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ENGINEERING SPECIFICATION
MINIMUM REQUIREMENTS FOR WELDING
PROCEDURE SPECIFICATION
FOR
CIVIL WORKS
FOR
HINDUSTAN PETROLEUM CORPORATION LTD.
VISAKH REFINERY

DHT PROJECT
TEIL JOB NO. : 6261
DOCUMENT NO. : H 331

29.12.2008

For Bid Enquiry

Rev.
no.

Issue Date

Description

UCM

PRK

Prepared by Checked by Approved by

TOYO ENGINEERING INDIA LIMITED


MUMBAI

SSV

INDIA

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Revision History
Rev.

Date

29.12.2008

Description
For Bid Enquiry

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DOC.No. H 331

MINIMUM REQUIREMENTS FOR


WELDING PROCEDURE
SPECIFICATION

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261


DHT PROJECT

Sheet 3 of 31

CONTENTS
Section
1

Topic

Page No.

GENERAL

1.1

Scope

1.2

Conflicts

1.3

Codes and Standards

1.4

Related Engineering Specifications

WELDING PROCEDURE SPECIFICATIONS (WPS)

2.1

Applicable Codes and Standards

2.2

Responsible Organizations

2.3

Preparation of WPS and PQR

2.4

Minimum Requirements for WPS

2.5

Procedure Qualification Test Requirements

MINIMUM REQUIREMENTS FOR WELDING PROCEDURE


SPECIFICATION

3.1

Welding Processes

3.2

Base Metals

3.3

Electrodes and Welding Rods

3.4

Dissimilar Joint

11

3.5

Low Temperature Service

13

3.6

Preheat and Interpass Temperature

13

3.7

Post weld Heat Treatment (PWHT)

14

ATTACHMENT 1
Table-1 List of Items for Welding Procedure Qualification (QW-451.1)
Table-2 Applicable Base Material Specification
Table-3 Selection of Electrodes and Welding Rods
ATTACHMENT 2
Attached Figure of Joint Sketch
ATTACHMENT 3
Appendix 1 Welding Specification for Pressure Piping

16
17
18
20
23
24
27

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1.

GENERAL

1.1

Scope

MINIMUM REQUIREMENTS FOR


WELDING PROCEDURE
SPECIFICATION

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261


DHT PROJECT

Sheet 4 of 31

This specification covers minimum requirements for welding procedure specification


(WPS) which shall be established for the piping construction work.
1.2

Conflicts
Any conflict between the requirements of this specification and the provisions of any
applicable codes, standards and Customers requirements shall be referred to PMC
for resolution prior to the work.

1.3

Codes and Standards


The following codes and standards shall be referred to the latest edition unless
otherwise specified:
ASME Sec.II Part C Specifications for Welding Rods, Electrodes, and Filler
Metals.
ASME Sec. IX

Qualification

Standard

for

Welding

and

Brazing

Procedures, Welders, Brazers, and Welding and Brazing


Operators.

1.4

ANSI/ ASME B31.1

Power Piping

ANSI/ ASME B31.3

Chemical Plant and Petroleum Refinery Piping

AWS D1.1

Structural Welding Code - Steel.

Related Engineering Specification


H-103

Piping Materials or Enclosures

H-109E

Piping Support

H-301E

Piping Construction Works

H-321E

Welders Qualification Test

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Sheet 5 of 31

2.

WELDING PROCEDURE SPECIFICATIONS (WPS)

2.1

Applicable Codes and Standards


This specification shall be used in conjunction with the piping code ANSI/ASME
B31.3.
For the piping support and shoe welding except the joints to pressure containing
parts, prequalified welding procedures only for SMAW meeting AWS D1.1 may be
applied for P-No.1 base metals without procedure qualification tests and WPS shall
be submitted to PMC for approval.
When the non-pressure containing or load bearing parts are joined to pressure
containing piping, this specification shall be applied.

2.2

Responsible Organizations
The construction LSTK contractor shall list the parameters applicable to welding that
he performs in construction of weldments build in accordance with this specification.
These parameters shall be listed in documents known as a Welding Procedure
Specification (WPS).

Each construction LSTK contractor shall qualify WPS by

welding test specimens, and recording the welding data and test results in
documents known as Procedure Qualification Records (PQR).
The welders or welding operators used to produce weldments to be tested for
qualification of procedures shall be under the full supervision and control of the
LSTK contractor during the production of these test weldments. It is not permissible
for the construction LSTK contractor to have the welding of test weldments
performed by another organization.

This specification recognizes a construction

LSTK contractor as the organization, which has the responsible operation control of
the production of the weldments to be made in accordance with the requirements of
this specification. If in an organization effective operational control of welding
procedure qualification for two or more companies of different names exits, the
company involved shall describe in their Quality Control System/ Quality Assurance

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Sheet 6 of 31

Program the operational control of procedure qualifications. In this case, separate


welding procedure qualifications are not required, provided all other requirements of
this specification are met.
Prior to production welding, the corresponding WPS and supporting PQR shall be
submitted to PMC for approval.

2.3

Preparation of WPS and PQR

2.3.1 Applicable WPS for the specific job shall be selected and prepared in accordance
with ASME B-31.3 and ASME SECTION IX, Engineering Specification H-103 and
H-301. WPS shall be identified by a unique number and shall contain complete data
including all the Essential, Supplementary Essential and Non Essential Variables
with maximum and minimum values qualified.
2.3.2 PQR to support related for the specific job shall be prepared in accordance with
Attached Table 1 List of Items for Welding Procedure Qualification. All test results
to be recorded into PQR shall be from specimens representative of the final
condition including all heat treatments of the weldment.
2.3.3 Joint designs referred to in each WPS shall be referred to Attached Figure Joint
Sketch.
2.3.4 The WPS and PQR shall be recorded and documented in the following forms:
APPENDIX -2 WELDING PROCEDURE SPECIFICATION (1/2 and 2/2).
APPENDIX -3 PROCEDURE QUALIFICATION RECORDS (1/3, 2/3 and 3/3).

2.4

Minimum Requirements for WPS


This

specification

and

APPENDIX-

WELDING

SPECIFICATION

FOR

PRESSURE PIPING shall give the minimum requirements and guidelines for the
establishment of WPS and supporting PQR for the most used manual welding
processes, Gas Tungsten Arc Welding (GTAW), Shielded Metal Arc Welding
(SMAW) process or a combination for the piping or a combination for the piping
systems based upon the piping code ANSI/ ASME B31.3 and B31.3.

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Any deviation from Minimum Requirements for WPS and related requirements on
this specification, including the application of other welding process than GTAW or
SMAW shall be informed to PMC for approval.

2.5

Procedure Qualification Test Requirements

2.5.1 Impact Test


Impact test for procedure qualification test shall be performed in accordance with
Table 323.2.2 REQUIREMENTS FOR LOW TEMPERATURE TOUGHNESS TESTS
FOR METALS in ANSI/ ASME B31.3.
The test temperature of impact tests shall not be higher than the design minimum
temperature.

If the sub-size specimens are used, a suitable reduction of

temperature must be done. (See Par. 323.3.4 Test Temperatures in ANSI/ ASME
B31.3).
2.5.2 Hardness Test
The welding procedure qualification test shall include hardness test when required
by the applicable codes, standards, or specifications for such process designs as
wet hydrogen sulfide, amine etc.

3.

MINIMUM REQUIREMENTS FOR WELDING PROCEDURE SPECIFICATION

3.1

Welding Processes

3.1.1 General
(1)

Welds shall be made by gas tungsten are welding (GTAW), shielded metal
are welding (SMAW) process or a combination thereof. Any other welding
process requires PMC approval.

(2)

The applications of backing rings and consumable inserts are prohibited.

(3)

All passes shall be uphill unless specifically approved by PMC.

(4)

Argon gas with purity of not less than 99.995% shall be used as shielding
gas.

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Sheet 8 of 31

Argon gas backing with purity of not less than 99.995% shall be performed for
P-No.9B metals, 5Cr-1/ 2 Mo and higher low alloy metals, stainless steels,
and nonferrous metals.

3.1.2 Gas Tungsten Arc Welding (GTAW)


(1)

GTAW process shall be applied to root pass welding for all groove joints
except for specified in Par. 3.3.1.

(2)

Gas composition and flow rate of the shielding gas and backing gas shall be
recorded in the PQR and specified in the WPS, where applicable.

3.1.3 Shielded Metal Arc Welding (SMAW)


(1)

AWS classification E6010 may be used for root pass and filler passes of
carbon steel, except Al-killed carbon steel, provided all of the following
conditions are met:
-

nominal pipe size of 2.1/2 inches and over.

the specified minimum strength of less than 70 ksi (483 Mpa).

(2)

In all cases, AWS classification E6012/ E6013 shall not be used.

(3)

All the SMAW electrodes for carbon and low alloy steels shall be low
hydrogen types except E6010/E6011.

3.2

Base Metals

3.2.1 P-Numbers 1, 4, 5A, 8 are covered in this specification, and examples of base
metals are listed in Attached Table 2. Other metals shall be qualified in accordance
with QW-424.1 in ASME Sec.IX.

3.2.2 Where the AWS D1.1 is applied for piping support and / or shoe welding, the
specification or designation of base metals shall meet those specified in H-109
Piping Support.

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3.3

MINIMUM REQUIREMENTS FOR


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SPECIFICATION

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Sheet 9 of 31

Electrodes and Welding Rods

3.3.1 Electrodes and welding rods shall be selected from Attached Table 3 Selection of
Electrodes and Welding Rods.
(1)

Attached Tables 3 shows ASME specifications and AWS Classifications of


the applicable electrodes and welding rods.

(2)

The manufacturers of electrodes and welding rods shall be chosen by the


construction LSTK contractor in his responsibility and approved by PMC.

(3)

Prior to using Non-listed electrodes and welding rods, a written proposal


accompanied by physical and mechanical properties, and chemical analysis
shall be submitted to PMC for approval.

(4)

Electrodes and welding rods shall be specified and identified in WPS and
PQR by ASME specification and AWS classification.

Brand name of

electrodes and welding rods shall also be specified in WPS.


(5)

When non pressure containing parts are welded to pressure containing


piping, the chemical and mechanical properties of deposited weld metal shall
be met the pressure containing base metal.

3.3.2 All electrodes and welding rods shall be used within the limits recommended by
manufacturers.

Batch test certificates of electrodes and welding rods shall be

obtained and verified by TEIL prior to commencement of welding work.

3.3.3 When H Grade is specified for type 304, 316, 321 and 347 stainless steels, the
filler metal shall have 0.04% of carbon content or more.

3.3.4 WPS shall be re-qualified whenever:


(1)

A filler metal in G classification is changed to any other manufacturer or


manufacturers designation.

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JOB NO. : 6261


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Sheet 10 of 31

The chemical composition of the weld deposit is changed from A-No. 1 to ANo.2 and vice versa.

3.3.5 Carbon Steel


(1)

For GTAW, the filler metals shall meet the chemical and mechanical
requirements of SFA5.18 classification ER70S-3, ER70S-6, TGS-50 (ER70SG: Kobe Steel Ltd) is acceptable for using.

(2)

For SMAW, the electrodes designated AWS classification E7016 or E7018


shall be used.

3.3.6 Al-killed Carbon Steel


(1)

For GTAW, the certificates of filler metals shall include impact test which have
been conducted at - 460C or minimum design temperature and the results
shall conform to the absorbed energy requirement.

(2)

For SMAW, the electrodes designated AWS classification E7016-1 or E70181 shall be used.
It is acceptable to use a trade designations of LB-52NS (SFA 5.5 E7016G:Kobe Steel, Ltd.) NB-1 SFA 5.5 E8016-G: Kobe Steel Ltd) provided that
the certificates of filler metals shall include impact test which have been
conducted at -460C or minimum design temperature and the results conform
to the absorbed energy requirement.

(3)

For sour service application (NACE MR0175), nickel content in the filler metal
shall not exceed 1.0%. NB-1 shall not be used for sour service because of
exceeding 1.0% of Ni content.

3.3.7 3.5 Ni steel


(1)

The certificates of filler metals shall include impact test which have been
conducted at -1010C or minimum design temperature and the results conform
to the absorbed energy requirement.

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Sheet 11 of 31

For GTAW, the welding rods designated AWS classification ER80S-Ni3 shall
be used.
The trade designation of TGS-3N (Kobe Steel, Ltd) can be used provided that
the certificates of filler metals include impact test which have been conducted
at -1010C or minimum design temperature and the results conform to the
absorbed energy requirement.

(3)

For SMAW the electrodes designated AWS classification E7016-C2L or


E7018-C2L shall be used
The trade designation of NB-3N (Kobe Steel Ltd) or N-16 (Nippon Steel
Welding Products & Engineering Co. Ltd) for SMAW can be used provided
that the certificates of filler metals include impact test which have been
0

conducted at -101 C or minimum design temperature and the results conform


to the absorbed energy requirement.
(4)

NB-3N shall be used where the design temperature is -600C or higher in case
of as-welded condition. If the design temperature falls within the range from 600C to -1010C, PWHT is required regardless of base metal thickness.

3.3.8

C-1/2Mo
ERXXS-G is specified for GTAW, the deposited weld metal shall have the
same chemical composition and mechanical properties as the base metal.

3.4

Dissimilar Joint

3.4.1 For dissimilar joint made of ferritic steel and austenitic stainless steel at the design
temperature above 4500C, nickel - chromium -iron filler metal (Inconel-type) shall be
used in order to minimize the carbon migration and thermal fracture during service.

3.4.2 Inconel - type welding rods and electrodes shall not be used, where the joints are
exposed to a sulfidation environment at the design temperature above 5370C.

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3.4.3 For dissimilar joint which includes P-No.8 metal, preheat, interpass and postweld
heat treatment conditions shall be confirmed from PMC.

3.4.4 The following guidance for special DISIMILAR WELDS and ELECTRODES are as
follows:
Whenever possible, dissimilar welds between stainless steel and carbon or low alloy
steel should be avoided in wet H2S and other services where hydrogen
embrittlement is possible. This is because of hard zone that occurs at the fusion line
of austenitic metal and the carbon or low alloy steel base metal. This hard zone can
not be completely removed with PWHT. When dissimilar welds between carbon
steel and UNS NO8825 or UNS S32205 are specified in the drawings. The following
guidance is offered.

a. Carbon Steel to Alloy 825 (UNS N08825)


For weld metal, use nickel-based filler metal type ER-NiCrMo-3(INCO 625) wire and
E-NiCrMo-3 rod (INCO 112).
b. Carbon Steel to Duplex 2205 (UNS S32205)
There is not an industry consensus on how to make a dissimilar weld between
carbon steel and Duplex 2205, suggests that the carbon steel side of the joint be
overlaid(buttered) with a first pass of low carbon steel (AWSR45 or equal). The
thickness of the buttershould be 1/16-1/8 inch {1.5-3} max. This will avoid the
problem of a hard zone in the AWS E2209 (UNS W39209) weld metal due to dilution
from the carbon in carbon steel. The low Carbon butter pass should be as close to
1/16 in (1.5mm) minimum as possible so that the strength of the joint is
adequate.After the butterpass of low carbon weld metal is deposited on the carbon
steel, weld the Duplex 2205 to the buttered carbon steel with E2209 electrodes.
This procedure must be qualified to make sure that the tensile strength of the
joint is adequate. As part of the welding procedure qualification a microhardness

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survey should be run across the weld to make sure that there is no hardness that
exceeds those recommended by NACE MRO103. In addition, because the yield
strength of the Duplex 2205 is so much higher than that of carbon steel, the welding
procedure should be qualified using longitudinal bends rather than transverse bends
as permitted by the code. This will avoid failure in the carbon steel before the Duplex
2005 begin to bend.
Some refiners weld carbon steel directly to Duplex 2205 using filler metal type ERNiCrMo-3 (INCO 625) wire and E-NiCrMo-3 rod (INCO 112). As part of the welding
procedure qualification a micro hardness survey should be run across the weld to
make sure that there is no hardness that exceeds those recommended by NACE
MRO103.
3.5

Low Temperature Service


Delta ferrite content of austenitic stainless steel filler metals shall be controlled as
follows:
Where the design temperature is at -1010C or lower, the electrodes (SMAW) and
welding rods (GTAW) shall be low carbon type. In addition, the ferric content of
electrodes (SMAW) shall be in the range of 2 to 5 percent (FN2 to FN5). Using low
ferrite content electrodes (SMAW) such as NC-38LT (Kobe Steel Ltd), WEL308LA
(Nippon Welding Rod Co, Ltd) is recommended.

3.6

Preheat and Interpass Temperature

3.6.1 Preheat temperature for procedure qualification test must be measured just before
start of welding and temperature shall be recorded in PQR.

3.6.2 The maximum interpass temperature for austenitic stainless steels shall not exceed 1800C.

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3.7

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Postweld Heat Treatment (PWHT)

3.7.1 PWHT for dissimilar joint between ferritic materials shall be at higher of the
temperature range for the materials in the joint.

3.7.2 PWHT cycles used for procedure qualification test shall be recorded in a chart and
attached to PQR for PMC approval.

3.7.3 PWHT cycles including

heating rate, the maximum and minimum holding

temperatures, holding time and cooling rate shall be specified in WPS.

3.7.4 PWHT shall be performed when it is stipulated in H-103 for certain services
regardless of base metal thickness.

3.7.5 When joining austenitic material to ferritic material of the thickness being required
PWHT by applicable code, the welding procedure and PWHT applications shall be
confirmed from PMC.

3.7.6 The requirements for PWHT of fillet weld joints and branch connections shall be
referred to the requirements on H-301 Piping Construction Works.
3.7.7 All 18-8 cold bends should be heat treated at 1500-16500F (843-8990C) , 1 hour per
inch of thickness, 1 hour minimum for resistance to chloride stress corrosion
cracking (CISCC).

3.7.8

Drain lines and lower points in austenitic stainless steel lines are particularly prone to
chloride stress corrosion cracking (CISCC) shall be PWHT. PWHT lowers the

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incidence of CISCC of drain lines. It does not eliminate it. Therefore, it is


recommends drains and low points be made of Alloy 625, Alloy 825 or Alloy 20Cb3.
3.7.9 Carbon steel piping joints , for thick walled piping in hydrogen or hydrogenhydrocarbon services, the wall thickness of pipe greater than (19 mm) should be
post weld heat treated.

3.7.10 All weld of 18-8 stainless steel for thick walled piping in hydrogen or hydrogenhydrocarbon services should be post weld heat treatment.

3.7.11 All weld of Cr-Mo steel piping for thick walled piping in hydrogen or hydrogenhydrocarbon services should be post weld heat treatment.

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ATTACHMENT 1
TABLE 1

LIST OF ITEMS FOR WELDING PROCEDURE QUALIFICATION


(QW-451.1)

TABLE 2

APPLICABLE BASE MATERIAL SPECIFICATION

TABLE 3

SELECTION OF ELECTRODES AND WELDING RODS

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Sheet 17 of 31

TABLE - 1
List of Items for Welding Procedure Qualification (QW-451.1)

Test piece
Material

Thickness t
of test
Classificat
coupon
ion
welded
Less than 1.6
mm (1/16 in.)
1.6 mm (1/16
in.) to 9.5 mm
(3/8 in.)
Classificat
ion
of
PNumber

Note *

Over 9.5 mm
(3/8 in.), less
than 19 mm
(3/4 in.)
19 mm (3/4
in.) to less
than 38 mm
(1 1/2 in.)
38 mm (1 1/2
in.) and over

Applicable
Thickness
in actual
work

Items of examination and number of test specimen


Tension

Face
bend

Root
bend

Side
bend

Impact

t - 2t

1.6 - 2t

4.8 - 2t

4.8 - 2t

4.8 - 203
(8 in.)

* 2 sets
(3
pcs/set
)
* 2 sets
(3
pcs/set
)
* 2 sets
(3
pcs/set
)
* 2 sets
(3
pcs/set
)

For
both
sides of all
test
specimen

Notch toughness test shall be made at the weld metal, base metal, and heat
affected zone when impact test is required.

Remark

Appearance

t = Thickness of Base Metal.

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TABLE - 2
Applicable Base Material Specifications
PNo.
1

Base
Metal
No.
1

Pipes

Material Specification
Fittings
Flanges

A106Gr B

A105

API 5L Gr B
A53 Gr A/B
A672 Gr.A55 CL.13
A672 Gr.A55 CL.22
A672 Gr.A60 CL.13
A672 Gr.B60 CL.12
A672 Gr.B60 CL.22
A333 Gr.1

A234 Gr WPB
A515 Gr. 55
A283 Gr. D

A350 Gr. LF2

Others

A105

A216
WCB

Gr.

A350 Gr. LF2

A350
LF2
A352
LCB

Gr.

A671 Gr.CC60 CL.13 A420 Gr.WPL6

Gr.

A516 Gr.60
4

A335 Gr P11

A182 Gr F11

A182Gr.
CL.1

A691 Gr.11/4Cr
A335 Gr P12

A234 Gr WP11
A387 Gr.11 CL.1
A182 Gr F12

A182
CL.1

F11 A217
WC6

Gr.

Gr.F12

A234 Gr WP12
A691 Gr.1Cr CL.22
A387 Gr.12 CL.1
A691 Gr.1 1/4Cr
CL.42
5A

A335 Gr P22

A182 Gr. F22 CL.1


A234
CL.1

Gr.

A182
CL.1

Gr.

F22 A217
WC9

Gr.

WP22

A691 Gr.2 1/4 Cr


8

A312 TP304
A358 Gr. 304 CL.2

A182 F304
A403 WP 304

A182 F304

A182 F304
A351
Gr.CFB

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A240 Type 304


11

A312 TP304H

A182 F304H
A403 WP 304H

12

A312 TP316

A182 F316

A358 Gr. 316 CL.2

A403 WP 316

A312 TP316L

A182 F316L

A358 Gr.316L CL.2

A403 WP 316 L

13

A182 F304H

A351
Gr.CF8M

A351
CF8M

Gr.

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ISSUED : 29.12.2008
DOC.No. H 331

JOB NO. : 6261


DHT PROJECT

Sheet 20 of 31

TABLE - 3
Selection of Electrodes and Welding Rods
Base Metal
SL. No.
(P-No.)

Nominal
Type of
Base Metals

(P-No.1)

Carbon Steel

(P-No.1)

Al-Killed
Carbon Steel

(P-No.3)

C-1/2Mo

(P-No.4)

1Cr1/2Mo,11/4
Cr-1/2Mo

9
10
11
12
13

(PNo.5A)
(PNo.5B)
(PNo.5B)
(PNo.9B)
(P-No.8)
(P-No.8)
(P-No.8)
(P-No.8)
(P-No.8)

14

(P-No.8)

5
6
7
8

21/4 Cr-1Mo
5 Cr - 1/2 Mo
9 Cr-1Mo
3-5Ni
Type 304
Type 304L
Type 304H
Type 316
Type 316L
Type 321 and
Type 347

Base Metal SL. No.


1
(1)

2
(2)

3
(2)

4
(2)

5
(2)

10
(4)

(4)

R/T

(3)

R/S

11

12

(4)

R/T

(3)

R/S

14

A/B

R/T

A/B

R/S

R/T(4)

R/T(4)

R/T(4)

R/T(4)

R/T(4)

R/T(4)

R/T(4)

R/T(4)

R/T(4)

R/T(4)

R/T(4)

R/T(4)

R/T(4)

R/T(4)

R/T(4)

R/T(4)

R/T(4)

R/T(4)

R/T(4)

R/T(4)

R/S

R/S

J
K

J
L

J
M

M
N

(3)

(3)

R/S

(3)

R/T

(4)

R/T

13

(4)

(3)

R/T

(4)

< Security Level 2 >

HPCL, Visakh

MINIMUM REQUIREMENTS FOR


WELDING PROCEDURE
SPECIFICATION

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261


DHT PROJECT

Sheet 21 of 31

ISSUED : 29.12.2008
DOC.No. H 331

Nomenclature:
Spec.
(SFA)
A
5.18
5.1
B
5.18
5.1
C
5.28
5.5
D

5.28
5.5

5.28
5.5

5.9
5.4
5.9
5.4
5.28
5.5

G
H

5.9
5.4

AWS (Class)
ER7OS-G (5)
E7016/ E7018
ER70S-G (6)
E7016-1/E7018-1
ERXXS-G (7)
E7016-A1/E7018A1
ER 80SB2
E8016-B2/
E8018-B2
ER90S-B3
E9016-B3/
E9018-B3
ER502
E502-16
ER505
E505-16
ER80S-Ni3
E7016C2L/E7018-C2L
ER308
E308-16

Spec.
(SFA)
5.9
5.4
5.9
5.4
5.9
5.4

ER308L
E308L-16
ER308H
E308H-16
ER316
E316 - 16

5.9
5.4

ER316L
E316L-16

5.9
5.4

ER347
E347-16

5.9
5.4
5.9
5.4
5.14
5.11

ER309
E309-16
ER309L
E309L-16
ERNiCr-3
ENiCrFe-2

K
L
M

S
T

AWS (Class)

ENiCrFe-3

DISSIMILAR ELECTRODES AND WELDING ROD:


a.
Carbon Steel to Alloy 825 ( UNS NO8825)
For weld metal, use nickel-based filler metal type ER-NiCrMo-3 ( INCO 625 ) wire
and E-NiCrMo-3 rod (INCO 112)
b.

Carbon Steel to Duplex 2205 ( UNS S32205)


For weld metal, follow as per para 3.4.4 strictly.

< Security Level 2 >

HPCL, Visakh

ISSUED : 29.12.2008
DOC.No. H 331

MINIMUM REQUIREMENTS FOR


WELDING PROCEDURE
SPECIFICATION

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261


DHT PROJECT

Sheet 22 of 31

Notes:
(1) Application of AWS classification E6010 (DC only) for root pass shall be subject to PMC
approval (see par. 3.3.1).
(2) Do not use E6010 (DC only) for root pass.
(3) When the applicable code requires PWHT for the ferritic base metal, the application of
welding procedure and PWHT shall be confirmed to PMC.
(4) When the applicable code requires PWHT for the ferritic base metal, the application of
welding procedure and PWHT shall be confirmed to PMC.
Type 309 welding materials shall not be used where the design temperature exceeds
4500C.
Inconel can not be used for the sulfidation environment at the design temperature
above 5370C.
(5) The filler metal shall meet the chemical and mechanical test requirements of SFA 5.18,
classification ER70S-2, ER70S-3 or ER70S-6.
(6) Filler metals for welds shall meet the same minimum impact test requirements as those
of the base metal.
(7) Chemical composition and mechanical properties of the deposited weld metal shall be
same as the base metal.

< Security Level 2 >

HPCL, Visakh

ISSUED : 29.12.2008
DOC.No. H 331

MINIMUM REQUIREMENTS FOR


WELDING PROCEDURE
SPECIFICATION

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261


DHT PROJECT

Sheet 23 of 31

ATTACHMENT 2
ATTACHED FIGURE OF JOINT SKETCH

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HPCL, Visakh

MINIMUM REQUIREMENTS FOR


WELDING PROCEDURE
SPECIFICATION

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261


DHT PROJECT

Sheet 24 of 31

ISSUED : 29.12.2008
DOC.No. H 331

ATTACHMENT 3
APPENDIX 1
WELDING SPECIFICATION FOR PRESSURE PIPING

< Security Level 2 >

HPCL, Visakh

MINIMUM REQUIREMENTS FOR


WELDING PROCEDURE
SPECIFICATION

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261


DHT PROJECT

Sheet 25 of 31

ISSUED : 29.12.2008
DOC.No. H 331

1.

A sheet of WELDING SPECIFICATION FOR PRESSURE PIPING is not effective as


a WPS.

2.

Either the ASME Code B31.1 or B31.3 is referred in a sheet.

3.

Identification
B3

SR
PWHT
Base Metal No. (2) (2)
Base Metal No. (1)
Code (3)

(1)

4.

The last part -SR indicates PWHT YES.

(2)

A Base Metal Number is correspondence to the numbers in TABLE 1.


But for dissimilar joints, P-No. 8 materials are designed as P8.

(3)

B3 means ANSI/ ASME B31.3 and B1 does ANSI / ASME B31.1.

The differences of the listed base metals between PWHT YES and PWHT NO
sheet are subjected to code requirements for :
(a)

a thickness of thicker component at the joint (B31.3)


a nominal base metal thickness (B31.3)

(b)

a specified carbon content

(c)

a specified minimum tensile strength ()

(d)

a specified chromium content

< Security Level 2 >

HPCL, Visakh

ISSUED : 29.12.2008
DOC.No. H 331

MINIMUM REQUIREMENTS FOR


WELDING PROCEDURE
SPECIFICATION

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261


DHT PROJECT

Sheet 26 of 31

APPENDIX 1

WELDING SPECIFICATION FOR PRESSURE PIPING


Sheet No. for Piping System based on ANSI / ASME B 31.1

B3-1.1
B3-1.8
B3-8.8
B3-4.4
B3-4.4 SR

< Security Level 2 >

HPCL, Visakh

MINIMUM REQUIREMENTS FOR


WELDING PROCEDURE
SPECIFICATION

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261


DHT PROJECT

Sheet 27 of 31

ISSUED : 29.12.2008
DOC.No. H 331

APPLICABLE CODE
THICKNESS RANGE
ASME B31.3
Groove Weld : Nominal Thickness T (mm) : T< 19
ASME SEC. IX
Fillet Weld : See Par. 3.9.3 in H 301.
BASE METALS (QW-403)
P-No. 1
Material Spec. (P-No./ Group No.)
Pipes

Fittings

A106 Gr B
API 5L Gr B
A53 Gr A/B
A672 Gr. A55 CL.13
A672 Gr. B60 CL.13
A672 Gr. B60 CL.13
IS 1239 Part I
IS 3589

(1/1)
(1/-)
(1/1)
(1/1)
(1/1)
(1/1)
(1/-)
(1/-)

A105
A234 Gr. WPB
A515 Gr. 55
A283 Gr. D

WELDING PROCESS
1)
Groove weld :
GTAW (Root Pass)

Flanges

(1/2)
(1/1)
(1/1)
(1/1)

PREHEAT (QW-406)
0
Preheat Temp. ( C)
0
Interpass Temp. ( C)
Preheat Maintenance

:
:
:

Min 10.
-

(1/2)

FILLER METALS (QW-404)


Spec. (SFA) AWS
GTAW :

SMAW (Filler Pass)

A105

Others

5.18

(Class)
ER70S-G 2)

5.1
5.1

E7016
E7018

A216 Gr. WCB


A 105

(1/2)
(1/2)

GAS (QW-4089)
Shielding gas :
Argon 99.9%
vol. or over
Gas Backing :
Not Applicable

POSTWELD HEAT TREATMENT (QW-407)


Required
: No.
0
Metal Temp. Range ( C)
: Min Holding Time (hr / 25mm)

TECHNICAL NOTES :
0
1)
A Minimum preheat of 95 C is applied when the nominal material thickness of either of the base metals
exceed 25.0 mm.
2)
Application of AWS classification E6010 (DC only) for root pass shall be subjected to PMC approval.
3)
Filler metals shall meet the chemical and mechanical test requirements of SFA 5.18, AWS class. ER70S-2,
ER70S-3, or ER70S-6. TGS-50 (ER70S-G: Kobe Steel) is acceptable for using.
4)
Process conditions such as caustic, amine and wet hydrogen sulfide may require PWHT regardless of
thickness.
5)
A1A, A2S, A6S Class H 103

< Security Level 2 >

HPCL, Visakh

MINIMUM REQUIREMENTS FOR


WELDING PROCEDURE
SPECIFICATION

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261


DHT PROJECT

Sheet 28 of 31

ISSUED : 29.12.2008
DOC.No. H 331

APPLICABLE CODE
THICKNESS RANGE
ASME B31.3
Groove Weld : Nominal Thickness T (mm) : T< 19
ASME SEC. IX
Fillet Weld : See Par. 3.9.3 in H 301.
BASE METALS (QW-403)
P No. 1 To P. No.8
Material Spec. (P-No./ Group No.)
Pipes

Fittings

A106 Gr B
API 5L Gr. B
A53 Gr A/B
A 312 TP 304
A 358 TP 304

(1/1)
(1/-)
(1/1)
(8/1)
(8/1)

Flanges

A105
A234 Gr. WPB

(1/2)
(1/1)

A182 F 304
A403 WP 304

(8/1)
(8/1)

WELDING PROCESS
Groove weld :
GTAW (Root Pass)

(1/2)
(8/1)

FILLER METALS (QW-404)


Spec. (SFA) AWS
GTAW :

SMAW (Filler Pass)

A105
A182 F 304

Others

5.9

(Class)
ER309

5.4

E309-16

A216 Gr. WCB


A105

(1/2)
(1/2)

A182 F 304

(8/1)

GAS (QW-4089)
Shielding gas :
Argon 99.9%
vol. or over
Gas Backing :
Argon 99.9%
vol. or over

PREHEAT (QW-406)
0
Preheat Temp. ( C)
0
Interpass Temp. ( C)
Preheat Maintenance

:
:
:

Min 10.
O
180 C
-

POSTWELD HEAT TREATMENT (QW-407)


Required
: No.
0
Metal Temp. Range ( C)
: Min Holding Time (hr / 25mm)

TECHNICAL NOTES :
1)
Filler metals shall meet the chemical and mechanical test requirements of SFA 5.9, ER 309 and SFA 5.4
AWS E 308-16

< Security Level 2 >

HPCL, Visakh

MINIMUM REQUIREMENTS FOR


WELDING PROCEDURE
SPECIFICATION

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261


DHT PROJECT

Sheet 29 of 31

ISSUED : 29.12.2008
DOC.No. H 331

APPLICABLE CODE
THICKNESS RANGE
ASME B31.3
Groove Weld : Nominal Thickness T (mm) : T< 19
ASME SEC. IX
Fillet Weld : See Par. 3.9.3 in H 301.
BASE METALS (QW-403)
P. No.8
Material Spec. (P-No./ Group No.)
Pipes

Fittings

A 312 TP 304
A 358 TP 304

(8/1)
(8/1)

A182 F 304
A403 NP 304

WELDING PROCESS
Groove weld :
GTAW (Root Pass)

Flanges

(8/1)
(8/1)

(8/1)
(8/1)

FILLER METALS (QW-404)


Spec. (SFA) AWS
GTAW :

SMAW (Filler Pass)

A182 F 304
F 316

Others

5.9

(Class)
ER308

5.4

E308-16

A182 F 304

(8/1)

GAS (QW-4089)
Shielding gas :
Argon 99.9%
vol. or over
Gas Backing :
Argon 99.9%
vol. or over

PREHEAT (QW-406)
0
Preheat Temp. ( C)
0
Interpass Temp. ( C)
Preheat Maintenance

:
:
:

Min 10.
O
180 C
-

POSTWELD HEAT TREATMENT (QW-407)


Required
: No.
0
Metal Temp. Range ( C)
: Min Holding Time (hr / 25mm)

TECHNICAL NOTES :
1)
Filler metals shall meet the chemical and mechanical test requirements of SFA 5.9, AWS class. ER 308 and
SFA 5.4 AWS E 308-16
2)
A1K, A1L, B3K, B1L Class of H 103

< Security Level 2 >

HPCL, Visakh

MINIMUM REQUIREMENTS FOR


WELDING PROCEDURE
SPECIFICATION

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261


DHT PROJECT

Sheet 30 of 31

ISSUED : 29.12.2008
DOC.No. H 331

APPLICABLE CODE
THICKNESS RANGE
ASME B31.3
Groove Weld : Nominal Thickness T (mm) : T< 12.7
ASME SEC. IX
Fillet Weld : See Par. 3.9.3 in H 301.
BASE METALS (QW-403)
P. No.4
Material Spec. (P-No./ Group No.)
Pipes

Fittings

A 335 Gr. P11


A 335 Gr. P12
A 691 Gr. 1 Cr.
A 691 Gr. 1 Cr CL-22

(4/1)
(4/1)
(4/1)
(4/1)

A 234 WP 11
A 234 WP 12
A 182 F 11
A 182 F 12
A 387 Gr. 11
A 387 Gr. 12

WELDING PROCESS
Groove weld :
GTAW (Root Pass)

Flanges

(4/1)
(4/1)
(4/1)
(4/1)
(4/1)
(4/1)

A182Gr.F 11
A182Gr.F 12

Others

(4/1)
(4/1)

FILLER METALS (QW-404)


Spec. (SFA) AWS
GTAW :

SMAW (Filler Pass)

5.28

(Class)
ER80S-B2

5.5

E8018-B2

A 217Gr. WC 6

(4/1)

GAS (QW-4089)
Shielding gas :
Argon 99.9%
vol. or over
Gas Backing :
Argon 99.9%
vol. or over

PREHEAT (QW-406)
0
Preheat Temp. ( C)
0
Interpass Temp. ( C)
Preheat Maintenance

:
:
:

Min 180 C
O
300 C Max
Yes

POSTWELD HEAT TREATMENT (QW-407)


Required
: No.
0
Metal Temp. Range ( C)
: NA
Min Holding Time (hr / 25mm)
NA

TECHNICAL NOTES :
1)
Filler metals shall meet the chemical and mechanical test requirements of SFA 5.28, AWS class. ER 80S-B2
and SFA 5.5 AWS Class E 8018-B2

LEGEND :- NA Not Applicable

< Security Level 2 >

HPCL, Visakh

MINIMUM REQUIREMENTS FOR


WELDING PROCEDURE
SPECIFICATION

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261


DHT PROJECT

Sheet 31 of 31

ISSUED : 29.12.2008
DOC.No. H 331

APPLICABLE CODE
THICKNESS RANGE
ASME B31.3
Groove Weld : Nominal Thickness T (mm) : T > 12.7
ASME SEC. IX
Fillet Weld : See Par. 3.9.3 in H 301.
BASE METALS (QW-403)
P. No.4
Material Spec. (P-No./ Group No.)
Pipes

Fittings

A 335 Gr. P11


A 335 Gr. P12
A 691 Gr. 1 Cr.
A 691 Gr. 1 Cr CL-22

(4/1)
(4/1)
(4/1)
(4/1)

A 234 WP 11
A 234 WP 12
A 182 F 11
A 182 F 12
A 387 Gr. 11
CL 1
A 387 Gr. 12
CL 1

WELDING PROCESS
Groove weld :
GTAW (Root Pass)

Flanges

(4/1)
(4/1)
(4/1)
(4/1)
(4/1)

A182Gr.F 11
A182Gr.F 12

Others

(4/1)
(4/1)

(4/1)
(4/1)
(4/1)

(4/1)

FILLER METALS (QW-404)


Spec. (SFA) AWS
GTAW :

SMAW (Filler Pass)

A 182 Gr. F 11
A 182 Gr. F 12
A 217Gr. WC 6

5.28

(Class)
ER80S-B2

5.5

E8018-B2

GAS (QW-4089)
Shielding gas :
Argon 99.995%
vol. or over
Gas Backing :
Argon 99.995%
vol. or over

PREHEAT (QW-406)
0
Preheat Temp. ( C)
0

Interpass Temp. ( C)
Preheat Maintenance

Min 180 C

:
:

300 C Max
Yes

POSTWELD HEAT TREATMENT (QW-407)


Required
: Yes, above
12.7 mm .
0
Metal Temp. Range ( C)
: 703 740
Min Holding Time (hr / 25mm)
2 Hrs. min.

TECHNICAL NOTES :
1)
Filler metals shall meet the chemical and mechanical test requirements of SFA 5.28, AWS class. ER 80S-B2
and SFA 5.5 AWS Class E 8018-B2

LEGEND :- NA Not Applicable