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    Petronas Technical Specification

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    Petronas Technical Specification

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    434 views18 pages

    PTS 30106018

    Uploaded by

    Amzar Kamil
    Petronas Technical Specification

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    PETRONAS TECHNICAL STANDARDS TECHNICAL SPECIFICATION WELDING OF METALS (AMENDMENT/SUPPLEMENTS TO API RP 582) PTS 30.10.60.18 OCTOBER 2011 PETRONAS Ais seve, Ne by any man (one, PTS Circular PETRONAS 2011-1 PTS No. 30,060.18 Publication Tile: Welding of Metals (Amendments/Suppiements to APIRP 582) This revision of PTS 30.10.60.18 - Welding of Metals (Amendments/Supplements to API RP 1582) (Revision 1) has been updated incorporating PETRONAS Lessons Learnt, Best Practice and ‘new information issued by relevant industry code and standards. All updates in the document are highlighted in italic font. The previous version of this PTS 30.10.60.18 (May 2004) will be removed from PTS binder/ e- repository from herein onwards, The custodian of this PTS is: Name: Abu Bakar Bin M Arif Tel No: 603-2783 6211 Please direct any questions regarding this PTS to the above-named Endorsed | Ir Pau Kiew Hua ‘Senior General Manager, GTS 4.M.MM Document Approval Name Designation Date ‘Signature Prepared |W Shahrzal Bin PRM Waters Enainesr Seen Woh z 24 /ie/ron Add avian |W Abu Bakar Bin W Aa] Pal ates 2g set ZOU ‘Approved | Zamaluddin Bin All Technical Authority, Materials, Corrosion & |2.9//0/2ev/ Inspeation, TS Verifed | Che Wan Trahin Bin | Senior Manager, > Che Wan Sudin Materials, Corrosion, & Ti a Inepeaton ors //'/2° Verified ‘Saifol Mualim Bin ‘General Manager, 7 1" ‘Anmad Yahaya Engneeing ors | 4/8 /1 Revision History RevNo | Reviewed by ‘Approved by Date 7 ir, Abu Bakar Bin W Ani | Zamaludain Bin Al October 2077 PREFACE PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication.of PETRONAS OPUs\Divisions. ‘They are based on the experience acquired during the involvement with the design, construction, ‘operation and maintenance of processing units and facilities. Where appropriate they are based on, oF reference is made to, national and international standards and codes of practice. ‘The objective is to set the recommended standard for good technical practice to be applied by PETRONAS' OPUs in oil and gas production facilties, refineries, gas processing plants, chemical plants, marketing faciities or any other such facilty, and thereby to achieve maximum technical and ‘economic benefit from standardisation, The information set forth in these publications is provided to users for their consideration and decision to implement. This is of particular importance where PTS may not cover every requirement or diversity of condition at each locality. The system of PTS is expected to be sufficiently flexible to allow individual operating units to adapt the information set forth in PTS to their own environment and requirements. ‘When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, it is expected of them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibilty, ‘consult the owner. ‘The right to use PTS rests with three categories of users: 1) PETRONAS and its affiliates. 2) Other parties who are authorised to use PTS subject to appropriate contractual arrangements. 3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users Feferred to under 1) and 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards. ‘Subject to any particular terms and conditions as may be set forth in specific agreements with users, PETRONAS disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any PTS, combination of PTS or any part thereof. The benefit of this disclaimer shall inure in all respects to PETRONAS andlor any company affliated to PETRONAS. that may issue PTS or require the use of PTS Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by users to any company or person whomsoever and the PTS shall be used exclusively for the purpose they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of PETRONAS. ‘The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe custody and PETRONAS may at any time require information satisfactory to PETRONAS in order 10 ascertain how users implement this requirement. TABLE OF CONTENTS PARTI 14 12 13 PARTI PART Ill INTRODUCTION...... SCOPE wren vnstunnnsrinmnneeen DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATI CHANGES FROM PREVIOUS EDITON. ee AMENDMENTS AND SUPPLEMENTS TO API 582. REFERENCES PARTI 14 12 13 PTS 30.10.60.18 October 2011, Page 2 INTRODUCTION SCOPE ‘This PTS specifies requirements for welding of steels and non-ferrous metals in the form of amendments and supplements to API 582 (Revision December 2008). ‘This PTS is a revision of the PTS of the same number dated May 2004; a summary of the main changes is given in 1.3, DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorised by PETRONAS, the distribution of this PTS is confined to ‘companies forming part of or managed by PETRONAS, and to Contractors nominated by them, ‘This PTS is intended for use in oil refineries, chemical plants, gas plants and exploration {and production facilities as well as distribution storage depots and installations, If national and/or local regulations exist in which some of the requirements may be more stringent than in this PTS, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable as regards safety, environmental, economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements of this PTS which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concemed, the objective being to obtain agreement to follow this PTS as closely as possible. CHANGES FROM PREVIOUS EDITON ‘The previous edition of this PTS was dated May 2004. Significant change has been made to align with API 582 2” Edition (December 2009) and its structure. Due to this restructuring, itis impractical to list the individual changes. PTS 30.10.80.18 October 2011 Page 3 PART Il AMENDMENTS AND SUPPLEMENTS TO API 582 In this part, general information is given on qualifications, welding processes and welding methods in the form of amendments and supplements to API 582, with reference to the original clause numbering, Clauses of API 582 which are not mentioned shall apply as writen, Clause | Action Description 2 Add Cross-references Where cross-references to other parts of this PTS are made, the referenced section number is shown in brackets. Other documents referenced in this PTS are listed in Part lll of this PTS. 3 ‘Add to clause 3.5 General definitions principal ‘The Principal is the parly which initiates the project and ultimately pays for its design and construction. The Principal will generally specify the technical requirements, The Principal may also include an agent or consultant authorised to act for, ‘and on behalf of, the Principal 3 ‘Addnew clause 37 | contractor ‘The Contractor is the party which carries out all or part of the design, engineering, procurement, _ construction, ‘commissioning, maintenance, inspection or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor. 3 ‘Add new clause 3.8 | manufacturer/suppli ‘The Manufacturer/Supplior is the party which manufactures ‘or supplies equipment and services to perform the duties specified by the Contractor. 3 ‘Add new clause 3.9 | The word shall indicates a requirement, ‘The word should indicates a recommendation. ‘The word may indicates a permissible option. 3 ‘Add new clause 3.8 | Specific definitions and abbreviations Design The code or standard specified by the code: Principal to which the equipment or piping shall conform, High-alloy Stainless steels, 12 Cr and higher = (eg. ASME P6, P7, P8, P10J and PIOK: ISO TR 15608 Group 7, 8 and 10) Low-alloy Steels from 0.5 Mo up to 9Cr-1Mo & Steels steel from 0.5 up to 9% Ni (eg. ASME 4, PSA, PSB, PSC; ISO/TR 18608 Group 4, 5,6, 9) Unalloyed Carbon manganese steels, including 0.3 and steel: 0.5 Mo steels PTS 30.10.60.18 Clause ‘Action October 2011 Page 4 Description — 7 (eg. ASME Pt and P3; ISOVTR 15608 Group 1.2, 3and 11) coq Carbon equivalent pss Duplex Stainless Stee! eew Electron Beam Welding ('SO process number 51) ERW Electric Resistance Welding (ISO process number 2) Esw Electro Slag Welding (ISO process number 72) ev Essential Variable (welding _ parameter Variable that wil intuence weld: properties) FCAW Fux cored Are Welsing (ISO process number 138) Fw Friction Welding (ISO process number 42) GMAW Gas Metal Arc Welding (ISO process number 431/135) GMAW-P Pulsed Arc Welding (ISO process number 131/135 Pulsed) GMAW-S —Short-Circuit Arc Welding (ISO process number 131 / 135) GMAW-ST Spray Transfer (ISO process number 131 / 135) GTAW Gas Tungsten Arc Welding (ISO. process number 141) GTAW-P Pulsed Are Welding (ISO process number 141 pulsed) GTAW-HW Hot Wire Welding (ISO process number 141) cw Gravity Welding (ISO process number 112) HAZ Heat Affected Zone Lem Laser Beam Welding (50 process number Mr Magnetic Particle Examination NDE Non Destructive Examination oFw Oxy Fuel Gas Welding (ISO process number 3tt) PAW Prgsma Are Welding (SO process number (W)PAR (Welding) Procedure qualification Record PT Liquid Penetrant Examination PWHT Post Weld Heat Treatment SAW Sub-merged Arc Welding ((SO process number 121) PTS 30.10.60.18 October 2011 Page § Clause | Action ~ Description - _ 7 SMAW Shielded Metal Arc Welding (ISO process number 111) urs Uttimate Tensile Strength Wes Welding Procedure Specification ‘Add new clause 4.0 No production welding shall be carried out until welding Procedures and welders are qualified according to this PTS and approved by the Principal 4 ‘Add new clause 4.5, “4.5, Welder performance qualifications ‘Welder performance qualification testing shall be carried out in accordance with the design code andior as specified by the Principal. Unless otherwise specified by local regulations, welder performance qualifications shall be in accordance with | fone or more of the following standards: ISO 9608, ASME IX, ‘API 1104 or equivalent. All welders certified to ISO 9808 and who have been qualified, certified and registered in accordance to the Asian Welding Federation (AWF) Common Welder Certification Scheme (CWCS) requirements (AWF CWCS Grp A Doc 01) or equivalent will be exempted from pre-qualification test provided the welder has remained an active welder in the last six months. The requirement shall apply only to facilities designed according to ISO standard. However, notwithstanding the above, the Principal reserved the right to accept and reject any welder that in its opinion has ‘not performed to the standard that is required of the welder. 4 Add new clause 4.6 ‘4.6, Welding documentation ‘The following documentation is considered to be essential for welding * Welding Procedure Specification; * Welding Procedure Qualifications; (qualifications in the Manufacturer's own format are acceptable provided the information presented contains all the essential and supplementary essential variables listed in the design code and this PTS) © Welder Performance Qualifications. ‘The contents of all documents shall at least comply with the requirements of the design code and this PTS. In order to confirm the qualification by validation, a welder performance register shall be kept up-to-date by the Manufacturer. This register shall at least contain the following data: + Welder’s name and stamp; ‘+ Welding position and X-ray number; ‘+ Data of welding inspection and the result; ‘+ Materials (base and consumable) PTS 30,10.60.18 October 2011 Pages Clause | Action Description _ + Geometrical data (alameter, wall thickness et) + Reference to welding procedure specification applied 528 | Addnew clause | dh EGWhallbe applied only to carbon steel materials 527 ‘ad new clause E274 SAW shall not be used for repair welding of pressure Vessels, storage tanks or pipelines 52 ‘Add new clause 528 | 528 OFW may be used only W all of the Tollowing are satisted + base material is carbon or carbon-manganese steel; . UTS < 490 N/mm; + service temperature is above 0°C; | © pipe diameters < DN 50 mm; | + wall thickness <8 mm 52 |Add new clause 52.8 | 52.8 GTAW : GTAW shall be used for root, fil and cap for all piping materials with a diameter equa to ot less than DN 80, except that OFW may be used i accordance wih 6.28 All GTAW machines shall be equipped with arc starting) devices (high reaueney It are). Scratch staring is strictly prohibited, 64 "| Delete 6.1 and replace | 6.1 General a By newcouse Welding consumables shall be purchased from manufacturers. who are currently acknowiedged by. bodes which independently test consumables, e.g. Controlas, Lloyd's Register of Shipping, American Bureau of Shipping and Det Norske Veritas All welding consumables shall have specified tensile, impact (ferrous materials ony) and chemical analyses values under their various intematonalclassiicatons. Welding consumables for low temperature service shall also comply withthe design code and PTS 30.10.02 31 Al consumables shall be identified on the WPS by their AWS Giassifcation or EN/ISO designation. depending on the design code, Welding fluxes. shall aiso be. speciied by manufacturer and type 6. ‘dé new cause to | Ferite Number assessment shall be done by point counting ba2t ee Delete 6.8 and replace | 6.8 Consumable sorage and handing by new clause ‘The storage, baking, issue and return of welding consumables shall be controlled by procedures with documented records. Basic low-hydrogen electrodes and fluxes shall give a weld ‘metal deposit with a diffusible hydrogen content which shall not exceed 10 mi100 g weld metal ‘Add new clause 7.7 Change title of the chapter Add new clause 8.5 PTS 30.10.60.18 ‘October 2011 Page 7 Description Extra moisture resistant (EMR) consumables with a diffusible hydrogen content of less than 5 mi/100 g may be used without preheated storage for a period of maximum 8 hrs. ‘The level of hydrogen shall be tested using the procedure in 1SO 3690 if there is any doubt as to the welding consumable control level or if extra moisture resistance needs to be confirmed. No electrodes shall be left lying about the site or in workshops. Electrodes so left shall be scrapped, as shall electrodes which have damaged flux coatings. ‘Submerged arc flux shall be supplied clearly identified in ‘mojsture-proof containers and shall be stored in a dry location, at a temperature above 20 °C. The identification shall be in ‘compliance with the relevant consumable standard. ‘Submerged arc, gas metal arc and flux-cored wire shall be Clearly identified and shall be stored in a dry location at a temperature above 20 *C. The identification shall be in compliance with the relevant consumable standard. Unidentifiable and/or rusty wire shall not be used. Submerged arc, gas metal arc and flux-cored arc consumables shall be withdrawn from store only when required for immediate use. Unused consumables for the whole day shall be returned to store on completion of the ‘welding operation. Batch numbers shall be recorded on issue. Unless otherwise stipulated by the manufacturer of the flux, submerged arc flux may be recycled but shall be free from fused fiux, slag particles, mill scale, dirt or other foreign matter. After issue from storage, agglomerated fluxes shall be held in a heated silo at 70 °C. Before re-use, the flux shall be re-baked in accordance with the Manufacturers instructions. 7.7 Shielding gases for GMAW ‘When flux cored wires are used, the filler wires used shall be compatible with the type of gas. New title *, Preheating and interpass temperature" and Welding 8.5 Welding 8.5.1 Weld preparation ‘The weld preparation shall be in accordance with the design ‘code and as specified by the Principal Flame cutting may be used for un-alloyed and low-alloy steels. Plasma cutting should be used for high-alloy steels and clad steels. For plates less than 25 mm thick, cold shearing may be used ‘Thermally-cut surface edges of low alloy and high alloy steels and cold-sheared plates shall be dressed back approximately 2 mm by machining or grinding to remove notches and scale. Clause | Action PTS 30.10.60.18 October 2011 Page 8 Description Cold-sheared plates of 10 mm and less need not be dressed back. Two-sided welding shall be applied whenever possible. Permanent backing strips shall not be used unless specified. ‘Temporary backing devices (ceramics, fluxes, copper backing strips etc) may be used provided that the chemical ‘composition of the weld metal is not influenced by the backing strip. The strip shall be removed without damage to the ‘surrounding material. The areas involved shall be ground flush and cleaned after removal. Welds of low-alloy ferric steels shall be inspected by MPI after the removal of the metallic backing strips or other temporary weldments, with acceptance criteria in accordance with the design code. 8.5.2 Weld fit-up Weld f-up shall comply with the design code. All surfaces to be welded shall be thoroughly cleaned from oxide, scale, oll or other foreign matter and be dry. The cleaned surface shall extend at least 25 mm beyond the substrate surface touched by the arc. Tack welding shall be carried out by qualified welders (ret 444). Tack welding using pieces of bar in the groove is prohibited. Temporary tack welds shall be removed by stinding or chipping and the area ground smooth without reduction of wall thickness, followed by MT or PT inspection to confirm the absence of linear indications. Non welded fit-up lamps shall be used for alignment of all pipe, pipeline and equipment work. Weld-on fit-up devices may be used with the approval of the Principal on structural steel work if the UTS of the material is below 480 Nimm?, They shall be attached in accordance with the qualified welding procedure specffication and shall be removed by chipping/grinding without damage or reduction in wall thickness of base material. Such areas shall be ground smooth and examined by MT or PT to confirm the absence of linear indications. 8.5.3 Welding conditions No welding shall be carried out when the parts to be welded are wet. No welding shall be performed unless the welder and the work are properly protected from wind and wind borne solids such as sand. When the base metal temperature is below 5 °C, both sides of the weld preparation shall be preheated to a temperature of approximately 50°C or the Preheat temperature prescribed in the WPS, whichever is higher. 8.5.4 Weld application Arc stikes shall be situated In the fusion path. If welding is interrupted, a proper restart procedure shall be applied, ‘ensuring full fusion with the previously deposited weld metal. Irrespective of the base material, root runs shall be made without interruption other than for changing electrodes or to allow the welder to reposition himself. Welds shall not be allowed to cool down until at least half the wall thickness has been welded. PTS 30.10.60.18 ‘October 2011 Page 9 Description | ‘Thorough inter-run cleaning and slag removal shall be carried | out. Back-chipping, or gouging and grinding, shall be carried out thoroughly to ‘sound metal before deposition of subsequent. layers. For very stringent or critical applications, intermediate NDE may be required (as specified by the Principal) Clause PTS 3010.60.18 October 2011 Page 19 84 Insert new clause att New clause after 8.1 to read. 8.1.1 Prohoat For preheating temperatures below 200 °C, fuel gas/air bumer systems, high-velocity gas/oil burners or infra-red radiators may be employed (either locally or in a furnace), or electric resistance, induction heating or infra-red radiators may be ‘employed. For preheating temperatures > 200 °C, electric resistance, induction heating or infra-red radiators may be | used. For piping welds made in the shop, electrical heating or ring torches burning sulphur-free fuel may be used. For piping welds made in the field, the following methods of | preheating shall be applied: | + pipe diameter < 250 mm, heating by appropriate torches is allowed (sulphur-free fuel}; quirements + pipe diameter > 250 mm, electrical heating or heat by means of infra-red or ring burners (sulphur-fee fuel) required, Specifically designed heating n ozzies and torches s hall be used; cutting torches shall not be used. (Oxy-acetylene preheating shall not be applied, ‘An even temperature distribution shall be achieved, ‘The width of the heated zone shall be as shown in Figure 1. If electric resistance elements are used, insulation shall be applied with a width as shown below, in which t = nominal wall thickness of the pipe. Wath orneated zone a9 | ome | [50mm | (wichover larger Width of insulated zone Figure 1 Set up for proheat The width of the insulated zone is at least equal to 2t or 100mm +180 mm The weld shall be completed before the preheat temperature is lowered, except that intermediate lowering of preheat temperature is permitted for unalloyed steels If at least 50% of the weld has been completed. The joint shall be cooled under insulation. Preheating shall be restored to the specified temperature and maintained for 30 minutes before welding is recommenced. ot | Replace contents of 9.4 with PTS 30.10.60.18 October 2011 Page 11 [ 9.1 Post-weld heat treatment (PWHT) PWHT temperature ranges and holding times for various ‘materials shall be in accordance with the design code. The welding procedure qualification test shall determine whether the temperature range and holding times are adequate to ‘meet the requirements, For production use, the heat treatment procedure shall be reviewed and approved by the principal prior to PWHT. ‘Any variation of the PWHT temperatures shall require Principal's approval NOTES: a) For quenchedinormalized and tempered steels, the PWHT temperature shall be such as to avoid an unacceptable decrease of mechanical properties of the parent material; PWHT temperature shall be at least 20 °C below the tempering temperature. b) For dissimilar metals the PWHT temperature shall be approved by the Principal No welding or heating shall be carried out after final PHT. NDE for acceptance purposes shall be carried out after final PWHT. Exothermic kits shall not be used. Ht PWHT is applied locally, the minimum heated band width ‘and the minimum insulation width shall be as shown in Figure 2: Misia heated bane with | asa | 25a Figure 2 Set up for local PWHT ‘Add new clause PTS 30.10.60.18 October 2011 Page 12 4 Thermocouples ‘Thermocouple attachments should be: © capacitor discharge connection, or ‘+ nut and bolt construction (as shown in Figure 3). “wo tack wes (oppeste each athe) Thermocouple ineeiton Figure 3. Thermocouple attachment If the latter method is used, the materials should be of a compatible composition. The weld metat shall be removed by careful dressing followed by MT or PT examination after | PWHT to confirm absence of linear indications. Other types of thermocouple attachments may be used provided it is demonstrated that the same temperature reading is obtained as with a capacitor discharge or a boltinut connection, All thermocouple attachments shall be adequately insulated to avoid temperature misreading caused by the effect of radiation The number and positions of the thermocouples shall be in accordance with the design code, but at least as described below: . For full body heat treatment, at least 3 thermocouples shall be directly welded on the work piece, as Indicated in Figure 4: Figure 4 Thermocouple placement for full body heat treatment NOTE: For a hollow configuration, there shall be one ‘additional thermocouple on the inside. | heat treatment of pipe the number of thermocouples 1 for pipe diameter < DN 50 2.for pipe diameter from DN 50 to DN 250, 3 for pipe diameter > DN 250 ‘The thermocouples shall be positioned on the OD on the weld PTS 30.10.60.18 October 2011 Page 13 ‘cap or on the HAZ as shown in Figure 5, Ds50 50

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