TECHNICAL STANDARD

PETROCHEMICAL AND REFINERY PIPING

GENERAL WELD INSPECTION REQUIREMENTS P8-1TS

DATE: 01 MAY 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 1 OF 6

TABLE OF CONTENTS

Section Title Page No.

1. GENERAL ......................................................................................................................................1
1.1 Scope..............................................................................................................................................1
1.2 Codes and Industry Standards .......................................................................................................1
2. CLASSES OF WELD INSPECTION ..............................................................................................1
3. WELD EXAMINATION ...................................................................................................................3
3.1 Limitations on Imperfections ...........................................................................................................3
3.2 Type and Extent of Weld Examination ...........................................................................................3
3.3 Special Radiography Requirements ...............................................................................................3

1. GENERAL

1.1 Scope

This standard covers the general inspection requirements for welds performed in shop and field fabricated
piping for use in chemical plants and petroleum refineries under the jurisdiction of ASME B31.3.

1.2 Codes and Industry Standards

The following documents are referenced herein and form part of the Order. Current editions of the industry
standards including all mandatory addenda in effect at the time of the order shall apply unless otherwise
indicated.

THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME Boiler and Pressure Vessel Code

Section V, "Nondestructive Examination"

ASME B16.5, "Pipe Flanges and Flanged Fittings NPS 1/2 through NPS 24"
ASME B31.3, "Process Piping"
ASME B46.1, "Surface Texture (Surface Roughness, Waviness and Lay)"

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A358/A358M, "Electric-Fusion-Welded Austenitic Chromium-Nickel Alloy Steel Pipe for
High-Temperature Service"
ASTM A671, "Electric-Fusion-Welded Steel Pipe for Atmospheric and Lower Temperatures"
ASTM A672, "Electric-Fusion-Welded Steel Pipe for High-Pressure Service at Moderate
Temperatures"
ASTM A691, "Carbon and Alloy-Steel Pipe, Electric-Fusion-Welded for High-Pressure Service at High
Temperatures"

2. CLASSES OF WELD INSPECTION

Classes of weld inspection shall be in accordance with Table I with:

a. ASME Pressure Classes and material specifications in accordance with ASME B16.5.

b. "Category M Fluid Service," "Category D Fluid Service," "Severe Cyclic Conditions," and "Safeguarding" as
defined in Paragraph 300.2 of ASME B31.3.
 TECHNICAL STANDARD
PETROCHEMICAL AND REFINERY PIPING
GENERAL WELD INSPECTION REQUIREMENTS P8-1TS

DATE: 01 MAY 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 2 OF 6

TABLE I
CLASSES OF INSPECTION

MATERIAL P No. INSPECTION CLASS

TEMPERATURE
(Note 1) (Note 2) I II III IV
Cl 150, Not
Category D Category D
Carbon Steel 1 850°F (454°C) or less
(Note 3) thru
Cl 900
C 1/2 Mo
3
1/2 Cr 1/2 Mo Cl 1500
1 to 2 Cr Mo 4 thru
2 1/4 to 9 Cr Mo 5 Cl 150 Cl 2500
12 Cr (Type 410) All - to
6
Cl 900
12 Cr (Type 405) 7
2 1/4 Ni 9A
3 1/2 Ni 9B
Cl 150, Not Cl 1500
-150°F thru 850°F
Category D Category D thru
Austenitic (-101°C thru 454°C)
8 thru Cl 900 Cl 2500
stainless Severe
Below -150°F (-101°C) All ASME Cyclic
- -
Above 850°F (454°C) Classes Conditions
5 Ni 11A-2 All ASME
All - -
9 Ni 11A-1 Classes or
Cl 150, Not
-150°F thru 400°F Category M
21 Category D Category D -
Aluminum alloys to (-101°C thru 204°C) thru Cl 600
25 All ASME
Below -150°F (-101°C) - -
Classes
Cl 150, Not
-150°F thru 400°F
Copper 31 Category D Category D -
(-101°C thru 204°C)
and to thru Cl 600
Copper alloys 35 Below -150°F (-101°C) All ASME
- -
Above 400°F (204°C) Classes
Cl 150, Not Cl 1500
-150°F thru 750°F
Nickel 41 Category D Category D thru
(-101°C thru 399°C)
and to thru Cl 900 Cl 2500
Nickel alloys 45 Below -150°F (-101°C) All ASME
- -
Above 750°F (399°C) Classes
51 -75°F thru 600°F Not
Titanium - Category D
52 (-59°C thru 316°C) Category D

NOTES TO TABLE I:

1. Steel alloys unless otherwise noted.

2. P Numbers are in accordance with ASME B31.3, suffix indicates group number.

3. "Category D" in this table is defined as Category D Fluid Service. Note that Category D Fluid Service is
limited to the temperature range -20°F (-29°C) thru 366°F (186°C).

SYMBOLS USED IN TABLE I:

Cl - abbreviation for ASME Pressure Classes in accordance with ASME B16.5.

 TECHNICAL STANDARD
PETROCHEMICAL AND REFINERY PIPING
GENERAL WELD INSPECTION REQUIREMENTS P8-1TS

DATE: 01 MAY 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 3 OF 6

3. WELD EXAMINATION

3.1 Limitations on Imperfections

The limitations on imperfections shall be as follows:

a. For Inspection Class I: Criteria for Category D Fluid Service in Table 341.3.2 of ASME B31.3.

b. For Inspection Classes II and III: Criteria for Normal Fluid Service in Table 341.3.2 of ASME B31.3.

c. For Inspection Class IV: Criteria for Severe Cyclic Conditions in Table 341.3.2 of ASME B31.3 except that,
external weld reinforcement shall not exceed 1/16 inch (1.6 mm).

3.2 Type and Extent of Weld Examination

3.2.1 The required weld examinations shall be in accordance with Table II and the accompanying Notes to
Table II contained herein. All visual and supplementary methods of girth weld examination shall be in
accordance with ASME B31.3 and the requirements of this standard.

3.2.2 Welds between dissimilar materials shall be examined by the method and to the extent required for the
material having the more stringent examination requirements, as determined by KBR.

3.3 Special Radiography Requirements

3.3.1 The thicknesses of penetrameters used in radiographic examination shall be in accordance with Article 2
of ASME Section V and ASME B31.3. Penetrameters other than the type specified may be used only with the
prior written approval of KBR.

3.3.2 For any lot of film examined, the nominal radiographic film density in the area of interest shall average
2.5. The density of each individual film shall not be less than 1.8 for x-ray sources, less than 2.0 for gamma ray
sources, or greater than 4.0 for either type of source.
 TECHNICAL STANDARD
PETROCHEMICAL AND REFINERY PIPING
GENERAL WELD INSPECTION REQUIREMENTS P8-1TS

DATE: 01 MAY 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 4 OF 6

TABLE II
TYPE AND EXTENT OF WELD EXAMINATION

TYPE OF WELD EXAMINATION

P - No.
INSPECTION TYPE OF
(Per ASME BUTT
CLASS EXAMINATION BRANCH SOCKET
B31.3) & MITER ATTACHMENT LONGITUDINAL
(Note 1) (Note 2)
GROOVE
I Visual All 100% 100% 100% 100% 100%
Visual All 100% 100% 100% 100% 100%
Radiography
All Random - - - (Notes 3, 5, 14)
(Notes 4, 10, 19)
Magnetic 1, 3, 4, 9A, 9B, - Random - -
Particle (Notes 3, 15)
II 100%
(Notes 4, 6, 19) 5, 6, 7 100% 100% 100%
(Note 7)
9A, 9B,
Liquid
(Note 8) 8,
Penetrant - Random - - (Notes 3, 16)
21-25, 31-35,
(Notes 4, 6)
41-45, 51, 52
Hardness 3, 4, 5, 6 (Note 9) (Note 9) (Note 9) (Note 9) (Notes 3, 17)
Visual All 100% 100% 100% 100% 100%
1, 3, 4, (Note 11)
Radiography 100%
All other - - (Notes 3, 18)
(Notes 10, 19) 100% (Note 13)
than 1, 3, 4
100%
Magnetic 1, 3, 4 100% - - (Notes 3, 15)
(Note 7)
Particle
(Notes 6, 19) 100%
III 5, 6, 7, 9A, 9B 100% 100% 100%
(Note 7)
9A, 9B, (Note 8)
Liquid 8, 11A-1, 100%
Penetrant 11A-2, 21-25, (Note 7) 100% 100% 100% (Notes 3, 16)
(Note 6) 31-35
41-45, 51, 52 100%
Hardness
3, 4, 5, 6 (Note 9) (Note 9) (Note 9) (Note 9) (Notes 3, 17)
(Note 9)
Visual
All 100% 100% 100% 100% 100%
(Note 12)
Radiography 100%
All 100% - - (Notes 3, 18)
(Notes 10, 19) (Note 13)
Magnetic Particle 1, 3, 4, 5, 6, 7,
100% 100% 100% 100% (Notes 3, 15)
IV (Notes 6, 20) 9A, 9B
8, 11A-1, 11A-2,
Liquid Penetrant 21-25, 31-35,
100% 100% 100% 100% (Notes 3, 16)
(Notes 6, 20) 41-45, 51, 52,
9A, 9B (Note 8)
Hardness 3, 4, 5, 6 100% 100% 100% 100% (Notes 3, 17)

NOTES TO TABLE II:

1. Branch welds shall consist of the welds between:

a. The header and reinforcing elements such as reinforcing pads, saddles, and outlet fittings.

b. The branch and reinforcing element except where buttwelded and flanged connections are
encountered.
 TECHNICAL STANDARD
PETROCHEMICAL AND REFINERY PIPING
GENERAL WELD INSPECTION REQUIREMENTS P8-1TS

DATE: 01 MAY 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 5 OF 6

c. The header and branch under the reinforcing pad or saddle.

2. Seal welds of threaded joints shall be given the same examination as socket welds.

3. The extent of examination of longitudinal welds of pipes and fittings shall be in accordance with
ASME B31.3; and as applicable, ASTM A671, ASTM A672, ASTM A691, or ASTM A358/A358M for shop
fabricated piping.

4. For random examination, the sampling of welds shall be not less than one weld from each 20 welds.

The welds selected for examination shall include each welding process, each welder, and each welding
operator, and shall not include pipe to flange welds. The entire length of the selected welds shall be
examined. If defective welding is revealed, progressive examination shall be conducted in accordance with
Paragraph 341.3.4 of ASME B31.3.

5. Spot radiography of longitudinal welds shall be in accordance with ASME B31.3 with at least one exposure
for each individual length of pipe or fitting.

6. The magnetic particle method and the liquid penetrant method of examination shall be in accordance with
Paragraph 344.3 and 344.4 respectively, of ASME B31.3. The entire accessible area of the finished weld
surface shall be examined. Branch welds shall be examined before and after any addition of a reinforcing
pad or saddle.

a. The liquid penetrant examination method may be substituted for the magnetic particle method,
provided the proper surface conditions exist in accordance with this standard and ASME B31.3.

b. When liquid penetrant examination is used, the surfaces shall be free of peened discontinuities. If
abrasive blast cleaning is used, it shall be followed by a light surface grinding prior to liquid penetrant
examination.

7. Examination not required if the entire length of the weld is radiographed.

8. Required only when welded with austenitic material.

9. If heat treatment is performed, hardness tests in accordance with Paragraph 341.5.2 of ASME B31.3 shall
be conducted after final heat treatment. One test is required in the weld and one test is required in the heat
affected zone. When dissimilar materials are welded, both heat affected zones shall be tested.

10. Ultrasonic examination, in accordance with the requirements of ASME B31.3, may be substituted for
radiographic examination only when specified by KBR. In-process examination shall not be substituted for
any required radiographic or ultrasonic examination.

11. If all of the following conditions are met, not less than one weld for each 4 welds made by the same welding
procedure and welder or welding operator shall be examined. If defective welds are revealed, with
limitations on imperfections as specified by ASME B31.3 for 100% examination, the other 3 welds made by
the welder or welding operator using the same procedure shall be examined.

a. The gas tungsten arc welding (GTAW) process is used for the root pass.

b. The inside diameters of the matching bevel root faces are controlled by machining.

c. The wall thickness of P-No.1 pipe is 1 1/4 inches (32 mm) or less.

d. The wall thickness of P-Nos. 3 and 4 pipe is 5/8 inch (16 mm) or less.

If any of the above conditions are not met, all welds shall be examined.
 TECHNICAL STANDARD
PETROCHEMICAL AND REFINERY PIPING
GENERAL WELD INSPECTION REQUIREMENTS P8-1TS

DATE: 01 MAY 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 6 OF 6

12. Visual examination shall consist of the following:

a. Preparation and alignment prior to welding.

b. Verification of correct welding procedure, electrode, and other critical variables.

c. External surface of the root pass.

d. External surface of completed weld for undercutting and a finish to within 500 µin. (12.5 µm) roughness
average (Ra, AA or CLA as defined in ASME B46.1) for severe cyclic conditions or Category M Fluid
Services without safeguarding.

13. Only required for fabricated lap and branch welds comparable to Figures 328.5.4E, 328.5.5D, and 328.5.5E
of ASME B31.3.

14. Examination (spot radiography) shall be in accordance with, as applicable, ASTM A358/A358M (Class 5),
ASTM A671, ASTM A672, or ASTM A691.

15. Examination shall be in accordance with, as applicable: ASTM A671, Supplementary Requirement S7;
ASTM A672, Supplementary Requirement S7; or ASTM A691, Supplementary Requirement S7.

16. Examination shall be in accordance with ASTM A358/A358M, Supplementary Requirement S3.

17. Examination shall be in accordance with Supplementary Requirement S3 of, as applicable, ASTM A671,
ASTM A672, or ASTM A691.

18. Examination (100% radiography) shall be in accordance with, as applicable, ASTM A358/A358M (Class 1),
ASTM A671, ASTM A672, or ASTM A691.

19. For materials having P-Numbers 3, 4, or 5, examinations shall be performed after completion of any heat
treatment.

20. Examination shall be performed after completion of any heat treatment.