RECORD OF REVISIONS

Date Revision Details Revision

Number

- This specification is prepared referring document number

25194-3PS-GAW-004, Rev 09

17.08.2012 Issued for Implementation 0

12.09.2014 Revised to include reference to details of Attachment-5 1

Contents
1. Scope ................................................................................................................................... 1
2. Codes, Standards and Project Documents .......................................................................... 1
3. Procedure Qualification....................................................................................................... 2
4. Welder Qualifications .......................................................................................................... 3
5. Preparation of Materials for Welding ................................................................................. 3
6. Welding Processes ............................................................................................................... 4
7. Welding Electrodes and Consumables ................................................................................ 4
8. Heat Treatment ................................................................................................................... 5
9. General Welding Requirements .......................................................................................... 7
10. Weld Metal Quality ............................................................................................................. 8
11. Non-Destructive Examination (NDE) ................................................................................... 9
APPENDIX 1 - Additional Requirements for Low Alloy Steel Piping
APPENDIX 2 :Additional Requirements for Stainless Steel and Nickel Based Alloy Piping
APPENDIX 3: The Indian Boiler Regulations - Latest Edition
APPENDIX 4 - NDT specification for typical cases not directly covered by existing specification
or codes
Figure 1 - Delta Ferrite Diagram
Appendix 5 - Form 167 - Piping Class wise NDE requirements
1
1. Scope
1.1. This document specifies the requirements for welding, heat treatment and non-
destructive testing for fabrication of piping to be installed in the Reliance
Complex, Jamnagar, India. This specification is applicable to shop fabrication and
site (field) welding, and inspection of piping in accordance with the Codes listed in
section 2.
1.2. Requirements specific to particular material groups and alloys are given in the
appendices.
1.3. In the event that additional Process Licensor requirements are not specified in this
document these shall be addressed in writing to the Purchaser.
2. Codes, Standards and Project Documents
2.1. Unless otherwise stated, the following Codes, Standards and Project Documents
shall be of the latest issue (including revisions, addenda and supplements) and are
considered part of this specification.
ASME B31.3 Chemical Plant and Petroleum
Refinery Piping
ASME B31.1 Power Piping
ASME B31.4 Liquid Transportation systems for
Hydrocarbons and other liquids.
ASME Section II, Welding Rods, Electrodes and Filler
PartC,2010 edition Materials
with 2011 adenda
ASME Section V, Non-Destructive Examination
2010 edition with
2011 adenda
ASME Section IX, Welding and Brazing Qualifications
2010 edition with
2011 adenda
NACE SP-0472,2008 Methods and Controls to Prevent In-
edition Service Cracking of Carbon Steel
Welds in P-1 Materials in Corrosive
Petroleum Refinery Environments
NACE MR0103,2007 Materials Resistant to Sulphide Stress
edition Cracking in Corrosive Petroleum
Refining Environments

10080-1-SS-MT-007,Rev.1 Page 1 of 31
 IBR Indian Boiler Regulations
API 1104, 2005 Welding of Pipelines and Related
edition Facilities

PROJECT
SPECIFICATION
10080-1-SS-PP-006 Piping Fabrication

10080-1-SS-PP-038 Piping Service Class Index / Material

Class
10080-1-SS-PP-007 Piping Erection and Testing

10080-1-SS-PP-029 Internal Lining of Piping Spools

3. Procedure Qualification
3.1. Welding procedures are welding procedure specifications (WPS) accompanied by
qualified welding procedure qualification records (WPQR).
3.2. Only COMPANY approved WPS, with qualified WPQR are to be used for welding.
All welding shall be carried out by qualified welding personnel only.
3.3. Separate WPS with their appropriate WPQR, are to be submitted to the
COMPANY within the time stated in the Request for Bids, Purchase Orders and/or
Contract, and prior to commencement of fabrication and/or welding. Welding
operations shall not commence until WPS have been reviewed and approved by
COMPANY, and welder qualifications have been verified on site or in the Seller’s
shop.
3.4. All welding procedure specifications (WPS) submitted to COMPANY shall include
welding details and appropriate test results (WPQR) in accordance with the
applicable Design Code and/or Job Specification(s).
3.5. SELLER/CONTRACTOR standard WPS/WPQR forms are acceptable provided they
meet the requirements and essential variables of the relevant Design Code and
relevant specifications. All documents shall be fully legible and shall be in English,
with test certificates independently witnessed and signed.
3.6. The SELLER/CONTRACTOR shall complete the Form 167 by listing the applicable
Welding Procedure for each piping class in the columns provided. Completed
forms, plus future revisions, shall be submitted to the COMPANY for approval (see
Attachment One).

10080-1-SS-MT-007,Rev.1 Page 2 of 31
3.7. Any revision to WPS/WPQR shall be submitted to the COMPANY for review and
approval.
3.8. The SELLER/CONTRACTOR is responsible for the submittal of sub-suppliers and/or
sub-contractors welding, NDE and PWHT procedures to the COMPANY.
3.9. Repair welding procedure specifications shall be submitted to the COMPANY for
review and approval prior to commencement of work.
3.10. No welding will be accepted that is not covered by a COMPANY approved WPS.
3.11. For carbon steel in Sour Service, each welding procedure test shall be subject to
hardness testing, during procedure qualification testing whereby the Weld, Fusion
Line, and Heat Affected Zone (HAZ) shall not exceed a Vickers Hardness of 248
Hv10 For the weld metal 248 Hv10 is the maximum allowable reading, but the
average shall be less or equal to 210 Hv10.
3.12. In addition each new weld qualification (performed for this project) shall be
hardness tested using a portable hardness tester, in accordance with section
11.14 of this document, if the material or service for which it is to be used
requires production hardness testing.
3.13. Weld Procedure Qualifications shall include impact testing when required by the
applicable Code.
4. Welder Qualifications
4.1. Welder qualification records shall be reviewed in accordance with the appropriate
Code and approved by the COMPANY or his representative. The review and
approval of the records shall be done at the SELLERS/CONTRACTORS works or the
construction site by the COMPANY or his representative. Records shall NOT be
submitted to the COMPANY head office.
5. Preparation of Materials for Welding
5.1. All welding preparation details are to be in accordance with COMPANY approved
drawings and WPS.
5.2. All preparation methods shall be carried out to recognized industry Standards,
Project Specifications and/or Code requirements.
5.3. Flame cut bevels in carbon and low alloy steel shall be machined or ground back a
minimum of 2 mm. For stainless steels and non-ferrous alloys, flame cutting is
not allowed. Bevels shall be prepared by plasma cutting or machining.
5.4. Oil, moisture, rust, scale, sand, paint, metallic coatings (e.g. Zinc), or other foreign
matter shall be removed from the weld surface and adjacent base material prior
to welding.

10080-1-SS-MT-007,Rev.1 Page 3 of 31
6. Welding Processes
6.1. The following welding processes are approved for use:
6.1.1. Shielded Metal Arc Welding (SMAW)
Gas Tungsten Arc Welding (GTAW)
Submerged Arc Welding (SAW)
Gas Metal Arc Welding (GMAW) Spray/Pulse Transfer Only
Gas Shielded Flux Cored Arc Welding (GSFCAW)
6.2. Use of alternative arc fusion welding processes is subject to COMPANY approval.
SELLER/CONTRACTOR should clearly identify the proposed welding process,
welding experience, level of automation and metal transfer mode.
6.3. The root pass of welds, other than attachments, in all materials except Galvanized
Iron shall be performed using the GTAW (TIG) process for the following
applications:
1. All pipes of nominal diameter less or equal to 2”.
2. All single sided alloy steel, stainless steel and nickel alloy piping.
For large diameter piping where there is access inside the pipe to allow double
sided welding, GTAW root may be omitted.
6.4. Flux shielded welding (SMAW, SAW, FCAW) of low alloy steels shall be carried out
using basic low hydrogen consumables. Low hydrogen consumables shall be
stored and treated (baked) to produce maximum deposited weld metal hydrogen
content of 5 ml/100 g.
6.5. GTAW welding shall be carried out with the addition of filler metal and with the
use of high frequency starting units.
7. Welding Electrodes and Consumables
7.1. All welding electrodes and consumables shall be subject to COMPANY approval as
part of the WPS.
SMAW electrodes for welding of carbon steel shall be in accordance following:

Material Specification Classification* Process

E6010 or SMAW
Carbon Steel AWS A-5.1, ASME SFA-5.1
E70XX

10080-1-SS-MT-007,Rev.1 Page 4 of 31
 * - Electrode coatings designated XX may be 15, 16 or 18.
E6010 shall be used for root runs only.
Use of E6013 and E7010 electrodes shall be subject to COMPANY approval.
Bare electrodes for GMAW, GTAW or SAW of carbon steel shall be in accordance
with the following:

Material Specification Classification Process

Carbon AWS A-5.17, ASME SFA- -- SAW
Steel 5.17 --

Carbon AWS A-5.18, ASME SFA- -- GMAW/GTAW

steel 5.18
Flux cored electrodes for GSFCAW of carbon steel shall be in accordance with
AWS A5.20, ASME SFA 5.20.
For low alloy steel and stainless steel requirements, see appendices 1 and 2.
7.2. All welding consumables shall be supplied with manufacturer’s certification.
7.3. The electrode/consumable chemistry shall meet the requirements of the base
material, and shall be selected such that the deposited weld metal exhibits
mechanical properties equal to or in excess of the base material.
7.4. For any dissimilar metal weld applications welding consumables and procedure
shall be subject to COMPANY approval.
7.5. All welding electrodes/consumables shall as a minimum, be stored and used in
accordance with the manufacturer’s recommendations. The SELLER/
CONTRACTOR shall produce a welding consumable handling procedure, which is
subject to COMPANY approval.
7.6. Carbon, low alloy and stainless steel electrodes and consumables shall be stored
separately.
7.7. For submerged arc welding, alloying is not permitted via the flux.
7.8. For welding of P91 piping, welding consumable brand is an essential variable and
is subject to COMPANY approval.
8. Heat Treatment
8.1. Preheat

10080-1-SS-MT-007,Rev.1 Page 5 of 31
8.1.1. Preheats shall be in accordance with that specified by the applicable Design Code.
In no instance shall the preheat be less than 10 C. Minimum preheats shall be
specified on the SELLER/CONTRACTOR WPS.
8.1.2. The minimum preheat temperature shall be maintained throughout the welding
cycle.
8.1.3. Minimum preheat requirements shall apply to all types of welding, including tack
welds, temporary attachments, repair welds, seal welds of threaded joints and
thermal cutting.
8.1.4. If a welding joint is wet or has surface moisture or condensation, it shall be dried
by heating.
8.1.5. Approved temperature indicating crayons, thermocouples, or contact pyrometers
shall be used to measure preheat and interpass temperatures.
8.2. Interpass Temperature
8.2.1. Maximum interpass temperature shall be stated on SELLER/CONTRACTOR WPS.
8.2.2. Maximum interpass temperature for austenitic stainless steels shall not exceed
175C. This includes dissimilar welds between austenitic stainless steel and
carbon steel.
8.2.3. Unless specified otherwise, maximum interpass temperature for P-1 materials
shall be 250C.
8.3. Post Weld Heat Treatment
8.3.1. Post Weld Heat Treatment (PWHT) shall be in accordance with the applicable
Design Code and/or Project Specification. When applying the rules of B31.3 Clause
331.1.3 can be used to determine the thickness of branch connections and
external attachment welds that require PWHT, only for P1 materials where PWHT
is not a service requirement.
8.3.2. A written PWHT procedure shall be submitted to the COMPANY for approval. The
procedure shall include calibration of equipment and, location and type of
thermocouples.
8.3.3. PWHT requirements shall be clearly identified on SELLER/CONTRACTOR WPS.
8.3.4. Exothermic PWHT is not allowed.
8.3.5. All flange faces and threaded connections shall be protected against oxidation
during heat treatment.
8.3.6. Carbon steel piping containing AMINE at any level of concentration shall be post
weld heat treated (see Form 167).

10080-1-SS-MT-007,Rev.1 Page 6 of 31
8.3.7. Carbon steel piping in process areas containing CAUSTIC at any level of
concentration shall be post weld heat treated. (See form 167). For offsite areas,
post weld heat treatment is only required for higher concentrations.
9. General Welding Requirements
9.1. Welding Equipment
9.1.1. SELLER/CONTRACTOR and their sub-suppliers and/or sub-contractors shall
maintain all equipment in good working order. Earth connections shall make
good contact with the work, and regular calibration checks shall be carried out on
all machines.
9.2. Technique
9.2.1. Vertical down welding shall not be used without COMPANY approval.
9.2.2. All welds shall be cleaned of foreign material (slag etc.) down to clean metal, both
on completion of each pass and when the weld is finished.
9.2.3. Single pass welding procedures are not acceptable.
9.2.4. All piping butt welds shall be full penetration welds.
9.2.5. A minimum of two passes shall be used on socket and seal welds.
9.2.6. Weld peening shall not be used without COMPANY approval.
9.2.7. All tack welds shall be made by qualified welders. The required preheat
temperature shall be attained prior to tack welding. Tack welds, which are to be
incorporated into the final weld, shall be thoroughly cleaned, prepared at each
end, and inspected for cracks. Any cracked tacks shall be removed before welding
the joint.
9.2.8. All welding shall be protected from rain, wind, air-borne dust and sand.
9.3. Weld Repairs
9.3.1. For the repair of a weld, either the original WPS or one originally submitted as a
designated repair WPS shall be used.
9.3.2. Repair plans that use welding for repair of welds or base metals, when allowed,
shall be submitted to COMPANY for review and approval, prior to use. A repair
plan shall include the following:
 The method of defining the type and the extent of the defect.
 Methods used for removing the defect and testing conducted to ensure that the
defect has been removed.
 Welding procedure employed and NDE procedure(s) used to inspect the completed
repair.
10080-1-SS-MT-007,Rev.1 Page 7 of 31
9.3.3. All repaired welds shall as a minimum, be inspected using the original testing
method. Additional test methods may also be required, if deemed necessary by
the COMPANY.
9.4. Additional requirements
9.4.1. For Carbonate Service, new piping classes have been generated and identified on
attached Form 167, PWHT is required at 650o.C for a minimum soak time of 2
hours for all sizes.
.
9.4.2. For the Flare System (Main, acid, & Sour Gas),It is confirmed that sour service
conditions apply during upset conditions, due to upset conditions hardness
testing on these systems is required in accordance with Section 3.11 of this
Specification. The same hardness testing applies to water draw-off lines from
crude tanks that are in sour service. This does not include production hardness
testing.
10. Weld Metal Quality
10.1. All welding shall meet the requirements of the applicable Design Code and
Specifications stated in Section 2.
10.2. Arc strikes outside the welding groove shall be removed by disc grinder, and
minimum design wall thickness shall be maintained.
10.3. Weld(s) containing cracks and their cause shall be reported to the COMPANY or its
representative. If cracking is found during NDE, examination levels shall be
increased at COMPANY discretion, until the cause of the cracking has been
identified, and steps taken to prevent its reoccurrence. Welds containing cracks
may be repaired by welding, unless stated otherwise in writing by the COMPANY
or his representative.
10.4. Acceptance standards for welds shall be in accordance with the applicable Design
Codes and Specifications.

10080-1-SS-MT-007,Rev.1 Page 8 of 31
11. Non-Destructive Examination (NDE)

11.1. All NDE shall be carried out in accordance with the applicable Code and/or
Specification. For Carbon steel (P-No.1) NDT can be performed before PWHT. The
minimum NDE percentage level stated on Form 167 shall apply.
11.2. A document listing the relevant NDE procedures, methods and techniques shall be
submitted to the COMPANY for review and approval. Site/NDT agencies shall
adhere strictly to such procedures approved by COMPANY. Any subsequent
revision on the approved procedure shall be submitted to the COMPANY for
further approval. The ultrasonic examination procedure shall be in compliance
with section V, article 5 and shall be approved by COMPANY. In case of stainless
steel, detailed procedures shall be submitted for approval on a case to case basis.
For applicability of UT, Form-167 shall be strictly followed.
11.3. Submittal of individual NDE procedures for review will be defined in the Request
for Bids, Purchase Orders and/or Contract.
11.4. All welds shall be uniquely identified for NDE examination and records.
11.5. For each piping class, the percentage of welds to be examined (NDE%) is listed in
the Form 167.
11.6. Where NDE level is less than 100%, the welds for NDE shall be selected to cover
work of each welder or welding operator with minimum NDE% as specified in the
Form 167. For this purpose, Pipe classes with matching NDE% and metallurgy can
be combined. This includes progressive examination in accordance with ASME
B31.3 Section 341.3.4.
11.7. NDE levels specified shall include socket welds in piping systems which shall be
liquid penetrant or magnetic particle examined.
11.8. The frequency of inspection for each piping class is specified in the attached 167
form. In addition 100% Radiography shall be applied to the following:
All butt welds to valves.
All butt welds to vessel nozzles.
11.9. All tack welds and temporary attachments outside weld joint areas shall be cut off
(not hammered), the area dressed with a grinder and examined by MPI/DPI.

10080-1-SS-MT-007,Rev.1 Page 9 of 31
11.10. All NDE for acceptance shall be carried out after any PWHT, when applied. Except
for Carbon steel (P-No. 1) where NDT can be performed before PWHT.
11.11. All NDE shall be performed by personnel qualified to a recognised National or
International Standard (e.g. PCN, ASNT Level II as a minimum, etc.). The
COMPANY or his representative shall review certification of NDE personnel at the
SELLER/CONTRACTOR works site. Certification shall NOT be submitted to the
COMPANY head office.
11.12. The results from all NDE shall be interpreted by personnel qualified by ASNT/ISNT
level II or equivalent.
11.13. Magnetic particle inspection shall be carried out using electromagnetic yokes.
D.C. prods are not permitted. The strength of the electromagnet (lifting power)
shall be checked each shift.
11.14. Production Hardness Testing
Hardness testing of completed welds shall be carried out using portable hardness
testing machines (Telebrineller or approved equivalent) on the following services:
 All Carbon Steel in (H2S) Sour Service - one reading on the centre of every butt weld
with Telebrineller or approved equivalent, max. hardness permitted 200 HB. Any
butt welds exceeding hardness level shall be reported and either removed and re-
welded or subjected to a PWHT at 593C min and re-tested.
 Low Alloy Steel (1¼, 2¼, 5 and 9 Cr) - after PWHT one reading on each weld and one
adjacent to each weld:
Max. Hardness Permitted - 225 HB (1¼ and 2¼ Cr)
- 241 HB (5 and 9 Cr)
Hardness testing frequency is reduced to 10% for furnace heat treated welds.
11.15. Summary of levels of NDE required.
INSPECTION LEVELS IN %
MATERIAL SERVICE V M RT/UT Hardness
i P (Note 5 & 8)
s I
u /5 5
Carbon Steel Utility 1 NA (Note 7)
a0 D
Process l0 5
P5 NA
Process I5
5 100 (Note 1)
1
(sour) 0 (
0 N
o
10080-1-SS-MT-007,Rev.1 Page 10 of 31
t
e

4
 Steam 1 Note-6 NA
0
0

11/4 Cr ½ Mo Process 1 1 100 100 (Note 2)

0 0 10
Steam (Note 3 & 6)
0 1
1 0
0
0
21/4 Cr 1 Mo Process 1 1 100 100 (Note 2)
0 0 100
5 Cr ½ Mo Process 100 (Note 2)
0 1 100
9 Cr 1 Mo Process 100 (Note 2)
1 0
0 2
0 0
1
0
0
316, 316L Proces & Utilities 1 55 NA
0
304,304H, 321, Process& Utilities 0
1 1 100 NA
347 0 0
N06625 Process &Utilities 0
1 1 100 NA
0 0
N08800
0
N08020 Utilities
N08825

Notes:
1 Hardness tests are only required on butt welds.
2 Hardness tests are only required on 10% of butt welds if piping is PWHT in
a furnace.
3 Hardness tests are only required on butt welds subject to PWHT.
4 For carbon steel and stainless steel MPI/DPI to be performed on socket
welds and branch welds. Anywhere if the requirement is found to be not

10080-1-SS-MT-007,Rev.1 Page 11 of 31
 covered by form 167, therein clause 11.15 of this specification to be
followed.
Up to 1 ½” NB MT/PT to be performed on all type of weld joints except as
specifically indicated in form 167. Where specifically RT is required as per
form 167 a fine grain film such as Agfa D2/D4 or Kodak MX 100/125
together with thicker lead screens shall be used with proper processing
technique to get required sensitivity, contrast and density. All the above
parameters are to be fixed by establishing radiography procedure by the
contractor.
For low alloy steel MT/PT shall also be performed on butt welds and
branch welds at level specified in the Form 167.
Only approved aerosol can applications shall be used for PT testing.

5 RT/UT to be performed on butt welds only.

6 Piping in accordance with ASME B31.1/IBR shall have levels of NDE as
specified on in Form 167 and Appendix 3 of this Specification.
7 Deleted
8 Ultrasonic examination of welds shall be performed strictly in accordance
with ASME Section V, Acceptance criteria shall be as per ASME Section VIII
Div-1 Appendix 12
9 In case of vessel trim lines the most stringent NDE conditions pertaining to
the piping class governing the vessel trim lines apply

10080-1-SS-MT-007,Rev.1 Page 12 of 31
 APPENDICES

1. Additional Requirements for Low Alloy Steel Piping

2. Additional Requirements for Stainless Steel and Nickel
Base Alloy Piping
3. THE INDIAN BOILER REGULATIONS, Latest Revision
4. NDT Specification for typical cases not directly covered by
existing Specification or Codes.
5. FORM 167 (For details, refer Standard Specification
document No. 10080-1-SS-PP-038-(Part-III))

10080-1-SS-MT-007,Rev.1 Page 13 of 31
 APPENDIX 1
Additional Requirements for Low Alloy Steel Piping
This appendix is supplementary to the requirements outlined in the main body of
this document and applies to all low alloy steels (ASME P-Numbers P4, P5A, 5B
15E).
Welding Process
 Flux Shielded Welding (SMAW, SAW, FCAW) shall be carried out utilizing basic low
hydrogen consumables treated (baked ) to produce a maximum weld metal
hydrogen content of 5 ml/100g
 The root pass of butt welds shall be performed by GTAW for all low alloy steel piping.
Welding Consumables
 Unless otherwise stated the following Specifications shall be of the latest issue and
are considered a part of this appendix:
AWS A-5.5, ASME SFA- Specification for Low Alloy Steel Covered Arc
5.5 Welding Electrodes
AWS A-5.23, ASME SFA- Specification for Low Alloy Steel Electrodes and
5.23 Fluxes for Submerged Arc Welding
AWS 5.4, ASME SFA 5.4 Stainless Steel Electrodes for Shielded Metal Arc
Welding
AWS 5.9, ASME SFA 5.9 Bare Stainless Steel Welding Electrodes & Rods
AWS 5.22, ASME SFA Stainless Steel Electrodes for Flux Cored Arc
5.22 Welding and Stainless Steel Flux Cored Rods for
Gas Tungsten Arc Welding
AWS 5.28, ASME SFA Low-Alloy Steel Electrodes and Rods for Gas
5.28 Shielded Arc Welding
AWS 5.29, ASME SFA Low Alloy Electrodes for Flux Cored Arc Welding
5.29

10080-1-SS-MT-007,Rev.1 Page 14 of 31
  SMAW electrodes shall be in accordance with the following:
Material Specification Classification
1¼Cr-½Mo AWS A-5.5, ASME SFA- E80XX - B2
5.5
2¼Cr-1Mo AWS A-5.5, ASME SFA- E90XX - B3
5.5
5Cr-½Mo AWS A-5.5, ASME SFA- E80XX – B6
5.5
9Cr-1Mo AWS A-5.5, ASME SFA- E80XX – B8
5.5
9Cr-1Mo-V AWS A-5.5, ASME SFA- E90XX – B9
5.5

* - Electrode coatings designated XX above may be 15, 16 or 18.

^ - For large catalyst carrying piping, 5Cr-½Mo materials electrode coatings may
be 15 or 16.
 Bare electrodes for Gas Shielded Arc Welding (GMAW, GTAW) shall be in accordance
with the following:
Material Specification Classification
1¼Cr-½Mo AWS A-5.28, ASME ER80S-B2
SFA-5.23
2¼Cr-1Mo AWS A-5.28, ASME ER90S-B3
SFA-5.28
5Cr-½Mo AWS A-5.28, ASME ER80S-B6
SFA-5.28
9Cr-1Mo AWS A-5.28, ASME ER80S-B8
SFA-5.28
9Cr-1Mo-V AWS A-5.28, ASME ER90S-B9
SFA-5.28

10080-1-SS-MT-007,Rev.1 Page 15 of 31
  SAW welding consumables for Low Alloys shall be in accordance with the following:
Material Specification Classification
1¼Cr-½Mo AWS A-5.23, ASME EB2
SFA-5.23
2¼Cr-1Mo AWS A-5.23, ASME EB3
SFA-5.23
5Cr-½Mo AWS A-5.23, ASME EB6
SFA-5.23
9Cr-1Mo AWS A-5.23, ASME EB8
SFA-5.23
9Cr-1Mo-V AWS A-5.23, ASME EB9
SFA-5.23
 The product analysis (weight %) content of Sn and P for welding consumables for
1¼Cr-½Mo pressure containing components :
Sn  0.015%
P  0.012%
The maximum room temperature tensile strength of all pressure containing welds
shall be 100,000 psi (7030Kg/cm2).
Impact Testing
 Qualification of weld procedures for all 2¼Cr-1Mo, and 1¼Cr-½Mo pressure
containing welds shall include Charpy V-Notch impact testing at -18ºC. Impact tests
shall be conducted in accordance with the test requirements ASME VIII Div. 1.
Dressing of Welds
 In hydrocarbon service, all 1¼Cr-½Mo and 2¼Cr-1Mo fillet welds attached to
pressure containing components shall be ground to a smooth, concave contour
(hydrocarbon piping only)
Preheat and Post Weld Heat Treatment
 Preheat levels as per ASME B31.3 shall be applied when flame cutting all low alloy
steels.
 Upon completion or interruption of low alloy steel shop welds and field run pipe to
pipe welds, the welds and adjacent base material shall be uniformly heated to 300oC

10080-1-SS-MT-007,Rev.1 Page 16 of 31
 (max.) wrapped with ceramic fibre insulation blankets before being allowed to cool
below the minimum preheat temperature.
 For field ‘tie-in’ welds preheating shall be carried out using electrical resistance pads
or coils controlled by thermo-couples or approved temperature indicating crayons
(e.g. Tempil Sticks). Welding should be completed in one operation. If this is not
practical, the weld shall be at least completed to a minimum of one third of the pipe
wall thickness.
 Upon completion of field ‘tie-in’ welds, the joints shall be uniformly heated (Post
Heat) to 300oC before cooling under wraps.
 For any interruption in welding for P No 5B and 15E material, where design code
ASME B31.1 applies, all joints, including shop and field, shall be held at or above the
maximum preheat temperature (300 maximum) prior to completion of welding.
 All 1 1/4 Cr - 1/2 Mo and 2 ¼ Cr- 1Mo piping shall be post weld heat treated in
accordance with ASME B31.3 (see Form 167). For hydrocarbon and steam piping of
all thickness shall be PWHT. 5Cr and 9Cr piping shall be PWHT in accordance with
the Code.
 For 9Cr-1Mo-V material the holding temperature shall be in accordance with
approved WPS.

Non Destructive Examination

 All 1¼Cr-½Mo, 2¼Cr-1Mo, 5Cr-½Mo, 9Cr-1Mo & 9Cr-1Mo-V hydrocarbon piping butt
welds, whether shop or field fabricated are to be radiographed 100% (see Form 167).
Hardness Testing
 Production and WPQR hardness testing shall be carried out after PWHT, one reading
on each weld and one adjacent to each weld. The hardness testing frequency is
reduced to 10% for furnace heat treated welds. The hardness requirements are
given in section 11.14 of this specification.
2¼Cr-1Mo Testing Requirements
If 2-1/4 Cr-1 Mo piping classes are used in process units having an operating
temperature over 371⁰C, the following requirements shall apply.
 Welding materials (consumables) for 2¼Cr-1Mo shall also be in accordance with the
following:
 Mn and Si levels shall be maintained at the lowest possible levels consistent with
good weldability.

10080-1-SS-MT-007,Rev.1 Page 17 of 31
  Each batch or heat of welding consumables and covered electrodes, including the
wire flux combinations used in fabrication shall be analysed for P, Sn, Sb and As.
 Analysis shall be performed on deposited weld metal. The Temper Embrittlement
Factor, X shall be a maximum of 15 part per million.
X= (10P+4Sn+5Sb+As)/100
Element concentrations are in parts per million
 Impact energy vs. temperature (transition) curves shall be developed from
weldments representing each batch or heat of welding consumables, covered
electrodes, and wire flux combinations for each welding process used in production
welds.
A minimum of six sets of three impact tests (of material subjected to the same heat
treatment as the completed item) shall be conducted for each curve. Sample
locations shall be as specified by the ASME code.
The six sets of impact tests shall be performed at different temperatures. The
generated transition curve shall clearly define the transition zone and upper shelf.
The maximum test temperature shall correspond to the upper shelf energy level.
 Step Cooling Tests shall be performed on weldments representing each batch or
heat of welding consumables, covered electrode and wire flux combinations for each
welding process used in production welds.
Step cooling shall be in accordance with the following temperatures, holding times
and cooling rates to the next lowest temperature:
Temperature,C Holding Time, Hour Cooling rate to the next
temperature, C per
hour
593 1 5.6
538 15 5.6
524 24 5.6
496 60 2.8
468 100 28
315 air cool

Impact tests of each Step Cool Test sample shall be performed and transition
curves developed following the procedure in the previous section.
Acceptance criteria for the material shall be in accordance with following:
CvTr40 + 2.5 SCvTr40SC  10C
Where:
10080-1-SS-MT-007,Rev.1 Page 18 of 31
 CvTr40 = Charpy V-notch 40 ft-lb impact energy transition temperature of
completely heat treated specimens, before step cooling.

SCvTr40SC = The shift in Charpy V-notch 40 ft-lb impact

energy transition temperature, after
step cooling.

10080-1-SS-MT-007,Rev.1 Page 19 of 31
 APPENDIX 2 :
Additional Requirements for Stainless Steel and Nickel Based Alloy Piping
This appendix is supplementary to the requirements outlined in the main body of
this document.
 Unless otherwise stated the following Specifications shall be of the latest issue and
are considered a part of this appendix:
AWS A-5.4, ASME SFA- Stainless Steel Electrodes for Shielded Metal Arc
5.4 Welding
AWS A-5.9, ASME SFA- Bare Stainless Steel Welding Electrodes & Rods
5.9
AWS A-5.11, ASME SFA- Specification for Nickel and Nickel Alloy Welding
5.11 Electrodes for Shielded Metal Arc Welding
AWS A-5.14, ASME SFA- Specification for Nickel and Nickel Alloy Bare
5.14 Welding Electrodes and Rods
AWS A-5.22, ASME SFA- Stainless Steel Electrodes for Flux Cored Arc
5.22 Welding and Stainless Steel Flux Cored Rods for
Gas Tungsten Arc Welding

 SMAW electrodes shall be in accordance with the following:

Material Specification Classification*
Type 304 AWS A-5.4, ASME SFA- E308XX
5.4
Type 304H AWS A-5.4, ASME SFA- E308HXX
5.4
Type 304L AWS A-5.4, ASME SFA- E308LXX
5.4
Type 316 AWS A-5.4, ASME SFA- E316XX
5.4
Type 316H AWS A-5.4, ASME SFA- E316HXX
5.4
Type 316L AWS A-5.4, ASME SFA- E316LXX
5.4
Type 321 or 321H AWS A-5.4, ASME SFA- E347XX

10080-1-SS-MT-007,Rev.1 Page 20 of 31
 5.4
Type 347 or 347H AWS A-5.4, ASME SFA- E347XX
5.4
N06625 AWS A-5.11, ASME ENiCrMo-3
SFA-5.11
N08020 AWS A-5.11, ASME ENiCrMo-3
SFA-5.11
N08800 AWS A-5.11, ASME ENiCrMo-3
SFA-5.11
N08825 AWS A-5.11, ASME ENiCrMo-3
SFA-5.11

* Electrode coatings designated XX above may be 15, 16 or 18.

 Bare electrodes for inert Gas and SAW shall be in accordance with the following:
Material Specification Classification
Type 304 AWS A-5.9, ASME SFA- ER308
5.9
Type 304H AWS A-5.9, ASME SFA- ER308H*
5.9
Type 304L AWS A-5.9, ASME SFA- ER308L
5.9
Type 316 AWS A-5.9, ASME SFA- ER316
5.9
Type 316H AWS A-5.9, ASME SFA- ER316H
5.9
Type 316L AWS A-5.9, ASME SFA- ER316L
5.9
Type 321 or 321H AWS A-5.9, ASME SFA- ER321 or ER347
5.9
Type 347 or 347H AWS A-5.9, ASME SFA- ER347
5.9
800H AWS A-5.14, ASME ERNiCr-3
SFA-5.14

10080-1-SS-MT-007,Rev.1 Page 21 of 31
 N06625 AWS A-5.14, ASME ERNiCrMo-3
SFA-5.14
N08020 AWS A-5.14, ASME ERNiCrMo-3
SFA-5.14
N08800 AWS A-5.14, ASME ERNiCrMo-3
SFA-5.14
N08825 AWS A-5.14, ASME ERNiCrMo-3
SFA-5.14
*For the application of Type 304H at elevated temperatures above 510ºC, Class
16-8-2 consumables are to be used if maintaining a weld joint reduction factor of
1.0.
 For stainless steels and nickel base alloys, flame cutting is not allowed. Bevels shall
be prepared by plasma cutting or machining.
 Only stainless steel brushes shall be used on stainless steels and nickel base alloys.
 Prior to welding of stainless steels and nickel base alloys, the weld joint shall be
cleaned. The oxide layer shall be removed by grinding to a bright surface followed
by cleaning with acetone or a similar solvent.
 The root pass of butt welds for stainless steels and nickel base alloys shall be
performed using the GTAW process.
 Bore purging with inert Argon or Nitrogen gas is required for stainless steel welds.
 For ambient temperature service, austenitic stainless steel welding materials for
pressure boundary and load bearing welds shall contain a minimum delta ferrite
content of five percent (WRC Ferrite No. 5), based upon chemical analysis and the
WRC Delta Ferrite Diagram (See Figure 1).
 The ferrite content of stainless steel welding materials for temperature service
above 472C shall not exceed nine percent (WRC Ferrite No. 10).
 For cryogenic service below minus 101C, austenitic stainless steel welding
consumables shall be selected to produce weld deposits with an optimum ferrite
content and chemical composition to balance the requirements for hot cracking
resistance and low temperature toughness. Each batch of welding consumables
shall be tested and certified.
 Stainless steel weld procedure qualification tests for cryogenic service shall include
impact tests on weld metal as per ASME B31.3 Table 323.2.2.
 Shielding gas for GTAW and GMAW of nickel base alloys shall be commercially pure
argon or a mixture of argon and 5-10% hydrogen.

10080-1-SS-MT-007,Rev.1 Page 22 of 31
  Maximum interpass temperature for austenitic stainless steels shall not exceed
175C. This includes dissimilar welds between austenitic stainless steel and carbon
steel.

10080-1-SS-MT-007,Rev.1 Page 23 of 31
 APPENDIX 3
THE INDIAN BOILER REGULATIONS, Latest Revision
1.0 TESTS ON COMPLETED WELDS ON PIPELINES
1.1 Classification
For the purpose of tests, pipelines shall be divided into two classes:
Class I - Pipelines for service conditions in which any one of the following limits is
exceeded:-
Design temperature 281o C (425oF)
Design Pressure 17.6 kg/cm2 (250 lbs/sq in)
Feed Water 24.6 kg/cm2 (350 lbs/sq in)
Class II - Pipelines for service conditions in which none of the foregoing limits is
exceeded.
1.2. Identification of Welds
The Welders’ identification mark shall be stamped without indentation, or
stencilled adjacent to each completed weld.
1.3. Tests for Class I pipelines
(i) Where the completed pipelines are not subjected to hydraulic test:
Where the completed pipelines are not tested by the application of hydraulic
pressure,
the welds shall be subjected to the following inspection procedure:-
Piping over 102 mm. (4 in.) bore - All butt-welds shall be subjected to non-
destructive
examination by radiographic or other approved methods. The entire
circumference of the first five welds made by each welder shall be non-
destructively examined. If these are found to be satisfactory and the Inspecting
Officer or Inspector is in other respects satisfied with the welding technique,
methods of control and supervision employed, relaxation in the extent of non-
destructive examination may be considered, but this relaxation shall in no case
permit the non-destructive examination of less than one-third of the
circumference of each of the remaining welds made by the welder concerned.
Piping 102 mm (4 in.) bore and under, but not less than 38 mm (1 1/2 in.) bore -
Five per cent of the butt-welds made by each welder with a minimum of two
welds per welder, selected at random shall be subjected to non-destructive

10080-1-SS-MT-007,Rev.1 Page 24 of 31
 examination by either radiographer or other approved methods or may be cut out
for visual examination and bend tests.
Piping less than 38 mm (1 1/2 in.) bore - Special tests are not normally required
but two per cent of the welds by each welder on a pipeline may be cut out from
the pipeline for visual examination and bend tests.
(ii) Where the completed pipelines are subjected to hydraulic test:
Where the completed pipelines are tested by the application of hydraulic
pressure, the welds
shall be subjected to the following inspection procedure:-
Piping over 102 mm (4 in.) bore - Ten per cent of the welds made by each Welder
on a pipeline with a minimum of two welds per welder, selected at random, shall
be subjected to non-destructive examination by radiographic or other approved
methods.
Piping 102 mm. (4 in.) bore and under, but not less than 38 mm. (1 1/2 in.) bore
– Two per cent of the welds made by each welder on a pipeline with a minimum
of one weld per welder, selected at random, shall be subjected to non-destructive
examination by radiographic or other approved methods or may be cut out for
visual examination and bend tests.
Piping less than 38 mm (1 1/2 in.) bore - Special tests are not normally required,
but two per cent of the welds by each welder on a pipeline may be cut out from
the pipeline for visual examination and bend tests.

1.4. Tests for Class II pipelines

 All pipelines under this classification shall be subjected to hydraulic test on
completion of erection.
 On completion of the first ten production welds made by each welder, one of the
welds shall be cut out for test purposes or alternatively, the welder shall prepare a
test specimen made up of two similar lengths of piping welded in a position as
closely representative of a selected production weld as is practicable. The test
specimen shall be subjected to visual examination and bend tests.
 Two per cent of the remainder of the welds made by each welder shall be selected
at random and cut out for test purposes, or, alternatively, the welders shall prepare
a test specimen made up of two similar lengths of piping welded in a position as
closely representative of a selected production weld as is practicable. The test
specimen shall be subjected to visual examination and bend tests.

10080-1-SS-MT-007,Rev.1 Page 25 of 31
 1.5 Re-tests
If any test specimen is unsatisfactory, two further weld specimen for re-test shall
be selected from the production welds and subjected to tests. In the event of
failure of any of the re-test specimens, the production welds carried out by this
welder subsequent to the previous test shall be subject of special consideration.)

10080-1-SS-MT-007,Rev.1 Page 26 of 31
 Appendix 4 - NDT Specification for typical cases not directly covered by existing
Specification or Codes
CASE 1 NDT REQUIREMENT REFERENC REMARKS
DESCRIPTION
1 E CODE
CATEGORY D PROCESS LINES/ OTHER
THAN CATEGORY D/
HIGH PRESSURE &
TEMPERATURE LINES
Branch 1 DP test on either RT or UT on either side of ASME Interpret as per
opening1 on or side of the the branch connection B31.3- the code of
close to. Weld branch along the weld seam for 328.5.4 - fabrication and
seams not connection along 150 mm (min). h/ASME repair
meeting the the weld for 150 SEC VIII accordingly.
minimum mm (min). DIV I –
distance of 6 UW14.
times the pipe
wall thickness
or 50mm
(whichever is
greater)

RF-pad 2 DP test the portion of the weld which is ASME Interpret as per
masking. getting masked and 40 mm(min) weld length B31.3- the code of
welded seam. on either side & pad test at 3.5 Kg/sqcm for 328.5.4 - fabrication and
10 minutes and drop in pressure is an g&h. repair
indication of leak. accordingly.
Saddle pads
3 DP test the portion of the weld which is ASME Interpret as per
for supports.
. getting affected during welding of the pad B31.3- the code of
and 40mm (min) weld length on either side. 328.5.4 –h fabrication and
repair
accordingly.
Seam 4 Inspect the RT or UT of 150mm (min) 10080- Interpret as per
staggering
. not staggered seam length of the staggered 3PS-PL- the code of
meeting by DP of 150mm seams including the 006 fabrication and
separation of and subsequent Circular seam. repair
ASME SEC
90deg or 10 by Hydrotest. accordingly.
VIII DIV I
times UW-9(d).
thickness
whichever is
less.

10080-1-SS-MT-007,Rev.1 Page 27 of 31
 Seam 5 Inspect the Inspect the staggered 10080- Interpret as per
staggering
. staggered seam seam by RT only in the 3PS-PL- the code of
(tapping close by DP of 150mm area, which does not 006 fabrication and
to CS/LS or and subsequent meet the requirement of repair
pipe support by Hydrotest. 40mm or twice the accordingly.
close by thickness of pressure
CS/LS) not part, but in no case less
meeting 40 than 75mm and
mm or twice subsequent by
of thick of Hydrotest.
pressure part
Wherever 6 For Butt welds For Butt weld 100% 10080- Interpret as per
minimum . 100% PT/MT RT/UT 3PS-PL- the code of
distance (edge 006 fabrication and
For Fillet welds For Fillet welds 100%
to edge) as repair
100% PT/MT MT/PT
specified in accordingly.
PL-006
between
circumferentia
l butt/fillet
welds can not
be met, the
following
additional
NDT shall be
followed. Also
the minimum
distances
between
fillet/socket
welds shall be
specified.

10080-1-SS-MT-007,Rev.1 Page 28 of 31
 PWHT is7not 1/ PWHT not 1/ PWHT not required
required. for required for P- for P-No. 1 materials ASME Interpret as per
fillet welds at No. 1 materials when weld throat B31.3 the code of
slip-on flanges when weld thickness is 16mm (5/8 Section fabrication
and sock welds throat thickness in.) or less, regardless of 331.1.3 (b)
in piping 2 inch is 16mm (5/8 in.) base metal thickness.
nominal bore or less, 2/ PWHT not for P-No.
and below and regardless of
3, 4, 5, or 10A materials
for attachment base metal when weld throat
of External thickness. thickness is 13mm (1/2
non-pressure 2/ PWHT not for in.) or less, regardless of
parts such as P-No. 3, 4, 5, or base metal thickness,
lugs or other 10A materials provided that not less
Pipe when weld than the recommended
Supporting throat thickness preheat is applied, and
elements in all is 13mm (1/2 in.) the specified minimum
piping sizes or less, tensile strength of the
under the regardless of base material is less than
following base metal 490 MPa (71 ksi)
conditions:.
thickness,
provided that not
less than the
recommended
preheat is
applied, and the
specified
minimum tensile
strength of the
base material is
less than 490
MPa (71 ksi).

10080-1-SS-MT-007,Rev.1 Page 29 of 31
 Figure 1
WRC diagram

10080-1-SS-MT-007,Rev.1 Page 30 of 31
 APPENDIX - 5
Piping Class wise NDE requirements

For details, refer latest Standard Specification document No. 10080-1-SS-PP-038-(Part-III)

1

10080-1-SS-MT-007,Rev.1 Page 31 of 31