9686-8470-SP-000-4005 - 01 Welding and NDT Spec

RAS MARKAZ CRUDE OIL PARK PROJECT (PHASE1)
SPECIFICATION FOR WELDING AND NDE OF EQUIPMENT AND PIPING

Doc No: 9686-8470-SP-000-4005 Rev. 01 Doc. Class 1 /Cat: 2
RAS MARKAZ CRUDE OIL PARK
SPECIFICATION FOR WELDING AND NDE OF

EQUIPMENT AND PIPING
Issued for
01 30 Jul 19 53 Jose Mathews Anna Raj Ramesh Xing hang
Construction
B1 26 Jun 19 54 Issue for Approval Wang Chengbin Anna Raj Ramesh Xing hang
Issue for Review / Wang

A1 12 May 19 51 Wang Chengbin Anna Raj Ramesh
Comments Dengkui
REV DATE PAGES DESCRIPTION PP CHK APP-1 APP-2
Page 1 of 53
Table of Contents
1 GENERAL ..................................................................................................................................................... 5
1.1 PURPOSE ........................................................................................................................................................ 5
1.2 DEFINITIONS AND ABBREVIATIONS ................................................................................................................... 5
1.2.1 Definitions............................................................................................................................................ 5
1.2.2 Abbreviations ....................................................................................................................................... 7
1.3 UNITS OF MEASUREMENTS .............................................................................................................................. 7
1.4 SITE ENVIRONMENTAL CONDITION................................................................................................................... 7
1.5 LANGUAGE ..................................................................................................................................................... 8
2 REFERENCE DOCUMENTS ........................................................................................................................ 9
2.1 ORDER OF PRECEDENCE................................................................................................................................... 9
2.2 PROJECT REFERENCE DOCUMENTS ................................................................................................................... 9
2.3 INTERNATIONAL CODES, STANDARDS AND REGULATIONS.................................................................................. 9
2.4 OTHER REFERENCE (IF ANY) ............................................................................................................................. 9
3 DEFINITIONS .............................................................................................................................................11
4 GENERAL WELDING REQUIREMENTS ...................................................................................................12
5 WELDING PROCESSES .............................................................................................................................15
6 WELDING CONSUMABLES (FILLER METAL AND FLUX) .....................................................................17
7 SHIELDING AND PURGING GASES ........................................................................................................20
8 PREHEATING AND INTERPASS TEMPERATURE ..................................................................................21
9 POSTWELD HEAT TREATMENT (PWHT) ...............................................................................................22
10 CLEANING AND SURFACE PREPARATION ........................................................................................24
11 SPECIAL PROCEDURE QUALIFICATION REQUIREMENTS / TESTING ............................................25
12 OTHER ITEMS ........................................................................................................................................27
13 ADDITIONAL REQUIREMENTS TO API RP582 ..................................................................................29
13.1 WELDER AND WELDING OPERATOR QUALIFICATION ....................................................................................... 29
13.1.1 General............................................................................................................................................... 29
13.1.2 Essential Variables ............................................................................................................................ 29
13.2 PRODUCTION TESTS ...................................................................................................................................... 29
13.2.1 Production Test Plates ...................................................................................................................... 29
13.3 NON-DESTRUCTIVE EXAMINATION (NDE) ...................................................................................................... 31
13.3.1 General............................................................................................................................................... 31
13.3.2 Radiographic Source ......................................................................................................................... 31
13.3.3 100% Radiography ........................................................................................................................... 31
13.3.4 10%, Spot or Random Radiography ................................................................................................ 32
13.3.5 Ultrasonics in lieu of radiograph ..................................................................................................... 32
13.4 WELD REPAIRS .............................................................................................................................................. 32
13.4.1 General............................................................................................................................................... 32
13.4.2 Inspection ........................................................................................................................................... 33
Page 2 of 53
13.5 WELD JOINT IDENTIFICATION AND WELD MAP REQUIREMENTS ....................................................................... 33

13.6 ALLOY MATERIAL CONTROL (PMI TESTING) ................................................................................................... 33
14 TABLES ...................................................................................................................................................34
15 API RP582 ANNEX B: WELD OVERLAY AND CLAD RESTORATION ..............................................38
APPENDIX A: ADDITIONAL REQUIREMENTS FOR DUPLEX STAINLESS STEEL WELDING ....................40
APPENDIX B: FABRICATION REQUIREMENTS FOR CUPRO NICKEL (IF APPLICABLE) ...........................50
Page 3 of 53
REVISION CONTROL SHEET

REV. NO. DATE PAGE NO. DESCRIPTION OF CHANGES
A1 12 May 19 All Pages First Issue
B1 26 Jun 19 All Pages Revised as per Company Comments
01 30 Jul 19 All Pages Revised as per Company Minor Comments
This page records the revision status of this document

NOTES:
Revisions after first issue are denoted as follows:
a) By a vertical line in the right-hand margin against the revised text and,
b) By a triangle symbol for graphics, the revision number being denoted within the symbol. Revision
symbols are positioned adjacent to the revision.
Page 4 of 53
1 GENERAL
1.1 Purpose
This Project Specification specifies welding and NDE requirements for pressure containing
equipment, tanks, and pipework. It is based upon:
API RP 582 (3rd Edition) Welding Guidelines for the Chemical, Oil and Gas Industries.
API RP 582 forms an integral part of this Specification and shall be read in conjunction with
this document. Revisions and additions are as noted herein:
The heading/paragraph numbering of this Project Specification corresponds to the paragraph

numbering of API RP 582. Only revisions or additions to API RP 582 are included in this Project
Specification, all other paragraphs of API RP 582 remain in force.
Revisions to paragraphs of API RP 582 are indicated by (R) in the margin,
Additional paragraphs are indicated by (A) in the margin.
The first and second heading is modified to match project document structure.
Unless stated otherwise, all the requirements stated within API RP 582 shall be considered
mandatory.
Where an edition date is not included for a code or standard, the latest edition in force at the
time of the EPC Contractor’s / Vendor’s proposal shall apply.
Revision as follows:
1.2(R) This document is general in nature and is intended to augment the welding
requirements of applicable Codes such as ASME BPVC Section IX, and similar Codes, standards,
specifications and practices such as those listed in Section 2. The intent of this document is to
be inclusive of chemical, oil and gas industry standards, although there are many areas not
covered herein, e.g. pipeline welding is not intentionally covered.
1.3(R) This document is based on industry experience. The defined requirements shall apply
unless otherwise agreed with the Company.
1.2 Definitions and Abbreviations

1.2.1 Definitions
The following definitions of terms used within this Project Specification shall apply:
Company : Oman Tank Terminal Company L.L.C. (OTTCO)

Contract : The EPC Contract between Company and EPC Contractor
EPC Contractor : China Petroleum Pipeline Engineering Co., Ltd. (CPP)
IPMT : Company Project Management Team comprising OTTCO and
Consultant personnel.
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Purchaser : The organization issuing the purchase order for the supply of the
package/equipment and services
Sub-contractor : Means any person or persons, firms, companies to whom any
part of the work has been subcontracted (directly or indirectly)
by EPC Contractor and the legal successors in title to each of
these parties
Shall Indicates Mandatory requirement
Should Indicates that the requirement is strongly recommended to be
adhered to
Vendor : Means a supplier of Goods and/or Equipment for the Facility
and/or the Works including related documentation and services,
where necessary, in connection with the installation, testing,
commissioning and start up support of any such Goods or
Equipment.
Major Weld Repair : A weld repair shall be considered major when:
• It is made to rectify a leak on pressure testing.
• It is extended through the thickness.
• The depth of the repair cavity exceeds 10% of the nominal
thickness or 25.4mm, whichever is smaller.
• The extent of the repair cavity exceeds 64.5cm2.
• It is made to rectify laminations in the base material.
• It is made to rectify cracks in the weld metal, HAZ or base
material.
• Edge defects greater than 20% of the edge length.
• Lack of penetration/ fusion of the weld metal.
PMI : Positive Material Identification, Evaluation or test of a material to
confirm that the material which has been or will be placed into
service is consistent with the selected or specified alloy material
designated by Material Specification. These evaluations or tests
may provide either qualitative or quantitative information that is
sufficient to verify the nominal alloy composition.
Pressure Retaining : Components acting as pressure envelope or boundary; breach of
Components this envelope or boundary would lead to loss of containment and
discharge of process fluids. Examples include, but not limited to,
product forms used for the fabrication of pressured piping and
equipment such as shells, heads, nozzles, tubes, flange bolting,
some types of gaskets, flanges, individual pipe lengths and fittings
(tees, elbows, reducers, special pipe components), drains, vents,
plugs, valve bodies and bonnets, pressure relief/safety valves,
pressure-retaining welds, pump casings, weld overlays/cladding
and thermowells.
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Non-pressure : Items that are not part of the pressure-retaining envelope and,
Components therefore, do not affect the pressure retaining capacity of
pressured components.
1.2.2 Abbreviations
ASME : The American Society of Mechanical Engineer
ASTM : American Society for Testing and Materials
AWS : American Welding Society
DMT : Design Metal Temperature

EGW : Electrogas Welding
FCAW : Flux Cored Arc Welding
GMAW : Gas Metal Arc Welding
GTAW : Gas Tungsten Arc Welding
HAZ : Heat Affected Zone
LODMAT : Lowest One-Day-Mean Ambient Temperature

MDMT : Minimum Design Metal Temperature
NDE : Non-destructive Examination
PAW : Plasma Arc Welding
PMI : Positive Material Identification
PQR : Procedure Qualification Records
PTP : Production Test Plate
PWHT : Post Weld Heat Treatment
ROL : Run-out Length
SAW : Submerged Arc Welding
SMAW : Shielded Metal Arc Welding

WPS : Welding Procedure Specification
1.3 Units of Measurements

All documents, calculations and drawings shall be carried out using International System of
Units (SI), in accordance with 9686-8850-PS-000-9001 Engineering Design Data (EDD) shall be
followed.
1.4 Site Environmental Condition

The site environmental conditions are defined in Engineering Design Data doc. no. 9686-8850-
PS-000-9001. Vendor shall comply with the requirements as defined in Engineering Design
Data.
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1.5 Language
All documentation shall be in UK English. Where documents (test certificates, vendor data etc.)
are originally produced in a non-English language, an English translation must be provided,
and the English language version shall take precedence.
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2 REFERENCE DOCUMENTS
2.1 Order of Precedence

The following list of documents is used in descending order of precedence in establishing
applicable requirements for the project if and when a conflict with a specification arises:
1. Local Laws & Regulations of the Oman
2. National Standards
3. Project Specifications, data sheets, as applicable
4. Industry/ International Codes and Standards
5. Service Authority Standards
The information given in each of the above shall be used, in conjunction with all other above
listed documents.
In the event of an inconsistency, conflict or discrepancy between any of the standards,

specifications and regulation requirements, the most stringent and safest requirement
applicable to the project will prevail to the extent of the inconsistency, conflict or discrepancy.
In such cases, EPC Contractor shall provide its interpretation in writing of the most stringent
requirement for Company approval. In all such cases of conflict, Company’s decision will be
final.
2.2 Project Reference Documents

9686-8470-SP-000-4004 : Specification for Positive Material Identification
9686-8850-PS-000-9001 : Engineering Design Data
9686-8230-SP-000-5001 : Piping Material Specification
2.3 International Codes, Standards and Regulations

Additions to Section 2 Normative References of API RP 582 as follows:
API 650 : Welded Tanks for Oil Storage
2.4 Other Reference (If any)

ASME B31.3 : Process Piping
ASME IX : Welding and Brazing Qualifications
ANSI Z49.1 : Safety in Welding, Cutting and Allied Processes
API 650 : Welded Tanks for Oil Storage

ASME BPVC Sec. II : Nonferrous Material Specifications
Pt. B
Page 9 of 53
AWS A2.4 : Standard Symbols for Welding, Brazing and Non-Destructive

Examination
AWS A3.0 : Standard Welding Terms and Definitions
AWS A5.30 : Specification for Consumable Inserts
AWS A5.17/A5.17 : Specification for Carbon Steel Electrodes and Fluxes for Submerged
M Arc Welding
AWS A5.23/A 5.23 : Specification for Low-Alloy Steel Electrodes and Fluxes for
M Submerged Arc Welding
EN 1011-2 : Welding - Recommendations for Welding of Metallic Materials - Part

2: Arc Welding of Ferritic Steels
EN 10204 : Metallic products. Types of inspection documents
ISO 10474 : Steel and Steel Products – Inspection Documents
ISO 15614-8 : Specification and qualification of welding procedures for metallic
materials - Welding procedure test - Part 8: Welding of tubes to
tube-plate joints
ASTM : Standard Specification for Straight-Beam Ultrasonic Examination of
A578/A578M Rolled Steel Plates for Special Applications
ASTM : Standard Specification for Quenched and Tempered Vacuum-
A508/A508M Treated Carbon and Alloy Steel Forgings for Pressure Vessels
UCS-66 of ASME : Impact Testing Requirements
SEC VIII DIV 1
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3 DEFINITIONS
This section is intentionally left blank in order to match with the document structure of API RP
582.
Page 11 of 53
4 GENERAL WELDING REQUIREMENTS
Revisions/Additions as follows:
4.3(R) All welding procedure specifications (WPSs) and procedure qualification records (PQRs)
shall be submitted to EPC Contractor/Company for review and approval prior to the
start of fabrication or construction. Weld maps, similar guides or fabrication drawings
which clearly identify the application of each WPS, indicating where and how these
WPSs will be used, shall be included in the submittal.
4.4(A) All pressure retaining welds and attachment welds to pressure retaining components
shall be welded using qualified WPS(s) and PQR(s) that fully meet the requirements of
the applicable code and this Project Specification.
4.6(A) All pressure retaining welds, including fillet welds and nozzle-shell welds, shall be
qualified using a butt weld test piece with full mechanical testing.
4.7(A) WPSs inclusive of impact testing render all supplementary essential variables applicable.
This shall also apply in the event impact testing is not a code requirement.
4.8(A) In addition to the requirements of the code, the WPS shall include the following details:
a. Typical weld deposition sequence.
b. Weld bevel and fit-up tolerances.
c. Electrical characteristics for each welding process and consumable diameter.
d. Oscillation width and frequency and contact tube-to-weld distance for semi-
automatic welding process.
e. Consumable manufacturer and brand designation.
f. Run-out length (ROL) or Run-out Ratio (ROR) for manual processes where heat
input is an essential variable.
4.9(A) Welding terms and definitions shall be in accordance with AWS A3.0. Welding and non-
destructive examination (NDE) symbols shall be in accordance with AWS A2.4.
4.10(A) Safety measures for protecting workers involved in welding and cutting operations
shall be in accordance with ANSI Z49.1 and all local regulations. Adequate ventilation
and fume extraction facilities shall be provided to minimise worker exposure to
harmful welding, cutting and NDE chemical fumes.
4.11(A) All welding processes shall be protected from adverse weather conditions that may
affect weld quality. When welding is performed outdoors in adverse weather
conditions, temporary shelters shall be erected to completely enclose the work area.
In addition, for gas shielded processes, windshields shall always be erected to prevent
loss of shielding gas coverage.
4.12(A) Vendor shall be responsible for implementing procedures that ensure the welding
parameters specified on the WPS(s) are adhered to during production welding, and
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shall perform regular audits to monitor their implementation. Arc monitoring

equipment shall be made available for the inspector to check that the welding
parameters are being adhered to during production welding.
4.13(A) Base metals not listed in ASME Section IX QW/QB-422 may be classified in a listed
P-number or S-number subject to the approval of EPC Contractor and Company.
4.14(A) All welding equipment, including wire feed or powder feed units, shall be calibrated
before use. Vendor shall check the calibration on a regular basis during production.
4.15(A) Equipment to demagnetise weld preparations shall be available in the event that “arc
blow” is encountered during fabrication.
4.16 (A) Materials
4.16.1 General
4.16.1.1 Materials for containment parts shall comply with the appropriate Code standards.
4.16.1.2 Materials for permanent attachments welded directly to any containment or load
bearing part shall be of the same nominal composition as the containment part.
4.16.2 Carbon, Carbon Manganese & Low Alloy Steel
4.16.2.1 Carbon and Carbon Manganese steels which are to be welded shall comply with the
following requirements:
a. Carbon content shall not exceed 0.23%, except for forgings which shall be
limited to 0.25% maximum.
b. Carbon Equivalent (CE) shall not exceed 0.43 where
CE = %C + %Mn/6 + (%Cr + %Mo + %V)/5 + (%Cu + %Ni)/15
c. Where a full analysis is not available, CE shall not exceed 0.42 where,
CE = %C + %Mn/6
4.16.2.2 The following limitations shall apply to low alloy (Cr-Mo) steels:
a. C = 0.20% max. (forgings only, up to 2% Cr)
b. C = 0.17% max. (all other forms, up to 2% Cr)
c. C = 0.15% max. (all forms, over 2% Cr)
4.16.2.3 Carbon and C-Mn steels shall be supplied in the as rolled, normalised and tempered,
or when specifically approved, quenched and tempered conditions.
4.16.2.4 Low alloy steels shall be supplied in the normalised and tempered or quenched and
tempered conditions. Tempering, when undertaken, shall be performed at a
temperature which is at least 20C higher than the upper temperature limit range for
post weld heat treatment.
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4.16.2.5 When specified, mechanical tests on material for equipment which is to be subject to
post weld heat treatment shall be carried out using coupons in the as-supplied and
simulated post weld heat treatment (PWHT) conditions. Simulated heat treatment
times shall include contingency for in-situ heat treatments for future repair or
modifications to the equipment by Company.
4.16.2.6 For plates and forgings exceeding 50mm thickness for pressure vessel wall and other
pressure retaining applications, the following additional requirements shall apply:
a. All plates and plate-like forgings (e.g. shell rings) shall be subject to straight
beam ultrasonic examination in accordance with ASTM A578.
a. All forgings, except plate-like forgings shall be subject to ultrasonic examination

in accordance with ASTM A508.
b. All surfaces of forgings shall be subject to 100% wet magnetic particle surface
inspection. The inside bore of nozzles (less than 12”) maybe subject to dye
penetrant examination, subject to agreement with EPC Contractor and
Company.
4.16.3 Notch Toughness
4.16.3.1 All materials shall have sufficient notch toughness to resist brittle fracture at the
Minimum Design Metal Temperature (MDMT), where, unless agreed otherwise with
EPC Contractor and Company, the MDMT is the lowest of the following:
a. The design minimum ambient temperature for the site. Generally this will be the
Lowest One-Day-Mean Ambient Temperature (LODMAT).
b. 10C below the lowest normal process operating temperature.
c. The minimum autorefrigeration temperature i.e. the atmospheric boiling point

(ABP) or atmospheric flash temperature (AFT) of the process fluid. If cold
repressurisation of the equipment is not necessary during plant operation,
reduction in membrane stress during blowdown may be taken into account
when establishing the MDMT, in accordance with the applicable design code.
d. 5C below the initial hydrotest temperature.
For tanks design the above values shall be read in conjunction with API 650 figure
4.1 a for Design Metal Temperature (DMT) definition, the most stringent figures shall
be applied.
4.16.3.2 Charpy V-Notch impact testing of carbon and ferritic alloy steels shall satisfy the
requirements of the governing code or standard for the MDMT specified. For storage
tanks impact test requirements shall follow Table 4.5 in API 650.
4.16.3.3 For carbon and carbon-manganese steel equipment designed to ASME VIII Div 1,
Vendor shall ensure that the requirements of UCS-66 are fully met with regards to
material grade and governing thickness of all pressure retaining components.
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5 WELDING PROCESSES
5.2 Limitations of Fusion Welded Processes
5.2.2 Automatic Pulsed Gas Tungsten Arc Welding (GTAW-P)
(A) Welding without the addition of filler metal (autogenous welding) shall be subject to EPC
Contractor and Company approval. Where this is proposed for 300 series stainless steel
materials and nickel-base alloys, Vendor shall ensure that suitable heats of steel are
identified and welding procedures developed to avoid weld metal penetration problems
associated with “cast-to-cast” variations.
The addition or deletion of consumable inserts for single welded butt joints (without
backing devices) requires a separate WPS(s) and PQR(s).
5.2.3 (A) Gas Metal Arc Welding (GMAW)
5.2.3.1(A) GMAW in any form (spray, short-circuiting, pulsed or globular transfer modes) shall
not be used in applications requiring impact testing unless agreed with EPC
Contractor and Company.
5.2.3.2(A) Complete butt or fillet welds may be welded with this process provided the wall
thickness of no member exceeds 1 in. (25.4mm) and either of the following
conditions is met:
• Welding is done in any position except vertical-down and the current is not
less than 170A.
• Welding is done in the vertical-up position (3G) and the heat input is not less
than 35000 Joules/in. (14,000 Joules/cm) (disregarding weld process thermal
efficiency).
5.2.5 Flux Cored Arc Welding (FCAW)
5.2.5.3(A) FCAW shall not be used in applications requiring impact testing and/or sour service
unless agreed with EPC Contractor and Company. Also FCAW shall not be used for
the root pass.
5.2.6(A) Electrogas Welding (EGW)
d) Where EGW is proposed for pressure vessels or storage tanks, all welding
procedures shall be qualified with impact testing of the weld metal and HAZ at the
lower of 0C or MDMT in accordance with Section 4. PTPs shall be taken for each
welding procedure used. The extent and testing requirements for the PTPs shall
be agreed with EPC Contractor and Company.
5.2.7 Submerged Arc Welding (SAW)
5.2.7.1(R) SAW procedures shall be re-qualified whenever the welding flux-wire combination
is changed from that stated on the PQR. Equivalence flux-wire designation under
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ASME Section II, Part C shall not be considered adequate for substitution without
re-qualification.
5.2.8 (A) Gas Tungsten Arc Welding (GTAW)
5.2.8.1(A) All GTAW equipment shall be equipped with arc starting (e.g. high frequency) and
crater eliminating devices.
5.2.8.2(A) Welding without the addition of filler metal (autogenous welding) shall be subject
to EPC Contractor review and Company approval. Where this is proposed for 300
series stainless steel materials and nickel-base alloys, Vendor shall ensure that
suitable heats of steel are identified and welding procedures developed to avoid
weld metal penetration problems associated with “cast-to-cast” variations.
5.2.9 Plasma Arc Welding (PAW)
5.2.9.1(A) PAW, using the transferred arc mode, with filler wire addition may be used for
welding all materials.
5.2.9.2(A) Welding without the addition of filler metal (autogenous welding) shall be subject
to EPC Contractor review and Company approval. Where this is proposed for 300
series stainless steel materials and nickel-base alloys, Vendor shall ensure that
suitable heats of steel are identified and welding procedures developed to avoid
weld metal penetration problems associated with “cast-to-cast” variations.
5.3 Single-Sided Welded Joints
5.3.1(R) For single-sided welded joints, welding processes using coatings or fluxes (including
the use of flux backing in-lieu of a backing purge gas or flux cored GTAW wires) shall
not be used for root pass welding of austenitic stainless steel and non-ferrous alloys
unless slag can be removed from the process side of root passes and the area
inspected for slag removal.
5.3.2(A) Ferritic steels exceeding ¼ in. (6mm) requiring butt welded pressure containing joints
in a single pass shall receive a subsequent austenizing heat treatment.
5.5 Mechanized and Automated Welding Processes
5.5.2(R) For mechanized and automated welding processes a change in the type of machine,
weld geometry, diameter, position, direction of welding, base material chemistry,
welding consumable manufacturer, thickness, and welding variable settings from that
stated on the PQR shall be considered essential variables for procedure qualification.
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6 WELDING CONSUMABLES (FILLER METAL AND FLUX)
6.1 General
6.1.1(A) Welding consumables shall be specified in each WPS by an appropriate national

specification and classification (e.g. AWS). Welding consumables shall be purchased
from consumable manufacturers holding approvals by an independent third party
unless otherwise agreed with EPC Contractor and Company.
6.1.6(A) Consumables shall be clearly identified with either the national material specification
or manufacturer’s brand designation, as applicable. The identity shall be maintained
until consumed. SMAW electrodes and manual GTAW wires shall carry this
identification on each individual electrode or wire, and reels of wire or strip shall be
individually identified. Consumables for which no identification exists shall not be
used.
6.1.7(R) All consumables shall be used within the primary classification limits specified by the
applicable consumable specification and the consumable manufacturer’s
recommendation (e.g. consumables classified for single pass welds shall not be used
for multiple pass welds, consumables classified in the as-welded condition shall not
be used where PWHT is a requirement). Flux dual certificates are acceptable subject
to the review of EPC Contractor/Company.
6.1.9(A) Each batch of consumables shall be certified in accordance with ISO 10474, 3.1. The
original consumable manufacturer’s certificate shall be supplied for each batch
irrespective of whether the consumables are purchased directly from the
manufacturer or through an agent or distributor.
6.1.10(A) When joining base materials with the same nominal chemistry, welding consumable
selection shall be based on obtaining weld deposits closely matching the base
material chemistry and mechanical properties and that are suitable for the intended
service. Proposals to use alternative welding consumables shall be submitted to EPC
Contractor and Company for review.
6.1.11(A) In addition to the requirements of the code, a welding procedure shall be re-qualified
if any of the following changes in welding consumables from that stated on the PQR
apply:
a) A change in the nominal chemical composition of deposited weld metal,

including change from ASME Section IX QW-442 A-No.1 to A-No.2 or vice versa.
b) A change in the consumable manufacturer and brand designation for tubular

flux cored or metal cored composite wires for FCAW, SAW or EGW.
c) A change between wire chemistry from one AWS classification to another or to

wire chemistry not covered by an AWS classification.
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d) For SMAW, SAW, FCAW or ESW a change from one consumable manufacture
and brand designation to a different manufacturer or brand designation shall
be considered an essential variable where corrosion testing is required.
6.4.1(R) Table A.2 provides recommended filler metal selections for typical stainless steels
applications. Filler-base metal combinations not recommended in this table shall be
submitted to EPC Contractor for review.
6.6 Submerged Arc Welding
6.6.4(R) Re-processed flux or re-crushed slag is not permitted for the welding of pressure parts
using this process. It is however permitted to weld structural and non-code
components provided all of the following requirements are met:
a) Markings that create a certain distinction for identifying the re-crusher and the
trade designation.
b) Requalification resulting in a separate WPS(s) and PQR(s).
c) Testing as per AWS A5.17/A5.17M, AWS A5.23/A5.23M, or equivalent

specification.
d) Acceptance from Company.
6.6.5(R) Only non-fused flux is permitted for reuse. Controls shall be in place to ensure flux
intended for reuse is not contaminated with fused flux during the recovery process.
The process shall meet the flux manufacturer’s requirements for protection from
moisture.
6.6.6(A) Active submerged arc fluxes may be used for carbon steel (P-1 material) welding
within all the following limitations:
a) Material wall thickness shall not exceed 1 in. (25mm).
b) Impact and hardness requirements have been met during the weld qualification
process.
6.6.7(A) A change in any of the below, to what is stated in the PQR, shall require re-qualification
of the welding procedure.
Consumable manufacturer and flux-wire.
Flux-strip combination or a change in the composite-cored electrode.
Metal powder manufacturer and brand designation.
6.6.8(A) The “punch-through" technique is permitted provided specifically formulated wires

and fluxes are used for the second side “punch-through” welding and the welding
procedure is impact tested at the MDMT or 0C, whichever is lower, in the area of the
weld cusp. Any change in the flux-wire combination for production welding from that
stated on the PQR will require re-qualification of the welding procedure.
6.8 Consumable Storage and Handling
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6.8.4(A) Conventional low hydrogen SMAW consumables shall be dried and stored in ovens
prior to issue to ensure that they are capable of meeting a maximum hydrogen level
of 8ml H2/100g weld metal (H8 designation in accordance with AWS classification)
prior to the commencement of welding. Electrodes shall only be issued for use in
portable electrode ovens capable of maintaining a temperature of 70ºC minimum.
After use, any remaining electrodes shall be re-dried in accordance with the
manufacturer’s recommendation. Electrodes shall only be re-dried twice before being
discarded.
6.8.5(A) Vacuum packed SMAW electrodes may be used direct from the packaging and shall
be handled, used and re-dried strictly in accordance with the consumable
manufacturer’s recommendation. Electrodes shall only be re-dried twice before being
discarded.
6.8.6(A) FCAW wires shall be stored in accordance with the consumable manufacturer’s
recommendation to ensure that they are capable of meeting a maximum hydrogen
level of 8ml H2/100g weld metal prior to commencing welding.
6.8.7(A) SAW fluxes shall be stored in sealed containers and dried to ensure that the flux-wire
combination is capable of meeting a maximum hydrogen level of 8ml H 2/100g weld
metal prior to commencing welding. During welding, flux shall be stored in heated
containers and shall be returned to heated storage when welding has ceased for
longer than four hours.
Page 19 of 53
7 SHIELDING AND PURGING GASES
7.4(A) There shall be at least ten volume changes of gas in the backing gas enclosure to reduce
the oxygen level to 1000ppm maximum before tack welding or root pass welding. An
acceptable level shall be confirmed by monitoring the oxygen content with a meter.
Oxygen content shall be monitored at 1000ppm maximum whilst the back purge is
maintained. It shall be maintained throughout the welding socket, seal, or any
attachment welds when the base metal thickness is less than ¼ in. (6mm).
Deletion of a back purging gas for butt joints welded from one side only without a
backing strip shall require a separate PQR.
7.5(A) Shielding gases for welding low alloy steels or martensitic stainless steels shall not
contain hydrogen.
7.6(A) Deletion or a change in composition of a purge gas from that stated on the PQR will
require re-qualification of the welding procedure, unless the root pass is ground back
to sound metal and re-welded.
7.7(A) Shield gas used for duplex stainless steel should contain small amount of nitrogen with
2 % maximum to improve corrosion resistance.
Page 20 of 53
8 PREHEATING AND INTERPASS TEMPERATURE
8.1(A) In addition to meeting Code minimum requirements, preheating shall be applied in

accordance with TABLES
Table 1 of this Project Specification. Preheat shall be applied before commencement of all
welding (including tack welding) and thermal cutting. When welding dissimilar metal
welds having different preheat temperature requirements, the more stringent preheat
requirement shall normally be applied. This temperature shall be established during the
welding procedure qualification. Below are temperatures for specific groups of alloys:
a) Unless low hydrogen processes or consumables are used, ASTM A105 carbon steel
flanges or equivalent shall be preheated to 80℃ (175℉).
b) Mn-Mo steels (e.g SA 302 or SA 533) shall be preheated to 150 ℃ (302 ℉ )

minimum.
c) Highly restrained joints may require higher temperatures.
d) ASME VIII, Appendix R shall remain non-mandatory for P-9 materials.
8.5(A) When welding heavy wall (>2in. [50mm]) pressure vessels, the retention of preheat,
dehydrogenation and/or intermediate stress relief, if necessary, shall be specified in the
WPS or on a supplemental datasheet.
8.8(A) Preheat may be applied by any suitable method. Where fuel gas or oil is used, the gas
or oil shall be sulphur-free. The fuel/air mixture shall produce a neutral flame to ensure
that no carbon deposit is left on the weld area.
8.9(A) TABLES
Table 1, of this Specification, indicates the maximum recommended interpass temperatures.
8.10(A) Where the specified minimum preheat temperature is 150ºC or higher, an intermediate
dehydrogenation post weld heat treatment shall be applied in accordance with Table
2 of this specification, or alternatively for equipment subject to PWHT, preheat shall
be maintained without interruption until the start of PWHT.
Page 21 of 53
9 POSTWELD HEAT TREATMENT (PWHT)
9.1(A) The WPS should unequivocally state whether PWHT shall be performed. Ambiguous
statements such as “PWHT if required by Code” are not acceptable.
9.6(A) PWHT of austenitic stainless steel, duplex stainless steel or non-ferrous alloys where
proposed by Vendor, shall be subject to review by EPC Contractor and approved by
Company.
9.8(R) Repairing a previously PWHT’d component without post-repair-PWHT shall be agreed

with EPC Contractor and Company and subject to the repair meeting the requirements
of Paragraph UCS-56(f), ASME Sec. VIII Div 1 and all that is listed below.
a) All carbon steel repair procedures employ temper beading.
b) P-(3, 4 and 5A) materials shall be MT or PT inspected after the material has been at
ambient temperature for not less than 48 hours.
c) Equipment is not exposed to alkaline environments that require PWHT for

environmental cracking protection.
9.13(A) Equipment subject to PWHT in an enclosed furnace shall be adequately supported to

prevent deformation during the heat treatment and thermocouples shall be located
on both the inside and outside surfaces, as a minimum, at the following locations to
ensure the correct temperature is attained:
a) The thickest and thinnest members (including nozzles).
b) Internal head attachment welds (if applicable).
c) The top and bottom of the equipment (as positioned in the furnace).
d) Bottom head (inside skirt).
9.13(A) For local PWHT, the following requirements in addition to the Code shall be met:
a) Local PWHT of circumferential welds shall encompass a complete circumferential

band around the equipment or pipework weld and shall include the soak, heating
and gradient control bands. There shall be no discontinuities such as nozzle or
branch connections, structural supports etc. within the circumferential band but
where this is unavoidable the bandwidth shall be extended to include the
discontinuity.
b) For nozzle-to-shell connections the entire vessel circumference shall be included

in the PWHT band.
c) For flange welds, the entire flange surface, inside and out, shall be insulated.
Wherever practical, the inside surface over the area of the heating band shall be
insulated, or if this is not practical, the ends shall be sealed to prevent draughts
and minimize convection currents.
Page 22 of 53
d) Thermocouples shall be located as follows:
• For circumferential welds four thermocouples shall be equally spaced

around the weld joint within the soaking band on both the inside and
outside surfaces. An additional two monitoring thermocouples shall be
placed at the edge of the soak band and at the edge of the heating band
to ensure that harmful thermal gradients are avoided. The temperature at
the edge of the heating band shall not be less than half the soak band
temperature.
• For nozzle-to-shell connections one thermocouple shall be placed across

the nozzle wall in the thickest section, one at the nozzle-to-shell weld on
the inside and outside surfaces and for components of dissimilar thickness’
one at the thickest and thinnest sections and one at the thickness transition.
• Where electric resistance elements or induction coils are used for local or
partial PWHT, a minimum of one control thermocouple shall be used for
each heating circuit to ensure overheating cannot occur.
9.14(R) Local spot PWHT over a radial band around nozzle-to-shell connections shall be
restricted to spherical pressure vessels or vessel heads and shall be subject to EPC
Contractor and Company review.
Page 23 of 53
10 CLEANING AND SURFACE PREPARATION
10.1(A) Prior to the start of welding, a distance of 50mm from the weld edge shall be
thoroughly cleaned of any contaminants (e.g. oil, grease, and NDE materials) which
may adversely affect the weld quality. For stainless steels and non-ferrous alloys the
weld area shall be scratch-brushed using a stainless steel wire brush solely reserved
for that material, followed by solvent cleaning. All cleaning fluids, solvents etc. shall
be non-injurious to the materials being cleaned.
10.2(R) Pressure vessels and above ground storage tanks that have internal, non-metallic
protective coating systems specified shall meet the following requirements:
10.2.1(A) The design, fabrication and surface finish shall meet the requirements of NACE
Standard SP0178 and any standards specified by the Engineering team of EPC
Contractor and approved by Company.
10.2.2(A) Surfaces shall have a smooth contour, free from discontinuities, crevices and sharp
projections. All sharp projections shall be rounded to a minimum radius of 3.2mm.
All internals shall be fully welded, including the inside surface of storage tank lap-
jointed roof plates.
10.2.3(A) All welds on surfaces to be coated shall be continuous with a smooth transition from
the weld metal to the base material and shall be completely free from surface or
surface-breaking flaws including but not limited to:
• Undercuts and cracks.
• Porosity and inclusions.
• Excessive reinforcement or penetration.
• Root or cap concavity.
• Lack-of-fusion.
10.2.4(A) Surface irregularities, spatter and weld flaws shall be remedied by welding and/or
grinding as agreed with inspector.
10.5(A) All slag shall be removed from the outside of each completed weld.
10.8(A) The use of carbon arc-air for gouging shall be subject to the following restrictions:
• Not permitted for use on 300 series stainless steels or non-ferrous alloys.
• The as-gouged surface shall be wire brushed followed by grinding to a bright

finish before welding to remove all deposits, dross etc.
• Evidence to confirm that arc-air operators have been properly trained and have
current experience shall be provided to EPC Contractor and Company on request.
Page 24 of 53
11 SPECIAL PROCEDURE QUALIFICATION REQUIREMENTS /

TESTING
11.1 General
Replace section in entirety with following:
11.1.1(A) Welding procedure qualification test pieces shall be tested in accordance with the
requirements of the applicable Code and this Project Specification. Test pieces shall
be left for at least 24 hours after welding is completed before NDE and destructive
testing is performed.
11.1.4(A) All welding procedure qualification test pieces shall be subject to visual examination
to the same standard applicable for the finished production weld.
11.1.5(A) Welding procedures for materials subject to PWHT shall be qualified with heat
treatment equivalent to the maximum PWHT cycle anticipated during fabrication
(including any repairs). For carbon steels in excess of 50.8mm nominal thickness and
for low alloy and Ni-alloy in excess of 12.7mm nominal thickness, an additional one
PWHT cycle shall be incorporated to simulate field repair or modification.
11.1.6(A) Welding procedures subject to impact testing in accordance with the code or EPC
Contractor and Company requirements shall meet the following requirements:
a) Weld metal and HAZ samples shall be taken to represent each welding process
used when the weld test piece thickness exceeds 12.7mm. If the weld test piece
is subject to back gouging or punch-through welding, one set of specimens
shall be taken from this area.
b) For carbon and low alloy steels, the use of any temperature reduction in the
code shall apply only down to -46C, i.e. weld metal and HAZ impact tests shall
be performed when the MDMT, including any temperature reduction, is lower
than -46C.
c) Impact tests on full-size specimens (10mm along the notch) shall meet the
criteria specified in Table 3 of this specification.
d) Heat input shall be recorded and calculated for each weld run. For manual
welding processes, heat input shall be recorded and controlled by measuring
the length of weld deposited per unit length of electrode (run-out-length (ROL)
or run-out-ratio (ROR)). For semi-automatic, automatic or machine welding
processes, the heat input shall be recorded by measuring and controlling the
amperage, voltage, travel speed and oscillation/maximum bead width and
depth.
e) An increase in the maximum electrode diameter, a reduction in the ROL/ROR,

an increase in the interpass temperature of more than 25C, a change in the
Tempering Parameter of 0.2 for PWHT or a change in the consumable
Page 25 of 53
manufacturer or brand designation from that stated on the PQR will require re-
qualification of the welding procedure.
f) Stringer bead width shall be limited to three times the electrode core diameter.
g) For single sided welds without backing, the root gap shall be measured during
procedure qualification and shall not be exceeded during production welding.
11.2 Tube-to Tube sheet Welding
11.2.1(R) When welded, tube-to-tube sheet design is specified, welds shall be strength welds.
The welding procedure shall be qualified and tested in accordance with the
applicable Code (e.g. ASME Section IX (QW 193 and QW 288) or ISO 15614-8.
11.2.3(A) When specified by the FEED ENGINEER and/or EPC Contractor, tube-sheet surfaces
require a weld overlay if either of the following conditions exist:
a) The root pass is deposited by GTAW welding without filler metal (autogenous
welding).
b) The tube sheet material requires PWHT according to the applicable code.
Page 26 of 53
12 OTHER ITEMS
12.1(R) Backing Materials
Backing materials shall meet the following requirements:
Permanent metallic backing strips are only permitted for closing welds in refractory-
lined piping. The material of the backing strip shall match the nominal metallurgy of
the base material and shall be fused into the joint for the complete length.
Single-sided weld with temporary metallic backing strip. If the temporary backing strip
is fused into the root pass, it shall match the nominal metallurgy of the base material
and be removed after welding is completed
Single-sided or double-sided weld with temporary ceramic backing strip. Where this
is proposed, the welding procedure shall be qualified with the same type of ceramic
backing strip present.
Consumable inserts in accordance with AWS A5.30 may be used. The consumable
insert shall nominally match the metallurgy of the base material and all welds shall be
subject to 100% RT or 100% UT to ensure complete fusion around the joint
circumference.
12.5 Stud Welding
12.5.3(R) Automatically timed arc and resistance stud welding for the attachment of non
load-carrying studs (such as extended heat transfer surfaces and insulation
attachment pins) shall be qualified on materials having the same nominal
chemistries and thickness as the production welds. Ten consecutively welded studs
shall be destructively tested to demonstrate the suitability of the WPS including the
specified percent fusion. The PQR shall include a record of all welding variables and
equipment settings used during qualification. A production test sample of at least
five consecutively welded studs shall be tested at the beginning of each shift and
after performing maintenance operations on automatic equipment.
* Production welds shall be inspected by hammer testing [2 lb (1 kg) hammer and

20 to 30 in. (500 to 750 mm) stroke] or 15-degree bend tests as agreed among EPC
Contractor, Company and Vendor.
12.6 Hardness Testing - Weld Procedure Qualification and Production Testing
12.6.1(R) Hardness testing and acceptance criteria for welding procedure qualification test
pieces shall be performed as required by Table 4 of this specification.
12.6.1.6(A) Where hardness testing is required for service reasons, e.g. wet H2S service, the
input used in production shall not be less than 10% below that used in the
procedure qualification.
12.6.2(R) Where production hardness levels are specified in Table 4 of this specification,
production hardness tests shall be performed as follows:
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12.6.2.2(R) Testing shall be performed after any required PWHT. The test location shall be in
accordance with NACE SP0472 with frequency as follows:
Non-PWHT Welds PWHT Welds
One test per 3m of weld per WPS Two tests per weld per WPS
12.6.2.4(R) Tests shall be performed on the weld metal (and HAZ where specified) on the
process fluid side where practicable.
12.6.2.5(R) The maximum allowable production hardness for welds shall be in accordance with
Table 4 of this specification.
12.6.2.7(A) Operators of portable hardness testers shall have undergone a training

programme in their use. Records of such training shall be made available to the
EPC Contractor on request.
12.6.2.8(A) Where production hardness values exceed those stated in Table 4, two sets of
additional tests shall be performed. If these two sets of tests meet the required
hardness levels the weld shall be considered acceptable. If the two sets of tests fail
to meet the required hardness levels, the weld shall either be heat treated and re-
tested or completely removed, re-welded and subsequently re-tested.
12.6.2.9(A) Production hardness testing shall be made with Telebrineller, Equoptip or Microdur
instruments.
Page 28 of 53
13 ADDITIONAL REQUIREMENTS TO API RP582
The following sections are in addition to the scope of API RP 582.
13.1 Welder and Welding Operator Qualification

13.1.1 General
Welders and welding operators shall be qualified in accordance with the applicable Code and
this Project Specification.
The acceptance of existing performance qualifications shall depend on documented evidence

of satisfactory performance in the three months prior to commencing work for EPC Contractor
and Company and shall be subject to meeting the essential variable requirements of the Code
and this Specification.
Arc-air operators shall undergo performance tests to demonstrate their ability to remove
metal by gouging in a controlled manner when required by EPC Contractor and/or Company.
Where doubt exists as to the quality of production welding, EPC Contractor and/or Company
reserves the right to require additional welder qualification test pieces to represent nozzle-
shell welds welded with GMAW or FCAW. The nozzle diameter of the test piece shall represent
the smallest diameter used and a minimum of four macrographs shall show no unacceptable
flaws. Additional UT of production welds may also be required by EPC Contractor and/or
Company.
13.1.2 Essential Variables

In addition to the requirements of the code, a welder or welding operator shall be re-qualified
if any of the following apply:
a. A change from one of the following consumable product forms to another for GMAW or
FCAW:
• Flux cored electrode;
• Metal cored composite electrode;
• Bare solid wire.
b. A change in the diameter of the SMAW, GMAW or FCAW welding consumable used for
the root pass in single-sided groove welds from that used to weld the test piece.
13.2 Production Tests

13.2.1 Production Test Plates
Production test plates (PTPs) shall be produced whenever required by the applicable Code
and the following:
a. Equipment subject to impact testing in accordance with this Project Specification.
Page 29 of 53
b. Equipment constructed of ferritic materials with tensile properties enhanced by heat

treatment.
As a minimum, the number of production test plates to be provided shall be as follows:
a. One PTP for each WPS used for each 50m, or part thereof, of the main shell longitudinal
(Category A) and circumferential (Category B) welds.
b. Large pressure vessels that cannot be heat treated as a whole in one heat treatment
charge shall be provided with the applicable PTP for each heat treatment charge. The
portions of the longitudinal weld that will be subject to two heat treatment cycles shall
be represented by separate PTPs that have undergone both heat treatment cycles.
Material for the PTPs shall be from one of the heats of steel used in the fabrication of the
equipment. Where the shell is fabricated from a forging and does not contain a longitudinal
weld the PTP for the circumferential weld shall be taken from a prolongation of the shell
forging.
The Inspector shall verify the identity of each PTP and verify that the PTPs are representative
of the production weld.
PTP thickness shall qualify production welding within the thickness range 0.75t  t  1.25t,
where t is the thickness of the PTP.
PTPs shall be welded by the same welders or welding operators assigned to weld the
equipment. PTPs for circumferential welds shall be welded concurrently with the start of
production welding.
For equipment subject to impact testing or step cool screening tests, the PTP shall be subject
to the same test regime as applied to the welding procedure qualification.
The initial PTP as required in this paragraph shall be subject to the required testing as early as
possible. For equipment subject to PWHT, the PTP shall be subject to a simulated heat
treatment prior to testing. A permanent record of the temperature and time of this simulated
heat treatment shall be maintained by equipment Vendor and included in the production data
book.
Where more than one production test plate is required, these additional test plates shall be
placed inside the equipment during any subsequent PWHT and retained for future testing as
required by EPC Contractor and Company.
Where the test results do not meet the specified requirements, two additional test specimens
may be re-tested to determine compliance. If these two additional test specimens meet the
requirements, the weld shall be considered acceptable. If the two test specimens fail to meet
the requirements, all further production welding shall be stopped until the cause of failure is
established. Once the cause is established, and subject to EPC Contractor and Company
review, the weld shall be completely removed and re-welded or a fitness-for-service
assessment performed to determine its acceptability.
Root pass weld visual inspection should be completed prior to proceed with other passes. In
case of any defects, the root cause (may be the welder, electrodes, welding machines or mostly
Page 30 of 53
the weather conditions) shall be identified and appropriate corrective actions shall be
implemented.
13.3 Non-destructive Examination (NDE)

13.3.1 General
The extent of NDE (100% or 10%/Spot/Random) shall be established on the basis of the
applicable Project Specifications and Design Code.
With the exception of carbon steel piping, radiography for acceptance purposes shall be
performed after PWHT where applicable.
Acceptance criteria shall be in accordance with the applicable Design Code.
All NDE shall be performed in accordance with written procedures approved by EPC
Contractor/Company. No examinations shall be performed prior to the written approval of the
procedures.
All NDE shall be performed by personnel certified in accordance with ASNT Recommended
Practice SNT TC 1A. unless agreed by EPC Contractor and Company. Certification of personnel
shall be made available to EPC Contractor and Company representative upon request.
Interpretation of results shall be performed by personnel certified as ASNT Level II or III.
Results of non-destructive examinations (NDE) shall be reported on forms authorized by EPC

Contractor/Company and copies of reports shall be provided to EPC Contractor/Company.
Company reserves the right to approve all final radiographs and results of other examinations
and tests.
13.3.2 Radiographic Source

All shop examination up to 50mm wall thickness for equipment and 25mm wall thickness for
piping shall use X-radiography. Gamma radiography using an Iridium 192 source may be
utilised for greater thicknesses. X-radiography can be utilised for field examination. In any
case, wherever a gamma source is used, the image sensitivity achieved shall be 2% or better.
13.3.3 100% Radiography

Where 100% radiography is specified all other pressure containing welds and all attachment
welds to pressure parts shall be examined in accordance with the following:
a. Support Skirt welds shall be subject to 100% magnetic particle test (MT) or 100% dye
penetrant test (PT) for items in non-ferro-magnetic materials (e.g. austenitic stainless
steel, nickel alloys).
b. All attachment welds shall be subject to 100% MT or 100% PT for items in non-ferro-
magnetic materials (e.g. austenitic stainless steel, nickel alloys).
c. Nozzle to shell welds shall be subject to 100% MT or 100% PT for items in non-ferro-
magnetic materials (e.g. austenitic stainless steel, nickel alloys).
d. Lifting Lug welds shall be subject to 100% MT or 100% PT for items in non-ferro-magnetic
materials (e.g. austenitic stainless steel, nickel alloys).
Page 31 of 53
e. For tanks NDE, the use of penetration oil is not permitted in lieu of MT or PT.
Where 100% radiography is specified for pipework in Normal Fluid Service or Category M Fluid
Service the acceptance criteria shall be as defined by the Code for the applicable fluid service.
Enhanced ASME B31.3 Code acceptance criteria as applicable for Severe Cyclic Conditions shall
only be applied where such conditions apply to the piping design and also refer to Piping
Material Specification (9686-8230-SP-000-5001)
13.3.4 10%, Spot or Random Radiography

Where 10%, Spot or Random Radiography is specified the following additional requirements
shall apply to attachment welds:
a. Lifting Lug welds shall be subject to 100% MT or 100% PT for items in non-ferro-magnetic
materials (e.g. austenitic stainless steel, nickel alloys).
b. For equipment, where there is no Code requirement for NDE of attachment welds or
nozzle to shell welds, 10% of attachment welds and 10% of nozzle to shell welds shall be
subject to 100% MT or 100% PT for items in non-ferro-magnetic materials (e.g. austenitic
stainless steel, nickel alloys).
c. For piping, where the extent is defined as a percentage this shall be interpreted as
complete examination of a defined percentage of welds.
d. Spots shall be selected so that each welder, each welding process and each longitudinal
and circumferential seam is represented in the examination.
e. For tanks NDE, the use of penetration oil is not permitted in lieu of MT or PT.
13.3.5 Ultrasonics in lieu of radiograph

For ferritic steel pressure vessels, where joint geometry or thickness makes radiography
impractical, ultrasonic examination (UT) may be used subject to agreement with EPC
Contractor and Company. The UT examination shall be in accordance with ASME Code Case
2235-9 or an equivalent agreed with EPC Contractor and Company.
For ferritic steel piping, where joint geometry or thickness makes radiography impractical,
ultrasonic examination (UT) may be used subject to agreement with EPC Contractor and
Company. The UT examination shall be in accordance with ASME B31.3 Case 181-2 or an
equivalent agreed with EPC Contractor and Company.
Requirements for Qualification block design, procurement and testing shall be reviewed by
EPC Contractor and agreed by Company at the time of acceptance of the proposal to utilise
UT in place of radiography.
13.4 Weld Repairs

13.4.1 General
Any unacceptable flaws found during NDE shall be repaired in accordance with an approved
repair procedure. Repair welding of minor defects shall be done only by qualified welders
using a qualified welding procedure. For Major Weld Repairs, the weld repair procedure shall
Page 32 of 53
be submitted for review by EPC Contractor. 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 NDE.
Wherever possible, unacceptable flaws shall be removed by grinding or machining provided

the thickness is not reduced below the minimum required. Arc-air gouging is permitted
subject to the restrictions. Removal of defects shall be verified by magnetic particle or liquid
penetrant examination.
13.4.2 Inspection
Where removal of a flaw requires subsequent welding to reinstate the required throat
thickness, the repair cavity shall be contoured to permit access for welding followed by 100%
MT/PT. A qualified welder using a properly qualified WPS shall perform the repair weld.
Normally, only SMAW or GTAW shall be used to make the repair weld.
Following welding, the repair area shall be subject to 100% NDE using the same technique(s)
as used to detect the flaw initially. Only two repairs at the same location are permitted,
thereafter the complete weld shall be removed, re-welded and re-examined.
All repairs and rectification work shall be fully recorded and evidence provided for EPC
Contractor and Company review and approval that all required NDE and production tests have
been performed.
13.5 Weld Joint Identification and Weld Map Requirements

Each and every production weld shall be assigned a weld number following the relevant weld
numbering procedure. Field and shop welds are normally differentiated. These weld numbers
shall be clearly marked in the isometrics (in case of piping) or on a drawing/development (in
case of vessels or tanks). This marked up isometric or the drawing/development is referred to
as the Weld Map. Weld Maps, similar guides or fabrication drawings which clearly identify the
application of each WPS, indicating where and how the WPSs will be used, shall be included
in the submittal.
This map is updated regularly with the actual production, repair status, welder ID numbers,
and the extent of NDT performed.
All pressure weld joints shall be legibly marked with the weld joint number and the welder's
ID. Construction Sub-contractor/Vendor QA/QC is held responsible for their welders’ ID
stamping on the welds. This should be a continuing Quality Check.
13.6 Alloy Material Control (PMI Testing)

For Alloy material control refer to Specification for Positive Material Identification (9686-8470-
SP-000-4004)
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14 TABLES
Table 1(5): Preheat and Interpass Temperatures
Nominal Minimum Preheat Maximum

P-No. Material Type Thickness at Temperature Interpass
Weld (mm) (C)(1) Temperature (C)
t  12.7 10(3) 315
12.7  t  25.4 75(1) 315
1 Carbon steel(2)
25.4  t  50.8 100(1) 315
t  50.8 150(1) 315
t  12.7 10(3) 315
12.7  t  25.4 75 315
C-½Mo
25.4  t  50.8 100 315
3
t  50.8 150 315
Mn-Mo, Ni-Mo All 150 315
t  12.7 125 315
4 1Cr-½Mo, 1¼Cr-½Mo 12.7  t  25.4 150 315
t  25.4 175 315
5A, 2¼Cr-1Mo, 3Cr-1Mo,

t  12.7 150 315
11A&B Ni-Cr-Mo, Mn-Mo-Ni
12.7  t  25.4 175 315
t  25.4 200 350
5B 5Cr-½Mo, 9Cr-1Mo
6 &7 400 series stainless steel All Per Code(4) (4)
8 300 series stainless steel All 10(3) 175
10H Duplex Stainless Steel All 10(3) 150
34-35 Cu-base alloys All 10(3) 200
41-45 Ni-base alloys All 10(3) 175
Notes:
1. Preheat temperatures are based on 8ml H2/100g weld metal hydrogen levels. Alternative
preheat temperatures may be calculated in accordance with EN 1011-2, in which case,
the WPS and PQR shall show all limiting factors such as combined thickness, CE value,
weld metal hydrogen content and heat input or run-out-length, upon which the preheat
level is based.
2. Preheat requirements are based on conventional carbon steel with S > 0.01%. Low
sulphur steels (S  0.01%) may be at higher risk of HAZ hydrogen cold cracking than
conventional carbon steels. Vendor shall review the necessity of increasing the preheat
temperature or lowering the specified CE value for these steels based on Vendor
experience and submit substantiating evidence for EPC Contractor and Company review.
Page 34 of 53
3. Not required other than to remove moisture prior to welding.
4. Preheat temperature for martensitic type steels shall be 200C minimum but shall not
exceed the martensite finish (Mf) temperature to ensure no untransformed martensite is
present during PWHT. The maximum interpass temperature shall not exceed the preheat
temperature by more than 100C.
5. This table is not applicable for storage tanks material, for tanks refer to table 7.1 in API
650.
Table 2: Post Weld Dehydrogenation Heat Treatment
Nominal Thickness at Weld

Post Heat Temperature
(mm)
t  12.7 Cool under insulation to ambient temperature
12.7  t  25.4 350C for 2 hours
25.4  t  50.8 350C for 4 hours

Intermediate stress relief at 600C for 2 hours or 650C
t  50.8
for 1 hour(1)
Note:
1. Low temperature dehydrogenation at 350C for 4 hours may be permitted where

satisfactory long-term experience can be demonstrated, subject to EPC Contractor and
Company review. In this case, only ultra low hydrogen processes (less than 4ml H2/100g
weld metal) shall be acceptable and SAW fluxes shall be non-hygroscopic fused or
specially manufactured bonded fluxes. For highly restrained weld joints and for NPS8
and greater self-reinforced nozzle-to-shell set-in weld joints (e.g. ASME VIII, Div.1, UW-
16.1(g), an intermediate stress relief shall be mandatory.
Table 3(2): Impact Test Acceptance Criteria
Specified
Material Minimum Tensile Acceptance Criteria
Strength (Rm)
P-No1, P-No.3, P-No.4, P-No.5,
Rm450N/mm2 27J ave./20J min. at MDMT
P-No.11A&B
P-No1, P-No.3, P-No.4, P-No.5,
Rm450N/mm2 40J ave./34J min. at MDMT
P-No.11B
P-No.4(1) All 47J ave./27J min. at minus 18C
P-No.5A(1) All 55 ave./47 min. at minus 29C
P-No.9A or 9B All 34J ave.28J min. at MDMT
Page 35 of 53
0.38mm min. lateral expansion at

P-No.8, P-No.31-34, P-No.41-45 All
MDMT
34J ave./28J min. at MDMT or
P-No.10H All
minus 10C, whichever is lower
Note:
1. Only applicable for P-No.4 and P-No.5 materials and welds that have a maximum design
temperature within the range 425C-600C.
2. This table is not applicable for storage tanks material, for tanks refer to table 4.5 in API
650.
Table 4: Hardness Testing Requirements
Maximum PQR Maximum

P- Service
Material Type Hardness Level Production Hardness
No. Environment
(HV10)(1)(4) Level (HB)(2)(3)(4)
Utility services
(air, water, N2, 300(5) Not required
etc.)
General
1 Carbon steel hydrocarbon,
248(5) Not required
including
caustic, amine
H2S 248 200
3 C-½Mo, Mn-Mo, Ni-Mo All 248 225
4 1Cr-½Mo, 1¼Cr-½Mo All 248 225
5A 2¼Cr-1Mo All 248 225
5B 3Cr-1Mo, 5Cr-½Mo, 9Cr-1Mo All 248 235
8 300 Series Stainless Steel All Not required Not required
10H Duplex stainless Steel All 310 295
Notes:
1. Hardness values shall be reported on PQR.
2. Where a figure is specified for production hardness level, production hardness testing
shall be performed.
3. Where pipe is locally heated for bending, production hardness levels shall meet the level
in or the base material specification, whichever is lower.
4. Hardness testing of the PQR is not required when following criteria are met:
Page 36 of 53
• SMAW process with E60YY or E70YY electrodes;
• GTAW or GMAW process with ER70S-2 or –3;
• FCAW process with E70T-1, -5, -9 or –12 or E70C-3;
• SAW process with F7XX-ELX or –EMX.
Page 37 of 53
15 API RP582 ANNEX B: WELD OVERLAY AND CLAD

RESTORATION
B1 General
B1.1(A) Weld Overlays
a. Weld overlay or back cladding shall be deposited in at least two layers, except
for ESW which has a minimal dilution. The number of weld layers in production
shall be equal to, or more than the number of layers deposited for the weld
overlay procedure qualification tests.
b. The minimum “total depth” of the overlay or back cladding shall be 3mm (1/8 in.)
in thickness, unless otherwise specified. The maximum overlay thickness shall not
exceed 9mm.
c. The “effective depth” of the overlay and back cladding shall be the uppermost
3mm of the top layer as a minimum, unless otherwise specified. This material
shall meet the specified chemical composition where chemical analysis of the
production overlay or back cladding is required.
d. In the event that multiple layer overlay or back cladding is required to meet a
specified chemistry and subsequent machining or grinding is required to satisfy
dimensional requirements, then the final machined or ground surface shall retain
the specified effective depth. Examples include machining of gasket grooves in
flanges and tube sheets, grinding of heat exchanger shell inside diameter to
permit insertion of tube bundle.
e. Weld overlay thickness shall be measured at the exposed edge of weld joint
preparations. In case of any doubt or dispute regarding overlay thickness,
ultrasonic thickness measurements shall be taken.
B1.3(A) PQR chemical analysis
The chemical composition at the "effective depth" of the overlay or back cladding shall
be reported for welding procedure qualification tests.
B1.4(A) Production Chemical analysis
Alternatively, the chemical composition at the "effective depth" of the overlay or back
cladding shall be reported for production welding, when specified by EPC Contractor
and Company Engineer. The acceptance requirements for production overlay and back
cladding are found for the particular alloy(s) in B.3 through B.6.
B1.6(A) Extent of chemistry and ferrite testing
The number of samples requiring chemical analysis for all types of weld overlay and
back cladding, as well as the number of ferrite measurements for austenitic stainless
steel deposits, shall be as specified below (a-d). Physical test samples shall be removed
(i.e. chippings, drillings), or in-situ tests shall be conducted, prior to final PWHT at
locations selected by the Inspector.
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a. Automatic weld overlay: One sample or test from each girth section and
equipment component (such as head, tubesheet, connection, etc.), and each
back clad seam, with the exception of samples required to satisfy Item B.1.6.c.
b. Manual weld overlay: Two samples or tests from each girth section and
equipment component (such as head, tubesheet, connection, etc.), and each
back clad seam, with the exception of samples required to satisfy Item B.1.6.c.
c. For back clad seams ≤ 24 in. (600 mm) in diameter, one sample for each 24
diametral-inch, or part thereof. The 24 diametral-inch measurement shall be
cumulative for all back clad seams 24 in. (600 mm) diameter and smaller
employing the same welding procedure, process, and filler metal. Example: One
20 in. manway and three 8 in. nozzles  44 diametral-inches; or one 500 mm
manway and three 200 mm nozzles  1100 mm diametral measurement.
Therefore, two tests are required.
d. Type 310 filler metal shall not be used for weld overlay.
Page 39 of 53
APPENDIX A: ADDITIONAL REQUIREMENTS FOR DUPLEX STAINLESS

STEEL WELDING
A1 Scope
This Appendix specifies additional requirements for the fabrication of the following
Duplex stainless steels; this is in addition to API RP 582 requirement:
• Lean 22Cr Duplex steels (e.g. UNS S32304)
• Standard 22Cr Duplex steels (e.g. UNS S31803, UNS S32205)
• High alloy 25Cr Duplex steels (e.g. UNS S32550)
• 25Cr Super Duplex steels (e.g. UNS S32750, UNS S32760).
Unless otherwise noted in this appendix, the requirements specified in the main text of
this Project Specification shall apply in full.
A2 References
Add the following references:
ASTM E562 : Standard Test Method for Determining Volume Fraction by Systematic
Manual Point Count
ASTM E1245 : Standard Practice for Determining the Inclusion or Second-Phase
Constituent Content of Metals by Automatic Image Analysis
ASTM G48 : Standard Test Methods for Pitting and Crevice Corrosion Resistance of
Stainless Steels and Related Alloys by Use of Ferric Chloride Solution
ASTM A923 : Standard Test Methods for Detecting Detrimental Intermetallic Phase in
Duplex Austenitic/Ferritic Stainless Steels
A3 Definitions
Add the following definitions:
PREN = Pitting Resistance Equivalence Number = wt%Cr + 3.3(wt%Mo+0.5wt%W) +

16wt%N
PREN for 22Cr < 40, PREN for 25 Cr>= 40.
A4 General
A4.1 The requirements of Section 4 of this specification shall be met in full.
A4.2 Fabrication of these materials shall be carried out in an area separate from that used
for carbon/low alloy steels, and copper alloys.
A4.3 Saws, grinders and other tools used on duplex stainless steel shall not be used on
other materials. Bare carbon steel equipment is not acceptable.
Page 40 of 53
A5 Cutting and Welding Preparation
A5.1 Cutting shall be by cold sawing or plasma-arc process. Fused edges and HAZ from
plasma-arc cutting shall be removed by grinding or machining.
A5.2 Welders shall be equipped with and shall wear clean gloves for handling duplex
stainless steels and their filler materials.
A5.3 All low melting point materials including copper, lead, and zinc compounds shall be
removed from the fabrication areas.
A5.4 Due care and attention shall be taken during installation and particularly hook-up
where the overspray of zinc containing must be avoided.
A6 Welding
A6.1 Welding Processes
A6.1.1 Acceptable welding processes shall be in accordance with API RP582 with the
exception that the Electro Gas Welding (EGW) process is not permitted.
A6.1.2 Gas Tungsten Arc Welding (GTAW) shall be used for all single-sided root runs.
A6.1.3 Autogenous welding is not permitted
A6.1.4 Heat input shall be restricted to the range 0.8-2.0 kJ/mm
A6.2 Welding Consumables (Filler Metal and Flux)
A6.2.1 In addition to the requirements in API RP582, when joining materials with the same
nominal chemistry, consumables shall be based on obtaining weld deposits with
equivalent mechanical properties and corrosion resistance to that of the base
material. Unless otherwise agreed with EPC Contractor, deposited weld metal shall
meet the following requirements:
Carbon 0.03% max.
Sulphur 0.01% max.
Phosphorous 0.02% max.
Nitrogen 0.14% min.
35 min. for 22Cr type consumables (e.g. E2209-XX, ER2209)

PREN
For 25Cr type consumables, PREN shall match the base material
as closely as possible but shall not be less than 40
Ferrite balance 30-65FN
A6.2.2 The use of overmatching filler wires for the root pass shall be subject to EPC
Contractor review.
Page 41 of 53
A6.2.3 Welding consumables producing low hydrogen deposits shall be used when
welding all grades of duplex stainless steel. Basic coated SMAW electrodes shall be
used when the nominal thickness at the weld joint exceeds 25mm.
A6.2.4 Each batch of consumables shall be certified in accordance with ISO 10474, Type
3.1.
A6.2.5 In addition to the requirements of paragraph 6.1.10, a welding procedure shall be

re-qualified if there is a change in the consumable manufacturer and brand
designation from that stated on the PQR.
A6.2.6 Dissimilar Welding Filler Materials
When joining materials of different nominal chemistry, the consumables noted

below should be used. Alternative consumable selection shall be submitted to EPC
Contractor for review and approval prior to commencement of welding.
Carbon and ferritic steels, 300 series Cu-base alloys

Base Material(1)
stainless steels Ni-base alloys
Lean 22Cr duplex
Standard 22Cr duplex E309L, E309LMo

Ni-base (e.g. ENiCrFe-3,
Duplex (e.g. E2209)
High alloy 25Cr duplex ENiCrMo-3)
Ni-base (e.g. ENiCrFe-3, ENiCrMo-3)
25Cr super duplex
Note 1. Above table refers to coated electrodes. For bare wire (SAW, GMAW, GTAW)
or FCAW welding, use equivalent AWS electrode classifications
A6.2.7 Shielding/Purging Gas
In addition to the requirements of Section 7 of this specification, a backing purge

gas shall be used to prevent oxidation of tack welds and the root pass in single-
sided welded joints. A backing purge gas shall also be used when welding
attachments directly to thin-wall components (wall thickness less than or equal to
6.4mm).
Shielding and purge gases shall meet the following requirements:
• Gases shall not contain hydrogen.
• Nitrogen and helium contents shall not exceed 2% and 10% respectively for
GTAW.
• Moisture content of gases shall not exceed 10ppm.
A6.2.7.1 Backing Gas
Backing gas shall be used and maintained for the duration of welding to prevent
oxidation of the inner surface.
Page 42 of 53
The extent of gas purging and the method of confining the backing gas shall be
specified on the WPS.
Oxygen levels in the backing gas enclosures shall be monitored before and
during welding. Welding shall not continue if the oxygen level exceeds the limits
stated on the WPS unless otherwise approved.
The use of nitrogen containing gas may be considered and its acceptance shall
be based upon satisfactory welding procedure qualification.
A6.2.7.2 Limits of oxidation
Heavy oxidation is unacceptable and indicated by a dark brown to dark blue

colour with possibly a coked weld surface. Areas of oxidations shall be lightly
ground with 60-35 micron grade abrasive paper. Coarser grades are not
permitted.
If access to the root is impossible, the oxidised surface shall be removed by

pickling to an approved procedure.
A6.2.7.3 Heavily oxidised surfaces, spatter, welding slag and other residues shall be
removed by grinding with rotary abrasive papers/cloths and by pickling.
A6.3 Preheating and Interpass Temperature
A6.3.1 Preheating is not required other than to remove moisture from the weld area prior
to the commencement of welding.
A6.3.2 Interpass temperature should be limited to 200ºC for 22Cr and high alloy 25Cr
duplex stainless steels, and 150ºC for 25Cr super duplex stainless steels.
Where the wall thickness is less than or equal to 6.4mm, a maximum interpass
temperature of 100ºC or lower is recommended.
Maximum interpass temperatures shall be stated in the welding procedure

qualification.
A6.3.3 Temperature indicating crayons shall be certified free from injurious contaminants,
such as sulphur, bismuth, halides etc.
A7 Post Weld Heat Treatment (PWHT)
A7.1 Unless otherwise agreed with EPC Contractor and Company, PWHT is not permitted.
A8 Cleaning and Surface Finishing
A8.1 In addition to the requirements in Section 10 of this specification, the following

requirements shall be met:
a. All preparation, cutting and welding operations shall be performed in a clean

area, segregated from the fabrication of ferrous materials and suitable for the
production of sound, non-contaminated welds.
Page 43 of 53
b. All tools shall be dedicated to duplex stainless steel fabrication only and shall
not have been used previously on any ferritic materials. Grinding wheels or discs
shall be iron-free and shall not be organic resin bonded.
c. Weld preparations may be cut or profiled by grinding, machining or plasma arc

cutting. The HAZ from thermal cutting shall be removed by grinding or
machining.
A8.2 Any tack welds shall be made exercising the same care as for root, fill and cap welds.
Tack welds shall only be incorporated into the root pass if they are sound.
A8.3 Carbon-arc gouging is not permitted for profiling or back-gouging of welds.
A9 Welding Procedure Qualification
A9.1 General
A9.1.1 Welding procedures shall be developed to ensure that the weld is essentially free
of intermetallic phases (i.e. less than 1%).
A9.1.2 The root pass for single-sided welded joints shall be welded by depositing a second
“cold pass” at approximately 75% of that used for the root pass.
A9.1.3 Heat input shall be in accordance with base material manufacturer’s

recommendations and consistent with the base material thickness to obtain
adequate fusion and weldment properties. The following limits are recommended
but acceptable heat inputs shall be established during procedure qualification:
Lean 22Cr duplex stainless steels 0.5-1.5kJ/mm for t  10mm

22Cr duplex stainless steels
High alloy 25Cr duplex stainless steels 0.5-2.5kJ/mm for t  10mm
25Cr super duplex stainless steels 0.5-1.5kJ/mm for all thickness
A9.1.4 For wall thickness’ less than or equal to 6.4mm, welding procedures shall be
qualified using the proposed production wall thickness in order to simulate the
actual heat sink effect.
A9.2 Tube-to-Tubesheet Welding
A9.2.1 In addition to the requirements in paragraph 11.2.1 of this specification, each test
sample shall be subject to the following tests:
• Microstructure and ferrite determination.
• Hardness determination.
• Corrosion testing (where specified).
A9.3 Weld Procedure Specification
A9.3.1 The WPS shall indicate all measures that should be taken, specific to welding duplex
stainless steels, so as to avoid contamination.
Page 44 of 53
A9.3.2 The WPS shall contain full details of shield and purge gas conditions including gas
composition, flowrate, closing dam type and maximum oxygen content in backing
gas closure.
A9.4 Procedure Qualification Record (PQR) Test Requirements
A9.4.1 In addition to the testing required in accordance with ASME IX, the following tests
shall also be performed for welding duplex stainless steel:
• Charpy Impact test where the requirements shall be agreed with EPC
Contractor and Company.
• Two weld test piece cross sections shall be subject to metallographic

examination. For qualification of tests in the 5G or 6G positions, the samples
shall be taken from the “3 o’clock” and “9 o’clock” locations. It is not a
requirement to take samples from specific locations for any other welding
positions.
• The austenite ferrite ratio shall be determined at both the cap and root areas
in accordance with ASTM E562 using the intercept method with a minimum
grid size of 25 and an accuracy of 1%. Fields shall be selected randomly and
magnification chosen appropriate to the ferrite lathe size (x500-x1000) is
preferred). The ferrite content shall be in the range of 45-50% for the base
metal and 35-60% for the weld metal and HAZ. The use of automatic
equipment in accordance with ASTM E1245 shall be subject to agreement with
EPC Contractor and Company.
A9.4.2 The microstructure shall be examined, with and without etchants, and should be
essentially free of grain boundary carbides and intermetallic precipitates (i.e. <5%).
A9.4.3 Where specified, corrosion testing in accordance with ASTM G48 Method A and
the following:
a. At least two samples with a nominal test face size of 50x25mm shall be
prepared for testing. Specimen weight shall be sufficiently low enough to
allow measurements to within ±1mg. The weld direction shall be
approximately parallel to the shorter edge of the test face with the weld
positioned equidistant from two ends of the specimen. The weld width should
not exceed one third of the specimen length.
b. The sides and ends of each specimen shall be ground to remove any
machining marks to produce a 1000-1200 grit finish and all corners shall be
rounded. The test face shall be in the as-received condition i.e. “ready for
service” with no additional preparation on the surface under test unless
otherwise agreed with EPC Contractor and Company.
c. Unless otherwise specified, the test temperature for Type 22Cr duplex stainless
steel shall be 22ºC ± 1.0ºC and 35ºC ± 1.0ºC for Type 25Cr duplex stainless
steel (Note; lean Type 22Cr steels do not require corrosion testing).
d. The test specimen shall be orientated with the test face uppermost and at an
angle of approximately 45º to the vertical.
Page 45 of 53
e. The test duration shall be 24 hours, thereafter the specimen shall be removed
and cleaned to remove any corrosion products.
f. Acceptance criteria shall be ≤1g/m2 with no visible pitting on the test face
under x20 magnification.
A9.4.4 Impact testing in accordance with paragraph 11.1.6 of this specification shall be
performed at -40ºC or the MDMT, whichever is lower. Samples shall be taken to
represent each welding process used when the test piece thickness exceeds 13mm.
Acceptance criteria for full sized specimens shall be ≥ 40J ave./28J min.
A9.4.5 Hardness testing shall meet the requirement of section 12.6 of this specification.
A9.5 Essential Variables
A9.5.1 Only approved material shall be used for the test.
A9.5.2 A change in any of the following from that stated on the PQR will require re-
qualification of the welding procedure:
a. Manufacturer or source of supply for 25Cr base materials.
b. Type 22Cr base materials to Type 25Cr base materials or vice versa.
c. A change in thickness of 0.75-1.5mm from that recorded on the PQR. For

production wall thickness’ less than or equal to 6.4mm no change in the
qualified thickness from that recorded on the PQR is permitted (refer to
paragraph 11.1.4).
d. Increase in the preheat or interpass temperature.
e. Composition of a shielding or purge gas.
A10 Other Items
A10.1 Backing Materials
Permanent or temporary backing strips are not permitted.
A10.2 Peening
The requirements of API RP582 shall be met in full.
A10.3 Weld Overlay and Clad Restoration (Back Cladding)
The requirements for weld overlay and back cladding are specified in this Project
Specification.
A10.4 Stud Welding
Stud welding shall only be permitted with approval of EPC Contractor and Company.
When permitted, the welding procedure qualification shall include a hardness
survey across the weld.
A10.5 Hardness Testing – Weld Procedure Qualification and Production Testing

Page 46 of 53
A10.5.1 Each welding procedure shall be hardness tested in accordance with Section 12.6
of this specification.
Acceptance criteria shall be as follows unless otherwise specified in the purchase

requisition:
Weld Metal Wet H2S(sour) service All other services
Type 22Cr 310HV10 350HV10
Type 25Cr 330HV10 350HV10
A10.5.2 Production hardness testing shall be performed in accordance with Section 12.6.
Acceptance criteria shall be as follows; unless otherwise specified in the purchase
requisition:
Weld Metal Wet H2S(sour) service All other services
Type 22Cr 260BHN 285BHN
Type 25Cr 270BHN 285BHN
A11 Welder & Welding Operator Qualification
The requirements in Section 13 of this specification shall be met in full.
A12 Fabrication
A12.1 In addition to the requirements of the Code, all cold spun heads with a nominal
thickness in excess of 13mm, prior to forming, shall be re-solution heat treated, in
accordance with the original material heat treatment, after forming irrespective of
the fibre strain induced.
A12.2 Pre-fabricated components shall be examined in accordance with section 13.
A12.3 Local flame straightening shall not be permitted without specific EPC Contractor
and Company approval. Where permitted, EPC Contractor shall review and
approve flame straightening procedures and shall be present during all flame
straightening operations.
A13 Quality Control
A13.1 General
A13.1.1 For single-sided welded joints, the internal root bead shall be inspected for
acceptable weld profile (root penetration) and surface condition (i.e., no
unacceptable oxidation).
A13.2 Non Destructive Examination
Page 47 of 53
A13.2.1 Welds shall be visually inspected in the as-welded condition for indications of
contamination after each pass. Welds shall not be ground, wire brushed or
dressed in any way that removes surface discolouration before inspection.
A13.2.2 A light straw colour discolouration is acceptable. Heavy oxidation, as indicated

by a dark brown or blue colour, with possibly a coked weld surface, is
unacceptable. Unacceptable oxidation shall be removed by light grinding with
60-35 micron grade abrasive paper or by pickling. Pickling procedures shall be
submitted for EPC Contractor review.
A13.2.3 Unless otherwise agreed with EPC Contractor and Company NDE shall be applied
as follows:
Extent of Inspection(1)
Area To Be Inspected
Before Pressure
Thickness at Weld After Pressure Test
Test
Weld preparations 13mm MT/PT -
Category A, B, C, D butt
All RT(2) & MT/PT Visual
welds
≤13mm MT/PT Visual
Category C, D full
penetration corner welds
13mm UT(3)& MT/PT Visual
Skirt attachment weld All - Visual + MT

Internal head attachment
All MT/PT Visual
weld
≤13mm MT/PT Visual
Major attachment welds
(external & internal)
13mm UT & MT/PT Visual
Minor attachment welds
All MT/PT Visual
(external & internal)
Temporary Attachment
All MT/PT Visual
welds
Notes:
1. The requirements of the Code shall be met in full. The extent of inspection stated
does not preclude Vendor increasing the level of inspection as part of its in-
house QC procedures. 100% visual examination is required during all inspection
stages. Unless stated otherwise, all examination specified is for 100% coverage
(internal and external) of the complete weld length.
2. Where the thickness or design precludes the use of RT, UT may be substituted
subject to EPC Contractor review.
3. Only applicable for nozzles with a nominal diameter > NPS 3.
Page 48 of 53
A13.2.4 In addition to the requirements of the code any lack of fusion or penetration at
the root face or surface-breaking porosity, either at the root or cap, is not
permitted.
A13.2.5 Ultrasonic examination shall meet the requirements of paragraph 13.3 of this
specification and a procedure, detailing additional measures to overcome the
anisotropic nature of the weld metal and evidence of the NDE operator’s
experience in the ultrasonic testing of these materials shall be submitted for EPC
Contractor review.
A14 Production Tests
A14.1 Production Test Plates (PTPs)
A14.1.1 In addition to the requirements in Section 12.6, PTPs shall be produced for each
50m, or part thereof, of longitudinal (Category A) and circumferential (Category
B) welds in hot formed heads.
A14.1.2 The PTP shall be subject to the same test regime as applied to the welding
procedure qualification unless otherwise agreed with EPC Contractor and
Company.
A14.2 Ferrite Determination
A14.2.1 Ferrite determination is required for each pressure-retaining weld. Acceptance

criteria shall be 30-65FN.
A15 Repairs
A15.1 General
A15.1.1 Only one repair at the same location shall be permitted, thereafter the weld shall
be completely removed and re-welded.
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APPENDIX B: FABRICATION REQUIREMENTS FOR CUPRO NICKEL (IF

APPLICABLE)
B1 Scope
B1.1 This Appendix addresses the special requirements for the fabrication of cupro nickel
materials and other copper alloy materials.
B1.2 This specification applies to 90/10 cupronickel and 70/30 cupronickel and copper
alloy materials specified in the equipment requisition.
B2 General
B2.1 All welding and brazing operations shall be carried out in conditions fully suitable for
the production of sound uncontaminated welds. Welding operations shall be carried
out away from the fabrication of other materials, in particular, the environment for
welding and brazing cupronickel shall be segregated from that associated with the
working and welding of steel.
B2.2 Wrought cupronickel is often used in conjunction with fittings and valves of other
alloys i.e. nickel-aluminium-bronze. Cupronickel shall not be welded to other
materials, but may be brazed to components which are specifically intended for
brazed connection. Leaded or free machining alloys shall not be brazed.
B2.3 Care shall be taken to avoid contamination of weld areas by temperature-indicating

crayons, marking inks, grease, etc.
B3 Cutting and Weld Preparation
B3.1 Cutting Methods
B3.1.1 Cutting cupro nickel can be by cold cutting with a sulphur free lubricant or plasma-
arc cutting. Post plasma-arc cut, fused and heat-affected material shall be removed
by machining or grinding.
B3.1.2 Grinding wheels or discs shall be iron-free and shall not be organic resin bonded.
B3.2 Weld Preparation
B3.2.1 Welders shall be equipped with and shall wear clean gloves for handling workpiece
and filler materials.
B3.2.2 The joint area shall be scratch brushed using a wire brush used only for copper-
nickel materials. This shall be followed by thorough solvent cleaning immediately
prior to welding.
B3.2.3 GTAW and GMAW filler wire shall be abraded with stainless steel wool and
degreased immediately before use.
B4 Welding
B4.1 Welding Process
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B4.1.1 Gas Tungsten Arc Welding (GTAW) shall be used for all single sided butt weld root
runs and normally for capping runs also.
B4.1.2 Gas Metal Arc Welding (GMAW) or Shielded Metal Arc Welding (SMAW) may be
used for capping runs on joints of 5mm or greater thickness
B4.2 Weld Consumables
B4.2.1 All Consumables shall comply with ASME II Part C and shall be purchased from
consumable manufacturers holding approvals by an independent third party.
B4.2.2 All filler materials for cupro-nickel shall be nominal 70:30, copper:nickel.
B4.2.2.1 Cupro-nickel welding consumables shall be totally segregated from other

materials and should normally be stored within the “clean” shop area.
B4.2.3 SMAW electrodes shall be 3.25mm or smaller diameter core size. Bead width shall
be a maximum of four times electrode diameter.
B4.2.4 Shielding and purging gas shall be oxygen-free argon, helium or a mixture of the
two. Back purging shall be maintained during all welding which shall include
tacking and capping runs.
B4.2.5 To overcome stop/start porosity, the arc shall be struck at the ends of the previous
run and then tracked backwards to remelt all of the previous end crater before
proceeding with welding.
B4.2.6 All slag and tarnish shall be removed between runs prior to resumption of welding,
a bright surface shall be achieved by scratch brushing.
B4.3 Pre-heating and Interpass Temperature
B4.3.1 Pre-heat shall not be used; however the temperature of the joint surfaces shall not
be less than 20ºC before commencement of welding.
B4.3.2 Interpass temperature shall be 150ºC maximum, checked using a contact

thermometer.
B4.3.3 Welding heat input shall be optimised to prevent lack of fusion.
B4.4 POST WELD HEAT TREATMENT (PWHT)
Post weld heat treatment shall not be used.
B5 Brazing
B5.1 Brazing Consumables
B5.1.1 Brazing shall generally be carried out using proprietary heavy duty silver braze
fitting with an insertive silver brazing alloy.
B5.1.2 Filler material for brazing shall conform to ASME IX F-No. 102, with a minimum of
50% silver.
Page 51 of 53
B5.2 Braze Preparation
B5.2.1 The workpiece shall be suitably sized and positioned to obtain a fine clearance
(0.005 in.) so as to enable capillary action during brazing.
B5.2.2 Pipe ends shall be square cut. Joint preparation and adjacent surfaces shall be
abraded using fine glass or emery paper immediately before brazing.
B5.2.3 After abrading joint surfaces, silver brazing flux shall be mixed and brushed on to
the joint surface. If the flux does not adhere well, surfaces should be degreased and
flux re-applied. The two halves of the joint shall be brought into contact whilst the
flux is wet.
B5.3 Brazing Operation
B5.3.1 Torch heating shall be by oxy-fuel torch using ‘soft’, neutral or slightly reducing
flame.
B5.3.2 Heat shall be applied evenly to the joint bringing it to brazing temperature ( 670ºC
min.) as quickly as possible.
B5.3.3 Heating shall continue for 15-20 seconds after melting to allow braze materials to
flow throughout the joint and develop maximum joint strength.
B5.3.4 Satisfactory joining is indicated by the presence of smooth, uniformly-visible

brazing ‘witness’ at the mouth of the joint. Further brazing alloy may be added to
the joint to achieve complete joining. However, excess joining should be avoided.
B6 Forming, Rolling and Bending
B6.1 All mechanical working shall be done cold. Hot bending is not permitted without
written prior permission from EPC Contractor and Company.
B6.2 Any filler materials shall be free from sulphur, lead, bismuth, antimony and any other
elements that are likely to result in intergranular cracking.
On completion of bending, all internal and external surfaces shall be thoroughly

cleaned of all filler and foreign material.
Filler materials and method of removal and cleaning shall be included in the bending
procedure submitted to EPC Contractor and/or Company for approval.
B6.3 Hardness testing of formed materials shall be carried out to the extent specified in
the Materials Requisition and Project Specifications.
B6.3.1 If any hardness value exceeds 100HV the component shall be annealed at a
temperature between 750ºC for a minimum period of 10 minutes.
B7 Weld Procedure Qualification
B7.1 Procedure Qualification Record (PQR) Test Requirements.
B7.2.1 PQR testing requirements shall be undertaken in accordance with ASME IX and
API RP 982.
Page 52 of 53
B8 Cleaning of Assembly
B8.1 All traces of welding slag, brazing flux, spatter, scale or other such material shall be
removed from the fabricated assembly.
B8.2 Joints shall be scratch brushed to produce clean, bright surfaces prior to inspection.
B9 Inspection
B9.1 All joints shall be examined as required by the design Code.
B9.2 Brazed joints shall be 100% visually examined and each shall have a uniform,
complete line of brazing alloy at the mouth of the joint.
B9.3 Welded joints shall be 100% visually examined and 100% liquid penetrant inspected.
Butt joints shall also be radiographically examined to the extent specified in the Code.
Acceptance criteria shall be as stated in the Code. However, lack of root penetration
in excess of 1.6mm shall not be permitted.
B9.4 Pressure containing assemblies shall be leak tested by a Code specified method
approved by the EPC Contractor and/or Company.
Page 53 of 53

9686-8470-SP-000-4005 - 01 Welding and NDT Spec

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9686-8470-SP-000-4005 - 01 Welding and NDT Spec

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RAS MARKAZ CRUDE OIL PARK PROJECT (PHASE1)

SPECIFICATION FOR WELDING AND NDE OF EQUIPMENT AND PIPING

RAS MARKAZ CRUDE OIL PARK

SPECIFICATION FOR WELDING AND NDE OF

Issue for Review / Wang

REV DATE PAGES DESCRIPTION PP CHK APP-1 APP-2

13.5 WELD JOINT IDENTIFICATION AND WELD MAP REQUIREMENTS ....................................................................... 33

REVISION CONTROL SHEET

This page records the revision status of this document

The heading/paragraph numbering of this Project Specification corresponds to the paragraph

Revisions to paragraphs of API RP 582 are indicated by (R) in the margin,

Additional paragraphs are indicated by (A) in the margin.

1.2 Definitions and Abbreviations

Company : Oman Tank Terminal Company L.L.C. (OTTCO)

DMT : Design Metal Temperature

LODMAT : Lowest One-Day-Mean Ambient Temperature

SMAW : Shielded Metal Arc Welding

1.3 Units of Measurements

1.4 Site Environmental Condition

2.1 Order of Precedence

1. Local Laws & Regulations of the Oman

3. Project Specifications, data sheets, as applicable

4. Industry/ International Codes and Standards

5. Service Authority Standards

In the event of an inconsistency, conflict or discrepancy between any of the standards,

2.2 Project Reference Documents

2.3 International Codes, Standards and Regulations

API 650 : Welded Tanks for Oil Storage

2.4 Other Reference (If any)

API 650 : Welded Tanks for Oil Storage

AWS A2.4 : Standard Symbols for Welding, Brazing and Non-Destructive

EN 1011-2 : Welding - Recommendations for Welding of Metallic Materials - Part

4 GENERAL WELDING REQUIREMENTS

a. Typical weld deposition sequence.

b. Weld bevel and fit-up tolerances.

c. Electrical characteristics for each welding process and consumable diameter.

e. Consumable manufacturer and brand designation.

shall perform regular audits to monitor their implementation. Arc monitoring

4.16 (A) Materials

4.16.2 Carbon, Carbon Manganese & Low Alloy Steel

b. Carbon Equivalent (CE) shall not exceed 0.43 where

CE = %C + %Mn/6 + (%Cr + %Mo + %V)/5 + (%Cu + %Ni)/15

a. C = 0.20% max. (forgings only, up to 2% Cr)

b. C = 0.17% max. (all other forms, up to 2% Cr)

c. C = 0.15% max. (all forms, over 2% Cr)

a. All forgings, except plate-like forgings shall be subject to ultrasonic examination

4.16.3 Notch Toughness

b. 10C below the lowest normal process operating temperature.

c. The minimum autorefrigeration temperature i.e. the atmospheric boiling point

d. 5C below the initial hydrotest temperature.

5.2 Limitations of Fusion Welded Processes

5.2.2 Automatic Pulsed Gas Tungsten Arc Welding (GTAW-P)

5.2.3 (A) Gas Metal Arc Welding (GMAW)

5.2.5 Flux Cored Arc Welding (FCAW)

5.2.6(A) Electrogas Welding (EGW)

5.2.7 Submerged Arc Welding (SAW)

5.2.8 (A) Gas Tungsten Arc Welding (GTAW)

5.2.9 Plasma Arc Welding (PAW)

5.3 Single-Sided Welded Joints

5.5 Mechanized and Automated Welding Processes

6 WELDING CONSUMABLES (FILLER METAL AND FLUX)

6.1.1(A) Welding consumables shall be specified in each WPS by an appropriate national