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Welding Inspection Ass 1
Welding Inspection Ass 1
COURSE INFO
Maklumat Kursus
Course Code
11-01/01/OGSP/2020/9
Kod Kursus
Venue
NIOSH PEJABAT WILAYAH SELATAN (SRO JBU)
Tempat
Course Date
Tarikh 23/1/2020
Kursus
APPLICANT INFORMATION
Maklumat Pemohon
Name
Nama
MyKad/Pass
port No.
No KP / No
Paspot
Nationality
Warganegar
a
D.O.B
Tarikh Lahir (Example For D.O.B : 10/11/1993)
Age
Umur
Gender
Jantina Male Female
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Jenis Darah
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Alergik
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Address
Alamat Surat
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Poskod
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Bandar
State
Negeri
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Position
Jawatan
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No Tel -
H/Phone
No Tel -
Bimbit
Holdername
Nama
pemegang
kad
Email
Emel
Immediate
Family
Member
Nama Waris
Relation
Hubungan
waris
Emergency
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No -
kecemasan
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Tajaan Self-Sponsored Company-Sponsored
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Nama
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Pegawai
untuk
dihubungi
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No tel -
pegawai
Fax No.
No Faks -
PAYMENT INFORMATION
Maklumat Bayaran
Course Fee
Yuran 265
RM
Kursus
Payment
Method
Kaedah
bayaran
ASME B16.20 Metallic Gaskets for Pipe Flanges-Ring Joint, Spiral Wounds and
Jacketed
ASME B16.21 Nonmetallic Flat Gaskets for Pipe Flanges
ASME B18.2.1 Square and Hex Bolts and Screws (Inch Series)
ASME Section IX Qualification Standard for Welding and Brazing Procedures, Welders,
This Method statement describes in detail the welding process for pipe work and the
Contents
2.0 Index
This document outlines the method for executing welding process for pipe work and
welding procedure qualification test for welders. This method statement covers all
piping welding works for Burj Dubai Tower Project either shop fabricated or site
installed.
The procedure provides guidance for assessing the activities for jointing mechanical
piping system. This guidance is based on the requirements set forth in the Safety
1.1 Objectives
This document provides guidance in implementing an effective program for all pipe
welding works. This includes addressing programs for the following: (1) implementing
commitments regarding the quality of the weld joints; (2) managing and providing
oversight to ensure installation and related quality control have been adequately
supervision and control to assure qualification of welders; and (4) recording installation
and test activities.
This and other procedures will be used, as needed, to provide assurance that construction
accomplished during any one inspection and/or every time the inspection procedure is
used. It is a continuing activity until all piping networks are installed and tested.
responsibilities for the pipe welding works is familiar with this method statement and is
The engineer should satisfy procedures provided by QA/QC inspections to ensure the
pipe welding works meet specified engineering requirements and drawings. As part of
acceptance criteria for determining the prescribed activities have been accomplished
satisfactorily.
The QC inspection personnel, in coordination with Site Supervisor, should verify that
the quality of the pipe welding works and related testing activities are within the project
The Supervisor should verify that the pipe welding works is accomplished in
The Supervisor should verify any as-built record of pipe welding works and testing, and
Pipe welding works need to follow strictly established codes and safety procedures.
Care should be taken to ensure that applicable codes and standards be strictly adhered to
at such a given time and in coordination with the construction progress, QA/QC
inspection and testing requirements. The Engineers should use judgment in determining
sample selection focusing on examination of the most important aspects of the particular
welding activity being inspected. The intent is to establish a high level of assurance that
Review the implementing procedures and safety standards for the pipe welding works
provided by the QA/QC. The QA/QC inspectors should verify that the procedures (1)
are approved, and (2) specify the requirements of the design and/or from the
The Supervisor should verify that the personnel have sufficient knowledge of the
procedure requirements. The Supervisor should review any training and qualification
3records for those individuals who shall do the task to determine whether they are skilled
enough to follow the procedure before the actual work is carried out.
2.0 Index
• General
• Welding Process
• Base Metals
• Filler Metals
• Temperature Requirements
• Type of Gas
• Electrical Characteristics
3.1 General
• Check all pipes and fittings to be used for joint are free from
• Remove foreign matter or dirt from inside of the pipe and fittings
Manufacturer’s instructions.
3.2 Pipe Joint Preparation
pipe fitting later. Works shall be carried out in accordance with the
squareness and straightness, after being cut to the correct angle and
shown below.
• Lay the two (2) pipes on top of the pipe stand or adjustable support,
with each pipe ends aligned near each other using adjustable bolt
7• Remove the adjustable bolt stoppers after fit up and grind flush all
• Place the spirit level over both pipes as shown on Figure 2 and
maneuver until both pipes are leveled. Adjusting the pipe support
• Place the 45° elbow to the end of the pipe leaving a small welding
• Place a 45° spirit level on the face of the elbow until bubble is
• Place the 90° elbow to end of the pipe leaving a small welding
gap the same as item 4.3.3 for Pipe to Pipe Fit up.
• Place a spirit level on the face of the elbow and maneuver the
Pipe supports.
welding gap the same as item 4.3.3 for Pipe to Pipe fit up.
• Place a spirit level on the face of the tee and maneuver the
surfaces.
welding gap the same as item 4.3.3 for Pipe to Pipe fit-up (In
5mm depth from the flange face to give enough space for a
fillet weld.
• Align the top two (2) holes of the flange with the spirit level.
A. Boom truck
H. Spirit level
I. Alignment Tools (Plumb Bob, Chalk line, Nylon String Line, Felt Tip Marker)
K. Hand tools
O. Welding Machines
5.1 Preparation
- Ensure all workers involved in the hauling operation put on PPE all times.
- The lorry transporting the pipes will be guided to the designated hoisting
area and released all the latching belts only after the lorry parked firmly.
- Ensure proper lifting method - with the correct equipments are used.
- Ensure the pipes are firmly placed on the designated location before
- Brief individual worker the roles and responsibilities before start work.
- Ensure the pipe lengths to suit site routes into designated work area.
- Ensure all tools to be used have been inspected and tag by Safety Dept.
personnel only.
- Ensure that welders are qualified, with the correct PPEs, and well versed on the
5.4 Housekeeping
- Pick up and dispose wastes & other debris prior to leaving site area.
- Remove safety yellow tape or other warning devices that were used to
- Store tools, equipment and unused materials properly at the end of the
workday.
areas under their control in pipe welding works. This inspection shall
appropriately installed and/or use, and if the job site is cleaned up after the
day’s work.
…………….
Observations :
Signature
Name
Date
15
When should I use 308L, 309L or 316L filler metal?
308L (including ER308LSi) is predominately used on austenitic stainless steels, such as types 301, 302, 304, 305 and cast
alloys CF-8 and CF-3. For high temperature applications such as in the electrical power industry, the high carbon 308H
electrode provides better creep resistance than does 308L.
316L (including ER316LSi) filler metal should be used with 316L and 316 base metals. CF-8M and CF-3M are the cast
equivalents of 316 and 316L, respectively.
Use 309L (including ER309LSi) when joining mild steel or low alloy steel to stainless steels, for joining dissimilar stainless
steels such as 409 to itself or to 304L stainless, as well as for joining 309 base metal. CG-12 is the cast equivalent of 309.
Some 308L applications may be substituted with 309L filler metal, but 316L or 316 applications generally require molybdenum
and 309L contains no molybdenum.
Type 347 stainless steel filler metal is ideal for 347 and 321 base materials because it matches these stabilized grades. CF-8C
is the cast equivalent of 347. Type 347 filler metal is also suitable most 308L filler metal applications.
Piping Fabrication and Erection Specification
This specification covers the minimum basic requirements for various aspects of the
above ground piping and in trench piping for the industrial plants as follow:
b) Installation of in-line instrument items like orifice flanges, control valves, rota
meters, safety valves, etc.
c) Installation of items like line mounted filters, ejectors sample cooler, etc.
1.1. Where this specification and the petroleum refinery piping code ASME B31.3
conflict, this standard shall govern. Sound engineering practice shall be followed in the
absence of specified standards or specification subject to OWNER prior approval.
1.2. CODES AND STANDARDS - Piping Fabrication and Erection
A. Piping Material
I. Piping Design
K. Painting Specification
2. DEFINITION
All piping will be fabricated by a field construction crew either in a pipespool fabrication
shop hereinafter referred to as the "shop” (as per ------) or in-place hereinafter called
the "field".
All pipespools to be constructed by the fabricator are listed in the Pipespool Index. Each index
is in numerical order for each field assembly area. The shop shall fabricate the pipespools in
the order they are listed in the index, unless a list giving some other priority is provided by
Consultant.
The index will show for each pipespool the pipespool number, quantity of
identical pipespools, revision mark, line number, material class, and special
information or treatment. The assembly area, revision date, and material are given at
the top of each sheet. Included with each index for each area is a Pipespool Index
Revision page. This page is a record of all revisions to the pipespool index. The shop
shall fill out and keep current the information columns on the pipespool indexes, and
provide copies to Consultant when requested or completed.
3. DRAWING APPLICATION
3.1. PIPESPOOL INDEX
All pipelines are identified with the line classification on the plan and isometric
drawing.
Where field installed material connects to shop fabricated pipespools, the shop
fabricated spool will include all branch connections for field piping, up to the first field
butt weld, first field socket weld, first screwed connection, or first flanged joint
including the first flange. Pipespools in all sizes of butt welded and socket welded
construction will be prefabricated in the shop. Threaded piping and threaded
components which are installed as attachments to shop fabricated pipespools shall be
termed field installed materials. Straight runs of piping indicated as random piping are
not pipespools. These straight runs are installed by the field crews in random
lengths. The division between the three different types is shown on the drawings as
indicated in figure.
Here, "S" means shop fabricated, "F" means field-installed material and "R" stands for
field-installed random lengths. "FW" is a weld done in the field.
Consultant will provide the isometric drawings for all 1-1/2 inch and larger for stainless steel
and 2 inch and larger for carbon steel. The isometric drawing will show also combined line
number, equipment nozzles to which the pipeline is connected, call outs and high point vents
and low point drains. A bill of material take off for the isometric shall be attached. The bill shall
include the code, size, quantity and description for each piping component.
3.4. SYMBOLS
Drawing symbols used on the piping drawings are defined on legend. The
following definitions specify what is required when certain letter symbols are used
on the drawings.
"FW" A field weld is the joining of two components, beveled for welding, made to drawing
dimensions, and to be welded at the construction site.
"FU" A fit-up weld is a field weld that allows some dimensional adjustment of a
pipe spool during final assembly. One of the mating ends is square-cut 3 inches longer than
the dimensions required. The other mating end is bevel-cut to the exact dimension indicated
on the drawings.
The Construction contractor shall locate on the piping erection drawings, field welds or fit-up
welds as required for site erection, except no location will be shown for socket weld
connections between pipe spools built in the shop and those built at the construction site.
3.6. DIMENSIONS
Unless otherwise specify all dimensions terminating at a flange are measured from the
gasket face for raised-face flanges and flat-face flanges, and the raised face of
ring-joint flanges. Gaskets are indicated by a short line placed beside or between the
dimension limit lines. Only gaskets which have a different thickness than the material
class gasket are dimensioned.
4. FABRICATION
Fabrication works shall comply with the drawings and this specification including
relevant Engineering and Construction Specifications.
4.1.1. All weld numbers and welder’s identification number shall be painted close to
the weld, to enable trace ability of each weld and each welder, socket welds shall be
numbered per fitting, e.g. S.W tee has one weld number.
4.1.2. Construction Contractor shall maintain the color coding on piping materials to
allow easy and quick reference in accordance with the project engineering
specification.
4.1.3. All materials included in the finished piping systems shall be undamaged.
4.1.4. Construction Contractor must provide adequate protection for piping, flange
faces, threaded connections, etc. to prevent damage during handling and storage.
Construction Contractor shall ensure that flange faces are protected from corrosion or
rust.
4.1.5. Piping shall be stored in a relatively clean, dry or well drained area on elevated
dunnage and protected against contact with salts or salty water.
4.1.6. All attachments to piping, i.e. saddles, pads, etc. are to be made of same
material to the pipe.
TOLERANCE
A. Wrought bends shall show no significant marks or corrugations and shall be smooth and
regular in outline. Flattening shall not exceed 8% of the pipe outside diameter for pressure
duties, or 3% of the pipe outside diameter for vacuum duties. There shall be no significant
thinning when the pipe bend radius is 5 x nominal diameter or greater.
B. In general thickness stainless steel pipe of equivalent to schedule 10S and thinner shall
not be bent.
Pipe Dimensions
Tolerances shall be ±1.5mm from flange face to flange face, or centerline of pipe to flange
face.
Flange faces shall not be concave. Convexity from flange bore to joint face periphery
shall not exceed 0.15mm per centimeter width of joint face.
Flanges shall be square to the axis of the pipe to within an angle of 0° - 18' (0.3°) I.E. 0.05mm
per centimeter measured across the face of the flange, with the pipe adequately supported.
Flange bolt holes shall straddle the established centerlines (Horizontal or vertical). However,
flanged connections on equipment may vary and should be individually checked. When these
connections differ, the bolt hole orientation shall be indicated on the isometric piping detail
sheet. Holes in double flanged pipes shall be correctly aligned.
The term "Butt-Weld" refers to circumferential butt joints only. Special requirements
may be imposed where longitudinal welds are to be made and these welds shall not
be carried out before Consultant has approved the methods to be used. Longitudinal
and spiral welds existing in pipes as produced at the mill are outside the scope of this
specification.
Preparation standard shall be applied to ASME B31.3 and the modifications to the standard contained within
clause 5.3.6 of this specification.
Root Gaps
Spacers shall be used while tack welding pipe and fittings in position to insure proper gap and full penetration in
welding. The tack welds complying with the requirements of ASME B31.3, 328.5.1(C) may be allowed to become
a part of the finished weld, whereas those not complying are not acceptable and must be chipped out before
completing the weld.
Bore matching and alignment shall be in accordance with ASME B31.3. Where pipe,
fittings and flanges are to be joined by circumferential butt-welds, the corresponding
parts shall be modeled and matched so that any misalignment at the inside of the
piping shall not exceed 1/16 inch at any point of the circumference of the joint.
Fit-up work may include pressing, hammering, local heating or grinding as required to reduce
any misalignment due to diameter tolerances, out-of-roundness or unequal wall thickness of
the parts of less than 1/16 inch. parts having unequal wall thickness and bores shall be
prepared in accordance with one of the details shown in ASME B31.3.
4.3.5. Cutting
Cutting method involving heating e.g. Flame or arc cutting for carbon steel are allowed providing the cut edge is
machined or ground back sufficiently far to give specified parent material properties at the cut edge with a
minimum of 1.5 mm.
Plasma-jet cutting may be use to cut austenitic stainless steel pipes and other materials.
Longitudinal seams in seam welded pipe shall be located so as to clear openings and external
attachments possible. Longitudinal seams in adjoining courses shall be preperably at
180°but a minimum between seams are in accordance with construction specification.
Branch connections shall be located as indicated on the piping detail sheet or isometric
piping drawings. All branch connections shall be designed in accordance with Para.
304.3 of ASME B31.3. Forged or extruded branch connections are preferred.
4.4.1. No Fitting
4.4.2. Forged branch attachments (Brancholets) shall be of the type specified on Consultant's
drawings and fitted accurately to the contours of the run pipe.
Reinforcing Pads
Reinforcing pads required by the referenced code or by piping detail sheets shall be provided
with at least one vent hole if fully welded. The hole shall be drilled and tapped with a 1/8 inch
pipe thread for testing and venting. The tapped hole shall be plugged using wood, plastic or
mastic material not capable of retaining pressure.
Reinforcing pads for structural attachment shall be provided with an untapped hole of 1/4 inch
(6 mm) diameter for venting.
C. Where reinforcing pads are fitted either for branches or structural attachments they shall
be accurately shaped so that no gap larger than 1/8 inch (3.0mm), measured before welding,
shall exist between the periphery of the pad and the pipe to which it fits.
Mitered bends shall be in accordance with piping material specification ------. The number of
cuts shall be as stated on the drawing. Mitered bends are used only when specified on the
drawings and shall be in accordance with ASME B31.3 Chapter V. A joint efficiency not
exceeding 70% shall be used in the strength calculations for mitered bends. The welds in
mitered bends shall penetrate the full thickness of the pipe and the bead on the inside of the
throat shall be smooth and have an even curvature. In order to prevent a notch effect.
4.4.5. Beveled Ends
4.5.1. Bends shall conform dimensionally to the drawings and relevant clauses of this
specification. Hot bend is not permitted.
A. Cold bends to a centerline radius greater than five (5) times the nominal pipe diameter may
be manufactured without a subsequent heat treatment unless a heat treatment is specified on
the project specification, piping detail sheets, or isometric drawings.
B. Cold bends to a radius less than five (5) times the nominal pipe diameter is not allowed.
Basic welding requirements are to be in accordance with ASME B31.3. Welders shall
be approved in accordance with the relevant clauses of this standard.
5.1.3. Backing rings shall not be used without prior written content and approval
of Consultant.
5.1.4. Where tack welding is carried out, tacks shall be as large as possible and to the
satisfaction of the Consultant inspection. Tack welds shall be removed so that they do not
form part of the finished weld unless they are produced fully qualified and tested welders to
the same procedure as the finished weld, in which case they may be absorbed into the finished
weld.
5.1.5. Flange faces shall be kept free from weld spatter and arc strike.
Welding procedures are to be qualified in accordance with the ASME boiler and
pressure vessel code section IX and ASME B31.3, and shall be approved by
Consultant before any work is carried out.
5.2.3. It is fabricator's responsibility to reference each weld to its welder and correct
procedure.
5.2.4. Electrodes and filler wires shall conform to the requirements specified in para.
7.1.
5.2.6. Fusion faces may be prepared by sawing, chipping, machining or grinding. They
shall be smooth and free from defects and together with the adjacent material shall be
thoroughly cleaned of oil, grease, paint and shall be free from all rust, scale, ice/water
for a distance of 50 mm from the edge of the weld.
5.2.7. The visible surface of all welds are to be clean of slag, regular uniform in contour,
without undercuts, crack or blowholes and free from spatter.
5.2.8. Weld reinforcement: The thickness of weld reinforcement shall not exceed the
following, considering the thinner component being joined:
Over 1 3/16
For double welded joints this limitation on reinforcement shall apply separately to the weld
reinforcement inside and outside. The finished internal and external surfaces of the weld shall
merge smoothly into the component surfaces or the weld toe.
5.2.9. When unacceptable defects are found in complete welds, they are to be removed by
grinding, chipping or machining.
5.2.10. The basic principles of the welding procedure initially used are to be employed
for repair of faulty welds.
5.3.1. Work control procedure shall be prepared prior to start the special process such
as heat treatment. Processing and result of special process shall be recorded and
maintained to verify the work quality.
5.3.2. Heat Treatment of flame-cut edges for carbon steel is not required when the
edges are dressed back in accordance with para. 4.3.5. B where dressing back
proves to be impossible, then such undressed or partly dressed edges shall be stress
relieved before welding.
A. When the welding procedure does not include pre-heating and the ambient conditions are
such that the metal temperature of the parts to be welded are below 4°C, the surface in a zone
extending 15 mm each side of the joint is to be heated to 20°C "Handwarm" before welding
commences.
B. Preheating shall be carried out in accordance with ASME B31.3 unless para. 5.3.4. A
applies.
5.3.4. Normalizing
Temperature 920°C/950°C
Cooling shall be uniform at a rate less than 250°Cper hour down to 300°C, thereafter
cool in still air.
A. Irrespective of pipe wall thickness, PWHT shall be performed on all type joints butt,
socket, etc, for piping classes A2T3MR, AUT3P, B2T3MR, B2T6MR, D2T3MR, A2D2,
B2D2V, BCDX, D2D2V, for other piping classes PWHT shall be carried out in
accordance with ASME B31.3.
C. Welds produced in austenitic stainless steel shall not require stress relief, unless
this is specifically called for in the drawings or pipeline specifications.
5.3.7. A record of the time/temperature for normalising and stress relief must be kept.
6.1.1. Where welds are to be produced between carbon steels and austenitic stainless steels,
the weld procedures, welding techniques etc., shall be those appropriate to the austenitic
stainless steel.
6.1.2. Electrodes and filler wire shall be ER 309, E309, or ER NiCr3, ENiCr Fe3 the
choice depending on service conditions. Any heat treatment required shall be that
appropriate to the grade and thickness of carbon steel involved. The welding
procedure proposed shall be approved in writing by Consultant.
6.2.1. Where welds are to be produced between low alloy steels and carbon steels, the above
procedures, electrodes, filler wires, welding technique and heat treatment etc., shall be
appropriate to the grade and thickness of the low alloy steel involved. Electrodes must be of
the basic type.
Where welds are to be produced between differing grades of stainless steels, the weld
procedures, electrodes, filler wires, welding techniques, etc., shall be those required
by the higher grade of material.
6.4.2. Electrodes and filler wires shall in general be of higher alloy content than the
austenitic stainless steel. Any heat treatment required shall be that appropriate to the
grade and thickness of low alloy steel involved.
A. All electrode and filler wires shall comply with AWS A5.1, AWS A5.2 and AWS A5.18.
B. Electrodes to be used for general butt welding of low carbon steel pipes will be as follows:
1) Pipe wall thickness up to 19 mm (0.75") use cellulosic electrodes E6010 and E7018.
2) Pipe wall thickness 19mm (0.75") and above and special carbon steel (for
low temperature or high carbon content), ER70S-3 & basic electrodes E7018.
A. All electrode and filler wires shall comply with AWS A5.4 and AWS A5.9.
B. Electrodes to be used for general butt welding of austenitic stainless steel will be rutile
type EXXX-16.
A. All electrode and filler wires shall comply with AWS A5.4 and AWS A5.5.
B. Welding electrodes to be used for general butt welding of alloy steel piping shall be as
follows:
A. All electrode and filler wires shall comply with AWS A5.5.
B. Welding electrode shall be 7018 A1.
A. The dissimilar metal welds should be avoided whenever possible, using instead some
mechanical joint such as a thread or flanged connection.
B. There are innumerable combination of dissimilar alloys which could be jointed, and most
of these combinations are special cases which must be handled on an
individual basis, with the welding procedure depending on the intended use.
C. The composition of the joining metal must be compatible with both alloys, or a buffer layer
must be placed between them.
D. If high temperatures are involved, particularly if cycle, the coefficients of thermal expansion
of the parent metals and diluted weld metal must be considered.
E. If hardenable alloys are involved, consideration must be given to eliminating hard areas
and brittle areas, or to restoring strength, hardness and toughness,
depending on whether or not the design requires a high strength member.
G. Mechanical, formability and other fabrication operations may require special consideration.
7.1.6. The particular brands of electrodes and wires chosen shall be approved in writing by
the engineer before use.
7.1.7. Storage of electrodes and other welding materials shall be in accordance with
the vendor's instructions.
7.1.8. Refer to following specification for complete list of electrodes and filler
materials.
A. Grinding shall be carried out using resin bonded alumina or silicon carbide grinding
wheels. Rubber bonded wheels or wheels containing sulphur shall not be used.
A. Wheels previously used on ferritic steels shall not be used on the carbon steels.
Inspection shall be in accordance with ASME B31.3 and the following inspection
requirements.
8.1.1. Inspection and test procedure/plan shall be prepared and approved prior to inspection
activity.
8.1.2. Result of inspection and test shall be recorded and maintained to verify the
quality of items and activities.
8.2. RADIOGRAPHY
Radiography shall be applied in accordance with Inspection & Test of Piping Construction
Visual examination shall be carried out in accordance with Inspection & Test of Piping
Construction
8.4.1. Pressure testing shall be carried out in accordance with ASME B31.3 and Pressure
Test of Piping System
8.4.4. Shop testing of finished fabricated piping is not required unless specified.
8.4.5. Where site hydraulic testing is to be avoided, all shop fabricated piping, including
make-up lengths and lengths with loose flanges, shall be shop tested hydraulically. Provision
shall be made by the fabricator for closing the open ends of pipe for this test. Where this
procedure is required, it will be specified on the drawings and pipeline specifications.
8.4.6. All pressure testing shall be carried out after the application of any specified heat
treatment.
8.4.7. For austenitic stainless steel pipelines, hydrostatic tests shall be carried out using clean
water unless other fluids are specified on the drawings or pipeline specifications. Particular
attention must be paid to using potable water. Chlorine content of less than 50 PPM should
be used wherever possible, water having a chlorine content above 100 ppm should not be
used in any circumstances, and where it is necessary to use water within a range of 50-100
ppm, lines shall be flushed with a chlorine-free liquid with a short period of testing.
9.1 All bores of all fabricated piping shall be free from all sand, scale, weld spatter etc.
refer also to para. 5.2.7 and 5.2.8.
9.2. If special cleaning is required, this will be the subject of a special specification.
9.3. The cleaning of austenitic stainless steel pipe surfaces prior to welding shall not
involve the use of hydrochloric acid, chlorine compounds, or water with a chloride
content in excess of 50 ppm.
10.2.1. Pipe-ends and flange faces shall be properly protected against the ingress of
dirt, mechanical damage and atmospheric corrosion. The term "pipe-end" shall
include any weld preparation. The protection applied shall not be capable of passing
into the bore of the pipe.
10.2.2. Threaded connections shall be fitted with a line class plug or covered with a
plastic sheet securely wired or taped to the spool.
10.2.3. Socket weld connections shall be fitted with taped polyethylene plugs or
plastic sheet securely wired or taped to the spool.
11.1. VALVES
Valves equipped with chain wheels shall have the stems arranged so that chains do not fall
on equipment. Hooks shall be provided to hold chains clear of operating areas. Chain wheels
will be shown on the piping drawings. Install valves so that the stems are not below a
horizontal position. Orient all valves so that the hand wheels do not obstruct passageways.
A flange cover shall be kept on all flanged connections to pumps, compressors, turbines, and
similar equipment until ready to connect the piping. Piping connecting to mechanical
equipment, such as pumps, turbines, and compressors shall be fitted-up in close parallel and
lateral alignment, prior to tightening the bolting or welding the joints. The installation shall be
approved by the inspector prior to tightening the bolting. Carbon steel piping that has not
required post-weld heat treatment may be heated for minor corrections in fit. The temperature
shall not exceed 660℃Cooling of the pipe shall not be accelerated by the application of water.
The inspector shall be notified when heating for fit-up is required.
All restrictions which would interfere with filling, venting, draining, or flushing shall not be
installed until after completion of the pressure test and line flushing operations. This includes
orifice plates, flow nozzles, venturis, rotameters, PD meters, turbine meters, magnetic meters,
strainer screens, and similar in-the-line equipment.
Protect gaskets from damage until final installation is complete. When temporary make up at
flanged joints is required in piping systems using special gaskets, make up the joint with a less
expensive sheet gasket and save the special gasket for the final installation.
All field supports shall be installed in accordance with the standard drawings. If the field
supports are not installed or are unavailable when the piping is erected, use temporary
blocking or other adequate means of support until the field supports can be installed. Careful
consideration must be given to the support of 2-inch and smaller piping to prevent excessive
deflection.
Check the expansion joint specification for special instructions. Corrugated expansion joints
shall be installed with length extended or compressed for the ambient temperature condition
at erection, depending on anticipated direction and magnitude of movement after the line
reaches the operating temperature. Make a final check to see that shipping ties have been
removed after line tests and that any preset that may be specified has been accounted for.
The variable and constant support type spring hangers are preset, for the cold condition, in
the factory. The gags and shipping spacers should be removed until after hydrostatic testing
of the line has been completed.
Any dimensional adjustments that have to be made to the load flange on the compression-type
springs, or to the rod assembly on suspended-type springs, should be made before the gags
are removed. Once the spring is unblocked it is very difficult to make any adjustments.
Golden weld joint is that joint in which the new piping is connected to the existing
piping. Hence this joint cannot be hydrostatically tested.
So it has to be ensured that it should be defect free as per the standard (eg: ASME
B31.3) that is followed.
Please learn more 345.2.3 Special Provisions for Testing in ASME B31.3 2016
edition
Welder assigned for this joint is a very important criteria. He have to be highly skilled
as the NDT requirements for this joint is normally higher than that of other joints.
My experience, the golden joints are subjected to RT, UT, MPI & hardness test. It
depends on the standard being followed and the client requirements.
Checklist – Before Welding
Ensure purchased material (base material and consumables) are those which
have been specified.
Check the cleanliness of the joint. Excessive levels of rust, oil, dirt,
paint and other contaminants are detrimental to weld quality.
Check individual weld passes. If there is a multi-pass weld make sure each
pass is adequate before placing the next weld. Problems can arise when
welding over passes that have excessive convexity, trapped slag at the toes
and other inconsistencies.
Check for visual cues that can indicate problems. This is the
responsibility of the welder. Surface contaminants, low-melting
elements and other things can cause a variety of problems. A welder can
see if he is not getting adequate penetration, something that can’t be
seen after welding unless ultrasonic, radiographic or other NDE tests are
performed.
Check for adequate weld length, especially when intermittent welds are
used.
2 - 4 Nickel Steels
9A, B, C
9 Chromium, 1 Molybdenum
15E
Not Used
16 to 20
High Aluminum Content (1000 and 3000 series)
21
Aluminum (5000 series - 5052, 5454)
22
Aluminum (6000 series - 6061, 6063)
23
Not Used
24
Aluminum (5000 series - 5083, 5086, 5456)
25
Not Used
26 to 30
High Copper Content
31
Brass
32
Copper Silicon
33
Copper Nickel
34
Copper Aluminum
35
Not Used
36 to 40
High Nickel Content
41
Nickel, Copper - (Monel 500)
42
Nickel, Chromium, Iron - (Inconel) (C22, C276, X)
43
Nickel, Molybdenum - (Hastelloy B2)
44
Nickel, Chromium, Si
45
47 to 50
Titanium Alloys
51, 52, 53
Zirconium Alloys
61, 62
information.
P - No. 34, or P - No. 41 through P - No. 49 P - No. 34, and P - No. 41 through P - No. 49
P - No. 21
Aluminum and aluminum -
through P - No. P - No. 104 and P - No. 105
base alloys
26
P - No. 31
Copper and copper - base
through P - No. P - No. 107 and P - No. 108
alloys
35
P - No. 41
P - No. 110 through P - No.
Nickel and nickel - base alloys through P - No.
112
49
P - No. 51
Titanium and titanium - base
through P - No. P - No. 115
alloys
53
P - No. 117
Carbon Manga
nese Steels, 4
Sub Groups
Group 1
up to
approx 6
5 ksi
1 1
Group 2
Approx
70ksi
Group 3
Approx
80ksi
Group 4
?
2 - Not Used
3 4 3 Sub Groups:- Typically half moly and half chrome half moly
10 Sub Groups:-
Mixed bag of high
11B ?
strength low alloy
steels.
12 to 20 - Not Used
21 21 Pure Aluminium
22 22a Aluminium Magnesium Grade 5000
24 - Not Used
26 to 30 Not used
31 Pure Copper
32 Brass
33 Copper Silicone
34 Copper Nickel
35 Copper Aluminium
36 to 40 Not Used
41 Pure Nickel
47 to 50 Not Used
B - For Piping Bends having a radius equal to SIX times the diameter or larger
variations in the finished pipe caused by bending including any folds and bulges shall
not exceed ± 3% x Nominal Ø of the Pipe.
C - Lateral translation of flanges in any direction from the indicated position shall not
exceed 1.5 mm.
D - Rotation of flanges from the indicated position as shown shall not exceed 1.5
mm.
E - Aligment of flanges shall not deviate from the indicated position measured
across any diameter more than 0.75 mm.
A - Variations in the indicated dimensions for Center to Face. Location of
attachments etc, shall not exceed 3 mm. (Tolerance shall be cumulative)
B - For Piping Bends having a radius equal to SIX times the diameter or larger
variations in the finished pipe caused by bending including any folds and bulges shall
not exceed ± 3% x Nominal Ø of the Pipe.
C - Lateral translation of flanges in any direction from the indicated position shall not
exceed 1.5 mm.
D - Rotation of flanges from the indicated position as shown shall not exceed 1.5
mm.
E - Aligment of flanges shall not deviate from the indicated position measured
across any diameter more than 0.75 mm.