Professional Documents
Culture Documents
STANDARD
Re-Issue:
PIPE FABRICATION, WELDING, ERECTION Last Issue Date
(No change):
AND INSPECTION January 2000
Re-Issue: X
(Amended): This Issue Date
December 2001
SUPERSEDES:
NONE
Author Authorised by
D T Hatfull P Avery
Inspection Group Maintenance Engineering &
Quality Co-ordinator Performance Superintendent
ATTACHMENTS: None
CONTENTS
2.0 REFERENCES
5.0 WELDING
5.1 General
5.2 Weld Procedures
5.3 Qualification Of Welders And Welding Operators
5.4 Welding Processes
5.5 Consumables
5.6 Alloy Cladding And Overlay
9.0 QUALITY
This standard defines the Refinery requirements for the fabrication and installation of
metallic piping systems including welding, inspection, non-destructive testing and post
weld heat treatment.
This standard also defines the requirements for welding pressure vessels, heater coils,
heat exchangers, pumps, compressors, tanks and other pressure containing equipment
The purpose of this standard is to establish a common quality level for the fabrication
and installation of metallic piping systems and for the welding of all other pressure
containing equipment.
BS 2600 Part 1 - Radiographic examination of fusion welded butt joints in steel: methods
or steel 2mm upto and including 50mm thick.
BS 2600 Part 2 - Radiographic examination of fusion welded butt joints in steel: methods
for steel over 50mm upto and including 200mm thick.
BS 2910 - Radiographic examination of fusion welded circumferential butt joints
in steel pipes.
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Welding Institute
BP GS’s
Inspection Procedure
German
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The Fabrication, Assembly, Erection and Inspection of Austenitic and Duplex stainless
steel, Cupro-Nickel, Nickel Base Alloy, Titanium and Zirconium pipework shall be in
accordance with THIS STANDARD, BP GS 118-7 and ASME B31.3 in that order of
precedence.
The use of the Inspection Classification Requirements Table 1 will achieve the required
quality level for all installed metallic piping systems. The inspection classification is also
detailed in each individual Piping Material Class ( See Coryton Engineering Standard No.
CES/42/001).
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TABLE 1
Notes :
1. All piping butt welds 2” nominal bore and below shall be GTAW.
2. All pressure containing fillet welds 1” nominal bore and below shall be GTAW.
3. Existing piping material classes under this classification are HP-41S and WCA-7.
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4.1 General
4.1.1 Where the butt weld ends of piping items are to be joined, accurate
alignment shall be made within commercial tolerances (within 1.5mm). If
the wall thickness misalignment is greater than 1.5mm (1/16 in.) the
heavier walled item shall be internally taper bored at 1:4 taper to give
approximately equal finished wall thickness. In No case shall the wall
thickness be reduced below the nominal - mill under tolerance of the
lower thickness pipe.
4.1.5 The toes of adjacent butt welds shall be no closer than two times the
nominal thickness of the pipe with, in the case of NPS 12 and below , a
minimum acceptable separation of 40mm. For pipe sizes greater than NPS
12 the minimum acceptable separation shall be 100 mm.
Branch and non pressure part attachment welds shall not cross
longitudinal seams or circumferential butt welds and shall be subject to
the toe to toe separation distance specified for circumferential butt
welds.
Where such intersections are unavoidable the main weld shall be subject
to non -destructive examination prior to making the attachment weld.
Joints involving the intersection of more than two welds shall be avoided.
See Figure 2.
4.1.6 Unless otherwise stated in the piping material class, fabricated branch
intersections shall be of the “set-on” type with the branch pipe prepared
to suit full penetration welding. Holes for branch connections shall be
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4.1.7 Socket weld connections shall be made up with a 1.5mm to 3mm gap
between the pipe nipple end and the counterbore shoulder of the fitting,
good working practice would be to use spacers/washers.
The weld shall be a minimum of two passes to achieve the required throat
thickness and leg length.
4.1.8 When used, pipe threads shall conform to ANSI/ASME B1.20.1. Threads
shall be correctly formed and tapered and free from damage. When male
and female threads are engaged and fully tightened to make a joint, the
disengaged length of incomplete or vanishing thread shall be 2.5 times
the thread pitch.
4.1.9 Where reinforcing pads are fitted, either for branches or structural
attachment, they shall be accurately shaped so that no gap larger than
1.5mm measured before welding shall exist between the periphery of the
pad and the pipe. The gap between the pad and the branch pipe should be
kept to a minimum but adequate to allow access for welding and fusion to
the parent pipe.
4.1.10 Openings for thermowells and other inserts shall be drilled through the
connection after welding and should be free from obstruction.
4.1.11 For 300# rating and above, the misalignment between branch pipe/fitting
bore and the parent pipe hole shall not exceed 1.5mm.
4.1.12 Weld neck orifice flanges shall be the same bore as the pipe to which
they are attached and shall be accurately aligned. All internal weld
protrusion shall be ground flush with the inside diameter.
4.1.13 All meter run lengths shall be good quality round and checked for ovality
- no welds shall be present along the meter run length.
4.1.14 Seamless pipework 12” NPS and smaller may be fabricated using hot or
cold formed pulled bends, where the bending radius shall not be less than
5 times the nominal pipe size. The bending and forming procedure
including preheat and post weld heat treatment shall have prior BP
approval.
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4.1.16 Pulled bends shall be free from cracks, buckling, wrinkling, flattening and
wall thinning. If flattening of any bend occurs it shall not exceed 5% of
the nominal outside diameter of the pipe when measured by the
difference of the maximum and minimum diameter at any cross section.
The maximum decrease in pipe wall thickness shall not exceed 10% of the
specified nominal wall thickness.
4.1.17 Temporary attachments to the outside surface of the pipe shall not be
made without prior approval by BP.
4.1.18 For all material grades other than PI all weld repairs shall be brought to
the attention of the Inspection Group.
For PI materials, which are in the PWHT, condition all weld repairs shall
be bought to the attention of the Inspection Group.
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CLEARANCES = Sp or Sa as applicable
NOTE : For Longitudinal seams in adjoining lengths of welded pipe, the clearance (stagger) shall
be 150mm minimum.
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4.4.1 Hot or cold formed pulled bends fabricated on site by the contractor in
accordance with an approved procedure are acceptable with prior BP
Inspection approval.
4.5.1 Hot bending of pipework shall only be performed off-site (shop) under
strictly controlled conditions to a procedure approved by BP Inspection
where :-
4.5.2 The heating of the pipework shall be by the use of electric elements or
full circumference gas rings. Local torch heating or quenching is
prohibited with the exception of Section 6.2.13.
4.5.3 Machine cold cutting of pipe and of weld bevels is preferred but flame
cutting may be employed providing that any cut edge is ground or
machined back 4.0mm, with one individual 3.0mm dimension, to sound
metal.. All cut edges shall then be examined for cracks using dye
penetrant or magnetic particle inspection. Any cracks shall be removed by
grinding. The BP inspector may, at his discretion, allow the percentage
number of cut edges being examined, to be reduced if the number of
cracks found in the material are sufficiently few.
4.6.1 Cold bending is preferred but hot bending is permitted off-site (shop)
only, under strictly controlled conditions and to a BP approved procedure.
The heating of the pipework shall be the muffle or semi-muffle type with
accurate temperature measurement and control. Any contact with an open
flame is prohibited.
4.6.2 The area used for fabrication needs to be totally segregated from the
area used for fabrication of carbon steel and other low alloys steels.
Adequate precautions need to be taken to prevent surface contamination
by contact with jigs, vices and other fixtures manufactured in non-
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4.6.3 Cutting of pipework and weld bevelling shall be machine cold cut or plasma
cut.
4.7 Monel
4.7.2 Localised heating for bending and forming is not permitted without prior
BP approval.
4.7.3 Cutting of pipework and weld bevelling shall be machine cold cut or plasma
cut. The weld bevel surfaces and adjacent areas shall be cleaned of all
extraneous matter and any atmospheric oxide film on the surface. The
cleaning shall be carried out using a fine grinding wheel or disc followed
by vigorous stainless steel brushing and finally solvent degreasing. This
cleaning shall be carried out immediately prior to welding.
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4.8.2 Cold bending and localised heating for bending or forming will only be
permitted with prior BP approval.
4.8.4 Cutting of pipework and weld bevelling shall be machine cold cut or plasma
cut.
4.8.5 Immediately prior to welding the weld bevel surfaces and adjacent areas
shall be cleaned of all extraneous matter and any atmospheric oxide film
on the surface. The cleaning shall be performed using a fine grinding
wheel or disc followed by vigorous stainless steel brushing and then
solvent degreasing.
4.9.1 All flanged piping systems shall be assembled using service gaskets and
studbolts as detailed in the individual piping material specifications,
except where line blinds are installed. At line blind locations non-asbestos
gaskets shall be installed initially for hydro-test and shall then be
removed and the correct service gaskets installed.
4.9.2 All studbolts shall be lubricated with high temperature lubricant; i.e.
“Coppercoat” or equal, with the exception to the Alkylation Unit where
Coppercoat is prohibited and a Nickel based lubricant should be used (i.e.
Nickel Never Seize). For grade “8” austenitic stainless steel studbolts
care shall be taken that the lubricant used does not contain chloride,
sulphur or any low melting point metallic compounds. The studbolt shall
have a minimum of two threads showing at each end without being too
long. The contractor is responsible for ensuring joint integrity i.e.
correct nuts, bolts, gaskets are used and that the joint is tight.
4.9.4 If “Cold Spring” is specified on the isometric or piping G.A., extra care
shall be taken with setting up, assembly and supporting of this pipework.
Local heating shall not be used to aid erection.
4.9.5 Temporary and permanent supports shall be installed and spring supports
shall be locked prior to hydro-testing. Temporary welded supports are to
be removed prior to hydro-testing.
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Piping material class KUZ-2 details the specific services and the spacer
layout to be used.
4.9.8 All piping systems, after hydro-test, shall be left in the “ready for
operation” conditions except for steaming through or flushing.
4.9.9 Where pipe spools are to be stored prior to installation, flange faces and
pipe ends are to be capped and protected to prevent damage.
4.9.10 All pipework shall be identified by indelible marking, free from sulphur,
chloride and other halogens. For spools that will be subjected to post
weld heat treatment a suitable titanium oxide pigmented heat resisting
paint marker containing less than 250 ppm of lead, zinc or copper shall be
used. Vibro-etching techniques may be used for identification transfer,
but adhesive tapes or hard stamping, other than with low stress stamps,
shall not be used. Painted or corocoated spools shall have metal tags
attached to the flanges for identification.
The marking applied shall identify the material and the fabricator and
include an item or spool number enabling the spool to be traced to the
relevant isometric, sketch etc.
5.0 WELDING
5.1 General
5.1.2 All welders and welding operators shall be qualified in accordance with
Section 5.3 of this standard.
5.1.4 Welding shall not be performed on wet metal surfaces. When the
atmospheric temperature is less than 0o C, the areas to be welded shall
be pre-heated to 10o C minimum for a distance of 75mm on both sides of
the weld joint before welding commences. All welds shall be protected
from high winds and adverse weather conditions whilst work is in
progress.
5.1.5 The root gap of the joint shall be adequate to ensure full penetration and
a sound root bead in accordance with the welding procedure. If required
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back welding after chipping and grinding can be carried out if safe to do
so.
5.1.6 Tack welds shall be made by qualified welders only. There shall be a
sufficient number of tack welds to maintain alignment during welding and
if these tacks are to be incorporated in the finished weld they shall be :
Full penetration
Below the finished weld surface
Twice the wall thickness in length (Minimum)
Tapered and feather edged each end
Other acceptable methods would be to bullet or bridge tack.
5.1.8 If any welder produces a weld with defects outside the code limits two
additional welds shall be fully examined. If more defective welds by the
same welder are found the extent of further NDE will be at the
discretion of the BP Inspector.
5.1.9 All slag shall be removed from welds internally and externally.
5.1.10 All welds shall be marked with the welders identification number using
marker pencils or paints which are in accordance with the restrictions of
section 4.9.10 of this standard.
Soft seated valves (e.g. butt welded valves or socket welded ball valves)
should not be welded in-line unless a weld procedure has been qualified to
demonstrate that the soft seats are undamaged or unless the soft seat
has been removed prior to welding.
5.1.13 Pressure containing fillet welds on 1” nominal bore and smaller pipes shall
use GTAW, with the addition of filler metals for all passes.
5.1.14 All butt welds 2” nominal bore and smaller shall use GTAW on all
materials, with addition of filler metals for all passes. GTAW is also the
preferred technique for the root pass in all alloy steels. SMAW may be
used for subsequent passes provided the electrode size does not exceed
2.5mm for the second (hot) pass.
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5.1.15 Back purging shall be employed for all joints involving alloy steels and/or
weld metals with a nominal chromium content of 21/4% or more. Purging
shall as a minimum, be maintained for the root and second (hot) pass.
5.1.16 SAW and, where permitted FCAW and GMAW shall not be used for pipes
smaller than NPS 6 unless otherwise agreed by BP Inspection.
The Text of ASME IX latest issue applies, except where amended by the
following text or in Engineering Design.
5.2.3 It is important to ensure procedures qualified for FCAW and GMAW that
the particular welding technique proposed for a given application is well
proven and will only be used by qualified and experienced welders.
Training and records of experienced personnel shall be supplied to BP
Inspection for review.
b). When the base material does not require impact testing , but the
material thickness exceeds 12.7mm (1/2in.) and the minimum
design temperature is -18oC (0oF) or lower.
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5.2.6 Backing rings are not permitted on pipework fabricated to this standard.
5.2.9 Procedure qualification tests for welding carbon steel shall also include a
hardness survey if any of the following conditions exist :
b) Filler metal contains 1.6% manganese and silicon exceed 1.4 and
0.8 %, respectively (such as AWS A5.17 filler metal EHXXX or
EC1).
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5.2.11 For gas tungsten arc welding (GTAW), the qualification record shall
include the composition and flow rate of the shielding gas and inert gas
backing when used.
5.2.13 All welding consumables not listed in ASME code, section ii, part C shall
be individually qualified.
5.2.14 Post weld heat treatment (time and temperature) shall be considered an
essential variable for P-3, P-4, P-5 and P-6 materials. A decrease in time
of more than 15 % and/or temperature of 10% or more from the range
qualified will require a separate welding procedure qualification.
5.2.15 Procedure qualifications for weld overlay deposits shall include complete
chemical analysis of the overlay, procedure qualification test record, and
sample of the overlay. Specimens taken for chemical analysis shall be
representative of material 2.5mm (0.1in.) below the surface. The weld
metal chemical composition shall be within the nominal range specified for
the alloy.
b) Side bend tests and longitudinal face bend tests for weld metal
soundness. Fissures shall not exceed four per specimen , nor shall they
exceed 1.6mm (1/16in.) in length. Cracks at specimen edges shall not be
considered as part of the examination.
5.3.1 The performance qualification tests are intended to determine the ability
of welders to produce sound welds to satisfy the requirements of the
various specifications, standards and codes of practice. The tests have
been designed to recognise variations in welding skills and welding
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The requirements set below are mandatory and may only be modified or
amended by agreement with BP Inspection.
5.3.2 All welders on or off the Coryton site shall hold a current welders
qualification test certificate for the relevant combination of materials
and welding processes to be used. These qualification certificates shall
be submitted for review and/or approval to BP Inspection prior to
commencement of work.
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5.3.5 Any Welders qualification tests carried out on site shall be witnessed
by the BP Inspector or an Independent Inspection Authority.
5.3.6 When qualifying welders for overlays a test shall be required if the
welder is not currently coded for the overlay material to be deposited.
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Notes to Table :
5.4.1 General
Welds shall be made by the shielded metal arc (SMAW), gas tungsten arc
(GTAW), gas metal arc (GMAW) welding processes. All other welding
processes, including submerged arc (SAW), oxyacetylene, electroslag,
require prior BP Inspection approval.
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5.4.2 All welding parameters shall be substantially the same as used in the
welding procedure qualification.
5.4.3 When using processes other than SMAW and GTAW such as GMAW and
SAW the following should be considered :
a) The FCAW process is not used for the root pass in single side welding.
e) Welding components with a large mass where the heat sink may affect
the integrity of the weld ; i.e. slip -on flanges, socket weld flanges and
fittings, branch fittings.
5.4.4 All welding processes shall be protected from wind, rain and other
harmful weather conditions that can affect quality.
5.4.5 All weld passes in the vertical position shall be performed uphill, unless
specifically approved by BP Inspection.
5.4.6 For butt welds 2” nominal bore and below the GTAW process shall be
used on all materials. However where GTAW on-site welding is not
considered practicable (purge problems, shelter, access) the weld shall
be made with compatible electrodes using the MMA process with prior BP
Inspection approval.
5.4.7 For pressure containing fillet welds 1” nominal bore and below the GTAW
process shall be used on all materials. However where GTAW on-site
welding is not considered practicable (purge problems, shelter, access)
the weld shall be made with compatible electrodes using the MMA
process with prior BP Inspection approval.
5.4.8 For off-site and on-site welding of low-alloy steels, austenitic stainless
steels, nickel alloys and non-ferrous metals the GTAW or GTAW/SMAW
shall be used. However where GTAW on-site welding is not considered
practicable (purge problems, shelter, access) the weld shall be made with
compatible electrodes using the MMA process with prior BP Inspection
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5.4.9 In an Inert gas shielded welding process, inert gas backing (argon or
helium) is not required for carbon steels, carbon-molybdenum steels, or
low alloy steels with a chromium content not exceeding 1 ½ % by weight.
Inert gas backing shall be used for all other alloy materials, including
aluminium and copper alloys. Nitrogen shall not be used for gas shielding
of stainless steel.
5.4.10 Welded joints shall be made by completing each layer before succeeding
layers are deposited Block welding is prohibited.
5.4.11 For carbon steel welding of hot-tap branches, new nozzles in vessels and
the repair of steel castings etc. A low hydrogen process shall be used.
5.4.12 Autogenous welding is prohibited when using the GTAW process unless
approved by BP Inspection.
5.5.1 Filler metals for welding similar materials shall be of the same nominal
analysis as the base material, except as follows :
a) AWS Type 347 filler metal shall be used for welding Type 321
stainless steel material.
b) AWS Type 308 filler metal shall be used for welding Type 304
stainless steel material. (Type 308L shall be used for Type 304L)
c) The following filler metals shall be used for welding 11 to 13% steels in
cyclic service, or for design temperatures over 350oC (660o F), only
Inco-weld A, Inconel 82 or Inconel 182 are acceptable.
5.5.2 Filler metal for welds joining dissimilar materials shall be in accordance
with Appendix C Table 2. Filler metals for combinations of materials
other than those in Table 2 shall be submitted to BP Inspection for
approval.
5.5.3 Filler metals for welds shall meet the same minimum requirements as
those imposed on the base metal.
5.5.4 In all welding processes, the filler wire shall contain all alloying elements
and shall meet all chemical compositions requirements for the wire
classification. Exceptions are subject to BP approval.
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5.5.5 All welding consumables shall be used within the limits recommended by
their manufacturers. The welding parameters shall be subsequently the
same as used in the procedure qualification.
5.5.6 Electrodes, filler wires, and fluxes shall be kept clean, dry and properly
stored according to manufacturers recommendations. No damp, greasy,
or oxidised electrodes, filler wires or fluxes shall be used.
5.5.7 Since various national specifications for welding consumables are not
freely interchangeable, equivalence to AWS specifications shall be
indicated. The basis of equivalence shall be subject to approval by BP.
5.5.8.1 For gas metal arc welding of carbon steels, base wire filler metals
shall conform to AWS A5.18 classification ER70S-2, ER70S-3, or
ER70S-6.
5.5.8.2 For gas tungsten arc welding of carbon steels, the filler metal
shall meet the chemical and physical tests requirements of AWS
A5.18, classification ER70S-2, ER70S-3, or ER70S-6.
5.5.8.3 For flux cored arc welding of carbon steels, the electrodes shall
conform to AWS A5.20 classification E70T-1 (or E71T-1) or to
E70T-5 (or E71T-5). These electrodes shall be used with an
external shielding gas.
5.5.8.4 Carbon steels shall not be welded with C- ½ Mo weld metal unless
the weld is postweld heat treated and the procedure qualification
record includes hardness weld data. This data shall show that the
weld and heat affected zone hardness have not exceeded 225HB
(238 HV10).
5.5.8.5 For welding carbon steel, submerged arc welding wires shall be
limited to AWS classifications ELXX and EMXXX and the
submerged arc welding fluxes shall be limited to F72 and F62,
unless otherwise approved by BP Inspection. Welding wire
classification EH14 may be used, but a hardness test survey of
the weld and HAZ, is required during procedure qualification.
Hardness shall not exceed 225HB. Recycled flux shall not be
used.
5.5.8.6 AWS classifications E6012, E7014 and E7024 shall not be used
for pressure containing fillet welds. These electrodes however
may be used for non-pressure containing fillet welds on P-1
materials. The E7024 electrode may be used for lap joint fillet
welds on tank floors in the flat position.
5.5.8.7 Low-hydrogen electrodes shall be used for all shielded metal arc
welding when any of the following conditions apply :
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5.5.8.8 For welding 5 through 9% nickel steels, the filler materials shall
be reviewed and approved by BP Inspection and qualified by
procedure testing in the maximum plate thickness specified for
the job.
Table 3
5.5.9 For cryogenic service temperatures of -100oC (-150oF) and lower, the
ferrite content of all austenitic stainless steels welding materials shall be
in the range 2 to 5% (FN2 to FN5).
5.5.10 Filler materials of E309, Inconel 182, or Inco-weld A shall be used for
welding carbon or low-alloy steels to austenitic stainless steels.
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5.6.2 For both integrally clad plate and weld overlay, the surface of the base
welds that would be exposed to the corrosive environment shall be
protected by depositing not less than two layers of corrosive resistant
weld metal.
5.6.3 In austenitic stainless steel overlays, the first weld layer shall be made
with type 309L. Subsequent layers of deposit shall be made with low-
carbon 18Cr-8Ni stainless steel or stabilised grades of austenitic
stainless steel, depending on service conditions.
5.6.4 For monel overlays on carbon or low-alloy steel, the first weld layer shall
be made with a high nickel consumable (62% nickel minimum). The second
and any successive layers shall be made with a filler metal that nominally
matches the monel chemical composition. The first layer of high nickel
deposit shall be applied over bright, clean and oxide free steel. Monel
overlays shall have a maximum iron content of 4.5%.
5.6.6 All internal exposed alloy welds joining clad components and all alloy weld
overlays inside vessels and heat exchangers shall be fully examined by
liquid penetrant examination.
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6.1.1 General
Oxy-fuel gas welding and cutting torches may only be used for pre-
heating when fitted with proprietary preheating nozzles. Quenching or
other means of accelerated cooling from pre-heat temperature shall not
be employed.
6.1.3 Carbon steel shall be preheated to 10oC, minimum for an area equal to
6.1.4 (h).
6.1.4 Carbon steel shall be preheated to 100oC when any of the following
conditions apply :-
g) The maximum preheat and interpass temperature for carbon steel and
low alloy steel shall be 300oC.
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h) The preheat zone shall extend 75mm or a distance equal to four times
the material thickness, which ever is the greater, beyond each edge of
the weld.
6.1.5 When P-4 or P-5 materials are welded to P-1, P-3, P-7, P-9, P-10, or P-11
materials the preheat temperature shall be a minimum of 175oC. The
welding of P-4 or P-5 to P-8 requires special consideration and prior BP
Inspection approval.
6.1.6 To preheat pipework 2” nominal bore and smaller, on-site, LPG fired
torches may be used together with temperature indicating crayons if
this method is approved by BP Inspection.
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Table 4
Minimum Preheat Temperatures For Ferritic Materials
6.2.1 General : Postweld heat treatment of welds, bends and forgings shall be
in accordance with Table 331.1.1 of B31.3 with the following
modifications:
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6.2.4 Thermocouples: -
6.2.5 Insulation :-
b) The insulation will be a band of width not less than 5 times the wall
thickness either side of the weld.
6.2.6 All post weld heat treatment shall be completed prior final radiography,
radiography can be carried out before PWHT at the contractors cost.
6.2.7 All carbon steel piping 19mm and over nominal thickness shall be post weld
heat treated. (Note: Process conditions such as amine and wet hydrogen
sulphide may require PWHT regardless of thickness). All other ferritic
alloy piping (P-3, P-4, P-5, P-6 etc.) shall be PWHT for all thickness.
6.2.8 The PWHT for welds joining austenitic stainless steels to dissimilar
materials shall be as specified in the qualified weld procedure and
approved by BP Inspection prior start of fabrication.
6.2.9 For P-6 materials, the PWHT temperature used shall be the lowest
possible to avoid overheating and hardening on cooling.
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6.2.10 Heat treatment is required for all carbon steel piping operating below
-29oC. PWHT is also required for all carbon steel piping in ammonia,
amine and H2S services.
6.2.12 Instrumentation used to verify the PWHT temperatures shall have been
calibrated within 60 days of the performance of the heat treatment.
6.2.14 All piping should be supported (and restrained as needed) in the furnace
during heat treatment to minimise warpage and other distortion. Valves
shall not be subjected to furnace PWHT without BP approval. PWHT of
ends of welds on valves shall be carefully performed so that the valve
packing, bonnet, gasket and internal trim are not damaged.
6.2.16 The PWHT shall follow immediately the welding operation without losing
the preheat temperature, unless the weld procedure specification (WPS)
specifies otherwise.
6.2.17 Holding time at PWHT temperatures shall be one hour per 25.4mm of
thickness, with one hour minimum. For Chromium-molybdenum steels ( ½
to 9% chromium) and 12% chromium stainless steels , the minimum holding
time shall be 2 hours.
6.2.18 For P-3, P-4 and P-6 materials the production PWHT (time and
temperature) shall be essentially the same as in the welding procedure
qualifications. The maximum Brinell hardness in all steels after heat
treatment shall be 225HB (238 HV10). If welds are furnace heat
treated, a minimum of 10% shall be tested to verify that the hardness
criteria has been met. If local heat treatment has been applied , each
weld shall be tested. Welds in critical service such as amine, wet
hydrogen sulphide and hydrogen fluoride, shall also not exceed a
maximum hardness in the deposited weld metal and the heat affected
zone of 200HB i.e. piping material class WCZ-41.
6.2.19 Hardness readings of the weld and heat affected zone shall be taken at
two circumferential locations 180o apart. It is the heat treatment
contractors responsibility on-site to record the hardness readings on the
heat treatment chart for each weld, this is to be verified by the
fabrication contractors QA.
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6.2.21 The soak time for carbon steel shall be one hour minimum and two hours
minimum for alloy steel.
6.2.23 Post weld heat treatment of austenitic stainless steel is not required
unless called for in the piping material specification, but for bending and
forming the following heat treatment is required :-
Note: The heat treatment is for piping material class BCM-32 only and shall be
for a minimum of two hours, then cooled in still air.
Upto 850 oC the heating rate shall be slow and may be faster thereafter.
Cooling shall be in still air for hot forming and bending but rapid cooling is
required for solution annealing.
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CES/18/001 (December 2001)
Table 5
Notes:
1. Temperature of any part of the weldment during PWHT shall not be less than
shown above.
2. Table does not apply to normalised and tempered materials or to quenched and
tempered materials. PWHT of such materials shall be approved by BP and shall
be such that the weld and HAZ hardness does not exceed 225HB and
mechanical properties are not less than the specification minimum.
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CES/18/001 (December 2001)
All fabricated pipework shall be 100% visually inspected for any imperfections, cracks,
surface breaking defects, mis-alignment or bad workmanship. If the inspector
has any doubts regarding the acceptability of the finished item, then for any
surface defect a magnetic particle or dye penetrant examination may be
performed in addition to any other test specified.
7.2.2 The radiographic techniques shall be in accordance with BS. 2910 for
piping butt welds or BS.2600 for butt joints in plate.
7.2.3 Image quality indicators of the wire type to BS 3971 or DIN 54 109 part
1 shall be used.
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CES/18/001 (December 2001)
7.2.4 Film density shall be 2.0 - 3.0 through the thickest portion of the weld
and the radiographic sensitivity shall be between 1.2% and 2.4%
depending on thickness.
7.2.5 The single wall, single image technique shall be used where ever possible,
lead intensifying screens and fine grain high contrast film shall be used.
Table 6
Acceptance Criteria For Welds
Incomplete penetration * ‘A’ shall apply to all welds in severe cyclic conditions or
normal fluid service
Internal porosity ‘D’ shall apply to all welds in severe cyclic or normal fluid
service. ‘E’ shall be applicable to category D fluid service.
Slag inclusion, tungsten inclusion, ‘F’ shall apply to all welds irrespective of service condition
or elongated indication*
Undercutting ‘H’ shall apply to girth and, where approved, mitre groove
welds in category D fluid service
Concave root surface (suck back) * Not permitted in severe cyclic or normal fluid service
unless a specific limit is set by engineering design. A
maximum of 1.6mm shall apply to welds in category D fluid
service
Reinforcement or internal For all welds irrespective of service conditions external
protrusion weld reinforcement shall be uniform, 1.6mm to 3mm in
height and shall merge smoothly into the pipe surface.
Positive root penetration shall not exceed 1.6mm for NPS
2” and smaller, or 3mm for larger pipe
* When these defects are permitted the total cumulative length of lack of root penetration, slag
inclusions or concave root shall not exceed 10% of the weld joint circumference.
7.3.1 The methods and acceptance criteria for ultrasonic examination of welds
shall be in accordance with ASME B31.3 Table 344.6.
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CES/18/001 (December 2001)
Dye Penetrant Inspection shall be performed in accordance with the BPV code
Section V, Article 6.
7.6.3 Where the approval does not include “Radiation Safety” a separate
certificate in Radiation Safety must be held.
8.1 All hydro-testing of pipework and equipment shall be in accordance with Coryton
Engineering Standard 10.
8.3 The fabricators test procedure, giving details of test fluid, minimum
temperature , test pressure recording and control method and holding time, shall
be reviewed by BP.
8.4 Subsequent to hydro testing , pipe spools that are to be stored prior to
installation shall have the ends sealed to prevent ingress of dirt, moisture or
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CES/18/001 (December 2001)
8.5 Hydro-testing shall be carried out after the completion of any specified heat
treatment.
8.6 Hydro-testing shall be only carried out after completion of any specified NDT.
8.7 Welds shall not be painted or insulated prior to hydro-testing or service testing.
9.0 QUALITY
9.1 The Contractor shall operate a quality system fully in accordance with the
applicable part of ISO 9000.
9.2 All maintenance repair work shall be in accordance with CRIG/INS024 Procedure
for repairs.
9.3 Before commencing fabrication the fabricator shall prepare a quality plan and a
set of design documents, both of which shall be subject to approval by BP.
9.4 These documents shall include materials, welding and consumable control
procedures, welding and non-destructive testing procedure specifications
together with qualification records and an illustration of their proposed areas of
application. Mechanical working, heat treatment and leak testing procedures
should also be included.
9.5 The quality plan shall include brief details and the sequence of all examinations
that will be performed by the fabricator. The names of the responsible
individuals responsible for the implementation of all quality assurance and quality
control functions shall also be included.
9.6 It shall be the responsibility of the contractor to inspect all materials upon
receipt to ensure that the correct grade of material has been supplied and the
identifications and dimension, material quality and end preparation are in
accordance with the requisite standards and specifications.
9.7 Different materials shall be kept in discrete sections of the storage area and all
material shall be marked in a manner that allows it to be related to the original
manufacturers certification.
9.8 All materials shall be stored above ground and kept free from dirt, grease and
other contaminants.
9.9 At all stages of fabrication the contractor is responsible for maintaining all
relevant production records, for maintenance work the minimum shall be in
accordance with CRIG/INS/024.
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CES/18/001 (December 2001)
2. Weld procedures.
4. Weld matrixes, identifying Weld number, size, Welder used, Inspection and
NDT results.
5. NDT reports.
7. Drawings.
9.10 BP reserve the right to carry out quality audits at the contractors and sub-
contractors facilities.
BP also reserve the right to call the contractor to provide a schedule of Quality
audits appropriate to the contractors and sub-contractors activities and for the
contractor to supply reports of such audits.
9.11 The contractor shall advise of any non-conformance’s which affects the ability of
the goods to conform to the purchase order / work order, or which may affect
operation, integrity or inter-changeability of the goods. The contractor shall also
advise details of proposed corrective actions or concession requests and details
of any consequential affects.
9.12 Any queries related to the work shall be formally submitted by a technical query
and registered with BP Inspection.
9.13 All concessions raised by the contractor shall be submitted to BP inspection for
approval or rejection.
9.14 The above quality assurance requirements shall apply to both on-site and off-site
contractors and all associated welding sub-contractors.
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CES/18/001 (December 2001)
APPENDIX A
1. Where reference to the carbon steel piping material class WCZ-41 is made then existing pipe
classes WCA-7 and HP-41S may also be taken to apply. Where reference to the Monel piping
material class WCP-21 is made then existing piping classes WCP-2 and HP-41M may also taken
to apply.
2. Piping and fittings 1” NPS and smaller shall be screwed, not seal welded and installed using
PTFE tape.
3. Socket weld construction is not permitted. All piping 1 ½ ” NPS and larger shall be butt
welded.
4. Couplings welded into lines for vents, drains, thermowells, branches etc., shall be installed in
accordance with Philips drawing No. HF-1008, see Appendix B. Alternatively, a “set-on”
fitting; i.e. a thredolet may be used, provided the attachment weld is full penetration and
meets the requirements of paragraph 8.
6. Piping shall be designed and installed so as to be self-draining to low points at equipment, i.e.
pumps, exchangers, vessels, control valves etc., to minimise the number of low point drains. If
low point drains are required on piping they shall be in accordance with the piping material
class details.
7. The edges of all piping flanges, valve bonnets flanges and gaskets shall be painted with one
coat of HF detecting paint Valsper No. 220-Y-7.
8. The first 5mm of any weldment in contact with HF acid shall be slag free. It is therefore,
recommended that the GTAW process is used for the first 5mm of deposited weld.
9. Post weld heat treatment (PWHT) shall be in accordance with section 6.2 of this standard for
the piping material classes WCP-21 and WCZ-41.
10. Piping shall be hydrotested using kerosene or gas oil. Water may be used with prior BP
approval provided that the piping sections can be blown completely dry after the Hydrotest.
11. For piping material classification WCZ-41 the maximum hardness of the weld metal and heat
affected zone (HAZ) shall be 200HB.
12. For piping material class WCZ-41 the butt welds shall have a TIG root run.
APPENDIX B
* See Piping, Heat Exchanger, Pump, and Instrument HF Service Specifications For Use and
Size.
See Appendix A.
CES/18/001 (December 2001)
A - AWS A5.1, Classification EXX15, EXX16, or EXX18. J - AWS A5.4, classification E505-XX
B - AWS A5.4 and A5.11, classification E309-XX, ENiCrFe-3 (Inconel 182), or ENiCrFe-2 (Inco-Weld A) K - AWS A5.4 and A5.11, classification E410-XX, E410 cb-XX
C - AWS A5.11, classification ENiCrFe-3 (Inconel 182) or ENiCrFe-2 (Inco-Weld A) E309-XX, ENiCrFe-3 (Inconel 182), or ENiCrFe-2
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, E8018-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 A5.4, classification E502-XX P - AWS A5.4 classification E308 -XX or E347-XX
I - AWS A5.4, classification E7Cr-XX Q - AWS A5.4 classification E316-XX or E316L-XX
Note : R - AWS A5.4 classification E309-XX
1. Blank spaces in Table 2 indicate combinations that are considered unlikely or unsuitable. For these combinations consult BP 2. Table 2 refers to coated electrodes. For bare wire welding (SAW, GMAW,
Inspection Group. GTAW), use equivalent electrode classification (AWS A5.9, A5.14, A5.17,