Dep 30.10.60.32 - Welding of Metals, Based On Iso Standards

DEP SPECIFICATION
WELDING OF METALS, BASED ON ISO STANDARDS

Copyright Shell Group of Companies. No reproduction or networking permitted without license from Shell. Not for resale
DEP 30.10.60.32-Gen.
February 2015
DESIGN AND ENGINEERING PRACTICE
DEM1
© 2015 Shell Group of companies

All rights reserved. No part of this document may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior
written permission of the copyright owner or Shell Global Solutions International BV.
This document has been supplied under license by Shell to:

Shell martin.ziade@shell.com 06/05/2015 18:45:16
DEP 30.10.60.32-Gen.
February 2015
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PREFACE
DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions
International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and
maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international,
regional, national and industry standards.
The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and
gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help
achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each
locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Fabricators use DEPs, they shall be solely responsible for such use, including the quality of their
work and the attainment of the required design and engineering standards. In particular, for those requirements not
specifically covered, the Principal will typically expect them to follow those design and engineering practices that will
achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Fabricator shall, without
detracting from his own responsibility, consult the Principal.
The right to obtain and to use DEPs is restricted, and is typically granted by Shell GSI (and in some cases by other Shell
Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and
other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three
categories of users of DEPs can be distinguished:
1) Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these
Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2) Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of
a Service Agreement or otherwise).
3) Contractors/subcontractors and Fabricators under a contract with users referred to under 1) or 2) which requires
that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with
the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims
any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person
whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs
or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The
benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these
companies, that may issue DEPs or advise or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall
not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the
DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after
use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The
copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell
GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.

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TABLE OF CONTENTS
1. INTRODUCTION ........................................................................................................ 5
1.1 SCOPE........................................................................................................................ 5
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 5
1.3 DEFINITIONS ............................................................................................................. 5
1.4 CROSS-REFERENCES ............................................................................................. 7
1.5 SUMMARY OF MAIN CHANGES ............................................................................... 7
1.6 COMMENTS ON THIS DEP ....................................................................................... 7
1.7 DUAL UNITS ............................................................................................................... 7
1.8 NON-NORMATIVE TEXT (COMMENTARY) .............................................................. 7
1.9 PRECEDENCE OF DOCUMENTS ............................................................................. 7
2. QUALITY PROGRAM ................................................................................................ 9
2.1 GENERAL ................................................................................................................... 9
2.2 PERSONNEL COMPETENCES ................................................................................. 9
2.3 INSPECTION AND TEST PLAN ............................................................................... 10
2.4 DEVIATIONS ............................................................................................................ 10
2.5 FINAL ACCEPTANCE .............................................................................................. 10
3. GENERAL REQUIREMENTS .................................................................................. 11
3.1 WELDING PROCESSES .......................................................................................... 11
3.2 MATERIALS .............................................................................................................. 11
4. WELDING PROCEDURE PREPARATION AND QUALIFICATION ....................... 14
4.1 GENERAL ................................................................................................................. 14
4.2 PREVIOUSLY QUALIFIED PROCEDURES ............................................................ 14
4.3 PROCEDURE DOCUMENTATION .......................................................................... 14
4.4 ESSENTIAL VARIABLES ......................................................................................... 14
4.5 WELDING PROCEDURE QUALIFICATION TESTING ............................................ 15
5 WELDER QUALIFICATION ..................................................................................... 20
5.1 GENERAL ................................................................................................................. 20
5.2 WELDER IDENTIFICATION ..................................................................................... 20
5.3 WELDER PRE-QUALIFICATION ............................................................................. 20
5.4 QUALIFICATION DOCUMENTATION ..................................................................... 20
5.5 TIME LIMITATIONS .................................................................................................. 20
6. PREHEATING AND POSTWELD HEAT TREATMENT .......................................... 21
6.1 PREHEATING ........................................................................................................... 21
6.2 POSTWELD HEAT TREATMENT ............................................................................ 22
7. WELD INSPECTION ................................................................................................ 28
7.1 METHODS AND EXTENT OF NONDESTRUCTIVE EXAMINATION...................... 28
7.2 TESTING QUALIFICATIONS ................................................................................... 28
8. WELD REPAIRS ...................................................................................................... 30
8.1 DEFECT REMOVAL ................................................................................................. 30
8.2 RE-WELDING ........................................................................................................... 30
8.3 NONDESTRUCTIVE TESTING ................................................................................ 30
8.4 DEFECT AND REPAIR RATE RECORDS ............................................................... 30
9. HEALTH, SAFETY, SECURITY, AND ENVIRONMENT CONSIDERATIONS ....... 31
9.1 GENERAL ................................................................................................................. 31
9.2 WELDING EQUIPMENT ........................................................................................... 31
9.3 ALIGNMENT ............................................................................................................. 31
10. MATERIAL-SPECIFIC ADDITIONAL REQUIREMENTS ........................................ 32
10.1 GENERAL REQUIREMENTS ................................................................................... 32
10.2 WPQR MONITORING .............................................................................................. 32
10.3 WPQR REQUIREMENTS ......................................................................................... 32
10.4 PARAMETER MONITORING ................................................................................... 33
10.5 CMN STEELS NOT INTENDED FOR LOW TEMPERATURE SERVICE ................ 34
10.6 IMPACT TESTED CMn STEELS (LTCS) ................................................................. 36

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10.7 3.5% NICKEL STEELS ............................................................................................. 41

10.8 LOW ALLOY STEELS .............................................................................................. 43
10.9 AUSTENITIC STAINLESS STEELS ......................................................................... 44
10.10 6% Mo AND OTHER SUPERAUSTENITIC STAINLESS STEELS .......................... 46
10.11 DUPLEX STAINLESS STEELS ................................................................................ 47
10.12 NICKEL ALLOYS ...................................................................................................... 50
10.13 COPPER ALLOYS .................................................................................................... 52
10.14 TITANIUM ................................................................................................................. 54
10.15 DISSIMILAR WELDING ............................................................................................ 55
11. REFERENCES ......................................................................................................... 60
APPENDICES
APPENDIX A REPORTING REQUIREMENTS FOR WELDING QUALIFICATION ............. 64
APPENDIX B RECOMMENDED PRACTICE FOR DETERMINING VOLUME
FRACTION OF FERRITE IN DUPLEX STAINLESS STEEL
WELDMENTS BY SYSTEMATIC POINT COUNTS ....................................... 66
APPENDIX C INSPECTION AND TEST PLAN EXAMPLE .................................................. 70

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1. INTRODUCTION
1.1 SCOPE
This new DEP specifies requirements and gives recommendations for organising and
managing quality assurance (QA) and quality control (QC) for welding of metals, based on
ISO standards.
This DEP is a counterpart to DEP 30.10.60.18-Gen., which is based on API RP 582.
This DEP is written in accordance with the latest regulations in force within the European
economic area including the European Pressure Equipment Directive (PED) 97/23/EC and
is based on the referenced standards, which cover all aspects of the design and fabrication
of pressure equipment.
This DEP recognises and builds on the expertise and good practices developed in previous
Shell specifications.
The scope of this DEP does not include pipeline or civil structural welding.
DEP 61.40.20.30-Gen., DEP 37.81.40.31-Gen. and DEP 30.10.60.30-Gen. cover pipeline
welding, and DEP 37.81.10.34-Gen. covers civil structural welding.
This DEP contains mandatory requirements to mitigate process safety risks in accordance
with Design Engineering Manual (DEM) 1 - Application of Technical Standards.
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Fabricators nominated by them. Any
authorised access to DEPs does not for that reason constitute an authorisation to any
documents, data or information to which the DEPs may refer.
This DEP is intended for use in facilities related to oil and gas production, gas handling, oil
refining, chemical processing, gasification, distribution and supply/marketing. This DEP
may also be applied in other similar facilities.
When DEPs are applied, a Management of Change (MOC) process shall be implemented;
this is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements could be more
stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable with regards to the safety, environmental, economic and legal aspects. In all
cases, the Contractor shall inform the Principal of any deviation from the requirements of
this DEP which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the Authorities concerned, the objective
being to obtain agreement to follow this DEP as closely as possible.
1.3 DEFINITIONS
1.3.1 General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Fabricator is the party that manufactures or fabricates the equipment and provides
services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The capitalised term SHALL [PS] indicates a process safety requirement.

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The word should indicates a recommendation.

The word Approval or Approved from the Principal indicates acceptance but the
responsibility remains with the Fabricator.
1.3.2 Abbreviations
Term Definition
ANSI American National Standards Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
AWS American Welding Society
B Maximum nominal pipe wall thickness for “as-welded” application
C Carbon (chemical element)
CI Confidence Interval
CMn Carbon Manganese
CSWIP Certification Scheme for Weld Inspection Personnel
EWF European Federation for Welding, Joining and Cutting
FCAW Flux Cored Arc Welding
GMAW Gas Metal Arc Welding
GTAW Gas Tungsten Arc Welding
HAZ Heat Affected Zone
IIW International Institute of Welding
ITP Inspection & Test Plan
IVB Independent Verification Body
MT Magnetic Particle Inspection
NDE Nondestructive Examination
NOBO Notified Body
OD Outside Diameter
PED (European) Pressure Equipment Directive
PREn Pitting Resistance Equivalent number
PT Liquid Penetrant Examination
PWHT Postweld Heat Treatment
RT Radiographic Testing
SAW Submerged Arc Welding
SMAW Shielded Metal Arc Welding
T Nominal Pipe Wall Thickness
TMCR Thermo-Mechanically Controlled Rolled
TOFD Time Of Flight Diffraction
USC United States Customary
UT Ultrasonic Testing
VT Visual Testing

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Term Definition
WPQR Welding Procedure Qualification Record
WPS Welding Procedure Specification
1.4 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section or
clause number is shown in brackets ( ). Other documents referenced by this DEP are listed
in (11).
1.5 SUMMARY OF MAIN CHANGES

This is a new DEP.
1.6 COMMENTS ON THIS DEP

Comments on this DEP may be submitted to the Administrator using one of the following
options:
Shell DEPs Online Enter the Shell DEPs Online system at

https://www.shelldeps.com
(Users with access to
Shell DEPs Online) Select a DEP and then go to the details screen for
that DEP.
Click on the “Give feedback” link, fill in the online
form and submit.
DEP Feedback System Enter comments directly in the DEP Feedback

(Users with access to System which is accessible from the Technical
Shell Wide Web) Standards Portal http://sww.shell.com/standards.
Select “Submit DEP Feedback”, fill in the online form
and submit.
DEP Standard Form Use DEP Standard Form 00.00.05.80-Gen. to record

(Other users) feedback and email the form to the Administrator at
standards@shell.com.
Feedback that has been registered in the DEP Feedback System by using one of the above
options will be reviewed by the DEP Custodian for potential improvements to the DEP.
1.7 DUAL UNITS

This DEP contains both the International System (SI) units, as well as the corresponding
US Customary (USC) units, which are given following the SI units in brackets. When
agreed by the Principal, the indicated USC values/units may be used.
1.8 NON-NORMATIVE TEXT (COMMENTARY)

Text shown in italic style in this DEP indicates text that is non-normative and is provided as
explanation or background information only.
Non-normative text is normally indented slightly to the right of the relevant DEP clause.
1.9 PRECEDENCE OF DOCUMENTS

1. In case of conflict between documents the following precedence of documents shall
apply:
a. First level - statutory laws and regulations
b. Second level - this DEP

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c. Third level - cross-referenced documents

d. Fourth level - International codes and standards
2. Any apparent conflict between the requirements of this DEP and any other relevant
document shall be brought to the attention of the Principal for clarification.

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2. QUALITY PROGRAM
2.1 GENERAL
1. Welding QA/QC of equipment and piping components shall be implemented under a
Fabricator quality management system that conforms to ISO 9001 and ISO 3834.
2. Comprehensive quality requirements shall be selected to be applied for all welded
components. This is specified in more detail in ISO-3834-2.
3. The Fabricator shall operate a quality system in accordance with ISO 3834-2 and
ISO 9001. This system shall be certified by an IVB unless otherwise approved by the
Principal.
4. For each WPS, the Fabricator shall specify the specific welding consumables, welding
processes, and welding operators. Approval for use shall be obtained from the
Principal.
5. Fabricator shall refer to ISO 3834-6 in the development and maintenance of its quality
system related to welding activities.
6 A welding procedure specification (WPS) shall be considered an engineering
document and is part of the detailed design of a component.
7. The requirements specified in ISO 3834-5 are applicable even if not specifically
referenced in this DEP.
2.2 PERSONNEL COMPETENCES

1. The Welding Coordinator, as defined in ISO 3834-2, shall be an EWF / IIW
International Welding Engineer or International Welding Technologist in accordance
with ISO 14731. The certified level of active experience of the Welding Coordinator,
according to the International Institute of Welding, shall be a minimum of three years,
based on evidence.
2. The Principal’s representative who approves welding documentation shall have
qualifications equivalent to those of the Welding Coordinator.
3. The Principal’s representative who approves deviation requests shall be certified in
accordance with the EWF / IIW in accordance with ISO 14731. The certified level of
active experience of the representative, according to the International Institute of
Welding shall be a minimum of five years, based on evidence or equivalent
qualifications.
4. For inspection purposes the equivalent competence levels are recognised by ISO
(IIW), CSWIP and AWS as detailed in the Table 1:
5. Table 1 reflects the existing regional practice and is not intended to be restrictive.

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Table 1 Competence levels for welding inspection personnel
Competence Country/ Applicable Inspector Position Designation

Level Region Standard
1 UK / Europe ISO 17637 Visual Welding Inspector 3.0
Netherlands / ISO 17637 / International Welding IWI-B
Europe 14731 inspector, Basic
USA AWS Certified Associate Welding CAWI-
Inspector
2 UK / Europe ISO 17637 Welding Inspector 3.1
Netherlands / ISO 17637 / International Welding IWI-S
Europe 14731 inspector, Standard
USA AWS Certified Welding Inspector CWI®-
3 UK / Europe ISO 17637 Senior Welding Inspector 3.2
Netherlands / ISO 17637 / International Welding IWI-C
Europe 14731 inspector, Comprehensive
USA AWS Senior Certified Welding SCWI-
Inspector
2.3 INSPECTION AND TEST PLAN

1. The Contractor shall submit to the Principal, for review and approval, an Inspection
and Test Plan (ITP) that conforms to DEP 82.00.10.10-Gen. and related method
statements prior to commencement of welding work. Approval of the ITP by the
Principal does not relieve the Contractor of the responsibility to comply with the
requirements of the Contract.
2 Fabricator shall include the relevant welding related control points for quality
assurance in the ITP. An example is given in (Appendix C).
3. The Contractor shall review and approve all documents from the Fabricator prior to
submission to the Principal.
2.4 DEVIATIONS
1. All deviations and non-conformances to the requirements in this DEP shall be
approved by the Principal. This approval shall be obtained in writing.
2. Any conflicts between the requirements of this DEP and other relevant documents
shall be referred to the Principal for resolution.
2.5 FINAL ACCEPTANCE

1. Contractor SHALL [PS] submit for approval of Principals' designated technical
authority all of the following before final acceptance of welding:
a. Fabricator's report and record of monitoring of production welds;
b. Fabricator's welding inspection report.

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3. GENERAL REQUIREMENTS
3.1 WELDING PROCESSES

1. All welding shall be performed with one of the following processes within the
requirements specified in this DEP, unless an alternative is approved by the Principal.
Process Name ASME EN/ISO

Designation Designation
gas tungsten arc welding GTAW 141
shielded metal arc welding SMAW 111
gas shielded flux cored arc welding (GS)FCAW 136
self-shielded flux cored arc welding (SS)FCAW 114
submerged arc welding – solid wire SAW 121
submerged arc welding – cored wire SAW 125
plasma arc welding PAW 15
gas metal arc welding (active gas) GMAW 135
metal-cored arc welding (active gas) MCAW 138
2. Gas shielded processes (GTAW, GSFCAW, GMAW, MCAW, PAW) shall be used in
the field only if adequate weather shielding, that is approved by the Principal, is
provided.
3. SAW systems shall be fully mechanised (automated).
4. GMAW or MCAW may be allowed if the Fabricator can demonstrate to the Principal’s
satisfaction, adequate experience with the processes, ongoing control over the
process, and the continued competence of the welders.
5. Unless otherwise approved by the Principal, the root and second pass of all single-
sided welds shall be made using GTAW.
6. Unless otherwise specified, all GTAW machines shall be equipped with arc starting
devices, e.g., high frequency starting unit, crater-eliminating, slope-out control, etc. If
regulations do not permit arc starting devices, alternative proposals shall be submitted
to the Principal for approval.
7. Permitted applications of the welding processes listed in (3.1, Item 1) are specified in
the relevant material section of this DEP.
3.2 MATERIALS
3.2.1 Grouping
1. Material groupings for substrate/parent materials and weld metals are defined in
ISO/TR 15608. Substrate/parent materials identified under different groupings shall be
defined as dissimilar metals to be welded.
2. Similar parent material welded with other grouping weld metal shall be treated as a
dissimilar metal weld.
3.2.2 Parent materials certification
1. Materials used for qualification of WPSs shall be representative of materials to be used
in production welding. The Principal shall confirm if a material used on a WPQR is
considered representative of the production material.
2. Materials shall be supplied to a recognised manufacturing specification and certified in
accordance with EN10204 (ISO 10474), inspection certificate 3.1.

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3. Materials certification shall demonstrate the following:

a. all required inspections have been carried out on the materials,
b. materials are traceable to specific chemical analysis/mechanical properties,
and
c. materials are technically consistent with the design requirements.
4. Specific requirements for each material group are specified in the relevant section for
material types in this DEP. Other non-specified materials shall comply with usual
industry standards plus any additional design requirements as advised by the
purchase order.
3.2.3 Welding consumables
3.2.3.1 General
1. Welding consumables shall be supplied by a Manufacturer accredited in accordance
with ISO 9001 or an equivalent quality specification approved by the Principal.
2. Welding consumables shall be approved by one of the following organisations or
another organization approved by the Principal:
a. Controlas
b. Lloyds Register of Shipping
c. American Bureau of Shipping
d. Det Norske Veritas
e. Bureau Veritas
3. Welding consumables for new WPQRs shall be approved by the Principal via the
proposed WPS prior to qualification. Their use shall be supported by consumable
Manufacturer recommendations and verified performance data.
4. As a minimum, all welding consumables used in production welding shall produce
welds with mechanical properties that are the same as those specified for the base
metal, unless otherwise specified. If alternative consumables are required, e.g., when
improved corrosion resistance is necessary, then these will be specified by the
Principal prior to WPS qualification.
5. Filler metals proposed for use in dissimilar base metal combinations shall be approved
by the Principal for each specific application.
6. Unless otherwise specified, all consumables shall be identified on the WPS by their
AWS or ISO classification and by their Manufacturer’s name and designation.
Identification by ISO classification alone may be acceptable to the Principal for solid
wire electrodes (ISO 636, ISO 14171 and ISO 4341).
3.2.3.2 Consumable certification
1. As a minimum, welding consumables shall be delivered in accordance with their
product datasheet and shall have certification (including chemical analysis) according
to EN 10204 (ISO 10474), Type 3.1.
2. Each consumable, or consumable batch, shall have individual marking relative to its
certification.
3. Batch testing of the welding consumables is also acceptable. In such case welding and
testing shall be carried out in accordance with a typical WPS and certification shall be
presented in the format of a WPQR. Production material or an equivalent parent metal
specification shall be used for such consumable certification.
4. Fluxes for SAW processes shall be delivered with certification according to EN 10204
(ISO 10474), Type 2.2.

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3.2.4 Consumable handling/storage

3.2.4.1 General
1. Stored consumables shall be clearly identified with brand name, classification and
batch number.
2. Consumable handling shall be controlled by a procedure approved by the Principal.
Storage shall be in accordance with the Manufacturers’ recommendations for the
consumable type.
3. All non-identified, damaged, wet, partially used, rusty or otherwise contaminated
consumables shall be discarded.
4. Records of consumables shall be maintained to ensure an auditable trail from receipt,
through pre-treatment, their issue to operators, and their return to stores so that their
identity can be verified at any stage.
5. Consumables that cannot be identified to the satisfaction of the Contractor or Principal
shall be removed from the work site and any welds made with such consumables shall
be cut out and re-welded.
3.2.4.2 Shielded metal arc welding
1. For SMAW, low hydrogen electrodes shall not be stored in heated cabinets containing
electrodes of other types, such as rutile or organic type electrodes.
3.2.4.3 Gas shielding welding process (GTAW/GMAW/FCAW)
1. Each batch of wire shall be labelled with the information from the supply container.
2. All bottles containing shielding gases shall have clear identification labels.
3. Wire spools for automatic and semi-automatic processes shall be stored in original
packaging preferably in cabinets.
4. GTAW filler wires for CRA and non-ferrous welding shall be cleaned with a solvent
immediately prior to their use.
5. Wire for automatic or semi-automatic welding, remaining from a partly used coil or
spool, may be reused as new wire if it is promptly repackaged after initial use in new
sealed containers and stored as a new consumable.
6. Unless otherwise specified, FCAW wires shall be returned to a controlled storage area
at the end of each shift. This requirement may be waived for seamless copper-coated
wires that are fully enclosed in the wire feeder.
7. Bare filler wire in coils or spools that have not been kept in sealed containers after use
or wire that has been contaminated with rust, grease or other debris, shall not be re-
used without cleaning in accordance with the wire Manufacturer’s advice.
8. All wire that cannot be cleaned without damage to the surface, change in size, or other
damage that would adversely affect its use shall be discarded.
3.2.4.4 Submerged arc welding
1. SAW fluxes shall not be left in machine hoppers for extended periods when welding is
not being carried out, e.g., overnight or during non-productive shifts.
2. Recycling of flux shall only be allowed if the procedure is endorsed by the consumable
Manufacturer and by the Principal.
3. Each batch of flux and wire shall be labelled with the information from the supply
container.

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4. WELDING PROCEDURE PREPARATION AND QUALIFICATION
4.1 GENERAL
1. Welding procedures for all welded joints SHALL [PS] be prepared and qualified n
accordance with ISO 15614, and this DEP.
2. Each Fabricator shall prepare its own WPSs and qualify its own welding procedures.
WPSs shall contain information as specified in ISO 15609 and (Appendix A).
3. The testing results for WPQR/weld test record shall be presented in a detailed format
and with traceable document trail (Appendix A).
4. Unless otherwise specified, multi-pass fillet welds may be qualified by the qualified
procedure for groove welds in accordance with ISO 15614, although separate WPSs
for groove and fillet welds shall be submitted. Single pass fillet welds shall be
separately qualified in accordance with ISO 15614.
5. The basis for rejection of WPSs shall be either non-compliance with this DEP, or non-
conformance to industry practice (ISO/TR documents).
6. The approval of WPSs by the Principal is subject to acceptable performance in
subsequent production welding. Approval may be withdrawn where excessive repair
rates are encountered that cannot be attributed to bad workmanship.
4.2 PREVIOUSLY QUALIFIED PROCEDURES

1. WPSs for welding procedures previously qualified by the Fabricator may be submitted
for approval as long as the WPSs meet the requirements of this DEP and they are
supported by WPQRs that are approved by an NOBO or a recognised independent
third party.
2. The Fabricator shall be able to provide evidence of successful previous application of
the welding procedures specified in the submitted WPSs.
3. The ownership of WPQRs and WPSs shall be in accordance with ISO 15614-1 Section
8.2 subject to approval of the Principal.
4.3 PROCEDURE DOCUMENTATION

1. Welding procedure documentation, including the final WPS, and welder instruction
cards (if adopted), shall be submitted to the Principal for final approval. The final WPS
may be modified from the original WPS according to the parameters actually used
during procedure qualification.
2. As a minimum, the WPQR and weld test record documentation shall include the
information specified in (Appendix A).
4.4 ESSENTIAL VARIABLES

1. Any change to a welding procedure outside the allowances to the essential variables
specified in ISO 15614, as amended by this DEP, shall require re-qualification of the
procedure.
2. If a welding procedure includes material thicknesses above a threshold such that more
stringent testing is required, the procedure qualification shall be limited to that
threshold, unless the more stringent testing is performed.
3. Unless otherwise specified, the qualified diameter range for process piping shall be
0.5xOD to 2xOD. Pipe diameter 168.3mm OD (DN150 (NPS 6)), and above, qualifies
greater, or equal to, 0.5xOD and plate.

DEP 30.10.60.32-Gen.
February 2015
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4. Weaving, shall be limited to the following ranges:
SMAW process Three times the electrode diameter
GTAW process Maximum equal to used cup diameter or 12 mm (1/2 in),

whichever is smaller
GMAW/FCAW Maximum equal to used cup diameter or 15 mm (5/8 in),

process whichever is smaller
Weaving is restricted as quality control in addition to heat input and mitigation of air
ingress to minimize risk of porosity on gas shielding welding processes.
4.5 WELDING PROCEDURE QUALIFICATION TESTING

4.5.1 General
1. Welding procedure qualification testing shall not commence without the presence of
the Principal or its representative and a NOBO or recognised independent third party.
2. The Fabricator shall record all the information required for WPQRs as specified in
(Appendix A).
3. Equipment, such as portable arc monitoring systems, current meters, temperature
measurement devices, etc., shall have current and valid certificates of calibration.
4. WPQRs, inclusive of all required information, shall be signed as witnessed by the
Fabricator and approved by the NOBO or a recognised independent third party.
5. The Principal or its representative shall review the final WPS/WPQR/weld test record
combination and give approval to the WPS (or WPS register) before production
welding starts.
6. Mechanical testing shall be performed per ISO 15614 and the additional requirements
in this DEP.
7. Designated testing laboratories shall have a quality system in compliance with
ISO 17025 or equivalent.
8. When PWHT is specified, it shall be carried out in accordance with (6.2) per the
planned production sequence.
9. Multi-pass fillet welds may be qualified by groove weld performance testing, however
production weld testing of the fillet welds shall be performed to provide evidence of
positive penetration of the root pass only.
4.5.2 Nondestructive testing
1. The following NDE shall be performed for welding procedure qualification.
Butt Welds Visual

MT ferrous materials or PT for non-ferrous materials
Radiography, (X-radiography technique)
Ultrasonic, if specified for the material.
Fillet Welds Visual
MT ferrous materials or PT for non-ferrous materials

DEP 30.10.60.32-Gen.
February 2015
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2. Visual examination of completed welds shall be conducted by both the Fabricator and
the Principal, or its representative. When NOBO witness is required this shall be
arranged by the Fabricator.
a. Cutting of a test piece for mechanical testing should not take place until it has
been visually examined and accepted by the NOBO or a recognised
independent third party.
b. Should the test piece diameter be too small to allow proper examination of the
weld root, the test piece shall be cut longitudinally to facilitate examination.
c. For new welding procedure qualifications where alternative or additional NDE
methods are proposed for production welding (e.g.; time-of-flight diffraction
(TOFD)), the test piece shall also be subjected to these methods.
3. When acceptance criteria is not defined in the purchase specifications, the acceptance
criteria shall be defined as “the design code requirements or ISO 5817 quality level B.”
The NDE acceptance criteria are normally covered by the selected design code for
the equipment or piping, for example PD 5500 or EN 13445.
4.5.3 Macro section examination
4.5.3.1 General
1. Macro sections shall be prepared so that the whole cross section of the weld, inclusive
of HAZ, and adjacent parent material can be examined. These shall be etched to
reveal individual passes and the full extent of the HAZ.
2. Macro sections shall be examined under magnification. This should typically be
between 3x to 8x.
3. WPQR documentation shall include photographs of the macro sections. Any hardness
survey indentations shall be visible on the photographs. Photographs shall be marked
to indicate the magnification. Only original photographs or good-quality digital images
shall be accepted as part of the WPQR documentation.
4. For weld acceptance the examination of the macro section shall not reveal any cracks,
lack of fusion (root, sidewall or inter-run) or volumetric defects (slag, porosity, etc.) that
are outside the limits set by the design code or ISO 5817 quality level B.
5. At the request of the Principal, volumetric defects shall be investigated further by
grinding and/or re-sectioning the macro section to determine the extent of the defects.
4.5.3.2 Hardness testing
1. Hardness surveys, as specified in ISO 15614, shall be carried out on macro sections
using Vickers hardness at 10 Kg load.
2. Hardness testing shall be in accordance with ISO 6507-1.
3. Unless otherwise specified, the following general hardness requirements for base
material, HAZ, and weld metal shall apply:
a. For sour environments in oil and gas production facilities, all hardness testing
and acceptance values shall meet the requirements of DEP 30.10.02.15-Gen.
b. For wet H2S environments in petroleum refining and related processing
environments, all hardness testing and acceptance values shall meet the
requirements of that DEP 30.10.02.17-Gen.

DEP 30.10.60.32-Gen.
February 2015
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c. In general, for carbon steel with base metal thickness ≤ 10 mm (3/8 in), 250
HV10 maximum hardness is permitted for the full weld thickness. However for
thickness > 10mm (3/8 in), 275 HV10 hardness is permitted in the cap when
the hardness impression is located at least 8 mm (5/16 in) from the internal
surface.(See sketch below).
d. For ferritic metals (for instance low allow steels) in process services, including
H2 service conditions, the maximum permitted hardness is 250Hv10 for the
entire weld and the HAZ.
e. For ferritic metals in sweet service without sour/H2S exposure, the maximum
permitted hardness is 300 HV10 for the HAZ and 275Hv10 for the weld metal.
f. For ferritic metals in utility services (steam, air, water, non-sour service), the
maximum permitted hardness is 300 HV10.
g. For 9 % Ni steels in the as-welded condition, the maximum permitted
hardness is 350 HV10.
h. For 9Cr-1Mo-V steel (P91, T91) in the PWHT condition, the maximum
permitted hardness is 290 HV10 and API TR 938-B shall be followed for
guidance.
i. For structural steels not directly welded to pressure containing parts, the
maximum permitted hardness is 325 HV10.
j. For 3.5 % Ni steel with base metal thickness ≤ 9.5 mm (3/8 in), the maximum
permitted hardness is 250 HV10. However, for joint thickness > 9.5mm (3/8
in), 275 HV10 hardness is permitted in the mid-thickness and cap when the
hardness impression is located at least 8 mm (5/16 in) from the internal
surface.
k. For duplex stainless steels, the maximum hardness for quality control purpose
shall target 334 Hv10 for 22%Cr DSS and for 25Cr DSS shall target 378 Hv10.
l. For austenitic stainless steels, the maximum hardness shall be 250 Hv10.
4.5.3.3 Low temperature, impact testing
1. For impact testing, ISO/TR 15608 specifies additional material group-specific
requirements.
The materials within each group have a unique response to low temperature
conditions, therefore, weld qualification impact testing is group specific.
2. The following Tables 2 and 3 shall be used in lieu of Tables 3 and 4 in ISO 15614-1 for
range of qualification for materials:

DEP 30.10.60.32-Gen.
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Table 2 Range of qualification for steel groups and sub-groups
Material (sub-) group of test pieces Range of qualification

a
1-1 1 -1
a
2-2 2 -2
c
3-3 3 -3c
b
4-4 4 -4
c c
5-5 5 -5
c c
6-6 6 -6
c c
7-7 7 -7
c c
8 -8 , except that UNS No is
8-8 essential variable where Mo > 4%
c c
9-9 9 -9
c c
10 -10 , except that UNS No is
10-10 essential variable
a. Covers the equal or lower specified yield strength steels of the same group
b. Covers steels in the same sub-group and any lower sub-group within the same
group
c. Covers steels in the same sub-group
Table 3 Range of qualification for nickel alloy and nickel alloy/steel groups
Material group of test pieces Range of qualification

41-41 41-41
42-42 42-42
43-43 43-43
44-44 44-44
45-45 45-45
46-46 46-46
47-47 47-47
48-48 48-48
4.5.4 Tube-to-tubesheet welding

1. When a welded tube-to-tubesheet joint is specified on the equipment data sheet, it
shall be a full-strength welded joint, unless otherwise approved by the Principal.
2. Unless otherwise specified, qualification of strength-welded tube-to-tubesheet joints
shall be in accordance with the requirements of ISO 15614-8.
3. Acceptance criteria shall be the following
a. no cracks allowed;
b. complete fusion required;
c. complete penetration required
d. no porosity to influence the minimum leak path.

DEP 30.10.60.32-Gen.
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4. The allowable expansion at tube-to-tubesheet joints shall be agreed between the

Fabricator and the Contractor, with consideration of the tube and tubesheet materials,
hardness, and potential for work hardening during the expansion process.
5. All mechanical testing shall take place after expansion.
6. A minimum of three tensile pull-tests shall be performed on a qualification test coupon.
7. For wet hydrogen sulphide or sour services, a micro-hardness survey for weld metal,
HAZs, and base metals shall be performed on a qualification test coupon. Micro-
hardness values shall comply with ISO 15156.
8. Autogeneous seal welds are not permitted (as indicated by ISO 16812).
4.5.5 Repair welding procedure
1. Dedicated WPSs shall be prepared for repair welding.
2. The Fabricator shall submit to the Principal, via the Contractor, for approval, a general
repair welding procedure detailing the following:
a. The method of defect excavation;
b. The shape and size of excavation prior to re-welding;
c. All inspections required prior to re-welding;
d. The WPQR, if different from those used for the original weld.
3. Repair welding shall normally be carried out to the same procedure as the original
welding. Therefore, unless otherwise specified in this DEP, repair WPQR shall not be
required.
4. Where a different welding procedure (i.e., a change of process or other essential
variable) is to be used for repair welding, the repair WPS shall be qualified in
accordance with this DEP. Qualification shall require the reproduction of a typical
production repair.
5. Full penetration and partial penetration excavations shall be qualified separately.
6. For partial wall excavations, the remaining ligament adopted for the test weld shall be
the smallest allowed in production.
7. Where impact testing is specified for the original weld, impact testing of the repair weld
metal and the adjacent HAZs, both in the parent material and the original weld metal,
shall be carried out at the test temperature of the original weld.
8. When a separate repair WPQR is required by the relevant material specific section,
and where the repair welding is performed using essentially the same procedure as
the original weld, tensile and bend tests are not required for the repair WPQR. All other
test requirements shall be met as specified.

DEP 30.10.60.32-Gen.
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5 WELDER QUALIFICATION
5.1 GENERAL
1. All welders and welding operators shall be qualified in accordance with ISO 9606.
Qualifications to other equivalent codes may be considered when reviewing the
performance range of the welder.
5.2 WELDER IDENTIFICATION

1. Whilst on site, the welders and welding operators shall be easily identifiable. This may
be by one of the following:
a. The welder wearing a badge bearing name, photograph and identification
number
b. The welder carrying a works identification pass including a photograph
2. The Fabricator shall maintain a report of welder IDs including name, photograph, and
welder identification number.
3. In the event that a welder leaves the work, the associated welder number shall not be
assigned to another welder employed on the work.
5.3 WELDER PRE-QUALIFICATION

1. Welders qualified on work other than for the Principal may be accepted by the
Contractor provided:
a. Their qualification has been carried out in accordance with ISO 9606 and the
requirements of this DEP.
b. Their qualification testing has been witnessed by a NOBO or independent third
party acceptable to the Principal, and the certificate of qualification is endorsed
accordingly;
c. The Fabricator can give proof that the welder has been continuously employed
by the Fabricator for the previous six months and has been welding with
reasonable continuity during that time, to the same, or similar, procedures with
satisfactory results.
2 The Principal reserves the right of final acceptability of welder pre-qualifications
5.4 QUALIFICATION DOCUMENTATION

1. Prior to commencement of work, the Fabricator shall submit the following:
a. A register of the welders to be used on the work, giving the procedures,
positions and thickness ranges in which they are qualified, together with the
identity number for each welder.
b. All weld performance qualification certificates, including relevant back-up
documentation, such as NDE and mechanical test certificates.
5.5 TIME LIMITATIONS

1. Welder and operator qualification certificates shall be valid for a six-month period from
the date of approval.
a. A qualification certificate may be re-approved for further six-month periods
provided the welder has been employed with reasonable continuity on welding
covered by the qualification certificate.
b. The essential variables in ISO 9606 applicable to performance qualification
shall apply to welding for re-approval of certificate.
2. If there are reasonable grounds to question a welder’s ability to weld to the specified
procedure, the Principal may demand the re-qualification of the welder, at any time.

DEP 30.10.60.32-Gen.
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6. PREHEATING AND POSTWELD HEAT TREATMENT
6.1 PREHEATING
6.1.1 Preheat temperature
1. For carbon-manganese and low alloy steels, the minimum preheat temperature shall
be as calculated in accordance with ISO/TR 17671-2 using the maximum carbon
equivalent allowed for the material to be welded and the weld metal hydrogen level
guaranteed by an approved consumable control procedure.
2. If higher preheat temperatures are necessary to meet the hardness values required by
this DEP, particularly for sour service conditions, in accordance with
DEP 30.10.02.15-Gen. or DEP 30.10.02.17-Gen., as applicable, the temperature
margin above the minimum required by ISO/TR 17671-2 shall be applied to all
thicknesses to be welded.
3. For reinforced branch fittings, such as “olets”, that are to be welded, the minimum
preheat temperature shall be 50°C (90°F) above that specified by ISO/TR 17671-2.
4. If preheat is not explicitly required by this DEP and ambient temperature is below 5°C
(41°F), or if condensation/moisture is apparent on work surfaces, then sufficient
preheat shall be applied to ensure work surfaces are dry and remain warm to the
touch.
5. For 3½ % nickel steels, a minimum preheat temperature of 100 °C (212 °F) shall be
used for welding all thicknesses.
6.1.2 Preheat application
6.1.2.1 General
1. For materials with wall thickness up to and including 19 mm (3/4 in), preheating shall be
by gas torch or electrical resistance heaters. For wall thickness above 19 mm (3/4 in),
electric resistance heating mats shall be used, unless it is agreed with Principal that access
or location makes it impractical.
2. Electrical resistance elements shall be controlled by thermocouples attached on or
adjacent to the weld preparation.
3. Thermocouple devices shall be regularly calibrated as specified in ISO 17663 and
ISO 60548-2, with a maximum interval of six months.
4. Preheating with oxy/fuel gas should only be by soft flame burners designed for the
purpose.
5. Handheld oxy/fuel gas burners should only be used for welds on pipes less than
168.3 mm OD (DN150 (NPS 6)) or attachment welds less than 300 mm (12 in) long.
This only applies where preheat above 20 °C (68 °F) is required.
6. The temperature of preheat implemented by non-electrical means shall be measured
using contact pyrometers, temperature indicating crayons, or thermocouples.
a. If there is access, temperature measurement shall be taken on the surface
opposite of the one being heated.
i. Measurement shall be taken at a location that is displaced from the
source of heat by a minimum of 25 mm (1 in) in a direction parallel to
the vessel, process piping, or other equipment axis.
ii. Measurement shall be taken after removal of the heat source.
b. If there is no access to the opposite surface, temperature measurement shall
be taken 75 mm (3 in) from both weld toes / edges and delayed for a period
not less than two seconds per mm of material thickness after removal of the
heat source.

DEP 30.10.60.32-Gen.
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7. Temperature indicating crayons shall be certified to be free (less than 1 ppm) of lead
and sulphur or any other low melting constituent.
8. Residue from crayons shall be removed from the weld surface before proceeding with
the weld.
9. Thermocouples shall be installed under resistance heater mats, unless test trials prove
the process will not expose the component to temperatures above the lower critical
transformation temperature of the base metal alloy.
6.1.2.2 Welding interruption considerations
1. When interruption of welding is required, loss of specified preheat temperature is
permitted for unalloyed steels (Group 1) with UTS of 450 N/mm² (65 ksi) or lower, or
for steels with UTS of 490 N/mm² (70 ksi) when welded with low hydrogen
consumables and with a welded thickness of less than 28 mm (1.1 in).
2. Unless otherwise specified, at least 30 % of the weld joint thickness shall have been
completed prior to interrupting welding. After interruption, the joint shall be slow cooled
under insulation. Preheating shall be restored to the specified temperature before
welding is recommenced.
3. If welding is interrupted, with associated cooling, and the completed weld ligament
depth is less than 30 % of the total joint thickness, then the appropriate surface
inspection (e.g., MT or PT) shall be performed to ensure freedom from deleterious
defects.
4. Other materials may allow for interruption of welding, but only as permitted by the
applicable code and relevant industry standards, and as a minimum, the root and
second pass shall be completed before it is permissible to interrupt welding progress
and allow the joint to cool.
6.1.3 Interpass temperature
1. In general, the maximum welding interpass temperature for production welding shall
not exceed that measured during welding procedure qualification WPQR by more than
50°C (122°F), though there may be additional limitations in the relevant material-
specific section.
6.2 POSTWELD HEAT TREATMENT

6.2.1 General
1. In general, PWHT shall be in accordance with the applicable design codes and as
specified in the appropriate standards included in the purchase order. Additional
guidance is given in tables 4A and 4B.
2. The standard for PWHT quality requirements is ISO 17663.
3. Special PWHT requirements in relation to engineering against low temperature
embrittlement are specified in DEP 30.10.02.31-Gen.
4. For quenched/normalised and tempered steels, the PWHT temperature shall be such
that it does not cause an unacceptable decrease of mechanical properties of the
parent material.
a. PWHT temperature shall be at least 25 °C (45 °F) below the tempering
temperature used during the manufacture of the base metal component and
recorded on the material certificate.
b. If the heat treatment needs to be performed within 25 °C (50 °F) of the
tempering temperature, the mechanical properties shall be approved by the
Principal and demonstrated with mechanical testing after PWHT at the
proposed temperature.
5. Unless otherwise agreed, the PWHT cycle shall be designed in such a way as to allow
for a minimum of one additional PWHT cycles in case weld repairs are required.

DEP 30.10.60.32-Gen.
February 2015
Page 23
Where conflict between this requirement and the base material temper develops, it
shall be brought to the attention of the Principal for resolution.
6. The Contractor or Fabricator shall purchase materials which will allow the additional
heat treatment cycles after welding.
7. When production test coupons are requested they shall have the same PWHT
conditions as the actual items in the assembly. This includes the heating method either
in a furnace or local heat treatment by resistance mats or induction coils
a. Total soak time and cycles for coupons shall be set according to the thickness
of the coupons and equipment thickness.
b. Soak time on the WPQR shall not be less than what is expected for the
maximum thickness range in production welding.
c. If additional PWHT cycles need to be applied on the material, additional
production test coupons exposed to the same heat cycle are required to verify
the mechanical properties stated in the WPQR are maintained.
8. Procedures for PWHT of dissimilar metal welds shall be approved by the Principal.
9. No welding or heating shall be carried out after final PWHT.
10. Unless otherwise agreed with the Principal, all welds in AISI 4130 material shall be
subject to PWHT.
11. Cooling in still air is permitted below 300°C (572°F).
6.2.2 Piping PWHT
1. If there is no subsequent machining operation, all piping threads and gasket surfaces
shall be protected from oxidation whilst the equipment is subjected to PWHT.
2. Non-ferrous and austenitic materials do not normally require PWHT. However, if
approval is granted or if directed by the Principal (e.g. where austenitic steel is to be
welded to CMn steel), PWHT shall be carried out generally in accordance with this
DEP section. Additional requirements as deemed necessary for the materials involved
will be advised by the Principal.
6.2.3 PWHT procedure
1. A PWHT procedure shall be submitted for approval to the Principal prior to
commencing PWHT. As a minimum, the procedure shall include the following
information:
a. name of (sub-)Contractor;
b. ruling specification;
c. material and item type;
d. method of heating;
e. fuel gas and method of atmosphere control (if gas-fired furnace);
f. size and type of electrical element (if electrical resistance);
g. type, location and number of thermocouples;
h. method of thermocouple attachment and removal;
i. details of loading and supporting arrangements to avoid distortion;
j. provisions to avoid flame impingement (if flame heated)
k. holding time and temperature;
l. heating and cooling rates;
m. type of recording equipment including number of channels;
n. chart speed.

DEP 30.10.60.32-Gen.
February 2015
Page 24
o. Calibration documentation
2. All PWHT shall be carried out in accordance with the approved procedure
6.2.4 Furnace PWHT
1. Unless otherwise approved by the Principal, PWHT shall be performed in a fully
enclosing furnace.
2. Fuel powered furnaces shall have adequate flame controls to avoid an oxidising
furnace atmosphere. Flame impingement onto PWHT items is not permitted.
3. Unless otherwise specified by the applicable code, the temperature during heating and
cooling shall not vary by more than 150 °C (270 °F) in any 4.5 m (15 ft) length of
piping.
4. The number of thermocouples shall be sufficient to ensure that the temperature and
thermal gradients of the whole of the work are within the required range.
5. One thermocouple shall be attached directly to each spool at the point of greatest wall
thickness.
6. If a large number of small spools are to be treated in one batch, thermocouples may
be attached to a representative number (no less than one in four) of the spools.
6.2.5 Local PWHT
1. Local PWHT may be used if size or installation restrictions prevent furnace PWHT.
2. For local PWHT, heating shall be by electrical resistance heating elements, unless
otherwise specified. Other heating methods may be considered. These shall be
submitted for review and approval by the Principal.
3. For local PWHT the soak temperature shall be achieved and maintained in a band
2.5 x weld thickness either side of the weld centre line. The width of the thermal
insulation shall be 7.5 x weld thickness either side of the weld centre line.
4. Circulation of air in the bore of the process piping or equipment work shall be
prevented.
5. The minimum number and position of thermocouples on pipe shall be as follows:
Pipe Diameter No. of Thermocouples per Weld ‘Clock’ Position

≤DN 100 (4 NPS) 1 12
>DN 100 to ≤DN 300 2 6, 12
(4 NPS to 12 NPS)
>DN 300 (12 NPS) 4 3, 6, 9, 12
6. Thermocouples shall be located on the weld centre line and shall be held in intimate
contact with the surface of the weld by mechanical means or by capacitance discharge
welding. The attachment points of capacitance discharge welded thermocouples shall
be dressed by grinding after removal.
7. For 2G oriented welds the thermocouples shall be placed below the bottom toe of the
weld bevel.
6.2.6 Equipment calibration
1. The sub- Contractor shall approve calibration procedures for all equipment measuring
and recording temperature. As a minimum, temperature recorders shall be calibrated
every three months.

DEP 30.10.60.32-Gen.
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6.2.7 Recording and reporting

6.2.7.1 General
1. As a minimum, the heating rate, holding time, temperature and cooling rate data shall
be recorded.
2. The temperature measured by each thermocouple should be recorded by means of a
multi-channel chart recorder. Each chart shall be marked with the date of the PWHT,
the weld or spool number(s), channel identification and signature(s) of sub- Contractor
personnel.
3. A heat treatment report shall contain sufficient information to ensure traceability to the
item(s) under treatment and confirm compliance with the approved PWHT procedure.
The report shall include the following:
a. Identification of the component being subjected to PWHT.
b. Actual heating and soaking rates as recorded on the temperature chart.
c. Actual soak and withdrawal temperatures as recorded on the temperature
chart.
d. Material dimensions and specification.
e. Applicable WPS number.
f. Project description/code.
g. An authorised signature confirming completion of works in accordance with
design requirements.
4. The completed charts and heat treatment report shall be available for Principal review.
5. All temperature measuring devices shall have valid calibration certificates.
6.2.7.2 Thermocouples
1. Thermocouple attachments should be capacitor discharge connections, or nuts and
bolts as shown in Figure 1. Other types of thermocouple attachments may be used
subject to approval of the Principal.
Figure 1 Thermocouple attachment

2. If nuts and bolts are used, the materials should be of a compatible composition and
treated as a temporary attachment. The attachment points of welded thermocouples
shall be dressed by grinding after removal.
3. All thermocouple attachments shall be adequately insulated to avoid temperature
misreading caused by the effect of radiation.

DEP 30.10.60.32-Gen.
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4. The number and positions of thermocouples shall be in accordance with the design
code. As a minimum, three thermocouples shall be directly attached on a work piece,
as indicated in Figure 2 below. For a hollow configuration, there shall be one additional
thermocouple on the inside.
Figure 2 Thermocouple placement for furnace heat treatment

6.2.8 Process service considerations
1. In addition to any code requirements, materials for the following process services shall
be subjected to PWHT:
a. Caustic and ammonia service
b. HF service
c. Rich or lean amine service irrespective of service temperature. If permitted by
Principal, for welds exposed to lean amine service below 60°C (140F) PWHT
can be omitted.
d. ANSI/NACE MR0175/ ISO 15156 specified severe sour service conditions
(check source, hardness control)
e. High pressure, high temperature hydrogen service)
f. Alkaline sour waters containing carbonates
2. In the above services, all carbon and low alloy steel welds of all thicknesses shall be
given PWHT and it shall be so indicated on the applicable equipment data sheet or
piping/line designation table.
3. Holding times at designated heat treating temperatures shall be a minimum of one
hour per 25 mm (1 in) of weld thickness. When PWHT is imposed because of
environmental cracking concerns, combinations of longer-than-designated holding
times at lower-than-designated heat treating temperatures are not permitted.

DEP 30.10.60.32-Gen.
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Table 4A Guidance on pre-heat and PWHT of weldments

Material Pre-heat Postweld heat treatment
1)
Wall Min. temp. °C Wall Temp. range °C min.- Holding time;
thickness thickness max. min. per mm
(F)
mm (in) mm (in) (F) (0.04 in) wall
2)
thickness
4)
Carbon Steel All Per ≤ 32 (1¼ in) 2.5
3) Optional
ISO TR 17671-2 11)
580°(1076)- 620° (1148)
> 32 (1¼ in) 11)
580°(1076)- 620° (1148)
4) 4)
Fine grained and low ≤ 19 (3/4 in) To ISO 17671-2 ≤ 32 (1¼ in) Optional 2.5
nickel alloy steels > 19 (3/4 in) > 32 (1¼ in)
100° (212)-150°(302) 540°(1004)- 580°(1076)
3.5% Ni steels all 100 (212)-150 (302) all 590 (1094)-630 (1166) 2.5
4)
0.3Mo – 0.5Mo steel ≤ 19 (3/4 in) 20°(68) ≤ 20 (0.8 in) Optional 2.5
> 19 (3/4 in) 100°(212)-150°(302) > 20 (0.8 in)
580°(1076)- 620°(1048)
Grade 4130 HSLA steel all 100 (212)-150 (302) all 660(1220)-700(1292) 2.5
5) 8)
1Cr 0.5Mo all 100°(212)-150°(302) all 640°(1184)- 680°(1265) 2.5
1.25Cr 0.5Mo 6) 7)
680°(1265)- 720°(1328)
5)7) 8)
2.25Cr 1Mo all 200°(392)-250°(482) all 630°(1166)- 680°(1265) 5
6) 7)
680°(1265)- 720°(1328)
7)9)
720°(1328)- 750°(1382)
5) 7 8)
5Cr 0.5Mo 9Cr 1Mo all 200°(392)-250°(482) all 680°(1265)- 720°(1328) 5
7) 9)
720°(1328)- 760°(1400)
10)
12-17 Cr martensitic ss all 200°(392)-300°(492) all 700°(1292)- 790°(1454) 2,5
NOTES: 1. If ambient temperature is below 5°C (41F) pre-heating at 40°C (104F) is recommended. (see also
6.1.1.)
2. Minimum holding time 1 hour.
3. Low hydrogen filler metals have to be used.
4. PWHT is required for Ceq ≥ 0,45 or C ≥ 0,23.unless otherwise agreed with the Principal.
5. For optimum high temperature creep properties in general the lower side of the temperature range
is used.
6. Temperature range in the case of service for hydrogen (H2) or general refinery services.
7. Minimum 10° below refinement temperature.
8. For the larger thickness (>25mm (>1in)) components De-Hydrogenation Treatment (DHT) need to
be considered when Intermediate Stress Relief (ISR), according to the industry best practices
such as API 934.
9. Temperature range for maximum softening.
10. PWHT temperature selection is based on the original heat treatment temperature of the base
metal used.
11. The higher temperature range is specifically for resistance to amine cracking 620°(1148) -
650°(1202) and carbonate cracking 649°(1200) - 663°(1225).

DEP 30.10.60.32-Gen.
February 2015
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Table 4B Heating and cooling rate requirements during PWHT
Heating and cooling Wall thickness Free range Controlled range

activity
Heating t ≤ 25 mm 0 – 300°C T > 300°C (572°F), rate maximum
(1 in) (32 – 572°F) 200°C(360F)/hour
Heating t > 25 mm 0 – 300°C T > 300°C (572°F), rate maximum

(1 in) (32 – 572°F) 5500/t(in mm) in °C/hr (396/t (in
inch) in F/hr, or 55°C(100°F)/hr
(whichever is greater)
Cooling t ≤ 25 mm 400 – 0°C T > 400°C (752°F), rate maximum
(1 in) (752 – 32°F), 200°C/hr (360°F/hr)
under
insulation
Cooling t > 25 mm 400 – 0°C T > 400°C, rate maximum 6875/t
(1 in) (752 – 32°F), in °C/hr(495/t (in inch) in F/hr, or
under 55°C (100°F)/hr
insulation (whichever is greater)
7. WELD INSPECTION
7.1 METHODS AND EXTENT OF NONDESTRUCTIVE EXAMINATION

1. The methods and extent of NDE for pressure vessels or piping are covered by other
applicable DEPs, the respective design code, and relevant design/purchasing
documents.
This DEP does not include complete requirements for testing and NDE for all
production welds. Only the NDE or testing which may be specific to, or resulting
from, the use of a particular welding process (e.g., GMAW, FCAW) or to assure in-
service weld performance (e.g., ferrite tests) are included.
2. The extent of piping inspection is covered by DEP-31.38.01.31-Gen.
3. The extent of pressure vessel inspection associated with the applicable pressure
vessel design code is covered in DEP 31.22.00.31-Gen
7.2 TESTING QUALIFICATIONS

7.2.1 General
1. Mechanical, chemical and electrical testing shall be performed with equipment
calibrated in accordance with applicable ASME, ASTM or ISO standards or in
accordance with a recognised local regulatory agency or third-party agency (e.g., TŰV,
Lloyds, DNV, EN, CSA).
7.2.2 Inspection personnel
1. Inspection personnel to be used by the Fabricator and Contractor shall be individually
approved by the Principal. The Principal reserves the option to interview operatives
and, when necessary, to require a practical skills test.
2. The minimum qualification requirements for inspection personnel are as follows:
a. Visual
MT ASNT, CGSB or EN 473 or ISO 9712, Level 2
PT ASNT, CGSB or EN 473 or ISO 9712, Level 2
b. Radiography

DEP 30.10.60.32-Gen.
February 2015
Page 29
ASNT, CGSB or EN 473 or ISO 9712, Level 2

c. Interpretation only
d. Ultrasonic
e. Additionally, supervisors responsible for overseeing and controlling NDE
activities shall be Level 3 qualified.
7.2.3 General requirements
1. Weld inspection, as specified below, shall be the responsibility of the Fabricator.
2. Unless otherwise approved by the Principal, the NDE company responsible for the
final inspection of welds shall have a quality system in compliance with
ISO/IEC 17020, or equivalent, and be accredited by a nationally recognised body.
3. In the event that the NDE company is not suitably accredited, then prior to award of
work, the company shall submit its NDE procedures to the Principal for review and
approval. These procedures shall clearly illustrate how visual, surface and volumetric
inspection techniques will confirm that all welded joints meet the quality requirements
of this DEP.
4. The Fabricator shall implement a system for uniquely identifying each weld, for the
control and recording of inspections (VT, MT, PT, UT and RT). It is recommended that
isometric drawings, marked with the individual weld numbers, be maintained for this
purpose. Prior to fabrication start-up, the Fabricator shall submit its identification
system for approval by the Principal.
5. The causes for each defect shall be immediately investigated and corrective action
shall be taken to prevent further occurrence. The defects shall be reported with
reference to the numbering system according with ISO 6520-1. On high level defect
class, the numbering can be classified as follows:
Numbering class Defect category
10xx Cracking
20xx Cavity, porosity
30xx Solid inclusions
40xx Lack of fusion and penetration
50xx Imperfect shape and dimensions
60xx Miscellaneous imperfections
6. Where PWHT is required, final non-destructive testing shall not take place until final
PWHT has been completed.
7.2.4 Visual Inspection
1. Welders shall perform visual inspection on all prepared joints prior to welding, during
welding (welder self-checks) and upon completed welds before release to inspection
routine.
2. Visual inspections shall include the internal surface of the weld wherever possible.
3. The visual acceptance of each weld shall be recorded by the Fabricator.

DEP 30.10.60.32-Gen.
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8. WELD REPAIRS
8.1 DEFECT REMOVAL

1. Surface profile defects or surface porosity on the cap, or root if accessible, may be
removed by disc grinding or burr grinding to a smooth profile subject to the minimum
material thickness being maintained.
2. Unacceptable defects in ferritic steels shall be excavated by mechanical means or
carbon arc gouging to a depth agreed with the Principal.
a. Excavation shall be followed by grinding.
b. Excavation by carbon arc gouging shall be applied with a dedicated repair
procedure, or with approval of the Principal.
c. Unacceptable defects in non-ferrous materials shall be excavated by
mechanical means only.
d. Excavation shall be ground to a smooth boat shape with no sharp edges and
have sufficient slope on the sides to permit proper access for welding.
e. Weld repair excavation depth shall be controlled by gauges to ensure the
minimum amount of material necessary is excavated to completely remove the
defect.
3. MT or PT surface inspection techniques shall be used to confirm removal of welds
defects.
8.2 RE-WELDING
1. If back purging was used on the original weld, the back purge shall be re-established if
the repair excavation encroaches closer than 6 mm (1/4 in) to the inside surface of the
vessel, process piping or equipment.
8.3 NONDESTRUCTIVE TESTING

1. All repair welds shall be 100% re-inspected by the methods specified for the original
weld.
2. It is recommended that preliminary NDE is performed before PWHT in case it is
required to avoid having to re-heat treat more than once.
8.4 DEFECT AND REPAIR RATE RECORDS

1. The Fabricator shall implement a system for recording of weld defect and repair rates.
The defect rates shall be recorded on a weekly basis for each production area and
shall be reported together with the accumulated defect rate.
2. Individual welders shall be identified in the defect rate recording system.
3. The Principal shall be informed when repair rates are above 3% in number of welds,
per individual welder, or length of weld.
For welding activity with long weld lengths and few welds in the construction
(such as tanks) the repair rate is defined by length of weld;
4. When required by this DEP, the Fabricator shall submit to the Principal via the
Contractor a procedure for production welding parameter monitoring. This procedure
shall include details of the method(s) used, the reporting process, and the frequency of
tests related to the number of welders, processes, and shift patterns.

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9. HEALTH, SAFETY, SECURITY, AND ENVIRONMENT CONSIDERATIONS
9.1 GENERAL
1. Unless local regulations are more stringent, the following shall apply:
a. Protective clothing for use in welding and allied processes shall conform to
ISO 11611;
b. Equipment for oxygen and acetylene shall conform to ISO 14114 and
ISO 5172;
c. Welding equipment shall conform to IEC 60974-x;
d. Ventilation of welding and cutting fumes shall conform to ANSI Z49.1 /
AWS Z49.1.
e. There are no ISO/IEC documents available to support a fume or ventilation
specification. Trichlorethylene, Acetone and other hydrocarbon based solvents
that produce toxic gases upon welding shall not be used as degreasing
agents.
Dedicated cleaning agents are available on the market for degreasing of
the weld bevel and consumable bare wire (GTAW).
2. HSSE assessment for confined space entry, ventilation, and welding is required as
part of the confined space entry and permit-to-work system. Specific attention shall be
paid to the oxygen depletion risks and visual inspection ability/restrictions for the
welder.
3. Welding close to live (gas) plant facilities shall require specific safety and risk
assessment, with regard to the use of habitats and specific requirements for gas
detection and power/circuit breakers of the equipment used.
4. Whilst it is generally undesirable to change the type of tungsten electrode used for
GTAW from that qualified (e.g., move away from thoriated tungsten), this change shall
not be considered an essential variable change when made for health and safety
reasons provided that there are no other significant welding procedure changes.
5. Thoriated tungsten electrodes shall not be used in production welding, unless
specifically approved by the Principal. In case approval is granted, automated
sharpeners with dust removal facilities shall be used, along with an approved removal
procedure. The number of thoriated tungsten electrodes at the welder location shall be
limited to three.
6. All equipment shall be in good condition and properly maintained with records to
support its ongoing safe operation.
9.2 WELDING EQUIPMENT

1. Amp meters and volt meters shall be fitted to welding equipment for the GMAW,
FCAW and SAW welding processes.
9.3 ALIGNMENT
1. Equipment used to hold and support process equipment, vessels, piping, etc., shall be
capable of bearing the load in a safe manner whilst maintaining the stability required
for working in both the vertical and horizontal planes.

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10. MATERIAL-SPECIFIC ADDITIONAL REQUIREMENTS
10.1 GENERAL REQUIREMENTS

1. Welding requirements vary according to the specific material as specified in (10.5) to
(10.14). Common requirements are specified in (10.3) and (10.4).
2. Material-specific welding requirements include lists of approved welding processes.
Alternative processes may be permitted by the Principal, subject to a detailed technical
justification including documented previous experience.
10.2 WPQR MONITORING

1. WPQR monitoring shall include the following:
a. WPQR run out lengths (ROLs) and stub lengths for SMAW.
b. WPQR minimum and maximum bead widths for each weld area.
c. WPQR interpass temperature at start of each pass.
10.3 WPQR REQUIREMENTS

10.3.1 General
1. WPQR requirements are generally in accordance with the relevant part of
EN ISO 15614, with clarifications and changes as indicated for the specific material.
2. The test piece locations should be in accordance with Figure 5.
10.3.2 Essential variables
1. Direction of Welding A change from vertical up to vertical down or vice versa

requires requalification.
2. Qualification Position a. Pipe except GMAW/FCAW: The position required to qualify
is H-L045 (6G). or alternatively;
b. Pipe GMAW/FCAW: The positions required to qualify are
PC (2G), PF (5G).
c. Plate: The positions required to qualify are PC (2G), PF
(3Gu), PE (4G).
d. Alternative combinations shall be approved by the
Principal.
3. Single/Double Sided Single-sided welds qualify double-sided welds.
4. Bevel / V Compound bevels qualify V-bevels but not vice versa.
5. Backing Addition or removal of backing strips or gas requires
qualification.
6. Shielding / Backing Minor constituents of gases may not be changed by more than
Gases 10% of their nominal value
7. Arc Voltage +/- 10% of the average measured for the specified weld region
8. Current / Wire Feed +/- 15% of the average measured for the specified weld region
9. Travel Speed +/- 20% of the average measured for the specified weld region
10. Arc Energy or Heat +/- 25% of the average measured for the specified weld region
Input
11. Arc Type A change in arc characteristics (e.g., dip, globular, spray)
requires requalification.

DEP 30.10.60.32-Gen.
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12. Electrode / Filler Rod SMAW filling & cap passes, Normal practice is one electrode
Size diameter change is allowed within the consumable
manufacturer recommended optimal parameters settings, max
4mm diameter use.
13. PWHT Increase in total PWHT time exceeding 25% requires
requalification
14. Automation a. Semi-automated and automated welding processes such
as orbital GTAW, Adaptive GMAW such as STT (Surface
Tension Transfer), RMD (Regulated Metal Deposition),
ESAB QSET (optimal short arc parameters settings) and
CMT (Cold Metal Transfer), require additional quality
control.
b. The full parameter settings shall be reported during
qualification, archived and fully traceable during the
fabrication stage.
c. Automatic weld parameter monitoring is required during the
qualification process. Optionally automatic welding
parameter monitoring may be selected for quality control
during fabrication.
15. Cladding of corrosion a. The heat input is restricted in reference with the
resistant alloys ISO 15614-7 by -10 / +25%. Also the electrode diameter
(process 111/SMAW) may be selected one diameter
up/down from the qualified condition.
b. The restriction for all changes to the “non-essential”
parameters is that the effect to the dilution of the base
material shall be minimal to the condition qualified.
c. For example, for the 111/SMAW process, the normal
recommended amperage and volt ranges shall be
implemented (not same amperage for lower electrode
diameter).
10.4 PARAMETER MONITORING

1. Requirements for parameter monitoring should reflect the sensitivity of the mechanical
and/or corrosion resistance properties of the material to be welded.
2. Parameter monitoring shall be executed per the approved ITP.
3. Records of parameter monitoring shall be reviewed by the Fabricator and Contractor.
Any discrepancies with the applicable WPS shall be highlighted to the welder for
correction and subsequently reported to the Principal.
4. Welding sets shall be calibrated or verified at intervals not exceeding 12 months.
5. Parameter monitoring acceptance criteria shall reflect the Fabricator’s standard
working practices and are intended to ensure repeatability across all machines, i.e.,
The Fabricator shall be able to demonstrate that welders are able to set and maintain
the required parameters using the specified site instructions.

DEP 30.10.60.32-Gen.
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10.5 CMN STEELS NOT INTENDED FOR LOW TEMPERATURE SERVICE

1. Typical Materials ASTM A285C, A515, A106B, A105, A234-WPB, API 5L Gr B,

A516, A216
2. Approved Root GTAW (141)
Processes
3. Approved Fill & Cap GTAW (141), SMAW (111), FCAW (136,114), GMAW (135),
Processes MCAW (138), SAW (121,125)
4. Consumable SMAW electrodes : Shall be type EXX16 or EXX18,
Restrictions
5. Consumable a. Generic applications:
Chemistry No additional restrictions to the standard.
b. Corrosive service:
For CO2 containing process service, root and second pass
limited to max 0.2% Ni, 0.6% Si, 0.5% Mo to avoid
preferential weld corrosion.
c. For HF service:
The limitation is Cr + Cu + Ni < 0.15% and 0.3% Mo.
d. Only matching type welding consumables can be used as
follows:
Type Code Designation
Bare Wire AWS A5.18/A5.18M ER70S-3
ISO 636 W 42 5 W2Si
ISO 14341 G 42 2 M G2Si
Coated AWS A5.1 E7018-1 H4R
Electrode
E7016 H4R
ISO 2560-A E 46 4 B 32 H5
E 42 3 B 12 H5
6. Hydrogen Control ≤ 5ml/100g to EN ISO 3690
10.5.2 WPQR requirements
1. WPQR Monitoring Automatic monitoring equipment preferred but not mandatory

2. WPQR Preheat If production hardness testing is part of the ITP and carried
Level out, the WPQR level of preheat is defined as the initial preheat
level of the test piece. Otherwise the WPQR level of preheat is
defined as the initial test piece preheat level or the initial
interpass temperature prior to starting the cap, whichever is
higher.

DEP 30.10.60.32-Gen.
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10.5.3 WPQR testing requirements
1. WPQR NDE Visual examination, Radiography + MPI (plus other, if used for
production)
2. Charpy Impacts, T Specification to be made by reference to design code,
> 5mm (0.2inch) DEP 30.10.02.31-Gen. and/or PED requirements. The
standard PED requirement is 27J minimum average (weld and
HAZ) at the minimum design temperature unless waived by the
appropriate harmonised design standard.
3. Charpy Impacts, T Specification to be made by reference to design code,
> 20mm (0.8inch) DEP 30.10.02.31-Gen. and/or PED requirements The standard
PED requirement is 27J minimum average (weld and HAZ) at
the minimum design temperature unless waived by the
appropriate harmonised design standard
4. Macro + Hardness Required as per EN ISO 15614. Photo-macrographs to be
Survey included with indicated magnification not less than 1X and
clearly showing all hardness indentations.
5. Maximum Hardness Refer to (4.5.3.2)
1. Carbon Equivalent Production CEq max = WPQR CEq +0.03, or 0.38 whichever is
higher.
Relaxation of this variable may be permitted based upon the
Contractor demonstrating QC controls which ensure the
application of suitable preheat for higher CE values and
implementation of appropriate production hardness testing,
approved by the Principal.
2. Thickness Limits As-welded thickness limit is defined in the selected design
(other) code
3. Bevel Angle Total included angle shall not be decreased by more than 10°
from WPQR
4. Electrode / Filler Rod Root electrode or filler wire size shall not be changed.
Size SMAW, Normal practice is one electrode diameter change is
allowed within the consumable manufacturer recommended
optimal parameters settings, max 4 mm (5/32 in) diameter use.
5. Preheat Decrease from that qualified is not permitted.
Deletion or addition is not permitted, except that maximum
50 C (122°F) is allowed for condensation mitigation
6. Interpass may be 50°C (90°F) above WPQR maximum
raised by
7. Interpass Limit 300°C (572°F) maximum
8. Heat Input or Arc Arc energy maximum recommended is 2.5 KJ/mm (63.5kJ/in)
Energy
9. Repair Welding Repair WPS to be issued. Separate WPQR not required
unless essential variables change.

DEP 30.10.60.32-Gen.
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10.5.5 Production controls
1. Parameter Random ROL or bead width checks are sufficient

Monitoring
2. Other Tack welding requires preheating to the minimum level
specified on the WPS or 50°C(122°F), whichever is higher.
10.6 IMPACT TESTED CMn STEELS (LTCS)

1. Typical Materials ASTM A537, A352, A333 Gr6, A350 LF2, A420 Gr WPL6, API
5L X##, A694 F##
Processes
3. Approved Fill and GTAW (141), SMAW (111), FCAW (136), SAW (121,125)
Cap Processes
4. Consumable SMAW electrodes : Shall be type EXX16 or EXX18
Restrictions
5. Consumable a. Generic applications:
Chemistry No additional restrictions to the standard.
b. Corrosive service:
For CO2 containing process service, root and second pass
limited to max 0.2% Ni, 0.6% Si, 0.5% Mo to avoid
preferential weld corrosion (see also section 9.6 in
information part of this DEP)
c. For HF service:
The limitation is Cr + Cu + Ni < 0.15% and 0.3% Mo
d. Typical matching type welding consumables are as follows:
Type Code Designation
Bare Wire AWS A5.18/A5.18M ER70S-3
ISO 636 W 42 5 W2Si
ISO 14341 G 42 2 M G2Si
Coated AWS A5.1 E7018-1 H4R
Electrode
E7016 H4R
ISO 2560-A E 46 4 B 32 H5
E 42 3 B 12 H5
6. Hydrogen Control <= 5ml/100g to EN ISO 3690
1. WPQR Monitoring Automatic monitoring equipment shall be used.

level of the test piece. Otherwise, the WPQR level of preheat is
defined as the initial test piece preheat level or the initial
interpass temperature prior to starting the cap, whichever is
higher.

DEP 30.10.60.32-Gen.
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Page 37
1. WPQR NDE Minimum required Visual examination, Radiography + MPI

(plus other, if used for production)
2. Charpy Impacts, T > Root : Weld, Fusion Line, FL+2mm (+0.08 in) (and FL+5 mm
5mm (0.2 in) when heat input > 2.0 kJ/mm (51 kJ/mm)).
3. Charpy Impacts, T > Root : Weld, Fusion Line, FL+2mm (+0.08 in) (and FL+5 mm
20mm (0.2 in) when heat input > 2.0 kJ/mm (51 kJ/mm)), including
Cap Weld Centreline
4. Macro + Hardness 5G or 6G: 3 off - 3 or 9 o’c, 6 o'c, 12 o'c positions. Other
Survey positions 1 off. Photomacrographs to be included with
indicated magnification not less than 1X and clearly showing
all hardness indentations.
5. Maximum Hardness Refer to (4.5.3.2)
1. Carbon Equivalent Production CEq max = WPQR CEq +0.03, or 0.38 whichever is
higher.
Relaxation of this variable may be permitted based upon the
Contractor demonstrating QC controls which ensure the
application of suitable preheat for higher CE values and
implementation of appropriate production hardness testing,
2. Material Supply Charpy impact and hardness acceptability for normalised,
Condition TMCR, Q&T materials shall be qualified or demonstrated in
accordance with low temperature qualification requirements
(4.5.3.3) and table 5.
3. Thickness For WPQRs with T < 5 mm (0.2 in), impact tests are not
required unless the WPS is to be used on material with
thickness greater than 5mm (0.2in)
4. Thickness Limits As-welded thickness limit is defined in the selected design
(other) code
5. Simple / Compound Change to/from compound bevel requires approval by the
Principal.
from WPQR
7. Process The welding process, combination of processes or order of
Combination welding processes shall not be changed unless approved by
the Principal.
8. Consumable The consumable brand name is an essential variable, though
the Principal may agree to changes for solid wires.
9. Electrode / Filler Rod Electrode or filler wire size shall not be changed at any stage
Size of welding
10. Polarity / Current Any change in polarity or current type requires requalification.
Type
11. Preheat Decrease from qualified preheat is not permitted.
raised by

DEP 30.10.60.32-Gen.
February 2015
Page 38
1. Parameter Scheduled, minimum one test per process, per shift

Monitoring
2. Other a. Welding sets shall be calibrated or verified at intervals not
exceeding 12 months.
b. Tack welding requires preheating to the minimum level
specified on the WPS or 50°C (122F) whichever is higher.
10.6.6 Charpy impact testing

1. As a minimum, Charpy impact testing is required to demonstrate compliance with the
European Pressure Equipment Directive (97/23/EC).
2. ASTM A105 and A106 grade B materials, shall be subjected to Charpy impact testing
at a minimum temperature of 0°C (32°F) or the minimum design temperature,
whichever is lower. Materials shall display a minimum Charpy impact resistance of 27J
(20 ft-lb).
3. For all other materials Charpy impact testing shall fully comply with the testing
requirements of this DEP. Testing temperature and acceptance criteria shall be in
accordance with Table 5 below.
Table 5 Charpy impact testing temperatures and acceptance criteria
Material Charpy Test Charpy Energy J (ft-lb) (1)

Temp.
° C (F) Average Individual
Energy Lat. Exp
mm (mils)
A333 Gr 6 -50 (-58)(note 4) 27 (20) 19 (14)
A350 LF2 & A420 WPL6 -50 (-58) 27 (20) 19 (14)
UNS S31803 (2) -50 (-58) 50 (37) 0.38 (15) 40 (30)
UNS S32550 (2) -50 (-58) 50 (37) 0.38 (15) 40 (30)
UNS S32750 (2) -50 (-58) 50 (37) 0.38 (15) 40 (30)
UNS S32760 (2) -50 (-58) 50 (37) 0.38 (15) 40 (30)
A333 Gr 3, A350 LF3, A420 WPL3 -80 (-112) (3) 27 (20) 19 (14)
NOTES 1. The acceptance criteria for subsize specimens shall be reduced to:
7.5mm x 10mm (0.3 x 0.39in) 0.83 x full size values
5mm x 10mm (0.2 x 0.39in) 0.67 x full size values
2.5mm x 10mm (0.1 x 0.39in) 0.5 x full size values
2. The application of duplex stainless steels is limited to -50 °C (-58 °F) and 40 mm (1.5 in) maximum
thickness, unless a fracture mechanics assessment is carried out to justify lower temperatures or
greater thicknesses, and is approved by the Principal. (see DEP.30.10.02.31-Gen)
3. If the design temperature is lower than -80°C (-112F), the test temperature shall be the same as
the minimum design temperature.
4. The Principal may accept pre-qualified procedure that are tested at -46degrees C with the same
acceptance criteria depending on actual minimum design temperature.

DEP 30.10.60.32-Gen.
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4. Charpy V-notch specimens shall be prepared and tested in accordance with ISO 148-
1. For welds made with a maximum heat input of 2 kJ/mm (51 kJ/in), a set of three
Charpy impact specimens shall be taken with notches (1) at the weld centre line, (2) at
the fusion line, and (3) at the fusion line + 2 mm (0.08 in) as shown in Figure 3 below.
(1) RW = Notch at root weld
2mm
(2) RF = Notch at root fusion

line
2mm
(3) R2 = Notch at 2mm from

fusion line (and R5 = at 5mm
for heat inputs over 2kJ/mm)
2mm 2 or 5mm
2mm
(4) CW = Notch at cap weld

centreline
2mm
(5) CF = Notch at cap fusion

line
2mm
(6) C2 = Notch at 2mm from
fusion line (and C5 = at 5mm
for heat inputs over 2kJ/mm)
2 or 5mm
NOTE:
(1), (2) and (3) - All welds
(4) - Additional for ferritic steels with wall thicknesses over 20mm.
(4), (5) and (6) - Additional for duplex stainless steels with wall thickness over 20mm.
Figure 3 Location of impact specimens

5. Where heat inputs greater than 2 kJ/mm (51 kJ/in) have been used during WPQR an
additional set of three specimens shall be taken at the fusion line + 5 mm (0.2 in).
6. For single sided welds, the specimens shall be taken with the lower surface no more
than 2 mm (0.08 in) above the inner surface.
a. For material thicknesses greater than 20 mm (0.8 in), a set of three specimens
shall be taken with their notches at the weld centre line and with their upper
surfaces within 2 mm (0.08 in) of the outer surface.
b. Each specimen shall be etched prior to notching and the location of the notch
relative to the fusion or weld centre line individually marked.
c. The notch shall be placed in the square face of single sided bevel welds.
7. The notch positions for double sided welds shall be agreed with the Principal.

DEP 30.10.60.32-Gen.
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8. Full size (10 mm x 10 mm (0.39 in x 0.39 in)) impact test specimens shall be used
wherever possible. Where this is not possible, the larger of three quarter size (7.5 mm
x 10 mm (0.3 in x 0.39 in)) or half size (5 mm x 10 mm (0.2 in x 0.39 in)) specimens
shall be used. Reduced acceptance values for reduced size samples are given in
Table 5, Note 1.
9. Unless otherwise specified, no impact test result shall be less than the specified
minimum individual value and not more than one result shall be less than the minimum
average value specified.
a. If the above requirements cannot be met, three additional specimens shall be
tested.
b. The average of the six specimens shall be not less than the minimum
specified average.
c. Only two values may be below the specified minimum average value and only
one of those may be below the specified minimum individual value.
10. Fabrication of impact tested CMn piping and fittings, for process piping service (i.e.
ASTM A333 gr6, A350 LF2, etc.), shall be subject to PWHT based on the
requirements in the applicable design code and DEP 30.10.02.31-Gen.
11. If the governing thickness for PWHT is ‘B’ for weld/pipe thickness in accordance with
the applicable code, the weld thickness above which PHWT is required for branch
connections shall be determined as in Figure 4 below.
A A
PWHT if
t 4B
t 38mm
Section 'A-A' Section 'B-B'

(illu5580480)
Figure 4 Weld profile – Weldolets

NOTE: ‘B’ is the PWHT threshold thickness, as defined by the applicable Code.

DEP 30.10.60.32-Gen.
February 2015
Page 41
10.7 3.5% NICKEL STEELS

1. Typical Materials ASTM A333 Gr3, A350 LF3, A420 Gr WPL3, A765 Gr III, A352
LC3, A203 D
Processes SMAW (111): Alternating current shall be used for root pass
welding, to avoid magnetic arc blow problems and consequent
lack of fusion.
3. Approved Fill & Cap GTAW (141), SMAW (111), SAW (121,125)
Processes
4. Consumable Matching : GTAW : ER80S-Ni2 / SMAW electrodes : Shall be
Restrictions 7016C2L, 7018C2L, 8016C2 or 8018C2
5. Consumable Non-Matching : GTAW : ERNiCr-3 / SMAW : ENiCrFe-2 or

Restrictions ENiCrFe-3
6. Consumable See restrictions above.
Chemistry
1. WPQR Monitoring Automatic monitoring equipment shall be used

level of the test piece.
Otherwise the WPQR level of preheat is defined as the initial
test piece preheat level or the initial interpass temperature
prior to starting the cap, whichever is higher.
1. WPQR NDE Radiography + MPI (plus other, if used for production)

2. Charpy Impacts, T > Root : Weld, Fusion Line, FL+2mm (and FL+5mm when heat
5mm input > 2.0kJ/mm)
3. Charpy Impacts, T > Root : Weld, Fusion Line, FL+2mm, including Cap Weld
20mm Centreline.
4. Macro + Hardness 5G or 6G : 3 off - 3 or 9 o’c, 6 o'c, 12 o'c positions. Other
indicated magnification not less than 1X and clearly showing
all hardness indentations.
5. Maximum Hardness refer to (4.5.3.2)

DEP 30.10.60.32-Gen.
February 2015
Page 42
1. Material Supply Charpy impact and hardness acceptability for Normalised,

Condition TMCR, Q&T materials must be qualified or demonstrated in
accordance with low temperature qualification requirements
(4.4.2.2) and Table 3.
2. Thickness For WPQRs with T < 5 mm (0.2 in), impact tests are not
required unless the WPS is to be used on material with
thickness greater than 5mm (0.2in)
3. Thickness Limits The maximum thickness for as-welded applications at a
(other) service temperature of -80 °C (-112 °F) is 12.5 mm (0.5 in). For
service below -80 °C (-112 °F), all thicknesses shall be PWHT.
Principal.
from WPQR
the Principal.
Size of welding
9. Backing gas A back purge with high purity Argon shall be required for
GTAW of 3½ % Nickel steels unless otherwise approved by
the Principal.
10. Heat input Maximum 1.8 kJ/mm (46 kJ/in)
11. Preheat A minimum preheat of 100 °C (212 °F) shall be used for
welding all thicknesses.
Decrease from that qualified is not permitted.
12. Interpass may be 25°C (45°F) above WPQR maximum (procedure qualification
raised by maximum is highest allowed in production)
1. Parameter Scheduled, minimum 1 test per process per shift

Monitoring
2. Other Welding sets shall be calibrated or verified at intervals not
exceeding 12 months.
Tack welding requires preheating to the minimum level
specified on the WPS or 100°C (212°F), whichever is higher.

DEP 30.10.60.32-Gen.
February 2015
Page 43
10.8 LOW ALLOY STEELS

1. Typical Materials ASTM A 387 types 0.5 Mo, 1 Cr-0.5 Mo, 1.25 Cr- 0.5 Mo, 2.25
Cr-1 Mo steels,5Cr 1Mo, 9Cr 1Mo, P91 (9Cr, 1Mo-V), AISI
4130
2. Approved Root GTAW (141) and GMAW (1xx) for P3 to P9
Processes
Processes
1. Reference 1.25 and 2.25Cr – API 934s and DEP 30.10.02.32-Gen.,

should be followed whenever applicable.
level of the test piece.
Otherwise the WPQR level of preheat is defined as the initial
test piece preheat level or the initial interpass temperature
prior to starting the cap, whichever is higher.
1. WPQR NDE Visual examination, Radiography + MPI (plus other, if used for
production)
2. Charpy Impacts, Specification to be made by reference to design code, low
T > 5mm (0.2in) temperature DEP 30.10.02.31-Gen. and/or PED requirements
3. Charpy Impacts, Specification to be made by reference to design code, low
T > 20mm (0.8in) temperature DEP 30.10.02.31-Gen. and/or PED requirements
4. Macro + Hardness 1 Required per EN ISO 15614. Photo-macrographs to be
clearly showing all hardness indentations
5. Maximum Refer (4.5.3.2).
Hardness
1. Material Supply Any change must be re-qualified

Condition
Principal.
from WPQR
the Principal.

DEP 30.10.60.32-Gen.
February 2015
Page 44
6. Backing gas A back purge with high purity Argon shall be required for
GTAW of 2.25 Cr steels and higher alloys unless otherwise
7. Electrode / Filler Electrode or filler wire size shall not be changed at any stage
Rod Size of welding outside what was qualified in the WPQR.
8. Preheat A minimum preheat of 100 °C (212 °F) shall be used for
welding all thicknesses.
Decrease from that qualified is not permitted.
raised by

Monitoring
2. Other Tack welding requires preheating to the minimum level
specified on the WPS or 100°C (212°F) whichever is higher.
10.9 AUSTENITIC STAINLESS STEELS

1. Typical Materials AISI 300 Series, Grades 304L, 304, 316L, 316, 321, 347
Processes
3. Approved Fill & Cap GTAW (141), SMAW (111), GMAW (135), SAW (121,125)
Processes FCAW (136): This can be used for design temperatures up to
150°C (302°F).
4. Consumable Matching filler materials to be used.
Restrictions
5. Consumable Principal alloying additions should not be made through flux

Chemistry additions.
1. WPQR NDE Visual examination, Radiography + DPI (plus other, if used for
production)
Acceptance criteria for oxidation of stainless steel weldments
DEP 30.10.60.31-Gen
2. Macro + Hardness Required per EN ISO 15614. Photo-macrographs to be
3. Maximum Hardness Maximum hardness shall be 250 Hv10.

DEP 30.10.60.32-Gen.
February 2015
Page 45
4. Micro Examination 5G or 6G: 2 off representing min and max heat input, 1 off for
other positions. Microstructure of weld and HAZ shall show
appropriate phase distribution and absence of micro-phases
considered deleterious to mechanical or corrosion properties.
Photomicrographs shall be provided of each region (typically
250X) with the WPQR.(ISO 9042, equivalent to ASTM E562)
5. Ferrite Test Ferrite number (FN) shall be 3-8FN in the root, cap and fill (i.e.
mid thickness) passes as per ISO 8249.Alternative acceptable
range may be specified for specific application, e.g. LNG flare
line.
from WPQR
Combination welding processes shall not be changed, unless otherwise
Size of welding outside of what was qualified in WPQR
4. Polarity / Current Any change in polarity or current type (including pulse
Type characteristics) requires requalification.
raised by

Monitoring
2. Material Segregation Required to separate from other alloys
3. Other a. Austenitic stainless steels may only be cut mechanically or
by plasma arc cutting.
b. All plasma spatters and other debris shall be removed from
the vessel, process pipework or other equipment surface by
dedicated disc grinder or emery disc .
c. Acceptance criteria for oxidation of stainless steel
weldments DEP 30.10.60.31-Gen
4. Ferrite Checks Ferrite check shall be done by means of approved ferrite
measurement device on weld metal on the fill (mid thickness)
and cap pass. Acceptance criteria shall be 3 to 8 ferrite
number (FN).

DEP 30.10.60.32-Gen.
February 2015
Page 46
10.10 6% Mo AND OTHER SUPERAUSTENITIC STAINLESS STEELS

1. Typical Materials UNS S31254, UNS N08367, UNS N08925, UNS N08926
Processes
3. Approved Fill & Cap GTAW (141), SMAW (111), FCAW (136), SAW (121,125)
Processes
4. Consumable Type ERNiCrMo-3
Restrictions
6. Autogenous Welding Not permitted
1. WPQR Monitoring Automatic monitoring equipment required.
1. WPQR NDE a. Visual examination, Radiography + DPI (plus other, if used

for production)
b. Acceptance criteria for oxidation of stainless steel
weldments DEP 30.10.60.31-Gen.
Survey positions 1 off. Photo-macrographs to be included with
indicated magnification not less than 1x and clearly showing all
hardness indentations.
3. Maximum Hardness 35HRC (335 HV10)
4. Root Chemical All principal alloying additions : minimum C, Si, Mn, P, S, Cr,
Analysis Mo, Ni, Cu, Nb, and Fe
5. Corrosion Test a. In an as welded condition by ASTM G48 Method A @ 35°C
(95°F) for 24 hours
b. The acceptance criteria shall be a weight loss < 4 g/m² and
no initiation of localised corrosion > 0.025mm at the test
face. Note that only corrosion (e.g., pitting) at the test face
counts. If the weight loss is > 4 g/m² and it can be positively
identified that this is only due to corrosion at the cut faces,
the test shall be invalid. In this case re-testing shall be
carried out on replacement specimens.
c. Previously accepted WPQRs on 6%Mo with corrosion
testing at 30°C (86F) do not require retesting at 35°C (95F).
d. In the pickled and passivated condition, testing by ASTM
G48 Method A @ 40°C (104°F) for 24 hours shall be done
with the same acceptance criteria as above.
6. Micro Examination a. 5G or 6G: 2 off representing min and max heat input, 1 off
for other positions.
b. Microstructure of weld and HAZ shall show appropriate
phase distribution and absence of micro-phases considered
deleterious to mechanical or corrosion properties.
c. Photomicrographs shall be provided of each region
(typically 250x and 400x) with the WPQR.

DEP 30.10.60.32-Gen.
February 2015
Page 47
1. Chemistry A change in UNS number requires requalification

Limitations
2. Position 2G + 5G qualification normally required for all positional
coverage.
3. Joint Type Single and multi-pass fillets require separate qualification
4. Root Gap Tolerance: -0 / +2mm (0.08in) of the WPQR and not outside
the range 2-5 mm (0.08 to 0.2 in)
5. Bevel Angle Total included angle shall not be changed by more than
+10°/ -5° from WPQR
the Principal.
Size of welding outside what was qualified in the WPQR
raised by
12. Heat Input Limits 1 kJ/mm (25 kJ/in) maximum
13. Repair Welding Separate procedure to be qualified
1. Parameter Scheduled, minimum 1 test per process, per shift

Monitoring
2. Material Segregation Required from other alloys
3. Other a. 6 Mo stainless steels may only be cut mechanically or by
plasma arc cutting. All plasma spatters and other debris
shall be removed by disc grinder or emery disc.
10.11 DUPLEX STAINLESS STEELS

1. Typical Materials UNS S31803, UNS32205 (22% Cr) and UNS S32550, UNS
S32750, UNS S32760 (25% Cr), excluding UNS32304
Processes
3. Approved Fill & Cap GTAW (141), SMAW (111), FCAW (136), SAW (121,125)
Processes
4. Consumable Root and 2nd pass of 22% duplex shall be made with 25%
Restrictions duplex consumable unless nitrogen containing shield gas and
purge are used.

DEP 30.10.60.32-Gen.
February 2015
Page 48
5. Consumable Shall overmatch nickel content (typically 2209 type for 22%
Chemistry duplex and 2509 type for 25% duplex). Principal alloying
additions should not be made through flux additions.
8. Back purging Inert back purge of the internal surface shall be maintained
rd
until completion of the 3 pass of the groove weld.
9. Material certification Both base metal and consumable material certification for
qualification shall be in accordance with ISO 10474 – 3.2
certificate.
production)
Acceptance criteria for oxidation of stainless steel weldments
DEP 30.10.60.31-Gen
2. Charpy Impacts, T > a. Root : Weld, Fusion Line, FL+2 mm (and FL+5 mm (0.2 in)
5mm when heat input > 1.75 kJ/mm(44 kJ/in))
b. Criteria for duplex include lateral expansion >0.38 mm. See
also Table 5.
3. Charpy Impacts, T > Root & Cap : Weld, Fusion Line, FL+2mm (and FL+5mm when
20mm heat input > 1.75kJ/mm (44kJ/in))
4. Macro + Hardness 5G or 6G : 3 off - 3 or 9 o’c, 6 o'c, 12 o'c positions. Other
indicated magnification not less than actual size and clearly
showing all hardness indentations.
5. Maximum Hardness The maximum hardness for quality control purpose shall target
334 Hv10 for 22%Cr DSS and for 25Cr DSS shall target
378 Hv10
6. Root Chemical All principal alloying additions : minimum C, Si, Mn, P, S, Cr,
Analysis Ni, Mo, Cu, Al, (W) and N and calculated PREn
7. Corrosion Test a. In an as welded condition by ASTM G48 Method A, the test
temperature 22°C for 22% duplex and 35°C for 25% duplex
for 24 hours.
b. The acceptance criteria shall be a weight loss < 4 g/m² and
no initiation of localised corrosion > 0.025mm at the test
face. Note that only corrosion (e.g., pitting) at the test face
counts.
c. If the weight loss is > 4 g/m² and it can be positively
identified that this is only due to corrosion at the cut faces,
the test shall be invalid. In this case re-testing shall be
carried out on replacement specimens.
d. If pickled and passivated, testing by ASTM G48 Method A
shall be done at a test temperature of 25°C for 22% duplex
and 40°C for 25% duplex for 24 hours with the same
acceptance criteria as above.

DEP 30.10.60.32-Gen.
February 2015
Page 49
8. Micro Examination a. 5G or 6G : 2 off representing min and max heat input, 1 off
for other positions.
b. Microstructure of weld and HAZ shall show appropriate
phase distribution and absence of micro-phases considered
deleterious to mechanical or corrosion properties.
c. Photomicrographs shall be provided of each region
(typically 250X and 500X) with the WPQR.
10. Ferrite Test Shall be 40-60% in parent and 30-70% in weld/HAZ according
to method in (Appendix B). Measurements to be made 1mm
from root and cap in weld, HAZ, and parent metal.
1. Chemistry A change in grade sub group requires requalification

Limitations
2. Thickness a. Welding procedure tests conducted on impact-tested
materials less than 5mm thick need not be impact tested.
However, such procedure tests shall not qualify for
thicknesses greater than 5 mm.
b. For 22 Cr duplex, the thickness ranges qualified shall be in
accordance with ISO 15614-1
c. For 25 Cr duplex, the thickness ranges qualified shall be
based on the WPQR thickness (t) as follows:
d. t < 5 mm (0.2 in) : t - 1.5t (limit 5mm if not impact tested)
t >= 5 mm (0.2 in) : 0.75t - 1.5t
3. Thickness Limits The thickness and low temperature reference to
(other) DEP 30.10.02.31-Gen.and subject to design code.
coverage.
5. Joint Type Multi-pass fillets may be qualified by butt weld fill and cap
parameters.
Principal.
from WPQR
the Principal.
the Principal may agree to changes for solid wires. PREn of
production consumables should not be more than 0.5 below
those used for the WPQR.
Size of welding outside of what was qualified in WPQR
raised by
13. Interpass Limit 125°C (257°F) for 25Cr duplex
150°C (302°F) for 22Cr duplex

DEP 30.10.60.32-Gen.
February 2015
Page 50
14. Heat Input Limits a. The arc energy and interpass temperature shall be
controlled to ensure an optimum cooling rate of the weld
with respect to the thickness. Typical arc energies are in the
range 0.5 to 1.75 kJ/mm.
b. The second pass is normally deposited at lower arc energy
than that of the root pass.
15. Repair Welding Separate procedure to be qualified
1. Parameter Scheduled, minimum 1 test per process per shift

Monitoring
3. Other a. Duplex stainless steels may only be cut mechanically or by

plasma arc cutting.
b. All plasma spatter and other debris shall be removed from
disc grinder or emery disc.
10.12 NICKEL ALLOYS

1. Typical Materials UNS N08825 (Alloy 825), UNS N06625 (Alloy 625), UNS
N04400 (Alloy 400), UNS N06600 (Alloy 600), UNS N0x925
(Alloy 925), UNS N0x718 (alloy 718), UNS N10276 (Alloy
C276)
Processes
Processes
4. Consumable a. The welding consumables shall be from equivalent
Restrictions chemical composition as specified by the materials
producer. The specific designation can be according ISO
14172, AWS 5.11 or EN 1600 for covered electrodes.
b. For wire the specific designation can be according ISO
18274 or AWS 5.14
c. For selection of non-matching welding consumable
approval from the Principal is required.

DEP 30.10.60.32-Gen.
February 2015
Page 51
1. WPQR NDE a. Visual examination, Radiography + DPI (plus other, if used

for production)
2. Macro + Hardness Required as per EN ISO 15614. Photo-macrographs to be
Survey included with indicated magnification not less than actual size
and clearly showing all hardness indentations.
3. Maximum Hardness With reference to ISO15156-3
1. Chemistry As per ISO 15614-1

Limitations
parameters.
from WPQR
the Principal.
Size of welding
6. Interpass may be 25°C above WPQR maximum
raised by
7. Interpass Limit 200°C maximum
8. Heat Input 1.5 kJ/mm (39 kJ/in) maximum.


Monitoring
3. Other a. Nickel and its alloys may only be cut mechanically or by
plasma arc cutting.
b. All plasma spatter and other debris shall be removed from

DEP 30.10.60.32-Gen.
February 2015
Page 52
10.13 COPPER ALLOYS

10.13.1 General requirements – Copper Alloys, expand on materials to be welded and
additional requirements
1. Typical Materials a. Cu/Ni alloys in the range of 90/10 and 70/30 materials
composition
Al-Brass alloys
Al-Bronze alloys
unalloyed copper
b. With reference to metallic materials DEP 30.10.02.11-Gen.
Processes
3. Approved Fill & Cap GTAW (141), SMAW (111), SAW (121)
Processes
4. Consumable a. The welding consumables shall be from equivalent
Restrictions chemical composition as specified by the materials
producer.
b. The specific designation can be according ISO 14172, AWS
5.11 or EN 1600 for covered electrodes. For wire the
specific designation can be according ISO 18274 or AWS
5.14
c. For selection of non-matching welding consumable
approval from the Principal is required.
5. Materials condition For the welding of copper materials it is evident to report the
materials supply condition (hardness/strength/deformation
grade/heat treatment, aging).
The weldability is very dependent on the actual material
condition.

production)
2. Macro + Hardness Required as per ISO 15614. Photo-macrographs to be
3. Maximum Hardness a. The maximum hardness is determined by the ordering
specifications. Normally the annealed condition hardness
requirement is also applicable for the weld area.
b. Specific service conditions in relation to ammonia and
mercury exposure require individual specifications by the
principal

DEP 30.10.60.32-Gen.
February 2015
Page 53
parameters.
from WPQR
the Principal.
Size of welding
raised by
8. Repair Welding a. For new fabrication:
Repair WPS to be issued. Separate WPQR not required
b. Repair/maintenance:
The WPS/WPQR shall be reviewed in relation to the
process contaminations for additional requirements in shop
and field repairs on process exposed components .

Monitoring
3. Other a. Copper and its alloys may only be cut mechanically or by
plasma arc cutting.
b. Immediately prior to welding the weld preparation and an
area 50 mm (2 in) on each side shall be abraded with a
stainless steel brush or stainless wire wool and degreased
with a non-toxic, non-inflammable solvent on both external
and internal surfaces.
c. All plasma spatter and other debris shall be removed from
4. Brazing a. Brazing of copper based alloys shall be qualified according
to ISO 13585 for brazer qualification or EN qualifications via
EN 13134 (procedure), ISO 13585 (brazer) EN 12799
(NDE) and EN 12797 (destructive testing). The reference
can also be made to ASME/BPVC Section IX.
b. The qualification is primarily valid for the workshop
performing the welding tests, and other workshops under
the same technical and quality management. It may also be
transferred to and used by a subcontractor, provided the
principles of ISO 3834-2 and ISO 14731 are implemented
and documented.
c. The WPQR/ documentation shall include the material
certificates for the base and filler materials applied in the
weld qualification test.

DEP 30.10.60.32-Gen.
February 2015
Page 54
10.14 TITANIUM
1. Typical Materials a. Ti-alloy grade 2 (R50400) is used specifically and referenced

to DEP 30.10.02.11-Gen.
b. ASTM B265 grade 2 (plate) ASTM B338 Gr2 (tube), ASTM B
861/862 grade 2 (pipe), ASTM B363 Gr.WPT2 (Fittings),
ASTM B381 Gr.F2 (Flanges)
c. Other grades via approval of the Principal
Processes
3. Approved Fill & Cap GTAW (141)
Processes
4. Consumable Same nominal composition as parent metal
Chemistry
5. Autogenous Not permitted
Welding
6. Secondary Maintained until metal temperature falls below 500°C (932°F)
Shielding and provided by: glove-box chamber, trailing shield, or
incorporated into the head of orbital welding equipment
production).
Survey positions 1 off. Photo-macrographs to be included with indicated
magnification not less than 1X and clearly showing all hardness
indentations.
3. Maximum Hardness a. Annealed condition is specified for base materials
(140 HV10 for plates).
b. ISO 15156-3 is indicating 100 HRB for sour service and
DEP 30.10.02.17-Gen. is indicating max 80°C for
application.
c. The maximum hardness for the weldment is base material
hardness + 50 HV10 or 200HV5, whichever is lower.
1. Thickness The thickness tested is the maximum thickness qualified.

coverage.
parameters.
Principal.
5. Root Gap Tolerance: -0 / +2 mm of the WPQR.

DEP 30.10.60.32-Gen.
February 2015
Page 55
6. Bevel Angle Total included angle shall not be changed by more than
+10°/-5° from WPQR.
Combination welding processes shall not be changed unless approved by the
Principal.
9. Electrode / Filler Electrode or filler wire size shall not be changed at any stage of
Rod Size welding.
11. Interpass may be 0°C (0°F) above WPQR maximum.
raised by
12. Interpass Limit 175°C (347°F) maximum.
13. Repair Welding Repair WPS to be issued. Separate WPQR not required unless
essential variables change.
1 Parameter Scheduled, minimum 1 test per process per shift

Monitoring
2. Material Required to separate from other alloys
Segregation
3. Other a. For titanium only machining or grinding is permitted for weld
preparation.
b. Immediately prior to welding the weld preparation and an
area 50 mm (2 in) on each side shall be abraded with a
stainless steel brush or stainless wire wool and degreased
with a non-toxic, non-inflammable solvent on both external
and internal surfaces.
c. Periodic checks for iron contamination shall be made by a
chemical method (e.g. ferroxyl) on surfaces to be welded.
Any inter-run tarnishing observed shall be removed by wire
brushing.
d. As-deposited weld beads and HAZs of titanium welds should
be inspected after each pass for the degree of oxidation.
Light and dark straw coloured oxides are permissible, but
dark blue, light blue, grey, and white deposits indicate
progressively unacceptable contamination that leads to
embrittlement. Removing these oxide deposits will not
improve the underlying damage to the material properties, so
welds exhibiting these undesirable oxide colours shall be
rejected. The cause of the contamination shall be rectified
before production continues.
10.15 DISSIMILAR WELDING

10.15.1 General
1. Dissimilar welding is not a recommended practice and should only be used as a last
engineering option. Approval of Principal shall be obtained before carrying out
dissimilar pressure retaining welds or other dissimilar welds critical to the integrity of
the equipment.

DEP 30.10.60.32-Gen.
February 2015
Page 56
2. A list/record of dissimilar welds shall be kept from the beginning of the project and
updated as the project progresses.
3. Suitability of a dissimilar weld design shall be decided after considering the service,
weldment and the weld design together. Their use shall be limited to applications
where other solutions are either deemed not practical or to involve excessive cost.
4. If welding materials with different hardenability, preheat and PWHT procedures shall
achieve sufficient tempering of the more hardenable material while preventing
excessive weakening or loss of toughness of the softer material.
a. Results of welding procedure qualification tests shall demonstrate
implementation of the above requirements.
b. Hardness tests and results meeting requirements of this DEP or NACE
RP0472 are mandatory for all dissimilar weld WPQRs.
10.15.2 Groups of dissimilar joints
1. There are two groups of dissimilar joints, equal physical properties joints and different
physical properties joints:
2. Group 1 – Equal physical properties joints
a. Joints between ferritic materials (carbon, Mo and Cr-Mo steels) – Dissimilar
joints between ferritic low-alloy and carbon steel shall be made by using filler
material with a chemical composition matching the lower-grade material.
b. Joints between austenitic materials (AISI 304, 321, 317, 347).
c. Joints between high-nickel alloys (Monel, Alloy 700, Hastelloys B and C, or
equivalents).
3. Group 2 – Different physical properties joints
a. Joints between ferritic and austenitic materials – This group of joints shall be
made by using a buffer filler material
The selection of weld metal largely depends on the service conditions, such
as temperature, thermal cycling, and possible galvanic corrosion.
10.15.3 Metal combinations of dissimilar joints
10.15.3.1 Welding carbon manganese or 0.5 Mo steels to Cr-Mo steels
1. The following shall be followed for PWHT of welds of carbon manganese or 0.5 Mo
steels to Cr-Mo steels:
a. An intermediate temperature shall be chosen between the PWHT temperature
ranges of the two materials, but lower than the tempering temperature of the
lowest grade.
b. The holding time specified for the higher grade shall be increased by 1.5
times. However, if the PWHT temperature so selected will not result in the
individual base materials and weld metal achieving the specified mechanical
properties, then a buffering technique shall be applied on the higher grade
side as shown in the sketch below:

DEP 30.10.60.32-Gen.
February 2015
Page 57
c. After buffering, PWHT shall be applied at the temperature suitable for the
buffered base material (2.25Cr-1Mo). After this PWHT, the joint shall be
completed and PWHT shall then be carried out at the temperature suitable for
the lower grade base material (C-Mn steel)
For dissimilar welds in steel operating in the creep range (e.g. 9Cr-1Mo or 9Cr-1Mo
modified to 2.25Cr-1Mo steels) carbon depletion in the low Cr base material or weld can
occur (carbon diffusion out of low chromium material into the neighbouring high
chromium steel) and will adversely affect the creep life.
10.15.3.2 Welding C steel to Ni or Cu alloys
1. The following consumables shall be used for welds of C steel to Ni or Cu alloys:
a. C-Mn steel shall be welded to Ni alloys with AWS A5.11 ENiCrFe-2, Alloy 182
or Alloy 82 consumables.
b. C steels shall be welded to Ni or Cu alloys with Monel 187/190 (ENiCu7).
c. C steels shall be welded to Ni-Cr-Fe alloys with AWS A5.11 ENiCrFe-2.
d. C steel shall be welded to aluminium bronze with special buffer-type
electrodes of Cu-8Al or Cu-10Al-1Fe.
10.15.3.3 Welding ferritic steel to austenitic steel
1. For hydrogen service, welds shall not be made between ferritic steel and austenitic
steel, unless approved by the Principal.
Welds between austenitic steel and ferritic steel are potentially sensitive to
cracking. The sensitive area is the local hard zone in the immediate vicinity of the
fusion line in the weld metal.
2. Welding of ferritic steel to austenitic steel in hydrogen service is restricted to a
maximum operating temperature of 350°C (660°F). This restriction does not apply for
short-term temperature excursions above 350°C (660°F) (e.g. hot hydrogen stripping)
because there is an incubation period necessary before hot hydrogen attack occurs.
The risk of cracking increases with temperature for reasons of thermal fatigue
(start-up/shut-down) particularly in the case of AISI 309 type of welds.
3. Limitations for sour and hot hydrogen service dissimilar welding shall be avoided for
application in wet H2S/sour service or other services where acid corrosion can occur or
in services over 450°C (842°F) in presence of hydrogen. If dissimilar welds have to be
used in such services the Principal’s Materials Specialist shall be consulted.
4. Care shall also be taken to avoid hot cracking in the weld metal. The weld preparation
shall be cleaned carefully and every weld bead deposited shall be ground smooth prior
to the next weld bead.
5. Chemical cleaning or pickling shall not be applied.
6. During weld procedure qualification, a micro-hardness survey on an etched sample
shall be done on the fusion line between the buffer layer and base material. The hard
zone on the interface may contain individual hard spots provided there is not a
continuous network (sequence) of hard spots.
7. Where PWHT is required for the ferritic material, in particular for wall thickness above
25 mm (1 in), the ferritic weld bevel shall be buttered with a buffer type consumable
followed by PWHT. After PWHT the buffer layer is then welded with matching to the
austenitic material – See sketch below:

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8. For wall thicknesses below 25 mm (1 in) a stainless steel pup piece/ring shall be
welded to the ferritic material with a buffer consumable followed by separate PWHT,
as buttering buffer layer onto "thin" materials is cumbersome. After PWHT the
stainless steel safe end is welded matching to the austenitic steel.
10.15.3.4 Welding austenitic stainless steel to Ni-Cr-Fe alloys
1. For high temperature applications, AWS A5.11 ENiCrFe-2 or Alloy 82 filler metal shall
be used.
2. For low temperature applications, Alloy 112/625 or AWS A5.11 ENiCrFe-2 filler metal
shall be used.
10.15.3.5 Welding other metal combinations
1. Welds for other metal combinations shall be designed with the input and approval of
Principal.
2. Design concepts used for the above combinations can be utilised on welds for other
metal combinations where applicable.
3. For design temperatures over 454°C (850°F), welds amongst different grades of
austenitic stainless steel shall be considered to be “other metal combinations”.
10.15.4 Nondestructive examination considerations
The weak link of dissimilar welds is the fusion boundary between a base metal and weld
made from the different material.
1. NDE coverage of dissimilar welds shall reflect their design and criticality. NDE
coverage shall be developed/assigned by the Project Material Specialist.
2. Dissimilar welds may require NDE coverage different from that required by the piping
class or standard project NDE schedules.
3. Dissimilar welds shall be designed to allow volumetric examination and shall be
examined by at least one such suitable method.
4. Critical dissimilar welds and pressure retaining welds not suitable for volumetric
examination and their NDE shall be approved by the Principal’s designated Technical
Authority.
10.15.5 Dissimilar weld register
1. All dissimilar welds shall be recorded in a dissimilar weld register prepared by the
Fabricator and included in the welding plan/map. As a minimum, the register shall
contain the following information:
a. Weld identifier;
b. Relevant drawing identifier (P&ID/MEFD/isometric or equipment fabrication
drawings);
c. P numbers of the alloys to be welded and brief description of the weld;
d. Criticality rating of the weld (as per Project criticality-rating procedures -
pressure-retaining welds should be considered critical);
e. Applicable welding procedure identifier (includes the name of the organisation,
which welded such weld.);

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f. Identification of the officer/function who decided approved the location of the

dissimilar weld;
g. Identification of the officer/function that ultimately approved the dissimilar weld
register.
2. The Contractor shall collate each Fabricator’s dissimilar weld register and keep it
current, available for Principal review and audit. The Contractor shall certify such
registers prior to final approvals by the Principal.
10.15.6 Final approvals
1. Use and design of pressure retaining and all other dissimilar welds listed on the
dissimilar weld register and critical to integrity of the equipment shall be reviewed and
accepted by the Principal’s designated technical authority (TA2).

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11. REFERENCES
In this DEP, reference is made to the following publications:
NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards/.
SHELL STANDARDS
DEP feedback form DEP 00.00.05.80-Gen.
Metallic materials – Selected standards DEP 30.10.02.11-Gen.
Materials for use in H2S-containing environments in oil and gas DEP 30.10.02.15-Gen.
production (amendments and supplements to ISO 15156:2009)
Wet H2S requirements for downstream pressure vessels and piping DEP 30.10.02.17-Gen.
Metallic materials – Prevention of brittle fracture in new assets DEP 30.10.02.31-Gen.
Materials and fabrication requirements for 2¼Cr-1Mo, 2¼Cr-1Mo- DEP 30.10.02.32-Gen.
¼V, 3Cr-1Mo & 3Cr-1Mo-¼V heavy wall pressure vessels
Welding of metals (amendments/supplements to API RP 582) DEP 30.10.60.18-Gen.
Oxidation of stainless steel weldments DEP 30.10.60.31-Gen.
Unfired pressure vessels DEP 31.22.00.31-Gen.
Shop and field fabrication of piping DEP 31.38.01.31-Gen.
Project quality assurance DEP 82.00.10.10-Gen.
Shell HSSE & SP Control Framework, Design Engineering Manual DEM1
(DEM) 1 – Application of Technical Standards
http://sww.manuals.shell.com/HSSE/
AMERICAN STANDARDS
Safety in Welding, Cutting and Allied Processes ANSI Z49.1
Qualification Standard for Welding and Brazing Procedures, ASME/BPVC Sec IX
Welders, Brazers, and Welding and Brazing Operators Welding
and Brazing Qualifications
Petroleum and Natural Gas Industries — Materials for Use in H2S- NACE MR0175
Containing Environments in Oil and Gas Production
Standard Recommended Practice – Methods and Controls to NACE RP0472
Prevent In-Service Environmental Cracking of Carbon Steel
Weldments in Corrosive Petroleum Refining Environments
EUROPEAN STANDARDS
Non-destructive testing – Qualification and certification of NDE EN 473
personnel – General principles
Metallic products – Types of inspection documents EN 10204
Brazing – Destructive tests of brazed joints EN 12797
Brazing – Non-destructive examination of brazed joints EN 12799
Brazing – Procedure approval EN 13134
Unfired pressure vessels EN 13445

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INTERNATIONAL STANDARDS
European pressure equipment directive (PED) 97/23 Directive 97/23
Arc welding equipment IEC 60974-x
Expression of the properties of sampling oscilloscopes IEC 60548-2
Metallic materials – Charpy pendulum impact test – Part 1: Test ISO 148
method
Welding consumables – Rods, wires and deposits for tungsten inert ISO 636
gas welding of non-alloy and fine-grain steels – Classification
Welding consumables – Covered electrodes for manual metal arc ISO 2560
welding of non-alloy and fine grain steels – Classification
Welding and allied processes – Determination of hydrogen content ISO 3690
in ferritic steel arc weld metal
Quality requirements for fusion welding of metallic materials ISO 3834-x
Information Processing – Magnetic tape cassette and cartridge ISO 4341
labelling and file structure for information interchange first edition
Gas welding equipment – Blowpipes for gas welding, heating and ISO 5172
cutting
Welding. fusion-welded joints in steel, nickel, titanium and their ISO 5817
alloys (beam welding excluded) – Quality levels for imperfections
Metallic materials – Vickers hardness test ISO 6507
Welding and allied processes – Classification of geometric ISO 6520-1
imperfections in metallic materials – Part 1: Fusion welding
Welding – Determination of Ferrite Number (FN) in austenitic and ISO 8249
duplex ferritic-austenitic Cr-Ni stainless steel weld metals
Quality management systems – Fundamentals and vocabulary ISO 9000
Quality management systems — Requirements ISO 9001
Steels – Manual point counting method for statistically ISO 9042
estimating the volume fraction of a constituent with a point grid
Approval testing of welders – Fusion welding ISO 9606-x
Non-Destructive Testing – Qualification and Certification of ISO 9712
Personnel
Steel and steel products – Inspection documents ISO 10474
Protective clothing for use in welding and allied processes ISO 11611
Brazing – Qualification test of brazers and brazing operators ISO 13585
Gas welding equipment – Acetylene manifold systems for welding, ISO 14114
cutting and allied processes – General requirements
Welding consumables – Solid wire electrodes, tubular cored ISO 14171
electrodes and electrode/flux combinations for submerged arc
welding of non-alloy and fine grain steels – Classification
Welding consumables – Covered electrodes for manual metal arc ISO 14172
welding of nickel and nickel alloys – Classification
Welding consumables — Wire electrodes and weld deposits for gas ISO 14341
shielded metal arc welding of non-alloy and fine grain steels —
Classification

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Welding coordination – Tasks and responsibilities ISO 14731

Materials for use in H2S-containing environments in oil and gas ISO 15156
production – Parts 1, 2 and 3
Specification and qualification of welding procedures for metallic ISO 15609
materials
Specification and qualification of welding procedures for metallic ISO 15614-x
materials – Welding procedure test
Petroleum, petrochemical and natural gas industries – Shell-and- ISO 16812
tube heat exchangers
General criteria for the operation of various types of bodies ISO 17020
performing inspection
General requirements for the competence of testing and calibrating ISO 17025
laboratories
Welding consumables – Tubular cored electrodes and rods for gas ISO 17633
shielded and non-gas shielded metal arc welding of stainless and
heat-resisting steels – Classification
Non-destructive testing of welds – Visual testing of fusion-welded ISO 17637

joints
Welding – Quality requirements for heat treatment in connection ISO 17663
with welding and allied processes
Welding consumables – Solid wire electrodes, solid strip ISO 18274
electrodes, solid wires and solid rods for fusion welding of nickel
and nickel alloys – Classification
Welding – Guidelines for a metallic material grouping system ISO/TR 15608
Recommendations for welding of metallic materials ISO/TR 17671-x
Specification for Unfired fusion welded pressure vessels PD 5500

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Location Alternative Specimens
1 n/a 12 o’c macro hardness (if required for 5G/6G)
2 2’ 1 Tensile and 2 bend tests
3 3’ Charpy Impacts and 3 or 9 o’c macro hardness (if

required for 5G/6G)
4 4’ 1 Tensile and 2 bend tests
5 n/a 6 o’c macro hardness
1-2 2’-1 Corrosion test specimen A (Duplex and 6%Mo)
4-5 5-4’ Corrosion test specimen B (Duplex and 6%Mo)
NOTES: 1. Locations are based on EN ISO 15614-#

2. Specimen location priority : 1st Macros, 2nd Impacts, 3rd Tensiles, 4th Corrosion Coupons, 5th
Bends.
3. Additional latitude is permitted for joints that are not in fixed 5G or 6G positions but care should be
taken to ensure that two tensile specimens or two pairs of bend specimens are not adjacent to
each other
Figure 5 Position of test specimens

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APPENDIX A REPORTING REQUIREMENTS FOR WELDING QUALIFICATION
A.1 WELDING PROCEDURE DOCUMENTATION

A.1.1 General
1. The following documentation shall be presented for approval for each welding
procedure qualified:
a. Weld Procedure Specification (final version);
b. Weld Procedure Qualification Record;
c. parent material certification;
d. consumable batch certification;
e. NDE reports on test weld (including visual examination);
f. post-weld heat treatment record charts (if applicable);
g. mechanical test reports:
h. Corrosion testing if applicable.
A.1.2 Welding Procedure Specifications
1. Welding Procedure Specifications (WPSs) shall be in a clean and clear format and
shall include the following information, in addition to the recommendations of
ISO 15609 annex A:
a. a unique procedure number including revision number;
b. the parent material(s) range to weld;
c. the thickness and diameter range to weld;
d. the weld preparation or preparations (including sketch with dimensions and
tolerances, backing if applicable)
e. method of clamping or tack welding, including weld parameters;
f. minimum preheat level and method (also condensation mitigation);
g. the maximum interpass temperature allowed;
h. travel speed for each pass or group of passes
i. bead width or run out length (for SMAW) range for each pass or group of
passes
j. The arc energy in kJ/mm is required to be reported. (NB. If factored to take
account of process thermal efficiency, i.e. a true heat input figure, this must be
clearly indicated)
k. electrode stick-out for SAW, GMAW and FCAW;
l. gas shroud diameter for GMAW, FCAW (gas shielded) and GTAW;
m. Automated welding parameters, such as oscillation, amplitude, frequency,
dwell time and pulse characteristics.
n. Any treatment for preparing and welding the second side (gouging, grinding,
machining).
o. Signatures by the Fabricator, third party authority and or principal depending
on document control requirement of the project or activity.

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A.1.3 Weld procedure qualification records

1. Weld procedure qualification records (WPQRs) shall include the following information,
in addition to the recommendations of ISO 15614 Annex A:
a. weld procedure qualification number, including revision control.
2. WPQRs shall be endorsed by the third party inspector(s) or NOBO, depending on the
application as a true record of the weld.
A.1.4 Record of weld test
1. The record of weld test shall include the following information, in addition to the
recommendations of ISO 15614 Annex A:
a. weld procedure number (including revision) and test weld/coupon number;
b. date and time of test;
c. parent material(s) certification details (heat, cast, certificate);
d. welding consumable, batch numbers;
e. welders’ identification number(s);
f. drawing(s) showing actual weld preparation dimensions and weld sequence;
g. method of alignment/tacking;
h. method of preheating;
i. reference to PWHT procedures and record charts if applicable;
j. welding machine(s), type, make and setup. This is significant for the more
automated/sophisticated welding sets.
k. range of bead widths (reference for weld monitoring during production phase).
l. electrode stick-out length (FCAW, GMAW, MCAW, or SAW).
2. In addition, the following information shall be recorded for each, individual weld run:
a. average run out length of electrodes and remaining stub length (for SMAW);
b. welding speed;
c. calculated arc energy;
d. interpass temperature immediately prior to commencement of run;
3. The record of weld test shall be endorsed by the Fabricator and by the third party
inspector(s) or NOBO, depending on the application as a true record of the weld.

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APPENDIX B RECOMMENDED PRACTICE FOR DETERMINING VOLUME FRACTION OF

FERRITE IN DUPLEX STAINLESS STEEL WELDMENTS BY SYSTEMATIC
POINT COUNTS
B.1 SCOPE
This appendix describes a recommended practice for estimating the volume fraction of
delta ferrite in duplex stainless steel by systematic point counts on transverse
metallographic sections.
B.2 BASIS OF PRACTICE

The practice involves the superimposition of a test grid over an image, produced by an
optical light microscope, of the appropriate microstructural area. The number of grid
points falling within delta ferrite are counted and divided by the total number of grid
points, to yield a point fraction which represents an estimate of the volume fraction of
delta ferrite present within the field of view. The average point fraction taken over a
number of appropriately selected fields gives an estimate of the volume fraction within
the region sampled.
B.3 TERMINOLOGY
Point count Number of grid points which lie within areas of a specific phase (in
this case delta ferrite).
Point fraction (Pp) Point count divided by the total number of points in the test grid.
Volume fraction (Vv) Volume of a specific phase per unit volume, expressed as a fraction.
B.4 SPECIMEN PREPARATION

B.4.1 General
1. Planar sections shall be taken through the parent material or the weldment, transverse
to the welding direction and perpendicular to the material surface.
2. Each specimen shall section the whole of the weldment and HAZ and an area of
parent material on either side of the weld.
3. Preparation of these specimens shall be in accordance with specification
metallographic techniques, such as described in Reference 1.
4. It is recommended that the last grinding stage should be with 600 grit, or finer,
abrasive and the final polish should be with 1 μm (0.04 mil), or finer, abrasive (e.g.,
diamond paste).
B.4.2 Etching
1. Specimens shall be etched electrolytically in 40% KOH solution (i.e. 400g KOH in
1000 ml of solution made with distilled water).
2. Etching shall be carried out in a container of sufficient size to allow immersion of the
specimen in the etch at a distance of ≤ 100 mm (4 in) from the platinum cathode.
3. Electrical contact between the specimen and power source may be made by means of
a suitably shaped conducting probe.
4. Acceptable contrast can generally be obtained at an anode/cathode voltage of 7-8V for
2-5 seconds, but trials may be necessary to determine the most appropriate conditions
for a particular specimen.
The contrast between the delta ferrite and austenite phases will probably vary
through the weldment.

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B.5 AREA SELECTION

1. Measurements shall be made 1mm below root and cap surfaces (excluding weld
reinforcement) in weld, HAZ, and parent metal.
2. The weld pass shall be stated (e.g. root, cap, fill - preferably with a number) as shall
the area which has been measured (i.e. weld metal, HAZ or parent material).
3. Where possible it should be indicated whether the area has been re-heated or is as-
deposited. Any uncertainty shall be noted.
4. The location of volume measurements shall be recorded on a sketch or photograph of
the section.
B.6 APPARATUS
B.6.1 Microscope
1. An optical light microscope that projects an image of the magnified micro-structure
onto a viewing screen shall be used. Preferably the microscope should have
graduated x and y translation controls.
2. The magnification shall be selected such that the ferrite particles have an average
dimension approximately one half of the grid point spacing. This should be judged
visually in more than one field of view, before measurements are made. For many
weldment microstructures, particularly in re-heated areas, a magnification in the range
x500 - x1000 is suitable, and is preferred.
B.6.2 Test grid
1. A test grid shall be marked on a transparent sheet that shall be superimposed on the
magnified image of the microstructure.
2. The grid shall consist of a square array of equally spaced points, produced by the
intersection of fine parallel lines (maximum width 0.3 mm (12 mils)), and shall have 16
or 25 points.
3. It is recommended that the spacing of the points should be 10 mm (3/8 in) along both
directions parallel to the edges of the grid, e.g. as in Figure B.1. At a magnification of
1000x this corresponds to a point spacing on the actual microstructure of 10 μm
(0.4 mils).
Figure B.1 Two grid types suitable for systematic manual point counting of delta ferrite in
duplex stainless steel

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B.7 PROCEDURE
B.7.1 Counting of points
1. Superimpose the test grid on the magnified image of the microstructure in the chosen
area of the parent material or weldment.
2. Count the number of points that lie within the delta ferrite phase; any points that cannot
be assigned positively to either phase shall be counted as one half.
Delta ferrite is the phase that is stained dark by the etch, although its colour may
vary significantly throughout the weldment. The austenite phase remains light
coloured in all areas after etching.
3. Move the specimen by a small amount in x and/or y so that another field is chosen.
4. Perform a second point count in the new field, provided that this field of view still falls
within the specified region of the parent material or weldment. If the field of view falls
outside the area of interest, move the specimen back, without rotating, to an
appropriate position within the specified area.
5. Where possible, move the specimen without looking at the micro-structure in order to
avoid bias in the choice of fields. It is recommended that the use of overlapping fields
be avoided.
6. Continue this process until a minimum of 400 points have been counted.
B.7.2 Heat affected zone considerations
1. When measurements are being made within the coarse grained HAZ, the operator
shall first assess whether the test grid can be superimposed over an area that is
entirely within the coarse grained HAZ.
a. The above can be done simply by attempting to fit the grid within a single
coarse grain. If the grid size is less than the grain size, then the procedure in
B.7.1 shall be used.
b. If the whole grid is too large, a smaller area of the grid shall be used, by
ignoring one or more whole rows of grid points.
c. The area chosen may be either square or rectangular. If a rectangular grid is
used, the specimen shall be rotated so that the long axis of the rectangle is
kept parallel to the fusion boundary.
2. Measurements in the coarse grained HAZ shall be made within approximately two
grain diameters of the fusion line.
B.7.3 Estimating volume fraction of ferrite
1. The volume fraction of delta ferrite shall be estimated by taking an average of the point
fractions counted in each of the n fields as follows:
where i is the field number.

2. The 95% confidence interval (CI) shall be calculated as follows:
where
3. The accuracy of the estimate shall comply with the allowable errors specified in
Table B.1.

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Table B.1 Allowable error in ferritic/austenite estimate
Volume % Error
45-50 ± 10%
40-45 ± 11%
35-40 ± 12%
0-35 ± 14%
B.8 REPORTING
1. The following shall be included in the ferrite determination report.
a. The number of sections taken from the weld.
b. The locations of sections taken along the weld.
c. The polishing procedure and etching conditions.
d. The magnification used.
e. The number of points and shape of the grid.
f. Whether the fields were chosen randomly or at regular intervals. If regular
intervals were employed, report the spacings used.
g. The location of the areas in which measurements were made, preferably on
sketch or photograph and in words, specifying parent metal or the weld pass,
the region of the weld pass (i.e. weld metal or HAZ) and, where practical,
whether the area was re-heated or not. Any uncertainty should be indicated.
h. A list of the point fractions of delta ferrite in each field.
i. An estimate of the volume fraction of delta ferrite, calculated as the average of
the point fractions.
j. The calculated value of the 95% CI.
k. Stage of manufacture, i.e. procedure qualification, production test, etc.
l. Location of sample and cast number.
m. Statement of conformance with specified ferrite content.
n. Signature of operator responsible for ferrite determination.
B.9 ACCEPTANCE CRITERIA

1. In the event that the ferrite determinations do not conform with the specified
requirement, then the product represented by the sample shall be rejected at the
discretion of the Principal.
B.10 SAFETY
This recommended practice involves materials, equipment and procedures that may
represent a health hazard. This document does not attempt to address the safety issues
associated with the described practice. It is the responsibility of the testing
establishment to ensure that the appropriate health and safety precautions are taken.
B.11 REFERENCES
1. ASTM E3-80 (Reapproved 1986) ‘Methods of Preparation of Metallographic
Specimens’.
2. Gladman T and Woodhead JH: ‘The Accuracy of Point Counting in Metallographic
Investigations’, JISI 1960, 194, 189-193.

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APPENDIX C INSPECTION AND TEST PLAN EXAMPLE
C.1 GENERAL
1. The ITP should begin with a list of applicable Shell DEPs, National and International
Standards/Specifications, and Fabricator procedures/method statements, plus any
relevant subcontractor procedures/method statements if their activities are included
instead of appearing on a separate ITP.
C.2 DEFINITIONS
1. The following definitions shall apply as specified in DEP 82.00.10.10-Gen:
a. Hold Point (H): A critical step in fabrication and testing where it is mandatory
that the Principal inspect the component/equipment or witness an activity.
i. Activities designated as a Hold Point shall not proceed unless the
Principal/Representative is present or the Hold Point is formally waived.
ii. The Principal shall be notified at a duration specified in the contract in
advance of the activity.
b. Witness Point (W): A critical step in fabrication and testing where it is desirable
that the Principal/Representative inspect the component/equipment or witness
an activity.
i. The Principal shall be notified at a duration specified in the contract in
advance of the activity.
ii. Once proper notification is given, the activity may proceed according to
the schedule regardless of the Principal’s attendance.
c. Monitor Point (M): A critical step in fabrication and testing where it is optional
that the Principal inspect the component/equipment or witness an activity.
advance of the first occurrence of the activity at each worksite. No
further notification for like activities at each worksite shall be required.
ii. The activity may proceed with or without the Principal’s attendance.
d. Approval Point (A): A critical step in design, procurement, and or fabrication
and testing where it is mandatory that the Principal approve a
document/qualification/equipment/or activity.
advance of the first occurrence of the activity or provided the document
in a period of time specified by the contract.
ii. The activity may not proceed without the Principal’s approval.
e. Review Point (R): A critical step in design, procurement, and or fabrication and
testing where it is desirable that the Principal review the
document/qualification/equipment/or activity.
advance of the first occurrence of the activity or provided the document
in a period of time specified by the contract.
ii. The activity may proceed with or without the Principal comments or
review.
2. The above definitions are specific to the Principal column. For use in other columns,
replace the word Principal with the named party.
3. The ‘Inspect/Test’ intervention may be used to describe any other activities such as
raising documentation, performing the work (e.g. welding), and should be the
Fabricator column default when none of the other interventions are applicable.

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4. The ‘Monitor’, ‘Witness’, and ‘Hold’ interventions are carried out at the Fabricator’s (or
their subcontractor’s) site.
5. The ‘Document Review’ intervention may be carried out at site or will be requested to
be sent to the project document control centre (DCC)
6. The ‘Document Approval’ intervention requires formal submission of the document
through the agreed project DCC.
7. The items enclosed in <> symbols in the ‘Controlling Procedure/Method Statement’
column are intended to be substituted by the Fabricator’s controlling document number
/ reference.

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C.3 EXAMPLE TEMPLATE
1. Depending on the type of fabrication, some items may need to be added to/deleted from this example template.
Company Name Inspection & Test Plan Contract / PO
Project Name Activity Pipework Fabrication Principal
ITP No. Location
Seq. Description / Activity Controlling Procedure / Specification / Verifying Document Intervention : Inspect/Test, Monitor, Remarks /
No Indicate [TA] where activity which Method Statement Acceptance Criteria Witness, Hold Point, Document Review, Audit Check
requires approval of Principal’s Document Approval
designated Technical Authority rd
Fabricator Contractor 3 Party / Principal
IVB (Shell)
1 GENERAL
1.1 Assign qualified welding engineer and <Company Quality Plan> DEP 30.10.60.32- CV, qualification HA A R A
welding coordinator [TA] Gen., ISO 3834-2, certificates
ISO 14731
1.2 Ensure that all required fabrication <Company Quality DEP 30.10.60.32- Procedures / Method RA A R A
procedures are in place. [TA] Manual / Operating Gen., ISO 3834-2, Statements
Procedures> ISO 14731
1.3 Procure piping materials <purchasing procedure> Compliance with Purchase order and IM R R
requisitions and MESCs / datasheets
standards
1.4 Procure consumables <purchasing procedure Approved WPS Purchase order and IM R R
and/or consumable consumables, DEP datasheets
handling procedure> 30.10.60.32-Gen.
1.5 Receive materials; inspect store and <material handling DEP ..., MESCs ... , Material receiving IM R R
issue procedure> ... , National and ISO report, material test
Standards & certificates,
Specifications material issue
voucher
1.6 Receive consumables; inspect store and <consumable handling Manufacturer’s Consumable IM R R
issue procedure> datasheets, DEP certificates,
30.10.60.32-Gen. consumable issue log
1.7 Carry out PMI as required on materials <PMI procedure> DEP 31.10.00.10- PMI Report IM R R
and consumables Gen. and material
chemistry
specification
1.8 Quarantine any non-conforming <quarantine and/or ISO 9000, ISO 3824- Non-conformance H R R R
material/consumables material handling 2 report (NCR)
procedure>

DEP 30.10.60.32-Gen.
February 2015
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ITP No. Location
IVB (Shell)
1.9 Ensure all welding and inspection <calibration procedure / DEP 30.10.60.32- Equipment log, IH R R
equipment is suitably calibrated prior to method statement> Gen. calibration
use certificates,
verification reports
1.10 Develop WPS proposals for any new <welding control method DEP 30.10.60.32- Proposal WPS, WPS IA A R A
WPQRs required statements> Gen., ISO 15614 Register
1.11 Run WPQRs, if required, test and <WPS Proposals> DEP 30.10.60.32- WPQR IAH H H H
document. Gen., ISO 15614
1.12 Identify requirement for and carry out any <welding method DEP 30.10.60.32- WQT certificate IAH W H W
new welder qualifications statements, applicable Gen., ISO 9606
WPS>
1.13 Prior to any welding commencing, <welding control method DEP 30.10.60.32- Approved welding RA A A A
ensure all relevant welding procedures statements> Gen., ISO 15614, specifications (WPS)
and site welding instruction sheets ISO 9606 with supporting
(SWIS) approved, and that welders are WPQRs, SWIS cards
suitably qualified [TA] and approved welder
qualifications (WQT),
WPS Register, WQT
Register
1.14 Ensure that all relevant NDE procedures <welding control method DEP 30.10.60.32- Approved NDE RA A R A
are approved, and that NDE technicians statements> Gen., Design Code, procedures, Register
are suitably qualified ISO 9712, ISO 17637 of approved operators
qualifications
2 PIPEWORK FABRICATION
2.1 Prior to cutting, all pieces to be marked <material handling Positive identification Material control sheet IM M M
with their unique identification no. procedure, welding to material test
control method certificates
statements >
2.2 For workshops : Cut material, lay out and <cutting method Compliance with Log book, reports IM M M
fit up items in accordance with approved statements / procedures> drawings and
dimensional control procedures fabrication tolerances,
DEP 31.38.01.31-
Gen.

DEP 30.10.60.32-Gen.
February 2015
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ITP No. Location
IVB (Shell)
2.3 For site welds : Erect spools - connect to <fabrication procedures, DEP 31.38.01.31- IM M M M
equipment, site run etc. method statements> Gen.
2.4 Carry out visual examination of surfaces <visual inspection DEP 30.10.60.32- Inspector logbook IH W M
to be welded procedure> Gen., WPS / SWIS
2.5 Weld items in accordance with approved <WPS / SWIS, welding DEP 30.10.60.32- Inspector logbook, IM M M
WPS / SWIS / Method statement and control method Gen., WPS / SWIS surveillance
carry out stage inspection as required statements> checklists / reports
2.6 Carry out welding parameter checks <parameter monitoring DEP 30.10.60.32- Inspector logbook, IM M M
and/or welding inspection Gen., WPS / SWIS monitoring reports
procedures>
2.7 Carry out visual inspection <visual inspection DEP 30.10.60.32- Visual reports and/or IH W M
procedure> Gen., Pipework Code weld history
2.8 Carry out PWHT where applicable (after <PWHT procedures> DEP 30.10.60.32- PWHT reports and IH W M
pre-PWHT NDE if specified) Gen., Pipework Code charts, weld history
2.9 Carry out Final NDE of welded joint <NDE procedures> DEP 30.10.60.32- NDE reports and weld IA MA MR R
Gen., Pipework Code history
2.10 In the event of a defective weld, <repair method DEP 30.10.60.32- Weld repair AH R, A(H) R R(A) () elevation
reference should firstly be taken with the statements, repair WPS> Gen. instruction, weld required if
Welding Engineer, prior to instigating the history, NDE report defect is a
repair procedure, and repeat steps 2.4- crack
2.9
2.11 Carry out PMI as required <PMI procedure> DEP 31.10.00.10- PMI Report IMA MA MR
Gen. and material /
consumable
chemistry
specifications
2.12 Carry out dimensional survey as required <dimensional control Compliance with Field log book and/or IMA MA MR
procedure> drawing and DEP dimensional survey
31.38.01.31-Gen. reports
2.13 Carry out inspection release of <inspection release Compliance with Release for painting HA MA MR
completed welds prior to release to procedure> procedures / method certificate
painters statements

DEP 30.10.60.32-Gen.
February 2015
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ITP No. Location
IVB (Shell)
3 SURFACE PAINTING / COATING
3.1 Carry out in accordance with separate See separate ITP No. ... DEP 30.48.00.31- Coating inspection A A R A
coating ITP Gen. (organic records
(NB. Discrete components subject to coatings)
individual pressure test should not be DEP 30.48.40.31-
coated until after pressure testing.) Gen. (TSA -thermally
sprayed aluminium)
4 FLUSHING AND PRESSURE TESTING
4.1 Raise test pack - obtain QC approval <fabrication and pressure DEP 74.00.10.10- Endorsement of test IA A R
testing procedures and Gen., pack
method statements> DEP 31.38.01.11-
Gen,
DEP 30.10.60.32-
Gen.,
Compliance with
procedure
4.2 Prepare system for test <fabrication and pressure DEP 74.00.10.10- Endorsement of test IM M M
testing procedures and Gen., pack
method statements> Compliance with
procedure
4.3 Flush system (where required) <flushing and/or pressure DEP 74.00.10.10- Flushing certificate IM M M
testing procedure / Gen.,
method statements> Compliance with
procedure
4.4 Carry out pressure test < pressure testing DEP 74.00.10.10- Pressure test IHA HA HA W
procedure> Gen., certificate & charts.
Compliance with Test Test pack records.
Procedure

DEP 30.10.60.32-Gen.
February 2015
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ITP No. Location
IVB (Shell)
5 REINSTATEMENTS
5.1 Drain system, remove test material <flushing and/or pressure DEP 74.00.10.10- Reinstatement IH W M
reinstate any items removed prior to test testing procedure / Gen., certificate
method statements> DEP 70.10.70.11-
Gen., Compliance
with drawings
5.2 Carry out post-test installation checks <fabrication and pressure DEP 31.38.01.11- Post-test check list IA A R
testing procedures and Gen., Compliance
method statements> with drawings
5.3 Carry out inspection of completed line <fabrication and pressure DEP 31.38.01.11- Inspection report IHA WA MR
and release for remedial coating / trace testing procedures and Gen., Compliance
heating insulation method statements> with procedure and
drawings
6 FABRICATION AND TEST
CERTIFICATION
6.1 Progressive compilation of all the <weld history method DEP 82.00.10.10- Approved certification IMR(A) MR(A) MR(A) A Ongoing MR
fabrication certification dossiers for the statement / procedure> Gen., Accurate and records, prior to MRB
project. Dossiers to be available for complete certification Manufacturers record handover for
review by all parties. [TA] dossiers book (MRB) A
7 PACKING & PRESERVATION
7.1 (For equipment packages only – not <preservation and DEP 70.10.70.11- Release note, IHA HA HA W
relevant to this example) packing shipment Gen. despatch
procedures> documentation.
NO FURTHER ITEMS
Inspection and Testing Activities Completed and Inspection Release Note Released
rd
Signed on Behalf Of Fabricator Contractor 3 Party Shell Principal
Signature
Print Name
Date


Dep 30.10.60.32 - Welding of Metals, Based On Iso Standards

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DEP SPECIFICATION

WELDING OF METALS, BASED ON ISO STANDARDS

DESIGN AND ENGINEERING PRACTICE

© 2015 Shell Group of companies

This document has been supplied under license by Shell to:

This document has been supplied under license by Shell to:

This document has been supplied under license by Shell to:

10.7 3.5% NICKEL STEELS ............................................................................................. 41

This document has been supplied under license by Shell to:

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

This document has been supplied under license by Shell to:

The word should indicates a recommendation.

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1.5 SUMMARY OF MAIN CHANGES

1.6 COMMENTS ON THIS DEP

Shell DEPs Online Enter the Shell DEPs Online system at

DEP Feedback System Enter comments directly in the DEP Feedback

DEP Standard Form Use DEP Standard Form 00.00.05.80-Gen. to record

1.7 DUAL UNITS

1.8 NON-NORMATIVE TEXT (COMMENTARY)

1.9 PRECEDENCE OF DOCUMENTS

This document has been supplied under license by Shell to:

c. Third level - cross-referenced documents

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2.2 PERSONNEL COMPETENCES

This document has been supplied under license by Shell to:

Table 1 Competence levels for welding inspection personnel

Competence Country/ Applicable Inspector Position Designation

2.3 INSPECTION AND TEST PLAN

2.5 FINAL ACCEPTANCE

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3.1 WELDING PROCESSES

Process Name ASME EN/ISO

This document has been supplied under license by Shell to:

3. Materials certification shall demonstrate the following:

This document has been supplied under license by Shell to:

3.2.4 Consumable handling/storage

This document has been supplied under license by Shell to:

4. WELDING PROCEDURE PREPARATION AND QUALIFICATION

4.2 PREVIOUSLY QUALIFIED PROCEDURES

4.3 PROCEDURE DOCUMENTATION

4.4 ESSENTIAL VARIABLES

This document has been supplied under license by Shell to:

4. Weaving, shall be limited to the following ranges:

SMAW process Three times the electrode diameter

GTAW process Maximum equal to used cup diameter or 12 mm (1/2 in),

GMAW/FCAW Maximum equal to used cup diameter or 15 mm (5/8 in),

4.5 WELDING PROCEDURE QUALIFICATION TESTING

Butt Welds Visual

This document has been supplied under license by Shell to:

This document has been supplied under license by Shell to:

This document has been supplied under license by Shell to:

Table 2 Range of qualification for steel groups and sub-groups

Material (sub-) group of test pieces Range of qualification

Material group of test pieces Range of qualification

4.5.4 Tube-to-tubesheet welding

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4. The allowable expansion at tube-to-tubesheet joints shall be agreed between the

This document has been supplied under license by Shell to:

5.2 WELDER IDENTIFICATION

5.3 WELDER PRE-QUALIFICATION

5.4 QUALIFICATION DOCUMENTATION

5.5 TIME LIMITATIONS