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KUWAIT OIL GOMPANY (K.S.C.}

EngÍneering Group

SpecifÍcatÍon Number
oî 5-wH-îool
Welding Procedure Approval
And WeldÍng Quality Reguirement

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1 17 JUL 94 ISSUED AS KOC ENG GROUP SPEC ,-:


0 7 MAR 93 ISSUED FOR INVITATION TO BID /.9,; 1a\
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015-WH-1001 0 17-7-94 2 o1 '14

CONTENTS

1.O SCOPE 3

2.O STANDARD SPECIFICATIONS 3

3.0 PROCEDUREOUALIFICATION 4

4.0 PREPARATION OF MATERIAIS FOR WELDING . . . . 4

5.0 WETDING PROCESSES 5

6.0 WELDING ETECTRODES AND CONSUMABTES I


7.O PREHEAT, INTERPASS TEMPERATURE AND PWHT 9
7.1 PreheatTemperatures 9
7.2 PWHT o

8.0 GENERAL WELDING REOUIREMENTS 10

9.0 WETD METAL OUALITY

1O.O NON.DESTRUCTIVE TESTING (NDTI 11

11.0 PACKING, MARKING AND DOCUMENTATION 11

ATTACHMENT I : HARDNESS SURVEY 12

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015-WH-1001 0 17-7-94 3of14

1.0 scoPE

1.1 This speciflcation covers the review of weld procedures, non-


destructive test¡ng and quallty standards required for the fabrication
or supply of pressure rotaining equipment and piping for installation
at the Facility in Kuwait.

1.2 The welding shall fully comply with all relevant contragtual
requirements specified in the Scope of Work and Technlcal
Specification of the Contract.

2.O STANDARD SPECIFICATIONS

2.1 All welding shall conform in design, mater¡als and performance,


€xcept where otherwise specified, with the current issue and
amendments of the following standards prevailing on the effective
data of the contract:

2.1.1 lnternational Standards

ASME V Non-Destructive Examination

ASME lX Welding and Brazing Oualifications

AWS

2.1.2 Br¡t¡sh Standard

BS51 35 Welding of Carbon and Carbon Manganese


Steels

2.1.3 Engineering Group Specificatlons

01s-AH-10O1 Basic Design Criteria

01 5-AH-1002 lnternational Codes and Standards :l ';ú"

015-KH-19O2 Spare Parts and Maintenance


Requirements

015-UH-1001 Packing, Marking and Documentation

015-XH-1O05 Shop and Field Painting

2.2 Compliance with this specification shall relieve the Contractor


of its responsibility to supply to meot the
specified service conditions and ns
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2.3 Where conflicts exist between this specification and other


Drawings, standards, codes and specifications, the most stringent
shall be applied.

3.0 PROCEDURE OUATIFICATION

3.1 Only Company-approved Welding Procedure Specificat¡ons (WPSI,


with Welding Procedure Oualification Records (WPOR) shall be used
for welding. Applicable welding procedures, weld maps etc., shall
be submitted as soon as possible after the award of work and
sufficiently ahead of the actual welding to allow for adequate
review and approval by the Company.

3.2 A welding procedure is defined as the method and sequencesto bo


adopted to achieve a satisfactory welded ioint when carried out by
competent workmen underthe expected conditions of manufacture.
All welding procedures submitted to the Cornpany shall include
welding details and appropriate test results in accordance w¡th the
applicable design code and/or job speciflcations. The Approved
Manufacturer's standard forms are acceptable for this purpose. lf
the Approved Manufacturer's standard forms do not detail all
required information, th€n the suggested forms in ASME lX' OW-
482 and 483 shall be used.

3.3 Repair welding procedures and qualification records shall be


submitted to th€ Company for review and approval as soon as
possible after the award of work in order that production is not
delayed when the noed for repair welding occurs.

3.4 No welding will be accepted that is not covered by a Company-


approved WPS/V\IPOR.

3.5 Welder qualiflcation records shall be reviewed by the Company's


Representative in the Vendor works, and should not be submitted
to th€ Company's office for review.

4.O PREPARATION OF MATERIALS FOR WELDING

4.1 Allwelding preparat¡ond€tails shall be in accordance with Drawings


and welding procedures approved by the Company.
Íl

4.2 lf flame-cutt¡ng or arc-gouging are used on steels contain¡ng more


than 2o/o chromium or on non-ferrous materials, the bevels shall be
finished machined or ground removing at least 1.5 mm of metal.

4.3 Permanently ¡nstalled backing rings or str¡ ps shall not be used


without prior written aPProval of
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4.4 Only stainless-steel brushes and tools shall be used on sta¡nless


steels, nickelalloys, and non-ferrous metals. Any rolls, clamps and
other handling devlces shall be cleaned prior to use to minimise
contamination.

4.5 Socket welds shall conform to design code requirements, but as a


minimum, a gap of approx¡mately 1.6 mm minimum to 3.0 mm
maximum between the bottom of the socket and the edge of the
pipe is required prior to weldlng.

5.O WELDING PROCESSES

5.1 The following welding processes with their respective restrictions


are permitted:

5.1.1 Shield MetaþArc Welding (SMAW)

Travel speed and heat input (kJ/mml shall be included in


welding procedures when paragraph 7.1.1 applies.

5.1.2 Submerged-Arc Welding (SAW)

Single-pass welds are not permitted. Two-pass welds


shall be subiect to Company approval.

b. Removable start¡ng and stopping tabs shall be used


for longitudinal welds.

c Deta¡ls of submerged-arc welding (SAWI procedures


shall include travel speed and heat input (kJ/mm).

5.1.3 Gas Tungsten Arc Welding (GTAWI

a. An internal argon gas purge shall be used for GTAW


root passes of steels with more than 2% Cr.

lf an argon purge is utilised on carbon, carbon 0.5 Mo .)


b.
or 1,25 Cr-O.5 Mo, the purgo may be removed when
welding of the root bead has been completed.

c For other alloy steels, the purge may be removed on ù

completion of the second pass. ln the case of


austenit¡c stainless steels, a nitrogen purge maY be
used instead of argon.

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015-WH-1001 0 17-7-94 6of14

5.1.4 Oxyacetylene Weld¡ng (OAW)

Limited to hard surfac¡ng of carbon steel and repa¡rs to


cast ¡rons only.

5.1.5 Gas-Metal Arc Welding (GMAW)

a GMAW using solid wire electrodes shall be carried out


in the spray transfer range.

b Short circuit dip or pulsed transfer is only permitted


for:

I Root pass to s¡ngle-sided welds in piping in the


flat and rolled (lGRl position subiect to
Company approval.

2. Tack welds, temporary attachments or other


applications where weld metal deposited by the
GMAW process is subsequently removed.

3. Weld metal overlays made in the lG position.


4. Non-pressure-reta¡n¡ng fillet welds where the
material being ioined does not exceed 7-mm
nominal thickness.

c. Joint preparat¡ons for th€ short-circuiting or pulsed


mode shall be treated as a welding variable (excluding
2 and 3 abovel.

d Allowable shielding gases for various materials shall


be as follows:

1. Ni and Ni alloys 99.99%


Argon

2 Stainless steel Argon +


spary or pulsed arc 1% Oxygen

3. Stainless steel Argon * 2o/o


dip transfer Oxygen

4. Carbon steel:Ultimate Coe


Tenslle Strength
upto 450 N/mm2 ÉR
T upto 20mm (,
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5 Carbon steel: Ultimate Argon/CO,


Tensile Strength over
45O N/mm2 and/or
T over 20mm

6. Carbon steels: Ultimate


Argon +
Tenslle Strength over20% COz
450 N/mm2 Low-alloy Steels

7 Carbon steels: Ultimate Argon +


Tensile Strength over 5o/o H2
450 N/mm2 Low-alloy steels

I Stainless steel Argon +


il o/o C
= 0.10 or + more ïVo H2
Nickel alloy including lncoloys

Notes:

Other gas mixtures shall be subject to Company


approval.
T = thickness
5.1.6 Flux Cored Metâl-Arc (FCAW)

a. FCAW shall be carried out ¡n the spray transfer range


and be used for welding carbon steel only.

b. FCAW shall be carried out with a shielding gas except


for:

1 Corrosion-resistant weld overlays when welded


in the flat position.

2 Clvil and structural applications and low-


pressure and atmospheric tanks with a
maximum internal gas or vapour space pressure
of I bar and a minimum design temperature of -
30c,
(
5.2 The maximum individualweld layer thickness for all processes shall
not exceed:

5.2.1 1O mm for materials less than 32 mm th¡ck.

5.2.2 12.5 mm for materials 32 m

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016-WH-1001 0 17-7-94 8of 14

5.3 Welding proce$ses and/or specific applications other than those


listed above shall be submitted for Company review and approval
provided that:

5.3.1 The Approved Manufacturer's ability to use the process is


approved by the Company.

5.3.2 The Approved Manufacturer's msthods of achieving and


maintainlng weld quality ars approved by the Company.

5.4 lnformation submitted to the Company shall include complete


details of the Approved Manufacturer's preparation, welding
techniques, welding procedures for specific applicat¡ons and past
experience in using the process.

5.5 No welding shall be left uncompleted overnight. Once started, all


welded joints shall be completed in one day.

6.0 WELDING ETECTRODES AND CONSUMABTES

6.1 The deposit analysis of weldlng consumable shall match that of the
base matsrial, e.9., carbon steel shall not be welded with C-0.5%
Mo consumable.

6.2 Actual weld deposit analysis and weld metal physical propert¡es are
required for all alloy welding. The information shall be taken from
the procedure qualification and/or relevant testing. Data l¡sted ¡n
the Approved Manufacturer's catalogues is aof acceptable.

6.3 The physical properties of the deposited weld metal shall be within
the l¡mits specified for the mater¡al being joined unless approved by
the Company for special applications.

6.4 As a minimum, all welding consumable shall be stored and/or dried


in accordance with the Approved Manufacturer's recommendations.

6.5 Unless specifically waived, all SMAW shallbe carried out using low ,r1''.t1fr':a;iir,
hydrogen type electrode when any of the following conditions /ï'7-,r ,r';ì "
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applv: J:-.; -V
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6.5.1 Steels having a specifled maximum carbon equivalent (CE)


above O.4O% (based on short formula CE = C + Mn/6) or
Motï '
ll";;sfi
with steels having a specified minimum tensile strength
above 45O N/mm2.

6.5.2 Weld repair of ferritic steel cast¡

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016-WH-100r 0 17-7-94 9of14

6.6 SMAW electrodes shall have core wires of nominally the same
analysis as th€ base material. Maior alloy additions are not to be
made via the flux coating.

6.7 Electrode classlfications E6012, E601 3,87014 andE7024 shall not


be used for welding pressure retaining parts.

These electrodes, however, may be used for non-pressure-retainlng


fillet welds of P-1 materials.

6.8 For SAW, alloy steel may only be welded with alloy wire and
neutral f¡ux.

6.9 For P-1 and P-3 steel piping materlals requiring the use of low-
hydrogen electrodes, the root pass only may be welded with
EXX1O/11 electrodes.

6.10 When required by the design code or specified on the purchase


order, carbon, carbon mangansse and low-alloy steel welds shall
not exceed 235 HB hardness in any area of the weld, heat-affected
zone or base material. This shall be demonstrated during welding
procedure qualificatlon tests and on subsequent production welds.
See Attachment 1 for procedure qualification survey requirements.

6.11 For welds requiring post weld heat treatment (PWHTI, hardness
tests shall be conducted on completion of heat treatment.

6.12 Where standard laboratory equipment cannot be implemented, test


equipment shall be commercially available portable hardness testing
machines.

6.13 Austen¡t¡c stainless steel (A-81 welding materials for pressure


boundary and local load-bearing welds shall contain a minimum
delta ferrite content of íoh (WRC Ferrite No.Sl based upon the
cert¡f¡6d chemical analysis and the WRC Delta Ferrite Diagram.

6.14 For PWHT applications and service over 427oC, the ferr¡te content
of stainless steels shall not exceed 90á (WRC Ferrite No.lO). This
shall be verified in the production using ferrite meters subject to the
4

approval of the Company.

6.15 SMAW electrodes of AWS Type E309 or E3O9L shall be used for
welding carbon or low-alloy steels to austenit¡c sta¡nless steels. 'û3

The use of alternative shall be agreed by the Company.

6.1 5.1 ln situations where PWHT of this weld type is required, the
carbon or low-alloy steel member "buttered" with
AWS type E309 or E309L, and treated prior
to welding to the austenitic

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015-WH-1001 0 17-7-94 10 of 14

6.1 5.2 Subsequent welding of the "buttered' layerto the stainless


stoel shall be carrled out with weld metal nominally
match¡ng the stainless steel parent metal.

7.O PREHEAT, INTERPASS TEMPERATURE AND PWHT

7.1 Preheat Temperatures

ln general, preheat temperatures shall be in accordance with the


applicable design code minima, except in situations whers the
specified hardness (see paragraph 6.101 cannot be met. ln these
cases, preheat shall be established by welding procedure
qualif¡cat¡ons.

7.1.1 ln addition to design code requ¡rements, carbon steels with


a specified minimum tensile strength greater than 450
N/mm2 shall have a preheat in relation to wall thickness,
welding heat input and base material composition
cons¡stent w¡th the requirements of Bs 5135, On the
Avoidance of Hydrogen Cracking.

7 .1 .2 The maximum interpass temperature for austenitic stainless


st€els shall be 175'C.

7.1,3 The maximum interpass temperature for all other materials


shall be as specified in the WPS.

7.1.4 Dissimilar welds between austen¡t¡c stainless steels and


ferritic steels shall be welded with a preheat determined by
the ferritic mater¡al, but shall not in any case exceed
175'C.

7.1.5 For the welding of castings the whole cast¡ng is to be


maintained within the approved preheat and interpass
temperature during the welding operation, unless
alternatives are approved in writing by the Company.

7.2 PWHT

PWHT shall bè in accordance with the applicable design code


and/or job specificat¡on.

7.2.1 A wr¡tten PWHT procedure shall be submitted to the


Company for approval' The submittal shall include a 111

Drawing showing thermocouple attachment points.

7.2.2 For P-6 materials, the PWHT used shall be at


least 28oC or 50oF below the re.

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015-WH-1001 0 17-7-94 11 of 14

7.2,3 Direct impingement by furnace burner flames is not


permitted.

7,2.4 Sufficient thsrmocouples shall be properly attached to the


workpiece so as to accurately indicate metal temperature
reached during PWHT.

7.2.5 Exothermic PWHT is prohibited on all alloy materials. The


Company's writtsn approval is required for exothermic
PWHT of carbon steel.

8.O GENEBAT WETDING REOUIREMENTS

8.1 Where double-sided bevels are used, the root bead of the f¡rst s¡de
welded shall be cleaned back to sound metal before the welding of
the second side commences.

8.2 Vertical welding shall be performed vertical-up. Vertical-down


welding is not permitted.

8.3 Weld peening is prohibited in all weld passes.

8.4 Welding of stainless steel and non-ferrous mater¡als shall be


performed in a dedicated area to prevent contamination.

8.5 Tack welds shall be performed by qualified welders using the same
parameters specified for the root run.

9.O WELD METAL OUATITY

9.1 All welding shall be done in a workmanlike manner, using correct


tools and equipment, and have adequate and competent supervision
at all times. All welding works shall be carried out by welders
qualified by the Company.

9.2 All arc str¡kes or stop/starts shall be confined to the welding groove
or shall be removed by grinding.

9.3 Weld(s) conta¡ning cracks shall be immediately reported to the ¿l


Company. The cause of cracking shallbe established. After review
with and agreement in writing from the Company, welds containing
cracks may be repaired; otherwlse, the entire weld{sl shall be re- 'r\..
prepared and re-welded in accordance with an approved welding \ù
procedure.

10.0 NON-DESTRUCTIVE TESTING (NDTI

10.1 All NDT shall be carried out in code


and/or other specifications as stated i

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10.2 A written procedure for each NDT technique to be used shall be


submitted to the Company for review and approval.

10.3 NDT shall be performed by personnel gualified to an approved


National or lnternational Standard. Deta¡ls of personnel including
their experience and qualification's shall be reviewed by the
Company.

10.4 ¡f NDT reveals conditions not meeting the design code or stated
specification requirements, ths cost of the rework for these non-
conforming condltions shall be to the Contractor's account without
extra cost or time to the Contract terms.

I 1.O PACKING. MARKING AND DOCUMENTATION

For all relevant requirements, refer to the Engineering Group Specification


entitled "Packing, Marking and Documentation" (Number 01 5-UH-1OO1 l.

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015-wH-1001 0 17-7-94 13 of 14

ATTACHMENT 1

HARDNESS SURVEY

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FUtt PENETRATTON T-JO|NTq FILTET WELDS í\


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016-WH-1001 0 17-7-94 14ol 14

lndentations are to be made along tfaverses, approximately 1 mm below e¡th€r


surface of the base material. ln the wsld metal a minimum of s¡x indentations
equally spaced along the traverses are to be made (except at weld root where two
should be obtainedl. ln the HAZ indentations are to be made along the traverses
for each 0.5 mm into unaffected material, and start¡ng as close to the fusion line
as possible.

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