MATERIAL LINDE

ASME SEC II Part A Ferrous Material (2010)

Code ASME B 36.10 M (2004) Welded & Seamless Pipe (Wrought Iron) ( Dimension Code)
ASME B 16.25 (2003) Butt Weld End Preparation ( Dimension Code)
 C.S.- Carbon Steel (-29ºC to 420ºC) Spec No. Grade P No. Group No.
 Grade ASTM A106 B 1 1 Seamless
 Gr. B: C- 0.30%, Mn.-0.29-1.06%, Si.- 0.1%, Page 195 A: C- 0.25%, C: C- 0.35%,
 Tensile 60 Ksi 415 Mpa Page 202
Spec No. Grade P No. Group No.
 A672, C60 1 1 Welded Page 1195
 C60 Plain carbon steel, killed, fine grain Plate A516 Gr. 60
 CL. 21,23 Stress relieved
 NACE MR 0103 + HIC,(Hydrogen Induced Cracking) (2007) Normalized done Pipe
 NACE MR 0175 sulfide stress cracking resistance metallic materials for oilfield equipment
 IS 1239,(GI) M.S. Tubes, Tubular and Wrought Steel Fitting (1990) < 6” (ERW) Plate 2062
 C 0.20 % Mn 1.3 %
 IS 3589, ERW Gr. FE 330 330 is tensile strength (2001)
 C 0.16 % Mn 1.2 %
 Up to 6” – Sch Hvy
 8” to 12” – 6mm, 14” to 18” – 8mm, 20” to 24” – 10mm
 API 5L Gr. B, PSL-2 X65 Page 36 (2004)
 Spec No. Grade P No. Group No.
 A 53 Gr. B 1 1 Black and Hot-Dipped, Zinc-Coated Welded and Seamless
 Used for Utility service C 0.28 % Mn 1.2 %
 PRODUCT SPECIFICATION LEVEL (PSL)
 PSL 2 has mandatory requirements for carbon equivalent, notch toughness, maximum yield strength, and maximum tensile strength.
 Grades B, X42, X46, X52, X56, X60, X65, X70 and X80
 Tensile 60 60 63 66 71 75 77 82 90
 PSL 2 pipe can be supplied in Grades B through X80.

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 MATERIAL LINDE

ASME II Part A Ferrous Material (2010)

 A.S..- Alloy Steel (Used above 420º C service)
 A335 Table 1 Page 541 Seamless Tensile 60 Ksi 415 Mpa Page 202
Grade P No. Group No.
 P11: 4 1 Cr- 1.25%, Mo.-0.5%,Si
 Grade P No. Group No.
 P22: 5A 1 Cr- 2.25%, Mo.-1.0%,
 Grade P No. Group No.
 P5: 5B 1 Cr- 5.0%, Mo.-0.5%,
 Grade P No. Group No.
 P9: 5B 1 Cr- 9%, Mo.-1.0%,
 Grade P No. Group No.
 P91: 5B 2 Cr- 9%, Mo.-1.0%, V- 0.18-0.25%
 A691 Page 1219 Welded
 Grade P No. Group No.
 P91: 15E 1 Cr- 9%, Mo.-1.0%, V- 0.18-0.25%
 P11,P22,P5, CL. 22 Stress relieved
 L.T.C.S.- Low Temp. Carbon Steel (Used Below -29º C to -46° C Service)
 Spec No. Grade P No. Group No
 A333 6 1 1 Page 539 Seamless
 Grade 6 C- 0.30%, Mn.-0.29-1.06%, Si.- 0.1%
 A671 CC60 1 1 Page 1145 Welded
 CC60 Plain carbon steel, killed, fine grain Plate A516 Gr. 60
 CL. 22 Stress relieved Normalized Done
 During Mfg. Manganese is added at higher level 1.06 % for high toughness at lower temp. for resistance to brittleness
 Impact tested at -45º C at 18 J of 10X 10 mm Test Piece. C- 0.10 %

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 MATERIAL LINDE

ASME II Part A Ferrous Material (2010)

 S.S.- Stainless Steel (ASME B 36.19) (Used Below -46° C Service)
 Spec No. Grade P No. Group No
 A312 TP 316/316L 8 1 Page 487 Seamless
 A358 TP 316/316L CL1 8 1 Page 627 Welded
 TP 304: Cr- 18%, Ni.-8%, Tensile 75 Ksi 515 Mpa Page 495
 TP 304L
 TP 316
 TP 316 L ( 2.5 % Mo.) : Cr- 18%, Ni.-12%,Mo. 2 % Tensile 75 Ksi 515 Mpa
 TP 321 Cr- 18%, Ni.-10%,Ti Tensile 70 Ksi 485 Mpa
 TP 347 Cr- 18%, Ni.-10%,Cb Tensile 75 Ksi 515 Mpa
 316:- C- 0.08% 316L:-C-0.035% 316H:-C-0.04-0.10%
 From -15º C to 427º C C.S. Below -15º C to -46º C Impact tested C.S.
 Below -46º C 316/316L SS (Dual Grade) Plate P 9 not available so P 9 welded pipe also not available

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 FITTING LINDE
Code ASME B 16.9 (2007) Wrought Butt Weld Fitting ( Dimension Code)
Elbow 90 , 45, Tee, Reducing Tee, Cap, Concentric Reducer, Eccentric Reducer
 C.S.- Grade ASTM A 234 WPB ASME II Part A (2010) Page 376
 A.S.- A 234 ASME II Part A (2010) Page 355
 P11: WP 11 CL 1 Cr- 1.25%, Mo.-0.5%,Si P9: WP 9 Cr- 9%, Mo.-1%
 P22: WP 22 CL 1 Cr- 2.25%, Mo.-1% P91 WP 91 Cr- 9%, Mo.-1% , V
 P5: WP 5 Cr- 5%, Mo.-0.5%,
 S.S.- A 403 ASME II Part A (2010) Page 725
 304: WP 304L Cr- 18%, Ni.-8%, 321 WP321 Cr- 18%, Ni.-10%,Ti
 316 WP 316 L Cr- 18%, Ni.-12%,Mo. 2 % 347 WP347 Cr- 18%, Ni.-10%,Cb
 L.T.C.S.- A 420 ASME II Part A (2010) Page 749
 WPL 6 C-0.3 WPL 3 C-0.2
 WPL 9 C-0.2 WPL 8 C-0.13
 Material Plate
 CS A285
 P11 A387 Gr. 11 P22 A387 Gr. 22
 P5 A387 Gr. 5 P91 A387 Gr. 91 SS A240 304,316,321,347

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 FITTING LINDE

ASME B 16.11 (2005) Socket Weld and Threaded Fitting ( Cast Iron) ( Dimension Code)
Elbow 90 45 , Tee, Cap, Concentric Reducer, Eccentric Reducer, Coupling Class 3000,6000,9000
ASME B 16.5 (2003) Forged Flange & Flanged Fitting ( Carbon Steel) ( Dimension Code) < 24”
ASME B 16.47(1996) Flange ≥ 26”
WN, SW, Slipon, Blind Class 150,300,400,600,900,1500,2500
 C.S.- A 105 ASME II Part A (2010) Page 189
 A.S.- A 182 ASME II Part A (2010) Page 237
 P11: F11 CL 2 Tensile 70 Cr- 1.25%, Mo.-0.5%,Si P9: F9 Tensile 80 ksi Cr- 9%, Mo.-1%
 P22: F22 CL 1 Tensile 60 Cr- 2.25%, Mo.-1% P91 F91 Tensile 80 ksi Cr- 9%, Mo.-1% , V
 P5: F5 Tensile 70 Cr- 5%, Mo.-0.5%,
 S.S.- A 182 ASME II Part A (2010) Page 237
 304: F304L Cr- 18%, Ni.-8%,
 316 F316L Cr- 18%, Ni.-12%,Mo. 2 %
 321 F321 Cr- 18%, Ni.-10%,Ti
 347 F347 Cr- 18%, Ni.-10%,Cb
 L.T.C.S.- A 350 ASME II Part A (2010) Page 563 LF 1,2,3,9 C-Mn-Si
 FLANGE
 SW/ SCRD : ASME B16.11 (For Fittings)
 BW : ASME B16.9 / B16.28 BW ends as per B16.25
 FLANGED : ASME B16.5 and ASME B16.47 SERIES ‘B’ / AWWA C207
 THREADED : ASME / ANSI B1.20.1 (NPT, Taper threads) (For bolts,studs & nuts)
 FACE FINISH
 This shall be to MSS-SP-6/ ASME B46.1/ ASME B16.5. The interpretation shall be:
‘ Serrated Finish’ : 250-500 AARH (6.3 – 12.5 μ_ in Ra) ‘ Smooth Finish’ : 125-250 in AARH (3.6 – 6.3 μ_ in Ra)
‘ Extra Smooth Finish’ : 63 AARH (1.6 μ_ in Ra)
 Up to 24” (150# - 1500#) ASME / ANSI B16.5 Up to 12” (2500#) ASME / ANSI B 16.5
 Above 24” (150# - 1500#) ANSI B16.47 SERIES ‘B’ / AWWA C207*
 Above 12”(2500#) Designed to ASME Sec VIII Div.1 Only for Category ‘D’ service to AWWA C207 Class D. Hub Type

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 ELECTRODE:- (SMAW) LINDE

ASME II Part C Electrode & Filler Metal (2010)

 C.S.- SFA 5.1 Page 21 E6010- F No.3
 Cellulosic Type, Hydrogen + Co2, 80-90ml/100 gm H2 in FLUX Coating, Good for Pipe Root Run, Deep Penetration,
 E7018- F No. 4 Basic Type, Calcium Fluoride + Calcium carbonate,MainlyCo2, Low Hydrogen Electrode, 5ml/100 gm H2 in Flux
Coating, High Quality, Backing 2500 2 Hr or Mfg. Reco. 300° for 1 hr., High Toughness, Iron Power.
 E6013- F No. 2 Rutile Type, Titania, Mainly Co2, 25-30ml/100 gm H2 in Flux Coating, Iron Powder, General & Structural Use, G.I. Use
 E7016-1 H4/H8 FCAW CS
 E7018/E7018-1 H4/H8 E71T-1
 L.T.C.S. SFA 5.1 F No.4 Page 21 E7018-1 Impact Tested of Bach ( 27 J at -46º C)
 A.S. SFA 5.5 F No.4 Page 117
 P11: E8018-B2 Low Hydrogen, Potassium, Iron Powder ,Backing as per Mfg. requirement, C>0.05%
 P22: E9018-B3 P5: E8018-B6 P9: E8018-B8 P91: E9018-B9
 B- Chemical Composition of Electrode
 B2- Cr. 1-1.5% B3- Cr. 2-2.5% B6- Cr. 4-6% B8- Cr. 8-10.5%
 Electrode Backing 2 hr. Baking Holding Quires
 E7018-1 250º C 150º C 70º C
 E8018-B2 300º C 150º C 70º C
 E316L-15 250º C 100º C 70º C
 S.S. SFA 5.4 F No.5 Page 85
 304: E308L 316: E316L – 15 Cryogenic material E316L – 16 Non Cryogenic material 321 E347
 E-7018 SFA 5.1 Page 40
 E- Electrode 60- Tensile Strength 60 000 PSI 70 -Tensile Strength 70 000 PSI 80 -Tensile Strength 80 000 PSI
 1 - ALL Position 2- Flat & Horizontal Position 4- ALL Position & Vertical Downhill
 0,1- Cellulose Coating 2,3,4- Rutile Coating 5,6,8- Low Hydrogen
 C.S.- ELECTRODE EWTh-2 E - Electrode W - Tungsten 98 % Th-2 - Thorium 2 %
 C.S.- FILLER WIRE SFA-5.18 F No. 6 Page 419
 ER 70S-2 S3,S6 E - Electrode R - Rode S – Solid 70 - Tensile Strength 70 000 PSI 2,3,4,6,7 Amount of deoxidizer

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 ELECTRODE:- (SMAW) LINDE

ASME II Part C Electrode & Filler Metal (2010)

 E7018-1 Mailam- 2.5,3.15,4.0 ER70S2 Bohler, ESAB -2.4
 E8018-B2 Mailam -2.5,3.15,4.0 ER80S-B2 2.4
 E316L-15 Metrode-2.5,3.2,4.0 ER316L Metrode- 1.6,2.4
 ADOR 7018 450 Length 2.5 mm 220 Nos. 5 kg, 20 kg (4 Box)
 3.2 mm 110 Nos, 4.0mm 55 Nos, ER 70 S2 140 Nos.(4 Box)
 For dissimiler CS suppprts are welded to SS pipe welded ENiCr-3 or ENiCrFe-3, E 309, AS to CS – E7018-A1
 Cryogenic SS E316L 15/16 Impact test/Lateral Expansion at -196º C
 For SS welding High Frequency Start up Welding machine Require
 Intergranuar corrosion test is required on PQR for SS E test of ASTM A 262
 Ferrite test shall be done for SS in PQR Ferrite no (FN) shall be between 3-10 FN as determine by magnetic instrument such as a
severn gauge or Ferrite scope.
 Feature of Coating Electrode Shielding, Alloying, De oxidation, Ionizing, Insulation.
 Heat Input
 CS & AS 1.5 KJ/ mm SS Unrestricted
 Calculated heat input shall not be increased by more than 20 % for any service & decreased by more than 10 % for sour service
 Heat Input = Voltage X Amp. X 60 = J/inch
Travel Speed (in/min.)
 Electrode 2.5 mm 80-100 amp, 3.15 mm 100-140 amp, 4 mm 140-190 amp

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 FILLER WIRE & PURGING :- (GTAW) LINDE
ASME II Part C Electrode & Filler Metal (2010)
 A.S. FILLER WIRE SFA-5.28 F No. 6 Page 631
 P11: ER80S-B2 (C > 0.05%) P5: ER80S-B6 P22: ER90S-B3 P9: ER80S-B8 P91: ER90S-B9
 S.S. SFA 5.9 F No. 6 Page 227
 304: ER308 304L: ER308L 316: ER316 316L: ER316L 321 ER 347
 L.T.C.S. ER 70S-G S- Solid G- General Low Alloy Electrode
 FLUX:- (SAW) Agglomerated - Granulated, pick moisture, Fused – Low Quality, like crystal
 Use in dia ≥ 6” & above Thk > 5 mm ≥ 31.75 thk per layer 12.7 mm ≤ 31.75 thk per layer 9.5 mm
 CS Flux F7A5-EM12K , F7P8-EH12K Wire EM12K
 (GMAW) MIG/MAG
 Spray or free flight: give high deposition rates , deep penetration., thick materials, Flat position only
 WFS 8.3 mm/ min, root passes only, for Thk. ≤ 9.5 mm Wire Ø 0.6 to 1.6
 Dip transfer: thinner section , all positional welding including v/down, Short Circuiting, WFS 3.2
 Globular transfer: intermediate range between spray and dip transfer mode, no manual application and success on mechanized
and automatic, Gravity Drop, High Heat
 Pulsed: arc is modified form of spray mode. Give high deposition rate and for all positional welding. No lack of root runs, regular
penetration. No spatter, good profile, high quality welds.
 FCAW
 Spray transfer mode without shielding gas ( self shielded, inner-shield etc) only for structure use
 Spray transfer mode with shielding gas for Fab. pipe use
 A.S. P5,P9,P91,P11, P22 Purging required
 All type of S.S. Purging required , GAS:- Argon/ Nitrogen, Flow Rate:- 12-15 LPM, For prevent Oxidation of Root
 Disposable purging dam(soluble), Neoprene blanking disc , Bladder type, Fixture type, Oxygen 1 % for SS, AS
 Up to root & hot pass or 6 mm Thk weld metal deposited


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 PREHEAT & POSTHEAT LINDE

ASME B 31.3 330 Page 66 (2008) Table 330.1.1

 To minimize detrimental Effect of high temp. & severe thermal gradient inherent in welding. To Slow Down rapid Cooling Rate
 & formation of martensite and Probable of cracking., Check preheat Temp Use Temperature indicating Crayons (Thermo chalk)
 It is performed by Oxy - De Acetylene Flames, Electric Coils
 POSTHEAT Defuse H2 from weld metal during post heat, Post Heat-To maintain uniform homogeneous structure
 C.S & L.T.C.S:- Thk. < 25 mm No Preheat Required Thk. ≥ 25 mm Preheat Temp. 79° C. Post heat Not require
 P11 1⁄2% < Cr ≤ 2% 149° C P22, P5, P9, P91 177° C Post heat Temp. 300º C For 30 Min.
 Inter Pass Temp. C.S. & L.T.C.S.- 250º C S.S. & A.S.- 150º C

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 PWHT LINDE:-
ASME B 31.3 Table 331.1.1Page 68 (2008)
ASME VIII Div.1 Table UCS-56 Page 169 (2010)
 Reduce Residual Stress, Improve Resistance to brittle Fracture, Restore Ductility, Increase corrosion resistance
 Thermocouple generates mili amp. & transferred to compensate cable & cable transfer it to recorder. Both shall be calibrated.
 Dist. Between two thermocouple 4 to 6 mm
 Up to 10” & Thk. 19mm Flame Heating, Above 10” & Thk. 19mm Electrical Heating
 Up to 4” & Thk. 6.4mm Flame Heating ( oxy- Acetylene torch), Flame Heating ( Propane Ring & stationary Burners) any Dia & Thk.
 Width of Heated zone shall be 2t or 100 mm which is greater
 Compensate Cable max. 30 m after heat loss, Calibration at 37°, 1 Year, Pannel calibration 1 year range 0-1300° C
 Thermocouple K type- ( Nickel chromium- Nickel aluminum pair 22 SWG) covered with ceramic ferrule.
 Flexible ceramic mat heaters of , Insulation ceramic fiber roll mat.
 Sour Service ,Amine Service , Caustic Service All Thk. PWHT Require. If sour service support ,weldolet should be PWHT
 Non sour service support & weldolet throat thk > 38 mm as per B31.3 PWHT shall be done
 Recorder, TC, Penal, Compensate cable should be calibrated, Max. 2 PWHT cycle permitted
 Copper /Constantan compensatory cable, Copper lead (+blue) to Nickel chromium conductor and Constantan (-white) to Nickel
Aluminum conductor
 C.S & L.T.C.S.- Thk. > 20 mm PWHT Required Socking Temp. 593°C-649° C
 Socking Time Min. 1 hr/25mm Thk., Above 1” thk. 2.5 min. per 1 mm thk.
 Uncontrolled Heating & Cooling Up to & After 300° C, Rising & cooling Temp. 200 ºC / hr as per B31.3 As per LINDE Heating 150° C
 Cooling 100°C
 A.S.- P11 All Thk PWHT Temp. 704°C-746° C, P22 Thk. ≤ 13 mm No PWHT Required, Thk. > 13 mm PWHT Required Socking
Temp. 704°C-760° C, P5, P9, P91 All Thk. PWHT Require. Socking Temp. 704°C-746° C Socking Time Min. 2 hr. 2.5 min/mm
 Additionally SS 321 and SS 347 grades shall be supplied with stabilised heat treatment solution heat treatment at 900ºC
 LINDE Termocouple Up to 4” 1 at Bottom 6” to 8” 2 Top & Bottom
 10” to 24” 3 120° Apart Above 24” 4 90° Apart
 Sour service & LTCS 100% PWHT & RT, SS one phase transfer so stress are not generated.
 CS, AS PWHT Require because 2 to 3 phase transfer done in iron carbon diagram so stress is developed

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 WELDER TEST LINDE

ASME XI Page 7 (2010)

 QW-191.2 Radiographic Acceptance
 (a) Linear Indications
 (1) any type of crack or zone of incomplete fusion or penetration
 (2) any elongated slag inclusion which has a length greater than
(a) 3 mm for t up to 10 mm
(b) 1⁄3t for t over 10 mm to 57 mm
 (3) any group of slag inclusions in line that have an aggregate length greater than t in a length of 12t
 (b) Rounded Indications
 (1) The max. permissible dimension for rounded indications shall be 20% of t or 3 mm whichever is smaller.
 (2) For welds in material less than 3 mm in thickness, the max. number of acceptable rounded indications
 shall not exceed 12 in a 150 mm length of weld.
 (3) For welds in material 3 mm or greater in thickness, the charts in Appendix I Rounded indications less than 0.8 mm in
maximum diameter shall not be considered in the radiographic acceptance tests of welders
 QW-182 Fracture Tests Page 7 (2010)
 The fractured surface shall show no evidence of cracks or incomplete root fusion, and the sum of the lengths of inclusions and
porosity visible on the fractured surface shall not exceed 10 mm or 10% of the quarter section
 QW-184 Macro Page 7 (2010)
 shall show complete fusion and freedom from cracks, except that linear indications at the root not exceeding 0.8 mm
 the weld shall not have a concavity or convexity greater than 1.5 mm
 there shall be not more than 3 mm difference in the lengths of the legs of the fillet

 Welder Disqualify rejection exceed 5% , First Production Joint RT, 0.75” (OD 26.67) Test Coupon 3 nos. for reach 150 mm
welding, 1 Test Coupon 1 Welder, During Test any stage can terminate welder

 Essential Variable Welder Test

 affect the ability of a welder to deposit sound weld metal
 change in welding process, deletion of backing, F-Number, Pipe Dia, Thk, Position, Progression
 Thk. Range ASME XI Page 142 (2010)
Test Thk. Qualified Thk
All 2t
≥13 mm Max. to be Welded particular process & F No. & with min. 3 layers

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 WELDER TEST LINDE

GROOVE WELDS IN PLATE — TEST POSITIONS

GROOVE WELDS IN PIPE — TEST POSITIONS

 Dia. Range
 Test Dia. Qualified Dia
1” to 2 7/8 1”,0.75” & Unlimited
Over 2 7/8 2 7/8 & Unlimited
0.5” 0.50” & Unlimited
 Qualified With Qualified For
 Any F No. 6 All F No. 6

 Welder test Test Specimens QW-452.5

FILLET-WELD
Thickness Macro Fracture
5 – 10 1 1

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 WELDER TEST LINDE

QW-461.5 FILLET WELDS IN PLATE — TEST POSITIONS

 Position. Range Pipe Groove

 Test Position. Qualified Position
 1G 1G
 2G 2 G, 1 G
 5G 5 G, 1 G
 6G All Position Groove & Fillet
 2G&5G All Position Groove & Fillet
 Position. Range Plate Groove
 Test Position. Qualified Position
 1G 1G
 2G 2 G, 1 G
 3G 3 G, 1 G
 4G 4 G, 1 G
 3G&4G 4 G, 3 G, 1 G
 2 G, 3 G, 4 G ALL

13
WELDER TEST LINDE

QW-461.6 FILLET WELDS IN PIPE — TEST POSITIONS

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 WELDER TEST LINDE

 Welder test Test Specimens QW-452.1 GROOVE-WELD

Thickness Side bend Face Bend Root Bend
Less than 10 1 1
10 to 2T 2
19 t and over 2

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 WPS LINDE

ASME XI Page 58 (2010)

 Essential Variable WPS affect the mechanical properties
 change in P-Number, F- Number, A- Number, Base Metal Thk. Qualified, welding process, preheat or PWHT, Filler Metal Thk.
 Supplementary Essential Variable WPS
 affect the notch-toughness properties
 Group No., Filler Metal Ø & Classification, Current or polarity, change in welding process, uphill or down vertical welding, heat input,
preheat or PWHT, Multiple to single pass
 Non Essential Variable WPS
 not affect the mechanical properties:-joint design, Filler Metal, Positions, method of back gouging or cleaning, Technique

 WPS Thickness Limits and Test Specimens QW-451 GROOVE-WELD TENSION TESTS AND TRANSVERSE-BEND TESTS
 Thickness Range of Thickness Tension Side bend Face Bend Root Bend
 Min. Max.
 Less than 1.5 T 2T 2 2 2
 1.5 to 10 1.5 2T 2 4 2 2
 10 to 19 5 2T 2 4 2 2
 19 to 38 5 2T 2 4
 WPS Fillet Weld Test Specimens QW-451.3 Macro 5
 P No.- Parent metal no. Group No.- Affect impact properties of materialF No.- Filler Metal No.
 A No.- Analysis No. It group the deposited weld metal
 Base Metals Used for WPS One metal from a P-Number to Any metals assigned that P-Number
any metal from the same P-Number
 For Approved WPS Amp. Volt can put 15% of PQR
 Test Method ASTM Tensile E8, Bend E190 , Impact E23
 WPS INDEX :- WPS, PQR, Material test Certi., Batch Certi for welding consumable, Mechanical Test Certi ( Tensile + Bend), Impact
Test Report, Hardness Test, Ferrite Test, Micro & Macro Examination report, RT, MPT, PWHT Reports
 Face Bend Face in tension After 12 mm Thk Side Bend Test
 FERRITE NO. TEST
1.6.1 For all austenitic stainless steels, the weld deposit shall be checked for ferrite content. AFerrite No. (FN) not less than 3% and not
more than 10% is required to avoid sigma phase embrittlement during heat treatment. FN shall be determined by Ferrite scope prior to post
weld heat treatment. FN 3 to 10

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 RT LINDE

 RT ASME B31.3 Chapter I Page 4 (2008)

 Category D Fluid Service: a fluid service in which all the following apply:
(1) the fluid handled is nonflammable, nontoxic ,and not damaging to human tissues
(2) the design gage pressure does not exceed 150 psi
(3) the design temperature is from −29°C through 186°C
 Category M Fluid Service: a fluid service in which the potential for personnel exposure is judged to be significant and in which a single
exposure to a very small quantity of a toxic fluid, caused by leakage, can produce serious irreversible harm to persons on breathing or
bodily contact, even when prompt restorative measures are taken
 Severe cyclic conditions: conditions applying to specific piping components or joints in which SE computed in accordance with para.
319.4.4 exceeds 0.8SA (as defined in Para. 302.3.5), and the equivalent number of cycles (N in Para. 302.3.5) exceeds 7000; or other
conditions that the designer determines will produce an equivalent effect.
RT ASME B31.3 Chapter VI Table 341.3.2 Page 73 (2008) Severe cyclic Condition, Girth Weld Acceptance Value Limits
 Crack, Lack of fusion, incomplete penetration, Undercutting, Surface porosity or exposed slag Zero
 Internal slag inclusion, tungsten inclusion, or elongated Indication
A Individual length ≤T / 3
B Individual width ≤ 2.5 mm and ≤ T / 3
C Cumulative length ≤ T in any 12T weld length
 Concave root surface Suck back Total joint Thk., incl. weld reinf.,
 Reinforcement Height:-
≤ 6 mm thk. ≤ 1.5 mm > 13 to ≤ 25 mm ≤ 4 mm
> 6 to ≤ 13 mm ≤ 3 mm > 25 mm ≤ 5 mm
 Internal porosity ASME VII Div. 1 App. 4 Page 419 (2010)
 Maximum size of Rounded indication shall be t⁄4 or 4 mm which ever is smaller Aligned Rounded Indication t in a Length of 12t
 Cluster Indication 2t or 25 mm & sum of the length of cluster 25 mm in 150 mm Rounded Indication Table 4.1 page 420 (2010)
 Pocket Dosimeter or TLD Badge, Survey meter, Radiation effect to be check by Dosimeter
 LINDE & AG W PC 1017 113 Rev 02 JECOBS
 ≥ 19 mm AGFA D7 8 ≥ TO < 19 AGFA D5 < 8 AGFA D D4
 RT Principal DIFFERENTIAL OBSORPTION of penetrating radiation by the part, Curie 30
 Iridium – 192 thk up to 3 inch, 75 Days, Densitometer, Density min. 2.0 to 4.0 (+30 % & - 15 % )as per ASME V T-282.1 page 14
 If film defect on weld give retake

4/29/2016 17
 RT LINDE

 Radiography techniques : -
 A. Single wall < 2, B. Double wall (DWSI) ≥ 2”, C. Panoramic
 For Pipe 2 “ and less Thk. 5.5 and less – very fine grain, slow speed, Kodak MX 125 or Agfa D4
 For Pipe above 2 “ and Thk. 5.5 Class – II : - Medium contrast, Medium speed Fine grain Kodak AA400 or AGFA D7
 Developing In developer the exposed silver bromide is reduced to silver 5 to 8 minutes at 20° C time as per Film Mfg
 Stop bath. Stops the Developing action by neutralising the alkaline developer 1 minutes Acetic acid
 Fixture. It removes all unexposed silver grains and clouded film starts to become clear. 5 min.
 Washing running water 15 minutes, Drying. Wetting agent for 1 minute
 The IQI or penetrametre should be placed as possible on the source side
 Film Dfects Fogging, streaks, water marks, Scratches, finger marks ,Lead mark, crimps, dirtiness, statics marks, tears
 Loss of detail due to poor screen to film contact Diffuse indications due to defective screens
 ≤ 1.5 “ SFD Source, ≥ 2” Direct Touch, Viewing – Illuminator
 Ir- 192- 0.5 R / Hr / 1 mt. Distance, Ranjan – unit of radioactive energy MR- mili Ranjan, Operator – 2000 MR/ Year, Public – 100 MR/
Year Safety Level 2mR/Hr.1 Ranjan= pass in 1 CC air, 1R = 1000 MR Radiation level check by survey meter, Dosimeter check how
many radiation taken by Men, Coli meter - for Radiation safety Lead pot
 180° 4 IQI in Panoramic Exploser, Up to 6” 1 IQI Above 6” 2 IQI In 1 Film
 Rating 600 & above 100 % RT servev Cyclic Condition 10% RT Normal & Category M Fluid Service
 RT Film Size 12”X15” & 12”X18” & 3”,4” X 350 m Length Roll for cross country pipe & X-Ray camera use for 1to 1.5 km length
 Operator wear TLD badge Over Exposure (< 5000mR/Hr), Camera Make QSA Global USA delta 880 Type : sentinel660/
Amertest660Model Techopx
 Film Overlap 25 mm, Intensifying screens- Lead Thk. 0.02
 RT 2” dia 10 mm Thk, Thk double 20 mm + 4 mm Reinforcement SFD= 12”+2”=14” = 2.5X 14”= 35”= 2 min
 Penetrametre T 276 of ASME Sec V
 Sensitivity min. 2 % = Minimum visible wire diameter X 100 .
Thickness of the job
 Geometric unsharpness Up to 50 mm- 0.51 mm
Ug = F d/D Ug = geometric unsharpness, F = source size,
D = distance from source of radiation to weld or object being radiographed.
d = distance from source side of the weld or object being radiographed to the film
C Crack NSD No Significant Defect, ISI Isolated Slag Inclusion, ICP Incomplete Penetration, ESI Elongated Slag Inclusion
IRP Inadequate Root Penetration, LF Lack of Fusion, BT Burn Through TI Tungsten Inclusion, RC Root Concavity, IP Isolated
Porosity, CP Cluster Porosity, UC Undercut , EP Excess Penetration, WH worm Hole

4/29/2016 18
 RT LINDE
 Lack of penetration.
 weld metal fails to fuse completely the root faces of the joint. Appears as a dark straight line through the centre of the weld
 Cause: - A. Use of incorrect size of electrode , B. Low welding current., C. Faulty fit-up
 Lack of fusion.
 boundaries of infused metal exist between the Weld metal & base metal or between the adjacent layers of weld metals.
 Appears as a dark indication usually elongated and varying in width.
 Cause: - A. Presence of scale, dirt, oxide, slag and other non-metallic substance B. Improper deslagging
 Undercut
 continuous or discontinuous groove at the toes of a weld pass and is located on the base metal or in the fusion face of a multipass
weld. Appears as a relatively straight and narrow dark line and can be located on either or both sides of the root opening locations
 Cause: -
 A. Excessive welding current., B. Too high speed of arc travel., C. Wrong electrode angle.
 Slag Inclusion
 Non–metallic particles of comparatively large size entrapped in the weld metal Appears darker than the surrounding area
 Cause: - A. Improper cleaning of slag between the deposition of successive passes. B. Presence of heavy mill scale, loose rust, dirt, grit
 Porosity presence of gas pores in a weld , clear boundary
 Cause: - A. Chemically imperfect welding consumables, for example, deficient in deoxidizer.
 B. Faulty composition of base material or electrode, for example, high sulphur content.
 C. Presence of oil, grease, moisture and mill scale on the weld surface.
 D. Excessive moisture in the electrode coating or submerged-arc flux.
 E. Inadequate gas shielding or impure gas in a gas –shielded process.
 F. Low welding current or too long an arc., G. Quick-freezing of weld deposit
 Crack Fracture of the metal is called crack. Two types of cracks: - Cold crack & Hot crack.
 Cold crack usually occur in HAZ of the base metal when this zone becomes hard and brittle due to rapid cooling
 after the weld metal has been deposited & sufficient hydrogen has been absorbed by the weld metal from the arc
 atmosphere.
 Appears as a dark jagged or straight line
 Cause: - A. Use of low carbon equivalent materials., B. Higher heat input during welding.
 C. Preheating. D. Use of low hydrogen electrode.
 G. Faulty weld size and profile
 Tungsten Inclusion lighter than the surrounding areas
 Burn Through:
 Appears as an individual darkened area of elongated or rounded contour which may be surrounded by a lighter ring

4/29/2016 19
 RT LINDE

 Up to 3” S.F.D. ≥ 4” Direct Touch Source

 2” thk. 10 mm thk double 20 mm+4 mm reinforcement SFD= 12”+2”=14”=2.5*14”=35”=2 min by scale
 Edge is not fused Lack of side wall fusion, Edge is fused is undercut, Two side no fuse lack of penetration

4/29/2016 20
 NDT LINDE

DP ASME VII Div. 1 App. 8 Page 436 (2010)

MPT ASME VII Div. 1 App. 6 Page 431 (2010)
 Only indications with major dimensions greater than 1.5 mm shall be considered relevant.
 A linear indication is one having a length greater than three times the width.
 A rounded indication is one of circular or elliptical shape with the length equal to or less than three times the width.
 ACCEPTANCE
 (a) Relevant linear indications;
 (b) Relevant rounded indications greater than 5 mm
 (c) Four or more relevant rounded indications in a line separated by 1.5 mm or less (edge to edge);
UT ASME VII Div. 1 App. 12 Page 454 (2010)
UT ASME B31.3 Para. 344.6.2 Page 80 (2008)
UT ASME B31.1 Para. 136.4.6 Page 95 (2007)
 Imperfections which produce a response greater than 20% of the reference level shall be investigated to the extent that the
operator can determine the shape, identity, and location of all such imperfections and evaluate them in terms of the acceptance
standards given in (a) and (b) below.
 (a) Indications characterized as cracks, lack of fusion, or incomplete penetrations are unacceptable regardless of length.
 (b) Other imperfections are unacceptable if the indications exceed the reference level amplitude and have lengths whichexceed:
(1) 6 mm for t up to 19 mm (2) 1⁄3 t for t from 19 mm to 57 mm (3) 19 mm for t over 57 mm
 DP ASME V Article 6 Page 125 (2010) MPT ASME V Article 7 Page 133 (2010)
 RT ASME V Article 2 Page 7 (2010) UT ASME V Article 4 Page 43 (2010) VT ASME V Article 9 Page 167 (2010)
VT ASME B31.3
 Crack, Surface porosity, slag Zero
 Undercut ≤ 1 mm & T/4 Concave root surface Total joint Thk
 Reinforcement Height:-
 ≤ 6 mm thk. ≤ 1.5 mm Height > 6 to ≤ 13 mm ≤ 3 mm
 > 13 to ≤ 25 mm ≤ 4 mm > 25 mm ≤ 5 mm
ASME B 31.3 Page 77 (2008)
 Visual examination of 5% min of fabrication, 100% visual examination of longitudinal welds
 Random visual examination during erection of piping

4/29/2016 21
 NDT UT LINDE

 Method:- Shared, Compression wave

 Compression wave (Lamination Scanning) Probe 0 deg, 5 Mhz, Welding -2 & 4 Mhz
 Principle :- Aqestic Impedance / Piezo Electric Effect
 Technique:- Pulse Echo Technique, Straight Beam and Angle beam.
 Types
 Emulsion, Conduct, Through Transmission, & Resonance Type
 V1- 300 x 100, R-100, 90, 85 slot, 35 x 15 - 1 mm dia hole T- 25 mm
 V2- 75 x 50, R-50, R-25 hole dia- T-12.5 mm
 Beam Path : t / cos θ Skip Distance : t / tan θ
 Depth of Defect : defective B.P x Cos θ Surface Distance : defective B.P x Sin θ
 Type of Scanning :A Beam Spread Angle :‫ ג‬x 1.22 / Dia
 UT not Possible below 2" & Wall thick less than 5 mm Transmitter receiver probe TR
 Normal, T/R, for Thk inspection Crystal Size Dia 10 mm & 25 MM
 Angle probes O, 45, 60, 70 Crystal Size 8 X 9, & 20X 22

 CALIBRATION OF EQUIPMENT V1 & Step Wedge Block (VW)

IIW (International Institute of Welding) V1& V2 blocks, DAC blocks with flat bottom holes, AAC blocks with flat bottom holes, ASME Basic
Calibration Blocks with side drilled holes and others calibration blocks with standard notches as per different specifications. Like mock
up test pieces as per T-530 of ASME Section V.
 Range calibration of TR probes are required to be done at regular interval . This is to be done with the help of multi step thickness
gage calibration block
 Longitudinal & Shear Wave, Reference dB 41, Scanning dB 41
 Equipment Model Epoch-XT OR Krautkramer USK – 7 Couplent Cellulose Paste
 Velocity of transverse wave in steel 3250, Velocity of Longitudinal wave in steel 5920
 Sensitivity of probe:- Which same condition small defect high amplitude it is high sensitivity
 Good Resolution Separate defect Bad Resolution Mix Defect
 Plate thk > 50 mm strait beam method ASTM A578 Acceptance Level B
 DAC Distance amplitude Correction Curve, DAC’s are prepared from reference blocks.
 Defect Report Level 50 % DAC, Defect Reject Level 100%
 Reflection & Refraction, Dead Zone Initial Width

4/29/2016 22
 NDT UT LINDE

 For plotting DAC on pipe weld joint rectangular notches are to be prepared on both inner and outer surface of the pipe, both in
longitudinal and transverse direction, to obtain the full coverage of the sensitivity level for both longitudinal and transverse scanning.
Here the first echo is obtained at ½ V paths and is set at 80% by increasing the dB then the rest maximum amplitudes of echoes are
marked respectively. (i.e. 1V , 11/2V , 2V etc).
 1 Compression wave probe
 Suppression or reject control shall be kept in off position
 Calibrate screen twice the thk. Of job
 Set the amplifier such that the first back echo is set to a min 80 of full screen height
 Increase amplifier setting by +6 db for scanning
 If back wall echo drops by more than 50 % investigate the area
 2 Angle beam probe
 Echo height greater than 20% DAC Shall be investigate to determine the shape identity and location of the reflector & evaluated
 Ultrasonic flaw detector with pulse echo contact beam method for thk 6 mm and above A scan, T-530 of article 5 of ASME Sec V
 Normal beam probe 4 mhz 10 mm dia
 T/R probe 4 mhz, 10 mm dia
 Angle beam probe miniature shear wave 4 MHz 45°,60°,70°
 IIWV1, IIWV2, ASTM E 164step wedge block
 The range calibration and DAC setting shall be verified prior to any insp.
 Scanning speed 150 mm/sec, Min. 10 % overlap maintained
 Referance block made from same mat. OD, ID,Notches used for plotting of DAC Fig. T 434-3
 Equipment Calibration :- Screen height linearity, Amplitude control Linearity, Horizontal Linearity once ia a year or first time use
 Compression wave ( Normal/

4/29/2016 23
 NDT UT
 V1 Block
35
165 100

R
50 25
30

10
0R
55

1.5
15

2
15

V1 BLOCK
Block Thickness 25 mm
4/29/2016 24
 NDT UT
25
 V2 Block 50

25R 50R
20

V2 BLOCK 7.7
BLOCK THICKNESS
12.5 mm

4/29/2016 25
 NDT UT
 Defect Find Out

 Probe 60°
 Range 0 – 150 1 div = 15mm
 Defect at 2.2 Div.

 Beam Path bp= 2.2 X 15 = 33

 Surface Dist. Sd = bp X sin Ø
= 33 X sin 60 = 33 X 0.86
= 28.38
 Depth d = bp X cos Ø
= 33 X cos 60 = 33 X 0.5
= 16.5

4/29/2016 26
 DP MPT PMI PLASMA LINDE

 DP
 By Capillary action (dia is less than 0.1mm) penetrate goes into defect, By Blotting action penetrate come out
 Wetibility, Surface tension, Viscosity, Penetrate dwell time 7 to 10 min., Developer dwell time 7 to 15 min.,
 Sensitivity of penetrate developer check by 20 micron nickel chromium test plate
 Temp. 10° to 52° , Acetone + red colour = Penetrate (solvent base visible)
 Penetrate – Low contact angle, wet ability, Cleaner is alcohol base, Company – Flow check “PMC”
 MPT
 Up to 4 mm, Kerosene + Iron Power , Field Indicator(Pie gauge) for check magnet
 Fero magnetic material – High + sascetivity, Iron, Cobalt
 Lifting Capacity Yoke AC 4.5 kg, DC 18.1 kg, ASTM E 709 AC use for surface, Dc for sub surface
 PMI (Optical emission Spectrometer)
 We can not gate carbon content only alloying element can check, PMI of CS is not posibal
 Equipment X MET 2000, 12.7 % For pipe acceptance, 10 % For Weld joint Acceptance
 Innov-X systems Alpha 2000 Alloy Analyser works on the principle of X Ray Fluorescence (XRF)
 Plasma Cutting
 Ionized gas, Oxygen or air, 7000 C, 22000 C
 plasma arc cutting (PAC): an arc cutting process that uses a constricted arc and removes molten metal with a high Velocity

4/29/2016 27
 HYDRO PNUMETIC TEST LINDE

 content of chlorine in water CS – 250 PPM., SS – 30 PPM. As per APHA 21nd Ed 2005, 4500-cl,B,4-70
 Hydro test 1.5 times of design pressure, Pneumatic test 1.1 time of design pressure B 31.3
 Holding time Bare pipe 30 min., Wrapping coating pipe 1 Hour
 Gauge & Transducer ( Chart Recorder) 1.5 to 4 times of Test pressure
 Difference between 2 gauges 10m 1 kg, higher at bottom side due to gravitational force
 Pneumatic test max. 8 bar due to safety, Pad Test with 1.25 bar pressure Temp. down is in British code
 Safety valve set as + 10 % of hydro test pressure, Water for hydro test = 5/4 D² X L, Water PH is 7
 PSI to Kpa Multiply by 6.895 1 PSI = 0.070307 Kg/cm2, Kpa to PSI Multiply by 0.145 Kpa to Kg/cm2 Multiply by 0.0101972
 1 Bar = 14.27 PSI, 1 Bar = 100 Kpa, 1 Bar = 1.01972 kg/ cm2
 Hydro holding time 1 Hour with chart recorder, Flushing Air Velocity 20m/sec & Water 4m/sec, Gauge Cal. 6 Months
 Hydro test package List Mark up P & ID , Isometric Drg. punch list, NDT reports LDT Line Designation Table
 Hydro test Acceptance Paper Gauge Calibration Certi.

4/29/2016 28
 PAINTING LINDE

 ISO 8501-1: 2007 (Swidish Code) Abrasive blasting to min. Sa 2 ½ (very thorough blast cleaning )according to Surface Profile No.3 BN 10
 Surface profile “medium” (G) according to EN ISO 8503-1.
 Painting Humidity 85%, Wind speed above 25 KMPH Hardener temp 30° C Temp. Less than 5 C or above 50 C
 Surface Profile 40- 60 micron, check by Profile Gauge, Comparator as per SSPC VIS 1 & Press-O-Film
 DFT check by Coat Measure or Alco meter
 Copper Slag Abrasive 30/60 mesh size 0.5 – 2.5 mm
 Paint Mfg Shalimar, < 120 C Grey, > 120 C Aluminum
 Virling Hygrometer 2 min. Rotation or Thermo Hygrometer Dry bulb Temp., 36
 Wet bulb Temp., 26 Difference 10 by chart we get Relative Humidity 45% & Due point temp. 22°
 After blasting with in 4 hrs painting should be start
 Measurement of surface profile as per NACE RP 0287 or ASTM D4417 and ISO 8502

 LINDE & AG W PC 1017.117 Rev 03 JECOBS 44LK-5100-00-V.02-0002-A4

 SYSTEM -"b" : STRUCTURES
 Primer - Zn Rich Epoxy 50 Mid coat - MIO 2 Pack Epoxy 100
 Inter - High Build 2 pack epoxy 100 Finish - Acrylic Modified 2 pack PU 50
 System "c" : BARE PIPING Temp. Max 100 C
 Primer - Self Priming Epoxy Aluminum 125 EPIPLUS556 Over Coat 24 hr.
 Mid coat - MIO 2 Pack Epoxy 100 EPIGARD 5 HB MIO BROWN Over Coat 18 hr.
 Inter - High Build 2 pack epoxy 100 EPIGARD 5 HB MIO BROWN Over Coat 18 hr.
 Finish - Acrylic Modified 2 pack Polyurethane 50 Shalithane HB Finish Over Coat 12 hr.
 System "g“ Temp 100 to 300 C Bare Pipe
 Primer - Heat Resistant Al-Silicone Paint 20 HR Lustrol Al Up to 250 C Over Coat 18 hr.
 Primer - Heat Resistant Al-Silicone Paint 20 Hr Lustrotherm HT 400 Up to 400 C Over Coat 4 hr.
 System "h“ Hot Insulation
 Primer - Inorganic Zinc Silicate 75 Tuffkote Zilicate Over Coat 24 hr.
 Defects:- Sagging, Low DFT,

4/29/2016 29
 Wrapping Coating LINDE

 Up to 60° C- coal tar enamel, 60° C to 90°- Polyethylene based cold tape - PVC backed bituminous compound tape
 Blast cleaning to grade Sa 2½ of the International Standards Organisation ISO 8501-1
 Shop Applied Coatings:- Primer - Within 4 hours, Synthetic resin based processed coal – tar pitch and refined coal – tar oil
 Coal tar enamel - plasticized coal tar pitch
 Inner wrap - Stabilized polyethylene tape, non-woven fibre glass tissue consisting of a uniformly porous mat of chemically resistant
boro-silicate glass containing not less than 5% B2O3
 Outer wrap:- Non-woven fibre glass tissue consisting of a uniformly porous mat of chemically resistant boro-silicate glass containing
not less than 5% B2O3
 Whitewash or latex emulsion
 Pie Test A square of 25mm X 25mm shall be cut from wrapping for determination of thickness, adhesion and position of the inner
wrap. This shall be carried out at the rate of one pipe per 50 coated Pie test values as per ASTM D 1000 Temp.
Pie Value N/cn
 23,30,35,40,45,50 15,10,7,5,3,2
 Field Applied Tape
• Tape shall be PVC backed bituminous compound, with excellent adhesion
 Holy day Test 12 kv 3mm Thk, 15 kv 4 mm Thk 10 kv
 2” & below copper plate Above 2” Ring use,
• ASTM D 4541
• Test method for pull off strength of coating using portable adhesion testers
• ASTM D 5162 Holyday test

4/29/2016 30
 OTHERS & HARDNESSLINDE

 Tempering
 This reduces hardness and increases toughness, but it also tends to reduce tensile strength. , 550-700 C
 Hold for sufficient time, Slow cool in air
 Annealing
 cooled very slowly to room temperature This produces a very soft structure, 920 C, Low Hardness,
 Decrease toughness,& Yield stress
 Normalizing cooled in air, 920 C, Increase Toughness, Grain refinement.
 Quenching 920 C, Fast cool, water or oil, High Hardness,
• A. The American Petroleum institute (API). B. The American Iron & Steel institute (AISI).
• C. The American Society for Testing and materials (ASTM).
• D. The American National standard institute (AISI). E. The American welding society (AWS).
• F. The American Water Works Association (AWWA). G. The American Society for Mechanical Engineers (ASME)
 H Manufacturer's Standardization Society Standard Practice (MSS-SP)
• A. Flat face. (FF), B. Raised face. (R/F) C. Tongue and groove. (T/G), D. Male and female. (M/F)
• E. Ring type joint. (RTJ), WPB W- Welded, F11 F – Forged
• SMAW (Shielded Metal Arc Welding) (US) or MMA(Manual Metal Arc Welding) (UK)
• GTAW (Gas Tungsten Arc Welding) or TIG (Tungsten Inert Gas Welding) SAW (Submerged Arc Welding)
• GMAW (Gas Metal Arc Welding) or MIG/MAG (Metal Inert Gas/Metal Active Gas Welding) FCAW ( Flux Cored Arc Welding)
• ASME B 31.3 Table 331.1.1Page 64 (2006)
 A.S.-
 P11 - 225 BHN P22 ,P5,P9 - 241 BHN
 NACE:- 200BHN Brinell Hardness Test Method ASTM E10

4/29/2016 31
 OTHERS& IBR LINDE

 Estimation for welding consumables for piping

• Wall Thk. GTAW SMAW
• In mm gm/inch dia gm/inch dia
• 4 20 26
• 5 28 37
• Productivity of the welder
• PIPE SIZE PLANT PIPING
• Up to Dia. 1 ½ “ 10 ID/welder/day
• Dia. 2” to 12” 16 ID/welder/day
• Dia. 8” to 12” 18 ID/welder/day
• Dia.14” & above 20 ID/welder/day
 Normally, 90 to 120 IM is erected per day per gang. One gang comprises the following:
• A. Welder : 01, B. Fitter : 01 C. Gas cutter : 0.5, D. Grinders : 0.5 E. Riggers : 04, F. Helpers & others : 02
 The correct definition is "Sour Service", a multi phase operating environment containing wet Hydrogen Sulphide or other gases
 fluids containing water and hydrogen sulphide (H2S) that is at a total pressure of 0.4MPa (65psia) or greater, and if the partial pressure
of hydrogen sulphide in the gas is greater than 0.0003MPa (0.05psia)". The acidity of the environment is below pH 3.5, and carbon
dioxide, and chlorides are also normally present.
 NACE standards provide guidance on materials selection and acceptance in a specific service or environment
• IBR
• Lines for which design pressure is 3.5 kg/sq. cm and above, Line size above 10” having design pressure 1.0 kg/sq.cm and above
• Any vessel Exceed 22.5 Ltr & generate steam, Steam, Condensate, & Boiler Feed water
• Form III A for pipe, Welder Certi. Form XIII (13), Form III C Fitting Chemical Compo., Tensile ,Bend, Hardness
 Amp. Volt check by clipon meter , Tong Tester
• Tensile Strength = Load (pounds) = PSI
• Area (square inch)

4/29/2016 32
 WELDING LINDE

 Weld Decay - Carbide formation, Granular crack., STRA(short transverse reduction area) – Lamellar Tear
 Leg length = 0.7 x Throat Thk, Toe Blend 30°, Porosity ≥ 1.6 Ø is blow hole,
 Effect of Alloying Element Aluminum; De-oxidizer, grain refiner, Carbon; Strength , Hardness
• Chromium; Corrosion resistance, Creep resistance and resist oxidation, Manganese; toughness
• Molybdenum; Creep resistance Nickel; Improve toughness at low temperatures, Silicon; De-oxidizer (0.2 – 0.3%)
 OCV ( Open circuit voltage) 50 to 90
 High Voltage – Excessive spatter , Porosity, Slag, High Travel speed – Narrow thin weld, undercut,
 High amp – Burn through, Undercut, porosity, spatter Slop up – Reduce tungsten inclusion, Slop out – Crater pipe
 High Heat Input , Transformer – Voltage to suitable Voltage, Rectifier – AC to DC
 Weave width less than 3 times dia of the electrode, PAW – Plasma Arc Welding
 Do not stop welding up to Root & Hot pass completion & 9 mm Thk or t/3
 AWS A 2.4 Symbol of welding, NDT Current (Amp) = [Diameter of Electrode (mm) X 40] ±20
 Brittle Fracture Flat, Fatherless, Rough Ductile - Shear lips at 45°, Torn & Rough, Fatigue - Smooth

4/29/2016 33
 PIPING LINDE

 Reinforcing pad gap 1.5 mm max., with 3 mm vent & test hole ,All branch stub On type
 Pipe Fabrication Institute (PFI) ES-3 Fabrication Tolerance, ASTM A36 carbon structural steel
 300 – Austenitic Series, 400- Ferrite or martensite SS, Structural groove weld 12.7 mm thk & over RT or UT
 Straightness of Columns Lengths of 10 m to15 m = 10 mm, True North is Actual North to 30º and Drg. Angle is 30º
 SUPPORTS Guide, Rpad, Shoue Anchor, Stiffener, Clamp, Bracket, Trunion,
• IMPACT TEST 1.3.1 For Pipe and fittings of carbon steel of thickness over 19mm and alloy steel of all thickness, Charpy-V notch
impact testing shall be carried out in accordance with paragraph UG-84 of ASME Section VIII, Div-1 for weld metal and base metal from
the thickest pipe, forging & fitting per heat of material and per heat treating batch. Impact test specimen shall be in complete heat
treated condition and accordance with ASTM A370. Impact energies at 0ºC shall average greater than 27J (20 ft-lb) per set of three
specimens, with a minimum of 19J (15 ft-lb).
 Pipe is identified by NB and thickness is defined by Schedule
 Tube is identified by OD & its thickness as BWG (Birmingham wire gauge or 1/100 inch).
 Thk. ≥ 40 mm UT, Above 2” UT for weldolet for mother pipe
 Socket weld Gapolet use & 1% RT to check gap
 Thk. Variation of fitting, pipe as per Code 10 %
 Circumference joint to joint dist. 4t or 150 mm 4” OR 5t
 Joint to weldolet 2t or 40 mm, Longitudinal 150 mm or 45° 100 mm or 30°
 From the size 14” and onwards NB = OD of pipe.
 Eccentric reducers = Pump suction to avoid Cavitations, To maintain elevation (BOP) in rack.
 Concentric reducers = Pump discharge, vertical pipeline
 Above 18” ERW pipes are used. Below 18” seamless
 Flange Serration Acceptance up to 24” B16.5 - 2003 Page 61 Table 3
 Flange Serration Acceptance 26” to 60 B16.47 - 1996 Page 46 Table 16
 14” & above pair of spacer & blind use Gasket graphite filled winding with SS 304 inner ring & CS outer ring
 OD = SIZE X 80 = 16” X 80 = 1280 1° = 1280/ 360 = 3.55 mm
 Exa. 80mm/3.55 = 22.53° Π X D for up to 12 “
 Pipe dimension shall be in accordance with ANSI B36.10, IS: 1239 & IS: 3589
 Above 900 rating consider 100% RT Longitudinal weld seam 30° or 100 mm, Dist between weld 101.6 mm(4 inch) or 5t

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 ASME SEC IX, B31.3, SEC IIIV, V, D1.1 LINDE

B 31.3
 Welding Inspector Qualified according to ASME B 31.3 Par 340.4 & B 31.1 Par 136.1.4
 Inspector have 10 Years Experience, Impact test performed as ASME B31.3 Par 323.2.2 & par 323.3
 Welder % 5% as per B 31.3, Welders for WPS shall be qualified ASME B 31.3 Par 328.2.3 and 328.2.4
 Two penalty joints, Single V, J, Composite V Joint Preparation B31.3 – 2003 page 60 Fig. 328.4.2
 Branch Conection Stub in & Stub out B31.3 – 2003 page 61 Fig. 328.4.4
 Socket weld Gap 1.5 mm & Fillet leg length 3 mm B31.3 Page 63 Fig. 328.5.2c & B16.11 Page 9 Fig 2 to avoid bottoming which
could result in excessive weld stress
D1.1
 Welding of support, Welding , NDT Symbol.
 Visual, DP, MPT Insp. Accept. Crack, Fusion, Undercut 1 mm, Porosity 1 mm in 10 mm & 20 mm in 300 mm in any length of
welding AWS D1.1- 2002 Page 218 Table 6.1
 UT Table 6.2 ,RT,MPT,DP Section 6 part C page 176
High Frequency (HF) units are mainly used for GTAW process.
 Starting the Arc: After gas flow is established and providing HF is used, the electrode does not have to touch the work piece or
starting block to effect arc ignition. The superimposed high frequency current bridges the gap between the electrode and the work piece
or starting block and thus establishes a path for the welding current to follow.
 High Frequency (HF): The high frequency mode will initiate and maintain the arc during the zero crossing of the A.C. sine wave.
Three positions exist on most GTAW machines.
 1. Start - This mode helps arc initiation without making actual contact to the work with the tungsten welding electrode. The “Start” mode
is most often used in D.C. welding.
 2. Continuous - this also helps initiate the arc and continues throughout the process to maintain the arc during periods when current
(amperage) is at the zero crossing point of the sine wave. This mode is most often used in A.C. welding. This type of mode is often a
built in feature on most CIGWELD GTAW machines, and occurs automatically when AC current for GTA welding is selected.
 3. Off - The high frequency system does not engage during any part of the process in this mode. Contact between the tungsten
electrode and work surface must occur before the arc can be initiated. A “Touch
Start or Scratch Start Practice” to initiate the arc can cause contamination of the the tungsten electrode in the GTAW process. The “Off”
mode is often used for DC- TIG or stick welding (MMAW) where scratch starting will initiate the arc

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 INSULATION LINDE

 N - None, P - Personal protection, C – Cold, F – Fire Proofing, S – Steam Trace HC- Heat Conservation , IH- Hot Insulation
 INSULATION MATERIAL
• Mineral wool Pipe section 140 / 150 kg/m3 Up to 24” Dia. Mineral wool boards 128 kg/m3 / blanket with both side S.S. wire mesh
100 kg/m3. Above 24” dia and equipments 0.043 w/m ° C thermal conductivity
 CLADDING MATERIAL Aluminized 0.5 mm 900 mm length 50mm overlap joint 3,6 O’clock direction Inside Epoxy Painting
 MASTICS AND SEALANT silicon Rubber , Sealant Foster 81- 84
 For SS Piping – mineral wool insulation contain less than 125 ppm of leachable chlorides
 Adhesive - pittcote 88, Finishing cement – thermocote 1-FW, Flashing compound – GE SCS 1200 or 1209 silicone mastic,
Insulating Cement – Thermocote 1 GP/FF, Joint Sealant – Pittseal 444, Vapour Barrier – Bakelite 110 , Weather proofing – childer
CP 10 and 11Vi- cryl, Metal Jacketing SS or GI
 < 10” 25 mm thk > 10” 38 mm thk Insulation Company Lyods Kapper
 1.6 mm dia wire titaning every 225 mm on LRV Blanket SS belt 19 mm width 0.5 thick every 450 mm on LRV
 SS Screw, Clip, Inspection Pocket for UT Strait line every 30 m dist. 12,6 O’clock direction
 In Elbow 1 after joint 1 in center 1 after joint 6”x 6” Box

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 MATERIAL:- (Fitting) LINDE
ASME B 16.34 (2004) Valve Flanged, Welding, Threaded (Cast Iron) ( Dimension Code)
 API 600 (2001) Bolted Bonnet Steel Gate Valve ( Dimension Code)
 API 602 (1998) Compact Steel Gate Valve ( Dimension Code)
 BS 1414, BS 1873 Globe Valve, BS EN ISO 17292 - Ball valve
 API 609 - Butterfly valve, API 594 - Water check valve
 ISO 15761(2002) British Standard Gate, Globe Check Valve 4” and Below
 Check Valve, Gate Valve, Butter Flay Class 150,300,400,600,800,900,1500,2500
 C.S.- A 216 ( Cast Iron) ASME II Part A (2010) Page 349
 WCA- C-0.25 WCB- C-0.30
 A.S.- A 217 ASME II Part A (2010) Page 353
 P11: WC6 P9: C12 P22: WC9 P91 C12 P5: C5
 S.S.- A 351 A 217 ASME II Part A (2010) Page 600
 304: CF3,CF8 321 F347 316
 L.T.C.S.- A 352 ASME II Part A (2010) WPL 6
Code MSS SP-97 ( Dimension Code)
Nipolet, Weldolet, Sockolet, Concentric Swage, Thredolet, Class Class 3000,6000,9000
 C.S.- Grade ASTM 105 A234 WPB ASME II Part A (2007) Page 376
 A.S.- A 182 ASME II Part A (2007) Page 257
 P11: F11 P9: F9 P22: F22 P91 F91 P5: F5
 S.S.- A 403 A182 ASME II Part A (2007) Page
 304: WP 304 321 F321 316 WP 316L
 L.T.C.S.- A ASME II Part A (2007) Page
 Stud Bolt B18.2.1 A193 B7 NUT A194 Gr. 2H Teflon Coated

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 Angle of bevel 37.5º ± 2.5º ASME B 31.3 (2006)Chapter V Fig.328.3.2 Page 57
& ASME B 16.25 Fig 2a (2003) Butt Welding Ends Page 6
Root face 1.6 ± 0.8 mm

Included angle 75º

Root gap 2 to 3 mm
 ROOT GAP DGS-6300-001 INTERNAL HI LO DGS-1300-185
 < 2” 1.5 mm up to 24” 1.6 mm up to 12 mm thk 1.5 mm B31.3 Fig K328.4.3
 2” to 10” 1.5 to 2.5 above 26” 3.2 mm over 12 mm thk 3 mm as DECO-RX-L-SP-2005
 > 10” 2.5 to 3.5
 SINGLE BEVEL SP-500-13-12-081 EXTERNAL MIS ALIGNMENT
 Up to 28” . - 32.5º ± 2.5º Thk. < 12 mm - Thk/4
 ≥ 30” - 22.5º ± 2.5º Thk. > 12 mm -3 mm
 ROOT FACE ASME B 16.25
 1.6 mm ±0.8

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 Supplementary Weld Symbols
Toes to be ground smoothly.
Field Weld (BSEn only)

Ground flush

Other
side Concave or Convex
Tail
Arrow Reference Line
Weld all round side

Welding process. Numerical BS

Arrow Ladder En & BS

Further supplementary information, such as WPS

number, or NDT may be placed in the fish tail*

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 Scope WELDING GAUGE ABOUT LINDE
 RELIANCE I.D. I.M.
 ESSAR I.D. 25000 I.M. 180000
 KHARAFI NATIONAL I.D. 1,068,487 I.M. 912708
 Painting M2 910,188
 Base Contract Value $ 727,500,000
CAIRN I.D. 63000 I.M. 145000
 Bridge cam gauge
 Undercut, Excess weld metal, Fillet Leg Length Fillet weld throat,
 Angle of preparation, misalignment out side
 Hi – Lo Gauge
 Internal misalignment, Pipe wall Thk. Weld Cap Height, Fillet leg length
 Fit up Gap 1.58,2.38 mm, Bevel angle 37 1/2
Founded in 1879 by Professor Carl von Linde
Work Force: about 55,000 spread across more than 80 countries.
Sales: 12.306 billion Euro in 2007 (13.9% increase)
Operating profit 2.424 billion Euro (18.1% increase)
≈ INR 15000 Crore
Linde Engineering: Sales 2.75 billion Euro (40.4% increase)
Operating profit 240 million Euro (39.5% increase) Achievements: Over 3800 plants in 80 countries

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