AL-HAJ ENTERPRISES (PVT) LIMITED

FEED FOR KOT PALAK FIELD DEVELOPMENT

STANDARD SPECIFICATION FOR PRODUCTION WELDING
SPEC NUMBER: DIK-2000-MEC-GSP-0001

CONSULTANTS

PETROCHEMICAL ENGINEERING CONSULTANTS

C-2, BLOCK NO 17, Gulshan-e-Iqbal, Karachi-
75300, Pakistan. Tel.: +92 (21) 34827780, 34961088 Fax.: +92 (21) 34961089
E-Mail : [email protected] web site: www.pcec.com.pk
Disclaimer
This report has been prepared on behalf of and for the exclusive use of AEPL and is subject to an
issue in accordance with the agreement between Petrochemical Engineering Consultants and
AEPL. Petrochemical Engineering Consultants accept no liability or responsibility whatsoever for
it in respect of any use of or reliance upon this report by any third party.

Copying this report without the permission of Petrochemical Engineering Consultants is not
permitted.

PEC CLIENT
REV DISCRIPTION ORIG REVIEW DATE DATE
APPROVAL APPROVAL
0 Issued for review OCT, 10
---------------- 2023
MK SAR Adeel
 SPECIFICATION NUMBER: MEC-GSP-0001

Table of Contents
1. GENERAL .........................................................................................................................................................3
1.1. Scope ................................................................................................................................................................. 3
1.2. Definitions....................................................................................................................................................... 3
1.3. Errors or Omissions..................................................................................................................................... 3
1.4. Deviations ....................................................................................................................................................... 3
1.5. Conflicting Requirements .......................................................................................................................... 3
2. CODES, STANDARDS & SPECIFICATIONS...................................................................................................4
2.1. Explanation Of Abbreviations .................................................................................................................. 4
3. WELDING PROCEDURE AND WELDER QUALIFICATIONS.......................................................................5
3.1. Welding Procedures .................................................................................................................................... 5
3.2. Qualification of Welding Procedures .................................................................................................... 5
3.3. Qualification of Welders & Welding Operators ................................................................................. 7
4. WELDING PROCESSES ...................................................................................................................................8
5. MATERIALS ...................................................................................................................................................10
5.1. Filler Material & Flux ................................................................................................................................ 10
5.2. Backing Rings & Consumable Inserts.................................................................................................. 10
5.3. JOINT PREPARATION, SPACING, AND ALIGNMENT ........................................................................ 10
5.3.1. Edge Preparation ..................................................................................................................10
5.3.2. Cleaning ........................................................................................................................................................... 10
5.3.3. Butt Joints........................................................................................................................................................ 11
5.3.4. Tack Welds ..................................................................................................................................................... 11
5.3.5. Weld Contour and Finish .......................................................................................................................... 11
5.3.6. Alloy Lining..................................................................................................................................................... 12
5.4. Thermal Treatment ................................................................................................................................... 12
5.4.1. Preheat & Inter-pass Temperature ...................................................................................................... 12
5.4.2. Post weld Heat Treatment (PWHT) ..................................................................................................... 13
6. INSPECTION AND EXAMINATION .............................................................................................................15
6.1. General ........................................................................................................................................................... 15
6.2. Radiographic Examination ..................................................................................................................... 15
6.3. Magnetic Particle Examination ............................................................................................................. 15
6.4. Liquid Penetrant Examination .............................................................................................................. 16
6.5. Ultrasonic Examination............................................................................................................................ 16
6.6. Extent Of Inspection .................................................................................................................................. 16

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 SPECIFICATION NUMBER: MEC-GSP-0001

6.7. Hardness Tests ............................................................................................................................................ 17

7. REJECTION AND REPAIR ............................................................................................................................18
7.1. Repairs and Alterations ........................................................................................................................... 18
8. WELD IDENTIFICATION .............................................................................................................................19
9. DOCUMENTATION .......................................................................................................................................19

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 SPECIFICATION NUMBER: MEC-GSP-0001

1. GENERAL

1.1. Scope

This Specification covers the basic requirements for welding, heat treating, and non-destructive
examination of certain pressure-containing components. This includes piping, pressure vessels, fired heater
coils, heat exchangers, pumps and compressors etc. requirements also apply to structural attachment welds
in such equipment

1.2. Definitions

COMPANY / OWNER “COMPANY” or “OWNER” means the person or persons, firm or Proprietor,
who has hired PEC for delivering engineering services.
CONSULTANT: PETROCHEMICAL ENGINEERING CONSULTANTS (PEC)
CONTRACTOR: “CONTRACTOR" means the person or persons, firm or Proprietor, whose
proposal, has been accepted by the COMPANY for construction,
installation / erection, testing and completion of all works as mentioned in
the SOW.

1.3. Errors or Omissions

The review and comment by the COMPANY of any CONTRACTOR’s or its manufacturer's drawings,
procedures or documents shall only indicate acceptance of general requirements and shall not relieve the
CONTRACTOR of its obligations to comply with the requirements of this specification and other related parts of the
Contract Documents.

Any errors or omissions noted by the CONTRACTOR in this Specification shall be immediately brought to the
attention of the COMPANY.

1.4. Deviations

All deviations to this Specification, other related specifications or attachments shall be brought to the knowledge of
the COMPANY in the bid. All deviations made during the procurement, design, manufacturing, testing and
inspection of the Works shall be with written approval of the COMPANY prior to execution of work. Such
deviations shall be shown in the documentation prepared by the CONTRACTOR.

1.5. Conflicting Requirements

In the event of any conflict, inconsistency or ambiguity between the Contract scope of work, this Specification,
National Codes & Standards referenced in this Specification or any other documents, the CONTRACTOR shall refer to
the COMPANY whose decision shall prevail.

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 SPECIFICATION NUMBER: MEC-GSP-0001

2. CODES, STANDARDS & SPECIFICATIONS

The following Guides and industry publications are referenced herein and shall be considered a part of this
Specification. Refer to the latest editions unless otherwise specified:

1. American Society of Mechanical Engineers (ASME);

a. ASME B31.3 Process Piping
b. ASME BPVC Sec-II:C – Material Specification – Welding Rods, Electrodes and Filler Metals
c. ASME BPVC Sec-V – Non-Destructive Examination
d. ASME BPVC Sec-II:B SE-94 – Standard guide for Radiographic Examination
e. ASME BPVC Sec-VIII – Rules for Construction of Pressure Vessels
f. ASME BPVC Sec-IX – Qualification Standard for Welding & Brazing Procedures, Welding & Brazing
Operators

2. American Welding Society (AWS)

3. Project Specifications
a. Piping Specification
b. Specification for Painting
c. Specification for Production Welding
d. Specification for Insulation

2.1. EXPLANATION OF ABBREVIATIONS

FCAW Flux Cored Arc Welding
FIN Ferrite Index Number
GMAW Gas Metal Arc Welding
GTAW Gas Tungsten Arc Welding
HAZ Heat Affected Zone
HB Brinnell Hardness
HSLA High Strength, Low Alloy
HV Vickers Hardness
NDE Non-Destructive Examination
PWHT Post Weld Heat Treatment
SAW Submerged Arc Welding
SMAW Shielded Metal Arc Welding
WRC Welding

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 SPECIFICATION NUMBER: MEC-GSP-0001

3. WELDING PROCEDURE AND WELDER QUALIFICATIONS

3.1. Welding Procedures

Welding procedures shall be in writing and shall be qualified in accordance with ASME SEC IX and this
Specification, using the latest revision in effect on the date of the purchase order for the equipment being
fabricated. All welding procedures shall include a weld procedure specification (WPS) and a procedure
qualification record (PQR).

Complete welding procedures for all materials to be welded shall be submitted to the COMPANY for review
and approval prior to use. These procedures shall include the following: Welding Procedure Specifications,
Procedure Qualification Test Records, ranges of variables qualified, a weld map or description identifying which
welding procedure will be used for each weld and the method and extent of inspection. The CONTRACTOR /
SUPPLIER shall furnish complete information for each applicable item, as required. For piping a typical drawing
representing all applicable weld procedures to be used on the work shall be submitted to the COMPANY for
approval prior to work commencing.

Complete welding procedures shall be submitted for approval sufficiently in advance of the actual welding, so
as to allow for adequate review and approval. A typical weld map (or specific weld map) where each procedure
will be used shall be included with this submittal. No welding shall be performed until all such welding
procedures are approved by the COMPANY.

The information contained in each welding procedure specification and in the procedure qualification test
records shall include, but not be limited to, the information contained on forms QW 482 and QW 483 shown in
ASME SEC IX.

All welding procedures shall be identified by number and referenced on all applicable fabrication drawings.

3.2. Qualification of Welding Procedures

P-number shall be considered an essential variable for all welding processes. Materials that do not have P-
numbers (not listed in QW 422 of ASME SEC IX) shall be qualified individually.

Welding position shall be considered an essential variable for groove welds in all welding processes.

All welding consumables not listed in ASME SEC II-C shall be individually qualified

For submerged arc welding, brand name and grade of flux shall be considered an essential variable, together
with changes in speed or heat input beyond the range qualified. The procedure qualification test record shall
indicate the name of the manufacturer, plus the trade name of the wire and flux used to qualify the procedure.

Post weld heat treatment (time and temperature) shall be considered an essential variable for P-3, P-4, P-5,
and P-6 materials. A decrease in time of more than 15 percent and/or in temperature of 10 percent or more,
from the range qualified, will require a separate welding procedure qualification.

Impact testing of welds and heat-affected zones (HAZ) for ferritic materials at minimum design temperature is
required for welding procedure qualification under the following conditions:
a. When the base material requires impact testing;
b. When the base material does not require impact testing, but the material thickness exceeds 12.7 mm
(1/2 in) and the minimum design temperature is 0°C (32°F) or lower;
c. When the base metal does not require impact testing, but the submerged arc welding process is used
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 SPECIFICATION NUMBER: MEC-GSP-0001

with weld pass thickness greater than 9.5 mm (3/8 in).

When impact testing is required, the Charpy V-notch impact values for parent material, weld metal and heat-
affected zones shall be not less than those specified in ASME B31.3, Table 323.2.2. The impact test shall be
performed on the same type (ASTM or other similar specification) and grade of material as will be used in
fabrication.

Procedure qualifications for weld overlay deposits shall include a complete chemical analysis of the overlay,
procedure qualification test record, and unless specifically waived by the COMPANY, a sample of the overlay.
Specimens taken for chemical analysis shall be representative of material 2.5 mm (0.1 in) below the surface.
The weld metal chemical composition shall be within the nominal range specified for the alloy. Monel overlays
shall have a maximum iron content of 4.5 percent. The procedure qualification tests shall include the following:
a. Dye penetrant examination of the completed weld.
b. Side bend tests per QW 453 for weld metal soundness.
c. Chemical composition analysis per QW 462.

Excessive fissuring shall be caused for rejection. Fissures shall not exceed four per specimen, nor shall they
exceed 1.6 mm (1/16 in) in length. Cracks in corners shall not be considered part of the examination.

The welding procedure qualification tests shall include hardness tests of base, HAZ, and weld for the following
materials:

a. Quenched and tempered carbon steel;

b. High-strength, low-alloy (HSLA) steel;
c. Carbon-molybdenum (C-Mo), manganese-molybdenum (Mn-Mo), and chromium-molybdenum (Cr-Mo)
steels;
d. Other air-hardenable materials.

Procedure qualification tests for welding carbon steel shall also include a hardness survey, if any of the
following conditions exist:

a. Submerged arc welding is performed with F8XX or higher flux designation;

b. Shielded metal arc welding is performed with covered electrodes of E80XX or higher classification;
c. Filler Metal contains at least 1.6 percent manganese, or manganese and silicon exceed 1.4 and 0.8
percent, respectively;
d. The job specifications or data sheets require a maximum specified hardness in the weld and/or heat-
affected zone.
e. Process conditions (wet hydrogen sulfide, amine, caustic) require production hardness testing.

The hardness testing for welding procedure qualification shall be performed on the base metal, weld, and heat-
affected zone, with an instrument having an indentor not larger than 1.6 mm (1/16 in) in diameter. The
hardness shall be reported as Brinell (HB) or Vickers (HV) equivalent numbers. Hardness surveys shall be
performed along two lines parallel to the outer and inner surfaces of the weld and located approximately 2 mm
(0.08 in) below them. The type of hardness test instrument shall report and the test results shall meet the
hardness requirement in accordance with ASME B31.3.

Welding procedure tests shall demonstrate that all details are capable of producing satisfactory full-
penetration butt welds, unless the weld joints are specifically designated as fillet welds.

For gas tungsten arc and gas metal arc welding, the qualification record shall include the composition and flow
rate of the shielding and inert gas backing, if used.

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 SPECIFICATION NUMBER: MEC-GSP-0001

For the gas metal arc process, the electrode diameter and extension, amperage, voltage, wire feed rate, and
travel speed shall be specified in the welding procedure.

Base material used in qualification tests shall have the nominal chemistry and mechanical properties of the
material to be welded. For carbon steel, the carbon content of base material shall be at the higher end of the
specification range.

3.3. Qualification of Welders & Welding Operators

Welders and welding operators shall be qualified in accordance with ASME SEC IX and local requirements, as a
minimum. Qualification shall be completed prior to start of fabrication. Performance qualification records shall
be made available to the COMPANY upon request. At the COMPANY option, witnessing of performance
qualification, welding, and testing may be required.

Qualification of welders and welding operators solely by means of radiography of a weld sample is subject to
the COMPANY approval.

Qualification of welders using the GMAW process shall be by mechanical testing only.

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 SPECIFICATION NUMBER: MEC-GSP-0001

4. WELDING PROCESSES

Welds shall be made by the shielded metal arc, gas tungsten arc, gas metal arc, or submerged arc welding
process. All other welding processing, including electro gas, electro-slag, oxyacetylene and the flux cored
process, require prior to the COMPANY approval.

The flux cored arc welding (FCAW) process may be used, subject to the COMPANY review and approval
(proposal to use FCAW must be submitted prior to order placement), provided the following conditions exist:
 Gas shielding is used
 Material to be welded is carbon steel or for application of weld overlay on carbon steel or low alloy steel.
 FCAW process is not "short arc"
 FCAW process is not used for the root pass in single-sided welding.
 Production consumables are restricted to the manufacturer and grade qualified.
 Only EXXT-1 or EXXT-5 (flat or horizontal position only) welding wires are used.
 Service is not hot hydrogen [over 260°C (500°F)], wet hydrogen sulfide, or hydrogen fluoride
 At least five percent of the individual welds are 100 percent radiographed or ultrasonically examined.
 Ten percent of the nozzle to shell or head welds (including at least one of each size) shall be 100 percent
radiographed or ultrasonically examined.
 Low hydrogen electrodes are used.

For all other applications not meeting the above conditions, FCAW process may be considered on a case-by-
case basis. The review will include the evaluation of the specific application, verification of the fabricator's
experience, additional qualification and/or NDE requirements, and the COMPANY witnessing of welding
procedure and/or welder qualification

The gas metal arc process (GMAW) in the "short circulating transfer" (short) mode may be used for the
following purposes:
 Root passes welding in a combination process.
 Fit-up welding that will subsequently be completely removed by back gouging, chipping, or grinding
 Weld metal overlays made in the flat position
 Non-pressure retaining fillet welds made in the flat, horizontal, or vertical up positions.

The short arc process shall not be used under the following conditions:
 Where the joint geometry or large mass can affect the integrity of the weld; for example, on nozzles, couplings,
slip-on flanges, socket-welded flanges, O-type branch fittings, or extended surface (FIN) attachments.

With ferritic or martensitic filler metal, for design service below 0°C (32°F).

During GMAW short arc welding of the root pass, the root gap (including tolerance) shall not be less than 2.4
mm (0.1 in) wide. The root face thickness (including tolerance) shall not exceed 0.8 mm (3/32 in). All tack welds
shall both ends ground to feather edge

Except for piping, double-welded butt joints shall be used wherever possible in Pressure-containing equipment.
Where access or wall thickness precludes of double-welded butt joints, single-welded joints may be made. This
requires a root pass deposited by the GTAW process or (subject to the COMPANY approval) by the GMAW
process.

A gas tungsten arc root pass is required for the following circumstances:
 Single-welded, full-penetration butt joints in C-Mo, Mn-Mo, and Cr-Mo steels; in all non-ferrous alloys; and in
carbon steel for hydrogen fluoride service.
 All heater tubes
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 SPECIFICATION NUMBER: MEC-GSP-0001

 All carbon steel single-welded, full-penetration butt joints over 38 mm (1.5 in) thick.

In an inert gas welding process, inert gas backing (argon or helium) is for carbon steels, carbon-molybdenum
steels, or low-alloy chromium molybdenum steels with a chromium content not exceeding 1½ percent by
weight. Inert gas backing shall be used for all other alloy materials, including aluminum and copper alloys. The
use of nitrogen, however, for gas shielding of stainless steel shall not be allowed.

The following restrictions and limitations apply to all welding processes.

 All welding processes shall be protected from wind, rain, and other harmful weather conditions that can affect
weld quality. CONTRACTOR / shall provide habitat arrangements that afford full weather protection as approved
by the COMPANY.
 Welding techniques shall be selected to ensure that specified tolerances for straightness and out-of-roundness are
not exceeded. If such tolerances are not stated in the drawings, standards, or specifications, the applicable section
of the relevant code shall govern.
 Welded joints shall be made by completing each layer before succeeding layers are deposited. Block welding is
prohibited.
 Vertical welding shall be performed vertically up; downward vertical position welding shall not be permitted
unless specifically approved in writing by the COMPANY.

The following limitations shall apply when welding aluminum:

 The gas tungsten arc process shall not use thoriated tungsten electrodes. Electrode configuration shall be shown in
the welding procedure and shall be considered an essential welding variable. In case any deviation, COMPANY
approval will be required.
 Except for piping, the gas metal arc process shall employ run on and run off tabs in all groove welding.
 For all processes, the welding procedure shall contain a detailed cleaning treatment indicating joint preparation
prior to welding. All full-penetration joints shall be back-purged with argon or helium.

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 SPECIFICATION NUMBER: MEC-GSP-0001

5. MATERIALS

5.1. Filler Material & Flux

Filler metal for welding similar materials shall be of the same nominal analysis as the base material, except as
follows:
 AWS Type 347 filler metal shall be used for welding Type 321 stainless steel material.
 AWS Type 308 filler metal shall be used for welding Type 304 stainless steel material. (Type 308L shall be used for
Type 304L.)
 The following filler metals shall be used for welding 11 to 13 percent chromium steels: Inco-Weld A; Inconel 82 or
182; AWS E309, E410, or E410Cb. However, for 11 to 13 percent steels in cyclic service, or for design temperatures
over 350°C (660°F), only Inco-Weld A, Inconel 82, or Inconel 182 are acceptable.
 For chromium-molybdenum steel, filler materials such as Inconel 82 or 182 or Inco-Weld A may be used, if
approved by COMPANY.
 Filler metals for welds joining dissimilar materials shall be in accordance Table 1. Filler metals for combinations of
materials other than those in Table 1 shall be submitted to COMPANY for approval.

5.2. Backing Rings & Consumable Inserts

Permanently installed backing rings or strips shall not be used. Consumable inserts shall be used only with prior
COMPANY approval.

5.3. JOINT PREPARATION, SPACING, AND ALIGNMENT

5.3.1. Edge Preparation

Welding bevels shall be suitable for the welding process to be used. For pressure-containing welds, the contour
shall permit complete fusion throughout the joint. Bevels shall conform reasonably to those used in the
procedure qualification.

All weld bevels and weld surfaces shall be free from cracks, porosity, slag inclusions, and other defects
indicative of inferior workmanship

Weld bevels shall be made by machining, grinding, or thermal cutting; the surfaces shall be smooth, free of
burning dross or fluting and true. Materials that require preheat for welding (refer to Section 10.1) shall be
preheated in the same manner for thermal cutting or gouging.

Special weld bevel preparation is required for quenched and tempered carbon steels, HSLA steels, and steels
containing more than 1/2 percent chromium. The steels shall be machined or ground back to clean and sound
metal if they are flame or arc cut. At least 1.6 mm (1/16 in) of metal shall be removed.

Socket-welded joints shall have a gap between the bottom of the socket and the end of the pipe to be welded.
The gap opening shall be at least 1.6 mm (1/16 in). The pipe for socket welding shall be square cut.

5.3.2. Cleaning

All surfaces to be welded shall be clean and free from paint, oil, dirt, scale, oxides, and other contaminants
detrimental to welding. Cleaning shall be performed in a manner that will not lead to additional contamination
of the weld or adjoining base metal.

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 SPECIFICATION NUMBER: MEC-GSP-0001

Only stainless-steel brushes and tools shall be used on stainless steel and nickel-alloyed materials.

Grinding disks containing sulfur (iron sulfide) shall not be used on steels with 5 through 9 percent nickel,
stainless and alloy steels, or on nonferrous materials.

Cleanliness shall be maintained after completion of welding. All stubs, rods, flux, slag, and foreign material shall
be removed from the vicinity of the equipment or piping.

5.3.3. Butt Joints

Full penetration welds are required for single-sided welded joints.

Double-welded joints shall be prepared for back welding by grinding, arcair gouging and grinding or chipping,
so as to allow complete penetration and fusion. The depth of the back cut shall be sufficient to remove all the
initial 1st pass welds but not deep enough to cause distortion in the welded joint by excess 2nd side welding

5.3.4. Tack Welds

All tacks in the weld groove shall be performed by qualified welders (in conformance with ASME SEC IX),
according to an approved welding procedure. Tack welding procedures, including for bridge and bullet tacks
shall be qualified prior to fabrication operations.

Non-groove tack welds to be incorporated into the main weld seams shall have the ends ground and feathered.

Tack welds made by non-ASME SEC IX welders shall be completely ground out. The ground areas shall be
examined by the magnetic particle or dye penetrant method prior to completing the permanent weld.

5.3.5. Weld Contour and Finish

Weld beads shall be contoured to permit complete fusion at the sides of the and to eliminate inter run and side
wall slag inclusions. Flux and slag shall be removed completely from weld beads and from the surface of
completed welds and adjoining base material. The flux removal shall be performed in a manner that will not
cause the weld or adjoining base material to become contaminated overheated.

Weld reinforcement and finish shall be as required by the applicable codes and standards. Undercutting of
base metal is prohibited, except for piping fabricated according to ASME B31.3, undercutting shall be removed
by smooth profile toe grinding, where allowed.

After removal of temporary welded attachments on all materials, except carbon steel (P-1) and austenitic
stainless steel (P-8), the weld area shall be dressed examined by magnetic particle or dye penetrant for the
detection of cracks. Any defects found shall be removed and repaired.

Peening of partial or completed welds shall not be permitted, unless prior approval is given by COMPANY and
the CONTRACTOR / SUPPLIER can demonstrate that the final weld joint integrity has not been affected.

All arc strikes, starts, and stops shall be confined to the welding groove. Arc strikes outside the welding groove
shall be removed by grinding and examined by magnetic particle or liquid dye penetrant.

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 SPECIFICATION NUMBER: MEC-GSP-0001

5.3.6. Alloy Lining

CONTRACTOR/VENDOR approval is required for any proposed alloy system.

For both integrally clad plate and weld overlay, the surface of base plate welds that would be exposed to the
corrosive environment shall be protected by depositing not less than two layers of corrosion-resistant weld
metal.

In austenitic stainless-steel overlays, where the base metal requires PWHT or design temperature exceeds
450°C (840°F), the first weld layer shall be made with Type 309L. Subsequent layers of deposit shall be made
with low-carbon, Cr-8 Ni stainless steel, or stabilized grades of austenitic stainless, depending upon service
conditions.

For Monel overlays on carbon or low-alloy steel, the first layer shall be made a high-nickel consumable (nickel
or Inconel). The second and any successive shall be made with a filler metal that nominally matches the Monel
chemistry. First layer of high-nickel deposit shall be applied over bright, clean, and oxide-free.

When integrally clad stainless plates are being joined, the following shall apply:
 The clad layer shall be stripped for a minimum distance of 8 mm (0.31 in) from the bevel. In addition, the base
material shall be etched with nitric acid or copper sulfate to ensure prevention of austenitic weld dilution.
 When the cladding is removed, the base material thickness shall not be reduced below the design thickness by
more than 1 mm (0.04 in).
 The procedure for back-cladding of internal attachments and requires approval by COMPANY. This procedure shall
include base metal examination, welding sequence, and final inspection.

All internal exposed alloy welds joining clad components, and all alloy weld overlays inside vessels and heat
exchangers shall be fully examined by the liquid dye penetrant method.

A certified report of the chemical analysis of production as-deposited alloy weld overlays, or alloy welds
covering base metal welds in clad plates, shall be furnished to COMPANY. The weld metal chemistry shall be
within the nominal range specified for the alloy. At least three drillings from each vessel section (vessel can),
each heat exchanger, and each head shall be made to obtain sample material for analysis. One sample shall be
taken at the beginning of the overlay and two samples at locations to be designated by the inspector. The
samples shall be taken 2.5 mm (0.1 in) below the surface of the material.

Welding overlays shall be qualified in accordance with the WPS and PQR requirements specified herein. The
Procedure Qualification Record shall also include corrosion testing of the weld overlays, specifically the ASTM
G48 test and the ASTM A262 test. The G48 test shall yield a corrosion rate of 5 mpy or less. The A262 test shall
show no evidence of cracking or pitting at 100x magnification

5.4. Thermal Treatment

5.4.1. Preheat & Inter-pass Temperature

The minimum preheat temperatures for thermal cutting, arc-air gouging, and welding (including butt, fillet,
socket, seal, and tack welds) shall be in with the requirements of the applicable code. Exceptions are as follows:
 No welding shall be performed when metal temperature is 0°C (32°F) or lower.
 Carbon steel shall be preheated to 10°C (50°F) , minimum, unless electrodes are to be used.
 Carbon steel shall be preheated to 93°C (200°F), minimum, when any of the following conditions apply:
 Base metal thickness exceeds 25.4 mm (1 in)
 Carbon content exceeds 0.30 percent
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 SPECIFICATION NUMBER: MEC-GSP-0001

 Carbon equivalent exceeds 0.43 percent, based on:

 The material is highly restrained; for example, nozzles or major attachments.

 All ferritic alloy materials shall be preheated in accordance with Table 2.
 The maximum inter-pass temperature for austenitic stainless steels shall be 180°C (350°F).

The maximum preheat and inter-pass temperature for carbon steel and low-alloy steel shall be 300°C (572°F),
unless otherwise approved by COMPANY.

During the welding of a casting, an area extending 300 mm (12 in) on either side of the weld shall be
maintained at the approved preheat and inter-pass temperature

Preheat and inter-pass temperature shall be determined by temperature-indicating crayons, contact

pyrometers, thermocouples, or other equally suitable means. Temperature-indicating crayons used on
austenitic stainless steels and nickel-base alloys shall cause no corrosive or other harmful effects. They shall not
contain more than one percent by weight of total halogens or sulfur, or 200 ppm by weight of inorganic
halogens. It is the fabricator's responsibility to determine suitable brands and melting temperatures that may
be used. This information shall be made available to COMPANY upon request.

When the specified preheat temperature is 150°C (300°F) or higher, the metal shall be maintained at preheat
temperature until the welds are completed. The preheat temperature shall be maintained until the start of
post weld heat treatment or unless an intermediate tempering treatment is performed, for welds in thickness
over 50 mm (2 in) or under a high degree of restraint (at nozzles, branch connections, and the like). COMPANY
shall be consulted if uncertainties exist regarding the degree of restraint. An intermediate tempering heat
treatment shall consist of heating to 600°C (1100°F), minimum, holding for a minimum of 15 minutes, and
cooling slowly to the ambient temperature.

As an alternative for butt welds only, a hydrogen out-gassing treatment can be substituted for the intermediate
tempering treatment. The hydrogen out-gassing procedure shall consist of either raising the preheat
temperature to 260°C - 300°C (500°F - 570°F) and holding for four hours, or raising the preheat temperature to
325°C - 400°C (620°F -750°F) and holding for two hours. All other pressure welds, such as nozzle and manhole
attachment welds, shall be given the full 600°C (1100°F) tempering treatment. The foregoing out-gassing
procedure does not apply to 5 through 9 percent nickel steels.

5.4.2. Post weld Heat Treatment (PWHT)

PWHT shall conform to the applicable construction code, except as follows:

 Minimum PWHT of ferric materials shall conform to Table 3.
 All ferritic piping materials, except carbon steel piping with wall thickness 19 mm (3/4 in) or less (nominal
thickness), shall be post weld heat treated.
 The PWHT for welds joining austenitic stainless steels to dissimilar materials shall be as specified in the qualified
welding procedure and approved by COMPANY prior to the start of fabrication.
 Under special circumstances (non-critical service), PWHT of field welds in low-alloy steels (C-Mo, Mn-Mo, and Cr-
Mo) made with Inconel filler metal may be omitted, subject to COMPANY approval.
 For P-6 materials, the PWHT temperature used shall be the lowest possible to avoid overheating and hardening on
cooling.
 Holding time at PWHT temperatures shall be one hour per 25.4 mm (1 in) of thickness, with a one-hour minimum.
For chromium molybdenum steels (1/2 to 9 percent chromium) and 12 percent chromium stainless steels, the
minimum holding time shall be two hours.
 For P-3, P-4, P-5, and P-6 materials, the production PWHT (time and temperature) shall be essentially the same as
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 SPECIFICATION NUMBER: MEC-GSP-0001

in the welding procedure qualifications.

 A sufficient number of thermocouples or other acceptable measuring devices shall be attached, so as to accurately
indicate metal temperature in all critical areas during PWHT.
 Direct flame impingement by torch or furnace burner during PWHT is not permitted.
 No exothermic heat treatment shall be allowed without prior written approval from COMPANY.

The maximum Brinell hardness of welds and heat-affected zones in all steels after heat treatment shall be in
accordance with ASME B31.3. If welds are furnace heat treated, a sufficient number (10 percent) shall be
tested to verify that the hardness criterion has been met. If local heat treatment has been applied, each weld
shall be tested.

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 SPECIFICATION NUMBER: MEC-GSP-0001

6. INSPECTION AND EXAMINATION

6.1. General

Examinations of welds shall conform to procedures and acceptance standards required by the ASME Code. The
exception is piping, which shall be in accordance with specification for fabrication/installation of piping and the
paragraphs of this section.

Table 4: Weld Examination Procedures and Acceptance Standards

Standard, ASME Code
Method
Section VIII
Radiography:
- Complete Par. UW 51
- Random Par. UW 52
Magnetic particle Appendix 6
Liquid penetrant Appendix 8
Ultrasonic Appendix 12
Notes:

 Examination of piping welds fabricated in accordance with ASME B31.3 shall be in accordance with Specification
for Fabrication/Installation of Piping. Minimum 10% RT shall be carried out for CS Joints and 100% for SS Joints.
 Detailed weld inspection procedures and acceptance criteria shall be reviewed and approved by COMPANY.

All inspection and non-destructive examination (NDE) procedures shall be in writing and submitted to
COMPANY for approval. All inspections and NDE shall be performed in accordance with the approved
procedures. The NDE operators shall be at least ASNT Level II certified for the examination they are
performing.

Welds that are to be examined by non-destructive methods shall be finished as required by the applicable
code.

6.2. Radiographic Examination

The following are additional requirements for radiographic examination:

 ASME SEC V-B-2-SE-94 Type 1 fine-grain film (Kodak AA or equivalent) shall be used
 Only lead screens shall be used.
 Use of penetrameters other than those specified in ASME SEC V-B-2-SE-94, Article 2 and 22 (ASTM SE 94), (such as
DIN/IIW wires) is permissible. However, the thickness sensitivity and hole sensitivity shall be equivalent to those
required by the applicable ASME Code, and prior approval shall be obtained from COMPANY.
 Suitable film density shall be used.
 Radiography of welds in NPS 2½ pipe or smaller may be performed by the elliptical projection technique. At least
two separate exposures are required at locations 90 degrees apart.

6.3. Magnetic Particle Examination

Following are additional requirements for magnetic particle examination:

 Only the yoke method shall be used after final post weld heat treatment.
 Permanent magnets or yokes shall be used on air-hardening steels.
 In examination by the prod method, the control switch shall be built into the prod handles, so as to prevent arcing.
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 SPECIFICATION NUMBER: MEC-GSP-0001

 Severe arc strikes resulting from magnetic particle examination shall be removed by grinding and the area subject
to 100% MPI or DPI.
 Magnetic particle inspection shall not be used on 5 through 9 percent nickel steels.

6.4. Liquid Penetrant Examination

Following are additional requirements for liquid penetrant examination:

 Except for piping, liquid penetrant shall only be used for non-magnetic materials and 5 through 9 percent nickel
steels, unless otherwise approved by COMPANY.
 Cleaning and developing solutions with a combined total residual sulfur and halogen content of one percent by
weight or greater shall not be used.

6.5. Ultrasonic Examination

Following are additional requirements for ultrasonic examination:

 The weld shall be examined from at least two different probe angles.
 Welds are not acceptable if the echoes from discontinuities exceed the reference curve. Each weld groove face
shall be completely examined from both sides of the joint. If however, complete examination can be performed
from one side only, echoes that exceed 50 percent of the reference curve are not acceptable. Echoes exceeding 20
percent of the reference curve shall be fully evaluated and accurately sized.
 All echoes from discontinuities that exceed 50 percent of the reference curve shall be recorded in the examination
report and transmitted to COMPANY. This record shall locate each area, the echo height, the dimensions, the
depth below the surface, and the classification.

6.6. Extent Of Inspection

The minimum inspection shall be as follows:

 All welds shall be visually inspected after completion and inspected per the construction code and this
specification.
 For piping, the extent and type of examination shall be as required in accordance with reference Codes and
Standards.

o All final non-destructive examinations shall be performed after post weld heat treatment, unless
otherwise approved by COMPANY. Final radiography or ultrasonic examination for vessels shall be
performed no sooner than 48 hours after the vessel has cooled to ambient temperature. In special
cases, based on equipment type, materials, and process conditions, NDE examination may be
separated; some performed before PWHT and some after.
o Where COMPANY allows non-destructive examination to be performed before the final post weld heat
treatment, the welds shall also be examined on all accessible surfaces by the magnetic particle method
(dye penetrant method for non-magnetic materials and all piping) after PWHT.
o The attachment welds between structural components and pressure parts of quenched and tempered
carbon steel, HSLA steel, and ferritic alloy materials shall be examined by the magnetic particle method
(dye penetrant for piping) after PWHT. This requirement does not apply to 5 through 9 percent nickel
steels.
o All pressure-containing equipment designed with 100 percent joint efficiency, irrespective of material,
shall have all nozzle and reinforcing pad attachment welds examined by the magnetic particle or liquid
penetrant method, as applicable. Inspection shall be performed on all accessible weld surfaces (inside
and outside).
o After completion of welding. This final inspection shall be made after post weld heat treatment, if any.
o When examination by radiography is specified but is not practical, ultrasonic examination or an
alternative non-destructive test method shall be proposed for COMPANY approval.
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 SPECIFICATION NUMBER: MEC-GSP-0001

o For all piping and heater coils requiring radiography, the minimum number of shots per circumferential
seam shall be as follows:
 Up to and including NPS 2 1/2 diameter: two shots (90 degrees apart)
 Over 2 1/2 NPS diameter: three shots (120 degrees apart)
o Where random non-destructive examination is specified, at least one weld shall be examined for every
material grouping, each welding process, and each welder. For each weld found to be defective, two
additional representative welds shall be examined. If these additional welds are free from defects, only
the defects indicated in the first examination shall be repaired and re-examined. However, if either of
the two additional welds shows defects, all welds represented shall be either (1) fully examined and
repaired as necessary, or (2) completely replaced.
o For spot radiography, at least one of each type and position of weld made by each welder shall be
examined.

6.7. Hardness Tests

The hardness of welds and HAZ, when used in the as-welded condition or after post weld heat treatment, shall
not exceed with reference Codes and Standards.

Where the following conditions occur, hardness tests of P-1 and P-3 materials shall be taken on the center of
the inside surface of weld seams, where possible; otherwise, on the outside surface of the weld seams at the
weld center line and also the HAZ interface between the weld metal and base material. (Including nozzle,
manhole, and attachment welds):
a. Submerged arc welding is performed with F70 or higher flux classification.
b. Shielded metal arc welding is performed with covered electrodes of E80XX or higher classification.
c. Filler metal contains at least 1.6 percent manganese, or when manganese and silicon exceed 1.4 and
0.8 percent, respectively.
d. For carbon steel in critical service, such as wet H2S, amine, HF, and caustic, the hardness of deposited
weld metal shall not exceed 200 HB

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 SPECIFICATION NUMBER: MEC-GSP-0001

7. REJECTION AND REPAIR

Defects that are outside the limits of the codes, job specifications, or other requirements stated on the
purchase order shall be cause for rejection. The CONTRACTOR / SUPPLIER shall provide rectification procedures
and take such remedial action as is necessary to re-establish the weld integrity and acceptance by COMPANY.
The cost of the remedial action shall be borne by the CONTRACTOR / SUPPLIER. The CONTRACTOR / SUPPLIER
shall only attempt 2 repairs of a defective weldment before the complete weld is removed and replaced.

Repairs of major defects, and all repairs in plate or forgings, require prior approval by COMPANY. Repairs of
weld defects are considered major when the defect size exceeds one-half the wall thickness and the thickness
of the component is over 25.4 mm (1 in); or when the defect resulted in leakage during a hydrostatic test. The
repair procedure shall be in writing and shall include information on methods used for defect removal,
inspection of cavity, welding procedures, welding techniques and details of non-destructive examination of the
excavated and repaired area.

All welds (including weld overlays) that are found by inspection to be unsound or that are deposited by
procedures differing from those properly qualified shall be rejected. They shall be completely removed from
the equipment and replaced in accordance with an approved procedure or be repaired, subject to COMPANY
written approval

Repair of local cavities in overlay welds that penetrate the base metal by more than 10 percent or 4.8 mm
(3/16 in), whichever is the smaller, shall include having the base metal re-welded. The welding procedure and
materials used shall be compatible with the original base metal.

Removal of defects by chipping, grinding, or gouging shall be done in such a manner as to avoid reducing the
adjacent base material thickness. If the adjacent material thickness is reduced, it shall be restored to its original
condition. Complete removal of defects shall be verified by non-destructive examination before repair is
started. Repair welding shall be performed only by qualified welders using qualified procedures.

When a welder's or welding operator's welding is judged unsatisfactory by COMPANY, the welder shall be
removed from the work. All such welding by that welder or operator shall be inspected by non-destructive
examination and removed or repaired at CONTRACTOR’s / SUPPLIER’s expense, as directed by CONSULTANT.
The welder may be reassigned after additional training and the completion of satisfactory re-qualification tests,
but only with the approval of COMPANY.

7.1. Repairs and Alterations

All repairs or alterations of existing welded equipment shall be done in accordance with the latest addition of
the applicable code for new construction. For pressure vessels, both code and non-code repairs and alterations
shall conform to ANSI NB-23.

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 SPECIFICATION NUMBER: MEC-GSP-0001

8. WELD IDENTIFICATION

In field and shop welding, each qualified welder or welding operator shall have an identification symbol
assigned to him to ensure all production welds are traceable to the welder, WPS and NDE report. The welder
shall permanently mark each pressure weld with this identification symbol. If more than one welder welds a
joint, each shall apply his symbol in such a manner as to indicate the part of the joint he welded. Alternatively,
subject to COMPANY written approval, an accurate record keeping system shall be established and maintained
to identify welds and the welders that fabricate them.

9. DOCUMENTATION

All CONTRACTOR/SUPPLIER as built data reports for new construction, alteration, and repairs shall be furnished
to COMPANY upon completion of the fabrication. Such documentation may include, but not be limited to, the
following elements: assembly and spool drawings, welding procedures, heat treating charts, inspection records,
and appropriate code documents. For details on as built documentation requirements, refer to specific
equipment guides and Contract requirements. CONTRACTOR / SUPPLIER shall provide a typical as built
documentation index to CONSULTANT prior to work commencing.

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