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EILJOBNo: 6987
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SPECIFICATION FOR EQUIPMENT EPCC3-X2-SW-008
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SPECIFICATION FOR EQUIPMENT WELDING
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INDEX
1 GENERAL
2 WELDING
3 WELDING PROCESSES AND RESTRICTIONS
4 FILLER METALS
5 CLAD PLATE AND OVERLAY WELDING
6 GENERAL REQUIREMENTS
7 PREHEAT AND INTERPASS TEMPERATURE
8 POSTWELD HEAT TREATMENT
9 POSTWELD HEAT TREATMENT FOR SERVICE
10 REPAIR
11 WELD HARDNESS
12 FERRITE MEASUREMENT
13 INSPECTION AND EXAMINATION
14 SPECIAL REQUIREMENTS FOR ITEM WITH SPECIFIC LICENSOR’S REQUIREMENTS
15 SUPPLEMENTARY WELDING REQUIREMENTS FOR ALLUMINIUM ALLOYS
ANNEX 1
ANNEX 2
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1 GENERAL
11 Scope
This specification establishes the minimum welding requirements for carbon stee!, low alloy
steels, stainless steel, Nickel alloys and non ferrous alloys (brass, Cu Ni ete) used for fabrication
of equipments, including but not limited to pressure vessels, heat exchangers, coolers, towers,
columns, filters, fired heaters, tanks and their attachments, This specification applies when
referenced on the data sheet, project specification, or in the purchase order.
This specification supplements and does not replace the requirements of the applicable codes and
standards. Requirements due to local authority regulations (like, IBR where applicable or as
specified on commodity speciation/drawing or data sheet) shall also be complied with and will
prevail on this specification,
‘This speci
code and
ation covers pressure and non pressure equipments designed according to ASME
shall be applied when so required by data sheets or purchase order.
1.2 Materials
If not otherwise indicated in Material requisition or supply specification, Carbon Stee! material
for Low Temperature (i.e. MDMT colder than -29°C) and low alloy steels shall be supplied by
steel mill with certificate including impact tests at the minimum design temperature specified on
the equipment data shect or at colder temperature. Qualification test by Stockist or Vendor in lieu
of this is not permitted.
Steel plates subject to heat treatment during fabrication (ie. PWHT, PFHT, hot forming ete.)
shall be supplied by steel mill with mechanical and impact test carried out after simulated heat
‘treatments, Simulated heat treatment parameters shall be defined by Equipment Vendor on the
basis of fabrication schedule and shall be submitted to TCM for verification and approval. The
approved simulated heat treatment parameters shall be included in the purchase orders of plates
to steel manufacturers, Parameters for simulated heat treatment shall be agreed between TCM
and equipment Manufacturer considering two additional heat treatment cycles for future weld
repair. Manufacturer shall submit steel mill certificates for review before starting the fabrication
to TCM.
1.3 Reference Standards and Codes
‘The following standards and codes have been references in this specification.
ASME Section II, Part C AWS DL.
ASME Section VIII DIV.1 & 2 ASME Seetion IX
ASME Sec V ASNT TC 1A
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14 Conflicts
Welding and other criteria covered by this specification supplement the requirements of any
codes referenced in the purchase specification. In case of conflict between the requirements of
this specification and such codes or other project specifications, the most stringent apply.
However TCM shalll be consulted and a ruling in writing shall be obtained by the vendor before
start of any work
15. Terms used in this specification mean the following:
Owner/Client is referred to ONGC Peto additions LIMITED (OPaL) or their
representatives (Third Party)
PMC is referred to Engineers India Limited (ELL)
‘TCM is referred to TECNIMONT (TCM) or their representative
Fabricator/Sub contractor is referred to the company entrusted for plant erection,
Examiner is referred to the personnel of the Contractor who is performing quality control
examinations,
Inspector is referred to Owner/Clien/TCM inspector or Statutory Agency inspector (IBR
for example).
2 WELDING
2.1 Weld Map and Weld Deseriptions (Welding Books)
Submit welding books (ie. weld map, weld descriptions, WPS/PQR) for review when so
required by the applicable purchase specification (M.R.) prior to commencement of production
‘welding. The weld map shall indicate each weld joint with a unique identification number/letter
on a simple single-line sketch of an item (refer Annexurc-I), All welds except minor non-
pressure attachments shall be identified. There should be proper correlation between each weld
joint and applicable WPS (Preferably in tabulated form). As an option weld description forms
‘may be used provided the required correlation is maintained (refer Annexure-II).
‘All welding documents shall be collected in an appropriate Welding Book for submission to
‘TCM review. For field-assembled equipment, the vendor shall submit two separate welding
books for shop and field welds. For field ‘welds, detailed technical instructions for handling,
welding, heat treatment, inspection, etc. shall be provided. And also test coupons; welding filler
metals, including surplus shall be included in the scope of supply unless otherwise stated in the
purchase documents.
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For items in IBR scope, any additional requirements for IBR compliance shall be fulfilled in
addition to what is required by eode or by this specification,
At the option of TCM, WPS issued on forms provided by ASME Sec. IX can be considered
substitute for weld descriptions if they indicate all actual (production) data.
Welding can only proceed after welding books have been received and reviewed by TCM.
Each sheet must be complete and show the purchase order number and applicable item number.
Identical items may be included in a single set of forms as long as the data is applicable. Data
will be reviewed by TCM’s material and welding engineer. Clarifications may be discussed over
phone or by email. If welding decuments are returned stamped as "NOT APPROVED" or
“APPROVED WITH COMMENTS”, the equipment Manufacturer shall revise and resubmit
‘such documents for approval.
“The unacceptability ("NOT APPROVED" or “APPROVED WITH COMMENTS”) of welding
book after the 2™ TCM review will require the presence of manufacturer in TCM office for due
clarifications. If so required by TCM and any consequence of extra man-hours shall be back
charged to the vendor.
Accepted Welding Books will be retumed to the vendor stamped as "ACCEPTED" or
“APPROVED WITHOUT COMMENTS”. Copies will also be sent to the assigned TCM’s
inspector for reference. TCM’s inspector may ask to see any of the vendor's original welding,
procedures/documents indicated on the weld description forms.
2.2 — Review and acceptance of vendor's welding documents by TCM does not relieve the
vendor of responsibility for meeting all of the requirements of the applicable eddes, the purchase
order, and this specification,
2.3 TCM’s acceptance of vendor's welding documents shall not be construed as authority for
deviation from the requirements of the applicable codes, the purchase order, or the project
specification.
Deviations may only be guaranteed in response to formal, written requests submitted to TCM.
2.4 — Qualifications
All welding including tack and stud welding shall be performed by qualified welders using
qualified welding procedures. Welders, welding operators and welding procedures shall be
‘qualified in accordance with ASME Section IX.
Previously qualified PQR under BIL, CEIL, Lloyds, DNV, TUV & Bureau Veritas shall also
be acceptable.
New POR shall be released (Wimessed) by official agency appointed for job.
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Copies of the welder and weldi
by TCM’s representative.
operator qualification test records shall be available for review
For items under IBR purview, all the welders shall be qualified by IBR in addition to ASME sec.
IX, (Regulation 602 through 617 for example.)
For thickness greater than $0mm, the PQR shall be conducted on material at least 90 percent of
the maximum production thickness.
Duplex stainless steel could require impact test per code of onstruction (e.g, ASME VIII Div. 1)
on both component and welding procedure qualification. When the impact test is required for
base metal it shall be included also in POR (W.M., H.AZ.).
‘When impact tests are required on material as per code or specification the welds shall also be
qualified for impact test. In such case the following additional requirement shall apply to the
procedure qualification,
+ Qualification tests shall be made on plates of the ASME specification as specified on the
drawing using electrodes of AWS or SFA specification and wire/flux of the specification
and brand as are to be used on the job.
2.5 Tube to Tube sheet welding
2.5.1 For tube-to-tube sheet welding, all joints shall be made by using minimum two weld
passes with each tube welded individually; welding continuously across the tube sheet doing half
of the tube circumference on successive tubes is not permitted, In case of manual welding start
and stops of successive weld passes shall be staggered.
Welding procedure/Welder qualifications shall meet the requirements of BIL, Spec: 6-15-0003
Rev3.
PQR shall be released (Witness) by official agency recognized by TCM (Refer para 2.4).
WELDING PROCESSES AND RESTRICTIONS
3.1, The following welding processes are permitted:
3.1.1. Shielded Metal-Arc Welding (SMAW). Not permitted for the root pass of single
side groove welds (except for carbon steels with E6010 electrode, when so permitted by
strength calculations and with prior written consent).
3.1.2 Gas Tungsten-Are Welding (GTAW).
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3.1.3 Automatic Submerged-Are Welding (SAW-AU).
a) Flux used shall be "neutral" and shall not contribute alloying elements to the weld.
bb) The flux-wire combination used for production welding shall be the same brand name
and type as used for procedure qualification.
¢) Maximum weld deposit per pass shall be 13 mm for carbon stee! (P-1) and 10 mm for
all other materials.
3.14 Flux-Cored Are Welding (FCAW) with an extemal shielding gas is permitted for
‘carbon (P No.1) only when impact testing is not required (ie. not for low temp
‘applications). This process is not permitted for root pass of a single side weld joint
without backing,
3.1.5 Gas Metal-Arc Welding (GMAW) in the short-circuiting mode may be used for
the following applications on earbon and stainless steels only.
) The root pass for any material thickness (subject to TCM’s approval)
b) Complete groove or fillet weld provided the wall thickness of either member does not
exeeed 6 mm.
©) Tack welds, temporary attachments or other applications where the weld meta!
deposited by the GMAW short cirguiting process is completely removed,
3.1.6 Gas Metal-Are Welding (GMAW) in the spray or globular transfer mode shall not
be used.
3.1.7 Plasma-Are Welding with transferred Arc (PTAW) for hard surfacing and.
overlaying.
‘Welding processes other than those listed above require specific approval by TCM and
shall not be assumed as aeceptable by the vendor during bid preparation.
FILLER METALS
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Use filler metal that is similar to the chemistry,
properties of the base metal being welded. The use of "G" classification is not permitted.
All welding and weld overlays shall be done with electrodes, fillers and fluxes of reputed make
with proven reproducibility of results.
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42 _ Filler metals shall conform to ASME Section Il, Part C.
Permission to use filler metals manufactured to other standards must be obtained prior to use.
Submit chemical and mechanical properties with the request for approval.
‘When low temperature design is specified and impact test is required for base material and/or
welding procedure qualifications, filler metal shall have impact test guarantees by relevant AWS.
af the temperature equal fo or colder than the specified design metal temperature.
Filler metals used in IBR item shall meet all the requirements of IBR (Regulation 94 through
98 for example.)
43 For welding carbon steels, the weld deposit should meet classification A-1 analysis of
ASME Section IX, Table QW-442,
For Low Temperature Carbon Steel (with MDMT colder than -29°C) the chemical composition
can execed Ai classifications to improve the toughness requirements; in particular, welding
material with 1 or 2% Ni {ER80 S Ni-I/ER80 SNi-2 / E7018-C3L)} shall be used if not
otherwise accepted by Contractor
Caution: welding materials containing 1-2%Ni (such as requested for LTCS materials) must not
bbe used for NACE, Hydrogen and H2S Services,
For these services electrodes type E 7016-1/E 7018-1 ete. shall be used and welding procedures
shall be agreed in writing with Contractor
‘The following requirements for the F-number (weld material certification as per ASME Section
IX, Table QW-432) shall also be applied.
Uso of filler metal with F No.1 and 2 is permitted only for non-pressure bearing fillet welds.
Use of filler metal with F=3 (clectrodes E6010 and £6011) may be permitted for root pass of
single sided groove welds as well as for fillet welds only (Low temperature applications
excluded) and when the strength calculation be satisfied. (Refer para 3.1.1).
Filler metal with F=4 (E7015, E7016, and £7018) shall be used for welding of out-pass or fillet
‘welds and not for root pass of single sided welds without backing.
‘Low-hydrogen electrodes are required for all shielded metal arc welding of carbon and low alloy
steel (excep) where permitted to use £6010).
C-0.5Mo filler shall not be used for welding CS/LTCS,
‘The table below shows the acceptable consumables to be used for various Austenitic Stainless
Steel base metals. Covered welding electrodes shall be in accordance with the specification
AWS AS.4/ASME IIC SFA-5.4. Welding rods and bare electrades used as filler metal shall be
in accordance with the specification AWS AS.9/ASME IIC SFA-5.9.
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Stainless Steels Electrodes
Type AISI 304 E-308
‘Type AISI 304L E-308L
Type AISI 304H E-308H
‘Type AISI 321 and 347 E-347
Type AISI 316 E-316LorE-318
‘Type AIST 316L, B-316L,
Type AISI 316Ti E-318
44 When joining two different ferritic steels, or when joining ferritic to martensitic steels,
the filler metal shall conform to the nominal chemistry of either base metal, However, for
attaching non-pressure parts to pressure parts, the filler metal chemistry shall match the nominal
chemistry of the pressure part.
4,8 For joining austenitic stainless steel (P. No. 8) to ferritic (P. No. 1 thro’ P, No. 5) or
martensitic steels:
Filler metal type 309/309Mo is permitted provided the design temperature is below 315°C and
no PWHT is required.
Except for the conditions below, for all items involving higher design metal temperature (315°C.
and above) and/or PWHT, ENiCrFe2, ENiC1Fe3, ERNiC13 or ENiCrMo3 filler metal shall be
used for buttering/welding for special application. The ferritic base metal shall be buttered and
heat treated then welded to stainless steel without PWHT. The use of Nickel based filler metal
shall require prior TCM approval for the verification of mechanical strength at the maximum
design temperature. .
Nickel based filler metal cannot be used for the application involving sulphur compounds at
temperature above 280°C. In this case, the manufacturer shall submit ‘the weld design for TCM
approval.
4.6 For joining nickel-based alloy to ferritic or martensitic steels, Nickel based filler metals
like; ENiCrFe-3 (Inconel 182), ERNiCr-3 (Inconel 82), and ENiCrFe-2 (Inco-Weld A) are
permitted,
4.7 Use of filler metal type 310 is restricted for welding of Stainless steel AISI 310 to 310
4.8 For welding Incoloy alloy825 filler metal shall confirm to type ENiCrMo-3/ENiCrMo-10
4.9 Storage and handling of filler metals and fluxes shall be in accordance with the
manufacturer's recommended practice and ASME Seetion Il, Part C.
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4.10 For welding Low alloy steel SA387 Gr.11& 12 (124 Cr-% Mo, I Cr-4 Mo) filler metal
shall confirm to ER80S-B2L/E8016-B21/E8018-B2L.
4.11 For welding carbon steel the submerged are welding wires shall be limited to AWS
classification EL-12 and EM 12K and fluxes shall be limited to F7 (A/P)-(X) unless otherwise
approved by TCM. EH 12K filler metal can be also accepted if the hardness, to be measured in
PQR and in production joints, does not exceed 200 HB (W.M.)-
4.12 IGC test as per ASTM A262 practice E (or practice ‘C’ when calls for on the base
material) shall be carried out for all austenitic SS consumables. The bend test specimen shall be
examined at a magnification of 200 X, and bend specimen shall be free of any eracks or grain
dropping.
5 CLAD PLATE AND OVERLAY WELDING
‘Welding of clad plates and corrosion resistant overlays shall meet the following requirements in
addition to the Code and other contractual requirements,
5.1 For welding of clad plates, at least 19 mm of cladding shall be stripped off from the plate
edges before welding of the base material. Saturated copper sulphate solution shall be used to
ensure the complete removal of the high alloy steel cladding, Welding of the base material shall
be carried out with suitable electrode as required in section 4, Wherever practicable, the root run
shall be laid from the clad side in order to minimize grinding and welding from the clad
‘The welding shall be carried out such that the weld on the clad side is flush with the base plate
surface or down to 0.5 mm from the surface provided that the reduction in base metal thickness
has been taken cafe of in the design calculation as well. Cate shall be taken to avoid any contact,
of ferritic weld metal with the austenitic or high alloy cladding.
Clad restoration, as well as overlay welding shall consist of at least two layers. The selection of
filler metal shall be made from the following table 1 below. Additional requirements (regarding
Chemical composition and Ferrite content) for base metals, if any shall also be applicable,
TABLE-1
CLADDING ‘WELD EILLER METALS ELEMENTS FOR
MATERIALS Barrier Layer Rest O/L welding CHEM, ANALYSIS.
“Austenitic Stainless Steels *
304 309L 308 CChNi
3041, 309MoL 3081, * GcnNi
316 309Mol. 316 ©, Cr, Ni, Mo,
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316L, 309MoL. 316L €, Cr, Ni, Mo,
321,347 309Nb 347 C, Cr, Ni, Cb
+* Entiro welding shall be performed by Inconel (ER NiCrFe2/ENiCrFe3) for joints between pipe
to pipe/fitting in alloy/SS lined construction if other side of the joint is not accessible.
52 A minimum of two samples of the weld metal overlay shall be taken from each overlaid
shell section and each head to confirm required chemical analysis. Each manual weld overlay,
such as those on nozzle and flanges, shall also be sampled. Analysis at depth of 2/3" of the
cladding thickness from top of the finished ovelay thickness shall conform to the chemistry
drawing. If any weld fails chemical analysis, all welds shall be checked. Submit corrective action
proposal to the TCM for review and approval,
53 Unless otherwise specified on the datasheets or project specification, minimum weld
overlay thickness shall be 3 mm, Weld overlay shall consist of at least two layers. For austenitic
stainless steel overlay, use Type 309X filler metal for the first layer. Use matching electrode for
the subsequent layer or layers (refer table 1).
Weld deposition cladding procedure shall be qualified separately in presence of authorised
inspector to yield a weld deposit that exhibits undiluted weld metal composition at a depth of
2/3" of the cladding thickness from top of finished overlay surface. Previously qualified &
approved procedures, not older than 5 years & meeting the requirements shall be acceptable.
5.4 — Weld overlays, both automatic-and manual, shall be 100% liquid penetrant examined
after each layer of deposit, including final layer. This includes the overlay required to cover
‘welds between courses and around nozzles. Weld deposit overlay on machined surface shall be
100% PT examined after machining. Weld deposit overlay shall be spot PT examined (minimum
10% of the surface, including not less than 1 sq.ft/in in each 10 sq.fVin or fraction thereof) after
final PWHT and shop hydrostatic testing. Flange facing need not be included in the spot
examination after hydro test
5.5 Weld overlay shall be relatively smooth with no notches and undereuts that would act as
stress intensifiers. Flaws on the surface of the base metal that would interface with bonding of
the overlay shall be removed by grinding. Cracks, fissures and circular defects greater than
1.6mm diameter shall be completely removed and repaired, and ropaired area shall be subjected
to 100% PT examination. a
5.6 Welding procedure qualifications shall include IGC testing as per para 4.12 and chemical
‘analysis check in accordance with para 5.2.
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Fissuring in the overlay procedure qualification test shall be cause for rejection (they shall
neither exceed four per specimen nor exceed 1.6 mm in length), Cracks in corners shail not be
considered as a part of examination of procedure qualification test.
8.7 CS/Low alloy weldment of $.0. flange and of RF pad shall be pneumatically tested for
Jeak tightness before depositing weld overlay.
5.8 For all weld overlays used in hydrogen or HaS service with design temperature greater
than 350°C, Hydrogen disbonding test shall be carried out. The test condition shall be
representative of the actual design conditions and the procedure shall be submitted to TCM for
approval. Rate of cooling shall be 100°C/hr (min) unless specified otherwise in
datasheets. Holding time shal! be 48 hours unless specified otherwise in datasheets.
GENERAL REQUIREMENTS.
6.1 All shell and head joints shall be double-welded butt joints with full penetration. In case
where double welding is impractical, the root pass shall be made by GTAW.
Double-welded groove joints shall have their root passes back gouged to sound metal on the
reverse side and examined by liquid penetrant before proceeding with welding on that side.
62 Al nozzles shall be setin type, unless otherwise specified in requisition. Set on type
‘nozzle for size 50 NB and below can be used with prior approval of TCM/EIL.
63 All single-welded groove joints of nickel alloy, stainless steel, and ferritic steel
containing more than two percent chromium shail be welded using a gas tungsten-are or a gas
‘metal-are root pass (only as permitted in 3.1.5) with an inert gas back purge. The back purge
shall be maintained for a minimum of two passes.
64 All welding including supports, clips, and structural parts shall be completed prior (o final
heat treatment.
6.5 Permanent weld backing bars other than consumable inserts are niot permitted,
66 Temporary backing bars must match the chemical composition of the base mefal being
welded. After welding is complete, they shall be removed flush with the base metal without
undercutting. All attachment areas shali be examined by magnetic particle or liquid penetrant
methods. :
6.7 Grinding and cleaning of stainless steels and nonferrous material shall be done only with
tools that will not leave detrimental deposits on the base metal; aluminium oxide (for austenitic
stainless steels) or silicon carbide (for non ferrous metals) grinding wheels and austenitic
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stainless steel wire brushes shall be used. These tools shall not have previously been used on
‘ther than the material to be cleaned.
68 — Peening is not permitted. The use of a needle gun for scale removal is not considered as
pening.
6.9 Welding of alloy butt joints should be completed in continuation from start to finish,
6.10 When the impact test is required for base metal, it shall also be included in PQR (HAZ,
weld metal & base material). ‘The filler metal used shall be impact tested at or below the
‘minimum design metal temperature (MDMT) and guaranteed by respective AWS classification.
6.11 All main weld seams shall be clear of nozzles, reinforcement pads, internals, tray
support rings, cleats and stiffening rings by 50 mm minimum (weld edge to weld edge). Incase
the same is unavoidable following requirements shall apply:
) Nozzles without reinforcing pad
i) Any weld seam having distance (weld edge to weld edge) to nozzles within 50
mm (but not fouling with weld seam) shall be fully radiographed and dye
penetrant examined to a length equal to 100 mm on each side measured from
nearest point to nozzle edge.
i) Any weld seam fouling with nozzle opening shall be fully radiographed and dye
penetrant examined to a length equal to 3 times of outside diameter of nozzle i.e.
1.5 times of outside diameter of nozzle on each side after installation of nozzles.
. ‘Nozzle to vessel fillet weld shall be provided with smooth concave radius.”
b) Nozzles with reinforcing pad
i) Any weld seam having distance (weld edge to weld edge) to reinforcing pad
within 50 mm (but not fouling with weld seam) shall be fully radiographed and
dye penetrant examined to a length equal to 100 mm on each side measured from
nearest point to reinforcing pad edge.
if) Any weld seam not fouling with nozzle opening but coming under reinforcement
pad shall be ground flush, fully radiographed and dye penetrant examined to a
Tength equal to portion of weld seam below reinforcement pad + 100 mm on each
side,
iii) Any weld seam fouling with nozzle opening shall be ground flush, fully
radiographed and dye penetrant examined to a length equal to higher of 3 times of
outside diameter of nozzle i.e. 1.5 times of outside diameter of nozzle on each
side or length equal to portion of weld seam below reinforcement pad + 100 mm on
each side,
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In case other attachments like internals, tray support rings, cleats etc. is fouling with weld
seam, the weld seam portion coming under the attachment plus 100 mm length on each side
shall be ground flush, fully radiographed and dye penetrant examined before welding of any
such attachment,
6.12 Longitudinal seams shall be staggered with the circumferential distance between the
centres of welds being at least 5 times the thickness of the thicker-plate, Weld seams shall be
located so as to avoid interference with weld scam of nozzles and external attachments.
6.13 Reinforcing pads whenever required as per drawings or Code shall be of the same material or
equivalent as the heat exchanger component to which it is welded. All reinforcing pads shall be
provided with two 1/8" @ mm) NPT tapped holes located 180 apart for air soap solution test
‘with a pressure of 1,25 ke/cm? (g). This test shall also be requited to be carried out for slip on
flanges. Higher test pressures are not recommended because of accompanying risks and also
because the soap bubbles have a chance to blow off. Tell-tale holes in the reinforcing pads
shall be plugged with hard grease unless otherwise indicated after the hydro test of the
exchanger.
7 PREHEAT AND INTERPASS TEMPERATURE
‘The minimum preheat shall not be less than that suggested by the applicable code (i.e. ASME
Section VIII Division 1, Appendix R, or ASME Section Vill Division 2, Table 6.7. and in no
cease less than 15°C.
Electrical resistance coils should be used for preheating/post heating of alloy steel welding.
‘The maximum interpass temperature shall be stated in the WPS.
‘The maximum interpass temperature for austenitic stainless steel shall be 100°C.
‘The preheating required for welding shall be applied also for thermal cutting are-air gouging.
For PI material (welds in heavy thickness over 50mm) and for P4, PS materials (all thickness), if
PWHT is not carried out immediately after welding, the weld joint and adjacent portion of the
joint at least SOmm on either side of weld shall be uniformly heated to 300 °C (unless @ high
‘temp ISR is specifically requested otherwise). This temperature shall be maintained for duration
‘of 1 hour/inch (30 minutes minimum) and cooled under insulation. Post heating shall also be
necessary for highly restrained joints or where heavy welding is carried out in a localised area
(eg. self reinforced nozzle welds)
8 POSTWELD HEAT TREATMENT
8.1 In addition to the requirements of the applicable code, the final post weld heat treatment
shall meet the following prescriptions:
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A continuous recording chart of the temperature indicated by all thermocouples shall be made
available to inspector. A copy of these chars shall be included in the fabrication and test records
furnished to TCM.
‘Vessels shall be post weld heat treated as a complete unit including skir/support, wherever
practicable.
82 If the vendor plans to use a local post weld heat treatment, a detailed description of the
local heat treatment procedure must be submitted to ‘TCM for review and acceptance prior to use.
Attach at least two thermocouples each to the outside and inside surfaces of the equipment
(number and location of thermocouples shall be indicated in PWHT procedue).
PWIHICT by internal firing method is not accepted,
Production welding test plates, when required, shall be heat treated in fumace together with the
vessel (extra PIC shall be preserved to take care of eventuality of retests).
For carbon steel in low temperature service, the PQR shall include all the heat treatment cycles
provided for production joints (the sum of holding time in one cycle is not permitted),
8.3 The lower post weld heat treatment temperatures permitted by ASME Section VIII, Table
UCS-56 or Table 6.16 by increasing holding time are not acceptable. Exception shall require
previous approval by TCM.
8.4. Flame impingement on parts being heat-treated is prohibited.
85 The temperature of post weld heat treatment of normalised and tempered or quenched
and tempered materials shall be kept at least 28°C below the tempering temperature indicated on
material certificates,
8.6 Localised post weld heat treatment may be accomplished by electric resistance or
induetion heating subject to the following restriction:
) A full circumferential band must be heated to the required temperature
b) Thermal gradients at the extremities of the heater band shall not exceed 80°C per 300mm
‘¢) Heater band shall extend five times the wall thickness on each side of the joint.
8.7 Forall fenitic steels with mechanical properties enhanced by heat treatment vendor shall
prove by actual mechanical test results that the cumulative effect of all intermediate and final
heat treatment during fabrication does not alter the mechanical properties of the material to
values that do not comply with specified requirements. This requirement applied to both parent
material and welds.
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‘SPECIFICATION FOR EQUIPMENT
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8.8 Whenever heat treatment on stainless steel is carried out, it shall be followed by micro
ctching test and IGC test as per ASTM A 262 practice E (on weld and HAZ) unless specified
otherwise to ascertain suitability and effectiveness of solution annealing,
8.9 The following precautions shall be observed during heat treatment of clad vessels
i) The clad material should not be exposed to a direct flame if gas or oil is used as a fuel.
ii) Stainless steel clad sicels require a neutral or oxidising atmosphere during heating.
‘Maximum sulphur content in the fuel should not exceed 0.5%,
iv) Marking paint and protective oil should be removed from the clad side before heating.
9 POSTWELD HEAT TREATMENT FOR SERVICE
9.1 Vessels in Amine, HIC, Hydrogen service and eyclic services shall be stress relieved.
9.2 When the vessel data sheet specifies post weld heat treatment for service conditions,
welding, hammering, or deformation are not permitted after post weld heat treatment, All
internal and extemal attachments, clips, insulation studs, nameplate bracket, and the Tike must be
‘welded to the unit before post weld heat treatment.
9.3 Onalll vessels post weld heat treated for service, paint on two sides of the shell in letters
at least 25 mm high, “POSTWELD HEAT TREATED FOR SERVICE. DO NOT WELD,
HAMMER, OR DEFORM”. The paint used must be compatible with both the primer and the
finish paint.
10 REPAIR 7 i
10.1 Minor defects
Repair of surface defects in welds by chipping, grinding and gouging is permitted provided the
thickness is not reduced below the minimum required. Removal of defects shall be verified by
magnetic particle or liquid penetrant examination. Only qualified welders using a qualified
welding procedure shall do repair welding of minor defects, as defined in Paragraph 10.3,
102 Major Defects
Major defects in welds and base metals, as defined in Paragraph 10.3, shall be repaired after a
written procedure for each individual repair has been prepared.
‘The written procedure shall include a sketch detailing extent and location of the defect, how
defects will be removed, how removal will be verified, qualified welding procedure to be used,
subsequent heat treatment and non-destructive examination. This written repair procedure will bé “-
included in the data package furnished with the equipment. *
‘Two repair attempts will be allowed on any one defective area, Additional repair attempts
require the written approval of TCM,
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‘SPECIFICATION FOR EQUIPMENT
EILJOBNo: 6987
EI /OWNER'D, CODE
EPCCS-K7-SW-008
WELDING CONTRACTOR JHENTIICATION. COO
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10.3 The following are the definitions of major and minor defects:
BASE METAL
MAJOR DEFECTS
Crack
Repair cavity greater than 6450
square mm (10 square inches)
Repair cavity deeper than
50 percent of thickness or 13 mm,
(A inch), whichever is less
Weld build-up to correct
manufacturing error *
Edge defects greater than 25 mm.
(Linch) deep or thickness of base
metal, Whichever is less
Edge defects greater than
20 percent of edge length
WELD METAL
Crack, except erater cracks
‘Repair cavity greater tha6450
‘square mm (10 square inches)
Repair eavity deeper than
50 percent of thickness or 13 mm.
(A inch), whichever is less
Lack of fusion and/or
penetration
* All weld build-up or buttering shall be 100 percent examined by RY of UT.
MINOR DEFECTS
Repair cavities or edge
defeets smaller than
above, excluding cracks
11 WELD HARDNESS
Weld hardness of producti
specification or Material Requ
‘The welding procedure qualification tests shall include hardness for qu
Porosity or Slag inclusions.
Undercut
Crater eracks
carbon steel Mn-Mo steel and Cr-Mo steel regardless of purchase specification.
Joints shall be performed when required by commodity
iched and tempered
11.1 Bach surface cut with oxy-fuel or Arc-Air, and left unwelded on the finished part, shall
algo be checked for hardness. All areas where temporary welds were made and.removed shall
also be checked for hardness.
Hardness shall be measured on both inside and outside after final PWHT for each vessel as
below.
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> Each longitudinal weld and HAZ (at centre of each shell section and fabricated nozzle)
> Each circumferential weld and HAZ shall be checked at four locations approximately 90°
apart, both internally and externally.
> Oneach T joint and HAZ
> On vessel to support joint (two locations)
> Each nozzle weld shall be checked at two locations, 180° apart, both internally and
extemally,
11.2 The hardness in base metals, weld and heat affected zone (HAZ) as per ASTM E10 shall
not exceed the maximum hardness values obtained on welding procedure. Hardness limits on
various materials are as indicated below:
Material Group Brinell hardness (Maximum)
PAL 200
P3, Pa 225
PS 235
In case of hardness as obtained on production test is more than the limit specified as above,
vendor shall submit the corrective procedure to lower the hardness in writing to TCM for
review/approval.
11.3 Nonferrous materials and austenitic stainless steel welds are exempted from hardness
testing unless otherwise specifically required by other specifications.
However in ease cold forming, hardness value after cold forming for austenitic steels shall not
exceed 235BHN. ‘
11.4 Procedure qualification: For each welding procedure qualification six test shall be made,
three in wold metal and three in HAZ. Hardness requirements shall be as sated in para 11.2.
In addition to the requirement of above, Viekers micro hardness test shall be made on a full
cross-section at 25mm intervals beginning at 3mm from the top surface with Skg load. Test shall
’be made at each level for each of the following locations as per ASTM E92.
Three tests shall be made in the weld metal, two tests in HAZ and one test in the base metal in
accordance with fig 1 and the hardness shall not exceed the following in base metal, weld and
HAZ.
Material Group ‘Vickers hardness (Maximum)
Pl 210
P-3,P4 237
PS 247
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SPECIFICATION FOR EQUIPMENT EPCC3-XZ-SW-008
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1G. NARONESS REQUIEMENT ON TEST COUPONS
11.5 For equipment fabricated from SA-537 Class 2 steel, conduct hardness tests as required
in 11.1, above, The maximum acceptable Brinell hardness is 225.
In addition, microhardness traverses shall be made on an etched cross section taken from the
welding procedure qualification test coupon. The base metal and weld filler metal shall be
equivalent to that which will be used in production, but not necessarily the same heat or lot,
12 FERRITE MEASUREMENT
12.1 Check the ferrite content of every austenitic stainless steel weld, including overlay welds,
in the as-welded condition using a Sevem gauge or a Feritoseope. The ferrite shall be between
FN 3- 10. The specified ferrite content shall be checked also in PQR.
‘Type 310 welds are exempted from this requirement
13 INSPECTION AND EXAMINATION
13.1 Personnel Qualification
‘NDE personnel shall be qualified to the requirements of the applicable code. As a minimum, the
qualification should be to the requirements of SNT-TC-1A. An up-to-date record shall be
‘maintained for each person who performs and/or interprets NDE work, The subject record
containing test results and applicable documents shall be made available to the TCM inspector
on request.
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13.2 Magnetie Particle Testing (MT)
‘Only A.C. yoke shall be used for MT after PWHTT. Permanent magnet or D.C, yokes shall not be
used.
MT examination and evaluation shall be in accordance with the ASME Code, Section-VITL
division 1, Appendix6 or Section-VIII division 2, para 7.5.6.
13.3 Liquid Penetrant Testing PT)
Penetrant, Cleaner and Developer solutions shall not have a combined residual sulphur and
halogen content more than 1%, ‘The penetrant and the developer must be from the same
‘manufacturer and the same generic type.
PT examination and evaluation shall be in accordance with the ASME Code Section-VIII,
division 1, Appendix 8 or Section-VIM division 2, para 7.5.7.
13.4 Radiographic Testing (RT)
Radiographic examination and evaluation shall meet the following requirements in addition to
those specified in code and the data-sheet.
13.4.1 RT examination and evaluation shall be in accordance with the ASME Code,
Section-VIII division 1, para UW 51 or UW 52 or Scction-VIII division 2, para 7.5.3,
Acceptable Class I films: Kodak M; Dupont NDT 45; Agfa Gevaert D2(se), D4;
Fuji 50.
Acceptable Class II films: Kodak AA; Dupont NDT 70; Fuji 100, Agfa Gevaert D4
Only lead screens shall be used.
13.4.2 The specified radiography of welds may be performed before or after PWHT. If
performed before PWHT, an additional radiography or altematively, ultrasonic
examination BY TOFD shall be performed after PWHT,
3 All nozzle fabricated from plate, irrespective of thickness of plate, shall be 100%
radiographed, Also weld seams of formed end shall be 100% radiographed after forming.
and heat treatment, if any.
13.5 _ Ultrasonic Testing (UT)
13.5.1 UT examination and evaluation shall be in accordance with the ASME Code,
Section VIII div] Appendix 12 or Section-VIII division 2, para 7.5.4 and 7.5.5.
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13.6 Minimum Inspeetion requirements
Examination of welds shall conform to procedures and acceptance standards required by the
applicable code and project specifications.
13.6.1 In addition to the requirements of applicable code and project specification the
following shall be complied with:
> All welds shall be visually inspected after completion.
> Welds joining nozzles shall be MT/PT examined: the root pass, the back gouged area
>
>
and the weld cover passes shall be included in the examination.
All welding edges shall be checked by MT/PT for detection of cracks, laminations or
segregation.
Additionally UT shall be carried out within five times the material thickness of edge
for low alloy stecls or when the service is low temp/hydrogen/HIC with acceptance
criteria as per ASTM AS78 level B.
All non-destructive examination shall be performed after post weld heat treatment,
unless otherwise approved by TCM.
Ferrite measurements of stainless steel weld overlays shall be made before PWHT (if
any).
Extemnal/Internal surfaces of all welds shall be checked by MT after hydro test on low
LAS vessels having 50mm and greater in thickness,
Al welded joints including nozzle to shell/head of all thickness shall be ultrasonically
tested in LAS vessels after PWHT.
‘Equipment containing hazardous fluids such as Teal, LPG, Carbon Monoxide and
flammable fluids could require extended radiography of welded joints when so
specified on drawings and/or project specifications.
> Alll pressure containing equipment designed with 100% radiography shall have all
nozzles and reinforcing pad attachment welds examined by MT or PT, Inspection
shall be performed on all accessible weld surfaces (inside and outside).
> Full radiography when specified shall imply 100% radiography of all butt welds
including nozzle flange to nozzle neck, pipe to pipe and pipe to fitting.
> All nozzle to shell welds and unhubbed tube sheet to shell welds shall be MT or PT.
checked at root and final weld.
vvvyvy
13,7 Production weld Test Coupon
Production Weld test coupon shall be carried out in accordance with stringent requirement of
ASME and EIL Specification para 4.4 of 6-12-0002, para 7.0 of 6-12-003, para 4.3.9.10 of 6-15-
0001 as applicable.
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13.8 PMI Testing
Vendor shall ensure that all Low alloy steel, Stainless steel components, welds, overlay and
cladding are properly identified and finally checked by P.M.Lanalyser (Positive Material
dentification) before dispatch when required by data sheet or project specification and shall be
carried out in accordance with BIL Specification 6-81-00.
14 SPECIAL REQUIREMENTS FOR ITEM WITH SPECIFIC LICENSOR’S
REQUIREMENTS,
14.1 GRINDING OF WELDS
‘The specific requirements for individual welds are given’ in the MDS/MRJSS. The following
definitions apply:
a) GROUND FLUSH AND SMOOTH: Weld seams ground flush with parent plate, No grooves
12 marks to be evident after completion of the operation,
‘GROUND FLUGH 2 SMOOTH
‘Note: This diagram is illustrative only. The principle is applicable to pressure vessel butt joints,
including joints clad in steel, which are to be ground flush & smooth. -
b) GROUND SMOOTH: Weld seams to be ground'to a smooth contour. Weld
eliminated so that there is no evidence of pits or crevices.
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EIL/OWNERIO. CODE
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‘Note: Typical as laid weld bead. For “Ground smooth” requirement. Ripple marks to be removed
by grinding, A smooth contour is to be maintained thus.
) AS-LALD: No grinding necessary except that excessive local penetration or reinforcement of
more than 3 mm is to be removed. The Design Code limit for reinforcement is to be
applied if this is less than 3 mm, All slag is to be removed.
18 SUPPLEMENTARY WELDING REQUIREMENTS FOR ALLUMINIUM
ALLOYS,
All welds shall be made with GTAW process with addition of filler metal, or the GMAW
process (thoriated tungsten electrode cannot be used).
Welded joint shall be made by completing each weld Iyer, before succeeding layers are
deposited,
‘The gas metal are welding shall employ starting tabs in all groove welding.
For all processes, the welding procedure shall contain a detailed cleaning procedure, indicating,
joint preparation prior to welding.
Filler metal for similar and dissimilar base metal combinations shall be per the table 1 of SFA-
5.10 of ASME BPY Sec IIC. TCM approval is required for alternate consumables.
Weld bead shall be contoured to permit complete fusion at the sides of the bevel and to minimise
inclusions. Oxidation shall be completely removed from weld beads and from the surface of
completed welds and adjofting base material. The oxide removal shall be done in a manner that.
will not contaminate or overheat the weld or adjoining taterial.
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1D Material of courses only (cg. ASL Gr.70 clad 321 fora cladded vessel)
2) Only for= describe the materials (e..all forgings and plates over 30 mm)
3)M.DM.T= Minimum Design Metal Temperatore
4) It must be indicated ifthe ltem is designed for a special service (0.9. hydrogen service, H2S
servic, tc)
{The sketch shall show the weld number, the shell inside diameter, the shell thickness (the range
{or shel! with different thickness) andthe heads thickness If different from shell
[Re Description = — | Prepared
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