Beruflich Dokumente
Kultur Dokumente
N-133
N
REV.. L
ENGLISH
E
02 / 2014
CO
ONTEC
C
Comiss
o de Normalizzao
Tcnica
Weldin
ng
SC-26
Welding
1st Amendm
ment
CONTE
ENTS OF THE
T
1st AME
ENDMENT - 02/2014
- Table 6
Alteratio
on of the textt of Note 1.
Include of Note 2.
- Subse
ection 5.12.4..2
Alteratio
on of the textt.
PROPE
ERTY OF PETROBRAS
4 pages
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Welding
Procedure
This Standard replaces and cancels its previous revision.
The CONTEC - Authoring Subcommittee provides guidance on the
interpretation of this Standard when questions arise regarding its contents. The
Department of PETROBRAS that uses this Standard is responsible for adopting
and applying the sections, subsections and enumerates thereof.
CONTEC
Comisso de Normalizao
Tcnica
SC - 26
Welding
Introduction
PETROBRAS Technical Standards are prepared by Working Groups - WG
(consisting specialized of Technical Collaborators from Company and its Subsidiaries), are
commented by Company Units and its Subsidiaries, are approved by the Authoring Subcommittees SCs (consisting of technicians from the same specialty, representing the various Company Units and
its Subsidiaries), and ratified by the Executive Nucleus (consisting of representatives of the Company
Units and its Subsidiaries). A PETROBRAS Technical Standard is subject to revision at any time by its
Authoring Subcommittee and shall be reviewed every 5 years to be revalidated, revised or cancelled.
PETROBRAS Technical Standards are prepared in accordance with PETROBRAS Technical
Standard N-1. For complete information about PETROBRAS Technical Standards see PETROBRAS
Technical Standards Catalog.
PROPERTY OF PETROBRAS
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Summary
Foreword................................................................................................................................................ 12
1 Scope................................................................................................................................................. 12
2 Normative References ....................................................................................................................... 12
3 Terms and Definitions........................................................................................................................ 15
4 General Conditions ............................................................................................................................ 17
4.1 General Welding Conditions ................................................................................................ 17
4.2 Welding Documents ............................................................................................................. 18
4.3 Welding Procedure Qualification .......................................................................................... 18
4.4 Personnel Qualification ........................................................................................................ 20
4.4.1 Welder and Welding Operator ..................................................................................... 20
4.4.2 Inspectors ..................................................................................................................... 21
4.4.3 Welding Supervisors or Welding Foremen .................................................................. 22
4.4.4 Certified Welding Specialist Engineer and Certified Welding Technologist................. 22
4.5 Welding Processes and Equipment ..................................................................................... 23
4.6 Welding Technique............................................................................................................... 24
4.7 Consumable ......................................................................................................................... 26
4.8 Environmental Conditions .................................................................................................... 28
4.9 Preheating and Interpass Temperature ............................................................................... 28
4.10 Post-heating ....................................................................................................................... 29
4.11 Inspection and Quality Control ........................................................................................... 29
4.12 Weld Repairs ...................................................................................................................... 30
4.13 Post Weld Heat Treatment (PWHT) ................................................................................... 30
4.14 Auxiliary Assembly Devices ............................................................................................... 31
4.15 Marking of Welded Joints ................................................................................................... 31
4.16 Safety in Welding ............................................................................................................... 32
5 Materials ............................................................................................................................................ 32
5.1 Carbon Steel and Carbon-Manganese Steel ....................................................................... 32
5.1.1 Introduction .................................................................................................................. 32
5.1.2 Weldability .................................................................................................................... 32
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5.3.4.4 FCAW-G............................................................................................................... 41
5.3.4.5 SAW ..................................................................................................................... 41
5.3.5 General Conditions for Consumables .......................................................................... 41
5.3.6 Preheating and Interpass Temperature ....................................................................... 43
5.3.7 Post-heating ................................................................................................................. 44
5.3.8 Post Weld Heat Treatment (PWHT)............................................................................. 45
5.3.9 Hardness Test in Homogeneous Joints ....................................................................... 46
5.3.10 Weld Repair ............................................................................................................... 46
5.3.11 Supplementary Requirements for Maintenance Weld ............................................... 46
5.3.12 Supplementary Requirements for Inspection ............................................................. 47
5.4 Nickel Steel .......................................................................................................................... 47
5.4.1 Introduction .................................................................................................................. 47
5.4.2 Weldability .................................................................................................................... 47
5.4.3 General Welding Technique ........................................................................................ 48
5.4.4 Applicable Welding Processes ..................................................................................... 48
5.4.4.1 SMAW .................................................................................................................. 48
5.4.4.2 GTAW .................................................................................................................. 48
5.4.4.3 GMAW.................................................................................................................. 48
5.4.4.4 SAW ..................................................................................................................... 49
5.4.5 General Conditions for Consumables .......................................................................... 49
5.4.6 Preheating and Interpass Temperature ....................................................................... 50
5.4.7 Post-heating ................................................................................................................. 50
5.4.8 Post Weld Heat Treatment (PWHT)............................................................................. 50
5.4.9 Weld Repair ................................................................................................................. 51
5.4.10 Supplementary Requirements for Maintenance Weld ............................................... 51
5.4.11 Supplementary Requirements for Inspection ............................................................. 51
5.5 Austenitic Stainless Steels ................................................................................................... 51
5.5.1 Introduction .................................................................................................................. 51
5.5.2 Weldability .................................................................................................................... 52
5.5.3 General Welding Technique ........................................................................................ 52
5.5.4 Applicable Welding Processes ..................................................................................... 55
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Figures
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Tables
Table 1 - Diffusible Hydrogen Limit in FCAW Electrodes ...................................................................... 33
Table 2 - Minimum Preheating and Interpass Temperatures Specified for Welding of Carbon Steel and
Carbon-manganese Steel ...................................................................................................... 34
Table 3 - Minimum and Maximum Preheating and Interpass Temperature of Heat-Treated Low Alloy
Steels .................................................................................................................................... 38
Table 4 - Designation of P numbers, According to ASME BPVC Section IX ........................................ 39
Table 5 - Consumables for Molybdenum and Chromium-Molybdenum Steels ..................................... 42
Table 6 - Consumables for Heterogeneous Welding of Molybdenum and Chromium-Molybdenum
Steels .................................................................................................................................... 43
Table 7 - Preheating and Interpass Temperature for Chromium-Molybdenum and Molybdenum Steels ... 44
Table 8 - Post-heating for Chromium-Molybdenum and Molybdenum Steels ...................................... 45
Table 9 - Hardness in Welded and Heat Affected Zone after PWHT .................................................... 46
Table 10 - Electrodes and Rods for Nickel Steel................................................................................... 49
Table 11 - Minimum Preheating and Interpass Temperature for Welding of Steels to Nickel Homogeneous Welding ......................................................................................................... 50
Table 12 - Minimum Preheating and Interpass Temperature for Welding of Steels to Nickel Heterogeneous Welding ...................................................................................................... 50
Table 13 - Consumables of Austenitic Stainless Steels ........................................................................ 57
Table 14 -Coated Electrode, Rod and Solid Wire for Welding of Superaustenitic Stainless Steels .... 61
Table 15 - Chemical Composition (% in Weight) of the Main Duplex Stainless Steels......................... 64
Table 16 - Additional Testing to ASME BPVC Section IX ..................................................................... 67
Table 17 - Consumables of Duplex and Superduplex Stainless Steels ................................................ 68
Table 18 - Electrodes and Rods for Martensitic Stainless Steels ......................................................... 72
Table 19 - Electrodes and Rods for Ferritic Stainless Steels ................................................................ 76
Table 20 - Electrodes, Rods and Solid Wires for Nickel and Nickel Alloys ........................................... 81
Table 21 - Rods for Copper and Copper Alloys .................................................................................... 85
Table 22 - Filler Metals for Coating Deposited by Welding - Weld Overlay - in Carbon Steel or Low
Alloy Base-Plate on Equipment with No Need for PWHT .................................................... 89
Table 23 - Filler Metals for Coating Deposited by Welding - Weld Overlay - in Carbon Steel or Low
Alloy Base-Plate on Equipment Requiring PWHT ............................................................... 90
Table 24 - Consumables, Preheating and Post-Heating Temperatures for Welding of Dissimilar Joints ... 92
Table A.1 - Simple Sampling Plan - Normal Inspection of Consumers Risk 5 % and 10 % ................ 96
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Foreword
This Standard is the English version (issued in 12/2013) of PETROBRAS N-133 REV. L 07/2013. In case
of doubt, the Portuguese version, which is the valid document for all intents and purposes, shall be used.
1 Scope
1.1 This Standard establishes the requirements and recommended practices for fusion welding of
steels and nonferrous alloys, except for 1.1.1 and 1.1.2.
1.1.1 In the event of welding or hot tapping of equipment, industrial pipes and pipelines in operation
with internal fluid, PETROBRAS N-2163 shall be used.
1.1.2 In the event of underwater welding, PETROBRAS N-2036 shall be used.
1.2 This Standard applies to the following materials and conditions:
a) carbon steel and carbon-manganese;
b) heat-treated low alloy steel;
c) chrome-molybdenum steel and molybdenum steel;
d) nickel steel;
e) austenitic stainless steel;
f) super-austenitic stainless steel;
g) duplex, super-duplex and hyper-duplex stainless steels;
h) martensitic stainless steel;
i) ferritic stainless steel;
j) nickel and nickel alloy;
k) copper and copper alloy;
l) coated sheet;
m) dissimilar welding.
1.3 This Standard applies to procedures started as of its date of issuance.
1.4 This Standard contains Technical Requirements and Recommended Practices.
2 Normative References
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document applies.
PETROBRAS N-1438 - Terminologia Soldagem;
PETROBRAS N-1738 - Descontinuidades em Juntas Soldadas, Fundidos, Forjados e Laminados;
PETROBRAS N-1859 - Qualificao de Consumveis de Soldagem;
PETROBRAS N-2036 - Soldagem Subaqutica;
PETROBRAS N-2163 - Soldagem e Trepanao em Equipamentos, Tubulaes Industriais
e Dutos em Operao;
PETROBRAS N-2301 - Elaborao da Documentao Tcnica de Soldagem;
PETROBRAS N-2349 - Segurana nos Trabalhos de Soldagem e Corte;
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ABNT NBR 5425 - Guia para Inspeo por Amostragem no Controle e na Certificao de
Qualidade;
ABNT NBR 5426 - Planos de Amostragem e Procedimentos na Inspeo por Atributos;
ABNT NBR 5427 - Guia para Utilizao da Norma ABNT NBR 5426 - Planos de
Amostragem e Procedimentos na Inspeo por Atributos;
ABNT NBR 14842 - Critrios para a Qualificao e Certificao de Inspetores de Soldagem;
ABNT NBR ISO IEC 17025 - Requisitos Gerais para Competncia de Laboratrios de
Ensaios e Calibrao;
ABNT NBR NM ISO 9712 - Ensaio No Destrutivo - Qualificao e Certificao de Pessoal;
FBTS 007 - Critrios para a Qualificao e Certificao de Engenheiro Especialista em
Soldagem e Tecnlogo de Soldagem;
ISO IEC 17024 - Conformity Assessment - General Requirements for Bodies Operating
Certification of Persons;
ISO GUIDE 65 - General Requirements for Bodies Operating Product Certification Systems;
API 510 - Pressure Vessel Inspection Code: In-Service Inspection, Rating, Repair, and
Alteration;
API RP 582 - Welding Guidelines for the Chemical, Oil, and Gas Industries;
API RP 934-A - Materials and Fabrication of 2 1/4Cr-1Mo, 2 1/4Cr-1Mo-1/4V, 3Cr-1Mo, and
3Cr-1Mo-1/4V Steel Heavy Wall Pressure Vessels for High-temperature, High-pressure
Hydrogen Service;
API TR 934-B - Fabrication Considerations for Vanadium-Modified Cr-Mo Steel Heavy Wall
Pressure Vessels;
API RP 934-C - Materials and Fabrication of 1 1/4Cr-1/2Mo Steel Heavy Wall Pressure
Vessels for High-pressure Hydrogen Service Operating at or Below 825 F (441 C);
API TR 934-D - Technical Report on the Materials and Fabrication Issues of 11/4Cr-1/2Mo
and 1Cr-1/2Mo Steel Pressure Vessels;
API RP 934-E - Recommended Practice for Materials and Fabrication of 11/4CR-1/2Mo
Steel Pressure Vessels for Service Above 825 F (440 C);
API TR 938-B - Use of 9Cr-1Mo-V (Grade 91) Steel in the Oil Refining Industry;
ASME BPVC - Section II, Part C - Specifications for Welding Rods, Electrodes, and Filler
Metals;
ASME BPVC - Section V - Nondestructive Examination;
ASME BPVC - Section VIII - Division 1 - Rules For Construction of Pressure Vessels;
ASME BPVC - Section IX - Qualification Standard for Welding and Brazing Procedures,
Welders, Brazers, and Welding and Brazing Operators;
ASTM A 262 - Standard Practices for Detecting Susceptibility to Intergranular Attack in
Austenitic Stainless Steels;
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ASTM A 370 - Methods and Definitions for Mechanical Testing of Steel Products;
ASTM A 380 - Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel
Parts, Equipment, and Systems;
ASTM A 1038 - Standard Test Method for Portable Hardness Testing by the Ultrasonic
Contact Impedance Method;
ASTM E 140 - Standard Hardness Conversion Tables for Metals Relationship Among Brinell
Hardness, Vickers Hardness, Rockwell Hardness, Superficial Hardness, Knoop Hardness,
and Scleroscope Hardness;
ASTM E 340 - Standard Test Method for Macroetching Metals and Alloys;
ASTM E 384 - Standard Test Method for Knoop and Vickers Hardness of Materials;
ASTM E 562 - Standard Test Method for Determining Volume Fraction by Systematic
Manual Point Count;
ASTM G 48 - Standard Test Methods for Pitting and Crevice Corrosion Resistance of
Stainless Steels and Related Alloys by Use of Ferric Chloride Solution;
AWS A3.0 - Standard Welding Terms and Definitions Including Terms for Adhesive Bonding,
Brazing, Soldering, Thermal Cutting, and Thermal Spraying;
AWS A4.2 - Standard Procedures for Calibrating Magnetic Instruments to Measure the Delta
Ferrite Content of Austenitic and Duplex Ferritic-Austenitic Stainless Steel Weld Metal;
AWS A5.01 - Procurement Guidelines for Consumables - Welding and Allied Processes Flux and Gas Shielded Electrical Welding Processes;
AWS A5.1 - Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding;
AWS A5.4 - Specification for Stainless Steel Electrodes for Shielded Metal Arc Welding;
AWS A5.5 - Specification for Low-Alloy Steel Electrodes for Shielded Metal Arc Welding;
AWS A5.6 Specification for Copper and Copper-Alloy Electrodes for Shielded Metal Arc
Welding;
AWS A5.7 - Specification for Copper and Copper-Alloy Bare Welding Rods and Electrodes;
AWS A5.9 - Specification for Bare Stainless Steel Welding Electrodes and Rods;
AWS A5.11 - Specification for Nickel-Alloy Welding Electrodes for Shielded for Metal Arc
Welding;
AWS A5.12 - Specification for Tungsten and Oxide Dispersed Tungsten Electrodes for Arc
Welding and Cutting;
AWS A5.14 - Specification for Nickel and Nickel-Alloy Bare Welding Electrodes and Rods;
AWS A5.17 - Specification for Carbon Steel Electrodes and Fluxes for Submerged Arc
Welding;
AWS A5.18 - Specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc
Welding;
AWS A5.22 - Specification for Stainless Steel Flux Cored and Metal Cored Welding
Electrodes and Rods;
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AWS A5.23 - Specification for Low-Alloy Steel Electrodes and Fluxes for Submerged Arc Welding;
AWS A5.28 - Specification for Low-Alloy Steel Electrodes and Rods for Gas Shielded Arc Welding;
AWS A5.29 - Specification for Low-Alloy Steel Electrodes for Flux Cored Arc Welding;
AWS A5.32 - Welding Consumables - Gases and Gas Mixtures for Fusion Welding and
Allied Processes;
AWS A5.34 - Specification for Nickel-Alloy Electrodes for Flux Cored Arc Welding;
AWS A5.36 - Specification for Carbon and Low-Alloy Steel Flux Cored Electrodes for Flux
Cored Arc Welding and Metal Cored Electrodes for Gas Metal Arc Welding;
AWS C5.5 - Recommended Practices for Gas Tungsten Arc Welding;
AWS D1.1 - Structural Welding Code-Steel;
AWS D10.8 - Recommended Practices for Welding of Chromium-Molybdenum Steel Piping
and Tubing;
AWS D10.10 - Recommended Practices for Local Heating of Welds in Piping and Tubing;
NORSOK M-601 - Welding and Inspection of Piping;
WRC 452 - Recommended Practices for Local Heating of Welds in Pressure Vessels.
NOTE
For documents referred in this Standard and for which only the Portuguese version is
available, the PETROBRAS department that uses this Standard should be consulted for any
information required for the specific application.
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3.6
FCAW-S - Flux Cored Self-Shielded Arc Welding
welding process using self-shielded flux-cored wire
3.7
GMAW - Gas Metal Arc Welding
arc welding process using shielding gas, with automatic wire feeding. Also known as "MIG/MAG"
3.8
GTAW - Gas Tungsten Arc Welding
arc welding process using shielding gas with non-consumable tungsten electrode. Also known as
"TIG"
3.9
level 2 welding inspector
professional certified by the Sistema Nacional de Qualificao e Certificao - Pessoal (SNQC-PS) as
welding inspector level 2 in the design standard applicable to the service
3.10
high level of diffusible hydrogen in the weld metal
hydrogen level exceeding 16 mL of hydrogen per 100 g of deposited weld metal
3.11
low level of diffusible hydrogen in the weld metal
hydrogen level above 4 mL and of 8 mL or below per 100 g of deposited weld metal (H8)
3.12
extra low level of diffusible hydrogen in the weld metal
hydrogen level exceeding 4 mL of hydrogen per 100 g of deposited weld metal (H4)
3.13
average level of diffusible hydrogen in the weld metal
hydrogen level above 8 mL and of 16 mL or below per 100 g of deposited weld metal (H16)
3.14
oscillating pass
the oscillation of the electrode exceeds in more than three times the diameter of the electrode core
wire
3.15
straight-line pass
straight-line pass with no significant oscillation, in order to ensure specific requirements for corrosion
resistance and toughness. In some cases, depending on the base material, the bead may have a
width up to three times the diameter of the coated electrode core wire
3.16
PAW - Plasma Arc Welding
welding process using plasma
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3.17
welding responsible technician of PETROBRAS
maintenance professional of PETROBRAS Operating Units and technician responsible for welding,
designated by the Operating Unit and qualified to assess the behavior of the welded joint regarding
the application and exposure to the environment. The selection of the Welding Procedure
Specification / Welding Procedure Qualification Record (WPS / RQPS) that best meets the service
conditions will be responsibility of this professional, who shall be registered in the Conselho Regional
de Engenharia e Arquitetura (CREA), have experience and solid background in the welding area
3.18
SAW - Submerged Arc Welding
welding process using submerged arc
3.19
SMAW - Shielded Metal Arc Welding
welding process using coated electrode
3.20
multiple pass welding
fusion weld produced by more than one progression of arc, flame, or the energy source (pass) along
the joint
3.21
welding supervisor or welding foreman
leader of the team of welders, responsible for the team performance based on his/her knowledge
about the qualification criteria of welders and welding operators, WPS, Instruction for Execution and
Welding Inspection (IEIS), welding position, range of thicknesses, welding symbols and terminology,
and technical drawing
3.22
SW - Stud Welding
welding process using studs
4 General Conditions
4.1 General Welding Conditions
4.1.1 This Standard shall be used in conjunction with the design, fabrication, assembly and post
fabrication standards, and with standards of additional requirements relating to the service conditions
of the equipment item or the structure. The conflicting requirements shall be discussed during the
clarification phase in bidding period, with PETROBRASs decision prevailing.
4.1.2 Welding is not permitted without the required qualification of welders and welding procedures,
according to the design code.
4.1.3 The requirements for welding operation are found in this Section, being valid for any of the
materials mentioned and all equipment items or structures made from those materials.
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4.1.4 Section 5 lists the requirements relating to various materials mentioned, such as, for example,
an indication of consumables, welding processes, pre-heating, post-heating and heat treatment
temperatures, and specific conditions for welding technique of the materials.
4.1.5 All welding requirements which depend on the characteristics of the equipment or structure,
such as, for example, details of bevels, adjustment of parts, dimensional tolerances, need for heat
treatment and its application method, requirements for inspection, and evaluation criteria of defects,
are not contained in this standard. This information is defined by design, fabrication, assembly and
post fabrication standards, and with standards of additional requirements relating to the service
conditions of the equipment item or the structure.
4.1.6 The heterogeneous welding shall be avoided, and its performance is mandatorily tied to prior
approval by PETROBRAS.
4.1.7 The autogenous welding shall be avoided, and its performance is mandatorily tied to prior
approval by PETROBRAS.
4.2 Welding Documents
4.2.1 All welding documents shall be prepared in accordance with PETROBRAS N-2301.
4.2.2 Welding documents shall be prepared and qualified in accordance with design, fabrication,
assembly and maintenance designs, as well as with technical specifications and contract
requirements, which may indicate additional testing, based on service or material conditions.
4.2.3 Welding documents shall be approved by the qualified welding professionals, according to
4.4.2.1 or 4.4.4, observing the responsibilities of each certification level, except as described in 4.2.4.
4.2.4 For welding in operation, maintenance or works under management of PETROBRAS' Operating
Units, the IESI may be approved by the welding responsible technician of PETROBRAS.
[Recommended Practice]
4.2.5 The selection of WPS/RQPS for welding operation and maintenance, when done by the welding
professional of the contractor, shall be endorsed by the welding responsible technician of
PETROBRAS.
4.2.6 Prequalified welding procedures provided in AWS D1.1 and the standard procedures specified
in ASME BPVC Section IX are not accepted by PETROBRAS.
4.3 Welding Procedure Qualification
4.3.1 The test specimens shall be identified in the test coupon before being removed, and their
identification shall be maintained until the tests are performed.
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4.3.2 The maximum tensile strength of the deposited weld metal shall be equal to or greater than the
minimum tensile strength specified for the base metal in the homogeneous welding. For dissimilar
welding, the maximum tensile strength of deposited weld metal shall be equal to or greater than the
minimum tensile strength specified for the base metal of lower strength.
4.3.3 In the bend test, the melted and heat affected zones of the joints shall be contained within the
bent portion of the test specimen and show plastic deformation.
4.3.4 Test specimens for mechanical tests shall undergo dimensional and visual inspection before
tests are performed.
NOTE
The dimensional tolerances and finish level of impact test specimens shall comply with
ASTM A 370. The notch inspection of the impact test specimen shall be made in a profile
comparator.
4.3.5 When impact testing on heterogeneous welds and dissimilar joints is required, all zones of
different chemical composition, such as Heat Affected Zone (HAZ) and the fusion zone, shall be
represented by complete set of test specimens with notch located within those zones.
4.3.6 When the design, fabrication or assembly standard requires hardness testing in qualification of
welding procedure, the Annex B of this Standard may be adopted on fusion zone, heat affected zone
and base metal, and its results shall be compatible with the reference standard. [Recommended
Practice]
NOTE
When Annex B is adopted, it shall not be partially applied; it shall be fully applied, as a
normative requirement.
4.3.7 The application method and trademark of protective varnish of bevel shall be evaluated during
the qualification of welding procedure, when its removal before welding is not provided.
4.3.8 For clad plates, a method that proves the complete removal of the coating material shall be
assessed and approved during the welding procedure qualification. This method may not leave
residues that contaminate the weld metal.
4.3.9 For pressure vessel and other equipment with toughness requirements, during the welding
procedure qualification, the test specimens to be submitted to mechanical testing shall undergo a Post
Weld Heat Treatment (PWHT) that simulates all PWHT performed during fabrication and assembly
phases, and an additional one, foreseeing a future repair of equipment.
4.3.10 In PWHT of the test coupon used for procedure qualification, the provisions of 4.13 shall be
observed.
4.3.11 Welding consumables shall be approved according to 4.7.1. In case of welding consumables
are required to be approved by PETROBRAS N-1859, the consumable trademark is not an essential
variable in qualified procedures, unless the trademark is an essential variable required by design
code.
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4.3.12 During fabrication or assembly using materials supplied in quenched and tempered or heatmechanical treatment condition, the welding procedure qualification shall be performed with the
material of the same fabrication and heat treatment process. For enlargement of existing facilities,
maintenance or rehabilitation of pipelines, the materials used shall have their quality certificate issued
by the manufacturer, containing analyzed mechanical and chemical composition properties. In these
cases, hardness shall also be measured. For maintenance services, in the occasional absence of the
manufacturers quality certificate, mechanical tests and chemical analyses shall be performed,
monitored by PETROBRAS, in order to fit in the design standard.
4.3.13 The welding procedure qualification and its tests for mirror tube welded joints shall comply with
the design standard and with API RP 582.
4.3.14 For H2S service, the minimum value of the final qualified range shall be limited to 10 % below
the value recorded by the test coupon presenting the lowest heat input.
4.4 Personnel Qualification
4.4.1 Welder and Welding Operator
4.4.1.1 Welders and welding operators shall be qualified in accordance with the applicable design
standards.
4.4.1.2 The qualification of welders and welding operators shall be documented by the Welding
Record Report (RRS) and the Certificate of Qualification of Welders and Operators (RQS).
4.4.1.3 Qualified welders and welding operators shall bear visible identification including name, the
Brazilian Register of Individual Taxpayers (CPF), the stamp number and qualification. For services
performed abroad, the CPF shall be replaced by code or numbering of the document that
unequivocally identifies the welders and operators.
4.4.1.4 A List of Qualified Welders and Welding Operators (RSQ) shall be issued.
4.4.1.5 Test specimens shall be identified in the test coupon, in order to be maintained traceable. The
identification shall be maintained until the tests are performed.
4.4.1.6 For qualification of the welder or welding operator, the methods for cleaning between weld
passes, removal of craters, and arc strikes in the bevel or auxiliary plate shall be the same as those
specified production welds.
4.4.1.7 The qualification of welder or welding operator shall include visual inspection of test coupon
welds, with the same interpretation criterion of the design, fabrication and assembly standard of
equipment or structure.
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4.4.1.8 The control over performance of welders shall be carried out using the Control Over
Performance of Welders and Welding Operators (CDS) form, according to the calculation
methodology defined in PETROBRAS N-2301. The acceptance criteria listed below shall be included
in the specific procedure of the contractor, which shall be evaluated and approved by PETROBRAS
before starting the services:
a) maintenance in workshop: in radiograph, a total not exceeding 5 % of disapproved films
(a film) in a minimum of twenty radiographed films, or, in ultrasound, the sum of defective
lengths not exceeding 2,0 % (60 mm) in at least 3,0 m of weld inspected in the
development of the welded perimeter;
b) maintenance in field: in radiography, a total not exceeding 15 % of disapproved films (a
film) in a minimum of twenty radiographed films, or, in ultrasound, the sum of defective
lengths not exceeding 5,0 % (150 mm) in at least 3,0 m of weld inspected in the
development of the welded perimeter;
NOTE 1 For radiography, it is understood that the welder shall be disqualified when four films for
welds in field or two films for welds in workshop are disapproved, regardless of reaching the
amount of twenty films in the period.
NOTE 2 For ultrasound, it is understood that the welder shall be disqualified when he/she obtains the
minimum repair length of 60 mm for welds in workshop or 150 mm for welds in field,
regardless of reaching the minimum length to be inspected of 3,0 m.
c) construction and assembly: in radiography, a total not exceeding 10 % of disapproved
films (two films) in a minimum of twenty radiographed films, or, in ultrasound, the sum of
defective lengths not exceeding 2,5% (75 mm) in at least 3 m of weld inspected in the
development of the welded perimeter;
d) fabrication: in radiography, a total not exceeding 10 % of disapproved films (four films) in
a minimum of forty radiographed films, or, in ultrasound, the sum of defective lengths not
exceeding 2,5% (150 mm) in at least 6 m of weld inspected in the development of the
welded perimeter.
4.4.1.9 The periodicity for presentation of CDS shall be sufficient to ensure the required corrections
are done with no difficulty and without compromising the execution term and quality of work or service
in progress. 4.4.1.9 In every case, the periodicity for presentation of CDS shall be previously approved
by PETROBRAS.
4.4.2 Inspectors
4.4.2.1 Welding inspectors shall be qualified in accordance with the Sistema Nacional de Qualificao
e Certificao de Inspetores de Soldagem (SNQC - IS), according to ABNT NBR 14842. The welding
inspector level 2 shall be qualified and certified in the main applicable standard to perform the
attributions provided in ABNT NBR 14842 in relation to welding documentation, monitoring and
approval of qualification tests, supervision of level 1 inspectors, etc. For welding services performed
abroad, welding inspectors shall be qualified and certified by international entities meeting the
requirements of ISO IEC 17024, in which case prior approval by PETROBRAS will be necessary. The
welding inspector level 2 employed abroad shall also be qualified and certified in the main applicable
standard or evidence a minimum of one year of experience working with the mentioned standard.
4.4.2.2 For services performed in Brazil, the qualification and certification of personnel for nondestructive testing shall be made by the Sistema Nacional de Qualificao e Certificao em Ensaios
No Destrutivos (SNQC - END), according to ABNT NBR NM ISO 9712, and the visual testing may
also be performed by welding inspector qualified and certified by SNQC - IS. For inspection services
performed abroad, non-destructive testing inspectors shall be qualified and certified by independent
international entities, accredited by national bodies in their respective countries, which fully meet the
requirements of ISO IEC 17024 and operate in full compliance with ISO 9712.
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4.4.2.3 The monitoring of welding performance activities by certified welding inspectors level 1 and
level 2 shall be made clear in applicable contracts.
4.4.3 Welding Supervisors or Welding Foremen
4.4.3.1 Welding supervisors and foremen shall have the following minimum knowledge:
a) interpret the welding information and parameters of IEIS;
b) know the control methodology of quality, storage and drying of consumables, specified in
the contractors procedure;
c) know the welder qualification limits;
d) know and instruct welders about the required precautions for pre-heating
(homogenization e temperature measuring), interpass temperature control, and
post-heating.
4.4.3.2 It is understood as activities of the welding supervisor or foreman, for example:
a) review the service orders, IEIS, bevel drawings of joints to be welded, so as to:
determine the quantity and type of consumables to be requested;
specify which welding machines and process shall be used in each work front;
assign welders and/or welding operators to adequate fronts;
explain the requirements for bevel preparation, pre/post-heating and inter-pass
temperatures for each work front to welders and/or welding operators;
b) ensure the correct consumables are delivered to each work front;
c) monitor the work fronts in order to ensure that:
every welder or welding operator in service in field/factory has been assigned to a task
within the scope of their certification;
every welding service in field/factory is performed within the requirements of IEIS;
the storage requirements of welding consumables in work fronts are complied with;
d) ensure that joints to be welded in next shift have the correct joint geometry, and, if not,
give feedback to the boiler supervision;
e) monitor the field assembly and adjustment of welding machines, ensuring they are
working properly;
f) at the end of each shift, ensure the consumables that returned to warehouse are duly
handled and stored;
g) manage the workforce under his/her supervision, in order to ensure safety and good
progress of welding services.
4.4.4 Certified Welding Specialist Engineer and Certified Welding Technologist
Welding specialist engineers and technologists shall be certified in accordance with the Fundao
Brasileira de Tecnologia da Soldagem (FBTS), with their attributions defined by FBTS 007.
NOTE
The certification process is being implemented by FBTS and will be available in January
2014.
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control and maintain the temperature up to 400 C, and have a thermometer, thermostat and vent with
a diameter larger than 10 mm.
4.5.6.1 Oven for drying coated electrodes shall have perforated or grid-shaped shelves at least 25
mm away from the vertical walls.
4.5.6.2 Oven for drying fluxes shall have a shaking device or trays at least 25 mm away from the
vertical walls.
4.5.7 Ovens used for keeping coated electrodes and fluxes dry shall be provided with a thermometer,
thermostat and electrical resistances to control and keep temperatures up to 200 C. Ovens for
keeping coated electrodes dry shall have perforated or grid-shaped shelves.
4.5.8 There shall be at least one storage oven, a drying oven, and an oven for keeping things dry,
which may be fixed or portable.
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4.5.9 The portable oven for keeping low hydrogen coated electrodes dry shall have electrical
resistances to keep the temperature between 80 C and 150 C, and to be of exclusive use for each
welder. The ovens shall be calibrated.
4.5.10 Equipment for pre-heating, post-heating and PWHT shall meet the fabrication and assembly
requirements of the equipment or structure.
4.5.11 Pre-heating, interpass and post-heating temperatures shall be checked by means of optical or
contact pyrometer, taking care so that the instrument adjustment is correlated with the emissivity of
the material. The temperature stick may also be used, as long as it does not conflict with Section 5.
4.5.12 Measuring and testing instruments shall be calibrated in accredited laboratories, according to
ABNT NBR ISO/IEC 17025. It is acceptable that the calibrations are performed using standards traced
by the Rede Brasileira de Calibrao (RBC) or INMETRO. For calibration performed abroad, the
laboratory shall have its metrological system formally recognized as operating in accordance with
ISO/IEC 17025. Calibration of measuring and testing instruments shall follow a Calibration Plan
contained in the Quality System of the unit or contractor.
4.5.13 Tungsten electrodes specified in AWS A5.12 shall be used. The electrode sharpening profile
shall be performed in accordance with AWS C5.5. Sharpening shall be performed longitudinally on the
electrode.
4.5.14 It is recommended the use of tungsten electrodes connected to Cerium (Ce), Lanthanum (La)
and Zirconium (Zr). [Recommended Practice]
4.5.15 For the preparation of the thoriated electrode tips, it shall be used a tungsten sharpener with
container that prevents dispersion in the environment.
4.6 Welding Technique
4.6.1 The use grounding clamps made of copper alloys is not allowed. In addition, there shall be no
contact of between copper pieces (or its alloys) and the areas heated or melted by welding and heat
treatment, except in the case of copper bars for lateral protection of electrogas welding and copper
butt-straps that are not consumable in any process.
4.6.2 The electrical welding arc shall be struck at the bevel or an appendix plate used for that
purpose.
4.6.3 Joints to be welded shall be free of oil, grease, rust, slag, paint, liquid penetrant testing
residues, sand, and soot from gas preheating, in an area of at least 25 mm on each side of the edges,
both internally and externally.
4.6.4 For welding with gas shielding, the bevel and edges shall be cleaned to white metal, in an area
of at least 25 mm on both internal and external sides.
4.6.5 When preparing the bevel, thermal or mechanical cutting irregularities and slag shall be
removed.
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4.6.6 Carbon, slag and copper deposits resulting from carbon electrode cutting operations shall be
mechanically removed to ensure complete removal of HAZ and the contaminants.
4.6.7 Stainless steel, nickel and nickel-alloy materials shall be stored, handled and processed
completely separated from other materials, in order to avoid the risk of contamination.
4.6.8 Slag removal and cleaning tools shall be made of materials suitable for each base metal.
4.6.9 The gas shielding shall comply with requirements of AWS A5.32. This requirement shall be
mandatory from July 2014 on.
4.6.10 When required in Section 5, the inert gas protection shall be used from the inside of the part
(purge) until it reaches the lower value between: deposit (root pass + filling) of 6.4 mm or the thickness
of the welded joint.
4.6.11 In general, controlled hammering of welds is not permitted; however, it may be accepted if
approved by PETROBRAS and supported by qualified procedure, except for the first and last layer, for
which it is always prohibited.
4.6.12 During the welding performance, pore, slag, and discontinuities identified by visual testing shall
be removed.
4.6.13 When liquid penetrant or magnetic particle testing after gouging is required, the surface
preparation for the test shall be made by grinding or other machining process.
4.6.14 The welding procedure for socket welds shall be with the GTAW process, with at least three
layers and a smooth convex profile. Special attention shall be given to protection against air currents,
humidity, rain and dust, due to the criticality of that joint configuration. It is required a liquid penetrant
testing on 100% of the joints, with no indication being allowed.
4.6.15 Specific conditions for the Flux Cored arc-welding (FCAW):
a) the self-shielded process (FCAW-S) shall be only used for welding carbon-steel structural
elements. When the metal structure shows impact requirement, only classifications of
consumables that have minimum impact evidenced by lot and with prior approval of
PETROBRAS may be used;
b) flux-cored wires identified by the manufacturer for multiple pass welding may be used;
c) the process with gas shielding may be used for welding of butt or angle joints of structural
elements and pressure components;
d) the use of welding consumables with AWS classification different from the one used in
the qualification procedure is not permitted;
e) The process for use in derivations, extensions, pipe connections with hull (nozzles) and
socket welds may be used as long as the welder is qualified in 6GR position, according to
AWS D1.1.
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The adoption of 6GR position does not imply in adoption of AWS qualification requirements,
and the same qualification requirements in the equipment or piping qualification standard
shall be used.
4.6.16 Specific conditions for the short circuit GMAW process welding (GMAW-S):
a) the process for use in derivations, extensions, pipe connections with hull (nozzles) and
socket welds may be used as long as the welder is qualified in 6GR position, according to
AWS D1.1;
NOTE 1 The adoption of 6GR position does not imply in adoption of AWS qualification requirements,
and the same qualification requirements in the equipment or piping qualification standard
shall be used.
NOTE 2 This requirement is not applied to controlled short circuit GMAW.
b) filling and finishing passes in butt or angle welds may be performed using this process, as
long as the thickness of any element does not exceed 3/8 (9,5 mm) and the vertical
welding is performed in ascending progression.
4.6.17 Specific conditions for the process of submerged arc welding (SAW):
a) the semiautomatic manual process is not permitted;
b) except for carbon steel welding without impact requirement, the change of flux
trademark is an essential variable for welding procedure;
c) for low hydrogen fluxes, they shall be kept in the conditions established by the
manufactured during the welding process.
4.7 Consumable
4.7.1 Consumables used in Brazil shall be certified by the Product Certification Body (OCP) as a
Conformity Assessment Body (OAC) accredited by INMETRO under the Sistema Brasileiro de
Avaliao de Conformidade (SBAC), according to PETROBRAS N-1859. When used abroad, they
shall be certified by an OCP accredited by INMETRO or a foreign OCP that complies with
ISO GUIDE 65 and after previous approval of PETROBRAS. In this case, the consumable trademark
does not comprise an essential variable in the qualified procedures. In case the welding consumables
are not certified by the OCP, the change in consumable trademark, even if this does not modify its
classification, results in the requalification of the welding procedure.
NOTE
4.7.2 Once the consumables with suffix G are not certifiable by OCP, their use shall be limited to
situations in which there is no specific classification to optimize a characteristic required for welding of
a given material, mentioned in 5.1. If their use is required, the RQPS and WPS shall clearly contain:
trademark, specified chemical composition of deposited weld metal, specific toughness requirements
(testing temperature and impact energy), and post-weld condition (as welded or treated). In addition, it
shall have lot control, according to AWS A5.01 Schedule J. The welding of that consumable shall be
used only with previous approval of PETROBRAS. The respective lot certificates shall present the
values specified and accepted by PETROBRAS. For use of consumables generically classified (which
means, equivalent to suffix G) with specification different from AWS, such as, for example, of
European standard (EN) or standard ISO, (only allowed when provided in the design standard of
equipment), the same requirements described herein for suffix G consumables of specification AWS
shall be met.
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4.7.3 The selection of consumables shall be in accordance with the requirements set forth in Section
5 of this Standard. For processes not covered by Section 5, the corresponding specification of ASME
BPCV - Section II, Part C shall be followed.
4.7.4 The package of the coated electrode, rod or rolled wire shall indicate, legibly and without
erasures, its trademark, specification, classification, diameter, heat number and fabrication date.
4.7.5 The coated electrode shall have individual identification through legible registration. The rod
shall be identified by punch marks at both ends. The rolled wire shall be identified on the reel.
4.7.6 Irregularities or discontinuities in the coating of coated electrodes, such as localized thickness
reduction, cracks, damages at the end, lack of adhesion, as well as dimensional deficiencies in length
and eccentricity beyond the limits of the specification and core oxidation signs, are unacceptable.
4.7.7 Bare electrodes or rods with oxidization signs are unacceptable.
4.7.8 The packages of coated electrodes and fluxes shall be free from defects that cause
contamination or damage to consumables.
4.7.9 When a consumable is used, it shall present the same conditions of receipt, regarding the
absence of defects, identification and condition of the package.
4.7.10 A specific consumable for a particular welding process may not be used in another process,
unless it is expressly indicated by the manufacturer.
4.7.11 Coated electrodes, bare electrodes, tubular electrodes, rods and fluxes in their original
packages shall be stored on supports or shelves, in ovens fulfilling the conditions mentioned in 4.5.5.
The following conditions shall be observed within the oven:
a) the temperature shall be at least 10 C above ambient temperature, but always 20 C or
above and never exceeding 40 C;
b) the maximum relative humidity shall be 50 %;
c) if the consumable manufacturer indicates temperature and humidity values more
restrictive than those required under a) and b), they shall be met.
4.7.12 When stored in vertical position, packages of coated electrodes shall be positioned with their
arcing ends facing up.
4.7.13 Packages shall be removed on a first-in first-out basis, thereby avoiding extended storage of
some lots.
4.7.14 Coated electrodes and low hydrogen fluxes shall be subjected to drying and conditions for
keeping them dry in ovens meeting the requirements of 4.5.5 to 4.5.9.
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4.7.15 For purposes of application of drying requirements, in general, the packages shall be
considered as not-waterproof. Drying may be skipped in cases of packages designed to be
waterproof, and with previous approval of PETROBRAS.
4.7.16 In the drying oven, coated electrodes shall be arranged on shelves, in a layer not exceeding
50 mm, and, in the oven for keeping them dry, in a layer equal to or less 150 mm in thickness.
4.7.17 In the ovens with trays for drying and keeping items dry, the flux layer shall be less than or
equal to 50 mm in thickness.
4.7.18 Drying and drying maintenance of coated electrodes and fluxes shall comply with the
parameters specified by the manufacturer.
4.7.19 Low hydrogen coated electrodes, whenever used in the field, shall be kept between 80 C and
150 C in portable ovens, as defined in 4.5.9.
4.7.20 Low hydrogen coated electrodes left outside ovens used to keep them dry and not used after a
working day shall be identified and separated, returning to storage oven so as to be re-dried. Only one
re-drying is permitted.
4.7.21 Submerged arc flux that does not melt during welding shall be sieved and re-dried, provided
that it did not have any type of contamination. Later, it shall be mixed with the new flux in the
proportion recommended by the manufacturer.
4.7.22 Covered electrodes shall be re-dried and kept at the temperatures recommended by the
manufacturer.
4.8 Environmental Conditions
4.8.1 Welding shall not be performed under rain, strong wind and dust in general, such as those from
abrasive blasting, application or removal of thermal and refractory insulation, unless the joint is
protected.
4.8.2 For all welding processes, protection means shall be used to prevent the action of air currents
that may alter welding conditions.
4.9 Preheating and Interpass Temperature
4.9.1 Preheating shall be applied when required in Section 5.
4.9.2 Welding shall not be performed when the part surface, in an area of 150 mm centered on the
joint to be welded, is wet or below the established preheating temperature for the material, according
to specific conditions in Section 5.
4.9.3 If preheating is not required, the temperature of the surface to be welded may not be below
10 C; in this case, the surface shall be preheated at 50 C, or as otherwise determined in Section 5.
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4.9.4 The preheating shall be performed by electrical resistance, induction or flame. Manual
preheating by blowtorch flame may be used, as long as there is no restriction to its use in Section 5.
Professionals responsible for the manual heating by flame shall receive prior training, and also shall
be guided about the possible metallurgical damage to the different materials to be welded if this
operation is poorly executed. For safety, the completion of preheating by gas and gas distribution shall
be on the opposite side where the welder is working. The use of cutting nozzle blowtorch in preheating
is not permitted.
4.9.5 Generally, the preheating temperature shall be measured on the base metal, on all joint
members, on the opposite side to the heating source, at a distance of 75 mm from the weld edges.
Preheating and temperature control procedures shall be prepared. This condition is not applied to
mirror x pipe welded connections.
NOTE
In case flame heating is used, where the temperature may only be measured from the side
of the source, heating shall be interrupted for at least 1 minute for every 25 mm of thickness
of the piece before it is measured.
4.9.6 The interpass temperature shall be measured on the weld metal, on the region in which the next
pass will be deposited. If using temperature stick, when permitted in Section 5, the measurement shall
be made in an adjacent area to avoid contamination of the following pass.
4.10 Post-heating
4.10.1 Post-heating shall be applied when required in Section 5.
4.10.2 Post-heating shall be performed by electrical resistance, induction or flame. Manual postheating by blowtorch flame may be used, as long as there is no restriction to its use in Section 5.
Professionals responsible for the manual post-heating by flame shall receive prior training, and also
shall be guided about the possible metallurgical damage to the different materials to be welded if this
operation is poorly executed. The use of cutting nozzle blowtorch is not permitted in post-heating.
4.10.3 The post-heating, when required, shall be applied immediately after the completion of welding.
To this end, the cooling cycle shall be interrupted in the post-heating temperature indicated for the
alloy in Section 5.
4.10.4 The post-heating temperature shall be measured on base metal, on all joint components, on
the opposite side to the heating source, at a distance of 75 mm from weld edges. If the base metal is
thicker than 75 mm, then a post-heating and temperature control plan shall be submitted for previous
approval of PETROBRAS.
NOTE
In case flame heating is used, where the temperature may only be measured from the side
of the source, heating shall be interrupted for at least 1 minute for every 25 mm of thickness
of the piece before it is measured.
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4.11.2 Tests applicable to each joint, as well as their extensions, shall be indicated in the IEIS
document, prepared in accordance with PETROBRAS N-2301.
4.11.3 All welds shall be 100 % visually inspected and evaluated with the acceptance criteria of the
applicable standard of manufacture. A visual inspection shall precede the other non-destructive tests.
4.11.4 Non-destructive tests required in this Standard shall be performed according to qualified
inspection procedure, as per applicable standards PETROBRAS.
4.11.5 Welding consumables shall be inspected upon receipt by sampling. It shall be performed in
line with an attribute inspection and compliance of consumables with 4.7.5 to 4.7.9 shall be checked.
Sampling shall be performed according to the instructions contained in Annex A.
4.11.6 The performance of welders and welding operators shall be controlled. The document "Control
Over Performance of Welders and Welding Operators" shall be prepared in accordance with
PETROBRAS N-2301.
4.12 Weld Repairs
4.12.1 Welding defects shall be repaired in accordance with the IEIS document applicable to repair,
prepared according to PETROBRAS N-2301, based on a qualified welding procedure.
4.12.2 The same inspection requirements needed for welded joints shall be applied to their repairs.
Non-destructive testing shall always be performed on 100 % of the surface on the excavated area
before the release of the repair filling.
4.12.3 The repair requirements for each material are detailed in Section 5 of this Standard. Additional
repairs require previous approval of PETROBRAS. Each repair shall be registered, for manufacture or
maintenance welds. In this case, the document Welding Record Report (RSS) shall be issued in
accordance with PETROBRAS N-2301.
4.12.4 The SAW process shall not be used in weld repairs, except for fabrication repairs involving
equipment of large dimensions and thicknesses.
4.13 Post Weld Heat Treatment (PWHT)
4.13.1 PWHT shall be applied when required by the design or fabrication and assembly designs of
equipment or structure, and shall comply with the conditions prescribed by those standards.
4.13.2 PWHT shall be performed by electrical heating, induction, or in furnace.
4.13.3 The zone to be heated to PWHT temperature shall cover the temporary weld areas referring to
auxiliary assembly devices, even when they have been removed.
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4.13.4 It is recommended that thermocouples are fixed to the parts by capacitive discharge, so as to
ensure electrical contact between the wires of the thermocouple and the heated surface.
[Recommended Practice]
4.13.5 The performance of PWHT shall be documented. The document Heat Treatment Record
Report (RRTT) shall be prepared in accordance with PETROBRAS N-2301.
4.13.6 PWHT requirements for each material, when applicable, are detailed in Section 5 of this
Standard.
4.13.7 When performing PWHT located in the circumferential welds, or in which the component has
the freedom of expansion during treatment, the conditions set forth in AWS D 10.10 or WRC 452 shall
be met.
4.13.8 Other settings of localized PWHT are not permitted, except when approved by PETROBRAS,
based on analysis of the thermal gradient generated by computer simulation.
4.14 Auxiliary Assembly Devices
Auxiliary assembly devices, when permitted by the fabrication and assembly standard of equipment or
structure, shall comply with the requirements of Section 5 and the following conditions:
a) welds of auxiliary assembly devices, tack welds and other temporary welds shall be
considered definitive welds for purposes of application of the requirements of this
Standard, including those regarding the qualification of personnel;
b) the number of auxiliary assembly devices preventing transverse contraction of weld shall
be minimized, and devices limiting angular deformation of the welded joint and allowing
transverse contraction shall be preferred;
c) auxiliary assembly devices shall not be removed by impact, and the area of temporary
weld, after it has been removed, shall be inspected using liquid penetrant or magnetic
particle testing and present no undercuts, pores, cracks, thickness reduction or
incomplete removal;
d) welds of auxiliary assembly devices shall be deposited at least 25 mm away from the
edges of the bevel or directly on the faces of the bevel.
NOTE
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For oil and gas pipelines, punch marking shall not be allowed.
5 Materials
5.1 Carbon Steel and Carbon-Manganese Steel
5.1.1 Introduction
5.1.1.1 For purposes of this Standard, low tensile strength steels are those presenting a minimum
tensile strength limit below 490 MPa (71 ksi) and P number 1 Group 1 or 2. High tensile strength
steels are those presenting a specified tensile strength limit of 490 MPa (71 ksi) or above and P
number 1 Group 3 or 4, in addition to alloy steels of P number 3 (except molybdenum steels C1/2Mo
and 1/2Cr1/2Mo, included in CrMo family in this standard), P number 10 (except for groups H, I, J) and
P number 11B.
5.1.1.2 Those steels shall not be used at temperatures above 400 C under continuous work.
5.1.1.3 It shall be observed the additional requirements of standards and specifications for quenched,
tempered and micro-alloyed High Strength and Low Alloy - HSLA steels, classified under P number 1
Group 3 or 4, 10 (except for H, I, J) and 11B.
5.1.2 Weldability
5.1.2.1 Those steels generally have good weldability when the carbon content is below 0.20% and/or
carbon equivalent (CEIIW) is below 0,44 %; however, they may be susceptible to hydrogen induced
cracking (cold cracking), especially when the chemical composition is enriched with alloying elements
and/or in welding of thick plates.
5.1.2.2 Preheating may be necessary to reduce the cooling speed and to favor the release of the
hydrogen, since, in some cases, it is inevitable the formation of microstructures susceptible to cold
cracking.
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5.1.2.3 Post-heating is not usually necessary; however, it shall be evaluated when it involves welding
of joints with large thickness and restriction.
5.1.3 General Welding Technique
5.1.3.1 Welded joint preparation may be done by machining, cold cutting, grinding, oxy-cutting,
plasma, laser or water jet cutting. For high strength steels, the HAZ formed by cutting processes shall
be removed by machining or grinding.
5.1.3.2 When impact testing is required, the multiple pass welding shall be performed with straight
and thin passes, not exceeding three times the diameter of the core of coated electrode in SMAW
process.
5.1.3.3 Basic type coatings of consumables and fluxes shall present maximum diffusible hydrogen of
8 mL of hydrogen per 100 g of deposited weld metal (H8), except for cases where a larger control of
hydrogen is required or specified. This requirement shall be mandatory from July 2014 on.
5.1.3.4 For the FCAW process, the diffusible hydrogen limits set forth in Table 1 shall be followed.
This requirement shall be mandatory from July 2014 on.
H16
H8
(587 MPa)
> 85 ksi (587 MPa)
H4
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5.1.4.2 GTAW
a) consumables shall follow the specifications of AWS A5.18;
b) it is not necessary to use gas for protecting the root of the weld from inside the part.
5.1.4.3 GMAW
a) consumables shall follow the specifications of AWS A5.18;
b) it is not necessary to use gas for protecting the root of the weld from inside the part;
c) the transfer mode by conventional short circuit may not be used in thicknesses above
10 mm.
d) the use of GMAW with controlled short-circuit is permitted to perform root pass in
pipelines or piping systems, except for derivations, extensions and socket welds.
5.1.4.4 FCAW
a) consumables shall follow the specifications of AWS A5.36. In equipment fabricated
according to ASME code, consumables shall comply with ASME Section II Part C;
b) the self-shielded process (FCAW-S) shall be only used for welding carbon-steel structural
elements. When the metallic structure has impact requirement, only classifications of
consumables that have minimum impact evidenced by lot and with previous approval of
PETROBRAS may be used;
c) the process with additional gas shielding (FCAW-G) may be used for welding of butt or
angle joints of structural elements and pressure components;
d) the possible variations of impact properties between different trademarks or even
between lots from the same manufacturer shall be considered; therefore, it shall be
observed the minimum impact requirements established for weld metal.
5.1.4.5 SAW
Consumables shall follow the specifications of AWS A5.17 or AWS A5.23.
5.1.5 Preheating and Interpass Temperature
5.1.5.1 Joints shall be preheated to temperatures equal to or above those indicated in Table 2.
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% Mn % Cr % Mo %V % Cu % Ni
6
5
15
(1)
T3 = 0
37,5 mm
37,5 mm
T1
T2
T1
T3 = T2
T2
NOTE
T3
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5.1.5.3 When there is a requirement of toughness, the interpass temperature shall not exceed 250 C.
When there is no toughness requirement, the temperature shall not exceed 315 C.
5.1.5.4 It is recommended that the manual heating by gas flame (blowtorch) is limited in tubes or
shells with thickness up to 25,4 mm and nominal diameter up to 10. [Recommended Practice]
5.1.6 Post-heating
It is usually not required, except when there is risk of hydrogen cracking, as for thick plates and high
restriction. In this case, use temperature of approximately 200 C with baseline time of 1 min/mm of
thickness of joint, but no less than 15 minutes.
5.1.7 Post Weld Heat Treatment (PWHT)
PWHT shall comply with the respective design code and applicable technical specification, including
the number of treatment cycles.
5.1.8 Weld Repair
5.1.8.1 Weld repair procedure shall be pre-qualified when there is toughness requirement.
5.1.8.2 The same weld area may not be repaired more than twice when there is a toughness
requirement. When there is no toughness requirement, the maximum number of repairs is limited to
three times.
5.1.8.3 The repair shall be performed in multiple pass, trying to quench the previous passes.
5.1.9 Supplementary Requirements for Maintenance Weld
5.1.9.1 In equipment soaked in hydrogen, it shall be assessed the need for a previous
dehydrogenation treatment (ranging from 300 C to 400 C, for at least 4 hours), which may vary
depending on the base material, complexity and thickness of the equipment. The temperature shall
not exceed 480 C.
5.1.9.2 If applying controlled deposition techniques in maintenance service, the procedure shall be
previously qualified and approved by PETROBRAS.
5.2 Heat-Treated Low Alloy Steel
5.2.1 Introduction
5.2.1.1 They are steels from the Chromium-Molybdenum and Chromium-Nickel-Molybdenum family.
Those steels are typically used in the petroleum and petrochemical industry as machine parts or
components. Most of those steels have carbon content between 0,28% and 0,45% of carbon, and
addition of alloying elements, granting a high hardenability.
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5.2.1.2 For the purpose of this Standard, AISI 4130/4140 steels shall be deemed ChromiumMolybdenum and AISI 4340/8630 steels shall be deemed Chromium-Nickel-Molybdenum.
5.2.2 Weldability
5.2.2.1 Those steels have better weldability in annealed or super-quenched condition (treated above
the typical quenching temperatures). Regardless the initial state of microstructure, those joints shall
undergo heat treatment for fitness of mechanical strength after welding.
5.2.2.2 The microstructure of HAZ of those materials, when subjected to "high cooling rates", will be
composed of martensite or bainite and martensite.
5.2.2.3 Since they are high hardenability steels, the cooling rate control is necessary in welding, by
controlling the preheating and interpass temperature.
5.2.3 General Welding Technique
5.2.3.1 For welding of those materials, in addition to a qualified welding procedure, there shall be
previous approval of PETROBRAS.
5.2.3.2 The preparation of the welded joint may be made by machining, oxy-cutting, plasma, laser or
water jet cutting. The HAZ formed by cutting processes shall be removed by machining or grinding.
5.2.3.3 Multiple pass welding shall be performed with straight and thin passes, not exceeding three
times the diameter of the core of coated electrode in SMAW process.
5.2.3.4 Consumables with maximum diffusible hydrogen content of 4 ml of hydrogen per 100 g of
deposited weld metal (H4) shall be used. This requirement shall be mandatory from July 2014 on.
5.2.3.5 Welding procedures shall be performed according to the hardness class of materials. In these
procedures, materials are described based on the AISI classification and with hardness required for
the mechanical elements to be welded.
5.2.4 Applicable Welding Processes
The SMAW, GMAW and GTAW welding processes are allowed.
5.2.5 General Conditions for Consumables
5.2.5.1 Due to the different heat treatments those steels may undergo during their fabrication, the
mechanical strength of the base material to be welded shall be observed when choosing the
consumable.
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5.2.5.2 Whenever possible, the chemical composition of filler metal shall be as close as possible of
the base metal.
5.2.6 Preheating and Interpass
Preheating and interpass shall be performed by electrical resistance, induction or flame, and the
manual heating by flame is only allowed for welding of tethers and auxiliary assembly parts not
subjected to internal pressure. Preheating and interpass temperatures shall comply with Table 3.
Table 3 - Minimum and Maximum Preheating and Interpass Temperature of HeatTreated Low Alloy Steels
AISI
4130
4140
4340
8630
Maximum
interpass
315 C
350 C
320 C
250 C
5.2.7 Post-Heating
Post-heating shall be performed from 250 C to 300 C, with baseline time of 1 min/mm of thickness of
joint, but no less than 30 minutes.
NOTE
It is recommended that, at the end of post-heating, the cooling is controlled with cooling rate
below 95 C/h up to 80 C and thermal insulation of joint up to ambient temperature.
[Recommended Practice]
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5.2.10.2 After welding, the welds shall be 100% inspected using liquid penetrant.
5.2.10.3 The final inspection shall be performed 48 hours after welding.
5.3 Chrome-Molybdenum Steels and Molybdenum Steels
5.3.1 Introduction
5.3.1.1 Cr-Mo ferritic steels are normally used in temperatures above 400 C for their good hot
strength. These alloys show low hot deformation rate and good resistance to hydrogen, with some
specifications being employed at temperatures up to 650 C. For purposes of this standard, chromemolybdenum and modified chromium-molybdenum steels are those alloys with chromium content
between 0,5% and 11,5%, and with molybdenum content between 0,44% and 1,1%.
5.3.1.2 Besides chromium and molybdenum, some alloys may have addition of other carbide formers
(V, Nb, W, Ti). In this case, it is common the presence of elements Ni, Al, N and/or B. The
molybdenum steel by familiarity was included in this subsection.
5.3.2 Weldability
5.1.2.1 Those steels have good weldability when the carbon content is under 0,15%. However, they
are susceptible to hydrogen induced cracking (cold cracking), especially when the chemical
composition is enriched with alloying elements and/or in welding of thick plates. In case of ASME
BPVC Section IX, those steels are denominated by the following P number, as shown in Table 4.
Cr-Mo
Cr-Mo-V
Basic composition
C-0,5Mo
0,50Cr-0,50Mo
1,0Cr-0,5Mo
1,25Cr-0,5Mo
2,25Cr-1,0Mo
3,0Cr-1Mo
5,0Cr-0,50Mo
7,0Cr-0,50Mo
9,0Cr-1,0Mo
2,25Cr-1,0Mo-V
9,0Cr-1,0Mo-V
P number
3
3
4
4
5A
5A
5B
5B
5B
5C
15E
5.3.2.2 Preheating is usually required to reduce the cooling speed and to favor the release of the
hydrogen, since the formation of bainitic and/or martensitic microstructures is inevitable in some
cases.
5.3.2.3 The post-heating for Cr-Mo steels is usually performed after welding.
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If the welding cycle is interrupted, the recommendations of AWS D10.8 shall be followed.
5.3.3.5 The manual heating by oxy-gas flame (shower-type blowtorch) shall be limited to pipes with
thickness below 13 mm and a nominal diameter of up to 8".
5.3.4 Applicable Welding Processes
The SMAW, GTAW, GMAW, FCAW-G e SAW processes are permitted. Other processes may be
applied upon previous approval of PETROBRAS. The FCAW-S process is not permitted.
5.3.4.1 SMAW
a) the use of synthetic consumables is not permitted;
b) root welding by SMAW process is not permitted.
5.3.4.2 GTAW
a) root purging with inert gas is required when welding components to which there is no
access from both sides of the joint, for steels with chromium content of 3 % or above, in
order to prevent oxidation on the internal root face;
b) for steels with 2,25 Cr-1Mo content, it is recommended purging with inert gas;
[Recommended Practice]
c) inert gas protection in welding of 9Cr-1Mo-V-Nb steel (Gr91) shall present 99,998 % of
argon (high purity).
5.3.4.3 GMAW
a) the only allowed transfer modes are by spray to a flat position, and pulsed for all
positions;
b) when shielding gas in welding by GMAW process has active characteristic, the wire shall
have deoxidizing elements. The use of pure CO2 is not permitted. However, argon
mixtures with up to 25 % of CO2 may be used;
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Type of
material
0.5Mo
0.5Cr-0.5Mo
1Cr-0.5Mo
1.25Cr-0.5Mo
Spec.
AWS
A5.5
A5.5
A5.5
Spec.
AWS
Fabrication
Alternative for
and
maintenance
maintenance
E7018-A1
A5.28
E8018-B1
E8016-B1
A5.28
E8018-B2
E8016-B2
A5.28
E701X-B2L
2.25Cr1Mo
A5.5
E901X-B3
A5.28
5Cr-0.5Mo
A5.5
E801X-B6
E801X-B6L
A5.28
9Cr-1Mo
A5.5
E801X-B8
E801X-B8L
A5.28
9Cr-1Mo-V
A5.5
E901X-B9
A5.28
Type of
material
0.5Mo
0.5Cr-0.5Mo
1Cr-0.5Mo
1,25Cr-0,5Mo
2.25Cr1Mo
5Cr-0.5Mo
9Cr-1Mo
9Cr-1Mo-V
Spec.
AWS
A5.29
A5.29
Spec.
AWS
Fabrication
Alternative for
and
maintenance
maintenance
E8XT1-A1M
A5.23
E8XT1-B1M
A5.23
ER70S-B2L
ER80S-B3L
-
A5.29
E8XT1-B2M
E7XTX-B2L
A5.23
EB2
A5.29
A5.29
A5.29
A5.29
E9XT1-B3M
E8XT1-B6M
E8XT1-B8M
E9XT1-B9M
E9XTX-B3L
E8XTX-B6L
E8XTX-B8L
-
A5.23
A5.23
A5.23
A5.23
EB3
EB6
EB8
EB9
5.3.5.2 The following indications and restrictions shall be followed in the application of Table 5:
a) alternative consumables for maintenance shall only be used after previous approval by
PETROBRAS;
b) for fabrication of coke drums, consumables E 7018-B2L and ER 70S-B2L may be
indicated, provided that the mechanical properties and chemical composition are
compatible with those specified in design;
c) consumable ER80S-G shall present similar chemical composition and mechanical
properties compatible with 0,5 Cr-0,5Mo steel. The certificates shall be submitted in
advance and approved by PETROBRAS;
d) The suffix M in the classification of consumable for cored wire indicates the shielding gas
is composed by 80 % Air + 20 % CO2 or 75 % Air + 25 % CO2;
e) for equipment manufactured with consumables of composition 1,25Cr-0,5Mo,
2,25Cr-1Mo and 2,25Cr-1Mo-V, for which there is an impact requirement in design code,
the (minimum) total level time for PWHT shall comply with the design specification. In this
case, the acquisition of those consumables shall comply with AWS A5.01 Schedule J,
and the lots shall be specified according to the following minimum criteria:
1,25Cr-0,5Mo steel (Gr 11): impact testing shall have an average of 55 J and
minimum individual of 47 J at a temperature of -18C after PWHT;
2,25Cr-0,5Mo steel (Gr 22): impact testing shall have an average of 55 J and
minimum individual of 47 J at a temperature of -30C after PWHT;
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E
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Other requ
uirements of the design sspecifications
s and applica
able standardds to fabricattion of the
equipmentt shall also be
b specified and complie
ed with in the
e request of welding con
nsumables
such as, fo
or instance, simulated
s
PW
WHT for Cha
arpy testing.
g) in case
e of heteroge
eneous weld
ding, when not prohibited
d by the dessign or fabric
cation and
assemb
bly standard
d of equipm
ment, consu
umables sha
all be speccified as es
stablished,
conside
ering the SM
MAW and GTA
AW welding processes and
a operatingg conditions as shown
in Table
e 6.
TABLE
E 6 - CO
ONSUMABLES
FO
OR
HET
TEROGEN
NEOUS
WELDING
G
MOLYB
BDENUM AND
A
CHR
ROMIUM-M
MOLYBDEN
NUM STEE
ELS
perating con
nditions
Op
OF
M
Maximum te
emperature of applicatio
on (C)
315
5
> 315 (prefferred)
> 315
Envirronme
Tem
mperature
n
nt
GTAW
SMAW
GTAW
SMAW
G
GTAW
SMAW
No sig
gnificant
Cyyclic
or
E
ENiCrFe-3
ENiCrFe-3
prese
ence of
ERNiCr-3
E
ERNiCr-3
E
ENiCrFe-2
E
ER
RNiCr-3
nott
E
ENiCrFe-2
Note 1)
(N
su
ulfur
No sig
gnificant
E
E309-XX
ER309
prese
ence of No
on-cyclic
E
E309MoER309Mo
E
XX
su
ulfur
NOTE 1 Maximu
um operating
g temperaturre of ENiCrFe
e-3 is 480 C
C.
NOTE 2 The tem
mperature lim
mitations for chemical co
ompositions (consumablees) indicated
d in the
table arre maintaine
ed for other a
arc welding processes
p
ad
dmitted to thee welding off Cr-Mo
steels.
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Minimum preheating and interpass temperatures for welding CrMo steels of different thicknesses (see Notes 1, 2 and 3)
Material - P number (PN)
C-0,5Mo - (PN 3)
0,5Cr-0,5Mo - (PN 3)
1Cr-0,5Mo - (PN 4)
1,25Cr-0,5Mo - (PN 4)
2Cr-0,5Mo - (PN 4)
2,25Cr-1Mo - (PN 5A)
2,25-3Cr-Mo-V - (PN 5C)
3Cr-1Mo - (PN 5A)
5Cr-0,5Mo - (PN 5B)
7Cr-0,5Mo - (PN 5B)
9Cr-1Mo - (PN 5B)
9Cr-1Mo-V-Nb - (PN 15E)
NOTE 1
NOTE 2
NOTE 3
NOTE 4
NOTE 5
07 / 2013
12
Thickness (mm)
> 12
Maximum interpass
temperature
(see Note 4)
All thicknesses
Not required
150 C
250 C
150 C
200 C
300 C
200 C
250 C
350 C
200 C
250 C
350 C
200 C
250 C
330 C
5.3.7 Post-heating
5.3.7.1 It shall be required under the following conditions, based on the material and thickness of the
joint, in accordance with Table 8.
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Basic composition
C-0.5Mo
0.50Cr-0.50Mo
1.0Cr-0.5Mo
1.25Cr-0.5Mo
2.25Cr-1.0Mo
5.0Cr-0.50Mo
7.0Cr-0.5Mo
9.0Cr-1.0Mo
9.0Cr-1.0Mo-V
2.25Cr-1Mo-V and 3Cr1Mo-V
Thickness
(mm)
> 25
> 20
Temperature (C)
Time
200
300
> 12
300
>6
300
> 12
350 - 400
1 min/mm
(minimum 15
min)
4 to 6 hours
5.3.7.2 Post-heating is not required for heterogeneous welds, except for joints with high restriction
and/or thickness, but it shall not exceed 175 C.
5.3.7.3 When post-heating is not required, the welded joint shall be protected from quick cooling
through insulating ceramic blanket.
5.3.8 Post Weld Heat Treatment (PWHT)
5.3.8.1 PWHT shall meet the relevant design code and applicable technical specification, including
the number of treatment cycles.
5.3.8.2 For Cr-Mo steels with P number 5A, 5B, 5C and 15E, the PWHT shall be initiated only after
the welded joint has cooled below 50 C.
NOTE
for materials with P number 5C in welding of joints with high restriction, as in the welding of
nozzles in equipment, the need to make the PWHT or, at least, the Intermediate TTAT
immediately after welding shall be provided, without letting the component/part/equipment
cool below the interpass temperature.
5.3.8.3 The welded joints in Cr-Mo that will be subjected to PWHT shall be carefully displaced in the
period between the end of welding and completion of treatment.
NOTE
5.3.8.4 Before PWHT, it shall be checked the need for backing or shoring of component, in order to
avoid plastic deformation without control.
5.3.8.5 Required non-destructive tests shall be performed after PWHT.
5.3.8.6 It is recommended that non-destructive tests are performed before PWHT. [Recommended
Practice]
5.3.8.7 For quenched and tempered materials, the maximum PWHT temperature shall be at least
30C lower than the tempering temperature of the base material.
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5.3.8.8 The PWHT temperature in dissimilar joints shall be specified as a function of the steel with
higher content of alloying element.
5.3.9 Hardness Test in Homogeneous Joints
In general, the hardness in the welded and heat affected zone after PWHT shall not exceed the limits
of Table 9. More restrictive values shall be used when indicated by the design standard.
Cr-Mo
Cr-Mo-V
Basic composition
C-0,5Mo
0,50Cr-0,50Mo
1,0Cr-0,5Mo
1,25Cr-0,5Mo
2,25Cr-1,0Mo
5,0Cr-0,50Mo
7,0Cr-0,5Mo
9,0Cr-1,0Mo
9,0Cr-1,0Mo-V
Hardne
ss
225 HB
(237 HV)
241 HB
(250 HV).
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5.3.11.3 It is not allowed the use of controlled deposition techniques as a way of avoiding PWHT in
5Cr-0.5Mo steels or with higher alloy content when PWHT is indicated by the design standard.
5.3.11.4 In weld maintenance, the parameters and weld techniques may show significant difference
when compared to the materials in new condition, requiring assessment of the physical state of the
material in aged condition. In this case, the repair procedure shall previously be evaluated and
approved by PETROBRAS.
5.3.12 Supplementary Requirements for Inspection
5.3.12.1 In equipment soaked in hydrogen, it shall be assessed the need for a previous
dehydrogenation treatment (in range of 350C to 450C, for at least 4 hours), which may vary
depending on the base material, complexity and thickness of the equipment. The temperature shall
not exceed 480 C.
5.3.12.2 In maintenance weld, the bevel on the side of the aged material shall always be previously
inspected with liquid penetrant before welding.
5.3.12.3 Portable hardness testers that use spheres with 10 mm of diameter shall not be used to
measure the hardness in the HAZ.
5.4 Nickel Steel
5.4.1 Introduction
5.4.1.1 Ferritic alloys with addition of nickel have good mechanical strength and toughness, being
used in cryogenic services or systems which occasionally may be subjected to low operating
temperatures. The minimum application temperature is a function of the percentage of nickel in the
alloy, and it may vary from -50 C to -196 C.
5.4.1.2 For the purpose of this standard, nickel ferritic steels are those with nickel content ranging
from 1 % to 9 %, and which meet the material specification indicated by the equipment design
standard.
5.4.2 Weldability
5.4.2.1 They have good weldability; however, the larger the addition of nickel is, the higher the
hardenability of steel is, particularly in steels with high nickel content (Ni 5 %) in which the HAZ
consists of martensite with relative toughness as a function of nickel content and control of carbon
content.
5.4.2.2 Mechanical properties and toughness may be compromised when there is overgrowth of
grains of HAZ due to the high heat input adopted.
5.4.2.3 In homogeneous and, specially, heterogeneous welding, the weld pool of C-Ni steels presents
low fluidity compared to pool of C-Mn steel.
5.4.2.4 Contaminants of foreign origin shall not touch these materials, especially the sulfur from
tempilstick, grease, soap, etc. C-Ni steels are classified as P number 9 and 11A, according to ASME
BPVC Section IX.
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5.4.2.5 Porosity may be avoided by controlling the diffusible hydrogen and by using a very short arc.
[Recommended Practice]
5.4.2.6 Due to the higher capacity of magnetization compared to carbon steel, extra care shall be
taken, particularly in 9 % Ni steel. Demagnetization or cancellation of the magnetic field in some cases
may be required before welding.
5.4.3 General Welding Technique
5.4.3.1 The welding shall be of multiple pass, with straight and slightly convex passes. Passes that
have excessive convexity shall be repaired by grinding to avoid lack of fusion.
5.4.3.2 Nickel steels and especially those with high nickel content, such as 9 % Ni, show a relatively
adherent oxide layer which shall be removed before the start of welding.
5.4.3.3 The heat input shall be below 2 kJ/mm in homogeneous and 1,5 kJ/mm in heterogeneous
welding. With the submerged arc welding process, it shall be lower than 2,8 kJ/mm and 2,5 kJ/mm,
respectively.
5.4.3.4 In the qualifying phase of heterogeneous welds, it is recommended longitudinal bending test
instead of the cross bending. [Recommended Practice]
5.3.3.5 The manual heating by oxy-gas flame (shower-type blowtorch) shall be limited to pipes or
hulls with thickness below 13 mm and a nominal diameter of up to 10".
5.4.4 Applicable Welding Processes
The SMAW, GTAW, GMAW, and SAW processes are permitted. Other processes may be applied
upon previous approval of PETROBRAS. The FCAW process is not permitted with or without shielding
gas.
5.4.4.1 SMAW
a) the use of synthetic consumables is not permitted;
b) the coating shall be basic and have a maximum diffusible hydrogen of H8. This
requirement shall be mandatory from July 2014 on;
c) root welding by SMAW process is not permitted;
d) the oscillation of the electrode shall be such that the pass width does not exceed three
times the coated electrode core diameter.
5.4.4.2 GTAW
a) the shielding gas of the root shall be argon, helium or a mixture of these gases;
b) the root purging shall be maintained until the completion of the second layer.
5.4.4.3 GMAW
Root welding and root enhancing pass by GMAW process are not permitted. It is not permitted to weld
derivations, extensions, pipe connections with hull (nozzles) and socket welds.
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5.4.4.4 SAW
a) the flux shall be neutral or basic, it is not permitted the presence of alloying elements, and
it shall contain a maximum diffusible hydrogen of H8. The requirement for diffusible
hydrogen shall be mandatory from July 2014 on;
b) special care shall be given to the flux regarding the contamination risk by dirt and
moisture.
5.4.5 General Conditions for Consumables
5.4.5.1 The consumables shall follow the instructions in Table 10.
AWS
Spec.
AWS Classification
Preferred
1,5 % Ni
2,25 % Ni
A5.5
A5.5
E801X-C1
E801X-C1
3,5 % Ni
A5.5
A5.11
E801X-C2
9 % Ni
A5.11
ENiCrMo-3
Type of
material
AWS
Spec.
1,5 % Ni
2,25 % Ni
A5.28
A5.28
A5.28
A5.14
A5.14
3,5 % Ni
9 % Ni
Alternative
(see Note)
E801X-C2
ENiCrMo-3
ENiCrFe-2
ENiCrFe-3
-
ERNiCr-3
ERNiCrMo-3
AWS
Spec.
AWS Classification
Alternative
Preferred
(see Note)
EBNi2
EBNi2
-
A5.23
A5.23
A5.23
3,5 % Ni
EBNi3
ERNiCr-3
A5.14
9 % Ni
A5.14
ERNiCrMo-3
NOTE
These consumables shall be used when the welded
joint is subjected to temperatures close to the lower
limit allowed for the base material.
5.4.5.2 Heterogeneous welding with consumables ER309 and E309 is only permitted as an
alternative to maintenance, after review and previous approval by PETROBRAS. The review shall
consider at least the following factors: compatibility with the fluid/corrosion, design temperatures, and
risk of thermal fatigue.
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Thickness (mm)
Minimum preheating
and interpass (C)
19 and C 0.2%
>19 or C > 0.2 %
12 and C 0.2%
>12 or C > 0.2 %
10 and C 0.2%
>10 or C > 0.2 %
15
100
15
150
15
150
Maximum
interpass (C)
250
250
230
Thickness (mm)
<50
50
<50
50
<50
50
Minimum preheating
and interpass (C)
15
100
15
100
15
100
Maximum
interpass (C)
150
150
150
5.4.7 Post-heating
It is not required, unless it involves plates thicker than 50 mm. In this case, it is recommended the
post-heating at 150 C, with 1 minute per mm of thickness. [Recommended Practice]
5.4.8 Post Weld Heat Treatment (PWHT)
5.4.8.1 Normally, PWHT is only prescribed for large thicknesses and shall be performed as per
design code. Generally, the PWHT for materials with up to 3,5 % Ni is only indicated from 20 mm or
35 mm on, depending on the code.
5.4.8.2 For steels with higher alloy content (5 % Ni and 9 % Ni), the treatment is usually required for
thickness above 35 mm; however, the design code is mandatory. In quenched and tempered
materials, the PWHT temperature shall be 30 C lower than the tempering temperature of the base
material. Due to the addition of nickel, the critical temperature of transformation of these steels is
always below 723 C.
5.4.8.3 The excessive baseline time reduces the toughness of C-Ni alloys.
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5.5.1.3 Austenitic stainless steels from 2XX series are not considered in this Standard.
5.5.2 Weldability
5.5.2.1 In general, they have good weldability; however, they are susceptible to precipitation of
carbides (sensitization) in alloys with higher carbon content.
5.5.2.2 They are susceptible to hot cracking (solidification, liquation, ductility reduction). This
phenomenon occurs especially on alloys with no delta ferrite or with ferrite number - FN lower than 3,
when the material contains impurities such as S and P (among others), or when eutectics with low
melting point are formed. Solidification cracking may be controlled by the presence of delta ferrite and
control of solidification mode (consumable composition and cooling rate of the weld pool).
5.5.2.3 They are generally classified as P number 8, according to the ASME BPVC Section IX.
5.5.3 General Welding Technique
5.5.3.1 The fabrication of stainless steel piping and equipment shall be made in a segregated and
protected area, preferably in a shed separated from other materials.
5.5.3.2 Hot cutting with graphite electrode or oxycutting is not permitted. Hot cutting shall be
preferably performed by plasma or laser, and the surface shall be ground in order to remove any signs
of oxidation and irregularities.
5.5.3.3 The root opening shall be slightly wider than the one commonly used for carbon steels,
because the root tends to close more often, which may result in lack of fusion. Austenitic stainless
steels have thermal expansion coefficient approximately 50% greater than the carbon steel, and lower
thermal conductivity. These factors generate high residual stress and higher tendency to distortion
(warping) in the welded joint.
5.5.3.4 In welding of austenitic stainless steel, some details of extreme importance shall not be
overlooked in order to reduce the risk of solidification cracking, such as: joint preparation, surface
cleaning, quantity of material deposited per pass, aiming the width/depth ratio equal to one, slight
convexity of passes, and suitable welding speed in order to avoid weld pool in drop form. Figure 2
shows the formation of cracks due to the width/depth ratio (A) (B) (C) and concavity (D).
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Fusing depth
Face width
Face width
Crack
Crack
Fusing depth
Crack
(A)
Butt weld
Crack
(B)
Angle weld
(C)
"T" weld
Crack
(D)
(E)
(F)
Wrong
Very large and
concave pass
Wrong
Very high and concave
finished pass
Right
Pass not very large and
slightly convex or flat
Weld metal
Weld metal
Base metal
Base metal
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5.5.3.9 Slag and flux residues shall be removed after welding, because they compromise the
corrosion resistance in operation (fluoride). Contact with chlorine or fluoride is extremely harmful,
causing stress corrosion or pitting.
5.5.3.10 Slag removal, cleaning and cutting tools shall only be used for these materials and shall
meet the following conditions:
a) slag removal and cleaning tools shall be made of stainless steel or coated with this
material;
b) the cutting disks shall be made of aluminum oxide with nylon core or of fiberglass.
5.5.3.11 Contamination by contact with sulfur, zinc, copper, tin, lead, among others, may irreversibly
compromise the austenitic stainless steels when exposed to high temperature.
5.5.3.12 Upon completion of welding and before the start of operation, soaps and detergents used in
bubble, liquid penetrant and industrial marker residue tests shall be eliminated. Tempilstick shall not
be used, being recommended the contact thermometer for temperature control.
5.5.3.13 Welding by GTAW and GMAW processes shall be performed with oxygen-free shielding gas
at the root of weld in order to protect the weld zone and HAZ. This protection shall be maintained until
the completion of the third weld layer or 6.3 mm, ensuring the absence of oxygen. If socket weld or
sealing is used, the purging is required up to a thickness of 6.3 mm of the base material. Above this
thickness, it shall be evaluated by PETROBRAS. Argon and helium may be used as purge gas. The
effectiveness of root purging may be identified by visual assessment. Figure 4, according to AWS
C5.5, illustrates the contamination caused by oxygen at different concentrations in the purge gas.
NOTE
This item is not applied to joints with full root removal and when 5.5.3.16 is applied.
No. 1 - 10 ppm
No. 2 - 25 ppm
No. 3 - 50 ppm
No. 4 - 100 ppm
No. 5 - 200 ppm
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5.5.3.14 Purging with nitrogen during welding is only permitted after previous review and evaluation of
PETROBRAS. The ferrite content in base material, gas purity, and risk of hot cracking after welding
shall be evaluated.
5.5.3.15 The authorization for joint welding without internal access shall be made after checking and
evidencing the oxygen content inside the tube. This measurement of residual oxygen shall be
performed using an oxymeter with threshold value of 50 ppm. The device shall be able to detect the
presence of oxygen from 0 to 1 000 ppm or mL/m3.
NOTE
In situations where, due to the distance between the inert gas injection point and the
measurement point, it is not possible to meet the requirement above, PETROBRAS shall be
informed so as to make a decision.
5.5.3.16 The contaminated base metal and face and root regions with coloring 4 or above shall be
treated after welding, therefore, extra care is essential to the purge. In general cases, the passivated
layer may be restored by removing the oxidized layer formed at high temperature, either by controlled
etching, sanding or blasting with glass beads, the latter indicated for large surfaces. Cleaning with acid
requires special care about the contamination of the environment and the health of the applicator. In
applications requiring corrosion resistance, passivation is indicated immediately after sanding or
etching. Pickling and passivation shall comply with ASTM A 380.
5.5.4 Applicable Welding Processes
The SMAW, GMAW-P, GMAW, FCAW-G, GTAW, SAW, and PAW processes are permitted. The
FCAW-S process is not permitted.
5.5.4.1 SMAW
a) the use of synthetic consumables is not permitted;
b) the welding of AISI 321 steel shall be performed with consumable 347 due to the low
transfer of titanium in the process;
c) whenever the material is exposed to temperature above 480 C in the operation, the
consumable shall be acquired according to AWS A5.01, Schedule J, ensuring its bismuth
content does not exceed 0,002 %.
5.5.4.2 GTAW
a) besides argon (99,99 %), the argon + helium mixture or only helium may be used as
shielding gas. the argon + H2 mixture (1 % H2 to 3 % H2 maximum) may only be used
with previous approval of PETROBRAS;
b) root purging with inert gas is required during welding in order to prevent internal oxidation
on the root face and HAZ;
c) when a cored wire specific for GTAW welding (100 % argon) is used, any flux residue
shall be removed, especially where there is contact with the fluid.
5.5.4.3 GMAW
a) the root pass welding may be performed with controlled short circuit, as long as welders
are trained and qualified using base material (test specimens) and austenitic stainless
steel consumables;
b) the process may be used for filling and finishing. The welding of derivations, extensions,
pipe connections with hull (nozzles) and socket welds is not permitted;
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c) The welding may be performed with inert gas, mixtures of those gases, argon + O2
(maximum 2 %) or Argon + CO2 (maximum 5 %). Other mixtures richer in CO2 may be
used, if previously approved by PETROBRAS, and if it is performed the intergranular
corrosion test during the welding procedure qualification, according to ASTM A 262;
d) root purging with inert gas is required during welding in order to prevent internal oxidation
on the root face and HAZ.
5.5.4.4 FCAW
a) the welding of austenitic stainless steel is only permitted by the FCAW process with
shielding gas;
b) whenever the material is exposed to temperature above 480 C in the fabrication (or
PWHT process), the consumable shall be acquired according to AWS A5.01, Schedule J,
ensuring its bismuth content does not exceed 0.002 %;
c) the gas may be an argon + CO2 mixture (E XXXTX -4) or only CO2 (E XXXTX - 1), as
long as it is not observed carburization with pure CO2 during the qualification process.
The carbon percentage shall be assessed through chemical analysis and/or intergranular
corrosion test, as in ASTM A 262.
5.5.4.5 SAW
a) whenever the material is exposed to temperature above 480 C in the operation, the
consumable shall be acquired according to AWS A5.01, Schedule J, ensuring its bismuth
content does not exceed 0,002 %;
b) weld fluxes shall be stored and handled so as to avoid contamination. Contamination in
stainless steels is critical, because it may reduce the corrosion resistance;
c) flux used in welding of austenitic stainless steel shall be neutral or basic, without
deleterious effect to the weld zone;
d) the use of linked fluxes is not permitted, except to compensate for loss of alloying
elements in the metal transfer;
e) moisture on plates or in the flux may cause porosity. wet fluxes shall be re-dried, as
indicated by the manufacturer.
5.5.5 General Conditions for Consumables
5.5.5.1 The consumables shall follow the instructions in Table 13. The alternative consumables shall
only be used with previous approval of PETROBRAS.
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AWS
Spec.
AWS Classification
304 / CF8
304L / CF3
304H
CH-20
(~309)
310/ (CK-20)
316
CF8M (~316)
316L
CF3M (~316L)
A5.4
A5.4
A5.4
Preferred
E308
E308L
E308H
A5.4
E309
A5.4
A5.4
A5.4
A5.4
A5.4
E310
E316 (Note 2)
E308Mo
E316L
E308LMo
Alternative
E308L
E347
E308 (Note 3)
E309 Mo
E309MoL
E310Nb
E316L
E316
E316L
316H
A5.4
E316H
317/CG-8M
317L
321
347
CF8C
347H
A5.4
A5.4
A5.4
A5.4
A5.4
A5.4
HK-40
AWS
Spec.
AWS
Spec.
AWS Classification
A5.9
A5.9
A5.9
Preferred
ER308
ER308L
ER308H
A5.9
ER309
ER309 Mo
A5.9
A5.9
A5.9
A5.9
A5.9
ER310
ER316 (Note 2)
ER308Mo
ER316L
ER308LMo
E316 (Note 3)
A5.9
ER316H
E317
E317L
E347
E347
E347
E347H
E385
E385
E347 (Note 3)
A5.9
A5.9
A5.9
A5.9
A5.9
E310-H (Note 1)
ER317
ER317L
ER321
ER347
ER347
ER347H
ER35Ni25Cr-0.4C
ER316L
ER316 (Note
3)
ER385
ER385
ER347
ER347 (Note 3)
ER310H (Note
1)
AWS Classification
304
304L
304H
310
A5.22
A5.22
A5.22
A5.22
Preferred
(see Note 4)
E308TX-X
E308LTX-X
E308HTX-X
E310TX-X
316
A5.22
E316TX-X
316L
A5.22
Alternative
-
Alternative
ER308L
ER347
ER308 (Note 3)
A5.9
A5.9
A5.9
A5.9
A5.
9
A5.9
AWS Classification
Preferred
(see Note 5)
ER308
ER308L
ER308H
ER310
ER316H
Alternative
-
E316LTX-X
ER316L
E316HTX-X
316H
A5.22
A5.9
ER316
(NOTE 3)
317
A5.22
E317TX-X
E317LTX-X
A5.9
ER317
ER317L
317L
A5.22
E317LTX-X
A5.9
ER317L
321
A5.22
E347TX-X
A5.9
ER321
347
A5.22
E347TX-X
A5.9
ER347
347H
A5.22
E347HTX-X E347TX-X (Note 3) A5.9
ER347H
NOTE 1 The electrode and the rod shall not be used in equipment operating under pressure.
NOTE 2 For operating temperatures above 400 C and any thickness, consumables whose
chemical composition of the deposited metal is equal to the electrode AWS A5.4, E16-8-2
with 1 to 5 FN may be used.
NOTE 3 Consumable with minimum carbon of 0,04 %C.
NOTE 4 The welding position is indicated by the manufacturer EXXXTX X, if digit 0, it is flat and
horizontal position (EXXXT0-X), if digit 1, it is all positions (EXXXT1-X).
NOTE 5 Only the consumable presents specification/AWS classification, with no similar for the
flux.
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5.5.5.2 In classifications 308, 316, 317 and 321, the minimum ferrite content in the deposits shall be
3 % or 3 FN. For classification 347, it shall be 5 % or 5 FN.
5.5.5.3 The maximum content of ferrite shall be lower than 8,5% or 9 FN in steels exposed to high
temperature ( 370 C) or in those subjected to at least one PWHT cycle (coating /weld overlay)
during fabrication. The measurement of ferrite shall be performed before PWHT, and the calibration of
the ferritoscope tool shall be performed according to AWS A4.2 or through quantitative microstructural
evaluation.
5.5.5.4 The ferrite shall be measured in qualification phase of welding procedure, and when
prompted, evidenced in fabrication weld.
5.5.6 Preheating and Interpass
5.5.6.1 Preheating shall not be permitted.
5.5.6.2 The interpass temperature shall be kept as low as possible and not exceed 150 C, except for
the 317L steel, which shall not exceed 120 C.
5.5.7 Post-heating
It shall not be required.
5.5.8 Post Weld Heat Treatment (PWHT)
It is generally not required.
5.5.9 Weld Repair
5.5.9.1 More than two repairs in the same location may irreversibly degrade the corrosion resistance,
due to precipitation of carbides or intermetallic phases. In this case, the joint shall be evaluated for the
presence of precipitates, and, if their existence is evidenced, it shall be removed, including HAZ, and
the section shall be replaced.
5.5.9.2 Before the authorization for welding, the surfaces to be welded shall be inspected with liquid
penetrant.
5.5.10 Supplementary Requirements for Maintenance Weld
In maintenance welding, the parameters and welding techniques may show significant difference
compared to the materials in new condition, requiring assessment of the physical state of the material
in aged condition. In this case, the repair procedure shall be previously evaluated and approved by
PETROBRAS.
5.5.11 Supplementary Requirements for Inspection
5.5.11.1 The liquid penetrant test shall be performed at 100% in the root pass and finishing.
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5.5.11.2 During maintenance, before the authorization for welding, the bevels shall always be
inspected with liquid penetrant.
5.5.11.3 Water used in hydrostatic testing shall present control of chloride, which shall be lower than
50 ppm.
5.6 Superaustenitic Stainless Steels
5.6.1 Introduction
5.6.1.1 The superaustenitic steels have fully austenitic microstructure and intermediate composition
between the 300-series steels and nickel alloys. They usually present the following composition: 20 to
25% Cr, 15 to 25% Ni, 4 to 8% Mo, 0,01 to 0,03% C, 0,2 to 0,6% N and Pitting Resistance Equivalent
Number (PRENN) above 45, according to the following formula:
PRENN = %Cr + 3,3 x (%Mo + 0.5x%W) + 16 x (%N)
5.6.1.2 The 317 LN, and 317LMN and 904L steels (20Cr25NiMoCu) are included in this group
because they are precursors of superaustenitic steels, due to the increase in the percentage of Mo
and addition of N, like the 317 LN and LMN.
5.6.2 Weldability
5.5.2.3 Superaustenitic stainless steels are generally classified as P number 8 or 45, according to the
ASME BPVC Section IX.
5.6.2.2 The welding is performed similarly to austenitic stainless steels, being susceptible to hot
cracking, because they solidify in austenite mode. There may be micro-cracks (liquation tracks) in
multiple pass welding.
5.6.2.3 During solidification, there usually is segregation of Mo from 3,5 %, becoming critical when the
content is lower than 6 %. This phenomenon may reduce the localized corrosion resistance. The
consumable shall compensate for the reduction of Mo due to the segregation, and, therefore, it shall
be always richer in this element.
5.6.2.4 It is recommended to use techniques that provide movement of the weld pool.
[Recommended Practice]
5.6.2.5 The welder shall be properly trained and accustomed to welding these materials, in order to
avoid lack of fusion due to the lower fluidity of pool when compared to carbon steel.
5.6.3 General Welding Technique
All requirements indicated for welding of austenitic stainless steels are mandatory and shall be applied
with the changes described in 5.6.3.1 and 5.6.3.2.
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5.6.3.1 The heat input shall not exceed 1,3 kJ/mm for SMAW, PAW, and GTAW. For the GMAW
process, it shall not exceed 1,5 kJ/mm.
5.6.3.2 Industrial marker shall not be used.
5.6.4 Applicable Welding Processes
The SMAW, GTAW, GMAW, and PAW processes are permitted. The FCAW process is not permitted
with or without shielding gas.
5.6.4.1 SMAW
a) the use of synthetic consumables is not permitted;
b) basic consumables tend to generate slightly convex weld beads, which reduce the risk of
hot cracking and have higher toughness;
c) for 317LN and 317LMN steels, the bismuth content in deposit shall not exceed 0,002 %
whenever the material is exposed to temperatures above 480 C in fabrication (in PWHT
process) or in operation.. In this case, the consumable shall be acquired according to
AWS A5.01, Schedule J;
d) solvents used to clean the joint shall be free of sulfur, chlorine and fluorine;
e) all slag waste shall be removed before the material is exposed to operational condition.
5.6.4.2 GTAW
a) the homogeneous welding is usually not performed without subsequent heat treatment of
solubilization;
b) besides argon (99,99%), the argon + helium mixture or only helium may be used as
shielding gas. the argon + H2 mixture (1% H2 to 3% H2 maximum) may only be used with
previous approval of PETROBRAS;
c) the shielding gas used in welding of the alloy 904L shall be 99,99% argon;
d) the shielding gas used in welding of alloys 317LN, 317LMN, 254SMO, 25-6Mo and
654SMO shall be argon 99,99% or argon + N2 (maximum of 3 to 5 %). In the qualification
procedure, it shall be reviewed the nitrogen percentage in welded and heat affected zone.
e) root purging with inert gas is required during welding in order to prevent internal oxidation
on the root face and HAZ.
f) the purge shall be performed with argon + N2 (maximum of 3 % to 4 %) for materials
317LN, 317LMN, 254SMO, INCONEL-25 6MO and 654SMO;
g) root purging shall be maintained until the completion of the third weld layer or 6,3 mm,
ensuring the absence of oxygen;
h) the welding shall be performed with straight passes;
i) solvents used to clean the joint shall be free of sulfur, chlorine and fluorine.
5.6.4.3 GMAW
a) the use of controlled short circuit GMAW process in root pass and root stiffener is not
permitted;
b) the filler and finishing welding may be performed by GMAW process, except in
derivations, extensions, pipe connections with hull (nozzles) and socket welds;
c) welding with active gas or mixtures containing active gases is not permitted. the welding
shall only be performed with inert gas or inert gas mixtures;
d) the shielding gas used in welding of the alloy 904L shall be 99,99% argon;
e) the shielding gas used in welding of alloys 317LN, 317LMN, 254SMO, 25-6Mo and
654SMO shall be argon 99,99% or argon + N2 (from 3 % to 5 %). In the qualification
procedure, it shall be reviewed the nitrogen percentage in welded and heat affected zone.
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f) root purging with inert gas is required during welding in order to prevent internal oxidation
on the root face and HAZ.
g) the purge shall be performed with argon + N2 (from 3 % to 5 %) for materials 317LN,
317LMN, 254SMO, INCOLOY 25-6MO, and 654SMO;
h) root purging shall be maintained until the completion of the third weld layer or 6,3 mm,
ensuring the absence of oxygen.
5.6.5 General Conditions for Consumables
5.6.5.1 The consumables shall follow the instructions in Table 14.
Table 14 -
Type of
material
AWS
Spec.
AWS Classification
Preferred
317LMN
(4-5Mo)
904L
(4,5Mo)(
Note)
254SMO
UNS
S31254
25-6MO
UNS
N08926
654SMO
UNS
S32654
Alternative
AWS Classification
Preferred
Alternative
5.11
ENiCrMo-3
E317LMN
ENiCrMo-10
5.14
ERNiCrMo-3
ER317LMN
ERNiCrMo-10
5.11
5.4
ENiCrMo-3
E385Mod (Mo)
E385
5.14
5.9
ERNiCrMo-3
ER385
5.11
ENiCrMo-3
ENiCrMo-4
ENiCrMo-10
5.14
ERNiCrMo-3
ERNiCrMo-4
ERNiCRMo-10
5.11
ENiCrMo-3
ENiCrMo-4
ENiCrMo-10
5.14
ERNiCrMo-3
ERNiCrMo-4
ENiCRMo-10
5.11
ENiCrMo-3
ENiCrMo-4
ENiCrMo-10
5.14
ERNiCrMo-3
ERNiCrMo-4
ERNiCRMo-10
NOTE 1 The choice of alternative consumable for 904L steel shall be approved by PETROBRAS
due to the corrosive medium and operating temperature. In this case, in homogeneous
welding, the maximum ferrite percentage in the deposit shall be lower than 5 % or 5 FN
(E385Mod and E385).
NOTE 2 For purposes of this Standard, consumable E385Mod is the one where the molybdenum
percentage in the deposit is higher than 5%, and may exceed 5,5%Mo (above the %Max
of AWS).
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5.6.7 Post-heating
The post-heating is not required.
5.6.8 Post Weld Heat Treatment (PWHT)
PWHT is not required.
5.6.9 Heat Treatment of Solubilization
5.6.9.1 When welding with consumables of higher alloy content, especially in molybdenum,
solubilization treatment is usually skipped; however, it shall be observed the mandatory design
specification.
5.6.9.2 Autogenous welding requires heat treatment of solubilization. The solubilization treatment
shall follow the specification standard of the base metal, shall be performed on whole part, and the
localized treatment of the joint may not be carried out.
5.6.10 Weld Repair
5.6.10.1 More than two repairs in the same location may irreversibly degrade the corrosion
resistance, due to segregation of molybdenum, precipitation of carbides and intermetallic phases. In
this case, the joint shall be cut, including the HAZ, and replaced.
5.6.10.2 Before the authorization for welding, the bevels shall always be inspected with liquid
penetrant.
5.6.11 Supplementary Requirements for Maintenance Weld
5.6.11.1 In maintenance welding, the parameters and welding techniques may show significant
difference compared to the materials in new condition, requiring assessment of the physical state of
the material in aged condition. In this case, the repair procedure shall previously be assessed and
approved by PETROBRAS.
5.6.11.2 During maintenance, before the authorization for welding, the bevels shall always be
inspected with liquid penetrant.
5.6.12 Supplementary Requirements for Inspection
5.6.12.1 In fabrication, assembly and maintenance, the root passes, root stiffener and finishing shall
be 100 % inspected by liquid penetrant.
5.6.12.2 Water used in hydrostatic testing shall present control of chloride, which shall be lower than
50 ppm.
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Both expressions have been used and meet respectively steels with and without W.
5.7.1.6 In this Standard, unless where otherwise stated, the term duplex stainless is referring to the
three trade names, according to Table 15.
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UNS
No.
EN
No.
Cr
Ni
Mo
Duplex - 22 Cr standard
21,0- 1,35- 0,1LDX2101
S32101 1.4162 0,04
22,0
1,7
0,8
21,0- 4,52,52205
S31803 1.4462 0,03
23,0
6,5
3,5
22,0- 4,53,02205
S32205 1.4462 0,03
23,0
6,5
3,5
21,5- 3,0- 0,052304
S32304
0,03
24,5
5,5
0,60
Superduplex - 25Cr
24,0- 5,53,02520
S32520 1.4507 0,03
26,0
8,0
4,0
24,0- 4,52,9F255
S32550 1.4507 0,04
27,0
6,5
3,9
24,0- 6,03,02507
S32750 1.4410 0,03
26,0 8,0
5,0
24,0- 6,03,0Zeron100
S32760 1.4501 0,03
26,0 8,0
4,0
24,0- 6,02,5DP3W
S39274
0,03
26,0 8,0
3,5
Hyperduplex
26,0- 5,50- 4,02707
S32707
0,03
29,0 9,50 5,0
29,0- 6,00- 3,03207
S33207
0,03
33,0 9,00 5,0
NOTE 1 Single % values are the maximum.
NOTE 2 (-) Not defined in the specifications.
Mn
Cu
PREN
0,20,25
0,080,20
0,140,20
0,050,20
4,06,0
0,10,8
28,0
2,00
30,5
2,00
34,1
2,50
0,050,60
0,200,35
0,100,25
0,240,32
0,200,30
0,240,32
0,300,50
0,400,60
1,50
1,50
1,20
23,0
0,52,0
1,52,5
37,1
35,2
0,50
0,51,0
0,20,8
0,51,0
1,502,50
1,50
1,00
48
1,50
1,00
48
1,00
1,00
37,7
40,0
38,6
5.7.2 Weldability
5.7.2.1 The duplex stainless steels usually have good weldability and are classified as P number 10H,
according to ASME BPVC Section IX.
5.7.2.2 Attention shall be given to the heat input and control of interpass temperature, especially in
multiple pass welding, for the risk of precipitation of carbides, nitrides and intermetallic phases due to
the permanence in critical temperature range.
5.7.2.3 In welding process, the goal is to achieve the correct balance between ferrite and austenite in
the weld metal and HAZ, and to avoid the precipitation of deleterious secondary phases on HAZ or
weld metal.
5.7.2.4 The filler metals with higher Ni contents ensure the weld metal properties compatible with the
base metal.
5.7.3 General Welding Technique
5.7.3.1 The fabrication of stainless steel piping and equipment shall be made in a segregated and
protected area, preferably in a shed separated from other materials. The duplex stainless steels shall
be clearly segregated from austenitic stainless steels during fabrication.
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5.7.3.2 Welding preparation may be performed through use of cold cutting, abrasive cutting disk,
milling, water jet cutting, machining, plasma, or laser. In plasma cutting, depending on the quality
required for cutting, air or Air+H2 mixture may be used in the following combinations: 85/15%, 80/20%,
and 65/35%. Higher H2 contents increase the arc energy, resulting in higher cutting speeds and/or
cutting of larger thicknesses. After the thermal cutting, the ends shall be trimmed in at least 1,0 mm.
Thermal cutting with graphite and oxy-cutting are not permitted.
5.7.3.3 Also due to the high viscosity of stainless steel consumables regarding the C-Mn steels, the
preparation shall provide larger joint angle than for those steels, minimizing the risk of lack of fusion.
5.7.3.4 Preparation and cleaning shall include a range of 50 mm to both sides of the joint. This area
shall be cleaned by grinding and solvent to remove grease, oxides, marker paints, and other
contaminants that may be harmful to welding.
5.7.3.5 Slag removal, cleaning and cutting tools shall be used exclusively for these materials, and
meet the following requirements:
a) slag removal and cleaning tools shall be made of stainless steel or coated with this
material;
b) the cutting and trimming disks shall be made of aluminum oxide with nylon or fiberglass
core wire;
c) additional precautions shall be taken to avoid contamination during the preparation of the
joints.
5.7.3.6 It is recommended that the surface of the parts is protected from adherence of spatter and
other projections resulting from welding, especially when the GMAW process is used.
[Recommended Practice]
5.7.3.7 The filler metals (wires and electrodes) shall be properly stored in clean and dry places, and
always handled with clean gloves. The wires shall be cleaned with solvents before use.
5.7.3.8 The use of tacking or fastening devices shall be contained, in details, in the welding procedure
to be submitted for previous approval of PETROBRAS, including specification of materials to be used
in the manufacture of devices, and the filler metals to weld them.
5.7.3.9 The part of the auxiliary devices of assembly touching or welded to the equipment or piping
shall be made of material with the same P number of base metal, in accordance with the classification
of BPVC ASME Section IX, or coated with consumable specified for welding of the metal with at least
two layers.
5.7.3.10 The heat input shall never be lower than 0,5 kJ/mm. A very low heat input of welding
increases the cooling rate, resulting in low formation of austenite, which may be below 35 %.
5.7.3.11 The heat input shall not exceed 1,5 kJ/mm, except for duplex 2205, which may reach up to
2,0 kJ/mm. Higher heat input values of welding may cause precipitation of deleterious secondary
phases, reducing the mechanical properties and corrosion resistance.
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5.7.3.12 The ratio between the heat inputs of the first and second pass shall be around 85 %,
according to the example of Figure 5.
1,7 kJ/mm
1,3 kJ/mm
1,4 kJ/mm
1,0 kJ/mm
2,0 kJ/mm
Damaging
Weld 1 - Wrong
Damaging
Weld 2 - Wrong
Balanced
Weld 3 - Right
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No. of tests
Standard
Acceptance
Visual
100 % welds
Radiography
Liquid penetrant
100 % welds
Bending
NORSOK M-601
10 mm 10 mm x 10 mm x
7,5 mm x 0,83 x 5,0 mm
above 10 mm, 0,66 mm x
above 27 Joules, and
minimum expansion of
0,38 mm, no single value
below 70% of the required
average
NORSOK M-601
No precipitations - 400X
ASTM E 562
ASTM G 48 A, 24HRS,
20 C for Duplex; 40 C for
Super and Hyperduplex
(as welded)
35 % to 65 %
Charpy V (-46 C) (6 mm
and larger thickness) or
minimum design
temperature
Microstructural
examination (+ photos)
Ferrite counting
Pitting corrosion
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5.7.4.3 GMAW
a) root pass welding by GMAW process is not permitted. The other passes may be welded,
except for derivations, extensions, pipe connections with hull (nozzles) and socket welds;
b) the following shielding gases may be used: pure argon, Ar + N2 (1,5 % to 2 %), Ar + CO2
(1 % to 2 %), the latter shall only be used with previous approval of PETROBRAS.
5.7.4.4 SAW
a) the flux shall not add alloying elements, except for compensation for losses in electric arc,
being usually basic fluxes with compensation for chromium;
b) the flux shall consist of low diffusible hydrogen with a maximum of 8 mL of hydrogen per
100 g of deposited weld metal (H8).
5.7.5 General Conditions for Consumables
The consumables shall follow the instructions in Table 17.
AWS
Spec.
S32003
S31803
(2205)
S32205
(2205)
S32304
(2304)
S32520
Coated electrode
(SMAW)
AWS Classification
Preferred
Alternative
A5.4
E2209
A5.4
E2209
A5.4
AWS
Spec.
Alternative
A5.9
ER2209
A5.9
ER2209
E2209
A5.9
ER2209
A5.4
E2209
A5.9
ER2209
A5.4
E2553
A5.9
ER2553
A5.4
E2553
A5.9
ER2553
E2594
A5.9
ER2594
E2594
A5.9
ER2594
A5.9
ER2594
A5.9
LDX2101
ER2209
S32550
(F255)
S32750
(2507)
S32760
(Z100)
S39274
(DP3W)
A5.4/A
5.11
A5.4/A
5.11
A5.4/A
5.11
S32101
A5.4
E2594
LDX2101
E2209
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5.7.7 Post-heating
Not applicable.
5.7.8 Post Weld Heat Treatment (PWHT)
Not applicable.
5.7.9 Weld Repair
No more than two repairs at the same region is permitted.
5.7.10 Supplementary Requirements for Maintenance Weld
During maintenance, before the authorization for welding, the bevels shall always be inspected with
liquid penetrant.
5.7.11 Supplementary Requirements for Inspection
5.7.11.1 Root passes, root stiffeners and finishing shall be 100 % inspected with liquid penetrant.
5.7.11.2 All butt welded joints shall be radiographed.
5.7.11.3 Water used in hydrostatic testing shall present control of chloride, which shall be lower than
50 ppm.
5.8 Martensitic Stainless Steels
5.8.1 Introduction
5.8.1.1 This family comprises stainless steels usually containing 12 % to 18 % of chromium, classified
as P Number 6, according to ASME BPVC Section IX.
5.8.1.2 In addition to the typical steels of this family, such as AISI 410, this Section also includes the
UNS J91540 (CA6NM) cast martensitic stainless steel and the UNS S41426 steel (Super 13 Cr).
5.8.2 Weldability
5.8.2.1 The main problem in welding of martensitic stainless steels is the susceptibility to hydrogen
cracking in weld metal and HAZ, due to the formation of high hardness martensite. Therefore, those
stainless steels are not normally used in welded constructions.
5.8.2.2 To avoid hydrogen cracking, steels of this family shall be preheated to slow the cooling rate,
and post-heated to promote the removal of hydrogen. PWHT shall be performed after welding to
increase toughness and reduce hardness.
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5.8.2.3 CA6NM martensitic stainless steels and Super 13 Cr, among others, have lower carbon
content (lower than 0,06% and 0,03%, respectively) to improve weldability. These steels also have
nickel and molybdenum to improve corrosion resistance and mechanical properties.
5.8.2.4 Martensitic stainless steels with more than 0,25 % C are considered not weldable.
5.8.3 General Welding Technique
5.8.3.1 Slag removal, cleaning and cutting tools shall be used exclusively for these materials, and
meet the following requirements:
a) slag removal and cleaning tools shall be made of stainless steel or coated with this
material;
b) the cutting disks shall be made of aluminum oxide with nylon core or of fiberglass;
c) additional care shall be taken as cleaning and preparation of the joint to be welded, in
order to prevent contaminants.
5.8.3.2 The surface of the parts shall be protected against spatter adhesion and other projections
resulting from welding.
5.8.3.3 The part of the auxiliary device of assembly touching or welded into the equipment shall have
the same P number of the base metal, according to the classification of ASME BPVC Section IX, or
otherwise be coated with at least two layers of the consumable specified for the welding of base metal.
5.8.3.4 The preparation of the welded joint may be made by machining, oxy-cutting, plasma, laser or
water jet cutting. In case of thermal cutting, the HAZ shall be removed by machining or grinding.
5.8.3.5 In the case of heterogeneous welding with filler metal in nickel alloys, the cleaning
requirements indicated in the welding of nickel alloys item are applied.
5.3.3.5 The manual heating by oxy-gas flame (shower-type blowtorch) shall be limited to pipes or
hulls with thickness below 13 mm and a nominal diameter of up to 10".
5.8.4 Applicable Welding Processes
The SMAW, GMAW, FCAW, GTAW and SAW processes are permitted. The FCAW-S process is not
permitted.
5.8.4.1 SMAW
a) the welding shall be performed with low hydrogen basic electrodes, generating a weld
deposit with hydrogen content not exceeding 8 mL per 100 g of deposited weld metal;
b) slag shall be completely removed before the material is exposed to operating conditions;
c) synthetic electrode is not permitted.
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5.8.4.2 GTAW
a) the gas to be used shall be argon 99,99 %;
b) in pipe welding, purging with argon or helium shall be done in the root pass and root
stiffener pass;
c) root purging shall be maintained until the completion of the third weld layer or 6,3 mm,
ensuring the absence of oxygen.
5.8.4.3 GMAW
a) root welding by GMAW process is not permitted, except for filling and finishing;
b) the welding may be performed with inert gas, mixtures of those gases, argon + O2
(maximum 2 %) or argon + CO2 (maximum 5 %) to avoid oxidizing or excessive
carburization of base metal and weld metal.
5.8.4.4 FCAW
a) the welding shall be done with shielding gas;
b) the gas may be argon + CO2 mixture (E XXXTX -4) or just CO2 (E XXXTX - 1), being the
latter limited to medium and high carbon steels;
c) the shielding gases to be used shall be those specified by the manufacturer of the wire.
5.8.4.5 SAW
a) the use of linked fluxes is not permitted, except to compensate for loss of alloying
elements in the metal transfer;
b) weld fluxes shall be stored and handled so as to avoid contamination. care shall be taken
to avoid contamination of the flux during welding. Contamination in stainless steels is
critical because it may reduce corrosion resistance;
c) moisture on plates or in the flux may cause porosity or cold cracking. wet fluxes shall be
re-dried, as indicated by the manufacturer.
5.8.5 General Conditions for Consumables
5.8.5.1 The consumables shall follow the instructions in Table 18. The alternative consumables shall
only be used with previous approval of PETROBRAS.
5.8.5.2 In the case of heterogeneous welding, when not prohibited by the equipment design or
fabrication and assembly standard, consumables shall be specified as written below, considering the
SMAW and GTAW welding processes:
a) cyclic operating temperature: AWS A5.11 ENiCrFe-2 (maximum temperature = 760 C) or
AWS A5.14 ERNiCr-3 (maximum temperature = 760 C). The temperatures indicated
above are the limits of use for nickel alloys, but the operating temperature of the
martensitic stainless steels shall be lower than 600 C. In case of use of the consumable
AWS A5.11 ENiCrFe-3, the operating temperature shall not exceed 480 C;
b) noncyclic operating temperature and lower than 315 C: AWS A5.4, E309 and AWS A5.9,
ER309.
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Material
type
410, CA-15
CA
6NM
UNS J91540
Super 13 Cr
UNS S41426
Material
type
410, CA-15
AWS
Spec.
Coated electrode
(SMAW)
AWS Classification
Preferred
Alternative
A5.4
E410
E410 Ni Mo
A5.4
E410 Ni Mo
A5.4
AWS
Spec.
A5.22
E2594
Cored wire
(FCAW-G)
AWS Classification
Preferred
Alternative
E410TX-X
E410NiMoTX-X
AWS
Spec.
AWS Classification
Preferred
Alternative
A5.9
ER410
ER410NiMo
A5.9
ER410 Ni Mo
A5.9
ER2594
ER2209 (Note 2)
AWS
Spec.
A5.9
Submerged arc
(SAW)
AWS Classification
Preferred
Alternative
ER410
ER410NiMo
CA
6NM
A5.22
E410NiMoTX-X
A5.9
ER410 Ni Mo
UNS J91540
Super 13 Cr
A5.22
E2594TX-X
A5.9
ER2594
UNS S41426
NOTE 1 Only the consumable presents specification/AWS classification, with no similar consumable for
the flux.
NOTE 2 The consumable ER2209 may be used only in the root pass, the others shall necessarily be
performed with consumable ER2594.
5.8.6 Preheating and Interpass
5.8.6.1 The parts shall be preheated according to the following indications:
a)
b)
c)
d)
e)
5.8.7 Post-heating
5.8.7.1 The post-heating shall meet the following indications:
a) designations 410, CA-15 and CA-15M, homogeneous welding: 300 C, for a period of
1 min/mm of weld dimension, but for 1 hour or longer;
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b)
c)
d)
e)
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5.9.2.3 Since they are less susceptible to cold cracking than martensitic steels, welding may be
performed without preheating. For thick plates, however, it may be useful for some alloys to reduce
the residual stresses, decrease the cooling speed and cold cracking risk.
5.9.2.4 Hot cracks are extremely rare, especially when the alloys do not have Ti and Nb in their
composition.
5.9.2.5 Steels from this family are usually not highlighted for its toughness in new condition, and may
present very low toughness when aged in operation at temperatures 400 C. Welded joints without
control of interstitial elements (C + N) and with high chromium content (above 18 %) always present
low toughness.
5.9.3 General Welding Technique
5.9.3.1 Slag removal, cleaning and cutting tools shall be used exclusively for these materials, and
meet the following requirements:
a) slag removal and cleaning tools shall be made of stainless steel or coated with this
material;
b) the cutting disks shall be made of aluminum oxide with nylon core or of fiberglass;
c) additional care shall be taken as cleaning and preparation of the joint to be welded, in
order to prevent contaminants.
5.9.3.2 The surface of the parts shall be protected against spatter adhesion and other projections
resulting from welding.
5.9.3.3 The part of the auxiliary device of assembly touching or welded into the equipment shall have
the same P number of the base metal, according to the classification of ASME BPVC Section IX, or
otherwise be coated, with at least two layers of the consumable specified for the welding of base
metal.
5.9.3.4 The preparation of the welded joint may be made by machining, oxy-cutting, plasma, laser or
water jet cutting. In case of thermal cutting, the HAZ shall be removed by machining or grinding.
5.9.3.5 In the case of heterogeneous welding with filler metal in nickel alloys, the cleaning
requirements indicated in the welding of nickel alloys item are applied.
5.9.4 Applicable Welding Processes
The SMAW, GMAW, FCAW, GTAW and SAW processes are permitted. The FCAW-S process is not
permitted.
5.9.4.1 SMAW
a) the welding shall be performed with low hydrogen basic electrodes, generating a weld
deposit with hydrogen content not exceeding 8 mL per 100 g of deposited weld metal;
b) slag shall be completely removed before the material is exposed to operating conditions;
c) synthetic electrode is not permitted.
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5.9.4.2 GTAW
a) the gas to be used shall be argon 99,99 %, except for steels with high chromium
percentage and control of interstitial elements (%C + %N), in which the argon
composition shall be 99,998 %;
b) the root purge shall be maintained until the 3rd weld layer or 6,35 mm, whichever is
thicker.
5.9.4.3 GMAW
a) root welding by GMAW process is not permitted, except for filling and finishing;
b) welding may be performed with inert gas, as indicated for the GTAW process.
5.9.4.4 FCAW
a) the welding shall be done with shielding gas;
b) the shielding gases to be used shall be those specified by the manufacturer.
5.9.4.5 SAW
a) the use of linked fluxes is not permitted, except to compensate for loss of alloying
elements in the metal transfer;
b) weld fluxes shall be stored and handled so as to avoid contamination. Care shall be taken
to avoid contamination of the flux during welding. Contamination in stainless steels is
critical because it may reduce corrosion resistance;
c) moisture on plates or in the flux may cause porosity or cold cracking. wet fluxes shall be
re-dried, as indicated by the manufacturer.
5.9.5 General Conditions for Consumables
The consumables shall follow the instructions in Table 19. The alternative consumables shall only be
used with previous approval of PETROBRAS.
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AWS
Spec.
Preferred
(see Note 2)
Alternative
A5.4
E410 (Note 1)
E409Nb
E410NiMo
A5.11
A5.4
405, 410S
409
A5.11
A5.4
430
AWS Classification
A5.11
439
A5.11
444 and
25 %Cr
(446, 447,
448)
A5.11
Preferred
(see Note 2)
Alternative
A5.9
ER410 (Note 1)
ER409Nb
ER410NiMo
ENiCrMo-3
ENiCrFe-2
A5.14
ERNiCr-3
ERNiCrMo-3
E409Nb
A5.9
ER409Nb
ENiCrMo-3
ENiCrFe-2
E430
ENiCrMo-3
ENiCrFe-2
ENiCrMo-3
ENiCrFe-2
A5.14
E430Nb
A5.9
A5.14
A5.14
ENiCrMo-3
ENiCrFe-2
A5.14
Cored wire
(FCAW-G)
Type of
material
AWS
Spec.
AWS Classification
Alternative
A5.22
E410TX-X
E409TX-X
E409NbTX-X
A5.34
ENiCrMo3Tx-y
ENiCr3Tx-y
A5.22
E409TX-X
A5.34
ENiCrMo3Tx-y
ENiCr3Tx-y
A5.22
E430TX-X
409
430
A5.34
439
A5.34
444 and
25 %Cr (446,
447, 448)
A5.34
ERNiCrMo-3
ERNiCr-3
ER430
ERNiCrMo-3
ERNiCr-3
ERNiCr-3
ERNiCrMo-3
ER439
ERNiCr-3
ERNiCrMo-3
Submerged arc
(SAW) (Note 3)
Preferred
(see Note 2)
405, 410S
AWS Classification
E409NbTX-X
E430NbTX-X
ENiCrMo3Tx-y
ENiCr3Tx-y
ENiCrMo3Tx-y
ENiCr3Tx-y
AWS
Spec.
Preferred
(see Note 2)
Alternative
A5.9
ER410
ER409Nb
ER410NiMo
A5.14
ERNiCr-3
ERNiCrMo-3
A5.9
ER409Nb
A5.14
ERNiCr-3
ERNiCrMo-3
A5.9
ER430
A5.14
A5.14
ENiCrMo3Tx-y
ENiCr3Tx-y
AWS Classification
A5.14
ER430Nb
ERNiCr-3
ERNiCrMo-3
ERNiCr-3
ERNiCrMo-3
ERNiCr-3
ERNiCrMo-3
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The preheating may be used in heterogeneous welding as a way to avoid PWHT, according
to the design code.
5.9.6.2 The parts shall have the interpass temperatures according to the following indications:
a) it shall not exceed 250 C for steels 405, 410S and 430;
b) it shall not exceed 150 C for steels 409, 439 , 444 and 25 %Cr (446, 447, 448).
5.9.7 Post-Heating
Generally, it is not required, except for thick plates with major restrictions.
5.9.8 Post Weld Heat Treatment (PWHT)
5.9.8.1 In homogeneous welding, PWHT is usually required in design codes; however, it may also be
required in heterogeneous welding, depending on thickness.
5.9.8.2 When prolonged, the PWHT may cause formation of Sigma and Chi phases.
5.9.9 Weld Repair
5.9.9.1 For steels with controlled carbon (low carbon), no more than two repairs at the same region is permitted.
5.9.9.2 Before the authorization for welding, the bevels shall always be inspected with liquid penetrant.
5.9.9.3 In welding maintenance, the parameters and welding techniques may show significant
difference compared to the materials in new condition, requiring assessment of the physical state of
the material in aged condition. In this case, the repair procedure shall be previously assessed and
approved by PETROBRAS.
5.9.10 Supplementary Requirements for Inspection
In case of heterogeneous welding with austenitic filler metal, in which the preheating is not required,
the liquid penetrant test shall be performed in the root pass.
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Monel is the trade name of the nickel alloy supplied by Precision Castparts Corp. This information is given to
facilitate the users in this Standard use and it doesnt mean a recommendation of the product mentioned on the
part of PETROBRAS. It is possible to use an equivalent product, since it gives an equal result.
2
Inconel is the trade name of the nickel alloy supplied by Precision Castparts Corp. This information is given to
facilitate the users in this Standard use and it doesnt mean a recommendation of the product mentioned on the
part of PETROBRAS. It is possible to use an equivalent product, since it gives an equal result.
3
Incoloy is the trade name of the nickel alloy supplied by Precision Castparts Corp. This information is given to
facilitate the users in this Standard use and it doesnt mean a recommendation of the product mentioned on the
part of PETROBRAS. It is possible to use an equivalent product, since it gives an equal result.
4
Hastelloy is the trade name of the nickel alloy supplied by Haynes International. This information is given to
facilitate the users in this Standard use and it doesnt mean a recommendation of the product mentioned on the
part of PETROBRAS. It is possible to use an equivalent product, since it gives an equal result.
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5.10.3.12 After the welding completion and before the start of operation, soaps and detergents used
in bubble and liquid penetrant tests shall be removed, since they may contain elements with low
melting point, especially sulfur.
5.10.3.13 Slag and flux residues shall be removed after welding, because they compromise the
corrosion resistance in operation (fluoride). Contact with chlorine or fluoride is extremely harmful,
causing stress or pitting corrosion.
5.10.3.14 The welding by GTAW and GMAW processes shall be performed with oxygen-free purging
gas at the weld root in order to protect the weld zone and HAZ. This protection shall be maintained
until the completion of the third weld layer, ensuring the absence of oxygen. Argon and helium may be
used as purge gas. Nitrogen shall only be permitted after previous evaluation and approval of
PETROBRAS. The measurement of residual oxygen shall be performed using an oxymeter with
threshold value of 50 ppm.
5.10.4 Applicable Welding Processes
The SMAW, GTAW, SAW, GMAW, and FCAW welding processes are permitted, the last two with
restrictions. The FCAW-S process is not permitted.
5.10.4.1 SMAW
a) the use of synthetic consumables is not permitted;
b) root welding and second layer by SMAW process is not permitted;
c) when the welding of nickel allows is performed using the SMAW processes, it is important
that the slag is completely removed before the joint gets into operation.
5.10.4.2 GTAW
a) consumables shall be constantly cleaned with acetone before the opening the arc;
b) besides argon (99,99%), the argon + helium mixture or only helium may be used as
shielding gas. The argon + H2 mixture (1 % H2 to 3 % H2 maximum) may only be used
with previous approval of PETROBRAS;
c) It is recommended to use tungsten electrodes with addition of Cerium or Lanthanum.
[Recommended Practice]
5.10.4.3 GMAW
a) root and root stiffener pass welding by GMAW process are not permitted;
b) the use of this process in equipment, ducts or pipelines subject to pressure shall have
previous approval of PETROBRAS;
c) welding with pure CO2 shielding gas is not permitted;
d) the shielding gas in GMAW process shall consist of pure argon, argon + O2
(2 % maximum), argon + CO2 (2 % maximum), argon + H2 (1 % maximum);
e) The limitations of using this process are due to increased susceptibility to lack of fusion,
low wettability and fluidity of nickel alloys.
5.10.4.4 FCAW
a) the use of this process in equipment, ducts or pipelines subject to pressure is not
permitted;
b) root and root stiffener pass welding by FCAW process are not permitted;
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c) coat welding by FCAW process with shielding gas is only permitted with prior approval of
PETROBRAS;
d) welding with pure CO2 shielding gas is not permitted;
e) the shielding gas in FCAW process shall be Argon + 25 % CO2 or Argon + 20 % CO2.
5.10.4.5 SAW
a) the flux shall be neutral or basic, and linked fluxes are not permitted;
b) when the welding of nickel alloys is performed using the SAW processes, it is important
that the slag and flux residues are completely removed before exposure of the joint in
operation.
5.10.5 General Conditions for Consumables
5.10.5.1 The consumables shall follow the instructions in Table 20.
Table 20 - Electrodes, Rods and Solid Wires for Nickel and Nickel Alloys
Material Type
AWS
Spec.
Coated electrode
(SMAW)
AWS Classification
Preferred
Alternative
(see Note 1)
AWS
Spec.
Alternative
(see Note 1)
Alloy 200/
201
A5.11
ENi-1
A5.14
ERNi-1
Alloy 400
A5.11
ENiCu-7
ENi-1
A5.14
ERNiCu-7
ERNi-1
Alloy 600
A5.11
ENiCrFe-1
ENiCrFe-2
A5.14
Alloy 625
A5.11
ENiCrMo-3
(Note 2)
A5.14
Alloy
800/800H/
800HT
A5.11
ENiCrCoMo-1
Incoloy 825
A5.11
ENiCrMo-3
(Note 2)
Hastelloy B
A5.11
Hastelloy C4
ERNiCr-6
ERNiCr-3
ERNiCrMo-3
(Note 2)
A5.14
ERNiCrCoMo-1
A5.14
ERNiFeCr-1
ERNiCrMo-3
(Note 2)
ENiMo-1
A5.14
ERNiMo-1
A5.11
ENiCrMo-7
A5.14
ERNiCrMo-7
Hastelloy C22
A5.11
ENiCrMo-10
A5.14
ERNiCrMo-10
Hastelloy
C276
A5.11
ENiCrMo-4
A5.14
ERNiCrMo-4
32Ni20CrNb
ER32Ni20CrNb
ERNiCrCoMo-1
HP(35Ni25Cr)
ER3525Ni-0 4C
(Nb)
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5.10.5.2 The consumables for coat welding by the FCAW and FCAW-G cored wire processes shall
comply with AWS A5.34. AWS classification TNiXXXXT1 or TNiXXXXT0-4-4.
5.10.6 Preheating and Interpass
5.10.6.1 Preheating is not required.
5.10.6.2 The interpass temperature shall be below 150 C.
5.10.6.3 In case of maintenance welding in aged materials using the cold welding technique, the
interpass temperature shall be below 90 C.
5.10.7 Post-heating
It shall not be required.
5.10.8 Post Weld Heat Treatment (PWHT)
It is usually not performed; however, it may be required depending on the fluid and according to
design specification.
5.10.9 Weld Repair
5.10.9.1 The defect shall be removed by manual or mechanized grinding, milling or machining.
5.10.9.2 After removing the defect, the region shall be examined with liquid penetrant. The welding
shall be performed with low heat input using the GTAW process.
5.10.9.3 In fabrication welding. only one repair is permitted.
5.10.9.4 In maintenance welding, a maximum of two repairs at the same region is permitted, due to
the formation of intermetallic phases that reduce the ductility and corrosion resistance, and to the
appearance of cracks after cooling the joint.
5.10.9.5 To perform the maintenance repair, the repair procedure shall be previously evaluated and
approved by PETROBRAS, due to the possible deterioration of material in service.
5.10.10 Supplementary Requirements for Inspection
5.10.10.1 In fabrication, assembly and maintenance, the root passes, second layer and finishing shall
be 100 % inspected with liquid penetrant.
5.10.10.2 During maintenance, before the authorization for welding, the bevels shall always be
inspected with liquid penetrant.
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5.10.10.3 Water used in hydrostatic testing shall present control of chloride, which shall be lower than
50 ppm.
5.11 Copper and Copper Alloys
5.11.1 Introduction
5.11.1.1 Copper and its alloys are generally used due to their high mechanical strength (especially
fatigue) and corrosion resistance, in addition to the excellent thermal and/or electric conductivity.
5.11.1.2 Several alloys are produced by adding the main following elements: aluminum, nickel, tin,
and zinc. Phosphorus and silicon are used as deoxidizers. For purposes of this Standard, besides the
commercially pure copper (99,3% Cu), the Copper-Nickel (Cu-Ni with 30%Ni) and Copper-Aluminum
(Bronze-Aluminum up to 8%AL) alloys are considered, with the following specifications:
5.11.1.3 The materials in this standard have solid solution hardening, homogeneous microstructure
with single phase CFC-, including the C-61400 bronze-aluminum, in which the percentage of
aluminum does not exceed 8%.
5.11.2 Weldability
5.11.2.1 In general, they have rapid cooling rate, favoring the lack of fusion due to the high coefficient
of thermal conductivity of copper.
5.11.2.2 A well pool of commercially pure copper has great fluidity.
5.11.2.3 Copper alloys, when enriched in solute atoms, become susceptible to hot cracking, which
may be softened by reduction of root opening, sharp deposition, and by preheating in some alloys.
5.11.2.4 The mechanical properties may be compromised by the quick formation of copper oxide.
This oxide is hygroscopic and highly reactive when exposed to oxygen at high temperature. The
mechanical strength is compromised by the formation of pores (oxides) and impurities (antimony,
arsenic, bismuth, and lead).
5.11.3 General Welding Technique
5.11.3.1 Hygroscopic oxide removal, slag removal, cleaning and cutting tools shall be used
exclusively for these materials, and meet the following requirements:
a) slag removal and cleaning tools shall be made of copper alloy, stainless steel or be
coated with this material, and only be used for welding of copper and its alloys;
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AWS Specification
AWS Classification
A5.7
ERCu
C-70600 (90Cu10Ni)
A5.7
ERCuNi
C-71500 (70Cu30Ni)
A5.7
ERCuNi
C-61400 (bronze-aluminum)
A5.7
ERCuAL-A2
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5.12.2 T
Types of Me
etal Coating
gs
5.12.2.1
1 Cladded Plate
P
bond obtaine
Bimetallic set with metallurgical
m
ed by co-lam
mination, co-e
extrusion or w
welding by explosion.
5.12.2.2
2 Plate with
h Coating De
eposited by Welding (W
Weld Overlay
y)
Bimetallic set with metallurgical
m
ed by arc we
elding.
bond obtaine
5.12.2.3
3 Plate with
h Lining
Bimetallic set without metallurgical bonding , being the adhesion ob
btained mechhanically, with sealing
welds at the ends, cover
c
weld orr sewing by e
electric resistance.
5.12.3 W
Weldability
The weldability of th
hese materia
als shall be evaluated by
b applicable
e constitutionnal diagrams
s, such as
Schaefffler, De Lon
ng, and WR
RC diagram
ms, among others, including for bbuttering. All welding
requirem
ments for eacch material shall
s
be conssidered indiviidually.
5.12.4 G
General We
elding Techn
nique
5.12.4.1
1 When there is access
s both by th
he substrate
e side and by
b the coatiing side: the
e junction
between
n coated pla
ates shall alw
ways be initia
ated by the homogeneou
h
us junction oof substrate, with prior
removal of the coatting in the re
egion adjace
ent the joint,, preventing that the weelding of the substrate
(base p
plate) is carrried out with
h contact an
nd dilution with
w
the coatting materiall. Figure 6 shows
s
an
example
e of a bevel for this situ
uation. The rremoval of the coating shall
s
be perfformed by grinding or
machiniing. The full removal of the
t coating sshall be chec
cked with a supersaturatted solution of copper
sulphate
e. Cutting wiith carbon ellectrode is n
not permitted
d. The recom
mposition of tthe coating layer shall
be made
e in at least two
t
layers.
Subsstrate
Co
oating
FIG
GURE 6 - JOINT
J
PRE
EPARATIO
ON OF CO
OATED PLATE WITH
H ACCESS
S ON
BOTH
H SIDES
5.12.4.2
2 When therre is access only
o
by the ssubstrate side, as in the case
c
of pipess and vessells of small
diamete
er: the full bevel
b
shall be
b filled usin
ng filler meta
al that meets
s the corrossion resistan
nce of the
coating,, the mecha
anical streng
gth of the ssubstrate an
nd does not present veery differentt physical
characte
eristics when
n exposed to
o operating te
emperature (reduction
(
of life due to thhermal fatigu
ue failure).
The we
elding joints of cladded ferritic micro
ostructure or coated "we
eld overlay" employing austenitic
09 and fam
stainless steel consumables (e
e.g. alloy 30
mily) shall be
e limited too maximum operating
tempera
ature of 315 C. Above 315
3 C shall be used only consumable nickel basse. Figure 7 shows an
example
e of a bevel for this situation. The p
preparation of
o the bevel shall be perf
rformed by grinding
g
or
machiniing. Cutting with
w carbon electrode
e
is n
not permitted
d.
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Subsstrate
Co
oating
FIGUR
RE 7 - PR
REPARATION OF JO
OINT FRO
OM COATE
ED PLATE
E WITH ACCESS
A
ON
NLY ON TH
HE SUBST
TRATE SID
DE
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5.12.4.3 In the case of coating deposited by arc welding (weld overlay), the sanitation of the substrate
shall be verified by non-destructive testing, being the defects repaired upon previous approval of
PETROBRAS. The preparation and cleaning of the substrate shall be to white metal. Preheating,
interpass and PWHT temperatures shall comply with 5.12.6 and 5.12.8.
5.12.4.4 Slag removal, cleaning and cutting tools shall meet the following requirements:
a) slag removal and cleaning tools shall be made of stainless steel or coated with this
material;
b) the cutting disks shall be made of aluminum oxide with nylon core, for coating plates of
stainless steel;
c) cutting disks shall have nylon or fiberglass core for coating plates made of Monel and
nickel alloys.
5.12.4.5 The surface of the coating shall be protected against spatter adhesion and other projections
resulting from welding, grinding and cutting operations.
5.12.4.6 The part of the auxiliary device assembly touching or welded into the coating shall be made
of material with the same P number, according to the ASME BPVC Section IX, or be coated with
consumable specified for coating welding, in deposits of at least two layers.
5.12.4.7 Welding with any process shall be performed with low dilution. The submerged arc welding
shall be performed with parameters and fluxes favoring the reduction of dilution.
5.12.4.8 The ferrite content of the weld metal of austenitic stainless steel coating shall be within 3 FN
and 9 FN after welding, except for stainless steel 347, in which the ferrite content shall be within 5 FN
and 9 FN. In case of PWHT, the ferrite content shall be determined before it.
5.12.4.9 During maintenance, when there is evidence of failure of coating in equipment that operated
with H2S or hydrogen, it shall be checked the need for a dehydrogenation treatment before any
intervention by welding.
5.12.5 Applicable Welding Processes
5.12.5.1 The welding processes applicable to the substrate and coating shall follow the specific
guidelines of this Standard for the corresponding material.
5.12.5 The Electroslag (ESW) and SAW processes with tape shall be used for coating large areas in
fabrication, with the ESW having advantage due to lower dilution. [Recommended Practice]
5.12.5.3 The use of GMAW-P process is recommended for its low dilution in large areas when the
equipment is already assembled. The welding by GMAW process with spray transfer is not permitted
in the first layer due to the high dilution. [Recommended Practice]
5.12.5.4 It is recommended the use of GTAW and PAW processes on small and medium equipment.
[Recommended Practice]
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5.12.5.5 The bismuth content in anticorrosive deposits using austenitic stainless steels by SMAW,
FCAW-G, SAW and ESW processes shall not exceed 0,002 % whenever the material is exposed to
temperatures above 480 C in fabrication (in PWHT process) or in operation. In this case, the
consumable shall be acquired according to AWS A5.01, Schedule J.
5.12.5.6 For the welding of Hastelloy C276 using the SAW process, additional tests shall be
performed to ensure that the silicon content is within specification.
5.12.5.7 Welding with pure CO2 is not permitted for stainless steels, nickel alloys and copper alloys.
5.12.6 General Conditions for Consumables
5.12.6.1 The consumable for welding of base-plate shall meet the information contained in this
Standard for the corresponding material.
5.12.6.2 The consumable for welding of the coating shall meet the required specification of the
equipment design. In the absence of requirements, the consumables listed in Tables 22 or 23 may be
adopted, according to API RP 582, depending on the need for PWHT.
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Table 22 - Filler Metals for Coating Deposited by Welding - Weld Overlay - in Carbon
Steel or Low Alloy Base-Plate on Equipment with No Need for PWHT
SMAW/GTAW/GMAW/SAW/ESW Process
Type of the
intended coating
material
AWS
Specification
405/410S
A5.11/A5.14/A5.4
/A5.9
430
A5.11/A5.14/A5.4
/A5.9
410
A5.11/A5.14/A5.4
/A5.9
304
A5.4 /A5.9
E/ER 309/309L
E/ER 309/309L
304L
A5.4 /A5.9
E/ER309L
E/ER 308L
316/317
A5.4 /A5.9
E/ER309LMo/309Mo
E/ER 316L/317L
316L
A5.4 /A5.9
E/ER 309LMo
E/ER 316L/317L
317L
A5.4 /A5.9
E/ER 309LMo
E/ER 317L/385
321/347
A5.4 /A5.9
E/ER309L/309Nb
E/ER 347
904L
A5.11/A5.14/A5.4
/A5.9
E/ER 309LMo//NiCrMo3
E/ER 385/NiCrMo-3
Duplex
A5.4 /A5.9
E/ER 309LMo
E/ER 2595
A5.11/A5.14/
E/ER Ni-1
E/ER Ni-1
A5.11/A5.14/
E/ER NiCu-7
Alloy 600/800
(NiCrFe)
A5.11/A5.14
E NiCrFe-2, ER NiCr-3
E NiCrFe-2, ER NiCr-3
Hastelloy C-276
A5.11/A5.14
E/ER NiCrMo-4
E/ER NiCrMo-4
Alloy 625
(NiCrMo)
A5.11/A5.14
E/ER NiCrMo-3
E/ER NiCrMo-3
Cu-Ni (Note 1)
A5.11/A5.14
E/ER Ni-1
Bronze aluminum
(Note 1)
A5.6/A5.7
E/ERCuAl-A2
E/ERCuAl-A2
AWS Classification
Buttering layer
Finishing layer
(see Note 2)
(see Note 2)
E NiCrFe-2/3, ER NiCr-3
E NiCrFe-2/3, ER NiCr-3
E/ER 309/309L
E/ER 309/309L
E NiCrFe-2/3, ER NiCr-3
E NiCrFe-2/3, ER NiCr-3
E/ER 309/309L
E/ER 309/309L
E/ER 430
E NiCrFe-2/3, ER NiCr-3
E NiCrFe-2/3, ER NiCr-3
E/ER 309/309L
E/ER 309/309L
E/ER 410/ 410NiMo
NOTE 1 For bronze aluminum, the preheating temperature ranges from 150 C to 250 C. For the
coating of Cu-Ni alloy, the preheating temperature of the first layer using consumable E/ER
Ni-1 shall not exceed 175 C. For the remaining layers with consumable AWS E/ER NiCu-7,
the interpass temperature shall not exceed 65 C.
NOTE 2 Regardless of the number of layers (buttering or finishing), the final chemical composition of
the coating shall meet the indicated composition for the finishing layer, except when the
welding is heterogeneously performed.
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Type of the
intended coating
material
AWS
Specification
405/410S
A5.11/A5.14/A5.4
/A5.9
430
A5.11/A5.14/A5.4
/A5.9
410
A5.11/A5.14/A5.4
/A5.9
304
A5.4/A5.9
E/ER 309/309L
E/ER 308/308L
304L
A5.4/A5.9
E/ER 309L
E/ER 308L
316/317
Not applicable
Not applicable
316L
A5.4/A5.9
E/ER 309LMo
E/ER 316L/317L
317L
A5.4/A5.9
E/ER 309LMo
E/ER 317L
321/347
A5.4/A5.9
E/ER 309L/309Nb
E/ER 347
904L
Not applicable
Not applicable
A5.11/A5.14/
E/ER Ni
E/ER Ni-1
A5.11/A5.14/
E/ERNiCu-7
Alloy 600/800
(NiCrFe)
A5.11/A5.14
E NiCrFe-2, ER NiCr-3
E NiCrFe-2, ER NiCr-3
Hastelloy C-276
A5.11/A5.14
E/ER NiCrMo-4
E/ER NiCrMo-4
Alloy 625
(NiCrMo)
A5.11/A5.14
E/ER NiCrMo-3
E/ER NiCrMo-3
Cu-Ni
Not applicable
Not applicable
Bronze aluminum
Not applicable
Not Applicable.
AWS Classification
Buttering layer
Finishing layer
(see Note 2)
(see Note 2)
E NiCrFe-2, ER NiCr-3
E NiCrFe-2, ER NiCr-3
E/ER 309L
E/ER 309L
E NiCrFe-2, ER NiCr-3
E NiCrFe-2/3, ER NiCr-3
E/ER 309L
E/ER 309L
E/ER 430
E NiCrFe-2, ER NiCr-3
E NiCrFe-2, ER NiCr-3
E/ER 309L
E/ER 309L
E/ER 410 / 410NiMo (Note 1)
E/ER 410 / 410NiMo
NOTE 1 It needs minimum preheating of 150 C, regardless the substrate thickness, whenever E/ER
410 or 410NiMo is applied; however, it shall only be used in special situations.
NOTE 2 Regardless of the number of layers (buttering or finishing), the final chemical composition of
the coating shall meet the indicated composition for the finishing layer, except when the
welding is heterogeneously performed.
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a) carbon steel and carbon-manganese base-plate with thickness below 30 mm, only for the
first coating layer: 100 C;
b) carbon steel or carbon-manganese base-plate with thickness below 30 mm, for any layer:
no preheating;
c) base-plate made of other materials: indication required by this Standard for
heterogeneous welding of the corresponding material of the base-plate.
5.12.7.3 The maximum interpass temperature for welding the coating shall not exceed the following:
a) carbon steel and carbon-manganese base-plate:
first layer: 175 C;
other layers: 150 C, except when this temperature is excessive and is not permitted
for the coating material;
b) base-plate made of other materials:
first layer: indication required by this Standard for heterogeneous welding of the
corresponding material of the base-plate;
other layers: 150 C, except when this temperature is excessive and is not allowed for
the coating material.
5.12.8 Post-heating
The post-heating for welding of coating plate is not required.
5.12.9 Post Weld Heat Treatment (PWHT)
When PHWT of the substrate is required, the welding procedure shall consider the possible
deterioration of the coating regarding the corrosion resistance, or the weakening of the interface
through PWHT stimulation in test specimens coated and evaluated according to tests from
ASTM A 262.
5.12.10 Supplementary Requirements for Inspection
5.12.10.1 Before welding of the base plate or substrate, it shall be checked if there is no residue of
the coating material on the surface of the plate next to the bevel. After welding, the joint shall be
prepared for visual inspection and non-destructive testing.
5.12.10.2 Before welding the coating in equipment, welded joints shall first be 100 % inspected by
liquid penetrant testing and released by radiographic or ultrasonic testing, according to percentage laid
down in the design code.
5.12.10.3 Before deposition of coating on hydrogen-soaked equipment in operation, the need for
dehydrogenation treatment shall be assessed.
5.12.10.4 During maintenance, the region adjacent to repairs in the substrate, before the deposition of
the coating, shall be inspected with ultrasound to check for cracks, in accordance with API 510 in the
pressure vessel manufactured in P number 3, 4 or 5 of ASME BPVC Section V. This inspection shall
be performed at least 24 hours after completion of the repair in the equipment.
5.12.10.5 Upon completion of the coating, when there is PWHT, liquid penetrant testing shall be
redone in the regions of welded joints. The other tests shall comply with requirements of the design
code.
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Carbon steel
and carbonmanganese
Carbonchrome2.5 Ni /
molybdenum- molybdenum 3.5 Ni
steel
-steel
Steel
5 Ni / 9 Ni
Steel
Austenitic
stainless
steel
5 Ni / 9 Ni Steel
Austenitic
stainless steel
HK-40/HP
F1
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Type of Material
Carbon steel
and carbonmanganese
Carbonmolybdenumsteel
chromemolybdenu
m-steel
2.5 Ni /
3.5 Ni
Steel
5 Ni / 9
Ni Steel
Austenitic
stainless
steel
Monel
Incoloy
800/800HT
D1
D1
Copper
Copper-nickel
Bronze aluminum
Duplex stainless
steel
Type of Material
HK40/HP
410
Stainless
Steel
200/201
Nickel
Monel
Incoloy
800/800HT
D1
F1
D1
5 Ni/ 9 Ni Steel
Austenitic
stainless steel
HK-40/HP
D2
D2
D2
D2
200/201 Nickel
Monel
D2
D2
Incoloy
800/800HT
D2
D2
Copper
Copper-nickel
Bronze aluminum
Duplex
steel
Carbon
and
carbonmanganese
steels
Carbonmolybdenum
steels
Carbonmolybdenum
steels
2.5 Steel Ni/ Ni
3.5
stainless
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Where:
A Consumable according to indication for carbon-molybdenum steel. Preheating, interpass
temperature and post-heating according to indication for chrome-molybdenum steel;
B Consumable according to indication for chrome-molybdenum steel with lower chrome
content. Preheating, interpass temperature and post-heating for chrome-molybdenum
steel with higher chrome content;
C Consumable according to indication for carbon steel (example: basic electrode AWS
E7018 or E7018-1). Preheating, interpass temperature and post-heating according to
indication for alloy steel;
D As indication for nickel alloys, consumable with specification AWS A5.11 ENiCrFe-2 and
AWS A5.14 ERNiCr-3;
D1 As indication for heterogeneous welding of chrome-molybdenum steel. Consumable with
specification AWS A5.11 ENiCrFe-2 and AWS A5.14, ERNiCr-3;
D2 As indication for heterogeneous welding of ferritic and martensitic stainless steel.
Consumable with specification AWS A5.11 ENiCrFe-2, ENiCrFe-3, and AWS A5.14,
ERNiCr-3;
E As indication for heterogeneous welding of ferritic and martensitic stainless steel;
F As indication for heterogeneous welding of chrome-molybdenum steel;
F1 As indication for heterogeneous welding of chrome-molybdenum steel using nickel alloy
compatible with the operating temperature;
G As indication for heterogeneous welding of nickel steel;
H As indication for any of the two base metals;
I As indication for the stainless steel with higher carbon content;
J As indication for 410 stainless steel, and heterogeneous welding may be generally
accepted;
L As indication for 200/201 Nickel;
M As indication for 200 or 201 Nickel, also accepting consumables with specifications: AWS
A5.11, ENiCrFe-2, ENiCrFe-3, and AWS A5.14, ERNiCr-3;
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normal inspection;
simple sampling plan;
general inspection level II;
carbon steel: QL=6,5 %; consumer's risk = 10 %;
other consumables: QL= 4 %; consumer's risk = 5 %;
A.2 Sampling
A.2.1 Sampling shall be performed in accordance with the ABNT NBR 5425, NBR 5426 and
NBR 5427.
A.2.2 The unit for lot and sample size is considered as a number of electrodes.
A.2.3 The sample sizes and acceptance and rejection criteria shall be obtained in Table A.1,
considering Normal Inspection, Simple Sampling and General Inspection Level II.
Table A.1 - Simple Sampling Plan - Normal Inspection of Consumers Risk 5 % and
10 %
Lot size
up to 500
501 to 1 200
1 201 to 3 200
3 201 to 10 000
10 001 to 35 000
35 001 to 150 000
Lot size
up to 500
501 to 1 200
1 201 to 3 200
3 201 to 10 000
10 001 to 35 000
35 001 to 150 000
QL = 2,5
T.A. Ac
Re
125
0
1
125
0
1
125
0
1
200
1
2
315
3
4
500
7
8
Consumer's risk = 5 %
QL = 4,0
QL = 6,5
T.A. Ac
Re T.A. Ac
Re
80
0
1
50
0
1
80
0
1
80
1
2
125
1
2
125
3
4
200
3
4
200
7
8
315
7
8
315
12
13
500
12
13 500
21
22
T.A.
50
80
125
200
315
315
QL = 10
Ac
1
3
7
12
21
21
Re
2
4
8
13
22
22
QL = 2,5
T.A. Ac
Re
80
0
1
80
0
1
125
1
2
200
2
3
315
5
6
500
8
9
Consumer's risk = 10 %
QL = 4,0
QL = 6,5
T.A. Ac
Re T.A. Ac
Re
50
0
1
50
1
2
80
1
2
80
2
3
125
2
3
125
5
6
200
5
6
200
8
9
315
8
9
315
14
15
500
14
15
315
14
15
T.A.
50
80
125
200
200
200
QL = 10
Ac
2
5
8
14
14
14
Re
3
6
9
15
15
15
A.2.4 Only consider for sampling electrodes from the same run.
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A.2.5 Perform sampling by opening at least one package at each ten received, and collect the sample
equally shared from the opened packages, randomly.
A.3 Guide For Determination of Sample Size and Acceptance and Rejection Limits
A.3.1 Determine the number of electrodes received in the lot (just estimate it by range, according to
Table A.1).
A.3.2 According to the consumers risk and the maximum allowable percentage of defective items in
the lot (QL), obtain the sample size (T.A.), the acceptance number (Ac) and rejection number (Re).
A3.3 Example:
a) carbon steel electrodes AWS E7018 with 3,25 mm of diameter;
b) lot size: 500 kg - corresponding to approximately 10 000 electrodes;
c) sampling characteristics:
simple sampling plan;
normal inspection;
inspection level II;
consumer's risk = 10% (for carbon steel);
QL = 6.5 (for carbon steel).
A.3.4 Since the consumer's risk is 10 % and QL = 6,5, entering in Table A.1, it is concluded that:
a) sample size = 200;
b) acceptance number (Ac) = 8;
c) rejection number (Re) = 9.
NOTE
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Figure B.1 is the only option for obtaining hardness profile in Double V bevel.
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B.2.3.4.4 For hardness measurement in welding procedure qualification in plate with coating
deposited by welding (Weld Overlay), hardness measurement points shall comply with Figure B.5.
Surface as
welded
2
Weld line
HAZ
0,5
0,5
2
NOTE
Dimensions in millimeters.
Figure B.5 - Hardness Measurement Points in Profile of Plate with Coating Deposited
by Welding (Weld Overlay)
B.2.4 Hardness Measurement in Field
When the design, fabrication or assembly standard requires a hardness testing, the welding procedure
qualification shall be complemented by this test at the weld zone, heat affected zone and on the base
metal. Its results shall be consistent with the reference standard.
B.2.4.1 Measurement Procedure
B.2.4.1.1 Hardness measurement procedure shall be submitted to PETROBRAS for approval.
B.2.4.1.2 Hardness measurement procedure shall contain at least the following items:
a) name of issuer (department of PETROBRAS or executing firm);
b) numerical identification and procedure revision;
c) objective;
d) personnel qualification requirements;
e) method and frequency of durometer calibration;
f) hardness method to be used;
g) drawing with location of measurement points in welded joint;
h) identification of durometer, including serial number;
i) calibration certificate of durometer and used standard blocks;
j) preparation technique and condition of surface to be tested;
k) maximum temperature of the part:
l) reference standards and/or values for performance and interpretation of results;
m) identification and signature of responsible technician;
n) report form for presentation of results.
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Any test specimen prepared for welding procedure qualification may be used, according to
A.2.3.3.
B.2.4.3.4 Finishing of surfaces requires a minimum preparation until 220 grit sandpaper, followed by
etching of joint, so as the HAZ region is revealed.
B.2.4.3.5 Hardness measurements performed on surface with portable instrument shall be compared
with those obtained with bench instrument in adjacent positions, 0,5 mm away, as per Figure B.6. For
equipment items in general, it is deemed as suitable an instrument presenting a range of individual
measurements from - 4 % to + 10 %. For equipment items subject to wet H2S service, the acceptable
range of individual measurements is from - 2 % to + 5 %.
B.2.4.3.6 The comparison results shall be previously submitted to PETROBRAS for approval.
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Base metal
HA
HA
Z
Base metal
Z
NOTE
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Dimensions in millimeters.
Figure B.6 - Hardness Measurement Points in Welded Joint Surface (Weld Metal, HAZ,
and Base Metal) for Validation of Portable Durometer
B.2.4.4 Surface Preparation
B.2.4.4.1 Hardness measurement shall be performed, whenever possible, on the surface in contact
with the process fluid. If the access is impractical, such as in vessels or pipes with small diameter, the
measurement may be performed by the opposite side.
B.2.4.4.2 The leveling of work surface shall be performed by removing the face or weld root stiffener,
sanding the surface on an area of 50 mm wide by 20 mm long for each side of welded joint, as per
Figure B.7.
NOTE
A transition between the removed area and the stiffener shall be performed, with maximum
inclination angle of 30 .
50
20
20
NOTE
Dimensions in millimeters.
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0,5
Weld metal
Z
HA
NOTE
0,5
Base metal
HA
Z
Base metal
Dimensions in millimeters.
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INDEX OF REVISIONS
REV. A, B, C, D, E, F, G and H
There is no index of revisions.
REV. J
Affected Parts
Description of Alteration
1.2
Revised
Revised
5.2.2.1
Revised
5.2.4.3
Revised
5.4.2.2
Revised
5.5.2.1
Revised
5.8.2.2
Revised
REV. K
Affected Parts
All
Description of Alteration
Revised
REV. L
Affected Parts
All
Description of Alteration
Revised
IR 1/1
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f) for 9Cr-1mo-V-Nb steel (Gr 91), the following minimum impact requirements shall be met:
average of 34 J (25 ft-lbs) with no value below 22 J (16 ft-lbs) at 20C (70F) after
PWHT for at least 2 hours for all processes, except for GMAW process. The GMAW
process is not permitted. The FCAW process shall not be used in pipes and
equipment subject to pressure, according to API TR 938-B. However, it may be used
in non-pressurized equipment if approved in advance by PETROBRAS, when the
average impact values are at least 22 J (16 ft-lbs) with no value below 15 J (11 ft-lbs);
NOTE
> 315
GTAW
SMAW
No significant
Cyclic
or
ENiCrFe-3
ENiCrFe-3
presence of
ERNiCr-3
ERNiCr-3 ENiCrFe-2 ERNiCr-3
not
ENiCrFe-2
(Note)
sulfur
No significant
E309-XX
ER309
presence of Non-cyclic
E309MoER309Mo
sulfur
XX
NOTE Maximum temperature of ENiCrFe-3 is 480 C.
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Substrate
Coating
Figure 7 - Preparation of Joint from Coated Plate with Access Only on the Substrate
Side
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