Welding and Heat Treatment Requirements For Equipment and Piping

STAR RAFINERI A.S.
(STAR)
UNIT N° 000
AEGEAN REFINERY
PROJECT (ARP) SH/OF
GENERAL PROJECT 1/34
SPECIFICATION STAR SPECIFICATION N°
STGPS –A14
REV F01 2 3 4
WELDING AND HEAT TREATMENT

REQUIREMENTS FOR EQUIPMENT
AND PIPING
GENERAL PROJECT DESIGN SPECIFICATION
Note to Revision: This specification was formally known as specification nº : BD0506A-88A1
4 Sep. 26, 2012 Approved for Design PMC (M.vd. B.) PMC (H.Gr’d) OWNER FLUOR
3 Sep.28, 2011 FIRST ISSUE PMC (M.vd B.) PMC (H.Gr’d) OWNER FLUOR
2 June 14, 2011 RELEASED FOR DESIGN PMC (H.Gr’d) PMC (P.H.) OWNER FLUOR
F01 Apr. 04, 2011 FINAL G.G. R.C. R.C. FWI
REV. ISSUE DATE REASON FOR ISSUE PREPARED BY CHECKED BY APPROVED BY COMPANY
STAR RAFINERI A.S. (STAR) UNIT N° 000
AEGEAN REFINERY
PROJECT (ARP) SH/OF
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TABLE OF CONTENTS
1 SCOPE .......................................................................................................................................3
2 PROCEDURES SUBMITTAL REQUIREMENTS.........................................................................3
3 PREHEAT ...................................................................................................................................5
4 WELDING ...................................................................................................................................7
5 WELDING FILLER METALS .....................................................................................................13
6 POST WELD HEAT TREATMENT (PWHT) ..............................................................................15
7 WELD QUALITY CONTROL .....................................................................................................16
EXHIBIT "A"- ACCEPTABLE WELDING PROCESSES ........................................................................22
EXHIBIT "B"- SPECIFIC ITEMS TO BE INCLUDED IN WELDING PROCEDURES .............................24
EXHIBIT "C"- FILLER METAL SELECTION GUIDE FOR WELDING FERRITIC STEELS ....................25
EXHIBIT "D": ACCEPTABLE FILLER METALS FOR JOINING FERRITIC STEELS .............................26
EXHIBIT "E": P.W.H.T. REQUIREMENTS FOR FERRITIC STEELS ....................................................28
EXHIBIT "F": ACCEPTABLE FILLER METALS FOR JOINING AUSTENITIC STAINLESS STEELS .....29
EXHIBIT "H": WIRES FILLER METALS FOR NICKEL ALLOY..............................................................31
EXHIBIT "J": ELECTRODES FOR NICKEL ALLOY ..............................................................................32
EXHIBIT “K”: FERRICYANIDE TEST PROCEDURE FOR ALLOY 400 RESTORING OR WELD
OVERLAY .................................................................................................................................33
EXHIBIT "L": ACCEPTABLE FILLER METALS FOR JOINING ALUMINUM AND ALUMINUM
ALLOYS ....................................................................................................................................34
AEGEAN REFINERY
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1 SCOPE
1.1 This Specification outlines the requirements for welding, including repair welding, back cladding,
weld overlay, tube to tubesheet welding, pre-heat and post-weld heat treatment of vessels, heat
exchangers, piping and piping components, heater tubing and other equipment, including tanks.
1.2 Except as supplemented in this standard, welding and inherent works shall conform to the
requirements of the latest edition and revision including all addenda, officially issued at the date
of purchase order award, of the following codes:
1. PED – Pressure Equipment Directive 97/23/CE
2. ASME Boiler and Pressure Vessel Code, all applicable sections (hereafter referred to as
the ASME Code).
3. EN ISO 15614, EN287.
4. EN ISO 15608
5. EN ISO 15609-1
6. ASME B31.1 - Power Piping
7. ASME B31.3 - Process Piping
8. EN 13480 – Metallic Industrial Piping
9. API 650 – Welded Steel Tanks for Oil Storage
10. API 620 – Design and Construction of Large, Welded, Low Pressure Storage Tanks
11. EEMUA Publication N° 143 (formerly OCMA Specification No. TEW 1).
12. All other Codes referred to therein or in Material Requisition or Purchaser's drawings.
13. State and local Codes.
Applicability of the above listed Codes shall be defined in relevant Material Requisition or piping
specifications.
1.3 In no case is this standard to be used to supersede, delete or lower applicable Code
requirements.
1.4 Any conflict between this standard and other Owner drawings, specifications, standards, codes,
etc., shall be brought to the attention of Owner in writing for clarification. The more stringent
requirements shall govern until written resolution is provided by Owner.
2 PROCEDURES SUBMITTAL REQUIREMENTS
2.1 Welding procedures shall be prepared as required by ASME Code, Section IX, latest revision
including all addenda officially issued by ASME at the date of purchase order or EN ISO 15614
and/or EN ISO 15609-1. The applicable information shall be recorded as recommended in
Forms indicated in codes. Although exact duplication of these forms is not mandatory, all the
information indicated therein shall be included.
1. Vendor shall prepare and qualify welding procedures to cover all welding situations,
including weld repairs. Vendor shall also qualify all welders and/or welding operators.
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2. The complete set of Welding Procedure Specifications (WPS) and Procedure Qualification
Records (PQR) shall be submitted together with the preliminary outline drawings as
requested by subsequent paragraphs of this specification. Owner reserve the right to reject
sets of WPS/PQR not complete.
3. All welding procedures shall be identified by number and all welds shall be referenced to
WPS identifying number on fabrication drawings. Vendor shall submit an index of all weld
procedures required for the job, including the PQR. A weld map shall be submitted for
each equipment.
4. Release for fabrication
Fabrication should not commence until all the involved documents have been reviewed by
Owner and returned to Vendor either with or without comments.
5. At the receipt from Owner of the reviewed welding procedures, Vendor shall implement
Owner comments. Any deviation to Owner comments shall be communicated by Vendor to
Owner through a dedicated letter or fax. Revised documents shall be submitted to Owner
for information only. No further copy will be sent back to Vendor with Owner stamp. It is
Vendor responsibility the correctness of data shown on his document, as well as the full
compliance with Owner comments. The Vendor document stamped/commented by Owner
shall be kept available for Owner inspection reference.
6. Any comment/acceptance does not relieve Vendor from his responsibility. The Purchaser
can issue further comments if deviations from Codes, Specifications and Engineering
Practice are discovered.
2.2 Specific information that must be included in Vendor's weld procedures and/or restrictions which
must be complied with are the following:
1. Detailed information specified in paragraph QW 201, of ASME Code, Section IX or in EN
15609-1.
2. Information/restrictions listed in Exhibit “A” and “B” of this standard.
3. Definite minimum preheat and interpass temperature and, if necessary, corresponding
maximum temperatures. (Maximum interpass temperature limits must be specified for
stainless steels and non-ferrous materials).
4. Definite range of holding temperature, holding time, and maximum heating and cooling
rated for post weld heat treatment.
2.3 Welding procedures shall be submitted to Owner. Owner reserves the right to review the
welding procedure and to issue comments, if deviation from code, contractual documents or
good engineering practice are found Procedures for PWHT , hot forming, tube bending, heat
treatment after forming/bending shall be prepared and submitted to Owner for review.
2.4 Welding procedures not subjected to Owner welding review, as per point 0 above, shall be
anyway sent to Owner by the Vendor and received by Owner for information only.
2.5 Owner can issue comments also on these documents, if deviations from code, contractual
documents or good engineering practice are found.
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3 PREHEAT
3.1 General Requirements
1. When, before welding, the base metal temperature is below 0°C, the base metal shall be
preheated to at least 20°C, and this minimum temperature maintained during welding
unless a greater temperature is specified in the following paragraphs.
2. Welding shall not be done when the ambient temperature is lower than -18°C. This value
does not mean the ambient environmental temperature but the temperature in the
immediate vicinity of the weld. The ambient environmental temperature may be below -
18°C, but heated structure or shelter around the area being welded could maintain the
temperature adjacent to the weldment at -18°C or higher.
3. Welding shall not be performed when condensation occur on the metal surfaces;
appropriate heating shall be provided.
4. In all cases, the minimum preheat shall not be less than 10°C.
3.2 Ferritic Steels
The minimum preheat temperature for carbon and alloy steels shall be per below requirements;
however the minimum value stated will be intended in dependence of a lot of combinations. The
Vendor is requested, under their full responsibility, to establish the minimum preheat
temperatures related to: chemical analysis, thickness, welding process and heat input, restraint
of the parts being joined, etc.
1. For equipment and vessels, as given in ASME Section VIII, Division 1, Appendix R, as a
minimum, and/or other applicable Code requirements, with the following exceptions:
a. All carbon steel in excess of 32 mm shall be preheated to 80°C minimum. A preheat of
100°C shall be used if carbon steel material of thickness over 32 mm but not
exceeding 38 mm are used without post weld heat treatment (PWHT).
b. All Mn-0,5Mo materials in excess of 16 mm shall be preheated to 120°C minimum.
2. For piping and piping components, as given in ASME B31.3, or in ASME B.31.1.
3. It shall be ascertained that specified preheat, if required, prevails throughout thickness of
parts being welded and not just at the surfaces.
4. Neither welding, even of temporary attachments, nor striking of arcs are permitted without
the specified preheat.
3.3 Austenitic Stainless Steels and High-Nickel Alloys
For all thicknesses of austenitic stainless steel, Incoloy and high nickel alloys except Hastelloy,
preheat shall be at least 20°C, preheat and max. interpass temperature shall not exceed 175°C.
For Hastelloy max. interpass temperature shall not exceed 120°C.
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3.4 Aluminum and Aluminum Alloys
1. In gas-shielded arc welding of aluminum and aluminum alloys, preheating of parts to be

welded is only required:
a. When the temperature of the parts is below 10°C
b. For GTAW of parts thicker than 5 mm with alternating current
c. For GMAW of parts thicker than 25 mm.
2. When preheating is required, a preheating temperature in the range of 65 to 95°C shall be
used. A higher preheating temperature shall not be used unless otherwise authorised in
writing by Owner.
3.5 Welding Dissimilar Metals or Thicknesses
For welding material combinations of dissimilar or of different thicknesses, the minimum

required preheat temperature shall be that for the material requiring the higher preheat unless
otherwise approved in writing by Owner, except for ferritic to austenitic steel weld, where the
austenitic side of the joint shall not be preheated.
3.6 Arc Cutting
Specified preheating is also required prior to electric arc cutting operations used for cutting or
grooving plates, for back gouging double welded joints and for gouging to remove defects.
3.7 Preheat Maintenance for Circumferential Butt Joints
1. For circumferential butt joints for which required preheat temperature is less than 120°C,
the welding and also the preheat may be interrupted provided the weld deposit thickness
is at least 25% of the joint thickness or 10 mm, which ever is greater. The weld shall be
allowed to cool slowly to room temperature. Prior to resumption of welding, preheat shall
be restored.
2. For circumferential butt joints and highly restrained joints of ferritic alloys normally
requiring a preheat of 120°C or higher, such as shell welds and nozzles to vessel or
nozzles to header welds, respectively, preheat shall be maintained without interruption
until the commencement of post weld heat treatment, unless either a 200°C preheat or a
post weld soak at 200°C for 2 hours is used and the weld is insulated and allowed to cool
slowly after welding.
See pare 0 below for specific requirements on P22 and P91 piping material.
3.8 Postheat
If postheat is applied in PQR, equivalent postheat shall be applied also in the production weld
(i.e. the supported WPS).
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3.9 Preheating / post-heating / interpass requirements for P22 and P91 piping
Preheating and post-heating shall be performed by means of electric resistance heating.

Preheating performed by flame is not admitted.
For the P91 base material the following parameters should be used before, during and after
welding:
- preheating temperature: min 250°C

- interpass temperature: max 300°C
- post-heating temperature: 350º C uptill 400 °C
- post-heating holding time: 1 hour for THK 15 mm
1½ hour for THK > 15 mm
After completion of welding and post-heating, the weld shall be allowed to cool down to below
100°C before starting PWHT.
If PWHT is not performed immediately, post-heating shall be followed by slow cooling under
insulation to room temperature.
For the P22 base material the following parameters should be used before, during and after
welding:
- preheating temperature: min 200°C

- interpass temperature: max 250°C
- post-heating temperature: 270300°C
- post-heating holding time: 45 minutes for THK < 11 mm
1½ hour for THK 11 mm
For bimetallic welds between P22 and P91 holding time for post-heating shall be 45 minutes for
THK < 11 mm and 1½ hour for THK 11 mm.
Preheating and post-heating temperatures shall be monitored and chart recorded by means of
thermocouples. Thermocouples shall be attached directly to the base material by means of a
capacity discharge. After thermocouples removal the area shall be inspected. As a minimum
two thermocouples located on the opposite side of the normal section of the piping shall be
used.
In the PWHT procedure shall be indicated the type, number and location of the thermocouples
by means of a sketch.
4 WELDING
4.1 General
1. The welding processes listed in EXHIBIT "A" "Acceptable Welding Processes" of this
standard are acceptable for fabrication subject to the limitations stated therein. Request to
use any other welding process shall be submitted to Owner for review.
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2. Unless otherwise allowed in writing by Owner, all butt joints which are accessible from
both sides shall be back gouged or ground to sound metal after welding the first side and
then back welded on the reverse side.
3. Where access or wall thickness precludes the use of double welded butt joints, single
welded joints shall be made using a root pass deposited by the GTAW (TIG) or GMAW
(Short Arc) process, except that for carbon steel piping the use of E-6010 electrodes for
root pass welding by SMAW is also acceptable. The use of consumable insert rings for
GTAW is acceptable after approval by Owner.
4. Permanent back rings shall not be used unless specifically allowed in writing by the
Owner. Temporary backing ring shall have the same chemical composition as the base
materials to be joined and shall be removed after welding. Consumables inserts are
acceptable for piping welds and shall have the same chemical composition as the base
metal or as the filler metal.
5. All welds of nozzles, manways, and their reinforcement to equipment shell, heads, skirts
and/or piping shall be full penetration.
6. All welds shall be regarded as requiring at least as much care as main seams. This
includes welds for items such as fit-up clips, insulation rings, ladder and pipe clips, etc.
Proper application of qualified procedures by qualified welders using the appropriate
preheat is essential. Preheat shall not be less than that used for main seams.
7. For any equipment fabricated from carbon steel and carbo-manganese steels the
limitations on Carbon Equivalent and Nb + V content shall be per applicable equipment
Job Spec.
8. For materials and material combination of Pn° or Sn° of 3 or greater (except Pn° or Sn°
equal to 8), each combination of welding process requires qualification as a combination,
unless specifically accepted by Owner. A process used only for root passes can be
qualified separately. Refer to CR ISO 15608 “Welding – Guidelines for a metallic material
grouping system” for group number when EN 15614 is applicable.
4.2 Base Metal Preparation
1. Joint preparation for welding may be performed by machining, grinding, thermal cutting, or
combination thereof. Excessively deep or sharp irregularities in joint edges shall be
removed by machining or by grinding. Joint edges shall be crack and lamination free prior
to welding.
2. When thermal cutting or carbon-arc gouging is utilized on ferritic or high alloy steels, the
bevellUNIT N°000ed surfaces shall be ground, approximately 1.5 mm to remove any
hardened or sensitised zone prior to welding.
3. Prior to welding, all oil, grease, dirt, rust and excessively thick or loose scale shall be
removed from the surfaces of the joint and the adjacent base metal within 25 mm from the
edge of the joint. Oil and grease shall not be removed by heating with a torch.
4. It is very important when welding ferritic steel components which are internally clad with
12% Cr or 18% Cr-8% Ni materials, to remove the high chrome material prior to any
cutting or welding operation.
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5. To insure complete removal of residual cladding from previously clad surfaces, all surfaces
shall be etched with an 8% nitric acid solution or similar solution approved by Owner. Acid
etching and grinding shall be repeated as required until high chrome material is completely
removed prior to welding or cutting. For other clad materials an appropriate test procedure
shall be proposed by Vendor and accepted by Owner.
6. For P22 and P91 piping, cutting and bevel preparation shall be made by machining.
4.3 Proprietary Items
Welding of proprietary items such as alonised pipe, etc. is not permitted without prior written
acceptance from Owner.
4.4 Welding Items Coated with Low Melting Point Metals
1. Parts painted with zinc rich paints or hot dip galvanised shall not be welded to any
pressure equipment, unless the zinc in the area adjacent to the zone to be welded is
completely removed by sand blasting, grinding or taping prior to welding. Removal of the
zinc rich areas by burning is not permitted.
2. Components coated with low melting point materials as lead, zinc, cadmium, etc. shall not
be welded to carbon or stainless steel.
4.5 Heat Exchanger Tube to Tubesheet Welds
1. Tube to tubesheet mock-up samples shall be prepared and tested at Vendor care and
relevant results shall be submitted to Owner for any of the following conditions:
a. When specified in the material requisition.
b. Material combinations involving P-numbers of 21 or greater. (P-number from ASME
Code, Section IX, Table QW-422).
c. When strength welds are specified.
2. Mock-up samples shall be constructed using actual production welders, materials and
procedures for the piece of equipment involved.
3. Mock-up samples shall have a minimum of 6 tubes 75 mm length from the backside of the
tubesheet, using the same pitch arrangement as the piece of equipment involved.
4. Qualification of welding procedure shall be carried out in accordance to EN 15614-8
5. The GMAW process is not permitted for tube to tubesheet welding.
4.6 Storage Tanks
Welding of storage tanks shall be according to the requirements of this standard. In addition the
vertical joints of shell courses shall be executed using SMAW (Manual) process unless
otherwise allowed in writing by Owner.
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4.7 Strip Lined Connections
1. The inside surface of base material shall be cleaned to remove rust, mill, scale, dirt, weld
spatter, etc. and weld reinforcement shall be ground flush with the inside surface.
2. Acceptable welding processes are manual GTAW (TIG) and SMAW.
3. Acceptable filler materials are the same as those used for clad restoring.
4.8 Welding Clad/Overlay Materials
The following requirements apply to equipment made of internally clad/overlaid steel plate:
1. The overlay welding procedure shall be developed and qualified in accordance with the
requirements of ASME Codes. The procedure qualification record shall contain the
following information as minimum:
a. Results of liquid penetrant test on first and last passes.
b. Results of guided bend tests
c. Ferrite content of the overlay, where applicable
d. Ferricyanide test, where applicable
e. Chemical analysis
2. Elements to be included in the chemical analysis of the weld metal overlay shall include C,
Cb/C ratio if applicable, plus all other elements contained in the filler metal in excess of one
percent.
3. Sample material for chemical analysis shall be taken at least 1.6 mm into the overlay. The
depth at which these samples were taken shall be indicated on the procedure qualification
record.
4. The overlay surface shall be relatively smooth (waving is permissible but without notches,
undercuts, etc. that would serve as stress risers). The interface between base metal and
overlay shall be prepared by grinding where necessary to eliminate pockets, sharp
notches and other flaws which would prevent full bonding of the overlay material.
5. Qualification weld test specimens shall be subjected to P.W.H.T., if required, equivalent to
that anticipated for fabrication, including aggregate time at temperature, with appropriate
allowance for repairs.
Ferrite measurement, where applicable, shall be made before PWHT if magnetic gages
are used.
6. Clad/overlay carbon steel or alloy steel components shall be welded using the following
sequence of welding and the filler metal specified in EXHIBIT "C" and "G".
a. Strip or grind the clad/overlaid material at least 6 mm from the weld preparation of the
base material. The stripped area shall be acid etched to insure complete removal of
the clad/overlaid material.
b. Tack weld joint from base material side.
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c. Weld the base material completely from the non-clad or overlaid side of the joint using
the appropriate filler metal indicated in EXHIBIT "C".
d. Back grind to sound metal the root of the base material (clad/overlaid side) and back
weld the joint with the same filler metal used in above step, flush with the base
materials surface. Filler metal shall not come closer than 2 mm to the clad/overlaid
material.
e. Overlay the joint between the clad/overlaid material with the appropriate filler metals
indicated in EXHIBIT "G". Overlay surface shall blend with the clad/overlaid surfaces.
f. Dye check overlay surfaces to assure that they are crack free.
7. Unless otherwise indicated on drawing, the top 1.6 mm of all overlay shall meet the full
chemical requirements for specified filler metal type (e.g. maximum carbon content for
309L, Cb/C ratio for 347, etc.). This type of overlay will be considered as corrosion
allowance. Maximum overlay thickness shall not exceed 10 mm, unless specifically
indicated in Material Requisitions. The surface of weld overlay shall be left in the "as
deposited" condition except for gasket surfaces or other surfaces requiring machining or
grinding to meet requirements stipulated in the Order or on the Material Requisition.
a. Samples for chemical analysis shall be taken using either a chipping or a drilling
technique. All areas from which samples have been removed for chemical analysis
shall be repaired by the fabricator using already qualified WPS and qualified welder.
b. Chemical analysis checks shall be conducted per the following:
1) For equipment, including cladded transfer lines, which are clad and require that
seams be overlaid, at least one (1) chemical analysis shall be made on each
circumferential and longitudinal overlaid shell and head welds.
2) For equipment which is entirely overlaid, at least one (1) chemical check shall be
made on each shell course and each head (minimum of five (5) checks per vessel)
for both automatic and manual weld applications.
3) Flanges, nozzles and piping which have been overlaid require that the deposited
overlaid material have a chemical analysis taken on weldments made for each
welder, each welding process, and each lot of weld wire and/or flux, with a
minimum of one (1) chemical check for every four (4) components, unless
otherwise specified in writing by Owner.
4) Chemical analysis samples shall be taken at locations designed by Owner
Inspector. The inspector shall consider those locations containing visual weld
abnormalities or where weld process; weld wire and/or welders have been
changed.
8. For situation where a clad (or overlaid) component is welded to a non-clad component,
cladding termination shall be welded to corresponding base material with a continuous full
fillet weld. Consult Owner for determination of the appropriate filler metal for each joint in
question.
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9. Indication of overlap between adjacent passes is to be indicated on WPS.

Overlap of adjacent weld beads shall be considered an essential variable and shall be the
same in production as that used to qualify the weld overlay procedure.
10. Special Requirements for Overlays and Clad Restoring
a. Equipment and piping involving austenitic stainless steel overlays or clad restoring
shall conform to the requirements below unless otherwise indicated by the drawings or
requisitions.
CHROMIUM CONTENT FERRITE Cb/C

of overlay Number Ratio
up to 20%, incl. 4-12 35 max.
20% to 22%, incl. 4-9 25 max.
greater than 22% 4-9 15 max
b. Frequency and location of measurements shall be the same as those required for
chemical analysis. Ferrite numbers may be determined by use of the Severn Gauge,
Fisher Ferrite meter, or Delong or Schaeffler diagram and shall be measured before
PWHT.
c. The magnetic gage shall be calibrated before measurement by the Manufacturer on at
least two standards (calibration test blocks) having a ferrite content in the range 3 to
10 and with a minimum spread of 5 numbers; the standards shall be either primary or
secondary weld metal standards as referenced in AWS A 4.2.
11. Equipment not complying with the chemical and/or ferrite requirements shall be reported to
the Owner for resolution.
12. Ferricyanide test shall be reported on PQR and applied to all finished welds in 70 Ni 30 Cu
cladding or overlay to ascertain the absence of iron pick-up. Ferricyanide test shall be
carried out as per exhibit “K”:
4.9 Hardfacing
1. Hardfacing deposits shall be qualified according to ASME Section IX Code and according
following restrictions, before productions welds are commenced.
Hardfacing qualification shall be performed using same procedure, materials,
welder/welding operator as in production.
2. A buffer layer shall be deposited on ferritic steels, using AWS E NiCrFe 2 or 3 or ER NiCr
3 materials, in order to provide suitable base material for hardfacing, unless otherwise
indicated on Material Requisitions.
In case of high sulphur service (S > 0,5%) at high temperature (T > 370°C) consult Owner
for further requirements.
3. Hardfacing material shall be AWS ER CoCrA or E CoCrA, unless otherwise indicated by
Material Requisitions.
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4. Hardfacing qualification special requirements:

a. In “non retaining pressure” parts the maximum acceptable width of hairline cracks shall
not exceed 0.8 mm. No cracks are acceptable in “retaining pressure” components,
unless otherwise required in Material Requisition or drawing.
b. Cracks shall not reach the base material.
c. Hardness test on cobalt base deposited material shall be 40 HRC minimum.
d. Hardness on H.A.Z. of ferritic base material shall be in accordance with what required
in this General Specification for the subject steel.
5. Production tests:
a. In “non retaining pressure” parts the max. acceptable width of hairline cracks shall not
exceed 0.8 mm. No cracks are acceptable in “pressure retaining” components, unless
otherwise required in Material Requisition or drawing.
b. Cracks shall not show evidence that they reach the base material.
c. Hardness test to be 40 HRC minimum.
4.10 Stud Welding
Welding of studs used to secure refractory material shall be qualified in accordance to ASME IX
QW-261.
A production test sample of at least five consecutively welded studs shall be tested at the
beginning of each shift and after performing maintenance operations on the stud welding
equipment.
5 WELDING FILLER METALS
5.1 Electrodes and/or filler metals shall be selected such that:

1. The strength of deposited weld metal shall be at least equal to the specified minimum
tensile strengths of the material being welded.
2. When joining similar materials the chemical composition of the deposited weld metal shall
match that of the base material as closely as possible.
However, this shall not preclude the use of welding materials containing alloying elements
of different types or in different amounts than those in the base materials provided there is
evidence that such elements are not harmful and are the only way to achieve desirable
weld metal properties, such as adequate tensile strength after post weld heat treatment or
adequate impact strength at low temperatures.
3. The chemical analysis of welds for materials other than carbon steel shall be checked as
per applicable Job Specification for positive material identification.
4. Requirements on chemical analysis restrictions and/or mechanical testing applicable to
pressure retaining welds shall be applied also to welds between pressure parts and
attachments.
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5.2 Ferritic Steels

Unless otherwise authorised in writing by Owner, filler metals for similar and dissimilar welds in
ferritic steels shall meet with requirements of EXHIBIT "C" "Filler Metal Selection Guide for
Welding Ferritic Steels" of this standard.
5.3 Austenitic Stainless Steel, High-Nickel Alloys, Duplex Stainless Steels

Unless otherwise authorised in writing by Owner, filler metals for joining similar and dissimilar
stainless steel shall meet the requirements of EXHIBIT "F", "Acceptable Filler Metals for Joining
Austenitic Stainless Steels" of this Engineering Standard, including notes.
Filler metals for joining similar and dissimilar high-nickel alloys shall meet the requirements of
EXHIBIT "H" including notes.
Filler metal for joining austenitic-ferritic (duplex) stainless steel shall be selected on the basis of
the recommendation from base material supplier. Vendor shall submit the Data Sheet of filler
metals together with the welding book.
If deposited weld metal ferrite content (as shown in the procedure qualification record) is greater
than 60 FN, the moisture content of duplex stainless steel electrodes shall be controlled to 0,2%
maximum as measured by the test procedure given in AWS A5.5, Sec. 14.
Weld surface of duplex in contact with fluid shall be pickled and passivated unless GTAW has
been used for the root pass in contact with fluid.
5.4 Aluminum and Aluminum Alloys

Unless otherwise authorised in writing by Owner, filler metals for joining similar and dissimilar
aluminum and aluminum alloys shall meet with the requirements of EXHIBIT "L", "Acceptable
Filler Metals for Joining Aluminum Alloys" of this standard.
5.5 Ferritic to Austenitic Steels and to High-Nickel Alloys
1. For Carbon and Low Alloy steels welded to 300 series austenitic steels with design
temperatures not exceeding 315°C and in the absence of thermal cycling and PWHT
requirements Type 309 or 309L Stainless Steel filler metal shall be used. For these
dissimilar base metal combinations with design temperatures above 315°C in non-sulphur
environment, Inconel welding electrode 182 (ENiCrFe-3) or Inconel filler metal 82
(ERNiCr-3) or Incoweld A (ENiCrFe-2) shall be used. These filler metals are also an
acceptable alternate to Type 309 for lower temperature service except where the
environment contains sulphur. If the environment contains sulphur above 315°C, or
thermal cycling conditions are anticipated and/or PWHT is required, consult Owner for
further requirements.
2. For carbon and low alloy steels welded to Inconel or Incoloy or Monel, and in absence of
thermal cycling and of PWHT requirements, filler metals listed in EXHIBIT "H" shall be
used. If PWHT and/or thermal cycling are involved, consult Owner for further
requirements.
AEGEAN REFINERY
PROJECT (ARP) SH/OF
STGPS –A14
REV F01 2 3 4
5.6 Filler metals for P22 and P91 piping welds shall be packaged in hermetically-sealed containers
or thermally treated according to filler metals Manufacturer instructions. Heated electrodes
holder shall be used for field and shop weld operations for a maximum time of four hours daily.
6 POST WELD HEAT TREATMENT (PWHT)
6.1 PWHT of carbon and low alloy steels shall meet with the following requirements:
1. Vessels and Equipment: ASME Sect. VIII, ASME Sect. I - TEMA - EXHIBIT "C" "Guide for
Welding Ferritic Steels" and the Equipment column of EXHIBIT "E" "PWHT Requirements
for Ferritic Steels" of this standard. If the Codes specify higher PWHT temperatures, they
shall take precedence.
2. Piping components: ASME B.31.3 or B.31.1 - EXHIBIT "C" "Guide for Welding Ferritic
Steels" and the Piping column of EXHIBIT "E" "PWHT Requirements for Ferritic Steels" of
this standard and as per piping class. If the Codes specify higher PWHT temperatures,
they shall take precedence. All sizes and wall thickness of P4 and P5 alloy steels shall be
post weld heat treated.
When joining parts of different thickness, holding time shall be that for the thicker material.
For base materials subjected to tempering heat treatment, PWHT holding temperature
shall be at least 30°C less than the tempering holding temperature of the base materials.
6.2 PWHT of solid austenitic stainless steel and/or high nickel alloy component shall not be
performed unless specifically required by Material Requisition/Drawing or by para 0 below.
PWHT procedure for joints between austenitic stainless steel and other materials shall be
submitted to Owner for review and acceptance.
6.3 PWHT of solid aluminum and/or aluminum alloy components shall not be performed unless
specifically required and accepted by Owner.
6.4 PWHT may be performed by electric induction, by electric resistance method, or in fuel-fired or
electrical furnaces. Equipment shall be provided to record the metal temperatures of the part or
components being heat treated and to control heating and cooling rates and holding times.
6.5 All machined surfaces shall be protected against oxidation during heat treatment.
6.6 Unless otherwise allowed in writing by Owner, neither welding nor striking of arcs are permitted
after final PWHT.
6.7 In case PWHT is specified for process reason, stainless steel, which is supplied as chemically
stabilised (321 or 347) and is subsequently welded (except for socket and seal weld) shall
receive a thermal stabilisation heat treatment after the performance of the welding operation.
The heat treatment shall consist of heating the material to 900°C plus or minus 14°C for 4 hours
followed by air cooling.
6.8 Only in cases where this cannot be avoided, local PWHT will be allowed. Local PWHT of
equipment shall be performed in accordance with WRC Bulletin 452. Local PWHT of piping shall
be performed in accordance with AWS Recommended Practice D10.10
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STGPS –A14
REV F01 2 3 4
7 WELD QUALITY CONTROL
7.1 Repair, Inspection, Rejection
1. Weld repairs shall comply with the requirements of the applicable code, including preheat
requirements or recommendations, post weld heat treatment requirements, and non-
destructive examination.
2. Defects shall be removed by chipping, gouging, or grinding and the repaired weld shall be
post weld heat treated, if PWHT was originally required, re-examined by the original
method(s) for freedom from defects.
3. Welds indicating irremediable or injurious defects, improper fabrication and/or excessive
repairs, shall be subject to rejection at any time, at Owner discretion.
4. For pressure-containing items, all required repairs of base metal shall be reported to
Owner for review prior to making the repair. Repair of base metals is only allowed with
previous approval of Owner.
5. When repairs are made to cladding or overlay welds on low alloy steels without
subsequent PWHT, a minimum remaining clad or overlay thickness of 5 mm is required
unless it can be demonstrated that no new HAZ is formed in the base metal with thinner
overlay.
6. Radiography shall be performed on all full thickness butt welds as stated below:
a. Piping
1) Radiographic technique and acceptance standards shall conform to ASME B31.3,
ASME or EN as applicable.
2) Three-fifths of the examined welds shall consist of welds joining a welding neck
flange to another component if the fabrication involves such joints.
3) The work of all welders and welding operators or combinations thereof of each P-
number shall be included in radiography. Sufficient coverage on random or spot
radiography shall also include the welding process(es) used by each welder or
welding operator.
b. Vessels and Exchangers
1) Radiographic technique and acceptance standards shall conform to ASME Boiler
and Pressure Vessel Code or EN as applicable.
2) The work of all welders employed on the job shall be included in this radiography.
3) When submerged arc welding has been used for main seams, all intersections of
seams, and all stopping and starting points of weld beads shall be radiographed.
7.2 Hardness Limitations
1. The following hardnesses shall not be exceeded in the base material, weld metal, and/or
heat affected zones of piping and equipment production welds:
AEGEAN REFINERY
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Base
Material Maximum Hardness
HB HV
P-1 200 210

P-3 225 230
P-4 225 230
P-5 (*) 241 (*) 253 (*)
P-6 241 253
P-7 241 253
(*): Limit for P91 (9Cr-1Mo-V) is 248HB max.
If other hardness limits are mentioned in equipment job specification, those values shall govern.
2. To verify the compliance with above hardness limitations, the following shall apply as
minimum:
a. For items or equipment - at least one hardness measurement shall be taken on 10% of
the longitudinal seams, on 10% of the girth seams and on 10% of the nozzles-shell
weldments.
b. For piping and piping components at least one hardness measurement shall be taken
on 10% of the welds on pipe which does not require PWHT or is PWHT’ed in furnace
(one on each furnace batch of piping which is heat treated after welding, hot forming,
and hot bending). At least one hardness measurement shall be taken on 100% of
those joints which are locally heat treated.
For P91 welds, after PWHT, for each welder, hardness test on the first four welds shall
be carried out as follows:
- n° 4 points 90° locations on each weld
- for each location five measurements points (BM; HAZ, WZ, HAZ, BM)
- if results are satisfactory on the first four welds, only one location for each weld will
be tested (location to be selected by welding inspector).
3. Areas to be checked shall be located by Owner inspector. If hardness measurements
exceed the limitations, Owner shall be contacted for further resolution.
4. Owner acceptance shall be obtained for all multiple stress relieves beyond that required by
code, item drawing, or this standard when used for the purpose of decreasing hardness.
5. Where two or more different base materials are joined, the maximum hardness of the weld
metal shall not exceed the lesser of the hardness required for the base materials involved.
The hardness of each affected zone shall not exceed the hardness requirement for the
adjacent base material.
For P91 welds, the Constructor shall prepare (before the starting of welding operations)
mock-up simulating the production welds in order to check that PWHT procedure foreseen
is suitable to meet the required hardness limits.
AEGEAN REFINERY
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REV F01 2 3 4
6. Additional Requirements for Welding Procedure Qualification:

a. Procedure qualification test for welding steels classified P-1, P-3, P-4, P-5, P-6 and P-
7 shall include hardness tests of the weld metal and heat affected zone in as welded
conditions or after PWHT, if any. For P-1, P-3 and P-4 material the maximum hardness
shall be 248HV. For other materials refer to Table in paragraph VII.B.1.
b. The terminal ends of the welding test coupon shall be cut and on the cross section of
the cut samples, after adequate surfaces preparation and etching, a hardness test
shall be carried out.
c. The hardness shall be checked in fused zone, in heat affected zone (to the distance of
0.5 mm from the nearest point of the fuse zone) and in base material. At least are
required six check points for each line as described here below:
1) The first line shall be positioned 1 mm below the external surface of the deposited
material;
2) The second line shall be positioned as near as practical midway between the
surface and the centre of thickness;
3) The third line shall be positioned perpendicularly to the above line and shall be
symmetrical to the welded area (centre of weld); all the position part of this line are
relevant to fused zone.
4) Where more than one welding process is involved (e.g. first pass TIG/SMAW all
the remaining passes, or SMAW/SAW combination) one additional check points
line shall be foreseen, so that the passes of all processes are crossed by lines
parallel to the first/second lines.
d. The test as specified in the above paragraph 7.2.6.c shall be carried out with Vickers
Pyramid (HV) [10N to 1200N load]. Use of Brinnel std. ball 10 mm 30.000N shall be
subjected to OwnerI approval.
e. If the manufacturer already holds record of hardness tests (on cross section),
performed other than indicated above, he may be exempted, only after Owner written
acceptance, to produce a new coupon to perform hardness test, providing that:
1) Weld hardness is detected on the weld surface of production-welds with the
material removed as minimum as possible to permit the test.
2) The ball for hardness detection is as small as necessary to avoid a blended
reading in HAZ (blending between WZ, HAZ and BM hardness).
7.3 Ferrite Measurements of Solid Austenitic Stainless Steels
The need for conducting ferrite measurements on austenitic stainless steel production
weldments shall be specified on Material Requisitions and shall conform to the following
restrictions:
1. Ferrite measurements shall be taken in the as-welded condition prior to PWHT.
2. Ferrite measurements shall be performed in the centre of the weld utilising a Ferritscope or
by using the Delong or Schaeffler diagrams in conjunction with the results of a chemical
analysis.
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REV F01 2 3 4
3. The chemical analysis samples shall be removed from the centre of the weld deposit at a
thickness of 2 mm from the weld surface.
4. The magnetic gage shall be calibrated before measurements by the manufacturer on at
least two standards (calibration test blocks) having a ferrite content in the range 3 10,
and with a minimum spread of 5 numbers; the standards shall be either primary or
secondary weld metal standards as referenced in AWS A4.2.
5. An annual calibration certification shall be available for the inspector.
6. One ferrite measurements shall be taken for every 3 m of weld with a minimum of 4
measurements for each circumferential and 2 measurements for each longitudinal weld. A
minimum of 2 measurements shall be taken on each piping circumferential and longitudinal
(if fabricated) joint. A minimum of one ferrite measurement shall be taken on all
nozzles penetration welds. Measurement sites shall be designated by Owner Inspector.
7. Unless otherwise specified in drawings, all ferrite measurements shall fall within the ferrite
number range 4 to 10. If any ferrite measurement falls outside the permitted range, two
additional measurements shall be taken adjacent to the original test. If these additional
measurements fall outside the specified ferrite number range, the readings shall be
referred to Owner for resolution and further action.
8. When ferrite measurements of solid austenitic stainless steel are required in production,
they shall be reported in the PQR; test methods acceptable values, etc. shall be the same
as for production welds.
When welding duplex stainless steel, the following requirement shall apply:
- FN for the weld procedure qualification and deposited weld metal shall be 30 70 FN
as determined by an instrument calibrated to AWS A4.2.
7.4 Supplementary Welding Requirements when Impact Test is required by Codes or Requisitions
1. Procedure qualification: only welding procedures that have been qualified for impact
properties using the Charpy V-notch method at a temperature not higher than that
specified on individual material requisition are acceptable.
2. Deleted
3. Prevention of stress risers
Special care shall be taken to eliminate or prevent stress risers which might causes low
impact strength due to notch effect or abrupt change in section.
a. Reference lines shall not be stamped upon the vessel.
b. Welder's and welding operator's symbols may be stamped upon the vessel in
accordance with the provisions of ASME Code, provided that a round nose stamp is
employed and that the symbol is located at least 25 mm from the edge of the weld.
4. Where impact test is required for base material, impact test shall be included in PQR.
AEGEAN REFINERY
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STGPS –A14
REV F01 2 3 4
7.5 Workmanship
1. Unless otherwise specified, reinforcement of butt weld on plate joints shall not exceed the
following:
Plate Thickness Max. Thickness of

mm Reinforcement, mm
up to 13 incl. 2
over 13 to 25, incl. 2.5
over 25 to 50, incl. 3
over 50 4
2. Weld reinforcement of pipe joints shall not exceed 2 mm for wall thickness up to and
including 13 mm or 3 mm for wall thicknesses over 13 mm and shall be dressed to blend
smoothly into the adjacent surface.
3. Internal penetration on single welded butt joints shall not exceed 3 mm.
4. For P91 welds, on the first four welds made by each welder, the reinforcement shall be
ground flush and inspected by 100% LP to assure that no defect have been induced in
correspondence of the end of bead. Additional spot checks may be required by welding
supervisor during fabrication.
7.6 PQR Witnessing
1. The qualification of welding procedures and of welders shall be in accordance with ASME
Code, Section IX or EN 15614 / EN 287 as applicable.
In case PED is applicable, PQR and WPQ shall be approved by a notified body for use
under PED. If such approval doesn’t exist, WPS/PQR and WPQ shall be submitted for
approval to the notified body indicated by Owner that will give approval for the specific
application under PED.
2. Welder and Welding Operator Qualification Test Record shall be available for evaluation
by Owner Inspector at all times.
7.7 Right of access
Representatives of Owner, the Authorised Inspection Agency and the Client or his Agent, shall
have access to the Vendor's facilities and equipment for the purpose of inspection and audit of
work and materials. Owner representative shall have free entry, at all times while work on this
Contract is being performed, to all parts of the Vendor's works that concern the fabrication,
assembly and/or installation.
The Vendor shall afford the Inspector all reasonable facilities to satisfy him that the work is
being furnished in accordance with the Contract. All inspections shall be conducted so as not to
interfere unnecessarily with the operation of the works.
AEGEAN REFINERY
PROJECT (ARP) SH/OF
STGPS –A14
REV F01 2 3 4
7.8 Subcontracting
1. Use of subcontractors by the Vendor for any operations required for the execution of this
contract by the Vendor is prohibited without prior permission and acceptance by Owner.
Subcontractors include other plant locations than the main, or identified plant of the
Vendor.
2. All the requirements of this document, including all the herein referenced documents,
codes, specifications, procedures, etc. are applicable to the subcontractors and are to be
included in Vendor's purchase orders to subcontractors.
3. Welding Procedure Qualification shall be carried out by the same organization that will
carry out the production welds. Different plant locations are considered different
organizations even though owned by the same Vendor, and require separate
qualifications.
AEGEAN REFINERY
PROJECT (ARP) SH/OF
STGPS –A14
REV F01 2 3 4
EXHIBIT “A” – ACCEPTABLE WELDING PROCESSES

Items to be specified Restriction
WELDING PROCESS in Welding Procedures (see below)
(see EXHIBIT "B") (15)
SMAW - Shielded Metal Arc a,b 16
GTAW - Gas Tungsten Arc a,b,c,d,e,f,h,k 1,13,19
PAW - Plasma Arc a,b,c,d,e,f,h 1
GMAW - Gas Metal Arc
- Fine Wire (Short a,b,e,f,h,k 1,2,3,12,13
Arc Micro Wire)
- GAS Spray Arc a,b,e,h,k 12,13
- Inert Gas (Mig) a,b,e,f,h,i,k 1,12,13
- Pulsed Arc a,b,e,f,h,i,k 1,2,3,12,13
FCAW - Flux-cored Arc
- GAS shielded a,b,e,h,i 9, 17, 18,20,22
- Self-shielded a,b,h,i 9, 14, 17, 18
SAW - Submerged Arc a,b,g,h,i,j 4,5,8,10,11,15,23
EGW - Electrogas a,b,e,h,i,j 6,9,17,21
ESW - Electroslag a,b,d,g,h,i,j 6,9,5,
OFW - Oxy Fuel Gas 7
RESTRICTIONS:
Unless otherwise authorised in writing by Owner, use of these welding processes is subject to indicated
restrictions:
1. Internal purging with inert gas is required for consumable insert welding of all materials and for
root/second passes of single welded butt joints in materials with over 3% total alloy content. For
P22 and P91, shielding and purging gas shall be argon and shall be certified according to EN 439.
Nitrogen shall not be used neither as shielding nor purging gas.
2. Manual short arc or pulsed arc welding is:
a. Allowed for root pass welding of butt joints in any material regardless of thickness.
b. Allowed for full thickness butt welds and fillet welds in pressure parts, structural supports and
equipment internals if the thickness of either material at the joint does not exceed 9 mm.
c. Not allowed where large material mass heat sinks can affect the integrity of welds, such as
nozzle welds, reinforcing pads, flange welds, etc.
d. Not allowed for piping of nominal diameter less than 90 mm, then only where the direction of
travel is indicated in the procedure.
e. To be inspected as stated in previous paragraphs, with 5% of welds radiographed in addition to
applicable code requirements. The work of all welders employed utilising this process shall be
included in the radiography.
f. Shall not be used to deposit filler passes or cover passes in the down hill direction.
3. Automatic short arc or pulsed arc welding is allowed for full thickness butt welds in all sizes of
piping within the following limitations:
a. 1G (Rolled) position only.
b. For thickness over 9 mm, use of an automatic arc oscillator is recommended and a minimum
current of 170 amperes is required for all passes after the root pass.
c. 5% of welds in thicknesses up to 9 mm and 10% of welds in thicknesses over 9 mm must be
radiographed in addition to any applicable code requirements. Technique and acceptance
standards shall be as stated in this specification. The work of all welders employed utilising this
process shall be included in this radiography.
AEGEAN REFINERY
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REV F01 2 3 4
d. Not allowed where large material mass heat sinks affect the integrity of welds, as with
couplings, weldolets, branch welds, fillet welds on slip-on flanges, socket-welded flanges and
fittings, etc., where the thickness of either material at the joint exceeds 9 mm.
e. Not allowed for piping of nominal diameter less than 90 mm, then only where the direction of
travel is indicated in the procedure.
f. Shall not be used to deposit filler passes or cover passes in the down hill direction.
4. The use of neutral flux (non-voltage sensitive) is required for submerged arc welding of carbon steel
base metals thicker than 25 mm and for all materials other than carbon steel. If voltage sensitive
flux is used, each production weld shall be tested for hardness. Max allowed hardness is 200 HB.
5. The use of alloy wire and neutral flux, rather than alloying through the flux, is required where an
alloy weld deposit is desired.
6. Welding shall be followed by appropriate normalising treatment to restore notch toughness to base
material and weldments.
7. Not allowed.
8. Use of manual submerged arc welding is not permitted. The manufacturer and brand name or
grade of flux shall be specified in the welding procedure.
9. This welding process is not acceptable for field welding.
10. Start and run off pads of same material as base material shall be used on all longitudinal seams.
11. The flux and wire combination actually used shall be the same used in the procedure qualification.
12. Gas Metal Arc Welding shall not be used for welding attachment of nozzles to vessels.
13. When this welding process is used for field welding, suitable precautions shall be taken to shield
the welding area from wind or drafts which could interfere with the shielding gas protection.
14. Self-shielded flux-cored arc welding, without external shielding gas, of carbon or alloy steels is not
acceptable for pressure parts or for welds subject to vibration.
15. Individual beads deposited by standard automatic processes shall not exceed 6 mm deep.
16. Only low-hydrogen electrodes shall be used for shielded metal arc welding of all carbon and low
alloy steels, except for root pass welding of single welded joints as specified in the relevant para of
this specification.
17. The use of this process for welds, weld overlay, clad restoring is subject to Owner authorization to
be asked by Vendor prior to the start of any welding operations.
18. FCAW filler metal on stainless steel, to be used for high temperature service (above 700°C), shall
be bismuth-free.
19. When automatic pulsed gas tungsten arc welding (GTAW-P) is used for root pass of single sided
joints, welding shall be performed with the same make and model of welding system using the
same equipment and/or program settings as those used in the procedure qualifications.
20. For welding pressure containing equipment, the diffusible hydrogen limit for FCAW electrodes shall
be H8 (per AWS A5.20 or A5.29) for specified minimum tensile strength for the electrode  70 ksi
and H4 for tensile strength > 70 ksi.
21. Welding consumables shall be limited to the classification and the Manufacturer’s trade name used
in PQR.
22. FCAW is not acceptable for low alloy steel.
23. SAW is not acceptable for 9 Cr. welding
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EXHIBIT “B” – SPECIFIC ITEMS TO BE INCLUDED IN WELDING PROCEDURES
CODE USED
IN DESCRIPTION
EXHIBIT "A"
a Welding current type, polarity, amperage and voltage(s) including

appropriate ranges.
b Filler metal type, classification, A-number and F-number where classified.

If no classification is available, give Manufacturer's designation.
c Non consumable electrode type.
d Arc starting aids or devices.
e Shielding gas composition and flow rate
f Composition and flow rate of internal gas purging.
g AWS classification, if any, and manufacturer's trade name or designation

for welding flux.
h Travel speed for mechanised welding.
i Special requirements such as constant potential power sources, pulse

setting, wire feed or oscillation rates, electrode stick-out, etc. (as
applicable)
j Single or multiple arcs
k Specific precautions that will be taken for field welding if applicable, to

prevent wind or drafts from interfering with the shielding gas protection.
AEGEAN REFINERY
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EXHIBIT “C” – FILLER METAL SELECTION GUIDE FOR WELDING FERRITIC STEELS
MATER. C.S. Mn-Mo 2.25Cr-Mo 9Cr-1Mo 9Cr-1Mo-V

TO BE C-0.5Mo 1.25Cr-0.5Mo 5Cr-0.5Mo 410 S
WELD. (NOTE 1)
Carbon A/B B/C B/D B/E B/F B/G B/H I -
Steel V W W X Y Z Z W
C-0.5Mo C C/D C/E C/F C/G C/H I -
W W X Y Z Z X
Mn-Mo D D/E D/F D/G D/H I -
W X Y Z Z X
1-1/4Cr E E/F E/G E/H I -
1/2Mo X Z Z Z Z
2-1/4Cr F F/G F/H I F (2)
1Mo Z Z Z Z
T
5Cr G G/H G/I -
1/2Mo Z Z Z
9 Cr H H/I -
1 Mo Z Z
410 S I -
(Note 1) -
9Cr-1Mo K
-V U
X/X : Filler Metal Code (see EXHIBIT "D")

X : P.W.H.T. (see EXHIBIT "E")
Note 1: Only applicable to non-pressure 410 S parts not exceeding 10 mm in thickness.

For thickness over 10 mm a preheat of 232°C shall be applied.
PWHT not required in accordance with ASME VIII Div. 1 Table UHA-32.
Note 2: Filler metal for P22 to P91 welds shall be P22 except for welding of P22 non pressure parts to P91
pressure parts where filler metal shall be P91.
AEGEAN REFINERY
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REV F01 2 3 4
EXHIBIT “D” – ACCEPTABLE FILLER METALS FOR JOINING FERRITIC STEELS
Note 12
Filler Manual Submerged Arc Flux Gas Gas
Code shielded Cored Tungsten Metal
from metal arc Wire Flux Arc Arc Arc
EXH.C (7) (8) (9)
A E6010 (1) C.S. Neutral E7XT-1 ER70S-3 ER70S-3
E6011 (1) (10) (11) E7XT-5 ER70S-2 ER70S-2
ER70S-6 ER70S-6
B E7018 Carbon Neutral E7XT-1 ER70S-3 ER70S-3
E7015 Steel E7XT-5 ER70S-2 ER70S-2
E7016 (10) (11) ER70S-6 ER70S-6
C E7018-A1 EA2 Neutral E70T5-A1 ER80S-D2 ER80S-D2
E7015-A1 EA3 E80T1-A1 (Mn-Mo) (Mn-Mo)
E7016-A1 Mn-Mo E81T1-A1
D(2) E9018-D1 EA3 E80T1-A1 ER80S-D2 ER80S-D2
(6) E81T1-A1 (Mn-Mo) (Mn-Mo)
E9015-G(3)
E(4) E7016-B2L EB2 Neutral (1.25 Cr ER80S-B2 ER80S-B2
E7018-B2L 0.5 Mo) ER70S- ER70S-
E8016-B2 E81T1-B2 -B2L -B2L
E8018-B2
F(4) E9015-B3 EB3 Neutral (2.25 Cr ER90S-B3 ER90S-B3
E8015-B3L 1.0 Mo) ER80S- ER80S-
E8018-B3L E91T1-B3 -B3L -B3L
E9018-B3
G E8015-B6 ER502 Neutral E502T-1 ER80S-B6 ER80S-B6
E8015-B6L
(5Cr)
H E8015-B8 --- --- E505T-1 ER80S-B8 ER80S-B8
E8015-B8L
(9Cr)
I(5) E309L-15 ER309L Neutral E309T1-1 ER309L ER309L
E309L-16
E309L-17
K E9018-B9
--- --- --- ER90S-B9 ---
(13,14) E9015-B9
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REV F01 2 3 4
EXHIBIT "D" (Cont'd)
NOTES:
1. Use only as root pass.

2. For hydrogen service, special order filler metals resulting in welds with 0.40 to 0.60% Mo content
must be used.
3. This refers to special E9015-G electrode developed by Champion to weld Mn-Mo steel.
4. For equipment operating in creep range, do not use low carbon grade of filler metal.
5. If austenitic stainless steel filler metal is used, thermal stresses resulting from difference in
coefficient of thermal expansion shall be considered.
6. All E9018-D1 electrodes shall have at least a 0.4% Mo content (minimum).
7. E6012, E6013, E7014, E7020 and E7024 electrodes are not suitable for welding non-pressure
attachments to pressure components.
8. Low hydrogen electrodes shall be stored and used only in accordance with electrode
manufacturer's instructions.
9. Welding electrodes shall have the alloying agents in the wire and not in the flux.
10. Manganese-Molybdenum steel electrode wires may be used provided that the weld metal hardness
does not exceed 200 BHN.
11. Electrodes specified in ASME SFA 5.17 and electrode classification EM12K specified in ASME SFA
5.23, shall not be used for submerged arc welding carbon steels having a minimum specified
tensile strength of 482 N/mm2 or higher, where P.W.H.T. is specified, unless a PQR with same
PWHT (or higher) temperature/time as production demonstrates that filler metal has sufficient
strength.
12. When filler metal designated under AWS classification "G" is used, the chemical analysis of filler
metal shall be reported in WPS and PQR.
13. Filler metals used in welding Gr 91 materials shall contain a manganese plus nickel total of less
than 1,3%.
14. Whenever practicable, welding of Gr 91 material should be performed using GTAW process. When
shielding metal arc welding is used, heated electrode holders must be used at all times.
15 ER70S-6 shall not be used for welds of equipment and piping in wet H2S Service
AEGEAN REFINERY
PROJECT (ARP) SH/OF
STGPS –A14
REV F01 2 3 4
EXHIBIT “E” – P.W.H.T. RECOMMENDATION FOR FERRITIC STEELS

TEMPERATURE RANGE [°C]
Code from Equipment Piping & Pip. See note(s)
EXHIBIT "C" & Vessels Components
V 595-645 595-645 (1)
W 595-645 595-645 (1), (2)

X 650 - 690 705 - 745 (2), (3), (6)
Y 675 - 700 705 - 760 (2), (3), (6)
Z 675 - 720 705 - 760 (2), (3), (6), (7)
T - 705 – 760 (3), (6), (7), (8)
U 730-775 730 – 775 (6), (9)
NOTES:
1. Weldment is only to be PWHT if required by Codes and/or by service requirements. If PWHT is
required, use the indicated temperature range for holding temperature. Heating and cooling rates
and holding time shall be as per requirements of applicable ASME, Piping Code, or applicable
Codes, unless otherwise specified.
2. PWHT over 650 degrees C may damage properties of C.S., C-1/2 Mo and Mn-Mo. Vendor shall be
responsible to procure materials that will satisfy specified materials properties after PWHT at the
specified temperatures. Mill test reports shall be based on test samples post weld heat treated at
the specified temperature. Consult with Owner if necessary.
In case of piping welds between CS and alloy materials requiring PWHT at temperature higher than
650°C, a welding procedure with buttering shall be used to avoid exposure of CS to high
temperatures.
3. Where restraint conditions necessitate the practice of PWHT the chrome-moly alloy steels
immediately upon completion of welding, it is recommended that the welds be cooled to 120-150°C
after welding and prior to initiating the PWHT.
4. Use for alloy steels having a minimum specified tensile strength equal to 482 N/mm2, or less, for
thicknesses greater than 19 mm.
5. Use for alloy steels having a minimum specified tensile strength greater than 482 N/mm2 for all
thicknesses.
6. Welds for all thicknesses shall require PWHT. Use the indicated temperature range for the holding
temperature. Heating and cooling rates and holding time shall be as per the requirements of the
applicable ASME Code.
7. The PWHT holding temperature should be as close as possible to the tempering temperature of the
base material as supplied by the mill (5 10°C below the tempering temperature) for P22 and
heating/cooling rates should be 80°C/h independently from the base metal thickness.
8. When components have both Gr 91 to Gr 91 and Gr 91 to Gr 22 welds, all Gr 91 to Gr 91 welds
shall be completed and PWHT’ed at 745 760°C prior to completing the Gr 91 to Gr 22 welds,
which will then be given the 705 735°C treatment.
9. The PWHT holding temperature should be as close as possible to the tempering temperature of the
base material as supplied by the mill (5 10°C below the tempering temperature).
For the P91 material the minimum heating and cooling rates should be as follow:
- 80°C/h from 300 to 550°C
- 55°C/h from 550 to 750/760°C
In no case, as-welded material shall receive long term exposure in the 620675°C range.
AEGEAN REFINERY
PROJECT (ARP) SH/OF
STGPS –A14
REV F01 2 3 4
EXHIBIT “F” – ACCEPTABLE FILLER METALS FOR JOINING AUSTENITIC STAINLESS

STEELS
NOTES(1) (2) (4) (5)
MAT.LS 301 304L 309 310 316 316L 317 317L 321 347 348
TO BE 302 309S 310S (3) (3) (3) (3) (6) (6)
WELDED 304 (6)
(6)
301 308 308 308 308 308 308 308 308 308 308 308
302 309 309
304
(6)
304L 308 308 308 308 308 308 308 308 308 308
L 309 L L L L L
309 309 309 309 316 317 317 347 347 348
309S 316 309 309 309 309 309 309
310 310 309 309 309 309 309 309 309
310S 316 316
316 316 316 316 316 316 316 316
(3) (6)
316L 316 316 317 316 316 316
(3) L L L L L
321 347 348
317 317 317 317 317 317
(3) L 347 348
317 317 317L 317L 317
L L L
348
321 347 347 347
(6) 348
347 347 347
(6) 348
348 348
NOTES:
1. Deposited type 300 stainless steel weld metal shall have a delta ferrite content as specified in this standard.
2. Low carbon filler wires will result in lower tensile strengths. They shall only be used if either specifically
requested by Owner or specifically approved in writing by Owner.
3. Filler metals used in welding 316, 316L, 317or 317L parts in fatty acid service shall contain a minimum Mo
content of 2.5% and a maximum carbon content of 0.03%.
4. DELETED
5. For materials and/or combinations of materials not listed in EXHIBIT "F", consult Owner for specific
recommendations.
6. Where high carbon grade materials (i.e. 304H, 316H, 321H, 347H) are welded together the filler metal shall
have a carbon content of 0.04% to 0.08%; this is applied in equipment and piping operating in "creep" range.
7. Poor ductility of type 347 filler material at high temperature (above 400°C) is reported. In case of operating
temperatures above 400°C, the use of type 347 filler material may be proposed by Vendor based on
successful previous experience.
AEGEAN REFINERY
PROJECT (ARP) SH/OF
STGPS –A14
REV F01 2 3 4
EXHIBIT “G” – ACCEPTABLE FILLER METALS FOR WELD DEPOSIT AND CLAD
RESTORING
CLADDING MATERIAL FILLER MATERIALS FOR WELD DEPOSIT AND

CLAD RESTORING (3) (4)
70 Ni 30 Cu (5) ENiCu7 (1)
12% Cr Do not overlay
Type 410
12% Cr Cyclic service : ENiCrFe3 ERNiCr3
Type 410 S Low sulphur T 425°C: E309L ER309L
(2) S 0.5% T > 425°: ENiCrFe3 ERNiCr3
High sulphur T 425°C: E309L ER309L
S > 0.5% 425°C < T 480°C: ERNiCrMo-3
Austenitic stainless steel First pass Subsequent passes
Type 304 309L 308
Type 304L 309L 308L
Type 316 309LMo 316
Type 316L 309LMo 316L
Type 317L 309LMo 317L
Type 321 or 347 309Nb 347
Nickel 200 E Ni 1
NOTES:
1. Monel welding electrode 190 or equal.
2. Consult Owner material/welding engineer for the selection of filler material.
3. The chemical composition of weld overlays shall meet the requirements of Section II part C, of the
ASME Code, pertinent specifications.
4. Overlays usually require a minimum of two layers, however, single-layer overlays are acceptable
provided dimensional requirement are met, chemical composition, at the specified depth, and
soundness are satisfactory. Owner acceptance is required prior to use in fabrication. The number of
layers in production shall not be less than the number of layers in the procedure qualification test.
5. Annealed Monel material.
AEGEAN REFINERY
PROJECT (ARP) SH/OF
STGPS –A14
REV F01 2 3 4
EXHIBIT “H” – WIRES FILLER METALS FOR NICKEL ALLOY

Alloy Nickel Monel Inconel Inconel Incoloy Incoloy Hastelloy Hastelloy Stainless Ferritic
200 400 (1) 600 625 800 825 & B2 C276 Steel Steel
Alloy 20
Nickel Nickel Monel 60 Nickel 61 Nickel 61 Nickel 61 Nickel 61 Alloy B2 Alloy C276 Nickel 61 Nickel 61
200 61 Nickel 61 Inconel Inconel Inconel Inconel Inconel 82 Inconel 82
82 82 82 82 Inconel 92 Inconel 92
Inconel Inconel Inconel Inconel
92 92 92 92
Monel Monel 60 Inconel Inconel Inconel Inconel Alloy B2 Alloy C276 Inconel 82 Monel 60
400 (1) 82 82 82 82 Inconel 92 Inconel 82
Inconel Inconel Inconel Inconel Inconel 92
92 92 92 92
Inconel Inconel Inconel Inconel Inconel Alloy B2 Alloy C276 Inconel 82 Inconel 82
600 82 82 82 82 Inconel 92 Inconel 92
Inconel Inconel Inconel Inconel
92 92 92 92
Inconel Inconel Inconel Inconel Alloy B2 Alloy C276 Inconel 82 Inconel 82
625 625 82 82 Inconel 92 Inconel 92
Inconel Inconel
92 92
Incoloy Inconel Inconel Alloy B2 Alloy C276 Inconel 82 Inconel 82
800 82 82 Inconel 92 Inconel 92
Inconel Inconel
92 92
Incoloy Incoloy Alloy B2 Alloy C276 Inconel 82 Inconel 82
825 & 65 Inconel 92 Inconel 92
Alloy 20
Hastelloy Alloy B2 Alloy B2 Alloy B2 Alloy B2
B2 Alloy C276
Hastelloy Alloy 276 Alloy C276 Alloy C276
C276
Stainless See See Para

Steel Exhibit "F" V.E.1
Ferritic See Exhibit

Steel "C"
Alloy B2 Bare: ER NiMo-7

Alloy C276 Bare: ER NiCrMo-4
Incoloy 65: ER NiFeCr-1
Inconel 62: ER NiCrFe-5
Inconel 82: ER NiCr-3
Inconel 92: ER NiCrFe-6
Inconel 625: ER NiCrMo-3
Monel 60: ER NiCu-7
Nickel 61: ER Ni-1
Notes: 1) Filler metals used in welding Monel parts in Hydrofluoric acid (HF) service shall not contain Cb (Nb)
AEGEAN REFINERY
PROJECT (ARP) SH/OF
STGPS –A14
REV F01 2 3 4
EXHIBIT “J” – ELECTRODES FOR NICKEL ALLOY

Alloy Nickel Monel Inconel Inconel Incoloy Incoloy Hastelloy Hastelloy Stainless Ferritic
200 400 (1) 600 625 800 825 & B2 C276 Steel Steel
Alloy 20
Nickel 200 Nickel Monel Nickel Nickel Nickel Nickel Alloy B2 Alloy C276 Nickel 141 Nickel 141
141 190 141 141 141 141 Inconel Inconel 182
Nickel Inconel Inconel Inconel Inconel 182 IncoWeld A
141 182 182 182 182 IncoWeld
IncoWeld IncoWeld IncoWeld IncoWeld A
A A A A
Monel 400 Monel Inconel Inconel Inconel Inconel Alloy B2 Alloy C276 Monel 190 Monel 190
(1) 190 182 182 182 182 Inconel Inconel 182
IncoWeld IncoWeld IncoWeld IncoWeld 182 IncoWeld A
A A A A IncoWeld
A
Inconel Inconel Inconel Inconel Inconel Alloy B2 Alloy C276 Inconel Inconel 182
600 182 182 182 182 182 IncoWeld A
IncoWeld IncoWeld IncoWeld IncoWeld IncoWeld
A A A A A
Inconel Inconel Inconel Inconel Alloy B2 Alloy C276 Inconel Inconel 182
625 182/112 182 182 182 IncoWeld A
IncoWeld IncoWeld IncoWeld IncoWeld
A A A A
Incoloy Inconel Inconel Alloy B2 Alloy C276 Inconel Inconel 182
800 182 182 182 IncoWeld A
IncoWeld IncoWeld IncoWeld
A A A
Incoloy Incoloy Alloy B2 Alloy C276 Inconel Inconel 182
825 & 135 182 IncoWeld A
Alloy 20 ncoWeld
A
Hastelloy Alloy B2 Alloy B2 Alloy B2 Alloy B2
B2 Alloy C276
Hastelloy Alloy Alloy C276 Alloy C276
C276 C276
Stainless See See Para
Steel Exhibit "F" V.E.1
Ferritic See Exhibit
Steel "C"
Alloy B2 Covered: E NiMo-7

Alloy C276 Covered: E NiCrMo-4
Incoloy 135: ------
Inconel 112: E NiCrMo-3
Inconel 182: E NiCrFe-3
Inco Weld A: E NiCrFe-2
Monel 190: E NiCu-7
Nickel 141: E Ni-1
Notes: 1) Electrodes used in welding Monel parts in Hydrofluoric acid (HF) service shall not contain Cb (Nb)
AEGEAN REFINERY
PROJECT (ARP) SH/OF
STGPS –A14
REV F01 2 3 4
EXHIBIT “K” – FERRICYANIDE TEST PROCEDURE FOR ALLOY 400 RESTORING OR WELD
OVERLAY
This test procedure is suitable for inspection on welding procedure samples both for shop and field construction.
a) Clean the weld and adjacent surfaces with any method iron free, such as: sand papers or other.
b) Clean the weld and adjacent surfaces with diluted HCl solution:
10% vol of concentred HCl 12.1N
90% vol of deionized or demineralized water;
c) Check weld deposit for cracks or other defects and repairs (if any).
d) Repeat step (b).
e) Check for iron contamination or porosity with a newly – made solution of:
10% vol of diluted solution prepared per step (b)
90% vol of potassium ferricyanide K 3 Fe (CN)6 solution to 4% wt in deionized or distillate water.
f) Drip with a dropper, or spry, the solution (e) on a ground surface of carbon steel. A blue coloration will
appear quickly. Repeat this test on solid alloy 400 surface.
The blue coloration will appear only after ten (10) minutes. If the coloration appears prior it means that the
solution is too much acid. Make a new solution and repeat the test.
g) Check with the solution (e) on weld metal. If the blue coloration appear prior two (2) minutes, the alloy 400
weld has to be considered contamined by free iron so it has to be eliminated and redone.
h) Rinse completely with fresh water all tested areas.
j) Neutralize tha excess of acid solution and drain in safe place. Keep also the concentrated acid and
ferricyanide crystals in strongly closed containers and store them in fresh and safe place.
AEGEAN REFINERY
PROJECT (ARP) SH/OF
STGPS –A14
REV F01 2 3 4
EXHIBIT “L” – ACCEPTABLE FILLER METALS FOR JOINING ALUMINUM AND ALUMINUM
ALLOYS
Note 1
Material to 5052 5154 6061
1060 1100 3003 3004 5050 5083 5086 5456
be welded 5652 5254 6063
ER 1260 ER 1100 ER 1100 ER ER 1100 ER ER ER 4043 ER 4043 ER 4043 ER 4043
ER 4043 ER 4043 ER 4043 4043 ER 4043 4043 4043 ER 5356 ER 5183 ER 5356
1060
ER
5356
ER 1100 ER 1100 ER ER 4043 ER ER ER 4043 ER 4043 ER 4043 ER 4043
ER 4043 ER 4043 4043 ER 5356 4043 4043 ER 5356 ER 5183 ER 5356
1100
ER ER ER
5356 5356 5356
ER 1100 ER ER 4043 ER ER ER 4043 ER ER 4043 ER 4043
ER 4043 4043 ER 5356 4043 4043 ER 5356 4043ER ER 5356
3003
ER ER ER 5183
5356 5356 5356
ER ER 4043 ER ER ER 5356 ER 5356 ER 5356 ER 4043
4043 ER 5356 4043 5356 ER 5556 ER 5654 ER 5556 ER 5356
3004
ER ER ER
5356 5356 5556
ER 4043 ER ER ER 5356 ER 5356 ER 5356 ER 4043
ER 5356 4043 5356 ER 5556 ER 5654 ER 5556 ER 5356
5050
ER ER
5356 5556
ER ER ER 5356 ER 5356 ER 5356 ER 5356
5052 4043 5356 ER 5556 ER 5654 ER 5556 ER 5556
5652 ER ER
5356 5556
ER ER 5356 ER 5356 ER 5183 ER 5356
5183 ER 5556 ER 5556 ER 5556 ER 5556
5083
ER
5356
ER 5356 ER 5356 ER 5356 ER 5356
5086
ER 5556 ER 5556 ER 5556 ER 5556
5154 ER 5356 ER 5356 ER 5356

5254 ER 5654 ER 5556 ER 5556
ER 5356 ER 5356
5456
ER 5556 ER 5556
6061 ER 4043
6063 ER 5356
NOTES:
1. The filler metal listed on the top line of each combination is the preferred wire. The filler metal list on the
bottom of each combination is an acceptable alternate.
2. The choice of filler metal may be limited by service conditions such as immersion in fresh or salt water,
exposure to specific chemicals, or to a sustained temperature between 65°C and 230°C. Contact
Owner if such condition exists for the specific recommendation.

Welding and Heat Treatment Requirements For Equipment and Piping

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STAR RAFINERI A.S.

WELDING AND HEAT TREATMENT

GENERAL PROJECT DESIGN SPECIFICATION

Note to Revision: This specification was formally known as specification nº : BD0506A-88A1

F01 Apr. 04, 2011 FINAL G.G. R.C. R.C. FWI

2 PROCEDURES SUBMITTAL REQUIREMENTS.........................................................................3

5 WELDING FILLER METALS .....................................................................................................13

6 POST WELD HEAT TREATMENT (PWHT) ..............................................................................15

7 WELD QUALITY CONTROL .....................................................................................................16

EXHIBIT "A"- ACCEPTABLE WELDING PROCESSES ........................................................................22

EXHIBIT "B"- SPECIFIC ITEMS TO BE INCLUDED IN WELDING PROCEDURES .............................24

EXHIBIT "E": P.W.H.T. REQUIREMENTS FOR FERRITIC STEELS ....................................................28

EXHIBIT "H": WIRES FILLER METALS FOR NICKEL ALLOY..............................................................31

EXHIBIT "J": ELECTRODES FOR NICKEL ALLOY ..............................................................................32

2 PROCEDURES SUBMITTAL REQUIREMENTS

3.1 General Requirements

3.2 Ferritic Steels

3.3 Austenitic Stainless Steels and High-Nickel Alloys

3.4 Aluminum and Aluminum Alloys

1. In gas-shielded arc welding of aluminum and aluminum alloys, preheating of parts to be

3.5 Welding Dissimilar Metals or Thicknesses

For welding material combinations of dissimilar or of different thicknesses, the minimum

3.6 Arc Cutting

3.7 Preheat Maintenance for Circumferential Butt Joints

Preheating and post-heating shall be performed by means of electric resistance heating.

- preheating temperature: min 250°C

- preheating temperature: min 200°C

4.2 Base Metal Preparation

4.3 Proprietary Items

4.4 Welding Items Coated with Low Melting Point Metals

4.5 Heat Exchanger Tube to Tubesheet Welds

4.6 Storage Tanks

4.7 Strip Lined Connections

4.8 Welding Clad/Overlay Materials

9. Indication of overlap between adjacent passes is to be indicated on WPS.

CHROMIUM CONTENT FERRITE Cb/C

4. Hardfacing qualification special requirements:

4.10 Stud Welding

5 WELDING FILLER METALS

5.1 Electrodes and/or filler metals shall be selected such that:

5.2 Ferritic Steels

5.3 Austenitic Stainless Steel, High-Nickel Alloys, Duplex Stainless Steels

5.4 Aluminum and Aluminum Alloys

5.5 Ferritic to Austenitic Steels and to High-Nickel Alloys

6 POST WELD HEAT TREATMENT (PWHT)

7 WELD QUALITY CONTROL

7.1 Repair, Inspection, Rejection

P-1 200 210

(*): Limit for P91 (9Cr-1Mo-V) is 248HB max.

6. Additional Requirements for Welding Procedure Qualification:

Plate Thickness Max. Thickness of

7.6 PQR Witnessing

7.7 Right of access

EXHIBIT “A” – ACCEPTABLE WELDING PROCESSES

EXHIBIT “B” – SPECIFIC ITEMS TO BE INCLUDED IN WELDING PROCEDURES

a Welding current type, polarity, amperage and voltage(s) including

b Filler metal type, classification, A-number and F-number where classified.

c Non consumable electrode type.

d Arc starting aids or devices.

e Shielding gas composition and flow rate

f Composition and flow rate of internal gas purging.

g AWS classification, if any, and manufacturer's trade name or designation

h Travel speed for mechanised welding.