ALN FP ESA MEC SPC 0001 - 92B2.1 General Welding, Fabrication and Inspection

General Welding, Fabrication and Inspection
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ALN-FP-ESA-MEC-SPC-0001 Rev. 00-C
RECORD OF AMENDMENT
REVISION SECTION PARAGRAPH DESCRIPTION OF CHANGE
DOCUMENT HOLDS RECORD

REVISION SECTION PARAGRAPH DESCRIPTION OF HOLD
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TABLE OF CONTENTS
1.0 SCOPE....................................................................................................................................... 5
2.0 CODES AND SPECIFICATIONS ............................................................................................... 5

2.1 Applicable Codes ............................................................................................................ 5
2.2 Standard Specifications .................................................................................................. 6
3.0 WELDING PROCEDURES ........................................................................................................ 6
4.0 WELDING PROCESSES (GENERAL) ....................................................................................... 7
5.0 WELDING PROCESS LIMITATIONS......................................................................................... 8

5.1 Shielded Metal Arc Welding ............................................................................................ 8
5.2 Gas Tungsten Arc Welding ............................................................................................. 8
5.3 Gas Metal Arc Welding ................................................................................................... 8
5.4 Flux Cored Arc Welding .................................................................................................. 8
5.5 Submerged Arc Welding ................................................................................................. 9
6.0 FILLER MATERIALS AND FLUXES ......................................................................................... 9
6.1 General ........................................................................................................................... 9
6.2 Shielded Metal Arc Welding .......................................................................................... 10
6.3 Gas Tungsten Arc Welding ........................................................................................... 10
6.4 Gas Metal Arc Welding ................................................................................................. 10
6.5 Flux Cored Arc Welding ................................................................................................ 10
6.6 Submerged Arc Welding ............................................................................................... 10
7.0 WELD JOINT PREPARATION AND WELDING FABRICATION ............................................. 11
8.0 CONTROL AND HANDLING OF STAINLESS STEEL, NICKEL AND NONFERROUS

ALLOYS................................................................................................................................... 12
9.0 CHARPY IMPACT (CVN) TESTING ........................................................................................ 12
10.0 PREHEAT AND INTERPASS TEMPERATURES .................................................................... 13
11.0 POSTWELD HEAT TREATMENT ............................................................................................ 14
12.0 NON-DESTRUCTIVE EXAMINATION, TESTING AND INSPECTION ..................................... 16

12.1 General ......................................................................................................................... 16
12.2 Hardness Testing .......................................................................................................... 17
13.0 CLAD RESTORATION, WELD METAL OVERLAY AND DISSIMILAR METAL WELDING .... 19
13.1 General ......................................................................................................................... 19
13.2 Dissimilar Metal Welding ............................................................................................... 21
14.0 DUPLEX STAINLESS STEEL WELDING ................................................................................ 22
15.0 ADDITIONAL WELDING REQUIREMENTS FOR STRUCTURAL STEEL FABRICATION ..... 23
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16.0 ADDITIONAL WELDING REQUIREMENTS FOR PRESSURE VESSELS AND HEAT

EXCHANGERS ........................................................................................................................ 23
17.0 ADDITIONAL WELDING REQUIREMENTS FOR ATMOSPHERIC AND LOW PRESSURE

STORAGE TANKS .................................................................................................................. 25
18.0 ADDITIONAL WELDING REQUIREMENTS FOR BOILERS, HEATERS AND FURNACES ... 25
19.0 ADDITIONAL WELDING REQUIREMENTS FOR ROTATING EQUIPMENT AND AUXILIARY

SUPPORT COMPONENTS ...................................................................................................... 26
20.0 ADDITIONAL WELDING REQUIREMENTS FOR FABRICATED PIPING AND PIPING

COMPONENTS ........................................................................................................................ 28
21.0 WELDING REPAIRS ................................................................................................................ 30
APPENDICES...................................................................................................................................... 31
Appendix 1: Welding Procedure Application Map for Review and Acceptance of Welding
Procedures ............................................................................................................................... 31
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1.0 SCOPE
This specification defines the minimum requirements for the welding of shop and field fabrication
and the weld inspection of the following equipment:
• Pressure containing equipment and piping whether code stamped or not, including but not
limited to rotating equipment, boilers, pressure vessels, heat exchangers, air coolers, shop
and field fabricated piping, fired heaters, storage tanks, and their attachments
• Equipment or piping containing toxic or corrosive materials when specified in the job
specifications.
• Structural steel fabrications
• Other fabrication where specified
This specification modifies the requirements of applicable ASME, ANSI, API and AWS codes and
standards in effect at the time. It also modifies API and AWS standards when specified. The
applicable edition, revision, addenda, etc., shall be specified in the equipment design, drawing
data sheet, job specification, and/or purchase order. If an applicable code or standard is more
stringent than this specification, that standard shall govern.
Conflicts between requirements of these specifications, related specifications, standards, codes,
purchase orders, or drawings shall be clarified with COMPANY prior to proceeding with the
fabrication of the affected parts. Regarding conflicts, COMPANY reserves the right for final
decision.
Any enhancements that CONTRACTOR believes to promote ease of operation or reduce
maintenance may be considered in addition to these requirements.
Any omission from these specifications does not relieve CONTRACTOR of the responsibility to
provide sound engineered and operational units.
In case of any conflict between this specification and any other specification and/or codes, the
CONTRACTOR shall clarify with COMPANY.
2.0 CODES AND SPECIFICATIONS
2.1 Applicable Codes

The following codes shall be interpreted as the minimum requirements applicable to the
subject work and no statement contained in this specification shall be construed as limiting
the work to such minimum requirements. Any requirements stated herein which violate
these codes or governmental regulations shall immediately be brought to the attention of
the COMPANY for resolution. The latest editions of the codes listed shall govern the work.
• ASME Section II, Part A; Ferrous Material Specifications
• ASME Section II, Part B; Nonferrous Material Specifications
• ASME Section II, Part C; Specifications for Welding Rods, Electrodes, and Filler
Metals
• ASME Section IX; Welding and Brazing Qualifications
• ASME Section VIII, Division 1; Pressure Vessels
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• ASME Section VIII, Division 2; Pressure Vessels

• ASME B31.1; Power Piping
• ASME B31.3; Process Piping
• ASME B16.25; Buttwelding Ends
• AWS D1.1; Structural Welding Code
• API 620; Design and Construction of Large, Welded, Low-Pressure Storage Tanks
• API 650; Welded Tanks for Oil Storage
• AWS A4.2; Standard Procedures for Calibrating Magnetic Instruments to Measure
the Delta Ferrite Content of Austenitic and Duplex Stainless Steel Weld Metal
• NACE MR0175; Materials For Use In H2S Containing Environments in Oil and Gas
Production
• NACE SP0472; Methods and Controls to Prevent In-Service Environmental Cracking
of Carbon Steel Weldments on Corrosive Petroleum Environments
• ASTM A923; Standard Test Method for Detecting Detrimental Intermetallic Phase in
Duplex Austenitic/Ferritic Stainless Steels
• ASTM E562; Standard Test Method for Determining Volume Fraction by Systematic
Manual Point Count
• ASTM G48; Standard Test Methods for Pitting and Crevice Corrosion Resistance of
Stainless Steels and Related Alloys by Use of Ferric Chloride Solution
2.2 Standard Specifications
The following COMPANY Standard specifications shall be applied to the subject work. In
cases of conflict between the COMPANY Standard specification and any of the applicable
codes, the CONTRACTOR shall immediately submit the matter in writing to COMPANY
which will provide written clarification.
• None
3.0 WELDING PROCEDURES

Welding Procedure Specifications and Procedure Qualification Test records for Vendor welding
covered by this specification shall be submitted to COMPANY for review and acceptance prior to
start of any welding. No welding shall commence until welding procedure specifications and
qualification records have been accepted.
Welding performed by sub-Vendors is also required to have welding procedures submitted for
review and acceptance by purchaser the same as above. Vendors shall review their sub-Vendor’s
welding procedures for conformance to this specification prior to submitting to COMPANY or its
designee for acceptance.
The information contained in Welding Procedure Specifications and Procedure Qualification Test
Records shall include, but not be limited to the information contained in ASME Code, Section IX.
Welding Procedure Specifications shall conform to ASME Section IX form QW-482 or equivalent.
Procedure Qualification Records shall conform to ASME Section IX form QW-483 or equivalent.
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Structural steel welding procedures may conform to AWS Prequalified or AWS recommended
formats.
This specification includes additional requirements or restrictions that may not be listed in the
Vendor's submitted welding procedure. They are to be listed, when required by this specification,
either in the welding procedure, special addenda to the welding procedure, or on the Welding
Procedure Application Map.
Applicable Vendor's Welding Procedure Application Map as illustrated in Appendix 1 of this
specification shall also be completed and submitted at the same time as welding procedures for
COMPANY acceptance.
Welding Performance Qualification test records shall be made available to COMPANY personnel
for review upon request. Welding Performance tests shall be in accordance with ASME Section
IX, under conditions of restraint and accessibility as demanding as those to be experienced in
production by the welder. Welding Performance test records shall conform to ASME Section IX
form QW-484 or equivalent. Structural steel welding performance qualification records may
comply with AWS recommended format.
When impact testing is required by the code or job specifications, impact test results for weld and
heat affected zone shall be reported with the welding procedure qualifications. Impact test results
shall include specimen size, notch location and type, test temperature, absorbed energy, and
when required by codes or specifications, lateral expansion and percent shear.
When maximum Brinell hardnesses are required by code, the job specifications, or this
specification, they shall be reported with the Welding Procedure Qualification Record and they
shall not exceed the maximum specified.
4.0 WELDING PROCESSES (GENERAL)

The following welding processes are permitted, subject to the limitations set forth below, providing
that satisfactory evidence is submitted showing that the procedures qualified are in accordance
with applicable codes, standards, job specifications and this specification.
• Shielded Metal Arc Welding (SMAW) - manual
• Gas Tungsten Arc Welding (GTAW) - manual, machine or automatic
• Gas Metal Arc Welding (GMAW) - semi-automatic, machine or automatic
− Regulated Metal Deposition (RMD) and Surface Tension Transfer Included
• Flux Cored Arc Welding (FCAW) - semi-automatic, machine or automatic
• Submerged Arc Welding (SAW) - machine or automatic
• Plasma Arc Welding (PAW) - manual, machine or automatic
Welding Processes other than those listed above require specific approval by COMPANY and
shall not be assumed to be acceptable by Vendor during bid preparation. First time use of a
welding process requires specific written approval by COMPANY prior to welding.
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5.0 WELDING PROCESS LIMITATIONS
5.1 Shielded Metal Arc Welding

Low hydrogen electrodes shall not be used for single sided groove welds on the root pass,
unless backgouging and backwelding can be accomplished.
All welding is by uphill method, unless specifically approved by COMPANY.
5.2 Gas Tungsten Arc Welding
Gas tungsten arc welding shall be used for pipe fabrication on the first two layers for all
low alloy, stainless steel and high alloy single sided groove welds.
A back-purge with argon shielding gas is required on all low alloy (P-5) and higher alloy
material single-sided groove welds. The purge shall be maintained a minimum of two
complete weld passes.
5.3 Gas Metal Arc Welding
The WPS shall state the mode of metal transfer, i.e., short circuiting arc, spray transfer,
etc.
Gas Metal Arc Welding (GMAW) is acceptable for carbon steel root passes only in piping
and equipment, and the completion of groove welds on base materials < 3/8 inch total
thickness and 3/8 inch fillet welds on plate and structural steel. When specific COMPANY
permission is obtained to exceed this maximum wall thickness, all such welds shall be
100% ultrasonically shear-wave examined throughout their entire length.
GMAW is acceptable for root passes only on low alloy and stainless steel material welds,
when backgouging and backwelding can be accomplished.
The shop and the welding personnel shall have demonstrated production welding
experience with each process to the satisfaction of COMPANY.
All welding shall be by the uphill method, except that root passes may be welded downhill.
5.4 Flux Cored Arc Welding
The FCAW process shall not be used for single sided groove welds on the root pass unless
backgouging and backwelding can be accomplished.
The short circuiting mode of metal transfer is unacceptable.
The spray transfer mode without shielding gas (self-shielded, inner shield, etc) is
acceptable for structural steel welding only.
FCAW, in the spray transfer mode with shielding gas is acceptable for welding shop
fabricated pipe, structural steel, and for welding pressure retaining parts of pressure
vessels provided the following conditions are met:
The spray transfer mode with shielding gas is acceptable for welding P-1 material welds
regardless of thickness, provided the Procedure Qualification Record contains the results
of hardness testing for both as-welded and PWHT’d conditions, as applicable.
FCAW is acceptable for root passes on low alloy and stainless steel material welds, when
backgouging and backwelding can be accomplished and for the fill and cap passes.
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5.5 Submerged Arc Welding
Automatic or machine type SAW shall be used. Manual or semi-automatic SAW is
prohibited.
Automatic or machine type SAW welding of P-1 materials shall be limited to 1/2 inch
maximum thickness per layer of deposit for material of 1-1/4 inch thickness or greater, and
3/8 inch maximum thickness per layer of deposit for material less than 1-1/4 inch thick.
6.0 FILLER MATERIALS AND FLUXES
6.1 General
Filler materials and fluxes shall be as specified in ASME, Section II, Part C. Filler materials
and fluxes other than those specified in the above code and which meet other
requirements of this specification shall not be assumed to be acceptable by Vendor during
bid preparation.
All welding shall employ a filler metal unless approved by COMPANY in writing. Welding
without filler metal shall not be assumed to be acceptable by Vendor prior to bid
preparation. Friction welding is prohibited.
Use of filler metals and fluxes for other than the manufacturer's primary recommended
application is prohibited. Filler wire intended for certain welding positions specified by the
manufacturer shall not be used in other welding positions. Fluxes recommended for single
pass shall not be used on multi-pass welds.
The use of ERXX-SG and GS, ER-XXC-G and GS of SFA 5.18 is prohibited without prior
submittal and approval of the filler metal material test reports (MTR’s) for each lot. Their
utilization shall not be assumed to be acceptable by the Vendor during bid preparation.
When use of this material is approved by COMPANY the material shall be marked and
segregated for the job.
P-1 materials shall be welded with A-1 analysis weld metal only. Use of other weld metal
analysis numbers requires COMPANY approval. Manganese (Mn) content shall be
<1.60% and Silicon (Si) shall be <1.0 for A-1 analysis weld metal.
When “sour service” or wet H2S environments are specified in the design criteria, the use
of filler materials with greater than 1.60% manganese (Mn) are prohibited.
For welding 70 KSI tensile strength P-1 material subject to a PWHT operation, filler metals
containing 1/2 percent molybdenum (Mo) are permitted in order to meet the minimum
tensile strength requirement.
Similar base materials shall be joined with a weld metal deposit that matches the base
metal in both chemistry and mechanical properties. In cases where this cannot be
accomplished, the Vendor shall propose a choice of filler for COMPANY review and state
the reasons for their choice.
The receipt, use, dispersal and retrieval of welding filler materials shall be maintained
under strict control, with storage, baking and drying as recommended by the manufacturer
to assure that completed welds conform to the approved welding procedure specification
requirements for welding materials.
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6.2 Shielded Metal Arc Welding

The use of SMAW electrode groups F-1, F-2, and F-3 as specified in ASME Section IX,
QW-432, are limited to fillet and buttwelds on materials not exceeding 65 KSI minimum
tensile strength, with thickness not exceeding ½ inch. F-3 electrodes may be used for root
passes in buttwelds regardless of base metal thickness. They are not to be used for
welding materials in which code or project specifications require impact testing. F-1 or F-
2 electrodes shall not be used for welding pressure retaining parts or non-pressure
retaining attachments to pressure retaining parts.
6.3 Gas Tungsten Arc Welding
P-1 materials in excess of 65 KSI minimum tensile strength shall be welded using SFA
5.18 AWS class ER70S-2, ER70S-3, ER70S-6, or ER70S-7 filler materials.
The use of ER70-SG and GS, ER-70C-G and GS of SFA 5.18 is prohibited without prior
Solar flux (Type B) shall not be used.
6.4 Gas Metal Arc Welding
5.18 AWS class ER70S-2, ER70S-3, ER70S-6, or ER70S-7 filler materials.
The use of ER70-SG and GS, ER-70C-G and GS of SFA 5.18 is prohibited without prior
Solar flux (Type B) shall not be used.
6.5 Flux Cored Arc Welding
5.20 AWS class E7X-T1, E7X-T5, or E71T-12MJ filler materials.
6.6 Submerged Arc Welding
The use of Lincoln 780 Flux for multipass welding is prohibited.
Fluxes used for welding carbon or Iow alloy steels shall not contribute alloying elements
to the weld.
A separate welding procedure qualification shall be required for each brand and grade of
flux and electrode combination when impact testing is required or equipment is in sour,
caustic, amine service or other defined severe service.
Welding procedures employing active fluxes for carbon steel shall demonstrate that
hardness does not exceed 200 BHN. Hardness shall be reported with the procedure
qualification record.
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Alloy steel shall be welded using an alloy wire and a neutral flux. Fluxes shall not
contribute alloying elements to the weld deposit.
Fluxes shall be reconditioned prior to re-use per manufacturer's recommendations. The
use of re-crushed slag is prohibited.
7.0 WELD JOINT PREPARATION AND WELDING FABRICATION

Weld joint design shall conform to the applicable code or project specification requirements.
Weld joints shall be prepared by machining, grinding, or thermal cutting. Alloy materials shall be
saw or plasma cut. When thermal cutting is employed, all slag and heat affected areas shall be
dressed by mechanical means.
The addition of permanent backing such as rings, bars, or strips is prohibited.
Temporary (removable) backing rings, bars, or strips shall not be used without specific
COMPANY approval. Their utilization shall not be assumed to be acceptable by the Vendor
during proposal stage.
In the event that temporary backing is approved by COMPANY, it shall be removed upon
completion of welding. The area of removal shall be dressed and examined for defects by visual,
liquid penetrant, or magnetic particle examination methods, as applicable. Defects shall be
removed completely and repaired using a COMPANY’ approved welding procedure.
Materials used as temporary backing shall conform to the nominal chemistry of the base metal,
except that copper backing strips may be used, when approved.
When the use of temporary backing materials is approved by COMPANY, the Vendor’s welding
procedure shall indicate that the welding was qualified with backing on the PQR, and that the
addition of backing shall be used on the WPS.
Consumable inserts shall not be used without specific COMPANY approval. Their utilization shall
not be assumed to be acceptable by the Vendor during proposal stage.
In the event that consumable inserts are approved by COMPANY, they shall conform to the
nominal chemistry of the base metal or filler metal. Root shielding with inert gas is required when
consumable inserts are used.
Weld joint tolerances for root opening and alignment shall meet the requirements of the applicable
codes, project specifications, and the weld joint detail sketches included with the approved
welding procedure.
When poorly fitted joints occur with excessive joint gap or offset, or any other discrepancies, a
repair procedure shall be prepared and submitted to COMPANY for review. Welding shall not be
performed on poorly fitted joints without COMPANY’s concurrence.
Tack welds that are to be incorporated into the final weld shall:
• Be performed in accordance with an ASME qualified and COMPANY approved welding
procedures
• Be performed by an ASME qualified welder or tacker
• Be made with filler metal of the same composition as shall be used for the first pass of the
weld, as stated in the COMPANY approved welding procedure
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• Be subject to the same preheat requirements as stated in the COMPANY approved welding
procedure
• Will have their starting and stopping points properly prepared by grinding or other suitable
means so that they shall satisfactorily incorporate into the final weld
• Have all slag thoroughly removed prior to welding root pass
• Tack welds that violate any of the above shall be completely removed (Completed welds
having tack welds found to violate any of the above shall be subject to complete removal)
Removable start-up and run-off tabs shall be used for longitudinal welds. Materials used for these
tabs shall be of the same nominal chemistry as the base metal.
The use of temporary welded attachments shall be avoided where possible. Where used,
temporary attachments shall be of the same P-No as the material they are attached to. All
locations of removed temporary attachments shall be examined visually after attachment removal.
Temporary attachments shall be removed by flame cutting, arc gouging, or grinding. Hammering
off is not permitted.
Defects discovered in the base metal after removal of temporary attachments shall be repaired
and re-examined.
8.0 CONTROL AND HANDLING OF STAINLESS STEEL, NICKEL AND NONFERROUS ALLOYS
Grinding and cleaning of austenitic stainless steels or higher nickel and nonferrous alloys shall be
done only with tools that have not been previously used on ferrous materials, copper alloys,
aluminum or zinc coatings (paint or galvanized) . Care must be exercised during fabrication and
shipping to prevent carbon contamination of austenitic stainless steels or other higher nickel and
nonferrous alloys. Contamination is caused by carbon steels contacting austenitic stainless steels
or other higher nickel and nonferrous alloys, therefore only stainless steel fasteners are permitted.
Handling equipment must be nonferrous and/or separators must be used between the carbon and
alloy material, including contact with the ground.
For all austenitic stainless steels and higher nickel and nonferrous alloys, marking paint or ink
shall not contain any chlorides, metal or metal salts, such as zinc, lead or copper, which cause
corrosive attack upon heating.
Surfaces to be welded shall be cleaned of oil, grease, scale, rust, paint and other deleterious
materials prior to welding. Materials that contain lead, sulfur, or any other low melting point
element shall not be used on welded components.
9.0 CHARPY IMPACT (CVN) TESTING

Production impact testing of pressure vessels and heat exchangers shall be performed when
required by ASME Code or other specifications.
When impact testing is required, impact test temperature and results shall be reported on the
PQR. Impact test results shall include specimen size, notch location and type, test temperature,
absorbed energy, and when required by codes or specifications, lateral expansion and percent
shear.
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Filler metal selection shall be based upon an AWS / ASME SFA specification that shows filler
metals capable of meeting the minimum impact values for the stated minimum design metal
temperature.
Except for dollar plates in hemispherical heads, production test plates for Category A weld seams
must be performed as an extension to the end of the first production weld. The first production
Category A, and as applicable, Category B weld shall be tested immediately after weld completion
and before extensive production welding is allowed to continue.
Test plates must be made from one of the heats of material used in the vessel. Test plates shall
be legibly marked with material type, grade and heat number and direction of mill rolling. A
reasonable number of large nozzle opening drops shall also be marked with material heat
numbers, direction of mill rolling and maintained until completion of fabrication.
Production test plates for all Category A and B joints must be welded identical to the actual
production joint, including any backgouging and backwelding that utilizes the same or other
welding processes or procedures.
Vendor’s written instructions to testing laboratories must included specific references to the
applicable section(s) of ASME Code that apply to testing and acceptance criteria. Laboratory
test reports must clearly describe the location within the test plate where specimens were
removed and state compliance to the applicable section(s) of ASME Code.
Test reports must indicate the applicable welding procedure specification that was used to weld
the test plate and should also identify the applicable heat / lot of the filler metal(s) used.
10.0 PREHEAT AND INTERPASS TEMPERATURES

Preheat shall be at least sufficient to dry surfaces to be welded, but not less than 50ºF.
Carbon steel (P-1) materials 1.25 inch and over in thickness shall be preheated to 200ºF minimum
prior to flame cutting and welding.
All flame cut surfaces shall be ground to bright metal to remove surface oxides, and shall be
visually examined to detect indications of cracking or laminations.
Minimum preheat temperatures for welding shall not be less than that stated in ASME Section
VIII, Division 1, Appendix R and Paragraph UCS-56; ASME B31.1, Paragraph 131; ASME B31.3,
Table 330.1.1, or AWS D1.1, as applicable. Minimum preheat temperatures shall be stated in the
WPS.
Preheat for arc gouging, tack welding and welding repairs shall be the same as required in
COMPANY’s accepted welding procedure.
Preheat maintenance is the maintaining of the stated minimum preheat temperature, without
interruption, from start to completion of welding. Vendor must either state in the WPS or the
addenda to the WPS, that preheat maintenance is required. Vendor must state on the Welding
Procedure Application Map (Appendix 1) that preheat maintenance is required. The loss or
interruption of continuous preheat shall require a liquid penetrant or magnetic particle examination
of the incomplete weld prior to further welding. Defective welding shall be repaired accordingly.
Preheat shall be maintained continuously throughout the welding operation for the following:
• All P-1 and P-3 materials 1.25 inch and over in thickness
• All P-4, P-5 and P-6 materials
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• All materials to be used in hydrogen service (Hydrogen service shall be specified in the design,
or when the process stream contains a hydrogen partial pressure of 50 psia or greater)
When preheat or preheat maintenance is required, welders and welding operators shall maintain
temperature indicating crayons or equivalent at the work station at all times.
The maximum preheat and interpass temperature for P-8 and all P-4X materials shall be 350ºF.
The maximum preheat and interpass temperature shall be specified in the WPS for all materials
P-7 and higher.
The maximum preheat and interpass temperature shall be specified in the WPS for all materials,
when impact testing is required.
11.0 POSTWELD HEAT TREATMENT

Post-weld heat treatment (PWHT) shall be performed in accordance with the requirements of the
ASME code as applicable. The applicable code for PWHT shall be referenced on the Welding
Procedure Application Map (Appendix 1). The maximum and minimum holding temperatures
shall be included in the WPS or on a COMPANY approved PWHT procedure.
Direct impingement by torch or burner is not acceptable.
Threads and gasket surfaces shall be protected from oxidation during PWHT.
PWHT of P-8 materials, nonferrous alloy materials, and dissimilar materials require specific
COMPANY approval.
When local PWHT is performed on materials 2 inches and greater in thickness, the minimum
required temperature must be monitored and verified on the unheated side of the material.
All PWHT methods require complete temperature control and chart recording capabilities. The
complete cycle of heating, holding and cooling temperatures and times must be included on the
chart.
Acceptable methods of PWHT are:
• Furnace method.
• Internal fuel firing method.
• Local resistance method.
• Local induction method.
Other methods of PWHT require specific COMPANY approval.
PWHT procedures for internal fuel firing and specialized local resistance heating methods on
equipment and piping shall be submitted to COMPANY for approval. The procedures shall be
developed in accordance with WRC 452 and shall include the following information and details:
• Equipment requirements for heating and recording controls. Include all spare equipment for
contingency purposes
• Dimensions of heating and soak bands
• Insulation requirements both internally and externally. Include type, thickness, and banding
requirements
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• Sketch or drawing showing equipment support, burner locations, thermocouple layout and
insulating boundaries
• Thermal growth considerations, including calculations
• Fuel supply or electrical power requirements
• Personnel requirements
• PWHT time / temperature requirements
Maximum PWHT shall not exceed the following temperatures for boilers, pressure vessels, heat
exchangers, fired heaters, storage tanks and their attachments, unless specific COMPANY
approval is obtained:
P-No. Base Material Max PWHT Temp. Min. Time Brinell Hardness
Hours Max.
1 Carbon Steel 1200ºF 1 200
3 Carbon ½ Mo 1300ºF 1 225
4 1 ¼ Cr - ½ Mo 1375ºF 2 225
5A 2 ¼ Cr - 1 Mo 1375ºF 2 241
5B 5 Cr - ½ Mo 1375ºF 2 241
5B 9 Cr - 1 Mo 1375ºF 2 241
6 13 Cr 1400ºF 2 241
Maximum PWHT and hardness shall not exceed the following temperatures for piping:
P-No. Base Material Temp. Metal Hrs./In. Min. Max. Brinell
Rise Temp. ºF Nom. Time Temp. Hardness
ºF/Hr. Wall Hrs. Fall, ºF/Hr Max.
(to 600ºF)
1 Carbon Steel 400 1100-1200 1 1 200 200
3 Carbon ½ Mo 400 1100-1325 1 1 200 225
4 1 ¼ Cr - ½ Mo 400 1300-1375 1 2 200 225
5A 2 ¼ Cr- 1 Mo 400 1300-1400 1 2 200 241
5B 5 Cr -½ Mo 400 1300-1400 1 2 200 241
5B 9 Cr- 1 Mo 400 1300-1400 1 2 110 241
6 13 Cr 400 1350-1450 1 2 110 241
PWHT may be required for carbon steel materials because of specific service conditions, even
when not required by the applicable code or standard. PWHT requirements for these services
shall be included in the project specifications. When not specifically addressed in the project
specifications, the following service conditions shall require PWHT as noted:
• Welds in piping and equipment in amine service for all operational temperatures shall be
PWHT’d.
• Welds in piping and equipment in caustic service shall be PWHT’d when the operating
temperature is above 140ºF and the caustic concentration is <30%; operating temperature is
above 110ºF and the caustic concentration is >30%; or, at any operating temperature when
the equipment or piping is heat traced or subject to steam out conditions.
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• Welds in piping and equipment in anhydrous ammonia service shall be PWHT’d, if the water
content is 0.2% or less by weight.
• Welds in equipment in wet H2S service (minimum 50 wppm H2S in a separate water phase)
shall be PWHT’d. Welds in piping in wet H2S service shall be PWHT’d when the thickness at
the weld joint > 3/4 inch, or at anytime that the as-welded hardness of the weld exceeds 200
BHN.
• Welds in piping and equipment in sour service (H2S in the presence of hydrogen at
temperatures above 450ºF and at partial pressure greater than 0.05 psi and total pressure
greater than 65 psia) shall be PWHT’d.
• Welds in equipment in hydrogen service (any process stream with hydrogen partial pressure
greater than 50 psia or when a Client or licenser specifies a stream to be in hydrogen service)
shall be PWHT’d if the operating conditions are within 100ºF of the Nelson Curve for the
material (API Publication 941).
12.0 NON-DESTRUCTIVE EXAMINATION, TESTING AND INSPECTION
12.1 General
Non-Destructive Examination (NDE) procedures and technician certifications shall be
available for review by the COMPANY inspector during the course of fabrication. NDE
shall be performed and evaluated in accordance with the applicable ASME code or API
standard. NDE in excess of code requirements shall be as specified in the project
specifications or this specification. The more stringent specification or code requirement
shall govern.
As a minimum, or when NDE is not specified, all welds shall be visually examined in
accordance with the applicable code or standard.
When PWHT is required on low alloy steels, all NDE shall be performed after PWHT for
final acceptance.
Plate material 2 inches and greater in thickness, when used for pressure retaining
components, shall be ultrasonically examined by the straight-beam method in accordance
with ASTM / ASME SA-578. The acceptance standard shall be Level B.
Plate edges, including weld bevel preparation, shall be examined for laminar-type
discontinuities on all P-1 materials >1-1/4 inch, P-3 materials >3/4 inch, and all P-4 and
P-5 materials regardless of thickness. Examination shall be by magnetic particle or liquid
penetrant methods. All relevant indications shall be removed by gouging or grinding, and
repaired by welding using approved welding procedure specifications. Relevant
indications shall be as defined in ASTM / ASME SA-20 section 9.3 and Table A1.14.
Plate materials used in the manufacture of 2-piece formed heads shall have the seam
weld radiographically examined 100% prior to forming.
The backside of double-sided groove welds shall be prepared by chipping, grinding or
gouging to clean sound metal. This area, and all finished weld surfaces, shall be examined
by the magnetic particle method for P-1 materials >1-1/4 inch, P-3 materials >3/4 inch, P-
4 materials >5/8 inch, and all P-5, P-6, and P-7 materials regardless of thickness. (Note:
The backside of double-sided groove welds in P-4, P-5, and P-6 materials need not be
examined unless there is an interruption of the preheat maintenance).
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The backside of double-sided groove welds and all finished weld surfaces in all non-
magnetic materials, either solid alloy or alloy clad, shall be liquid penetrant examined.
12.2 Hardness Testing
Hardness testing shall be performed when PWHT is specified, or when required by
applicable codes, standards, project specifications or purchase documents. Hardness
testing shall be performed using a portable hardness tester. Each indentation shall be
made to include part of the weld and part of the heat affected zone (HAZ) whenever
practical. Hardness testing shall be performed by the Brinell Hardness Test method,
unless specific approval is given by COMPANY to deviate from this test method.
Whenever possible, production hardness readings shall be taken on the side of the
weldment which shall be exposed to the process environment.
When hardness testing is required on ASME Section VIII, Division 1 or 2 pressure vessels,
shell and tube exchangers and air cooled exchangers, the tests shall be taken as follows:
• One test for each longitudinal weld seam per shell course section, on the I.D. where
practical
• One test for each 50 lineal feet of circumferential weld seam, on the I.D. where
practical
• One test for longitudinal and end plate weld seams on box headers for air-cooled
exchangers
• One test for each 4 inches diameter nozzle and above, unless more stringent
requirements of an API standard apply
• As a minimum, one test shall be taken on pressure retaining welds for each welding
process employed and one test for each welder or welding operator used
• When PWHT is required, hardness tests shall be taken after PWHT
Hardness tests on piping, not covered by ASME Code, shall be as stated in the project
specifications.
Hardness tests on equipment other than pressure vessels, heat exchangers, and piping,
shall be as stated in the applicable code, standard or project specifications.
Results of hardness tests shall be documented by the Vendor and available for review by
the COMPANY inspector. The COMPANY inspector shall be consulted on the choice of
locations for the tests.
Hardness test results shall be reported by the Vendor with the PQR when submitting
welding procedures to COMPANY for review and acceptance for the following:
• When hardness tests are required by applicable codes, standards or project
specifications
• When equipment or piping is PWHT’d
• When automatic or machine type SAW process, or FCAW process is to be used for
welding P-1 through P-6 materials
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Hardness for carbon steel shall not exceed 200 BHN. Hardnesses for low alloy materials
shall be in accordance with applicable codes and standards or as stated in this
specification.
When NACE service is specified for carbon and low alloy steels in wet H2S service (NACE
MR-0175),welding procedures shall be qualified with hardness surveys performed in
accordance with the applicable Figures 2, 3, 4 or 5 found in NACE MR-0175. Acceptance
criteria shall be per NACE MR-0175, Table A.1.
When NACE SP-0472 is specified Welding procedure qualification (PQR) shall contain
the results of a cross-sectional Vickers Hv10 hardness survey using a maximum test load
of 10 kg. Hardness survey shall be performed in accordance with Figure 2 of NACE SP
0472. Hardness results shall not exceed 248 HV in the heat affected zone (HAZ) and
weld deposit. The average weld deposit hardness shall not exceed 210 HV. Production
hardness testing shall be performed 100% on all welds, using the Brinell Hardness test
methods. Production hardness results shall not exceed 200 HB.
For both NACE MR-0175 and RP-0472 applications, the following additional welding
procedure variables shall be considered as essential:
• The wire brand name and type used for production welding shall be the same as used
in procedure qualification.
• The wire size used in production shall be the same as used in procedure qualification
• Heat input used during welding shall not vary by more than +25% and -10% from that
used in procedure qualification. If impact testing is also required, heat input shall not
exceed the maximum on the procedure qualification record (PQR). Heat input shall be
calculated according to the methods defined in ASME Section IX and shown on the
procedure qualification record (PQR). The welding procedure specification (WPS)
shall state the maximum allowable heat input within the tolerances specified above.
• Preheat and Interpass temperatures used during production welding shall be greater
than or equal to that used in procedure qualification.
• For welds in pressure containing components, the diffusible hydrogen limit for FCAW
filler metals shall be measured in accordance with AWS A4.3. Limits of diffusible
hydrogen shall be as follows:
Specified Minimum Tensile Strength Maximum Diffusible Hydrogen

for FCAW Electrode (Per AWS/SFA Designation (Per AWS/SFA 5.20 and
5.20 and 5.29) 5.29)
≤70 ksi H8
>70 ksi H4
• Shielding gas shall be checked to confirm a dew point of -40°F or lower. This may be
accomplished by obtaining written certification of each shielding gas cylinder, by actual
dew point measurement of each cylinder or by ordering and marking in compliance
with AWS / ASME SFA 5.32.
• If preheat is not used in procedure qualification, the maximum base metal thickness of
production weldments shall not exceed the thickness of the procedure qualification
(PQR) test specimen.
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13.0 CLAD RESTORATION, WELD METAL OVERLAY AND DISSIMILAR METAL WELDING
13.1 General
Corrosion-Resistant Weld Metal Overlay, Hard-Facing Weld Metal Overlay, Joining of
Composite (Clad Metals), and Applied Linings:
Welding procedures shall be qualified to ASME Section IX, Paragraph(s), QW-214, QW-
216, QW-217, and QW-218 as applicable, unless more stringent requirements of this
specification apply.
Corrosion-resistant weld metal overlay and clad restoration welding shall control dilution
as evidence by a chemical analysis for the PQR per ASME Code Section IX, QW-462.5
(a). The chemical analysis shall indicate that the minimum chemical requirements meet
the minimum specified for the weld metal or base metal as follows:
• For 300 Series austenitic stainless steels and nickel-based alloys - The chemical
composition of the analysis shall be within the minimum requirements of the applicable
SFA designation and AWS Classification of the filler materials major alloy elements.
• For 400 Series ferritic or martensitic stainless steels - The chemical composition of the
analysis shall be within the minimum requirements of the applicable SFA designation
and AWS Classification of the filler materials, unless austenitic stainless steel or nickel-
based alloy filler materials are used. In these instances, the chemical composition of
the analysis shall be within the minimum requirements for chromium content of the
applicable base material specification.
Corrosion-resistant weld metal overlay and clad restoration welding deposits shall be a
minimum of two passes, unless otherwise authorized by COMPANY.
The following arc-welding processes may be used for corrosion-resistant weld metal and
hard-facing overlay, clad restoration welding and welding of applied linings:
• Shielded Metal Arc Welding (SMAW) - Manual
• Gas Tungsten-Arc Welding (GTAW) - Manual, machine or automatic, cold or hot wire
• Submerged Arc Welding (SAW) - Automatic or machine, wire or strip electrode, single,
tandem or multi-head
• Gas Metal Arc Welding (GMAW) - Semi-automatic, machine or automatic spray,
globular, or pulsed transfer modes only. Limited to three (3) deposit passes only
• Flux Cored Arc Welding (FCAW) - Semi-automatic, machine or automatic spray
transfer mode only. Auxiliary shielding gas only, unless otherwise authorized by
COMPANY
• Electroslag Welding (ESW) - Resistance Electroslag Surfacing (RES) process
• Plasma-Arc Welding (PAW) - Plasma-arc hot-wire welding, gas-metal plasma-arc
welding or plasma-MIG welding
The following preparations shall be used on all alloy clad materials prior to clad restoration
welding:
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• Cladding shall be stripped back to a minimum of 1/4 inch from the edge of the backing
material bevel by machining, grinding, or arc gouging. If removed by arc gouging,
resulting oxidation and surface roughness shall be removed by grinding.
• A minimum radius of 1/16 inch shall be used at the limit of the cladding removal, unless
the clad material is beveled at least 30º.
• Removal of cladding shall not reduce the thickness of the backing material below the
design thickness.
• The area where cladding has been removed shall be examined by standard copper
sulfate examination, (Blue Vitriol) 5-10% in water, to assure complete removal of the
cladding.
The following NDE examinations and production test requirements shall be used on all
alloy clad materials, clad restoration welding and corrosion-resistant weld metal overlay:
• All alloy clad materials, whether roll bonded or explosion bonded, shall be examined
in accordance with ASTM / ASME SA-578 for both the backing steel and the clad
material, at the mill. The acceptance criteria for the backing steel shall be Level B.
• After the completion of forming operations (i.e., rolling, pressing, flanging, dishing, etc.)
on alloy clad materials, whether roll bonded or explosion bonded, a 10% random
examination for lack of bond shall be performed using the straight beam ultrasonic
method. ASTM / ASME SA-578 shall be the basis for the examination, excluding the
extent of scanning.
• After the completion of clad restoration welding or weld metal overlay, a chemical
analysis to determine alloy content of the deposited weld metal shall be performed on
each shell section and major component (i.e., heads, tubesheets, etc.), and on each
longitudinal and circumferential weld seam. In addition, all manway attachments and
a representative number of nozzles, at least one of each size, shall also have a
chemical analysis performed on them. Production chemical analysis shall also include
a minimum of one test per welding procedure used and one test for each welder or
welding operator employed in production of the component.
• Chemical analysis may be performed using X-ray spectrometer, X-ray emission, X-ray
fluorescence, optical spectroscopy or wet chemical analysis techniques and
equipment. Unless otherwise specified herein or within other applicable specifications
or codes, the depth of chemical analysis shall be no less than the minimum specified
overlay thickness.
• Where 300 Series austenitic stainless steel corrosion-resistant weld metal overlay and
clad restoration welding is specified to meet the chemical composition of equivalent
300 Series austenitic stainless steel base material, or the minimum requirements of
the applicable SFA designation and AWS Classification of the filler metals, the ferrite
content shall be checked with a Severn Gauge, Ferritiscope, or other magnetic test
device traceable to AWS A4.2, Standard Procedure for Calibrating Magnetic
Instruments to Measure the Delta Ferrite Content of Austenitic Steel Weld Metal. The
acceptable range for as-welded ferrite content shall be a ferrite number from 3FN to
12FN, unless the backing material is to be PWHT’d in which case the maximum ferrite
content shall be ferrite number 10FN.
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• When ferrite content analysis is required, it shall be performed on each shell section
and major component (i.e., heads, tubesheet, etc.), and on each longitudinal and
circumferential weld seam. In addition, all manway attachments and a representative
number of nozzles, at least one of each size, shall also have a ferrite content analysis
performed on them. A ferrite content analysis shall also include a minimum of one test
per welding procedure used and one test for each welder or welding operator
employed in production of the component.
• Standard copper sulfate examination, (Blue Vitriol) 5-10% in water, shall be performed
prior to hydrostatic testing, on all finished surfaces of clad restoration welding and
corrosion-resistant weld metal overlay.
• Liquid penetrant examination shall be performed following the hydrostatic testing, on
all finished surfaces of clad restoration welding and corrosion-resistant weld metal
overlay.
13.2 Dissimilar Metal Welding
Welds joining pressure-containing parts of two different ferritic steels shall have a weld
metal deposit conforming to the nominal chemical composition of the higher alloy base
material unless otherwise approved by COMPANY.
Welds joining two different ferritic steels, only one of which is a pressure containing part,
shall have a weld metal deposit conforming to the nominal chemical composition of the
pressure containing part base material, unless engineering design specifies otherwise, or
approval is obtained from COMPANY.
When joining two different austenitic stainless steels, the filler metal (A No. 8) may match
either, unless a stabilized grade of material is involved, in which case the filler metal shall
match the nominal chemical composition of the stabilized grade of material. The resulting
as-welded ferrite content shall be from 3FN to 12FN. Delta ferrite shall be determined
from the certified chemical composition analysis of the filler metal manufacturer and the
WRC Delta Ferrite Diagram.
When joining ferritic steels (P-1 through P-5) to martensitic stainless steels (P-6), ferritic
stainless steels (P-7), or austenitic stainless steels (P-8), the filler metal shall be Type 309
or 309L for design temperatures not exceeding 600º F. Type 309Cb should not be used
when PWHT is required, except for weld overlay. Nickel-based alloy filler metals may be
selected using design conditions as shown in the table below.
Type 310 filler material is prohibited. (Note: Type 310 filler materials are acceptable only
for welding of Type 310 base materials to themselves).
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AWS Filler Metal Max. Design Max. Design

Designation Temperature Temperature
(non-sulfur (sulfur environment)
environment)
ENiCrFe-3 1000ºF (540ºC) 700º F (370ºC)
ERNiCr-3 1400ºF (760ºC) 750ºF (400ºC)
ENiCrFe-2 1400ºF (760ºC) 750ºF (400ºC)
ERNiCrMo-3 1100ºF (590ºC) 1100ºF (590ºC)
14.0 DUPLEX STAINLESS STEEL WELDING

When welding duplex stainless steels, the following requirements shall apply:
• Minimum pitting resistance equivalent number (PREN) shall be 36 for UNS S32205 (Duplex)
and 40 for UNS S32750 (Super Duplex) materials.
• All filler metals shall contain 0.14 to 0.20 nitrogen for UNS S32205 and 0.23 to 0.28 nitrogen
for UNS S32750
• Heat input shall be between 15-65KJ/in for UNS S32205 materials and 5-38KJ/In for UNS
S32750 materials. Heat input shall be closely monitored for compliance with the WPS during
production welding.
• The procedure qualification shall be tested using the highest and lowest heat input shown on
the WPS.
• The minimum preheat shall be 50°F. Preheat can be used to control the cooling rate when
qualifying the PQR. The cooling rate may need to be controlled when relatively small welds
are required on relatively large or thick sections in order to obtain the required microstructure.
• The maximum interpass temperature shall not exceed 300°F.
• All single sided welds shall be made with a GTAW root pass and the Argon gas backing shall
be maintained until a least ¼” of weld metal thickness has been deposited.
• Shielding and gas backing shall be with Argon with a purity of at least 99.95%. Oxygen
content of the back-purged volume shall be less than 0.5% (5000 ppm). Shielding gas may
have a maximum of 3% nitrogen added.
• Procedure qualification testing shall include:
− Ferrite/austenite phase balance determination using the point count method per ASTM E-
562. Ferrite shall be determined for the base metal, heat affected zone and the weld
metal. Ferrite number for the PQR shall be 35 – 65.
− Charpy impact tests shall be performed in accordance with ASTM A923, Test Method
B. Acceptance criteria for Duplex steels shall be in accordance with ASTM A923, Table
2. Acceptance criteria Super Duplex steels: The average absorbed energy value obtained
from a set of full-size (10mm x 10mm) specimens shall be at least 40 ft. lbs with no
individual value less than 30 ft. lbs.
− Pitting /corrosion testing in accordance with ASTM G48, Method A. Vickers hardness
testing with a 10Kg load. At least 8 readings at a depth of 0.100 inch below the inside and
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below the outside surfaces shall be recorded for both base metal, heat affected zone and
weld deposit. Hardness shall not exceed HV310.
• If the deposited weld metal ferrite content as shown in the PQR is greater than 60 FN, the
moisture content of duplex stainless steel electrodes shall be controlled to 0.2% maximum as
measured by the test procedure given in AWS A5.5, Section 14.
• Production ferrite testing shall be determined by an instrument calibrated to AWS A4.2 and
shall be between 35-60 FN. Production ferrite testing of equipment and piping fabricated from
duplex stainless steel shall include 10% of all welds per welding procedure. Each welder’s
work shall be represented in the examinations.
15.0 ADDITIONAL WELDING REQUIREMENTS FOR STRUCTURAL STEEL FABRICATION

All structural steel welding shall be in accordance with the most recent edition of AWS D1.1. AWS
Prequalified or AWS Recommended Welding Procedure Specification formats may be used for
structural steel welding.
Acceptable welding processes for structural steel welding include the following:
• Shielded Metal Arc Welding (SMAW)
• Gas Tungsten Arc Welding (GTAW)
• Gas Metal Arc Welding (GMAW) - Shop welding only using the spray or globular transfer
modes only, completion of groove welds on base materials < 3/8 inch total thickness and 3/8
inch fillet welds on plate and structural steel and any seal welding
• Flux Cored Arc Welding (FCAW) - Spray transfer mode only. May be self-shielded or auxiliary
gas shielded
• Submerged Arc Welding (SAW) - Automatic or machine only
Welding processes other than those listed above require written approval from COMPANY, and
shall not be assumed to be acceptable during proposal stage.
Galvanized structural steel must be ground and cleaned to bright metal prior to welding.
Column and beam splices, full penetration welds for moment connections and groove welds in
structural steel 1/2 inch and over in thickness, shall be non-destructively examined by
radiographic or ultrasonic methods for volumetric weld integrity. Acceptance criteria shall be in
accordance with AWS D1.1.
16.0 ADDITIONAL WELDING REQUIREMENTS FOR PRESSURE VESSELS AND HEAT

EXCHANGERS
All welding shall be in accordance with the most recent edition of ASME Section VIII, Division 1
or Division 2, as applicable.
All Welding Procedure Specifications shall be in accordance with the most recent edition of ASME
Section IX.
Acceptable welding processes for welding of pressure vessels and heat exchangers include the
following:
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• Gas Tungsten Arc Welding (GTAW) - Manual, machine, automatic, or orbital.

• Gas Metal Arc Welding (GMAW) - Short circuiting, spray or globular transfer modes (See
Welding Process Limitations section in this document.)
• Flux Cored Arc Welding (FCAW) - Spray transfer mode and auxiliary gas shielded only is
acceptable for welding P-1 through P-8 materials
When poorly fitted joints occur with excessive gap or excessive offset, the supplier shall submit a
separate weld repair procedure indicating with a sketch, the method proposed to bring the joint
back to original design requirements specified in the original COMPANY accepted welding
procedure specification. The supplier shall not assume that backing rings and temporary or
permanent backing strips are acceptable without COMPANY’s review and approval. Any weld
joints of this nature found to be slugged with supplementary filler metal are unacceptable, and
shall be removed. Buttering of beveled ends to close excessive gap is unacceptable without
COMPANY review and approval.
When specified on heat exchanger data sheets, a “mock-up” of strength welded tube-to-tubesheet
joints shall be submitted to COMPANY prior to production welding. The mock-up sample shall be
suitably sectioned and etched to show full fusion, minimum leak path, and microhardness test
results.
• Tube and tubesheet materials for qualification testing shall conform to the actual material type
and grade to be used in production.
• Tube and tubesheet thicknesses for qualification testing shall conform to the actual
thicknesses to be used in fabrication, except that the tubesheet thickness of the mockup need
not exceed 2 inches.
• The clearance between the outside surface of the tubes and the inside surfaces of the tube
holes shall not exceed clearance used in the Welding Procedure Specification (WPS)
qualification tests.
• The edges of the tubesheet at the tube holes on the side to be welded shall be free of burrs.
The edges of the tubesheet at the tube holes on the side opposite the weld shall have sharp
corners removed.
For critical tube-to-tubesheet applications and where specified on heat exchanger data sheets, a
mock-up prepared and tested as noted above shall also be Shear Load tested and liquid penetrant
examined in accordance with ASME Section IX, QW-193.
All test results, weld samples, and welding procedure specifications shall be submitted for
approval.
When strength welding of the tube-to-tubesheet is specified on the heat exchanger data sheet,
production weld joints shall be tested after the completion of the first weld pass, and the second
weld pass when specified, by means of an air and soap test. The air pressure shall be a minimum
of 5 psig, and shall be applied from the shell side of the tubesheet. A bubble forming solution
shall be applied to the weld joints to test the integrity of the weld. This test shall be performed
prior to tube rolling. Test procedures shall be in accordance with ASME Section V, Article 10.
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Weld overlay of tubesheets shall be liquid penetrant examined prior to hydrostatic testing.
Peening of welds to enhance mechanical properties is prohibited.
17.0 ADDITIONAL WELDING REQUIREMENTS FOR ATMOSPHERIC AND LOW PRESSURE

STORAGE TANKS
All welding shall be in accordance with the most recent edition of API-650 and API-620, as
applicable.
Section IX.
Acceptable welding processes for welding atmospheric and low pressure storage tanks include
the following:
• Gas Tungsten Arc Welding (GTAW)
• Gas Metal Arc Welding (GMAW) - Semi-automatic process, shop fabricated tanks only.
Machine or automatic process shall be used for field fabricated tanks; Root welds that are
backgouged and back-welded may be by short-circuiting transfer mode; All other welding
passes to be by spray or globular transfer modes only (See Welding Process Limitations
section in this document.)
• Flux Cored Arc Welding (FCAW) - Semi-automatic process, shop fabricated tanks only.
Machine or automatic process shall be used for field fabricated tanks; Spray transfer mode
with auxiliary gas shielding only
Downhill welding of the wash and cover passes using the SMAW process and low hydrogen
electrodes is subject to written authorization from COMPANY.
The weld seams of sketch plates for tank bottoms and floating roofs shall consist of a minimum
of (2) two weld passes. Single pass weld seams are unacceptable.
18.0 ADDITIONAL WELDING REQUIREMENTS FOR BOILERS, HEATERS AND FURNACES

All welding shall be in accordance with the most recent edition of ASME Section I, Section VIII,
Division 1, and B31.1, as applicable.
Section IX.
Acceptable welding processes for welding of boilers, heaters and furnaces include the following:
• Gas Tungsten Arc Welding (GTAW) - Manual, machine, automatic or orbital
Welding Process Limitations section in this document.)
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• Flux Cored Arc Welding (FCAW) - Spray transfer mode and auxiliary shielding for pressure
boundary welding; Spray transfer, self shielded or auxiliary gas shielded, may be used for
non-pressure boundary welding and structural attachment welding
shall not be assumed as acceptable during proposal stage.
GTAW shall be used on a minimum of the first (2) two weld passes of single-sided groove welds
on ferrous alloy and non-ferrous alloy tubes.
A back-purge with argon shielding gas is required on all low alloy (P-5) and higher alloy material
single-sided groove welds. The purge shall be maintained a minimum of two complete weld
passes.
The material used for tube purging dams, and methods employed in their placement, use, and
subsequent removal shall be included in a procedure which specifies the composition and purity
of the gas and the flow rates and time required to obtain adequate purging. This information may
be provided on the Welding Procedure Specification or as a separate procedure, for COMPANY’
review and approval.
19.0 ADDITIONAL WELDING REQUIREMENTS FOR ROTATING EQUIPMENT AND AUXILIARY

SUPPORT COMPONENTS
All welding shall be in accordance with the most recent edition of ASME Section VIII, Division 1,
B31.3, or applicable API Code, as applicable.
Section IX.
Acceptable welding processes for welding of rotating equipment and auxiliary support
components include the following:
• Gas Tungsten Arc Welding (GTAW) - Manual, machine or automatic
• Gas Metal Arc Welding (GMAW) - Short circuiting, spray or transfer modes (See Welding
Process Limitation section in this document.)
• Flux Cored Arc Welding (FCAW) - Spray transfer mode and auxiliary gas shielding for
pressure boundary welding; Spray transfer, self-shielded or auxiliary gas shielded may be
used for non-pressure boundary welding and structural attachment welding
Major weld repairs of defects in castings shall have COMPANY’s prior approval. A proposed
repair procedure shall be submitted for COMPANY’s review and approval. The repair procedure
shall include as a minimum:
• A sketch which maps the physical location of the defect(s) within the casting. The major
dimensions of the defect(s) and the severity level associated with them must also be included.
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• The NDE method used to detect the existence of the defect(s), and the method planned to
assure its removal and repair.
• The Welding Procedure Specification proposed for the welding repair.
• Any thermal heat treatment procedures required for post-welding applications.
NOTE: A weld repair is considered major when it is made to correct leakage on hydrostatic
testing, or when the depth of the cavity prepared for welding exceeds 20% of the actual wall
thickness or 1 in., whichever is smaller, or when the extent of the cavity exceeds approximately
10 sq. in.
Welding of structural steel for base components and skid units shall be in accordance with the
most recent edition of AWS D1.1. AWS Prequalified or AWS Recommended Welding Procedure
Specification formats may be used for structural steel welding. The equipment supplier shall
receive and approve all sub-Vendor welding procedures for structural steel welding applications.
All requirements of section Additional Welding Requirements For Structural Steel Fabrication in
this document shall apply for structural steel welding. The supplier shall submit Vendor’s Welding
Procedure Application Map along with Welding Procedure Specifications and Procedure
Qualification Records to COMPANY for review and approval.
Welding of lube oil piping and piping components for equipment lubrication systems shall be in
accordance with the most recent edition of ASME B31.3. All Welding Procedure Specifications
shall be in accordance with the most recent edition of ASME Section IX. The equipment supplier
shall receive and approve all sub-Vendor welding procedures for lube oil piping applications. All
requirements of section Additional Welding Requirements for Fabricated Piping and Piping
Components shall apply for welding of lube oil piping. The supplier shall submit Vendor’s Welding
Procedure Application Map along with Welding Procedure Specifications and Procedure
Qualification Records to COMPANY for review and approval.
Welding of ASME code stamped filters and coolers, storage and run-down tanks, and any other
equipment associated with the lubrication system shall be in accordance with the most recent
edition of ASME Section VIII, Division 1. All Welding Procedure Specifications shall be in
accordance with the most recent edition of ASME Section IX. The equipment supplier shall
receive and approve all sub-Vendor welding procedures for equipment associated with lube oil
systems. All requirements of section Additional Welding Requirements for Pressure Vessels and
Heat Exchangers in this document shall apply for welding of equipment associated with the lube
oil system. The supplier shall submit Vendor’s Welding Procedure Application Map along with
Welding Procedure Specifications and Procedure Qualification Records to COMPANY for review
and approval.
Welding of ASME code stamped, or API Plan seal pots and seal oil system shall be in accordance
with the most recent edition of ASME Section VIII, Division 1, or ASME B31.3, as applicable. All
Welding Procedure Specifications shall be in accordance with the most recent edition of ASME
Section IX. The equipment supplier shall receive and approve all sub-Vendor welding procedures
for seal oil systems. All requirements of sections Additional Welding Requirements for Pressure
Vessels and Heat Exchangers and Additional Welding Requirements for Fabricated Piping and
Piping Components in this document shall apply for welding of seal oil systems. The supplier
shall submit Vendor’s Welding Procedure Application Map along with Welding Procedure
Specifications and Procedure Qualification Records to COMPANY for review and approval.
The supplier shall submit all Welding Procedure Specifications and Vendor Welding Procedure
Application Maps as part of the equipment data books.
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20.0 ADDITIONAL WELDING REQUIREMENTS FOR FABRICATED PIPING AND PIPING

COMPONENTS
All welding shall be in accordance with the most recent edition of ASME B31.1, B31.3, as
applicable.
End preparation for groove welds shall be as specified in the welding procedure specification and
ASME B16.25.
Section IX.
Acceptable welding processes for welding fabricated piping and piping components include the
following:
• Gas Tungsten Arc Welding (GTAW) - Manual, machine or automatic
Welding Process Limitation section in this document.)
• Flux Cored Arc Welding (FCAW) - Spray transfer mode and auxiliary gas shielded only is
acceptable for welding P-1 through P-8 materials
Root pass welding of P-1 piping materials may be accomplished using the SMAW, GTAW, or
GMAW welding processes.
Low hydrogen electrodes used with the SMAW processes shall not be used for root passes of
single-sided groove welds, unless backgouging and backwelding can be accomplished.
A back-purge with argon shielding gas is required on all low alloy (P-5) and higher alloy material
single-sided groove welds. The purge shall be maintained a minimum of (2) two complete weld
passes.
The GTAW process shall be used on all welding of piping and piping components as follows:
• All low alloy, stainless steel and high alloy single-sided groove weld root and hot passes, as
a minimum
• All root and hot passes in buttwelds of P-1 materials 2 inches NPS and less
• All root and hot passes in buttwelds of compressor suction piping
• All root and hot passes in buttwelds of lube oil and seal oil piping
• All root and hot passes in buttwelds of piping in processes that involve the conveying of solid
materials
The gap on pipe-to-socket fitup for socket welding shall result in a minimum of 1/16 inch before
welding.
Socket welds shall have a minimum of two (2) complete passes, regardless of diameter. For
socket welds on piping diameters of 2 inches NPS and greater, there shall be a minimum of two
(2) cap passes visible.
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Branch connections such as weldolets, threadolets, sockolets, and stub-ins shall be joined to the
header by full penetration welds. Incomplete penetration as defined by Table 341.3.2, Note B of
ASME B31.3, is not acceptable.
Branch connections shall be prepared in accordance with Figure 328.4.4 (A), (B) or (C) of ASME
B31.3. A minimum root gap of 1/16 inches shall be maintained during welding. The root gap
shall be stated in the welding procedure specification.
The sequence of weldout shall not result in excessive distortion in the piping. Root passes shall
be completed prior to block, or step welding of the remaining weld passes. P-1 material piping
distortions may be corrected using localized flame heating. All low alloy, stainless steel and high
alloy material piping shall not be heated using localized flame heating to correct distortion.
Alternative corrective actions must be proposed to COMPANY, in writing, for approval.
Buttwelds attaching orifice flanges to piping shall have the internal surface of the root passes
ground smooth and flush with the inside diameter of the piping.
When the maintenance of preheat is required for low alloy piping welds, it shall be maintained
continuously throughout the welding operation. See Control and Handling of Stainless Steel,
Nickel and Nonferrous Alloys section in this document. If preheat is interrupted for any reason,
the weld shall not consist of less than 2/3 the total weld thickness or (2) two complete weld passes,
whichever is greater. All other requirements of Control and Handling of Stainless Steel, Nickel
and Nonferrous Alloys section in this document will apply.
The entire weld area shall be held at the minimum preheat temperature during the welding
operation, and continuing until the completion of the weldout. Maintaining a minimum interpass
temperature measured at the initiation / termination point of the weld bead shall not be considered
maintaining preheat, except as allowed below. Acceptable methods of preheat application and
maintenance are as follows:
• Flame Heating (By Oxy-Acetylene Torch) - The use of the rosebud heating torch manually
applied and controlled is considered to be an intermittent method of maintaining preheat.
Measurement of preheat temperature is performed after the termination of the welding
operation, either when the welder is changing positions or filler metal, or terminating a weld
pass. Provided the interpass temperature measured does not fall below the minimum
specified preheat temperature, reapplication of heat from the rosebud torch may not be
necessary. This method is acceptable for socket welds and buttwelds (Max. 4 inches NPS
and Wall Thickness Less Than or Equal to 0.250 inch).
• Flame Heating (Propane Ring and Stationary Burners) - The use of propane ring or stationary
burners is considered to be a continuous method of maintaining preheat. Most commonly
used in shop fabrication applications where rolling of the piping component is feasible. This
method is acceptable for any diameter or wall thickness considerations, provided the quantity
of burner orifices in the ring, or the stationary burner size is sufficient to obtain uniform and
adequate heating of the metal surface.
• Resistance Heating Elements - The use of resistance heating elements is considered to be a
continuous method of maintaining preheat. In addition, this method provides a means to
perform slow controlled heating and cooling prior to and after completion of the welding
operation. This temperature control is exceptionally critical as the alloy content increases in
the material. Resistance heating elements are most commonly used in field fabrication
applications due to the quantity of welds that can be preheated at one time (limited only by
the size of the controller), and the fact that the welds that require this preheat also require
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postweld heat treatment, which can be accomplished with the same heating element
installation, thereby reducing setup and installation time for postweld heat treatment
operations. This method is acceptable for any diameter or wall thickness considerations.
Radiography acceptance criteria for all piping welds shall be per the acceptance criteria in ASME
B31.3, Table 341.3.2 for the applicable service condition, i.e. Normal Fluid Service, Severe Cyclic
Conditions or Category D Fluid Service or ASME B31.1, 136.4.5, as applicable.
21.0 WELDING REPAIRS

Routine welding repairs shall be performed using COMPANY approved welding procedures.
COMPANY reserves the right to require detailed written weld repair procedures when deemed
necessary by COMPANY or their Client.
Defective welding shall be completely removed by chipping, grinding, gouging or other
COMPANY approved methods. The excavated area shall be examined by magnetic particle or
liquid penetrant test methods to assure complete removal of the defect(s).
Excavations for repairs performed by arc gouging shall have the same preheat requirements
imposed as the welding procedure used to perform the original welding.
Welding for cosmetic repairs (i.e., undercutting, gouged base metal, etc.) that do not penetrate
the full thickness of the weld or base metal, shall be preheated in accordance with the
requirements for full penetration welding specified in the original Welding Procedure Specification.
Weld undercutting may be repaired by blend grinding provided the base metal is not reduced
below the minimum required thickness.
Welding repairs shall be re-examined by the NDE method originally used to detect the defective
welding.
In the event that cracking is found, or there is to be more than one repair attempt on any one
defective area, repairs shall not be performed without COMPANY’s authorization. The Vendor
shall submit a welding repair procedure for COMPANY’s review and approval prior to performing
welding repairs. The repair procedure shall contain as a minimum the following information:
• The method for defining the type and extent of defective welding.
• The method for removing the defect.
• The NDE method used for assuring that the defect has been completely removed.
• The Welding Procedure Specification that shall be used for the repair welding.
• The NDE method used to re-inspect the weld for acceptability.
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APPENDICES
Appendix 1: Welding Procedure Application Map for Review and Acceptance of Welding
Procedures
Vendor Name Vendor Document No:
Vendor Shop Order #
COMPANY PO # Pressure Vessel
Item / Tag # Heat Exchanger
Min / Max Thickness Storage Tank
Design Temperature Fabricated Pipe Spools
Design Pressure Other
Min. Design Metal Temp.
Preheat Maintenance Req’d. Yes Temp. No
Postweld Heat Treatment Yes No Required by: Code Service
Time and Temperature
Impact Testing Yes No Required by: Code Service
Temperature Sour H2S Service Yes No
Applicable Code or Standard
Draw a single-line sketch of the apparatus. For pipe spools, only show typical weld joints, i.e., butt, branch, attachments, by
P-No.
Locate an example of all types of typical weld joints, dissimilar welds and attachments.
Identify each different welding procedure by separate letter or number.
Attach detailed tables for multiple items
This form completed by This space for COMPANY Review Stamp
Telephone
Revision
Date
This space for listing welding procedures referenced in sketch
Page 31 of 31

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General Welding, Fabrication and Inspection

DOCUMENT HOLDS RECORD

2.0 CODES AND SPECIFICATIONS ............................................................................................... 5

4.0 WELDING PROCESSES (GENERAL) ....................................................................................... 7

5.0 WELDING PROCESS LIMITATIONS......................................................................................... 8

8.0 CONTROL AND HANDLING OF STAINLESS STEEL, NICKEL AND NONFERROUS

9.0 CHARPY IMPACT (CVN) TESTING ........................................................................................ 12

10.0 PREHEAT AND INTERPASS TEMPERATURES .................................................................... 13

11.0 POSTWELD HEAT TREATMENT ............................................................................................ 14

12.0 NON-DESTRUCTIVE EXAMINATION, TESTING AND INSPECTION ..................................... 16

15.0 ADDITIONAL WELDING REQUIREMENTS FOR STRUCTURAL STEEL FABRICATION ..... 23

16.0 ADDITIONAL WELDING REQUIREMENTS FOR PRESSURE VESSELS AND HEAT

17.0 ADDITIONAL WELDING REQUIREMENTS FOR ATMOSPHERIC AND LOW PRESSURE

19.0 ADDITIONAL WELDING REQUIREMENTS FOR ROTATING EQUIPMENT AND AUXILIARY

20.0 ADDITIONAL WELDING REQUIREMENTS FOR FABRICATED PIPING AND PIPING

21.0 WELDING REPAIRS ................................................................................................................ 30

2.0 CODES AND SPECIFICATIONS

2.1 Applicable Codes

• ASME Section VIII, Division 2; Pressure Vessels

3.0 WELDING PROCEDURES

4.0 WELDING PROCESSES (GENERAL)

5.0 WELDING PROCESS LIMITATIONS

5.1 Shielded Metal Arc Welding

All welding is by uphill method, unless specifically approved by COMPANY.

6.0 FILLER MATERIALS AND FLUXES

6.2 Shielded Metal Arc Welding

7.0 WELD JOINT PREPARATION AND WELDING FABRICATION

9.0 CHARPY IMPACT (CVN) TESTING

10.0 PREHEAT AND INTERPASS TEMPERATURES

11.0 POSTWELD HEAT TREATMENT

12.0 NON-DESTRUCTIVE EXAMINATION, TESTING AND INSPECTION

Specified Minimum Tensile Strength Maximum Diffusible Hydrogen

AWS Filler Metal Max. Design Max. Design

14.0 DUPLEX STAINLESS STEEL WELDING

15.0 ADDITIONAL WELDING REQUIREMENTS FOR STRUCTURAL STEEL FABRICATION

16.0 ADDITIONAL WELDING REQUIREMENTS FOR PRESSURE VESSELS AND HEAT

• Gas Tungsten Arc Welding (GTAW) - Manual, machine, automatic, or orbital.

17.0 ADDITIONAL WELDING REQUIREMENTS FOR ATMOSPHERIC AND LOW PRESSURE

18.0 ADDITIONAL WELDING REQUIREMENTS FOR BOILERS, HEATERS AND FURNACES

19.0 ADDITIONAL WELDING REQUIREMENTS FOR ROTATING EQUIPMENT AND AUXILIARY

20.0 ADDITIONAL WELDING REQUIREMENTS FOR FABRICATED PIPING AND PIPING

21.0 WELDING REPAIRS

This form completed by This space for COMPANY Review Stamp

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