GFG-002 e No. IRPC Technical Data $10332100-3002 ZN uSen loons via (unrou) Welding Standard a IRPC Bic Company Une TABLE OF CONTENTS SECTION 10. " 12, 13, 14. 15, SCOPE APPLICABLE CODES, STANDARDS AND REFERENCE SPECIFICATION WELDING PROCESSES GENERAL REQUIREMENTS WELDING PROCEDURE AND WELDING PERFORMANCE QUALIFICATION FILLER METAL REQUIREMENTS WELD JOINT PREPARATION AND CLEANING REQUIREMENT PREHEATING TACK WELDING WELDING POST WELD HEAT TREATMENT (PWHT) HARDNESS TESTING REPAIR WELDER AND WELDING OPERATOR QUALIFICATION QUALITY CONTROL OF WELDING WORK PAGEGFG-002 e No. IRPCO Technical Data $10332100-3002 ZN \uBdn loo sid Syria (urnsu) Welding Standard ete: Page IRPe ste Company Lined 2 1. Scope ‘This specification covers the minimum requirements for shop and site welding of ferrous and non ferrous materials, equipment, piping and supplements. The discrepancy caused by this specification to any project specification will be settled subject to the clarification made by IRPC. 2. Applicable codes, Standards and reference specifications Welding shall at least conform to, but not limited to, the requirements of the following codes, standards and specifications, 2.1 American Society of Mechanical Engineers boiler and pressure vessel code (ASME) Description Power boilers Material specification. Part A, B,C and D Nondestructive Examination Pressure Vessel, Division 4 and Division 2 Welding and Brazing Qualification 2.2 (ASME / ANS!) Standards Standards | Description B3tt Power Piping B313 Chemical Plant & Petroleum Refinery Piping 2.49.1 ANSI__| Safety in Welding and Cutting 2.3 American Petroleum Institute (API) ‘Standard Description 610 Centrifugal pump for general refinery services 61 General purpose steam turbines for refinery services 612 ‘Special purpose steam turbines for refinery services 613 ‘Special purpose gear unit for refinery services 614 Lubrication, Shaft-Stealing and Control-Oil system for special purpose 616 ‘Type H Industrial combustion gas turbines for refinery 617 Centrifugal compressors for general refinery services 618 Reciprocating compressor for general refinery services 620 Design and construction of large, Welded, low-pressure storage tanks 650 Welded steel tanks for oil storage 661 Air-cooled heat exchangers for general refinery services 674 Positive displacement pumps-Reciprocating 675 Positive displacement pumps-Controlled volume 676 Positive displacement pumps-rotary 24 American Welding Society (AWS) Standard Description ‘Aza ‘Symbols for Welding A30 Welding Terms and Definition Code Dit Structural Welding Code. Stee! 2.8 Tubular Exchanger Manufacturers Association (TEMA) 26 Local Laws, Regulations and Codes 2.7 The applicable project specificationsGFG-002 e No. IRPC Technical Data rea SG oorsi8 fia (urs) Welding Standard Date Page Ree bt Canpay Land 3 6 Where reference is made to a code, specification or standard, the reference shall refer to the latest edition of that code, Specification or standard, including their addendum, supplements and revisions. Where there are any conflicts in code, standard or specification, the most stingent requirement shall be 3. Welding processes ‘The acceptable welding processes are - SMAW (Shielded Metal Arc Welding) - SAW (Submerged Arc Welding) - GTAW (Gas Tungsten Arc Welding} ~ GMAW (Gas Metal Arc Welding) - FCAW (Flux Cored Arc Welding) ‘Other welding processes may be used only upon approval by IRPC. FCAW shall not be used for a pressure retaining part 4, General requirements 4.1. Welding terms and definitions shall be in accordance with AWS specification A 3.0. Welding symbols shall be in accordance with AWS specification A 2.4. 4.2 Safety measurement for the protection of welders and welding operators who involve in welding and cutting, shall be in accordance with the practices specified in ANS! Standard Z 49.1 unless specified different by local law or reguiation. 43 All pressure retaining, butt welds shall be full penetration double welded joints with multiple passes. Where access or wall thickness precluding the use of double welded butt joints, the single ‘welded joints shall be made instead. In such that case, the root pass shall be applied using the GTAW process except for the carbon steel and alloy steel piping of which the use of are welding process is acceptable subject to IRPC's approval. 4.4 In case of rain and relative humidity exceeding 85% , preheating is required to remove moisture, 4.5 Tack weld shall not iess than 2 inches on wail surface of low and high pressure vessels, For tack ‘weld which will be co-operated to root pass shall be grinding at start and stop points to remove porosity, cracking, ete. During welding process, welder grinding of starts and stops shall be done. ‘Also, proper cleaning between each weld layer shall be done. 4.8 When reinforcing pads are required for branch connection, after welding branch pipe to main pipe shall be PT/MT/UT prior to reinforcing pad installation. 5. Welding procedure and welding performance qualification 5.1 Welding procedure and welding performance qualification shall comply with ASME IX ASME / ANSI B 31.3, AWS D 1.1 or related specifications, 5.2 Welding procedure specification and procedure qualification record shall be submitted to IRPC prior to starting the works. 5.3 Weld map or similar documents indicating location of WPS's shall be submitted with its relevant WP's. 6. Filler metal requirements 6.1 Welding material shall conform to ASME II, Part C. 6.2 To joint similar materials, the filer metal shall be selected so that the chemicat composition in the deposited weld metal is similar to the nominal composition of the base metal or better. To joint dissimitar materials, the filler metal shall be selected according to the applicable appendices in ASME Il. Part C 6.3 Covered arc welding electrodes shall be of the low hydrogen coating type for pressure parts, except for the electrode E7016 . For water lines, the electrode E8013 Classification may also be Used for intermediate and final passes upon IRPC’s approvale No. IRPC Technical Data $10332100-8002 A 80h loors8 fro ume) Welding Standard a Page IRPC Public Company Lirnited 4 GFG-002 6.4. Neutral fluxes shail be used for submerge arc welding of alloy steel. 6.5 Suitable storage of electrodes, fluxes and other welding materials shall be ensured. Precautions shall be taken to minimize absorption of moisture for all consumable welding materials, However if electrode taken from the oven longer than 4 hours it shall be redried. Redrying shall not more than twice recommended by manufacturer. 6.6 Electrode brand name shall be to IRPC's approval. 7. Weld joint preparation and cleaning requirement In addition to the code and standard mentioned in section 2 , the joint preparation shall be in accordance with the following requirements. 7.4 Weld joint preparation may be made by machining, grinding or thermal cutting (Oxy-fuel cutting, plasma are cutting) ; ‘The surface shall be smooth. When thermal cutting required, the joint surface shall be ground to sound metal prior to welding, 7.2 Edge Preparation - For carbon steel, flame cutting and bevelling is acceptable only ifthe cut is reasonably smooth and true and all oxides are removed by grinding from the flame cut surfaces. - For low alloy steel, flame cutting and bevelling is acceptable only if the cut is reasonable smooth and true and all oxides are removed by grinding from the fame cut surfaces - For stainless steel, mechanical means or plasma cutting shall be used. The groove face shall be smoothly finished by removing completely all burrs caused by machining, and surface oxides caused by plasma cutting, 7.3 All surfaces being welded shall be cleaned and free from paint, oil, grease, dit, rust, loose scale and other foreign material, The adjacent base metal surfaces shall be cleaned, at least 25 mm. from the edge of the welding joint 7.4 Flux, weld spatter and slag shall be removed from each weld layer prior to depositing the succeeding pass and from the completed weld. 7.5 Peening is only permitted to the extent necessary to clean the weld of pressure retaining parts. 8. Preheating In addition to the code and standard mentioned in section 2 and certified welding procedure, the preheating shall be in accordance with the following requirements, 8.1. Temperature shall conform to the applicable procedure specification (WPS) 82 Preheating shall be performed so that the surface of the weld part is deposited by 80 MM.. from the welding point in every direction, at the same or above temperature specified 83 For austenitic stainless steel, Nickel alloys, Nickel base materials , the interpass temperature shall be limited and control heat input 84 Unless otherwise specified different, preheating shall be performed by electric heater for piping, ‘The preheat temperature shall be checked and recorded, For vessel and tank, preheating shall bbe done by electric heater other with specification by IRPC small bare size 2" and lower. 85. Carbon steel thickness 25 mm. and above shall be preheating. 86 Preheat temperature and temperature between passes in dissimilar welding shall be as follows in the case of dissimilar welding between carbon steel and low alloy steel, the preheating temperature and the temperature between passes shall conform to the conditions temperature between passes shall conform to the conditions on the alloy steel side. Preheat shall not be done on the austenitic stainless steel side, as a rule 9. Tackwelding 9.1. Tack welding shall be performed by qualified welder. 9.2. When preheating required for welding, tack welding shall be applied also. 9.3 Iffinger bar allowed for fit up, material shall be at the same condition with its base material, 9.4 Welding electrodes to be used for tack welding shall be the same brand as those to be used for the actual welding,e No. IRPC Technical Data $10332100-3002 LN GFG-002 {U8 loorsé fit (umauy Welding Standard Date) Page IRPC Public Company Limited 8 6 10. Welding 10.1. For pressure vessel tank and process piping, weave technical shall be limited at 2 times of electrode diameter. 10.2. When preheating required for alloy steel, welding shall be continuously performed with no interruption. 40.3. Backing gas for low and high alloy by nitrogen, stainless steel shall be inert gas or specified by IRPC. 10.4 Rain, unless approved protection facilities are provided. 40.5 Wind velocity more than 0.5 misec. For GTAW, 3misec for SMAW, unless approved protection facillies are provided 11, Post weld heat treatment (PWHT) 11.1. Post weld heat treatment shall be in accordance with applicable code, standard and certified procedure. 14.2. Written procedure shall be submitted to IRPC for review prior to commencement. 413 Thermocouple pyrometers requirement for piping = 1112" and 6" one point = B' and 10” two point = 12" and 16" three point = 18° up Four point, 44.4. Onlly type K cover rang ~180 °C t to 1,260 °C thermocouple is permitted for PWHT by the capacitive discharge technical attached to pipes. 14.5 Welding shall not be allowed after post weld heat treatment. 41.6 For piping materials P number 3, 4, by code and P number 5 , 9A, 9B, 10A butt weld and branch ‘connection shall be PWHT regardless of thickness. NACE requirements and amine service shall be PWHT regardless of thickness and / or joint configuration 11.7 PWHT of piping shall be electric heater and temperature recorded. 41.8 PWHT is required test and NDE inspection shall be done after completion of PWHT IRPC acceptable. 42. Hardness testing 12.1. For the PWHT welded joint, the hardness test shall be performed after its heat treatment. ‘Accaptable criteria hardness of the base metal and of the weld metal and heat affected zone. 12.2 Maximum acceptable hardness shall exceed the following valves - Pt 200 HB MAX - P3,P4 225 HB MAX ~ PS, P6, P7 235 HB MAX = PA, P22, 235 HB MAX. = NACEREFER STDMR 0175 13. Repait 43.1 Repair welding on material, equipment and piping shall comply with the applicable codes, standards and project specifications where specified 43.2 All procedures required for welding repair of base material shall be submitted for IRPC's approval prior to the repair commencement. 14, Welder and welding operator qualification Welder and welding operator qualification shall be performed according to the ASME IX with the exception of the followingGFG-002 e No. IRPC Technical Data $10332100-3002 LN TRPC Public Company Lented 6 {hows fa meu) Welding Standard Date Page $ 14.1. The requalifcation is needed when the welder or welding operator does rot work continuously more than 3 months. 44.2. Final judgment of visual inspection and film evaluation shall be to IRPC inspector's decision, 45. Quality control of welding work 15.1. Shop and field quality control program shall be prepared and submitted to IRPC. 15.2 Welding activities, supervision and inspection shall be performed by qualified personnel 15.3 IRPC’s inspector and representative shall have unlimited access to working areas at all me on easonabie basic. 15.4 Contractor shall provide proper facility and equipment for observation and inspection. 45.8 Non destructive testing 45.5.1 NDT shall be performed in according with, but not limited to the ASME V as detailed below, ~ Visual inspection according to article 9 = Magnetic Particle ‘according to article 7 ~ Dry penetrate test according to article 6 © Radiographic Examination according to articie 2 = Ultrasonic testing according to article § ‘Acceptance criteria shall be in accordance with relevant codes, standard and specification. Written procedure shall be submitted to IRPC for approval 48.5.2. The IRPC's visual inspection will taken the following into account as minimum, ~ No undercut exceeding 0.3 mm, = Weld reinforcement limited to 3 mm. = No any misalignment exceeding 3 mm. = Good workmanship shown. 15.5.3. Dye penetrate test (PT) ~ After backgouging of double sides weld PT shall be done to ensure good sound metal and developer shall remove before welding commencement - For temporary attachment weld and arc strikes, the PT or MT shall be applied after removal ~ Pressure vessel including its attachment weld shall be 100% PT after finishing. The attached weld of storage tank shall be 100% PT. 16.5.4 Magnetic particle test (MT) ~~ Dry magnetic particle shall not be used on field 18.5.5. Radiographic testing (RT) = Recording to 3200-306 Rev. 0 15,5.6. Ultrasonic testing (UT) = UT may be used in lieu of RT subject to IRPC’s approval