REFERENCE STANDARDS:
WELDING QUALIFICATIONS:
MATERIAL SPECIFICATION:
Materials have been grouped,
on the basis, of composition, mechanical properties and
weldability as given in Table-1 .
The typical, Material specification, have also been
indicated.
TABLE -1
Material Pgroup number
1
1
Material
type
C S up to
0.35 C
CS for low
Carbon- Moly
temp service
below 33 C
Steel
Typical Specifications
Mo steel
2 Cr-1 Moly
Steel.
17 Cr-Mo-V10
3 Ni steels
Gr.620/621,DIN17175Gr.10,Cr-Mo 44
ASTM A335 Gr P22, A234 Gr P22
A 182Gr.F22,BS3604 Gr.622,DIN 17175
Gr10, Cr-Mo 910
--ASTM A333 Gr3, A420 Gr.WPL
WELDING PROCESS
Welds shall be made by one of the process:
FILLER METALS:
Electrodes, rods or filler wires used for inert gas shielded metal
are welding (MIG) and inert gas shielded tungsten are welding
(TIG) shall be of fabricators recommended type.
Welds Produced shall have mechanical and metallurgical
properties equivalent to those of the base metal.
TABLE-2
Specification
1.
AWS A 5.1
F-3
AWS A 5.1
F-4
AWS A 5.5
E 7015-C1, E 7018-G
F-4
1 a.
Carbon steel
CS for Low
Electrodes
class
F-No.
Temp Service
(-11 to -33 C )
up to 50 C
below -33 C
3
4
5
6
7.
Carbon moly
(C-1/2 Mo)
1Cr-1/2Mo &
1 1/4 Cr-1Mo
2 1/4Cr-1Mo
17Cr-Mo-V10
3 1/2 Ni
AWS A 5.5
AWS A 5.5
E 8018-C1, E up to 70 C
F-4
E 8015-B2 or E 8018-B2
F-4
AWS A 5.5
E 9015-B3 or E 9018-B3
BOILER FOX IN 9 kb
AWS A 5.5
E 8015-C2, E 8016-C2,
E 8018-C2
F-4
F-4
NOTES ON TABLE 2:
ALIGNMENT
PREHEATING:
PREHEATING:
Preheating requirements shall also apply to tack welding
as well as welding of structural attachments to piping.
The rate of preheating shall not exceed 100C per hour
or 6C /T/hour, where T is thickness in mm, whichever is
the smaller.
FIT UP:
In case of piping of nominal pressure more than
25 kg/cm2 with thickness 4 mm or larger, the pieces to
be butt welded shall be coupled by yokes or bridge Cclamp.
For alloy steel and low temperature service below-33C,
electrodes conforming to E309 shall be used.
Where Cr >2%, the pipe surface shall be preheated
locally to 150-200 C before welding of the clamps.
For welding of yokes or bridge C- clamps, 2.5 mm or
3.25 mm electrodes shall be used.
Care shall be taken to avoid undercuts.
During the root run, yokes or bridge C- clamps shall be
removed avoiding craters or damages on pipe.
Any crater on pipe shall be repaired and surface
irregularities on the pipe after removal of yokes or
clamps shall be ground off.
FIT UP:
For thickness 4 mm or less, tack weld in the groove in
place of clamps may be permitted provided they are
subsequently removed during the root run.
Preheating is required as per Table-3.
In case of piping of PN less than 16 kg/cm2, the tackwelds may be left provided they are re-melted in the
weld and complete penetration is achieved.
However, cracked tack weld shall be removed.
In case of fillet welds, tack welds are permitted for fit-up
and they may become a part of the weld, provided they
are free from defects and re-melted in the subsequent
welding.
Pre heating is required as per Table-3.
Thermal
cutting
oxy- acetylene welding
==============================================================================
Material Type of Thickness for
Min. Pre Thickness for which
Min. Pre heating
group
steel
which Pre heating heating
Pre heating is required
Temp. C
is Required, mm. Temp C
mm.
---------------------------------------------------------------------------------------------------------------------------------------1
CS up
> 18
100
to 0.35% C
2
CS for low temp.
< 5
150
services below -33C
3
Carbon- Moly
12
100
All
150
4
5
6
7
C- Mo
1Cr- Mo
1 Cr Mo
2 Cr- 1 Mo
17 Cr. Mo- V 10
3 Ni
All
100
All
150
All
All
All
150
150
250
All
All
All
200
250- 300
350
WELDING PROCEDURE:
The electrode size for root pass shall not be greater
than 3.25mm.
The filling shall be made by shielded metal are welding
(SMAW) with electrodes not larger then 4 mm.
Direct current shall be used, with electrodes holder
connected to the position pole.
For pipe in horizontal fixed position the upward
technique shall be used as a rule.
Where root run is made by TIG or MIG, the inside of the
pipe shall be protected with the shielding gas.
The root run of butt joints, regardless of the technique
used, shall be such to achieve full penetration.
Fit-up tack welding shall be removed progressively
during the root run, except in cases mentioned in clause
10.3 and 10.4.
After the welding is started and until the joint has not
been completed, displacements, shocks, vibrations or
stresses shall be carefully avoided, in order to prevent
cracks or breaks in the weld.
TABLE-4
Material
Material Type of
Thickness for
which post weld heat
Soaking
temp.C
Time at Temp.
Brinnel
per 25 mm of
hardness,
steel
treatment is required, mm
thickness, hrs.
max
=====================================================================
1
CS up to0.35% 18 mm. or more
600- 650
1 ( Min )
1.a CS. LT service All welds to be
600 -650
1 (Min )
- 11 to - 33 .C stress relieved for
Temp. 15 .C &
thickness over 5 mm.
2
CS LT service As indicated in
600 650
1 ( Min )
( below -33 .C ) Table-5
3
C- Mo steels
All
630 670
1 ( Min )
225
4
1 Cr Mo
All
630 - 670
1 ( Min )
225
1 Cr Mo
5
2 Cr 1 Mo.
All
680 - 720
1 ( Min )
240
6
17 Cr Mo- V 10
All
680 - 720
1 ( min )
240
7
3 Ni
12 mm. or more 580 620
1 ( Min )
-
The local heat treatment procedure shall meet the following minimum
requirements:
The heating rate shall not exceed the following values:
Carbon steel and 1/2 Mo steels
The above values may be increased by 100C when the treatment is made by
induction equipment.
The cooling rate for welds shall not exceed the following values
up to a temperature of 400C.
Carbon steels and 1/2 Mo. steel
70C /hr. for thickness over 30 mm and all low temperature (LT
piping).
The weld shall be covered till completion of cooling.
RECTIFICATION OF DEFECTS
All defects in excess of those specified shall be
completely removed by chipping, grinding, machining or
thermal cutting to sound metal before re-welding.
The ends and sides of the cut shall be gradually tapered
from the base of the cut to the surface of the weld metal.
The size and profile of cut shall be such as to give
adequate access for welding.
Where a faulty weld has been cut, re weld the entire girth
and there shall be no serious loss of pipe-length.
The edges shall be prepared for re-welding as specified
for the original weld.
In case of shortening of pipe length after cutting a faulty
weld, a length of pipe containing the faulty weld shall be
removed and a new length of pipe welded, with the edge
prepared as specified.
RECTIFICATION OF DEFECTS:
TABLE-5
weld heat-treatment
required, mm13 and above
9 and above
5 and above (thickness of the pipe
not to exceed 37 mm)All (thickness of the pipe not to
exceed 25 mm)