w TH BASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.: D PAGE 1 OF 21 SPECIFICATION FOR DUPLEX AND SUPER DUPLEX STAINLESS STEEL PIPING WELDING D- | REASSUED FOR APPROVAL | 2019827 | ZHANGY.H | CHENLJ FAN XH DONG L. | REISSUED FOR APPROVAL | 2019.60 | zHANGY.H | cHENLJ FAN KH DONG L. 8 | RerssuEDFoRAppRovaL | 2017.9.20 | zHaNcy.H | wANGHX | FANXH DONG L. A ISSUED FoR APPROVAL | 2016810 | surge | wANGHx | cHENLI | DONGL. REV. DESCRIPTION DATE PREP'D cHK’D REVD APP’DBASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 2 OF 21 CONTENT 1.0 GENERAL .. 1.1 Purpose. 1.2 Definitions. 2.0 CODES AND STANDARD.. 3.0 ABBREVIATIONS. 4.0 WELDING PROCESSES. 5.0 WELDING CONSUMABLES... 5.1 General... 5.2 Control of Welding Consumables during Production Welding 6.0 SHIELDING AND BACKING GAS... 7.0 WELDING PROCEDURE ... eee e@NNNmauvanva 7.4 WPS 72 PQR. 7.3 WPQ. 8.0 PRODUCTION WELDING... 81 General 82 Bovel... 83 Alignment. 8.4 Preheating and Interpass Temperature. 85 Tack Welding 8.6 Temporary Welding 8.7 Welding Process Requirement 8.8 Post Weld Heat Treatment (PWHT).BASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 3 OF 21 89 Weld Monitoring. 18 8.10 Pickling and Passivation .. 9.0 INSPECTION 19 9.1 Visual Examination 19 9.2 Non-destructive Test (NDT). 19 20 9.3 Hardness Testing 9.4 Ferrite Measurement. .20 10.0 REPAIR & RE-EXAMINATION... -20 10.1 Repair welding procedure 20 10.2 Re-examination. 24 11.0 OTHERS 21BASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 4 OF 21 REVISION HISTORY Revision A is completed on Aug 10th, 2016. Revision B is updated on Sep 20th, 2017. Due to related standards update and the relevant technical clauses will be revised. In addition, some clauses are revised to cleariy specify the technical requirements. According to PCH comments on May 25, 2019, the comment is not applicable for welding specification. And the chemical composition of SDSS is in HFY-GEN-PIP-SPC- 0021 Specification for Super Duplex Stainless Steel $32760 Piping Material which is submitted for approval. So, specification of Revision C is updated with no change. Due to related standards update and the relevant technical clauses will be revised on Revision D. In addition, some clauses are revised to clearly specify the technical requirements. The detail medication shall be as per revision marker in the documents. Major changes. as followings: Chapter Revised to 20 Add “ASTM A380" & “ASTM A967”. ‘Add “for Ar or ArtHe mixtures” to sentence “For GTAW, shielding gases 60 Ar or Ar+He mixtures sometimes N> addition to the gas are used to ‘compensate for N-losses from the weld metal, normally 2-3% Nz addition is used.” ‘Add sentences: “The microstructure shall be suitably etched and examined at 400 72.4 | Magnification and shall have grain boundaries with no continuous precipitates. Intermetallic phases, nitrides, and carbides shall not exceed 0.5% in total. The sigma phase shall not exceed 0.5 %.” 24 ‘Add “for DSS and 120°C for SDSS” to sentence “Generally, the . maximum interpass temperature shall not be more than 150°C.” ‘Add sentence: “The pickled liquid should be chosen according to ASTM A380 table ato | At-1. The final solution, exposure time and temperature, etc. for pickling - and passivation shall be included in the picking and passivation procedure. The detailed requirements and more information about pickling and passivation shall comply with ASTM A380 and ASTM A967."= _ os «< = I BASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 5 OF 21 1.0 GENERAL 11 Purpose This specification establishes the respectively minimum welding requirements for duplex stainless steel (DSS) and super duplex stainless steel (SDSS) including pipes, fittings, bends and special items where they shall be welded together. 1.2 Definitions WORD MEANING COMPANY PetroChina Intemational iraq FZE Iraq Branch “The organization selected and entrusted by COMPANY to perform the CONTRACTOR Engineering, Procurement, Construction, Start-up, pre-Commissioning and Commissioning of the Project. “The party who is in charge of awarding agreement on behalf of PURCHASER COMPANY I CONTRACTOR far the sippy af gands and services in ‘connection with the work. “The party tothe contract andlor purchase order which has undertaken ee REACT CE | the obligation to supply the goods andior services which are ordered and speoied herein, Shall Indicates a mandatory requirement ‘Shoula Indicates a strong recommendation to comply with the requirements of this document 2.0 CODES AND STANDARD Contractor shall meet the requirements of the latest edition of the following codes, regulations and standards, except as superseded herein. In cases where more than one code, regulation or standard apply to the same condition, the most stringent shall be followed. In the event of a conflict between this specification and other specifications or correspondence, the Company shall be consulted and a ruling, in writing, shall be obtained before any work is started.BASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 6 OF 21 ASME — BPVC. Section V ASME — BPVC. Section IX ASME B31.3 ASTM A790 VN ASTM A380 ASTM AS67 ASTME 92 ASTM E340 ASTM E562 ASTM G48. AWS ASA AWS ASQ AWS A532 ISO 10893-4 EN 10204 ASTN Practice No.SNT-TC-1A Non-destructive Examination Qualification Standard for Welding and Brazing Procedures Welders, Brazers, and Welding and Brazing Operators Process Piping Standard Specification for Seamless and Welded Ferritic/Austenitic Stainless Steel Pipe Standard Practice _for Cleaning, _Descaling, _and Passivation_of Stainless Steel_Parts, Equipment, and Systems ‘Standard Specification _for__Chemical__ Passivation Treatments for Stainless Stee! Parts Standard Test Method for Vickers Hardness of Metallic Materials Standard Test Method for Macroetching Metals and Alloys, Standard Test Method for Determining Volume Fraction by Systematic Manual Point Count Standard Test Methods for Pitting and Crevice Corrosion Resistance of Stainless Steels and Related Alloys by Use of Ferric Chloride Solution Specification for Stainless Steel Electrodes for shielded Metal Arc Welding Bare Stainless Steel Welding Electrodes and Rod Specification for Welding Shielding Gases Non-destructive Testing of Steel Tubes-Part 4: Liquid Penetrant Inspection of Seamless and Welded Stee! Tubes for the Detection of Surface Imperfections Metallic Products-Types of Inspection Document Personnel Qualifcation and Certification in Nondestructive Testing ‘Some requirements in this specification may be modified by specific requirements in the Procurement Requisition by the Company. In case of conflict, the specific requirements supersede this specification. Any deviation from this specification must be approved, in writing, by the Contractor. ‘Such written approval must be obtained prior to the commencement of any work which would constitute such a deviation 3.0 ABBREVIATIONS AWS American Welding SccietyBASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 7 OF 21 40 5.0 54 cVN Charpy V-notch Test DSS Duplex Stainless Steel FN Ferrite Number GTAW Gas Tungsten-Arc Welding cmaw Gas Metal-Arc Welding HAZ Heat Affected Zone NOT Non Destructive Test POR Procedure Qualification Record PWHT Post Welding Heat Treatment RT Radiographic Test spss ‘Super Duplex Stainless Steel SMAW Shielded Metal-Arc Welding wea Welder Performance Qualification wps Welding Procedure Specification UT Ultrasonic Test WELDING PROCESSES The following welding processes are permitted for DSS and SDSS piping welding. ™ SMAW: Do not use SMAW for the root welding. = GTAW = GMAW Welding processes other than those listed above require specific approval by the Contractor and shall not be assumed as acceptable by the Contractor during bid preparation. WELDING CONSUMABLES: General Welding consumable brand name shall be considered as essential variable. Welding ‘materials shall have certificate of qualification. Certificates shall be according to EN- 10204 type 3.1. Log number on material package shall conform to the cettificate. Coating of electrode shall not be affected by damp, fall off or have clear crack. Oil stain and rust stain on welding wire shall be removed. Electrode shall be baked according to the product instruction or welding operation instruction. It shall be dry during use. Electrode whose ex-works date exceeds one year shall be tested with welding performance. Qualified electrode can be used.BASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 8 OF 21 5.2 The base metal: DSS UNS $31803 SDSS UNS $32760 ‘The recommended welding material end welding processes should comply with Table 5.1-1, as following: Table 5.1-1 Recommended welding process and welding consumables Welding Consumable Welding Passes Process 831803, 832760 Root Pass GTAW ER2209 (AWS AS.9) | _ER2594 (AWS A5.9) GTAWIGMAW | _ER2209 (AWS A5.9) | _ER2594 (AWS A5.9) Filler & Cap Passes SMAW £2209 (AWS A54) E2594 (AWS 5.4) The chromium content shall match the parent material at least and the nickel content shall overmatch the parent material analysis unless the weld is to be subjected to a solution annealing neat treatment. In addition, the maximum sulfur content of welding consumables shall not exceed 0,015%, and nitrogen content range shall be 0.14~0.20% for E(R)2209 and 0.20~0.30% for E(R)2594, which helps to prevent the formation of o phase. Control of Welding Consumables during Production Welding Welding consumables for DSS and SDSS shall be stored with care on a specific separate area, under dry conditions in their original unopened packing. After opening shipping contain of electrodes, fluxes and other welding materials, storage and handling ‘shall be as specified the Vendor's recommendations of welding consumable. No electrode, filler wire or flux that is damaged, damp, and greasy or oxidised may be used. Welding electrodes shall be stored in ovens at the temperature between 120°C and 150°C. When issued for production they are placed in heated quivers capable of maintaining a minimum temperature of 70°C and used within 4 hours. Electrodes not used within 4 hours, or for some reason exposed to adverse atmospheric conditions, shall be baked again in accordance with the above conditions. Electrodes. may be baked twice only. If these electrodes are not used within four hours after the second baking treatment, they shall be discarded. Wire for automatic and semi-automatic welding process shall be stored in their original packages and shall be clearly identified. Wire without identification shall be discarded. In addition, the oxidised end of partly used filler wire shall be snipped off prior to re-use.BASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 9 OF 21 6.0 AX 70 TA ‘SHIELDING AND BACKING GAS For GTAW, shielding gases Ar or ArtHe mixtures sometimes Nz addition to the gas are used to compensate for N-losses from the weld metal, normally 2-3% Nz addition is used for Ar or ArtHe mixtures. Backing gas may be 100% Ny or AriNp mixture with no less than 5% No. ‘The WPS shall indicate the shielding gas (or gas mixture), percent composition and flow rate. In addition, shielding gas shall meet the purity requirements of AWS A5.32. Gas purity shall be recorded on POR and WPS when a single gas is used Shielding gas for welding of duplex stainless steel shall not contain hydrogen. In addition, the oxygen content of the backing gas, measured in the effluent gas immediately prior to welding, shall not exceed 0.25% to get good pitting resistance. Measurement shall be made by means of a suitable oxygen meter. The backing gas shall be maintained and monitored for the minimum number of weld passes qualified by the PAR, WELDING PROCEDURE Welding procedures required by ASME BPVC Section IX will include a written welding procedure specification (WPS) and procedure qualification record (PQR). The WPS provides direction to the welder while making production welds to ASME Section IX code Tequirements. The PQR is a record of the welding data and variables used to weld a test, coupon and the test results used to qualify the welding procedure. The Contractor shall develop welding procedures, and submit the approved WPS, POR for Company review. WPS and PAR shall be submitted on ASME BPVC Section IX Forms, QW-482 and QW- 483 or equivalent. All items on these forms must be completed. No production welding shall be carried out before WPS and PQR are eligible and qualified in accordance with requirements of ASME BPVC Section IX. All the welding procedure specifications recommended in this specification or those proposed by the Contractor shall be qualified in accordance with requirements of ASME BPVC Section IX prior to start of work. wes The Contractor shall submit evidence of his abilty to qualify welding procedures for each piping. This evidence shall be based on previous experience and qualification test results. All welds including weld repairs shall be supported by a relevant WPS. All WPS shall be in writing and shall be qualified and certified in accordance with the applicable code. All supporting PQR shall be witnessed, or at least certified, by a recognized inspection authority Each WPS shall be identified by a unique number. ‘The Contractor shall develop welding procedures, and the completed WPS for a welding process addresses all essential variables. For all pipes in this project, the NotchBASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 10 OF 21 72 toughness is required, so all the supplementary essential variables shall be treated as essential variables. Essential variables affect the mechanical properties of the weld. When any of the essential variables for procedure qualification listed in QW-250 clause of ASME BPVC Section IX (including supplementary essential variables for notch toughness) and essential variables listed below is changed beyond the relevant requirements, the approved WPS shall require re-qualification. a) Thickness (T): In addition to ASME BPVC Section IX requirements given in QW- 403.6, the maximum qualified thickness is 100mm. b> Joint design: A change from single to double side welding or vice versa. ©) Filler met trade name. > Filler metal size: Any change in diameter of the filer metal ) Shielding gas flow rate: Any change in flow rate beyond -20% to +10% 1) Backing gas composition: Any change in gas composition. 9) Electrical characteristics: Any change in type of current, polarity, or pulse range. > Interpass temperature: Any change in maximum interpass temperature. i) Heat input: Any change greater than: 10%. In case of conflict between above-mentioned essential variables and essential variables in QW-250 clause of ASME Section IX, the strict requirement shall be executed. ‘The WPS shall state the actual welding consumable or flux trade name, type and AWS classification, composition and flow rate of inert gas shielding, composition and flow rate of backing gas, interpass temperature, heat input, polarity, current and voltage, wire feed rate and travel speed as well as other related essential variables and non-essential variables. ‘Tack welds shall be made to a qualified welding procedure that has been approved by the Company and by approved welders. Tack welds shall be completely removed prior to welding. Fit-up lugs and strong backs and other temporary attachments shall be attached using a qualified procedure approved by the Company and shall be welded by approved welders. PaR The purpose of PQR is to establish the properties of the weld joints. The format of POR is not fixed, provided it addresses all essential variables and supplementary essential variables. An example form is available in ASME BPVC Section IX, Appendix B. Welders and welding operators shall be qualified in accordance with the applicable code prior to fabrication. Records shall be submitted to the inspection agency for approval. Alternative qualifications may be accepted subject to the inspection agency approval. Welding operators and welder qualtications shall be valid for one year from last qualification performance date, beyond which requalification is required. However, a validity period of two years may be considered if sufficient evidence is shown that the ny change in the diameter of welding consumables or classification orBASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 11 OF 21 724 7.22 723 telated welder has regularly used the same welding process and materials with no interruption exceeding six months. Welders and welding operators are subject to requalification when the quality of their work, during fabrication, appears to be below the requirements of this specification. All POR tests shall be witnessed and certified by an inspection agency recognised by ‘Company. Each welding procedure qualification shall include the following tests Tensile Test The tensile test shall be carried out according to clause GW-150 of ASME BPVC Section IX. The acceptance criteria shall meet the following requirements: For DSS $31803, the yield strength Rios shall be not less than 450MPa, and the minimum tensile strength Rn shall be 620MPa. For SDSS $32760, the yield strength Rios shall be not less than 550MPa, and the minimum tensile strength Rj, shall be 750MPa. Guide Bend Test Transverse bend test chall be two face bends and two root bends for wall thickness<10mm, and four side bends for thickness>10mm. The jig diameter shall be four times the wall thickness of steel plate. The relevant acceptance criteria shall meet the requirements of clause QW-163 in ASME BPVC Section IX. Impact Test Chary V-notch Testing (CVN) shall be carried out to three sets of three specimens in accordance with ASTM A370 at 0’C, and each set of three specimens taken from weld metal, fusion line and fusion line + 2mm shall be notched at each of following positions: ™ Root weld centre line; ™ Root fusion line (50% intersection of notch); ™ Root fusion line + 2mm. If the wall thickness exceeds 20mm, and additional set of three specimens shall be prepared from same location for each of following positions: = Cap weld centre line; = Cap fusion line (50% intersection of notch); = Cap fusion line +2mm. ‘Specimens shall, wherever possible, be 10 x 10 mm full size. If these dimensions are not possible, sub-size 10 x 7.5 mm shall be extracted. If the latter are not possible, the ‘specimens shall be 10 x 5 mm. CVN may be omitted if a specimen at least 5 mm thick cannot be extracted, Each set of three specimens shall meet the following requirements, as shown in Table 724:BASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 12 OF 21 724 Ay 7.25 726 727 Table 7.2-1 Requirements for the results of CVN Charpy Energy Joules Specimen size, mm Minimum Averaged Minimum Single/d 10X10 50 40 10X75, 38 at 40x5: 25 20 Metallographic Examination Four transverse macrographic examinations shall be carried out in accordance with ASTM E340 as well as four micrograptic examinations according to ASTM E562. The microstructure shall be suitably etched and examined at *400 magnification and shall have grain boundaries with no continuous sipitates. Intermetallic phases. nitrides. and carbides shall not exceed 0.5% in total. The ‘sigma phase shall not exceed 0.5 %. Hardness Test Vickers HV10 hardness test shall be carried out to weld metal, HAZ and base metal according to ASTM E 92 standard. In the weld metal, a minimum of six measurement points are taken in the cap pass and a minimum of three measurement points in the root pass. The distance between indentations shall be a maximum of 1 mm for base metal and weld metal, and 0.5 mm for HAZ beginning on the fusion line. ‘The average hardness shall not exceed 310HV10, and no individual reading shall exceed 320HV10 for weld metal and HAZ of DSS S31803. For SDSS $32760, the average hardness shall not exceed 330HV10, and maximum hardness shall be 340HV10 in weld metal and HAZ. Ferrite Content Test Ferrite content test shall be carried out according to ASTM E562, and the relative accuracy shall be less than 20%. Ferrite content shall be measured on metallographic specimens 1mm from both the inside and outside surface and be reported for base ‘metal, HAZ and weld metal. The average ferrite content shall be within the range of 40% to 60% for base metal, and 35% to 60% in the weld seam and HAZ regions. Pitting Corrosion Resistance Test The pitting corrosion test procedure shall be carried comply with the method A defined in ASTMG 48. The test specimen shall have a dimension of full wall thickness by 25 mm along the weld and 50 mm across the weld. The test shall expose the external and intemal surface and ‘a cross section surface including the weld zone in full wall thickness. Specimen prepare shall be as per ASTM G 48.BASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 13 OF 21 7.2.8 73 8.0 84 ™ Test solution: ASTM G48 ferric chloride test solution (about 6% FeCl, by mass). Test temperature: 22°C for DSS $31803 Welding, 40°C for SDSS $32760 Welding m= Test duration: 24 hours. The acceptance criteria, as follows: ™ No evidence of pitting, under visual examination with a magnification of 20X. = Weight oss shall be recorded and no more than 4g/m?. Retest If the results of destructive testing are unsatisfactory owing to defective specimen preparation or a localized weld defect, the Contractor shall inform the Principal and obtain agreement to proceeds with retests. wea The Contractor shall provide effective welders or welding operators’ qualification certificate that examined and verified by the Company or the representative of Company, and be responsible for conducting tests to qualify the performance of welders and welding operalors in accordance wilh qualified WPS approved by Company. A welder shall use the same welding technique and proceed with the same speed he will use if he passes the test and is permitted to do welding. WPQ shall be conducted in presence of Tepresentative acceptable to the Company. Qualification of welders and welding operators by others is not acceptable. Copies of the welder and welding operation qualification test records shall be available for review by the Company's representative. All welding, including piping welding, repair welding and tack welding, shall be performed by qualified welders using qualified welding procedures. Welders or welding operator shall be qualified and scope of welders qualification shall be in accordance with ASME BPVC Section IX The qualification is for the welding process used, and each different welding process requires qualification. A change in any essential variable listed for the welding process of QW-350 of ASME BPVC Section IX requires the welder to re-qualify for that process. Re-qualification of a welder may be required whenever there is reason to question his ability to make welds that meet the requirements of this specification or when he has not, performed welding of similar qualification for a period of two months. PRODUCTION WELDING General All the preparation and welding of pipes and components shall be carried out by qualified welders in accordance with the qualified and approved WPS. ‘Any welding performed prior to review and acceptance of welding documents shall not be permittedBASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 14 OF 21 82 Fusion faces, the surrounding internal and external surfaces within a minimum of 25 mm of the joint shall be clean and free from heavy scale, slag, moisture, oil, gears, paint, dit, oxide or any other substance which may have a deleterious effect on the weld quality or progress. Before welding, bevels and adjacent inner and outer surfaces polluted by greasy, cil, gears, paint, etc. other substance shall be cleaned. Welding wires shall be cleaned with acetone and rags without plush. The Contractor shall ensure a good earth connection and periodically examine the condition of the earth cables and attachments. Connections shall be made to the work by stainless steel clamps. Earth cables shall not be welded to pipeline components. If the pipe size exceeds DN300 at leest two welders shall weld simultaneously around the pipe circumference. If following situations happen in constuction site for welding of pipe and no protective ‘measure are taken, welding operation shall be stopped. ) Environment temperature is lower than 0°C ) Environment humidity is more than 90%RH ) Environment wind velocity is more than &m/s (SMAW) and 2m/s (GMAWIGTAW) 4d) The restis rain, snow and blowing sand (with high wind) Anything which results in the weld metal or HAZ being overheated or heated for prolonged periods, e.g. the welder pausing or weaving, slow welding speed, welding without continuous filler addition, excessive slope up/downtime for craters elimination, excessive inter pass temperature, will affect and reduce corrosion properties and shall be avoid. The open ends of the pipe shall be capped when interruptions to work expected to last two or more hours occur. All open ends of pipe strings shall be capped off and sealed when welding is completed Backing gas shall be maintained unti at least 6.5mm depth of weld metal has been deposited. The same requirement applies also for tack welding. For socket, seal, and other attachment welds on base materials less than 6.5mm thick, the backing gas shall be maintained throughout the welding operation. All cutting and welding operation on DSS & SDSS shall be performed in a clean area, segregated from the fabrication of carbon steel. Bevel The joint bevels shall be prepared in accordance with the approved WPS, and field bevels of pipe end shall be made by machining and/or grinding with the exception that plasma cutting is permissible provided a machine-guided torch is used. Plasma-cut ends shall be left free of slag and the cut surface shall be ground to a smooth, bright, uniform finish with the removal of a minimum of 0.5 mm of metal.BASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 15 OF 21 83 The bevel surfaces shall be visually examined and shall be free of defects, such as laminations, tears, split end, burns, small score marks, indentations, other imperfections and linear indications etc., shall be unacceptable and the pipe end shall be re-prepared. Where a cut back has been made as a result of laminations in the pipe, the area for the new end preparation shall be subjected to ultrasonic testing to confirm the absence of laminations. Repair by welding shall net be permitted. Alignment The pipe components shall be firmly supported in both the vertical and horizontal plane and no welding shall be carried out until the alignment that has achieved the requirements of approved WPS. Before alignment of weld joints, inner and exterior faces of piping end shall be removed by manual or mechanical method. There shall be no paint, burr, rusty stain, scale and other sundries in 25mm range at two sides of bevels that can adversely impact welding. The space between abutting pipe ends shall conform to the WPS to insure complete penetration without burn-through. The alignment of abutting ends shall minimize the offset between surfaces. For pipe ends of the same nominal thickness, the offset shall comply with requires of WPS, and not exceed 1.5mm. ‘Any misalignment shall be reduced to a minimum by rotation of the pipe to achieve the best fit. Hammering or heating of the pipe shall not be permitted If the offset exceeds 1.5 mm, provided that it is caused by dimensional variations within the specified tolerances, or if alignment of two pipe components of different nominal thickness and the same outside/inside diameter is required, joint design shall be in accordance with ASME B31.3. The outside and inside surface of thicker components shall be made by tapering, and any taper shall not be steeper than 1 in 4 (L24 (61-62), as shown in Figure 8.3-1: Wifi 31: Wall thickness for thicker component; 52: Wall thickness for thinner component; L: Taper length Figure 8.3-1 the machining requirement of different wall thickness pipeBASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 16 OF 21 84 For longitudinal seam welded pipe, this seam shall be within the top 120° of the circumference. The longitudinal seams of consecutive pipes shall be offset by at least 100 mm. Flanges shall be attached to piping so that the bolt holes straddle the established centerlines (horizontal, vertical, or layout centerlines) but shall meet the orientation of ‘equipment. In socket weld assembly, the pipe shall be inserted into the socket to the maximum depth and then withdrawn approximately 2 mm away from contact between the end of the pipe and the shoulder of the socket. Do not assemble weld joints by peening. Preheating and Interpass Temperature Preheat is not mandatory requirement; however, the pipe wall temperature shall be such that the pipe is free from condensation and moisture. Preheating to a maximum of 95°C may be remove moisture; however, the weld joints should be allowed to cool to room temperature prior to welding, Where preheat is required by WPS, it shall be applied prior to any welding, tack welding. Welding or cutting torches shall not be used. The temperature measurement for preheat (if necessary) and inter pass temperature ‘may be by tempil stick, digital pyrometers or contact thermometer. The interpass temperature shall be monitored to confirm compliance with the limit established by the PQR or qualified WPS. Generally, the maximum interpass temperature shall not be more than 150°C for DSS and 120°C for SDSS because excessive interpass temperature can cause embrittlement and low impact value in root, region, and measured at the point of the each restart welding and within joint bevel. In addition, heat input shall be in compliance with WPS or PQR, if it is required. Generally, welding should adopt a relatively lower heat input, the range of 0.5~2.5kJ/mm is recommended for DSS and 0.2~1.5kJ/mm for SDSS. Tack Welding tack welding procedure shall be submitted by Contractor for approval by Company. If the use of external or internal clamp is not possible, tack welding could be preferably done without filler metal. If filler metal is used, the tacking points shall be done with qualified procedure by qualified and shall be completely eliminated by grinding before root pass finishing. Tack welds shall be temporary bar tacks using suitable duplex stainless steel material. Welding parameters shall be in accordance with the appropriate fil pass, and fully penetrating root tacks shall not be allowed. Tack length should be 10mm~15mm, thickness should be 2mm~4mm and not more than. 2/3 of wall thickness. A suitable distance between tacks is 150~200mm. However, tackBASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 17 OF 21 86 a7 welds shall be of sufficient cross section and length in order to avoid cracks, especially on high strength stee! materials. After assembly and tack welding, the process welding shall be applied in time. Temporary Welding Welding for temporary handling attachments, lugs, etc. shall be minimized. When temporary welding is deemed necessary, welding shall be performed with the same approved procedures as for the main fabrication welding The temporary welding shall subsequently be removed by gouging or grinding according to an approved procedure and ground flush with the base material, and then inspected by Dye Penetrant. The method of removing attachments shall not injure the metal surface (i.e. they shall not be removed by hammering off). Any defect found during this inspection shall be removed and repaired by a qualified welder using welding procedures approved by the Company. Welding Process Requirement Whichever the welding process used for filling, the two first passes shall be carried out using the GTAW process, and the shield gas shall be Ar+2~3%N) or Ar+He mixtures + 2~3%N>, backing gas may be 100%N, or Ar/N, mixture with no less than 5% No. All manual GTAW shall use a high frequency start and a post-purge gas flow for the torch. Whenever the welder stops welding, the welding current shall be gradually decreased by use of welding machine with function of current attenuation. The torch shall be held in position close to the weld poo! until the gas shielding post-purge flow is ‘completed to prevent oxidation Distance between 2 continuous circumferential welds shall be at least 1 times of outside pipe diameter and not less than 100mm for pipe diameter equal and less than DN150. For pipe diameter above than DN150, this distance shall be not less than 150mm. Welds of branch connections and attachments should not overlap main seam welds. Do not generate the arc or test current on surface of weldments, and permanent backing material is not allowed. Quality of arc starting and arc stopping shall be guaranteed. Arc crater shall be filled up when stopping arc. Interlayer joints of multilayer welding shall be stagger. Two beads shall not be started at the same location, and the distance shall be larger than 30mm. In addition, scale and slag shall be removed from each bead and bevel. Interruption of welding should be avoided. If interruption is unavoidable, a minimum of three passes or one-third of the joint thickness, whichever is greater, shall have been deposited. On resumption of welding any preheat requirements specified in the approved WPS shall be applied. The partially completed weld shall be visually inspected prior to resumption of welding to check for cracks, dirt/contamination and corrosion. Welds shall be left as welded and shall not be treated with a flame torch or other mechanical means to change their appearance other than cleaning and dressing operations specified in the WPS. When fabrication is completed, all surfaces adjacent toBASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 18 OF 21 the welds shall be cleaned of spatter, burrs and other imperfections which could interfere with radiographic or ultrasonic inspection. Peening of welds shalll be restricted. Special care shall be taken in the selection and usage of tools to avoid contamination. Tools shall be iron free and be suitable for use with stainless steels. The number of filler and finish beads shall allow the completed weld @ substantially uniform cross section around the entire circumference of the pipe. At no point shall fall below the outside surface of the pipe, nor shall it be raised above the parent metal by more than 1.6 mm. All attachment welds to the piping shall be continuous (skip welding not permitted). Fillet welds shall have a minimum leg length of 4 mm: ‘The welder shall inspect and repair the weld bead oneself, and fill in the relevant original record. Welding may only start when qualified welding procedures and welders have been approved by the Company and the Inspection agency. Post Weld Heat Treatment (PWHT) Post weld heat treatment is not norrrally necessary. If it becomes necessary for any reason, it should be done at 1040°C minimum for S31803 DSS and 1070°C minimum for '$32760 SDSS, followed by rapid cooling. Exposure in the range 650~1000°C is very harmful to toughness and corrosion resistance because of formation of carbides, or ‘sigma or other intermetallic phases. Weld Monitoring The welding of duplex stainless steel or super duplex stainless steel shall be monitored bya Quality Control representative on a regular basis as follows: 1m The first production weld of each welder shall have the root and hot passes monitored and periodically the welding process filing. = Measuring equipment used for weld monitoring shall be calibrated. ™ Monitoring check list shall be used to record the findings of all weld monitoring. It is mandatory that actual values are recorded. Whilst the monitoring of welding is being carried out particular attention must be paid to the cleanliness of weld preps and consumables, content of oxygen back purge, all pass temperatures measured by Digital Contact Thermometer with close monitoring of root and hot passes and actual recorded heat input values, and run-out-lengths. = All completed weld monitoring check lists shall be issued to the welding department for review. ™ Welders found to be working out of the parameters of the weld procedure or unable to maintain the required heat input values shall stop welding immediately and report. Immediate corrective action shall be taken.BASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 19 OF 21 8.40 A 9.0 94 9.2 Pickling and Passivation Any ground surface, external weld surface and adjacent base metal shall be pickled and passivated immediately after grinding or welding according to an approved procedure. The pickled liquid should be chosen according to ASTM A380 table A1.1. The final ‘solution, exposure time and temperature, etc, for pickling and passivation shall be included in the picking and passivation procedure. The detailed requirements and more information about pickling and passivation shall comply with ASTM A380 and ASTM A967. For final rinsing, only fresh water with a chloride ion concentration of less than 50 ppm shall be used INSPECTION Visual Examination All welds shall be 100% visually inspected after completion and before any NDT technique is applied. Surface of weld joints shall be treated according to the requirement before inspection of weld joints. Appearance of weld joints shall be satisfactory. Both edges of weld joint shall cover 2mm width of two edges of groove. Surface of seam cannot be lower than that of pipe, and the height of weld should not be raised above the base metal by more than 1.6 mm. Height of leg shall meet the requirements of design documents. The surface shall be smooth, and width of cap shall be at least 1mm wider than bevel at each side. Requirement for quality of weld joint’s surface is no crack, not fusion, bubble, slag, and splash; Surface of weld seam shall be free from undercut. Depth for undercut of weld joints cannot be larger than 0.5mm. Continuous length for undercut cannot be longer than 100 mm. Total lengths for undercut at two sides of seam cannot exceed 10% of total length of the seam. All welds shall be visually inspected and all cracks, crater cracks, surface pores, laminations, spatter residual slag or stray arc strikes shall be considered as defects. Non-destructive Test (NDT) AIL NDT shall be performed in accordance with the requirements and methods specified in ASME BPVC Section V. Welding joints shall be nondestructively examined in accordance with the following requirements after passing the measurement of geometric dimensions, visual examination as well as other related testing. Personnel performing NDT other than visual shall be qualified in accordance with ASNT Practice No.SNT-TC-1A, or equivalent. The equivalency must be documented. Only individuals qualified for NDT Level | and working under the NDT Level 1 or individuals qualified for NDT Level II may perform NDT.BASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 20 OF 21 93 94 10.0 10.1 All butt and full penetration welds shall be 10 % inspected by RT examination for low pressure and 100% RT for high pressure (210MPa) firstly, and UT shall be conducted when RT is impracticable. For some types of branch connections and filet welds, liquid penetrant (chloride free) examination shall be conducted. Internal surfaces shall be examined where accessible. For DSS and SDSS piping welding, upon the completion of NDT inspection, the relevant inspection report or record shall be written. Acceptance criteria shall be according to ASME B 31.3 and ASME BPVC Section V. Level of severity pertaining to cyclic conditions shall apply and with the following additions: ™ No lack of fusion is permitted ™ No lack of root fusion is permitted ™ No lack of penetration is permitted Hardness Testing Hardness testing shall be conducted on a 20 % random sampling of all production welds. Both the welds metal and HAZ shall be tested. Testing shall be conducted with portable hardness testers, and maximum allowable individual hardness value shall not exceed 26HRC for DSS and 28HRC for SDSS Ferrite Measurement The ferrite content of completed welds shall be checked. It shall be within the range of 35% to 60% ferrite using the appropriate Ferrite Number (FIN) based on the correlation established by the POR requirements. 5% of the welds shall be inspected. Per weld, the average of three measurements shall be considered. REPAIR & RE-EXAMINATION Repair welding procedure Open root repairs are forbidden. For full repair without opening, the minimum ligament (distance between the inner surface and the bottom of excavation) shall be 3 mm. For partial and cap repair, the excavation area shall ensure that all defects are completely removed and cleaned thoroughly prior repair welding. Re-repair in the same area is forbidden The back gas protection requirements shall be the same for the repair procedure as for the main welding procedure. Preheating and heat treatment shall be as required for the original weldingBASIC DESIGN DOC. NO.: GEN-PIP-SPC-0017 REV.:D PAGE 21 OF 21 10.2 11.0 Cap repair could be covered by pettial repair procedure but the converse is not acceptable. All repairs shall be subject to 100 % NDT as the main weld procedure. Defects necessitating repair shall be entirely removed to sound metal. ‘The removal of weld metal, or portions of the parent material, shall be by machining or grinding, and thermal gouging methods shall not be used. Repair excavations shall be smoothly contoured and tapered, having a minimum included groove angle of 50°. Visual inspection of the repair weld grooves shall be carried out prior to re-welding to confirm complete removal of the defects. The total repair length shall not exceed 40% of the total weld length. The maximum length of a single repair portion shall be less than 30% of the total weld length. Groove taper shall be included in the measurements. Re-examination When the unacceptable defects are disclosed at welded joints by visual or radiographic ‘or ultrasonic examination, the welded joints shall be repaired by welding after defects removed, and be re-examined by radiographed whether the defect in the original weld was detected by radiographic examination or not. All repairs which require excavation and re-welding shall be re-radiographed. The radiograph shall extend for a minimum distance of 50 mm beyond either end of the repaired area measured on the face of the weld OTHERS For piping under non-destructive examination, some traceable markings shall be made as per project requirements, such as serial number of weld seam, code of welder, position of welding, method for non-destructive examination, position of weld seam for Tework, position of weld seam for expanded detection, etc.