SP 90 13

SASOL SPECIFICATION SP-90-13
REVISION 3
WELDING OF SHOP AND FIELD FABRICATED STRUCTURES
Mauritz Faling Marcel Rabie

2020-06-01 12:08:29 +02:00 2020-06-03 09:41:40 +02:00
Originator: Originator
Reviewer: I recommend this document
Mauritz Faling Marcel Rabie
Andrew Dacre
Approved by: 2020-06-01 08:18:15 +02:00

I approve this document
Andrew Dacre
For interpretation of Specification, the following person(s) can be contacted:
CM Faling, M Rabie, JJ Kruger
PREVIOUS REVISIONS
A Revision Description Sheet is included to assist in identifying the changes in the latest
revision.
ISSUE
REV No PROPOSED BY REVIEWED BY APPROVED BY DATE
DATE
1 Jan 1986 De Gifford CZ Pretorius JP Nell 16 Oct 1985
2 Nov 2004 P Motaung AR Benade C Thirion 29 Nov 2004
Any questions, queries, comments and proposals for revisions or additions can be
directed in writing to the Sasol Specification Coordinator at
specifications@sasol.com
VALIDATION This Specification is only regarded as controlled in the electronic format on the official Sasol Livelink/Intranet
website. When printed, this document is deemed as uncontrolled and thus for information only. It is the responsibility of the user
of a printed copy of the document to ensure validity before use. When issued on a CD to a registered user, it is a controlled
document and users will be notified and issued with the latest revision. If it is issued for a specific project, it is valid for the duration
of the project, unless agreed otherwise.
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COPYRIGHT This Specification is protected by copyright and is the sole property of Sasol. The information is proprietary to
Sasol and is for the sole use of the identified project or defined scope of work. Any unauthorised use, disclosure or copying or
any other means of duplication or reproduction, is prohibited.
Copyright © 2020. Sasol. All rights reserved.
Copyright SASOL
Provided by Accuris under license with SASOL - Uncontrolled Copy Licensee=Sasol Supplier Account - PM Approval Required/5906396008, User=Sambo, D
No reproduction or networking permitted without license from Accuris Not for Resale, 04/29/2024 05:44:19 MDT
Revision 3
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TECHNICAL COMMITTEE OF SPECIFICATION SP-90-13, Revision 3
NAME COMPANY AND DEPARTMENT
Badenhorst, CH (Kallie) Secunda Chemicals Operations,

Technical Support
Botha, PJ (Pieter) Group Technology, E&PS
De Klerk, WP (Willem), Group Technology, S&P
Dorfling, CA (Charl) Secunda Synfuels Operations,

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Welding Services
Du Plessis, AL (Awie) Group Technology, E&PS
Faling, CM (Mauritz) Group Technology, S&P
Grobler FJ (Franco) Group Technology, E&PS
Kruger, JJ (Johan) Group Technology, S&P
Kruger, P (Pieter) Natref, Technical Support
Mitchell, JP (John) Secunda Chemicals Operations,

Inspection Authority
Rabie, M (Marcel) Group Technology, S&P
Prins, C (Chris) Group Technology, E&PS
Swanepoel, DB (Niel) Secunda Synfuels Operations,

Metallurgy
ACKNOWLEDGED PERSONS:
Kobus van Zyl, Rex Engineering Supplies (Pty) Ltd.
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REVISION DESCRIPTION SHEET
REVISION 3
SP-90-13 has been completely revised.
A grading for steel structures is introduced with this revision whereby only the requirements
applicable to the grade of structure need to be complied with.
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FOREWORD
In the following paragraphs of the specification, each requirement is categorized into a Core,
Site Specific or Negotiable requirement. The categorization is placed immediately after each
paragraph in “Bold”.
Example:
1.1.1 Paragraph ends. Core
The definitions of Core, Site Specific and Negotiable are shown below. The colour
associated with each categorization is also used.
Classification Tag Colour Definition

Core CORE Red Non-negotiable requirements that are applicable to
all Sasol sites, including international sites, taking
into consideration:
<0000> Safety
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World best practice
Site Specific RSA Blue Non-negotiable requirements applicable to all
(RSA) South African based sites, taking into
consideration:
Legal requirements of the country
Standardization issues
Environmental implications
Site Specific Secunda Blue Non-negotiable requirements applicable to the
(Secunda) Secunda site only, taking into consideration:
Site Specific Sasolburg Blue Non-negotiable requirements applicable to the
(Sasolburg) Sasolburg site only, taking into consideration:
Site Specific Natref Blue Non-negotiable requirements applicable to the
(Natref) Natref site only, taking into consideration:
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Classification Tag Colour Definition

Site Specific International Blue Non-negotiable requirements applicable to all non-
(International) South African based sites only, taking into
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consideration:
Negotiable Negotiable Green Requirements that must be agreed by both the
project team and client at an appropriate time.
Once agreed, this requirement becomes
mandatory for the specific job.
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TABLE OF CONTENTS
PAGE
1 GENERAL ..................................................................................................................1
1.1 SCOPE .........................................................................................................1
1.2 LEGAL REQUIREMENTS ............................................................................1
1.3 ORDER OF PRECEDENCE .........................................................................1
1.4 ABBREVIATIONS .........................................................................................2
1.5 DEFINITIONS ...............................................................................................3
1.6 DEVIATIONS ................................................................................................3
2 REFERENCED CODES AND STANDARDS.............................................................3

2.1 SOUTH AFRICAN NATIONAL STANDARDS (SANS) SPECIFICATIONS ..3
2.2 AMERICAN SOCIETY FOR MECHANICAL ENGINEERS (ASME)
STANDARDS................................................................................................3
2.3 AMERICAN WELDING SOCIETY (AWS) SPECIFICATIONS......................4
2.4 AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) STANDARDS ..4
2.5 SASOL SPECIFICATIONS, DRAWINGS AND DATA SHEETS...................4
2.6 METRIC VS CUSTOMARY UNITS...............................................................5
3 GENERAL WELDING REQUIREMENTS ..................................................................5

3.1 PREFERENCE OF WELDING CODES........................................................5
3.2 GRADING OF STRUCTURES......................................................................5
4 PROCEDURE QUALIFICATION AND WELDER QUALIFICATION .......................11

4.1 WELDING PROCEDURES AND QUALIFICATION....................................11
5 CHARPY IMPACT TESTING ...................................................................................14

5.1 REQUIREMENT FOR IMPACT TESTING..................................................14
6 WELDING PROCESSES .........................................................................................15

6.1 ACCEPTABLE WELDING PROCESSES ...................................................15
7 MATERIAL REQUIREMENTS .................................................................................18

7.1 FILLER AND BASE METAL REQUIREMENTS..........................................18
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8 WELDING.................................................................................................................20
8.1 WELD JOINT PREPARATION ...................................................................20
8.2 WELD CLEANING REQUIREMENTS ........................................................20
8.3 WELD CONTOUR AND FINISH .................................................................21
8.4 PREHEATING.............................................................................................22
9 POST WELD HEAT TREATMENT ..........................................................................23

9.1 POST WELD HEAT TREATMENT REQUIREMENTS ...............................23
10 INSPECTION AND TESTS ......................................................................................23

10.1 INSPECTION AND TEST REQUIREMENTS .............................................23
10.2 VISUAL EXAMINATION .............................................................................25
10.3 MAGNETIC TESTING (MT) AND PENETRANT TESTING(PT).................25
10.4 HARDNESS TESTING ...............................................................................26
10.5 RADIOGRAPHIC TESTING (RT) ...............................................................26
10.6 ULTRASONIC TESTING (UT) ....................................................................26
11 REPAIRS..................................................................................................................26
11.1 WELD AND STRUCTURE REPAIRS .........................................................26
12 END OF JOB DOCUMENTATION...........................................................................27

12.1 DOCUMENATION AND SIGN OFF............................................................27
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1 GENERAL
1.1 SCOPE
This specification defines the welding, thermal treatment related to welding, and weld
inspection requirements for shop and field fabricated structures. Structures include:
platforms, walkways, handrails, steps and cat ladders;
skid frames, supports, structures and platforms for process plants and individual
equipment;
pipe racks, pipe bridges, pipe supports, clamp-on pipe shoes;
lifting equipment such as bridge cranes, jib cranes, rigging and crane support
structures and crawl beam structures;
warehouses, workshops, equipment houses and carports;
palisade fencing, security gates and turnstiles;
Internals for equipment, vessel and column such as trays, cartridges, beams and
attachments, all only exposed to non-severe service conditions.
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Excluded from the scope:
Storage tanks, equipment supports welded directly to pressure equipment such
as the cradle supports for a horisontal vessel, welded pipe shoes, etc;
Internals for vessel, column, equipment, etc. for severe services;
Structures other than carbon steel structures.
1.2 LEGAL REQUIREMENTS
1.2.1 All engineering, design, equipment and installations in accordance with this
Specification shall meet the mandatory requirements specified in the Occupational
Health and Safety Act (Act No 85 of 1993) and Regulations of the Republic of South
Africa, referred to as the OHS Act in this Specification. RSA
1.2.2 This specification is governed by the law of contract. CORE
1.3 ORDER OF PRECEDENCE
When special requirements are specified in the Sasol Contract document, those
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requirements shall govern and supplement this Specification. In the event of conflict
between the various relevant documents, the order of precedence shall be:
1. Law and statutory regulations of specific region where this specification will be
applied.
2. Codes specified in the Contract document.
3. The Contract document.
4. Drawings as approved by Sasol or Sasol's Representative.
5. This specification.
6. Other referenced specifications. CORE
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1.4 ABBREVIATIONS
AC Alternating Current
AFC Approved for Construction
HAZ Heat Affected Zone
HB Brinell Hardness
HV Vickers Hardness
MT Magnetic Testing
NCR Non-conformance Report
NDE Non-Destructive Examination
PQR Procedure Qualification Record
PT Liquid Penetrant Testing
PWHT Post Weld Heat Treatment
QC Quality Control
QCP/ITP Quality Control Plan / Inspection and Test Plan
RT Radiographic Testing
SI System International
UTS Ultimate Tensile Strength
WPS Welding Procedure Specification
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1.5 DEFINITIONS
These definitions are standard to the Sasol specifications and are contained in SP-
00-03. The identified definitions are listed below:
1.5.1 Approval or Approved by Sasol
1.5.2 Contract document. This refers to the agreement between Sasol's Representative
and the fabricator.
1.5.3 Engineer
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1.5.4 Engineer of record
1.5.5 Engineering Contractor
1.5.6 Fabricator
1.5.7 Sasol
1.5.8 Sasol’s Representative
1.6 DEVIATIONS
Any deviation from the requirements in this specification shall require written
approved by Sasol. CORE
2 REFERENCED CODES AND STANDARDS
Where reference is made to a code, specification or standard, the reference shall be

taken to mean the edition of the code, specification or standard, including addenda,
supplements and revisions thereto as agreed and specified in the Purchase Order.
CORE
2.1 SOUTH AFRICAN NATIONAL STANDARDS (SANS) SPECIFICATIONS
SANS 2001-CS1 Construction Works Part CS1: Structural Steelwork. RSA

SANS 10160 Basis of structural design and actions for buildings and
industrial structures, Part 1 to 8. RSA
2.2 AMERICAN SOCIETY FOR MECHANICAL ENGINEERS (ASME) STANDARDS
ASME Section II, Part C, Welding Rods, Electrodes and Filler Metals
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ASME section V Non-destructive Examination
ASME Section IX Qualification Standard for Welding and Brazing Procedures,

Welders, Brazers, and Welding and Brazing Operators
NEGOTIABLE
2.3 AMERICAN WELDING SOCIETY (AWS) SPECIFICATIONS
AWS A2.4 Standard Symbols for Welding, Brazing and Non-destructive

Examination
AWS A3.0 Standard Welding Terms and Definitions
AWS D1.1 Structural Welding Code – Steel
CORE
2.4 AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) STANDARDS
ANSI Z49.1 Safety in Welding, Cutting, and Allied Processes. CORE
2.5 SASOL SPECIFICATIONS, DRAWINGS AND DATA SHEETS
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SP-00-03 Specification definitions
SP-20-06 Civil and Structural Construction Works
SP-42-02H Pressure Vessels Supplement for Severe Services
SP-90-01 Welding of Pressure Vessels – Classes A, B and C
SP-90-01A Welding Consumables
SP-90-17 Heat Treatment
SP-90-31 Units of Measure
SP-90-37 Requirements for Sasol Owner Documentation
SP-110-6 Impact Testing of Metallic Materials

CORE
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2.6 METRIC VS CUSTOMARY UNITS
The metric and customary version of the applicable AWS code that is available
cannot be used interchangeably since the units of measure were rationalised in the
2000 metric edition and there will rarely be a direct conversion equivalent to the
Customary edition.
The Metric version of the AWS code shall be used. CORE
3 GENERAL WELDING REQUIREMENTS
3.1 PREFERENCE OF WELDING CODES
The Codes to be used for weldments, materials, fabrication, performance and

procedure qualifications, inspection, etc. applicable to the fabrication scope shall be
specified in the Contract documents and agreed upon prior to construction. It shall
be ensured that the codes listed are legally allowed for use in the specific region
where the structure shall be in operation. Also refer to paragraph 1.3. CORE
3.2 GRADING OF STRUCTURES
3.2.1 Welding requirements for structural steel in this specification is determined based on
the following grading of structural members, connections and structures. CORE
3.2.2 Grade A structural members and connections:
This grade is designated for individual structural members and connections that the
Engineer of record has identified as critical to the stability or integrity of the overall
structure or members as identified below.
a. A formal design is required by an Engineer of record, with fabrication drawings
and fabrication procedures approved by the Engineer and Sasol's
Representative.
b. The member or connection may be exposed and vulnerable to torsional,

moment, dynamic or fatigue loading.
c. The qualification of PQRs and WPSs require impact and hardness testing.
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d. The welded joints of the members or connections require PWHT and production
hardness testing as specified by the Engineer of record or in this specification.
e. Heavy members and connections with weld thickness >35mm.
f. The structural Design and Fabrication QC is generally based on three levels of

checking, and in some cases, regulated third party checking, i.e. final checks
performed by Sasol's Representative, and/or an Inspector mandated by
legislation.
g. Examples of members in this Grade:
i) Members and connections subjected to fatigue or dynamic loading.
ii) Members, connections or weld joints subjected to rotational or moment

forces.
iii) Welded splices of main members.
iv) Bridge crane frames.
v) Heavy girders fabricated from thicker gauge plate material and requiring
higher than normal weld throat thicknesses.
vi) Long and slender plate-girders where there is an inherent risk of

distortion due to weld heat effects during fabrication,
vii) Welded joints where the bulk of the loading is applied perpendicular to
the weld direction,
viii) Welded fabrication of rigging equipment and accessories such as

spreader bars requiring full penetration welds.
ix) Welded lugs for lifting or suspended loads where the weld thickness >
35mm.
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CORE
3.2.3 Grade B structures:
This grade of structure is intended for most elevated and load bearing structures.
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a. A formal design by an Engineer or record is required with fabrication drawings

and procedures for these structures approved by the Engineer and Sasol's
Representative.
b. Load bearing structures for this purpose is defined as multi-member structures

with a superimposed load carrying capacity of 4.8kN/m2 or more.
c. The structure may support lifting equipment and if so, will then be subjected to
periodic load testing.
d. The structure may be exposed to dynamic or fatigue loading. Specific high

stressed structure members or connections identified via a dynamic/ fatigue
load analysis by the Engineer of record as critical, will be Grade A structure
members or connections.
e. The structure may contain structure members or connections for which there is
a need for impact or hardness testing during qualification of PQRs of WPSs
when required as identified by Contract documents or the Engineer or record.
These specific members or connections will be Grade A structure members or
connections.
f. The structure may contain structure members and connections for which there
is a need for PWHT or production hardness testing when required by the
Engineer of record or this specification. These specific members or connections
will be Grade A structure members or connections.
g. The structure may contain structure members and connections with weld
thickness > 35mm. These specific members or connections will be Grade A
structure members or connections.
h. Structural Design and Fabrication QC is generally based on three levels of

checking, with checking from Sasol's Representative as the final check.
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i. Examples of structures in this Grade:
i) Structures consisting of columns, girders, beams, ties, braces and other

structural members of industrial scale, also those containing lifting
equipment, cranes and crawl beams.
ii) Boiler houses and large industrial structures.
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iii) Structures such as pipe racks and pipe bridges, access and support
structures for process plants and large individual equipment.
iv) Warehouses, workshops, equipment houses.
v) Structures that will receive special loading during construction, e.g.

structural modules.
CORE
3.2.4 Grade C structures:
This grade of structure is intended for light industrial applications and supports.
a. A formal design is required by an Engineer, with fabrication drawings and
procedures for these structures approved by Sasol's Representative.
b. The structure is not supporting any lifting equipment and is therefore not
subjected to periodic load testing.
c. The structure will not be subjected to dynamic or fatigue loading (from an

analysis done by the Engineer, when applicable).
d. There is no need for impact or hardness testing during qualification of PQRs of

WPSs.
e. There is no need for PWHT or production hardness testing of any welded joints.
f. The height of the structure (other than personnel access platform) is not more
than 2.5m.
g. Fabrication of carbon steel internals for vessels, columns, tanks, equipment,

etc. for non-severe process conditions (refer to SP-42-2H for severe service
definitions).
h. Carbon steel attachments external to vessels, tanks, etc.
i. Design and fabrication QC is primarily based on procedural separate checking,

i.e. checking by different persons than those originally responsible, and in
accordance with the procedure of the Engineering Contractor or fabricator.
j. Examples of structures in this Grade:

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i) Most personnel access structures such as platforms, walkways,

handrails, stairs, cat ladders, pipe crossings and bridges.
ii) Suspended operating and maintenance platforms not integral to the

stability of a greater structure (such as a platform on the side and top of
a tank, vessel or column).
iii) Shop fabricated equipment skid frames.
iv) Standard pipe supports, clamp-on pipe shoes, large bore valve supports
– generally all-welded construction.
v) Barriers around exposed valves or hydrants.
vi) Carport canopies.
vii) Screens and structures for safeguarding of machinery.
viii) Carbon steel trays for columns.
CORE
3.2.5 Grade D structures:
This grade of structure is intended for non-industrial applications.

a. A basic design is required, but no formal fabrication drawings or procedures are
required. It can typically be fabricated off standard drawings and details.
b. The structure is not normally load-bearing.
c. Design and fabrication QC is primarily based on self-checking, i.e. checking

performed by the person who has prepared the design and workshop QC for
fabrication.
d. Examples of structures in this Grade:
i) Fencing and steel palisading.
ii) Security gates for doors and turnstiles.
iii) Sliding doors and gates.
CORE
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3.2.6 The paragraphs in this specification will each time indicate where a requirement is
only intended for a specific grade of structure. Where no grade is indicated, it is
applicable to all structure grades, or when the topic is relevant.
3.2.7 The designer of the structure will grade each structure based on the criteria of
paragraphs 3.2.2 to 3.2.5, which will be approved by Sasol's Representative. CORE
3.2.8 Fabricators performing welding work shall provide evidence of a welding quality
management system and the adherence thereto, relevant to the grade of welding work
that will be undertaken based on this specification. CORE
3.2.9 All welding design, materials, fabrication and inspection requirements shall conform
to AWS Structural Welding Code as a minimum, and this Specification. Welding
procedure- and welder performance qualifications in accordance to AWS Structural
Welding Code is not mandatory. Refer to paragraph 4.1.1. for these requirements.
Sasol’s written approval is required prior to any other international welding codes
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being used. (Grade A) CORE
3.2.10 Welding terms and definitions shall be in accordance with AWS A3.0. Symbols for
welding and non-destructive examination (NDE) shall be in accordance with AWS
A2.4. CORE
3.2.11 The fabricator shall take measures to ensure the health and safety of welders and
operators involved in welding and cutting. The fabricator’s safety standard shall
generally be in accordance with ANSI Z49.1, which shall also be the fall-back
requirements when no fabricator standards are available. CORE
3.2.12 The fabricator shall submit to Sasol's Representative for review and acceptance the
a. Quality Control Plan/ Inspection and Test Plan, procedure qualification records,
welding procedure specifications (Grade A, B submit for approval, Grade C
available on request),
b. weld and NDE map (Grade A, B submit for approval, Grade C available on
request),
c. NDE procedures (Grade A),
d. method statement prior to any fabrication work commences,
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e. material heat number transfer procedure (Grade A, B submit for approval,

Grade C available on request).
CORE
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3.2.13 The use of non-qualified welding procedures is prohibited. Welds deposited with non-
qualified welding procedures shall be removed. (Grade A, B). For Grade C structures,
standard welding procedure specifications (as per AWS Structural Welding Code or
ASME IX) may be used within the restrictions and limitations of the applicable code.
CORE
3.2.14 The welding and NDE details shall be indicated on the detail connection drawings or
separate Weld and NDE map to be submitted to Sasol's Representative for review
and approval (Grade A, B). CORE
3.2.15 All new structures, modifications and repairs to load bearing structures shall be
monitored by Sasol's Representative’s quality representative to ensure that
construction is done to AFC documents. CORE
3.2.16 Tack welds shall be subjected to the same WPS requirements as the final weld. Tack
welds deposited without an approved welding procedure shall be removed and not
form part of the final weld. Tack welds that will remain part of the weld shall be visually
inspected for defects prior to subsequent welding. (Grade A, B, C) CORE
4 PROCEDURE QUALIFICATION AND WELDER QUALIFICATION
4.1 WELDING PROCEDURES AND QUALIFICATION
4.1.1 Welding procedure qualifications and welder’s performance qualification shall

conform to the requirements of the relevant AWS Structural Welding Code or ASME
Code Section IX. The specific code allowed for use shall be listed in the Contract
documents. The Engineer or Engineer of record (as applicable) shall ensure that the
code used is accepted by legislation in the specific region where this specification is
applied. Take note of the additional essential variables listed in paragraph 0. (Grade
A, B, C) CORE
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4.1.2 Where the production weld(s) deposited does not conform to the Welding Code
identified in the Contract documents the weld(s) shall be deemed un-qualified and
shall be removed. Refer to paragraph 3.1. (Grade A, B, C) CORE
4.1.3 Charpy impact tests are required for the qualification of the welding procedures and
qualifications for Grade A members and connections and shall be done in accordance
with AWS Structural Code requirements and SP-110-6, irrespective of the
qualification code used. (Grade A) CORE
4.1.4 For Grade C applications it is permissible to use standard welding procedure

specifications as per AWS Structural Welding Code or ASME IX (whichever is stated
in the Contract documents). It shall be used within the restrictions and limitations of
the applicable code. The use of standard welding procedures shall not be allowed in
case essential variables in paragraph 6 apply for Grade C structures. In case these
variables apply the procedures for use shall be qualified accordingly. (Grade C)
CORE
4.1.5 Grade D structures do not require formally qualified welding procedures. However,
good workmanship shall still be expected with acceptable weld integrity and surface
finish. See paragraph 10.1.10. (Grade D) CORE
4.1.6 Review and approval of welding procedures by Sasol's Representative Welding

Engineer is required prior to use (Grade A, B). The necessity to review welding
procedures for Grade C structures remains at the discretion of Sasol's Representative
Welding Engineer. CORE
4.1.7 Hardness measurements shall be applicable as per the following tables:

Table 4-1: Hardness requirements – Butt welds
Grade PQR Production
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A X X
B X
Table 4-2: Hardness requirements – Fillet welds

Grade PQR Production
A X Note 1 X Note 2
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Note 1: Cross section hardness measurements shall be taken on all size fillet
welds. No surface hardness measurements are required.
Note 2: Surface hardness measurements shall be taken on fillet weld leg
lengths exceeding 19mm.
Surfaces (weld metal & HAZ) for hardness measurements shall be prepared in
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accordance to requirements listed in SP-90-1. Additionally, equipment and
procedures to be used for hardness testing shall conform to requirements listed in
SP-90-1. CORE
1 mm Maximum
1 mm Maximum
Figure 4-1 - Required hardness indentation location for performing a Vickers

hardness survey on cross section butt and fillet weld samples as per
paragraph 4.1.7
4.1.8 Hardness acceptance criteria shall be maximum 230 HB and 280 HV10 for carbon
steels. Wherever AWS Structural Welding Code states more conservative values
these values shall govern. Conversion of results from one test method to another is
not allowed. (Grade A, B) CORE
4.1.9 HAZ indents shall have the first indent placed as close as possible (not more than
0.5mm) to the fusion line on the base metal side with adjacent indents spaced 0.75mm
apart. (Grade A, B) CORE
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4.1.10 Welding personnel are required to be informed in the use of the welding procedure
and its correct application according to a weld map. (Grade A, B, C) CORE
4.1.11 Welder’s performance qualification records shall be made available for Sasol's
Representative’s review upon request. Sasol's Representative reserves the right to
require the testing or retesting of welders for qualification in accordance with the AWS
Structural Welding Code or ASME IX, (as selected in the Contract documents) should
the supporting welding documentation not be correct or incomplete. All costs and
material required for the qualification of welders shall be at the fabricator's expense.
(Grade A, B, C) CORE
4.1.12 Qualified welders shall be used for all tack welding. (Grade A, B, C) CORE
5 CHARPY IMPACT TESTING

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5.1 REQUIREMENT FOR IMPACT TESTING
5.1.1 When required by contract drawings, code or specifications and for Grade A structure
members or connections, welding procedures shall be qualified with Charpy impact
testing in accordance with the AWS Structural Welding Code and Specification
SP110-6 and shall meet the acceptance criteria of AWS D1.1 Structural Welding Code
or SP-110-6 (whichever is more stringent). Impact testing is a requirement for
structures subjected to fatigue loading. (Grade A) CORE
5.1.2 Where impact testing is required, a demonstration by the welder or operator of his
ability to control the heat input as per relevant production WPS/PQR during welding
is required. The welding foreman shall keep a record of the heat input at least once
per shift per welder. These records shall be verified by the fabricator’s welding
engineer. This requirement shall be listed as an intervention point on the relevant
QCP. (Grade A) CORE
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6 WELDING PROCESSES
6.1 ACCEPTABLE WELDING PROCESSES
6.1.1 Table 6-1 below lists the acceptable welding procedures to be used:
Table 6-1 - ACCEPTABLE WELDING PROCESSES
AWS LETTER
WELDING PROCESSES
DESIGNATION
Shielded Metal-Arc Welding SMAW
Gas Metal-Arc Welding (Pulse
GMAW
and spray transfer)Note 1
Gas Tungsten Arch Welding GTAW
Flux Cored-Arc Welding (Gas
FCAW - G
assisted only)
MCAW
Metal Cored Arc WeldingNote 2
Submerged Arc Welding SAW
Stud Welding (only non-load
SW
bearing, Cat C, D)
Note 1: Pulsed transfer includes proprietary controlled short-circuiting

processes
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Note 2: MCAW shall be treated as a form of GMAW with unique wire form. It
is acceptable for use, subject to it meeting the requirements specified for
GMAW
6.1.2 Combinations of the processes given in Table 6-1 may be submitted for approval.
(Grade A, B, C) CORE
6.1.3 Other welding processes may be used only upon specific written approval by Sasol's
Representative. The fabricator shall submit pertinent data with the request for
evaluation of the proposed process. (Grade A, B, C) CORE
6.1.4 The following requirements shall apply with use of semi-automatic FCAW, GMAW
(conventional and pulsed transfer) and MCAW processes:
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a. Use of these processes shall be limited to wall thicknesses of 12mm maximum

(Grade A and B);
b. Short circuiting transfer mode shall only be used as temporary backing at the
root. It shall be completely removed with back grinding/ gouging. The
manufacturer shall have a system in place to record that temporary backing has
been completely removed in order to serve as proof. Proprietary controlled
pulsed short-circuiting processes (such as STT®, CMT® and RMD®) may be
proposed for welding of root passes only, subject to Sasol’s Representative
review and approval. Additional essential variables as per d shall apply where
proprietary controlled pulsed short-circuiting processes are used. For
conventional spray transfer it shall be ensured that the WPS used state realistic
parameters (electrical parameters, filler size, shielding gas etc.) to obtain the
desired transfer mode (Grade A, B, C);
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c. GMAW (conventional spray transfer), FCAW-G and MCAW shall not be used
on single sided groove welds without backing applied. The use of backing gas
is not considered here as the required backing (Grade A, B, C).
d. Pulsed (including proprietary controlled pulsed short circuiting processes)

GMAW and MCAW are allowed to be used for single-sided welds with and
without backing subject to Sasol's Representative approval provided welders
are qualified as per 6.1.6. Additional essential variables shall apply. CORE
6.1.5 Additional essential variables for GMAW (spray and pulsed), MCAW and FCAW-G
a. An increase in filler wire diameter from that qualified in PQR. (Grade A, B, C)
b. For FCAW-G and MCAW, any change in consumable brand name. (Grade A,
B)
c. Change in groove design (V to U and vice-versa) and a reduction in bevel angle

of more than 5°. (Grade A, B)
d. For pulsed GMAW (includes controlled short circuiting processes and those of
pulsed waveforms). (Grade A, B, C)
i) Equipment make and model. (Grade A, B, C)
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ii) Program number and all other essential settings (which can be program
numbers for Synergic power sources but can also be specific pulse
parameters such as pulse time, peak and background currents, tail-out,
feedback control and arc correction parameters etc. (Grade A, B, C)
CORE
6.1.6 Welders for GMAW (conventional and pulsed transfer), MCAW and FCAW-G shall be
qualified and tested as follows:
a. As a minimum each welder shall be tested as per the applicable qualification

code stated in the Contract documents. In addition to code minimum tests each
welder shall weld a sample representing the joint type to be welded in
production at least 2 weeks prior to production. Tests per joint shall be carried
out as following (Grade A, B).
Table 6-2 : Test methods
Test method Butt weld Branch weldNote 1 Fillet weld
Visual X X X
RT X X
Macro-examination X X
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Note 1: A branch weld (T, Y or K joint) shall be represented by a butt weld
test (RT) and a branch weld connection which shall undergo visual and
macro-examination.
i) Macro-examinations shall be carried out as follows:
Test coupons dimensions, preparation and etching shall

conform to the performance qualification requirements of AWS
Structural Welding Code or ASME IX (refer to Contract
documents).
Macro test specimen shall be taken at the stop/start.
Examination shall be done at 10x magnification.
ii) Acceptance criteria of macro-examinations shall be as follows:
Visual examination of the cross section of the weld metal and

HAZ shall show complete fusion at the root, between weld metal
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and base metal and adjacent layers of weld metal.

No cracks are allowed.
b. For Grade C applications the following requirements shall apply:
i) Using GMAW (conventional transfer), including MCAW and FCAW-G the

requirements as per 6.1.6 a) shall apply.
ii) Using GMAW (pulsed transfer including proprietary controlled short

circuiting processes) and MCAW only code minimum tests shall be
required provided 6.1.6 d) is adhered to.
c. Consumable brand and tradename for MCAW shall be an essential variable.

Filler material AWS classification shall be a welder’s essential variable for
FCAW-G. (Grade A, B)
d. For pulsed GMAW and MCAW processes including proprietary or complex

pulsed waveforms such as controlled short circuiting (STT®, CMT® and
RMD®), the welder shall qualify with the same equipment (model and brand) as
well as essentially the same settings (e.g. program number) to be used in
production welding. The applicable WPS shall capture all such settings and
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variables and shall accordingly be appended to the welder qualification record.

(Grade A, B, C)
CORE
7 MATERIAL REQUIREMENTS
7.1 FILLER AND BASE METAL REQUIREMENTS
7.1.1 EN 10204 3.1 base material certification shall be available for verification prior to
welding. (Grade A, B, C). CORE
7.1.2 Welding filler materials shall comply with appropriate national specification and
standards and shall be purchased from filler material manufacturers holding approvals
by an independent third-party organization recognised by Sasol. CORE
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7.1.3 Filler materials shall conform to the requirements of SP-90-1A in respect of the
following:
a. Selection of filler materials

b. General
c. Handling and storage
Filler material for Grade D applications does not need to comply to the above
requirements provided 7.1.2 is complied with. (Grade A, B, C)
7.1.4 In case Charpy impact test requirements are stipulated in the Contract documents
and for all Grade A structure members and connections, the filler material used shall
be qualified and certified with Charpy impact testing. CORE
7.1.5 In case PWHT is required and stipulated in the Contract documents the filler material
used shall be qualified and certified for all heat treatment conditions in accordance to
SP-90-17. Tests to be performed in the particular conditions shall be specified in
Contract documents. (Grade A) CORE
7.1.6 Filler materials shall be ordered and purchased in accordance to SP-90-1A

requirements. (Grade A) CORE
7.1.7 Filler materials shall be ordered and purchased in accordance to the following
requirements (Grade B, C):
Table 7-1 : Ordering requirements
Process type/Type: Lot class: (SFA-5.01) Testing schedule; (SFA-5.01)
Covered electrodes C1 I or 4
(e.g SMAW)
Bare solid S1 I or 4
electrodes and rods
(e.g GTAW, GMAW,
SAW wire
Flux or metal cored T1 I or 4
electrodes
SAW flux F1 Flux-wire combination to be
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tested in accordance to I or 4
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7.1.8 There are no ordering and purchasing requirements for Grade D applications,
provided 7.1.2 is adhered to.
8 WELDING
8.1 WELD JOINT PREPARATION
8.1.1 Weld preparations may be done by machining, grinding, or thermal cutting. If welding
is to be done on thermal cut surfaces, the oxide layer from these surfaces shall be
removed prior to welding by grinding or a similar process. The prepared surface shall
be smooth and true to the mating surface within construction code tolerances. CORE
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8.1.2 Backing strips, when required on the design drawings, shall be of the same nominal
chemical composition as the base material. CORE
8.2 WELD CLEANING REQUIREMENTS
8.2.1 All surfaces to be welded shall be free of paint, oil, dirt, scale, oxides and other foreign
materials detrimental to the integrity of the weld. CORE
8.2.2 Weld spatter and slag shall be removed from each weld bead prior to depositing each
subsequent pass and from the completed weld. CORE
8.2.3 Peening is permitted only to the extent required for cleaning the weld. CORE
8.2.4 Cleanliness shall be maintained during fabrication welding. All stubs, rods, weld
spatter, slag and other foreign material shall be removed from the structural steel
components. CORE
8.2.5 All arc strikes shall be removed by grinding (Grade A, B, C) and MT/PT tested. (Grade
A, B) CORE
8.2.6 Temporary attachment welds on ladders, stairs and structures shall after removal be
conditioned to remove protrusions, sharp or jagged surfaces which would pose a
hazard to personnel. These areas shall be ground smooth into the surrounding
surfaces. CORE
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8.2.7 All temporary attachments shall not be removed by impact but by cutting and grinding.
The surface shall be dressed to a smooth contour. For Grade A and B structures the
dressed areas shall also be examined by MT/PT. The manufacturer shall have a
system in place to ensure that the temporary attachment welds are identified which
can be traced to NDE reports. (Grade A, B) CORE
8.3 WELD CONTOUR AND FINISH
8.3.1 Welds shall be finished as required for the applicable inspection method irrespective
whether full or partial NDT is required. Coarse weld ripples are not permitted with no
undercut. The NDT examiner shall have the right to request for additional surface
conditioning in case weld surface condition interferes with the final evaluation. (Grade
A, B, C) CORE
8.3.2 For Grade A, B applications tolerances for fit-up and joint dimensions shall be in
accordance with the requirements stated in AWS Structural Welding Code. For Grade
C applications reference to the tolerance limits shall be stated in the Contract
documents. For Grade D there are no specified limits. Good workmanship shall
however be performed. CORE
8.3.3 During welding the weld beads shall be contoured to permit complete fusion at the
sides of the bevel and to minimise slag entrapment. (Grade A, B, C) CORE
8.3.4 Weld reinforcement of butt welds and toes of fillet welds shall have a gradual transition
to the plane of the base material surface. For fillet welds the maximum difference in
leg lengths shall be 1:1.33. The fabricator shall ensure that this principle is fully
understood by all welders and welding operators. See image below and applicable
AWS code for examples of acceptable and unacceptable weld profiles. (Grade A, B)
CORE
b (b/a <1.33)
a
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8.3.5 When weld joints are indicated on the drawing as “critical” or “fatigue” welds, weld
surfaces shall be free of stress raisers. Coarse weld ripples and undercut is not
permitted. Weld symbols for “critical” or “fatigue” welds shall clearly indicate the
profile and method how to achieve the contour. (Grade A) CORE
8.3.6 For welds requiring fatigue finish, weld surface finish quality acceptance criteria will
be approved by Sasol's Representative on welded specimens produced by the
manufacturer and submitted to Sasol's Representative prior to production welding.
These specimens shall be used continuously on the shop floor for visual acceptance
of welds. The samples shall be kept until final release of job. CORE
8.3.7 Grinding technique to be used shall not damage the base material, welding material
or mask surface welding defects. All NDE shall always be done after final grinding.
CORE
8.4 PREHEATING
8.4.1 The minimum preheat requirements shall be in accordance with applicable AWS
Structural Welding Code requirements irrespective of construction code used. In case
material is not listed in AWS, paragraph 8.4.3 below shall be followed. (Grade A, B)
CORE
8.4.2 A reduction in preheat temperature from the qualification documentation is an

essential variable. When actual production preheat was found to be below the
qualified preheat temperature the weld shall be removed, and an NCR shall be raised.
(Grade A, B). CORE
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8.4.3 Welding carbon steel with minimum specified UTS exceeding 450MPa shall require a
preheat of 100°C minimum. In case AWS Structural Welding Code is more stringent,
it shall govern. (Grade A, B) CORE
8.4.4 Materials that require preheat for welding shall also require preheat for tack-welding,
thermal cutting or thermal gouging. CORE
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9 POST WELD HEAT TREATMENT
9.1 POST WELD HEAT TREATMENT REQUIREMENTS
9.1.1 Post weld heat treatment (PWHT) shall be required when specified in the Contract
documents or fabrication drawings. (Grade A). CORE
9.1.2 When PWHT is required, a fabrication PWHT procedure shall be submitted to Sasol's
Representative for review and acceptance. The procedure shall conform to SP-90-
17 requirements in addition to the minimum requirements stipulated in AWS Structural
Welding Code. Sasol's Representative reserves the right to request for the
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qualification of the procedure. (Grade A) CORE
9.1.3 When PWHT is required, the base material, welding consumables and PQR shall be
qualified with the anticipated fabrication PWHT cycle. (Grade A) CORE
10 INSPECTION AND TESTS
10.1 INSPECTION AND TEST REQUIREMENTS
10.1.1 The extent of all NDE, its procedures, techniques and acceptance criteria shall be in
accordance with AWS Structural Welding Code, this specification and the Contract
documents. CORE
10.1.2 The Engineer or Engineer of record may prescribe additional NDE and these
requirements shall be specified on the general arrangement drawings or detail
connection drawings. CORE
10.1.3 The fabricator will provide an NDE map with all required NDE, referencing the
applicable fabrication drawings. CORE
Self-explanatory.
10.1.4 All NDE shall be performed in accordance with written procedures and shall be
controlled via a QCP. (Grade A, B, C). CORE
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10.1.5 Procedures shall be submitted and approved by Sasol's Representative prior to

fabrication starting. Each NDE procedure shall be submitted with a technique sheet
(Grade A, B). CORE
10.1.6 All NDE shall be performed by personnel qualified (i.e. ASNT recommended practice
SNT-TC-1A, or Sasol's Representative approved equivalent) to perform these
examinations. NDE personnel qualifications shall be submitted to Sasol's
Representative for review upon request. (Grade A, B, C). CORE
10.1.7 Results of all NDE shall be reported on forms approved by Sasol's Representative
and copies of reports shall be included in the fabricators welding data book. (Grade
A, B, C) CORE
10.1.8 All NDE shall be carried out after final grinding. Visual inspection shall be accepted
before carrying out any other NDE. (Grade A, B, C). CORE
10.1.9 The type and extent of the NDE required shall at least include the following:
a. All welds shall be subjected to continuous visual inspection: before, during and
after welding. The 100% visual inspection on completed welds will be recorded
and documented.
b. Welded joints of Grade A members and connections will require 100% MT/PT.
c. A minimum of 10% MT/PT is required for welded joints of Grade B and C

structures.
d. Additional NDE requirements as per the Contract documents and those

specified by the Engineer or Engineer of record will be included during
fabrication, which may include production Hardness testing and RT/UT.
e. When members or connections require PWHT, examination of these shall be

done with the same type of NDE method prior to and after performing PWHT.
CORE
10.1.10 Grade D structures will only require visual inspection of the weld surface quality in
accordance with an agreed QCP/ITP. CORE
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10.1.11 All applicable NDE shall be completed and signed off prior to releasing the members
for corrosion protection. CORE
10.2 VISUAL EXAMINATION
10.2.1 The fabricator shall visually inspect all prepared surfaces to ensure metal soundness
prior to welding. CORE
10.2.2 The fabricator will provide welded specimen templates as per paragraph 8.3.6 prior
to the start of fabrication. These templates will continuously be used to evaluate
productions welds. (Grade A) CORE
10.2.3 All completed welds shall be visually inspected for undercutting, porosity, cracks,
penetration, temporary attachments removal marks, thermocouple weld marks, weld
contour and dimensions as per requirements of AWS Structural Welding Code, before
any other NDE is carried out. (Grade A, B, C) CORE
10.2.4 Reports of visual examination shall be included in the welding data book. (Grade A,
B, C) CORE
10.3 MAGNETIC TESTING (MT) AND PENETRANT TESTING(PT)
10.3.1 PT may replace MT where MT is not practical due to restricted access and
geometrical conditions. CORE
10.3.2 MT procedures shall employ electromagnetic AC yokes in accordance with

requirements and methods specified in AWS Structural Welding Code. Any other MT
technique proposed is subject to approval by Sasol's Representative. CORE
10.3.3 Penetrant materials shall meet the requirements of paragraph T-641 of Article 6,
ASME V for sulphur and halogen content, regardless of the type of material to be
examined. NEGOTIABLE
10.3.4 MT or PT of welds shall include a band of base metal at least 25 mm wide on each
side of the weld, ensuring coverage of the entire HAZ. (Grade A, B, C) CORE
10.3.5 If arc burns occur during MT, the arc burns shall be ground smooth and the area
examined by the electromagnetic AC yoke method. (Grade A) CORE
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10.3.6 Reports of MT/PT shall be included in the welding data book. CORE
10.4 HARDNESS TESTING
10.4.1 Hardness shall be performed in accordance with ASTM E10 and E110. In the isolated
cases where rebound-type hardness testing is approved by Sasol's Representative,
it shall be done in accordance with ASTM A956. The maximum allowable hardness
values shall be as specified in this specification or the Contract documents. The
fabricator shall have a documented procedure which describes the type of hardness
testing used, the equipment used, material preparation, etc. CORE
10.5 RADIOGRAPHIC TESTING (RT)
10.5.1 At least one image quality indicator shall appear on each separate radiographic film.
Image quality indicators shall be of wire type in conformance with ISO 1027,
equivalent to DIN 45109 at Category 1 quality level. CORE
10.5.2 Radiographic film shall be ultra-fine grain, high contrast type in accordance with EN
584-1 Class C3 or ASTM E1815 Type I. CORE
10.5.3 RT films and reports shall be included in the welding data book. CORE
10.6 ULTRASONIC TESTING (UT)
10.6.1 UT equipment, procedure, calibration, extent and modes of scanning and technique
shall be documented in the procedure that will be submitted to Sasol's Representative
for approval. CORE
11 REPAIRS
11.1 WELD AND STRUCTURE REPAIRS
11.1.1 Repairs to correct weld defects shall be made using the same procedure used for the
original weld, or a designated qualified weld repair procedure. (Grade A, B, C) CORE
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11.1.2 The repaired areas shall be re-examined using the same inspection procedure by
which the defect was originally detected. MT or PT shall be done as a minimum as
well as 100% visual inspection. (Grade A, B, C) CORE
11.1.3 Base material repair shall only be done with prior approval from Sasol's
Representative in accordance with approved repair procedures. (Grade A, B, C)
CORE
11.1.4 Structural members shall not be built up by welding when it was dimensionally cut too
short. CORE
12 END OF JOB DOCUMENTATION
12.1 DOCUMENATION AND SIGN OFF
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12.1.1 All drawings submitted to Sasol's Representative as part of end of job documentation
shall be in accordance with the requirements of Specification SP-90-37.
Measurements shall be reported in SI units as specified in Specification SP-90-31.
CORE
12.1.2 A welding procedure summary shall be used to document all the welding
documentation. It will include all the documentation requirements per Grade as
required by this specification. (Grade A, B, C) CORE
12.1.3 The completed welding data book shall be part of the end of job documentation for
the fabrication of the entire structure. Refer to SP-20-06. (Grade A, B, C) CORE
12.1.4 Final acceptance of the welding works will include approval by the Sasol's
Representative inspector or an assigned third-party inspector. (Grade A, B, C) CORE
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SASOL SPECIFICATION SP-90-13

Mauritz Faling Marcel Rabie

Mauritz Faling Marcel Rabie

Approved by: 2020-06-01 08:18:15 +02:00

SASOL SPECIFICATION SP-90-13

WELDING OF SHOP AND FIELD FABRICATED STRUCTURES

TECHNICAL COMMITTEE OF SPECIFICATION SP-90-13, Revision 3

NAME COMPANY AND DEPARTMENT

Badenhorst, CH (Kallie) Secunda Chemicals Operations,

Botha, PJ (Pieter) Group Technology, E&PS

De Klerk, WP (Willem), Group Technology, S&P

Dorfling, CA (Charl) Secunda Synfuels Operations,

Du Plessis, AL (Awie) Group Technology, E&PS

Faling, CM (Mauritz) Group Technology, S&P

Grobler FJ (Franco) Group Technology, E&PS

Kruger, JJ (Johan) Group Technology, S&P

Kruger, P (Pieter) Natref, Technical Support

Mitchell, JP (John) Secunda Chemicals Operations,

Rabie, M (Marcel) Group Technology, S&P

Prins, C (Chris) Group Technology, E&PS

Swanepoel, DB (Niel) Secunda Synfuels Operations,

SASOL SPECIFICATION SP-90-13

WELDING OF SHOP AND FIELD FABRICATED STRUCTURES

REVISION DESCRIPTION SHEET

SP-90-13 has been completely revised.

SASOL SPECIFICATION SP-90-13

WELDING OF SHOP AND FIELD FABRICATED STRUCTURES

1.1.1 Paragraph ends. Core

Classification Tag Colour Definition

SASOL SPECIFICATION SP-90-13

WELDING OF SHOP AND FIELD FABRICATED STRUCTURES

Classification Tag Colour Definition

SASOL SPECIFICATION SP-90-13

WELDING OF SHOP AND FIELD FABRICATED STRUCTURES

2 REFERENCED CODES AND STANDARDS.............................................................3

3 GENERAL WELDING REQUIREMENTS ..................................................................5

4 PROCEDURE QUALIFICATION AND WELDER QUALIFICATION .......................11

5 CHARPY IMPACT TESTING ...................................................................................14

6 WELDING PROCESSES .........................................................................................15

7 MATERIAL REQUIREMENTS .................................................................................18

SASOL SPECIFICATION SP-90-13

WELDING OF SHOP AND FIELD FABRICATED STRUCTURES

9 POST WELD HEAT TREATMENT ..........................................................................23

10 INSPECTION AND TESTS ......................................................................................23

12 END OF JOB DOCUMENTATION...........................................................................27

1.2 LEGAL REQUIREMENTS

1.2.2 This specification is governed by the law of contract. CORE

1.3 ORDER OF PRECEDENCE

AFC Approved for Construction

HAZ Heat Affected Zone

NCR Non-conformance Report

NDE Non-Destructive Examination

PQR Procedure Qualification Record

PT Liquid Penetrant Testing

PWHT Post Weld Heat Treatment

QCP/ITP Quality Control Plan / Inspection and Test Plan

UTS Ultimate Tensile Strength

WPS Welding Procedure Specification

1.5.4 Engineer of record

1.5.5 Engineering Contractor

1.5.8 Sasol’s Representative

2 REFERENCED CODES AND STANDARDS

Where reference is made to a code, specification or standard, the reference shall be