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No.

Technical Data S10332100-3002 0

Welding Standard Date Page


5 NOV 2010 1 6

SUPPORT TO S10332100-2001

TABLE OF CONTENTS

SECTION
PAGE

1. SCOPE 2

2. APPLICABLE CODES, STANDARDS AND REFERENCE 2


SPECIFICATION

3. WELDING PROCESSES 3

4. GENERAL REQUIREMENTS 3

5. WELDING PROCEDURE AND WELDING PERFORMANCE 3


QUALIFICATION

6. FILLER METAL REQUIREMENTS 3

7. WELD JOINT PREPARATION AND CLEANING REQUIREMENT 4

8. PREHEATING 4

9. TACK WELDING 4

10. WELDING 5

11. POST WELD HEAT TREATMENT (PWHT) 5

12. HARDNESS TESTING 5

13. REPAIR 5

14. WELDER AND WELDING OPERATOR QUALIFICATION 5

15. QUALITY CONTROL OF WELDING WORK 6


GFG-002
No.
Technical Data S10332100-3002 0

Welding Standard Date Page


5 NOV 2010 2 6

1. Scope

This specification covers the minimum requirements for shop and site welding of ferrous and non ferrous
materials, equipment, piping and supplements. The discrepancy caused by this specification to any project
specification will be settled subject to the clarification made by IRPC.

2. Applicable codes, Standards and reference specifications

Welding shall at least conform to, but not limited to, the requirements of the following codes,
standards and specifications.

2.1 American Society of Mechanical Engineers boiler and pressure vessel code (ASME)

Section Description
I Power boilers
II Material specification. Part A, B, , C and D
V Nondestructive Examination
VIII Pressure Vessel, Division 1 and Division 2
IX Welding and Brazing Qualification

2.2 (ASME / ANSI) Standards

Standards Description
B 31.1 Power Piping
B 31.3 Chemical Plant & Petroleum Refinery Piping
Z 49.1 ANSI Safety in Welding and Cutting

2.3 American Petroleum Institute (API)

Standard Description
610 Centrifugal pump for general refinery services
611 General purpose steam turbines for refinery services
612 Special purpose steam turbines for refinery services
613 Special purpose gear unit for refinery services
614 Lubrication, Shaft-Stealing and Control-Oil system for special purpose
616 Type H Industrial combustion gas turbines for refinery
617 Centrifugal compressors for general refinery services
618 Reciprocating compressor for general refinery services
620 Design and construction of large, Welded, low-pressure storage tanks
650 Welded steel tanks for oil storage
661 Air-cooled heat exchangers for general refinery services
674 Positive displacement pumps-Reciprocating
675 Positive displacement pumps-Controlled volume
676 Positive displacement pumps-rotary

2.4 American Welding Society (AWS)

Standard Description
A 2.4 Symbols for Welding
A 3.0 Welding Terms and Definition Code
D 1.1 Structural Welding Code. Steel
GFG-002

2.5 Tubular Exchanger Manufacturers Association (TEMA)


2.6 Local Laws, Regulations and Codes
2.7 The applicable project specifications
No.
Technical Data S10332100-3002 0

Welding Standard Date Page


5 NOV 2010 3 6

Where reference is made to a code, specification or standard, the reference shall refer to the latest edition
of that code, Specification or standard, including their addendum, supplements and revisions.
Where there are any conflicts in code, standard or specification, the most stingent requirement shall be
goven.

3. Welding processes

The acceptable welding processes are :


- SMAW (Shielded Metal Arc Welding)
- SAW (Submerged Arc Welding)
- GTAW (Gas Tungsten Arc Welding)
- GMAW (Gas Metal Arc Welding)
- FCAW (Flux Cored Arc Welding)
Other welding processes may be used only upon approval by IRPC. FCAW shall not be used for a
pressure retaining part.

4. General requirements

4.1 Welding terms and definitions shall be in accordance with AWS specification A 3.0. Welding
symbols shall be in accordance with AWS specification A 2.4.
4.2 Safety measurement for the protection of welders and welding operators who involve in welding
and cutting, shall be in accordance with the practices specified in ANSI Standard Z 49.1 unless
specified different by local law or regulation.
4.3 All pressure retaining, butt welds shall be full penetration double welded joints with multiple
passes. Where access or wall thickness precluding the use of double welded butt joints, the single
welded joints shall be made instead. In such that case, the root pass shall be applied using the
GTAW process except for the carbon steel and alloy steel piping of which the use of are welding
process is acceptable subject to IRPC’s approval.
4.4 In case of rain and relative humidity exceeding 85% , preheating is required to remove moisture.
4.5 Tack weld shall not less than 2 inches on wall surface of low and high pressure vessels. For tack
weld which will be co-operated to root pass shall be grinding at start and stop points to remove
porosity, cracking, etc. During welding process, welder grinding of starts and stops shall be done.
Also, proper cleaning between each weld layer shall be done.
4.6 When reinforcing pads are required for branch connection, after welding branch pipe to main pipe
shall be PT/MT/UT prior to reinforcing pad installation.

5. Welding procedure and welding performance qualification

5.1 Welding procedure and welding performance qualification shall comply with ASME IX,ASME /
ANSI B 31.3, AWS D 1.1 or related specifications.
5.2 Welding procedure specification and procedure qualification record shall be submitted to IRPC
prior to starting the works.
5.3 Weld map or similar documents indicating location of WPS’s shall be submitted with its relevant
WPS’s.

6. Filler metal requirements

6.1 Welding material shall conform to ASME II, Part C.


6.2 To joint similar materials, the filler metal shall be selected so that the chemical composition in the
deposited weld metal is similar to the nominal composition of the base metal or better.To joint
dissimilar materials, the filler metal shall be selected according to the applicable appendices in
ASME II. Part C.
GFG-002

6.3 Covered arc welding electrodes shall be of the low hydrogen coating type for pressure parts,
except for the electrode E7016 . For water lines, the electrode E6013 Classification may also be
used for intermediate and final passes upon IRPC’s approval.
No.
Technical Data S10332100-3002 0

Welding Standard Date Page


5 NOV 2010 4 6

6.4 Neutral fluxes shall be used for submerge arc welding of alloy steel.
6.5 Suitable storage of electrodes, fluxes and other welding materials shall be ensured. Precautions
shall be taken to minimize absorption of moisture for all consumable welding materials. However
if electrode taken from the oven longer than 4 hours it shall be redried. Redrying shall not more
than twice recommended by manufacturer.
6.6 Electrode brand name shall be to IRPC’s approval.

7. Weld joint preparation and cleaning requirement

In addition to the code and standard mentioned in section 2 , the joint preparation shall be in accordance
with the following requirements.
7.1 Weld joint preparation may be made by machining, grinding or thermal cutting (Oxy-fuel cutting,
plasma arc cutting) ;
The surface shall be smooth. When thermal cutting required, the joint surface shall be ground to
sound metal prior to welding.
7.2 Edge Preparation
- For carbon steel, flame cutting and bevelling is acceptable only if the cut is reasonably smooth
and true and all oxides are removed by grinding from the flame cut surfaces.
- For low alloy steel, flame cutting and bevelling is acceptable only if the cut is reasonable
smooth and true and all oxides are removed by grinding from the flame cut surfaces.
- For stainless steel, mechanical means or plasma cutting shall be used. The groove face shall
be smoothly finished by removing completely all burrs caused by machining, and surface
oxides caused by plasma cutting.
7.3 All surfaces being welded shall be cleaned and free from paint, oil, grease, dirt, rust, loose scale
and other foreign material. The adjacent base metal surfaces shall be cleaned, at least 25 mm.
from the edge of the welding joint.
7.4 Flux, weld spatter and slag shall be removed from each weld layer prior to depositing the
succeeding pass and from the completed weld.
7.5 Peening is only permitted to the extent necessary to clean the weld of pressure retaining parts.

8. Preheating

In addition to the code and standard mentioned in section 2 and certified welding procedure, the preheating
shall be in accordance with the following requirements.
8.1 Temperature shall conform to the applicable procedure specification (WPS)
8.2 Preheating shall be performed so that the surface of the weld part is deposited by 80 MM.. from
the welding point in every direction, at the same or above temperature specified.
8.3 For austenitic stainless steel, Nickel alloys, Nickel base materials , the interpass temperature
shall be limited and control heat input
8.4 Unless otherwise specified different, preheating shall be performed by electric heater for piping.
The preheat temperature shall be checked and recorded. For vessel and tank, preheating shall
be done by electric heater other with specification by IRPC small bare size 2” and lower.
8.5 Carbon steel thickness 25 mm. and above shall be preheating.
8.6 Preheat temperature and temperature between passes in dissimilar welding shall be as follows in
the case of dissimilar welding between carbon steel and low alloy steel, the preheating
temperature and the temperature between passes shall conform to the conditions temperature
between passes shall conform to the conditions on the alloy steel side. Preheat shall not be done
on the austenitic stainless steel side, as a rule.

9. Tack welding

9.1 Tack welding shall be performed by qualified welder.


GFG-002

9.2 When preheating required for welding, tack welding shall be applied also.
9.3 If finger bar allowed for fit up, material shall be at the same condition with its base material.
9.4 Welding electrodes to be used for tack welding shall be the same brand as those to be used for
the actual welding.
No.
Technical Data S10332100-3002 0

Welding Standard Date Page


5 NOV 2010 5 6

10. Welding

10.1 For pressure vessel tank and process piping, weave technical shall be limited at 2 times of
electrode diameter.
10.2 When preheating required for alloy steel, welding shall be continuously performed with no
interruption.
10.3 Backing gas for low and high alloy by nitrogen, stainless steel shall be inert gas or specified by
IRPC.
10.4 Rain, unless approved protection facilities are provided.
10.5 Wind velocity more than 0.5 m/sec. For GTAW, 3m/sec for SMAW, unless approved protection
facilities are provided.

11. Post weld heat treatment (PWHT)

11.1 Post weld heat treatment shall be in accordance with applicable code, standard and certified
procedure.
11.2 Written procedure shall be submitted to IRPC for review prior to commencement.
11.3 Thermocouple pyrometers requirement for piping
- 1 1/2” and 6” one point .
- 8” and 10” two point .
- 12” and 16” three point.
- 18” up Four point.
o o
11.4 Only type K cover rang –180 C t to 1,260 C thermocouple is permitted for PWHT by the
capacitive discharge technical attached to pipes.
11.5 Welding shall not be allowed after post weld heat treatment.
11.6 For piping materials P number 3, 4, by code and P number 5 , 9A, 9B, 10A butt weld and branch
connection shall be PWHT regardless of thickness. NACE requirements and amine service
shall be PWHT regardless of thickness and / or joint configuration.
11.7 PWHT of piping shall be electric heater and temperature recorded.
11.8 PWHT is required test and NDE inspection shall be done after completion of PWHT IRPC
acceptable.

12. Hardness testing

12.1 For the PWHT welded joint, the hardness test shall be performed after its heat treatment.
Acceptable criteria hardness of the base metal and of the weld metal and heat affected zone.
12.2 Maximum acceptable hardness shall exceed the following valves
- P1 200 HB MAX
- P3, P4 225 HB MAX
- P5, P6, P7 235 HB MAX
- P11, P22 235 HB MAX
- NACE REFER STD MR 0175

13. Repair

13.1 Repair welding on material, equipment and piping shall comply with the applicable codes,
standards and project specifications where specified.
13.2 All procedures required for welding repair of base material shall be submitted for IRPC’s
approval prior to the repair commencement.

14. Welder and welding operator qualification


GFG-002

Welder and welding operator qualification shall be performed according to the ASME IX with the exception
of the following.
No.
Technical Data S10332100-3002 0

Welding Standard Date Page


5 NOV 2010 6 6

14.1 The requalification is needed when the welder or welding operator does not work continuously
more than 3 months.
14.2 Final judgment of visual inspection and film evaluation shall be to IRPC inspector’s decision.

15. Quality control of welding work

15.1 Shop and field quality control program shall be prepared and submitted to IRPC.
15.2 Welding activities, supervision and inspection shall be performed by qualified personnel.
15.3 IRPC’s inspector and representative shall have unlimited access to working areas at all time on
easonable basic.
15.4 Contractor shall provide proper facility and equipment for observation and inspection.
15.5 Non destructive testing
15.5.1 NDT shall be performed in according with, but not limited to the ASME V as detailed
below.
- Visual inspection according to article 9
- Magnetic Particle according to article 7
- Dry penetrate test according to article 6
- Radiographic Examination according to article 2
- Ultrasonic testing according to article 5
Acceptance criteria shall be in accordance with relevant codes, standard and
specification. Written procedure shall be submitted to IRPC for approval.

15.5.2 The IRPC’s visual inspection will taken the following into account as minimum.
- No undercut exceeding 0.3 mm.
- Weld reinforcement limited to 3 mm.
- No any misalignment exceeding 3 mm.
- Good workmanship shown.

15.5.3 Dye penetrate test (PT)


- After backgouging of double sides weld. PT shall be done to ensure good sound
metal and developer shall remove before welding commencement.
- For temporary attachment weld and arc strikes, the PT or MT shall be applied after
removal.
- Pressure vessel including its attachment weld shall be 100% PT after finishing.
- The attached weld of storage tank shall be 100% PT.

15.5.4 Magnetic particle test (MT)


- Dry magnetic particle shall not be used on field.

15.5.5 Radiographic testing (RT)


- According to 3200E-306 Rev. 0

15.5.6 Ultrasonic testing (UT)


- UT may be used in lieu of RT subject to IRPC’s approval.
GFG-002

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