewelding shall be done only with the prior approval of Company Inspector.





of 67

12.8 For all materials, inspection by magnetic particle or liquid penetrant methods of areas shall be performed where temporary welds have been removed (see 12.6) or weld repairs to ground areas of the base material have been made (see 12.7) or arc strikes after repair by grinding (see 12.5).

12.9 Temporary attachments, grounding lugs, or supports welded to any component shall be made with a compatible material. Under no circumstances shall rebar or galvanized steel be used.

12.10 Coated and clad or overlaid surfaces shall be protected from the welding arc, associated weld spatter, and damage from ground clamps or other associated equipment.

12.11 Peening is not permitted

12.12 Adjacent beads of a weld shall be staggered and not started in the same location.

12.13 Back purging

12.13.1 An inert backing gas shall be used for GTAW or GMAW root passes on single-sided groove welds for materials of ASME P-No. 5 and higher.

12.13.2 For P-No. 5 and higher materials, any back purging shall be maintained until at least 10 mm of the weld deposit thickness has been completed.

12.13.3 The back purge shall be sufficient to reduce the oxygen level below 1%. The method of back purge and the flow rate shall be specified on the WPS.

12.13.4 The use of nitrogen as a backing gas for austenitic stainless steels is prohibited.

12.13.5 The back purge for stainless steel and nickel alloys shall reduce the oxygen level below 0.05%. An oxygen analyzer should be used to determine the oxygen content in the back side pipe during purging. It is the inspector responsibility to determine the analyses frequency.

Full visual or boroscopic examination using AWS D18 2 1999 “Guide to Weld Discoloration Levels on Inside of Austenitic Stainless Steel Tube” may be used in replacement of oxygen measurement for P Number 8 and higher. Blue color is not accepted





of 67

Commentary Note:

If it is not possible to use gas purging then we may accept using cleaning compound/tool to remove the oxide discoloration on the back side of the weld. The inspector should be consulted to evaluate/accept the cleaning method.

12.14 Seal welding

Threaded connections are not accepted.

12.14.2 Sealing compounds or tapes shall not be used on joints that are to be seal welded.

12.15 Forced or accelerated cooling of welds is prohibited without the specific approval of COMPANY.

13 Preheat

13.1 Preheat shall be in accordance with the applicable division of ASME SEC VIII and this Standard. For materials not covered in this Standard, the preheat shall be as specified in the approved welding procedure.

13.2 The minimum preheat shall not be less than the greater of the following:

a) 10°C.

b) The required or recommended preheat listed in ASME SEC VIII div 1 apdx R or table 9, whichever is the more restrictive.

Commentary Note:

The listed preheats are minimum requirements. The actual preheat temperature selected and used by the fabricator must be sufficient to prevent cracking and to achieve the required hardness, if specified.

13.3 For steels with specified minimum yield strengths above 414 MPa, the preheat shall be as specified in the approved welding procedure. Special applications may require special weldability tests to evaluate the preheat temperature.

13.4 If a weld joint is wet or has surface moisture or condensation, it shall be dried by heating for a distance of 100 mm from the weld joint and shall be warm to the hand before welding unless a greater preheat temperature is required.

13.5 Temperature-indicating crayons, thermocouples, or calibrated contact pyrometers shall be used to measure preheat and interpass temperatures.





of 67

13.6 The preheat temperature shall be established over a minimum distance of 75 mm on each side of the weld.

13.7 If the wall thickness exceeds 25 mm and preheating is to be done from the same side as the welding, then the heat source shall be removed for 1 minute to allow for temperature equalization prior to measuring the temperature.

13.8 Unless specified otherwise, the maximum interpass temperature shall be 177°C for P-No. 8, P No. 3X and P-No. 4X materials and 315°C for P-No. 1, P3, P-4 and P-5 steels.

13.9 Interpass temperature shall be measured according to ISO 13916

TABLE 9- PREHEAT

PREHEAT

MATERIAL (3) Wall Thickness (mm) Minimum Temperature (°C)

Carbon and Carbon Manganese Steels

< 30 30 to 50

> 50

20 (1) 20 (2) (1)

100

High Strenght CS < 50 > 50

100 125

0.3-0.5 Mo Steel All 100

1 Cr -0.5 Mo, 1.25 Cr -0.5 Mo

All 150*

2.25 Cr - 1 Mo All 200**

5 Cr - 0.5 Mo, 9 Cr - 1 Mo

All 250

2.5 Ni 3.5 Ni

All All

120 150

12 - 17 Cr Martensitic Steels

All 200

Notes:

1: If ambient temperature is below 5°C, preheat to 40°C is mandatory

2: 80°C minimum if specified UTS is equal or greater than 490 MPa and weld heat input is less than 20kJ

3: In case of dissimilar welds, preheat temperature shall be the highest of the two.





of 67

(*) For thickness below 25mm slow cool down under insulation; for thickness higher than 25mm intermediate post heat treatment at 200°C during 2 hours and then slow cool down under insulation. Intermediate PWHT shall be performed immediately after welding

(**) For thickness below 25mm intermediate post heat treatment 200°C during 2 hours and then slow cool down under insulation. For thickness higher than 25mm intermediate post heat treatment at 250°C during 3 hours and then slow cool down under insulation. Intermediate PWHT shall be performed immediately after welding

14 Post Weld Heat Treatment

14.1 Post weld heat treatments (PWHT) shall be in accordance with ASME SEC VIII. A written procedure describing the general PWHT requirements shall be submitted for review and approval. The PWHT procedure shall include descriptions of the equipment, method of heating, location and type of heating elements, temperature measurement, and thermocouple locations. The review and approval process shall be the same as described for welding procedures (paragraph 8.1).

14.2 The reduced temperature permitted by Note 1 of Table UCS-56 or AF402.2 shall not be used without written authorization from the Company Representative.

14.3 Prior to the start of work the company representative or fabricator shall prepare a data sheet for each vessel (or joint for localized PWHT) requiring heat treatment, which shall be submitted to Company Inspection for review and approval. The data sheet shall include the following information: wall thicknesses (for shell, heads, and nozzles), material, heating rate, cooling rate, soak temperature, and soak time.

14.4 For carbon and low alloy steels, the following process conditions require PWHT. Other process conditions may also require PWHT, as determined during the project design. .

14.4.1 All caustic soda (NaOH) solutions, including conditions where caustic carryover may occur.

14.4.2 All monoethanolamine (MEA), methyldiethanolamine (MDEA) and diethanolamine (DEA) solutions, at all temperatures.

14.4.3 All diglycol amine (DGA) solutions above 138°C design temperature.

14.4.4 All rich amino diisopropanol (ADIP) solutions above 90°C design temperature.

14.4.5 All lean ADIP solutions above 60°C design temperature.

14.4.6 Boiler deaerator service (i.e., ambient temperature vacuum deaerators are exempt).





of 67

14.4.7 Hydrogen service for P-No. 3, 4, and 5A/B/C base materials.

14.4.8 deleted.

14.4.9 Wet H2S service (for wet H2S service Appendix C and JERES-A-301 shall be followed)

14.4.10 Items in amine and caustic service: PWHT shall be performed according to appendix C.

14.4.11 Items in carbonate service: PWHT shall be performed according to appendix C.

14.4.12 The applicable industry code must be followed for PWHT requirement for any service not listed above. Other process conditions may also require PWHT, as determined during the project design. Code exemptions for PWHT are not permitted if PWHT is specified for process conditions.

14.4.13 These requirements apply to external welds to attach non-pressure containing component to the vessels (e.g., reinforcement pad or sleeve attached to the pipe) and to seal welds. Seal welds on threaded valves may be exempt from the PWHT requirements if the PWHT will damage the valve internals, if they cannot be removed.

14.5 The specified PWHT shall be applied over an area extending at least 6 times the thickness of the material being welded from each edge of the weld but not less than 25 mm from each edge of the weld, whichever is greater.

14.6 For PWHTs that are not performed in a furnace, insulation shall be applied a minimum of 300 mm on either side of the weld that is to be PWHTed. The insulation shall not be removed before the temperature has cooled to below 150°C. The internal surface must also be insulated to avoid lowering the temperature on the inside surface of the joint.

14.7 Code exemptions for post weld heat treatment are not permitted for vessels requiring PWHT for service conditions.

14.8 Code exemptions for post weld heat treatment of ferritic materials based on the use of austenitic or nickel-based electrodes are not permitted.

Commentary Note:

Austenitic or nickel-based electrodes shall not be used for ferritic materials except dissimilar metal welds listed in 7.9 and overlays.





of 67

14.9 Code exemptions for post weld heat treatment of P-No. 4 and P-No. 5 materials are not permitted for applications involving either sour service or materials exceeding 2.5% nominal chromium content.

14.10 For applications where PWHT is required by the service fluid or where hardness limits are specified:

a) Any reductions in the PWHT temperature or alternative temperatures below the normal holding temperatures listed in the applicable Code are not permitted.

b) The minimum PWHT soak time shall be 1 hour.

c) If hardness limits are specified, the soak time for production welds shall not be less than 80% of the PQR soak time unless approved by COMPANY.

14.11 All temperatures within the heated zone for furnace or localized PWHT shall exceed the specified minimum holding temperature. The actual temperature range for the soak period, as recorded by thermocouples, shall not have a spread of more than 40°C.

14.12 Welding or heating to joints that have been PWHTed requires re-PWHT. Post weld heat treatment shall follow all welding and repairs but shall be performed prior to any hydrotest.

14.13 PWHT shall be carried out using one or more of the following types of heat sources:

a) Permanent or semi-permanent furnaces using gas or oil or electric heaters (a vessel itself may be considered a furnace if heated internally and externally insulated).

b) Electrical resistance heaters.

c) Induction heaters.

14.14 Thermocouple locations shall include both the inside and outside surfaces of the vessel for weld thicknesses in excess of 75 mm. For all vessels PWHTed in a furnace, the thermocouple locations shall include:

a) The thinnest major component.

b) The thickest member.

c) The top of the vessel (as oriented during PWHT).

d) The bottom of the vessel (as oriented during PWHT).

14.15 Localized PWHT





of 67

14.15.1 Localized post weld heat treatment of weld joints is not permitted except for:

a) Circumferential Closure seams if previously approved by Company

14.15.2 If localized PWHT of the vessel shell is used, it shall be monitored using at least four sets of thermocouples, with each set consisting of one thermocouple each on the inside and outside surfaces. Each set shall be placed at 90 degree intervals around the vessel circumference. Additional thermocouple sets are required if multiple heat control zones are used when a control zone is not monitored by one of the four primary sets.

14.15.4 Localized PWHT shall conform to the requirements of ASME SEC VIII (e.g., full circumferential band around vessel) except for field repairs and modifications to in-service vessels that were not originally PWHTed. For these cases, the requirements shall be established by COMPANY.

14.16 Thermocouples and a calibrated temperature chart recorder shall be used to provide an accurate and legible record of all PWHTs. All charts shall be marked with the date and sufficient information to uniquely identify the vessel (or joint/component for localized PWHT) being heat treated. Multipoint chart recorders shall clearly differentiate/identify each channel/point by use of different colored inks or automatic number stamping.

14.17 Temperature recorders shall be calibrated every three months and a current calibration sticker shall be maintained on the recorder. The calibration frequency may be extended to 12 months with the approval of Company Inspector if the documented calibration checks for that particular recorder demonstrate acceptable accuracy for a suitable period.

14.18 Thermocouples

14.18.1 Only Type K (Chromel-Alumel) or Type J (iron-Constantan) thermocouples are permitted. All extension cables, compensating cables, and jumper cables in the measurement or control circuits shall be the specified thermocouple wire or the matching extension wire (i.e., KX or JX, as appropriate). For Type K thermocouples, copper-Constantan (Type T) compensating cables may be used with the following conditions:

a) The junction between the copper-Constantan compensating cable and the Type K thermocouple lead shall be a minimum of 0.5 m outside the insulated area.

b) The acceptable temperature range of the junction between the compensating cable and the thermocouple lead is from 0 to +80°C.





of 67

14.18.2 The national standard that the thermocouple conforms to shall be indicated in the PWHT procedure. The procedure shall also include a listing of the insulation coloring of each core wire and the overall sheath for both the compensating cable and thermocouple. This information is required for site inspectors to verify that the proper wires have been used and are connected in the proper polarity.

14.18.3 Thermocouples shall be attached to the component by capacitive discharge welding only. Other methods of attachment are not permitted. The thermocouples shall not be in direct contact with electrical heating elements or subjected to flame impingement by gas or oil burners.

14.19 Prior to the start of the PWHT, components shall be checked to ensure that all restraints are removed, the component is free to expand and contract, and suitable and sufficient supports are used. In addition, the PWHT chart should be marked, prior to PWHT, with identification number of the weld(s).

14.20 All machined surfaces, such as flange faces, threaded bolt holes, threads, etc., shall be protected from oxidation during the heat treatment by coating with deoxaluminite or other suitable material.

14.21 All PWHT chart records shall be submitted to Company Inspection for review and approval. All records shall be submitted as part of the equipment file for permanent record.

14.22 After completion of the PWHT all thermocouples shall be removed and the attachment areas ground smooth to clean and sound metal. If specified by the Inspector, the areas shall be examined by MT or PT after grinding.

14.23 PWHT shall be performed before NDE is conducted.

15 Production Weld Hardness Testing

15.1 Hardness testing is required on production welds for the following applications:

a) For all materials in sour service.

b) For vessels PWHTed for service (see 14.3).

c) Vessels of P-No. 4 or 5 material.

Personnel performing hardness testing shall be familiar with all hardness testing procedures and test methods.





of 67

Procedures and test methods used for portable hardness testing shall be in accordance with ASTM E110 as applicable and submitted to COMPANY REPRESENTATIVE for review.

Hardness test shall consist of at least one hardness measurements in weld metal and HAZ which shall be taken on each longitudinal and circumferential weld seam and each diameter of branch connection nozzle. Each welding procedure used shall be tested.

Each weld forming part of prefabricated head shall be as well hardness tested.

Hardness results shall not exceed

− 200 HB for P No 1 material for sour service applications

− 225 HB for P. No 3

− 225 HB for P4 and P5 Gr 1 material. (For 9% Cr material – 9Cr-1Mo, 235HB is the maximum limit)

− 238HB for P No 5 Gr 2 material

Hardness testing results shall be expressed in Brinell numbers. The hardness report shall indicate actual hardness reading for the test method used, type of hardness tester, personnel conducting hardness tests, type of material, and calibration.

15.2 The testing shall be in accordance with NACE RP0472 and the requirements listed below. All welding processes and consumables, including SMAW and GTAW, shall be tested. The testing location and frequency shall be in accordance with NACE RP0472. For all other materials, it shall be the equivalent hardness as specified in JERES-A-301 (equivalent hardness conversions shall be in accordance with ASTM E140). Welds for external attachments on vessel shells are exempt from hardness testing.

Commentary Note:

NACE RP0472 exempts welds from hardness testing if they are made with specific processes and consumables, unless otherwise specified by the user. This paragraph imposes the hardness testing for all welds (e.g., including E6010, E7018, and ER70S-2), i.e., it does not permit the exemptions to be used.

15.3 The testing guidelines listed in Appendix A of NACE RP0472 shall be mandatory.





of 67

15.4 Testing shall be conducted with portable hardness testers (TeleBrineller or approved equivalent) that comply with ASTM A833. The Brinell scale shall be used unless another scale is specifically approved by COMPANY. The hardness of the reference bar shall be within ±10% of the maximum specified hardness.

Commentary Note:

Equotip is not accepted for production weld hardness test.

15.5 The weld reinforcement shall be ground to provide a smooth flat surface for testing.

15.6 Hardness indentations shall be made at or near the middle of the deposited weld bead.

15.7 If any reading exceeds the specified limit by no more than 10 BHN, then a minimum of three (3) additional indentations shall be made near the original high reading. If all three (3) retests are below the specified limits, then the joint is acceptable. If any of the retest readings are found to exceed the specified limits, then the weld shall be considered unacceptable.

16 Vessels Production Weld Test coupons

In addition to ASME code requirement, vessel production test coupon shall be required for each Welding Procedure Qualification used for joint of categories A and B on PWHT treated vessels or group of vessels (1). Vessel production test coupon shall undergo the final Post Weld Heat Treatment together with the vessel in the furnace.

For vessels of thickness greater or equal to 50 mm in P N° 1 and for all vessels in P N° 3 and higher, all mechanical tests required on PQR shall be performed on the test coupon with the same acceptance criterias as for PQR.

For vessels of thickness lower than 50 mm the test coupon shall be kept by the Vessel manufacturer and tested only in case were PWHT chart exhibit any deviation from the required parameters (id: holding temperature, heating cooling rates range…).

Note:

(1) Definition of group of vessels is given in ASME VIII Div. 1, clause UG84.

Test coupons shall be of sufficient length to allow for all mechanical tests to be taken.





of 67

Test coupons shall be welded attached to the part being welded where possible and shall reflect the actual welding and heat treatment conditions of the equipment.

17 Weld Identification

17.1 All weld joints shall be marked for identification by a weld number and a welder symbol. These identifications shall be made with a suitable weather-proof marking material. The markings shall be placed in a location such that they will be easily observed and remain visible for a time suitable to the authorized Company inspector.

17.2 The fabricator shall establish and submit for approval an identification system that shall uniquely identify each component and weld joint. The identification system shall be used to identify all examinations, surveys, inspections, etc. This system shall also be used to identify the final position of each piece of pressure-retaining material (including each heat number) in the completed vessel.

18 Repairs

18.1 Welds may be repaired twice at any defect location. If a weld is still not acceptable after the second repair, then Company has the sole authority for the decision to permit additional repair attempts or to require that the entire weld be cut out. The limitation on the number of repairs does not include adjacent sequential repairs where the length of the area to be repaired is limited by structural strength or other considerations.

18.2 Repair of cracks that are fabrication related shall require the approval of Company assigned inspector. The repair procedure including inspection, excavation, approved welding procedures shall be reviewed and approved by the inspector. Cracks that are related to the base metal or welding consumable shall be evaluated by COMPANY before any repair attempts.

Commentary Note:

Crater cracks do not require special repair and shall be ground out only.

18.3 In-process repairs (i.e., repairs performed prior to completion of the joint using the same welding procedure as for the original fabrication) during production do not require a separate repair procedure except for cracks (see 18.2).

18.4 The repair procedure may utilize a welding procedure previously approved by COMPANY in conjunction a separate method statement or it may be a separate detailed welding procedure.





of 67

18.5 All repaired welds shall, as a minimum, be inspected using the original testing method. Additional test methods may also be required, if deemed necessary by the authorized Company inspector. Replacement welds (cut-outs) shall be examined as a repair.

18.6 Damage or deformation to the base metal or welds, including dimensional changes, caused by external forces (intentional or accidental) requires special repair and inspection procedures be submitted to Company Inspector and if necessary forwarded to COMPANY for review and approval prior to undertaking the repairs.

18.7 Any weld not meeting the acceptance criteria of the applicable code or standard shall be cut out or repaired. Other methods, such as sleeving, shall not be permitted.

19 Miscellaneous Requirements

Welding power supplies should be validated in accordance with BS 7570 or an approved equivalent if impact toughness test is required by the applicable company or industry specifications or codes. In any case, welding power supplies shall be calibrated.

The fabricator must also use calibrated amps/volt meter to measure the welding current and voltage and compare the readings against the welding machine indicators. Discrepancies in the readings shall be rectified before commencing/continuing welding.

20 Proximity of Welds

20.1 The welds, and longitudinal welds in particular, shall be positioned such that they do not overlap the openings in the vessel, their reinforcements, attaching or supporting devices, gussets, etc.

20.2 Whatever the case, it is better for a tube to cross a weld rather than be too close to it provided it is previously agreed by Company and that UT testing is performed on 200 mm of weld on shell and tube.

20.3 Welds attaching manways, nozzles and their reinforcement pads and other structural attachments to pressure components shall not be closer than 50 mm (toe-to-toe) from any welds under stresses due to pressure.

20.4 Unless conditions make it is impossible (in which case special measures are required) the distance between the edges of two welds (and not their centerlines) shall not be less than the greater of the two values





of 67

− 50 mm between a circular weld and a tube weld (or its reinforcement),

− 50 mm between a longitudinal weld and a tube weld (or its reinforcement) (recommended an preferred value is 100 mm),

− 50 mm between two tube welds (or their reinforcements).

− 75 mm for any others welds non pressure retaining attachment fillet welds.

20.5 The longitudinal welds of two adjacent shell rings shall be offset by at least 60° for vessels of 6 meters diameter or less, and by 45° for larger vessels.

20.6 Where a weld seam and an attachment weld intersection seems unavoidable, Radiography Testing and Magnetic Testing after grinding of the seam weld shall be carried out prior to making the attachment weld. The examination shall be on a distance of 100 mm or three times the shell thickness

20.7 Horizontal cylindrical vessels

They shall not feature any:

- Longitudinal welds situated more than 30° below the generating surfaces corresponding to the horizontal diametrical plane, (see sketch below)

Circular welds located less than 50 mm from the supports (metal or concrete).





of 67

20.8 External stiffeners for vessels subjected to vacuum

In horizontal and vertical vessels the stiffeners shall have opening when they cross to the longitudinal welds or connection pieces.

In vertical vessel the welds of stiffeners shall be continuous fillet welds on the upper section and on the lower section and also trough the rat hole if any.

top

bottom

Cross sectionnal area of vessels

Horizontal diametrical plane

30° 30°

Longitudinal welds shall not be in this area





of 67

Appendix A: STRENGHT WELD OF TUBE - TUBE SHEET CONNECTIONS

1.1 Scope

Whatever the Construction Code, This chapter is applicable when strength welded tube/tube sheet connections have been specified and is intended to supplement ASME VIII Div. 2 Article F-3, which is mandatory by this specification, and ASME Code Sect. IX QW-193 recalled in.

1.2 General

No production welding shall be carried out until the proposed welding procedures have been reviewed and accepted by the COMPANY REPRESENTATIVE in accordance with the requirements of the Code and this Chapter.

1.3 Preparation of tubes and tube SHEET

The ends of the tubes which are to be welded shall be cleaned with a suitable non-residue forming solvent, both inside and outside. The solvent used for degreasing materials shall be chloride free, e.g. acetone.

The tubesheet shall be machined and the tube holes bored or drilled and reamed as required by the approved drawings.

The face of the tubesheet, the holes and the tubes shall be free from dirt, grease, scale and other foreign matter when they are assembled. To avoid possible damage during assembly or entrapment of contaminants, baffle and support plate holes should be free from burrs and effectively cleaned prior to the commencement of tube threading.

1.4 Welding procedure and welder qualification

1.4.1 Procedure Test Piece (PQR)

The test pieces shall be in accordance with ASME VIII Div 2 - Article F-3 and ASME IX QW-193.

The procedure test shall be welded in the same position as the actual welding to be done, i.e. vertical or down-hand. Also the welding sequence/configuration shall be part of the procedure qualification.

All tubes used for procedure testing shall be of the same diameter, wall thickness and nominal chemical composition as those proposed for production. Tubesheet material to be used for the procedure test shall also be of the same nominal composition as to be





of 67

used in production. The thickness of the coupon sheet shall equal that of the tube sheet to be used in production and not need to exceed 50 mm thickness.

1.4.2 Examination of Test Pieces

Mockup welds shall be examined as per QW 193 of ASME IX. And additional ones as per the following:

− Macro-graphic examination on two tubes at magnification X5.

− Hardness survey HV 10 Vickers for ferritic steel across above macro examination specimens such as to include weld, heat affected zones and base metal (both tube and tube-sheet side)

− One set of micrographic weld examination at magnification X200 for P-No 3 and greater to show the weld, H.A.Z. with tube and tubesheet.

− Three (3) shear load/pull out tests according to ASME VIII div. 1 Appendix A - for fixed tube sheet only.

SUMMARY OF TESTS REQUIRED

Type of Test Required

Procedure Qualification

Welder Qualification Production Mock-up test

Visual Yes Yes Yes

Dye penetrant Yes Yes Yes

Macro Examination Yes Yes Yes

Micro Examination Yes No No *

Hardness test survey HV 10

Yes (ferritic steel) * No Yes (Ferritic steel) *

Pull test as per ASME VIII Div. 1

Yes (fixed tubesheet only)

No No

* REQUIRED FOR TUBE IN DUPLEX STAINLESS STEEL.

1.4.3 Weld Quality Requirements

The following defects shall not be allowed (N.A.)

− Cracks

− Lack of fusion

− Burn through of the tube bore





of 67

− Excessive weld spatter

− Gas porosity

1.5 Effective weld throat thickness

The manufacturer shall follow the provisions of ASME VIII Div 1 UW-20 “full Strength welds”.

1.6 Hardness

Hardness test results shall not exceed limits given in paragraph 7.5 of this specification.

1.7 Welder Qualification

Every welders employed shall demonstrate his competence by making a test piece in accordance with QW-193.2 of ASME IX and additional requirements as per above mockup test piece.

1.9 Welding process

GTAW Welding shall be carried out preferably with automatic orbital machine.

Welding shall include two weld passes minimum for strength welds, with minimum one pass with filler metal.

The uses of other processes require the prior acceptance of the COMPANY REPRESENTATIVE.

1.9 Examination of production welds

For manual GTAW process after each weld run, the welds shall be, visually, examined. All defects detailed in § 1.4.3 shall be repaired.

Dimensional examination shall be performed after completion of all welds.

All complete welds shall be examined by dye penetrant. After dye penetrant testing, all traces of dye, developer and solvents shall be removed. Where dye penetrant testing is not possible due to accessibility, visual examination shall be performed.





of 67

1.10 PRODUCTION MOCK-UP TEST

Unless otherwise specified on data sheet or in particular specification, production mock-up test shall be carried out concurrently with the fabrication when any of the following conditions apply:

− Pressure rating 1000 Lbs and above

− Hydrogen service

− Design Temperature above 400°C

− When welding dissimilar material (P “Number” material to other P “Number”)

Number of test shall be as follows:

− For each heat exchanger or group of similar heat exchangers (group of heat exchangers is given in ASME VIII Div. 1, clause UG84).

− One tube to tube-sheet weld for each welder or operator by shift.

− Minimum 1% with not less than 5 tubes

Testing and acceptance criteria shall be in accordance with § 1.4.2 of this attachment.

1.11 Leak Detection

When specified, the final hydrostatic test shall be preceded by a low pressure air test and/or by a gas leak test.

Air testing

The tube to tube sheet welded joints shall be tested for leak detection by applying a pressure of 0.5 bar (ga) (7.25 psig). While the shell is under pressure, a soap detergent shall be used to indicate any leakage (API 660 para 10.3.1).

Leak investigation

All leaking weld locations shall be marked for repair.

Gas leak testing

When specified, a tracer gas leak test shall be used instead of the air test. The tracer gas is usually helium, but other gases may be used subject to company representative approval.





of 67

1.12 Repairs

Defects associated with fully automatic GTAW welding incorrect settings or tracking, may be rectified by re-welding at corrected settings or locally repaired by manual GTAW process. When any defects occur, particularly cracking, the cause shall be established prior to repair.

Any defect shall be completely removed to sound metal and repaired using an approved repair procedure.

1.13 Light Expansion

Where light expansion after welding is specified, it shall be carried out after the successful completion of the low pressure pneumatic test or leak testing when specified.

Light expanding is performed to close the gap between tube and tube sheet after welding to avoid fluid or media circulation and subsequent crevice corrosion and to isolate the weld to any vibration from the tube. This expanding doesn’t provoke hard deformation between the tube and the tubesheet. The expansion value can be 3 - 5 percent.

Expansion after welding shall be also performed on qualification and production mock up

After expansion, the tube internal shall be visual inspected to assure no damages of tubes.





of 67

Appendix B: Heavy Expanded Tube - TubeSheet Connections

1 Scope

This chapter is applicable when strength expanded tube/tube sheet ( with grooves) connections have been specified in Data sheet

2 General

Mock up testing shall be used for procedure and operators performance qualification.

Expansion procedure shall include expansion method, expanding tools definition and torque definition within maximum and minimum deviation of 5%.

No production expansion joint shall be carried out until the proposed expansion procedures have been reviewed and accepted by the Company Representative in accordance with the requirements of this Chapter.

3 Preparation of Tubes and Tubesheet

Heavy expansion joints shall be qualified as follows:

The mock up shall be drilled, respecting essential variables listed below and with sufficient non-peripheral tubes to represent:

− Maximum diameter within tolerance (minimum 10 tubes)

− Maximum admissible diameter out of tolerance (recommended 5 holes by over range)

The essential production variables shall be the same as per mock up variables within validity range. These are:

− pattern

− pitch

− tube-sheet material

− tube material

− external tube diameter

− tube thickness





of 67

− expansion ratio T= ⎟⎟⎠

⎞⎜⎜⎝

⎛ −−

edd idudgp

2 0

1100 where dp is the maximum drilled hole

diameter ,didudg is internal diameter of tube after expansion and e0 is tube thickness before expansion

− expansion length

− number and design of grooves

− diameter, length and number of expanding rolls

4. Qualification Test

The expanding procedure and operators shall be qualified as per the following requirements:

4.1 Test required

A shear load / pull out test shall be performed on one or several non-peripheral tubes.

Pull out strength shall be superior to according following conditions:

− Single value superior to 3 times the axial load in case of one tube testing − Average value superior to 1,5 time the axial load in case of 3 tubes testing.

4.2 Qualification range

− Qualified length qualifies superior lengths

− Qualified Expansion Ratio more or less 2 %

− Qualified pitch qualifies greater pitches

− Qualified triangular pattern qualifies squared pattern

− For an expanding ratio between 5 and 15%, qualification of tube thickness e0 and tube external diameter dt qualifies same external diameter with greater thicknesses

− For an expanding ratio between 5 and 15%, qualification of tube thickness e0 and tube external diameter dt qualifies same thickness with greater diameters

− Without grooves qualification qualifies with grooves procedure

− Qualification for tube and tube sheet material combination qualifies all combinations within correspondent P number material.





of 67

A change in diameter, length and number expanding rolls shall lead to a new qualification.

Expanding ratio definition for tube and tube sheet material group combination: same P-Number

4.4 Operator qualifications

Operators shall be qualified according to the same procedure as for qualification.

4.5 Production Mock-Up Test and Production recording

Unless otherwise specified on data sheet, production mock-up test shall be carried out concurrently with the fabrication:

− For each heat exchanger or group of similar heat exchangers (group of heat exchangers is given in ASME VIII Div. 1, clause UG84).

− One tube to tube-sheet strength expansion for each operator by shift.

Testing and acceptance criteria shall be in accordance with § 4.1 of this attachment.

The production test piece shall be tested in the same conditions as for qualification and shall meet the same minimum strength value.

Each hour, the torque device shall be measured on 3 values and recorded.

4.6 Test Report

Test Report shall include as a minimum:

− Pull out test results on production test piece

− Expansion ratio on a mock up and on random basis on production (1% mini, no less than 5 tubes)

− Expanded length.

This test report shall be included in the manufacturing dossier.





of 67

Appendix C ADDITIONAL REQUIREMENTS FOR WELDING THE VESSELS USED IN WET H2S AND AMINE SERVICE THIS APPENDIX SHALL BE READ IN CONJUNCTION WITH APPENDIX F OF JERES-A-301

1 FILLER PRODUCTS

For equipment in sour wet H2S services the following supplementary requirement shall be apply:

− Nickel content of the welding consumables shall not exceed 1%.

− Pressure retaining welds shall be made with low hydrogen consumables.

− Low hydrogen electrodes shall exhibit a very low diffusible hydrogen (less than 5 cm3 H2/100 gr of metal deposit) in accordance with ISO 3690 (Mercury testing), AWS A 4.3 or equivalent standard.

− Mn content in all weld deposit metal shall not exceed 1,6% in weight and P&S content shall be limited to 0, 010 % in weight

2 SHIELDING GAS

The shielding gases shall not contain hydrogen. Their dew point shall be ≤-40°C. 3 FABRICATION

3.1 Forming

Carbon and low alloy steels shall be thermally stress-relieved following any cold deforming by rolling, cold forging, or another manufacturing process that results in a permanent outer fiber deformation greater than 5 %. Thermal stress relief shall be performed in accordance with an appropriate code or standard. The minimum stress-relief temperature shall be 595 °C (1 100 °F).

3.2 Welding

In the case of vessels containing hydrogen at temperatures above 200°C, wet H2S and HF, parts joined to the walls shall be welded with full-penetration welds, or failing this, have discontinuities at the low points for degassing.





of 67

4 POST-WELDING HEAT TREATMENT (PWHT)

Vessels built in the shop shall undergo a PWHT.

The PWHT temperature and time shall be in the range of 600°C to 625°C, 1 hour per 25 mm of thickness, 1 hour minimum. Using a lower temperature for a longer period of time is not permitted. The heat-up and cool-down rates shall be in accordance with ASME Section VIII Division 1 or 2, as applicable.

5 MODIFICATION OF THE EXTENT OF INSPECTIONS

All accessible surface of welds of pressure retaining parts shall be 100 % inspected by wet magnetic fluorescent particle test (WMFT) after PWHT according to chosen code.

For thickness ≤ 40 mm, 100 % ultrasonic examination or radiography of butt welds including full penetration fillet welds is required after PWHT.

For thickness > 40 mm, a 100 % radiography or ultrasonic examination is required before and after PWHT.

6 STAGE OF TESTING PERFORMANCE

Tests are to be performed no sooner than 48 hours after welding completion.





of 67

Appendix D

ADDITIONAL REQUIREMENTS FOR 5% CHROMIUM STEEL MATERIAL FABRICATION AND TESTING

1. Scope

This specification covers general requirements for the material, fabrication, welding and inspection of pressure vessel and heat exchangers in 5 Cr – 1/2 Mo steel with or without weld overlay cladding.

Requirements for Pn° 5B material detailed in the body of this Job Specification remain applicable

2. Base Material

2.1 General

All base materials shall be supported by 3.1 inspection certificate according to EN 10204.

2.2 Plates. 2.2.1 Base material plates

The plates to be used for fabrication of equipment shall comply with all requirements of grade SA 387 Grade 5 with supplementary requirements S1, S2, S3, S5, S8, S12 and the following additional requirements

2.2.2 Steel making process/heat treatment

The steel plates shall be made by either the electric furnace or basic oxygen furnace vacuum degassed steel process, according SA 20 Supplementary requirement S1.

Plates may be supplied both in Normalized with accelerated cooling by liquid quenching and tempered or Quenched and Tempered condition.

Holding time shall be sufficient to obttain a uniform temperature throughout the plate.

Accelerated cooling from the austenitizing temperature by air blasting or liquid quenching may be employed in such a manner to ensure a homogeneous structure throughout the wall thickness.





of 67

Subsequently the plate shall be tempered in accordance with SA 387 for a sufficient time and temperature to produce the mechanical properties required by this specification. VESSEL MANUFACTURER is responsible for the selection of optimum heat treatments (quenching, accelerated fast cooling, austenitizing, tempering parameter) to produce the properties required in relation with the final PWHT conditions to be given to the equipment.

The minimum tempering temperature shall be always 20°C higher than the final Post Weld Heat Treatment of the equipment.

2.2.3 Simulated Heat Treatment

Plates shall be ordered and tested considering 3 cycles of original Post Weld Heat Treatment (to anticipate any potential repair in fabrication and on site) and any influence of production Post Heating after welding in the total Heat treatment cycle using Larsen Miller parameter.

2.2.4 Mechanical Properties

Depending on the heat treatment condition the following mechanical tests will be carried out for each heat of plate (mother plate) from both ends (head and foot).

After maximum simulated heat treatment (Max HT): − Tensile tests at room temperature (Ultimate Tensile Strength, Yield Strength at

0.2% and Elongation)

− One (1) set at each location of three (3) Charpy-V notch impact test specimens tested at Minimum Design Metal Temperature.

− Macro-hardness testing (on one plate of each heat only)

a) Tensile Tests

For thicknesses below 50 mm, tensile (transverse) shall be taken from one of ends of each plate from transverse ¼ thickness location at room temperature in accordance with ASTM/ASME standards requirements.”

For thicknesses over 50 mm, tensile (transverse) shall be taken from one of ends of each plate from transverse ¼ T and ½ T location at room temperature

b) Impact Testing





of 67

For thicknesses below 38 mm, impact testing shall be taken from both ends of each plate in the transverse direction at 1/4T location and according to ASTM/ASME standards requirements

For thicknesses over 38 mm, impact testing shall be taken from both ends of each plate in the transverse direction at 1/4T and ½ T plate location according to ASTM/ASME standards requirements.

Impact tests shall be conducted in accordance with code requirements, except that there shall be no exemptions from impact testing, and the test temperature shall be the Minimum Design Metal Temperature with the following requirements:

− 55 Joules for minimum average value

− 48 Joules for minimum individual value

Should any values fail to meet above requirements, retesting defines in SA370 shall apply.

Lateral expansion and percent shear fracture for each specimen shall be reported.

c) Macro hardness testing

Hardness survey shall be performed on macro cross section according to the Vickers hardness test method defined in the ASTM E 92 under 10 KG load.

Each specimen shall include hardness survey across the wall thickness of the plate and shall not exceed 248 HV10 with a target at 235 HV10 max.

2.2.5 Non destructive examination

All plates shall be ultrasonically examined in accordance with SA578 supplementary requirements S1 (scanning shall be continuous over 100% of the plate surface).

In case of integrally bounded clad plate, supplementary requirement S12 shall be applied.

Acceptance criteria shall be in accordance with SA578, level B.

Ultrasonic examination procedure from plate supplier shall be submitted to COMPANY REPRESENTATIVE for approval.

2.2.6 Dimensional/visual





of 67

Any under thickness beyond to code acceptance limit shall be cause of rejection of the plates.

Unless otherwise agreed by the COMPANY REPRESENTATIVE, repair by welding shall not be permitted.

2.3 Forgings

2.3.1 Base material

Forgings including those used for shell, heads, flanges and nozzles, shall conform to all requirements of SA 336 Grade F5

2.3.2 Steel making process/heat treatment

The restrictions defined for plates shall be fully applied for forgings. Forgings may be accelerated cooled in a liquid medium from an austenitizing temperature.

The forging manufacturer shall report the size of billet (or ingot) used for each part, the final reduction in cross-sectional area and amount of upsetting with respect to the billet (or ingot) and the complete heat treating procedure.

Proposed forging procedure shall be submitted to COMPANY REPRESENTATIVE. The forging ratio, that is the cross section before forging divided by the cross section after forging shall be equal to 2 as a minimum.

The minimum temperature of tempering shall always be higher than the final Post Weld Heat Treatment of the equipment by more than 20°C.

2.3.3 Simulated Heat Treatment

One set of mechanical test specimens shall prepared and subjected to the simulated heat treatment of 3 cycles of original PWHT (to anticipate any potential repair in fabrication and on site) and any influence of production Post Heating after welding in the total Heat treatment cycle using Larsen Miller parameter.

2.3.4 Mechanical Properties

As per previous point 2.2.4

a) Tensile Tests





of 67

For thicknesses over 3 inches (75 mm), tensile tests shall be performed at ¼ and ½ thickness location at room temperature and transverse to the direction of the greatest elongation.

For thicknesses below 75 mm, tensile tests shall be performed at ¼ thickness location at room temperature and thickness location at design temperature and transverse to the direction of the greatest elongation and according standard requirements”

b) Impact Testing

For thicknesses over 3 inches (75 mm), one set of three Charpy V-notch impact tests shall be taken from each forging at each tensile test location. The test specimens shall be oriented transverse to the direction of greatest forging elongation. Impact test specimens shall be taken from the 1/4T and 1/2T thickness location.

For thicknesses below 75 mm, one set of three Charpy V-notch impact tests shall be taken from each forging at each tensile test location. The test specimens shall be oriented transverse to the direction of greatest forging elongation. Impact test specimens shall be taken from the 1/4T thickness location.”

Impact tests shall be conducted in accordance with code requirements, except that there shall be no exemptions from impact testing, and the test temperature shall be the Minimum Design Metal Temperature with the following requirements:

− 55 Joules for minimum average value

− 48 Joules for minimum individual value

Should any values fail to meet above requirements, retesting defines in ASTM A370 shall apply.

Lateral expansion and percent shear fracture for each specimen shall be reported.

c) Macro hardness testing

Hardness survey shall be performed on macro cross section according to the Vickers hardness test method defined in the ASTM E92 under 10 KG load.

Each specimen shall include hardness survey across the wall thickness of the plate and shall not exceed 248 HV10 with a target at 235 HV10 max.

2.3.5 Non destructive examination





of 67

All forgings, except those produced in standard dies, shall be machined after heat treatment and prior to final magnetic particle and ultrasonic examination. The surface finish shall be Ra 6.3µm / 250µinch AA (See ANSI B46.1) or smoother.

− All forgings shall be 100% ultrasonically tested in accordance with SA 388 using both straight and angle beam. Acceptance criteria shall be as specified in ASME VIII Div 2 § AM 203.2

− All forgings shall be examined either by magnetic particle or dye penetrant examination.

Ultrasonic examination procedure from the forging supplier shall be submitted to COMPANY REPRESENTATIVE for approval.

Unless otherwise advised by the COMPANY REPRESENTATIVE repair by welding are prohibited.

2.3.6 Dimensional/visual

Any under thickness beyond to code acceptance limit shall be cause of rejection of the plates.

Unless otherwise agreed by the COMPANY REPRESENTATIVE, repair by welding shall not be permitted

2.4 Welding consumables

Prior to fabrication, welding consumables are subjected to screening test.

2.4.1 Screening tests

Each lot of welding consumables (filler metal, covered electrodes, wire/flux combinations) shall be tested by the pressure vessel manufacturer prior to fabrication using the intended WPS.

Screening groove weld test assemblies can be done either:

− on the same base material of the order or equivalent (equivalent material shall be approved by the COMPANY REPRESENTATIVE) of sufficient base material thickness but not less than 1”½ (38 mm)

− or concurrently with the Procedure Qualification (PQR).

− Screening test program shall be done after 3 cycles of PWHT





of 67

− Chemical analysis

− Tensile Tests

− Impact test.

− Hardness test

3 Welding Qualifications

Same testing as per base material as defined in paragraph 2.

4 Preheating

Refer to main part § 9

5 Post heating

Heating rate ≤ 100°C per hour up to 150°C and then ≤ 150°C per hour to the holding temperature.

Minimum heating rate shall not be less than 50°C/hour.

Degassing temperature shall be at least 50°C above the equipment operating temperature where possible, but always at least 20°C lower than material tempering temperature and 250°C minimum.

The recommended degassing holding temperature range is between 350°C and 400°C. Holding time shall be 15 minutes per 5mm-wall thickness or part thereof. For metal thickness above 40 mm degassing time shall be at least 5 min per mm of wall thickness.

Cooling rate ≤ 150°C per hour down to 200°C and then cool in still air. Minimum cooling rate shall not be less than 50°C/hour.

Cooling shall be slow down under fibber glass.

6 Post Weld Heat Treatment

The equipment shall receive Post Weld Heat Treatment in a furnace (Local PWHT shall not be used). However, final closing seam with local PWHT shall require COMPANY REPRESENTATIVE approval.





of 67

PWHT shall be accomplished after all welds of the pressure boundary have been completed (including lugs or attachment welds).

A minimum of six thermocouples shall be used, attached to the thickest and thinnest weldments, at top and bottom of the pressure boundary and the test coupons if any. In case of wall thickness exceeding 50mm a minimum of two thermocouples shall be located inside the vessel, and located close to main nozzles like manways or large inlet/outlet nozzles. All thermocouple attachments shall be adequately insulated to avoid temperature misreading caused by the effect of radiation.

Temperature shall be continuously recorded. A chart of the heatup, soak and cooldown while at temperature above 300 °C is required. Time intervals shall be recorded with temperature clearly indicated.

Thread and gasket surfaces shall be suitably protected from excessive oxidation during heat treatment.

Unless otherwise specified by steel maker and code requirements the recommended range of temperature is minimum 705°C

PWHT procedures shall be submitted to the COMPANY REPRESENTATIVE for review prior to setting up the qualified welding procedure.

PWHT procedures shall include as a minimum the following information

− Temperature range,

− Holding time,

− Heating and cooling rates,

− Number and location of thermocouples reported on a sketch

− Calibration of thermocouple,

− Furnace type

− Support type number and location

− Extent of heat treatment/sequences,

All welding shall be completed before final Post Weld Heat Treatment.

7 Non Destructive Examination extend for 5% Chromium welds





of 67

Non destructive examination shall be as specified by code and Company Representative’s specifications supplemented by the following:

Type of Joint Before PWHT After Final

PWHT

After

Hydrostatic test

Butt

RT 100% (1)

MT 100%

PMI (2)

UT 100% (1)

MT 100%

Hardness (3)

MT 100%

Corner

UT 100%

MT 100 %

PMI (2)

UT 100% (1)

MT 100%

Hardness (3)

MT 100%

Tee and nozzles connections full

penetrated

RT or UT 100%

MT 100 %

PMI (2)

RT or UT 100% (1)

MT 100%

Hardness (3)

MT 100%

Fillet welds MT 100 % MT 100 % N.A

Repaired welds RT 100% (1)

MT 100 %

RT 100% (1)

MT 100%

Hardness (3)

N.A

Temporary welds 100% MT or PT 100% PT N.A.

Notes: 1) In case of difficulties, RT may be substituted by UT with approval of COMPANY REPRESENTATIVE.

Substitution possible when thickness over 35 mm with double wall technique and thickness over 50 mm with single wall technique

2) 100% of welds and components..

3) Hardness test shall consist of at least one Hb brinell hardness measurements in weld metal and HAZ which shall be taken on each longitudinal and circumferential weld seam and each diameter of branch connection nozzle. Each welding procedure used shall be tested

Hardness results shall not exceed 235 HB

Non-destructive examination procedures and performance shall be qualified in accordance with applicable code requirements and local regulations prior to production fabrication.

8 Additional testing

All machined surfaces of flanges for gaskets shall be 100% penetrant tested after PWHT

9 Particular requirement for STHE





of 67

Floating head made of 5% Cr shall be of the flange and dish construction type (API 660 paragraph 7.5.4, figure 1 b))

JERES-W-010 Welding Requirements for Pressure Vessels

Documents

Transcript of JERES-W-010 Welding Requirements for Pressure Vessels