SPECIFICATION FOR DOCUMENT No.

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SPECIFICATION FOR FLANGES WITH

WELD OVERLAY

0 31.01.05 ISSUED FOR BIDS SANJEEV KKM LBJ

Rev. Prepared Checked Approved
Date Purpose
No by by by

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved
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CONTENTS

1.0 SCOPE

2.0 CODES AND STANDARDS

3.0 MATERIALS

4.0 WELD PROCESS FOR WELD OVERLAY

5.0 DIMENSION OF THE WELD OVERLAY

6.0 BASE METAL SURFACE PREPARATION

7.0 WELD OVERLAY PROCEDURE

8.0 PROCEDURE QUALFICATION FOR WELD OVERLAY

9.0 SURFACE FINISH OF WELD OVERLAY

10.0 STORAGE

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1.0 SCOPE

This specification covers the minimum requirements for manufacture, inspection,

testing and supply of flanges with INCONEL 625 overlay to be used for well fluid
pipelines. Contractor shall develop a complete detailed specification along with the
drawing of the flanges & submit for company’s approval before start of any
procurement action.

The base metal and the overlay metal shall meet the requirements of ASTM/ASME.

2.0 CODES AND STANDARDS

The manufacture, inspection, testing and supply of flanges under this specification
shall comply with the latest revisions of following codes and standards besides this
specification:

ASTM A694 Standard specification for Carbon & Alloy steel forging
for Pipe Flanges, Fittings, Valves and parts for High
Pressure transmission service
ASME B16.5 Pipe Flanges and Flanged Fittings
ASME Section II Part C Specification for welding rods, electrodes and filler
metals
ASME Section V Non destructive examination.
ASME Section VIII Division I Rules for construction of Pressure Vessels
ASME Section IX Welding and brazing qualifications

3.0 MATERIALS

The material of the flanges shall be ASTM A694 Gr. F60. The dimensions of the
flanges shall be as per the tolerances on dimensions for the connected pipe/5D bend
as described in the respective specifications. The internal diameter of the flanges and
facing shall be made with weld overlay. The finished machined thickness of the weld
overlay on the flange shall be equal to the cladding thickness of the piping. Weld
overlay shall be made with minimum two layers. After weld overlay on the flange, the
sample shall be taken from the top of the overlay surface to a depth of 2.0 mm and
chemical analysis shall confirm the composition of the specified cladding material.
The neck of the flange selected shall suit the nonstandard OD of the adjoining pipe or
5D bend (Pipe line riser). However the ID and neck thickness of the flange shall be
such that internal diameter of the flange after weld overlay shall match with the
internal diameter of the adjoining pipes or 5D bends as the case may be for free
passage of the pig.

4.0 WELDING PROCESS FOR WELD OVERLAY

The weld overlay on the flanges shall be carried out by the listed welding processes
only. They are arranged in the following order of preference

Submerged Arc Welding (SAW)

Flux cored Arc Welding (FCAW)
Gas Tungsten Arc Welding (GTAW)
Shield Metal Arc Welding (SMAW)
Gas Metal Arc Welding (GMAW)
Friction Stir Welding (FSW)

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Any other process of weld overlay cladding process shall be employed subject to
approval of the company or its representative. Care must be taken during the weld
overlaying to obtain minimum dilution. The surface of the weld overlay deposited shall
be smooth with minimum ripples. The process chosen shall be such that the adjacent
weld beads shall be completely fused between each other and the surface of the weld
overlay shall be smooth without any interbead grooving.

5.0 DIMENSION OF THE WELD OVERLAY

The dimension of the weld overlay defines the finished total thickness of the weld
overlay on the flanges. The minimum thickness shall be 3.0 mm consistent with the
specified chemical composition of the weld overlay at the tip layer.

In order or to achieve the chemical composition requirements, an increase in the clad

thickness may be used with written concurrence from ONGC/EIL.

6.0 BASE METAL SURFACE PREPARATION

The surface of the base metal where overlaying shall be rendered smooth and free
from rust, by using fresh machining grinding or wire brushing. Any heavy scale,
formed on the base metal, may be removed by grit or shot blasting. Weld ripples or
reinforcement, if any, shall be ground flush with the base metal. Just prior to weld
overlay deposition; the mechanically prepared surface shall be cleaned by solvent
cleaning procedures to completely remove traces of the oily substances.

7.0 WELDING OVERLAY PROCEDURE

The weld overlay shall be made in two or more layers. The first barrier layer shall be
made using higher alloy consumable. This barrier layer shall be sound and free from
any defects. The subsequent layers, shall be made by using an appropriate
consumable to exhibit the corrosion resistance properties similar to that corrosion
resistant clad material on the pipe recommended for the service.

A detailed procedure for welding overlay on the flange shall be submitted for the
Company’s approval. The procedure shall include the welding procedure, chemical
composition of the overlay material and consumables, heat treatment etc. as
minimum.

When strip cladding process is used the overlap between neighboring beads deposits
shall be ensured to effect inter bead fusion. Weaving can be used in the case SMAW
process and gas shielded processes subject to the maximum recommended by the
consumable/equipment manufacturers.

The consumable details of the weld overlay shall be furnished for the approval of the
company or its representative so that the final chemical composition of the weld
overlay meet the required corrosion resistance properties in the post weld heat
treated condition. For all the weld overlaying consumable the Dilution pattern shall be
carefully examined during the evaluation, prior to employment in the procedure
qualification testing.

7.1 PREHEATING OF THE BASE METAL

The preheating temperature to be weld overlay shall be as mentioned in Table 1,

based on the base metal thickness composition & preheating heating elements. In

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case other gas torch-heating is preferred, then the heating should be done on the
back side of the base metal avoiding any impingement of flame on the surface to be
deposited. The preheat temperature shall be measured on the overlay surface.

7.2 POST WELD HEAT TREATMENT OF THE COMPONENT

The component, after weld overlay, shall be post weld heat treated based on the total
thickness including base metal thickness and weld overlay. The post weld heat
treatment temperatures and holding rates are furnished in table 1:

Table-1 Preheating and Post weld heat treatment requirement

Base UTS Total Preheat Post weld heat treatment

metal Thickness Temperature requirement
type Including minimum
Weld Holding Holding Min.
overlay Temperature Time rate Holding
Time

(Psi) (mm) (oC) (oC) (hr/in) (hr)

Carbon # 71000 # 19.0 10 No PWHT (None)
Steel
# 71000 20-25.4 10 595 – 650 1 1

# 71000 > 25.4 100 595 – 650 1 1

> 71000 All thickness 100 595 – 650 1 1

The post weld heat treatment of the corrosion resistant weld overlay component shall
be carried out in neutral or oxidizing atmosphere. The surface shall be free from any
iron particles, rust, oil, grease and organic coating substances. The fuel as heating
medium in the furnace shall be free from sulphur, zinc and any metal that could
produce a low melting compound. The base metal of the weld overlay component
shall be placed on a clean surface in the furnace with the weld overlay side facing up.

7.3 VISUAL INSPECTION OF THE WELD OVERLAY

The surface of the completed weld overlay on the base metal shall be examined
visually. No scratch, porosity, cracks or any inclusion such as iron particles shall be
permitted on the surface. The surface shall be finished smooth.

7.4 NON-DESTRUCTIVE EXAMINATION OF THE WELD OVERLAY

The liquid penetrant examination shall be carried out in accordance with Article 6 of
ASME Section V. The acceptance criteria shall be according to Appendix 8, ASME
Section VIII, Division I.

7.5 ANALYSIS OF THE CHEMICAL COMPOSITION OF THE WELD OVERLAY

The chemical analysis shall be carried out randomly on the weld overlay piping
component to check the homogeneity of the composition of the weld overlay. The
sample for analysis shall be taken in the as furnished condition as shown in Sketch
no.1. The number of samples shall be decided by the company or its representative.
The sample shall be taken at a distance of 2.0mm from the top finished surface of the

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weld overlay. If dilution in chemical composition is experienced, the thickness of weld

overlay can be increased from the specified minimum thickness of 3.0mm, In any
case, no dilution is permitted at the depth at which chemical analysis is carried out.

Sketch no.1 Sampling for chemical analysis

t = total thickness of weld overlay in mm,

ds = Distance in mm from the top finished surface to the sampling point.
ds = 2.0 mm

7.6 MEASUREMENT OF THICKNESS OF WELD OVERLAY

The range of thickness of the weld overlay shall be measured recorded and reported
for the review and approval of the company.

Measurement of dilution

Dilution pattern of the overlay deposit shall be traced by taking chemical composition
across the thickness of the deposit by an appropriate chemical analysis procedure
and macro/micro structural characterization.

7.7 REPAIR OF DEFECTS ON THE WELD OVERLAY

The weld overlay surface with unacceptable defects such as cracks, porosity,
inclusions etc may be permitted for repair with the approval of the company or its
representative. The repaired regions shall be examined by the same testing
procedure applicable for production overlay.

7.8 RECORDS DURING ACTUAL PRODUCTION WELD OVERLAY

The quality control programme shall be established before the actual production weld
overlay on base metal commences. The reports shall include the identification
number, visual inspection report, liquid penetrant testing results measurements of
thickness of the base metal and the weld overlay, chemical analysis of weld overlay
and the details of repairs if any. The reports along with all the test results shall be
duly signed by the authorized inspector.

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8.0 PROCEDURE QUALIFICATION FOR WELD OVERLAY

The procedure for weld overlay shall be qualified in accordance with ASME section
IX. The thickness of test coupon shall be of 25.0 mm or the actual thickness of the job
whichever is less.

8.1 NON-DESTRUCTIVE EXAMINATION OF WELD OVERLAY

The weld overlay test coupon surface shall be subjected to liquid penetrant
examination in accordance with ASME section VIII, division 1, Appendix 8. The weld
overlay test coupon shall be sectioned for extracting four guided side bend test
specimens. Two of the four specimens shall be cut oriented parallel to the direction
of welding and the other two specimens shall be oriented perpendicular/transversal to
the direction of the welding. All the four specimens may be oriented perpendicular to
the direction of welding as an alternative arrangement. These specimens shall be
subjected to side-bend tests in accordance with QW-466, ASME section-IV.

8.1 MEASUREMENT OF WELD OVERLAY THICKNESS

After completing the weld overlay welding, the thickness of the finished weld overlay,
from the top finish layer shall be measured. The measured thickness of the weld
overlay shall be at least 3.0 mm or at least the approved thickness in accordance with
WPS when higher thicknesses are permitted.

8.3 ANALYSIS OF CHEMICAL COMPOSITION OF WELD OVERLAY

The sample may be taken from the top finished surface of the production weld
overlay for the chemical analysis. Alternatively positive Material Identification
procedures could be adopted for spot checking of the surface chemistry of the PQR
sample for the purpose of quality control.

8.4 QUALIFICATION FOR WELDER

The welders engaged in the overlay welding shall be qualified prior to actual
production in accordance with ASME section IX. For welder qualification, the
thickness of the test coupon shall be 25.0 mm or the thickness of the actual job,
which ever is less, minimum employing the qualified welding procedure.

8.5 RECORDS DURING QUALIFICATION

The weld overlay procedure qualification and the qualification for the welders shall be
recorded along with the results of non-destructive examination and mechanical
testing for the approval of the company or its representative. The results shall be
shown corresponding to the identification number of the component to be weld
overlayed.

9.0 SURFACE FINISH OF WELD OVERLAY

The weld overlay component shall have smooth surface, free from any iron-particles
and shall have the proper dimensional match such as with the inner diameter of the
clad piping. If required, the weld overlay surface may be cleaned by employing the
cleaning paste or gel after obtaining the approval from the company.

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10.0 STORAGE

The weld overlay component shall be prevented from external corrosion, pitting,
mechanical damage including dimensions. Care shall be taken to protect the weld
overlay surface from settlement of external particles or condensing moisture.

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved