Polaris Engineering Standard

140.10 Rev.: 0 Page: 1 of 24 Date: 07/06/09

GENERAL WELDING, FABRICATION AND INSPECTION TABLE OF CONTENTS I. II. III. IV. V. VI. VII. VIII. IX. X. XI. XII. SCOPE REFERENCES WELDING PROCEDURES WELDING PROCESSES (GENERAL) WELDING PROCESS LIMITATIONS FILLER MATERIALS AND FLUXES WELD JOINT PREPARATION AND WELDING FABRICATION PREHEAT AND INTERPASS TEMPERATURES POSTWELD HEAT TREATMENT NON-DESTRUCTIVE EXAMINATION, TESTING AND INSPECTION REPAIRS SUMMARY OF WELDING VARIABLE LIMITATIONS, RESTRICTIONS AND OTHER REQUIREMENTS PROCEDURE FOR REVIEW AND ACCEPTANCE OF VENDOR WELDING PROCEDURES PAGE 2 2 3 4 5 6 9 13 14 17 20 21

XIII.

22 24

APPENDIX I - WELD MAP

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GENERAL WELDING, FABRICATION AND INSPECTION I. SCOPE A. This Standard covers the minimum welding requirements, for welding of shop and field fabrications and the weld inspection of the following: 1. Pressure containing equipment and piping, whether code stamped or not, including but not limited to: rotating equipment, boilers, pressure vessels, heat exchangers, air coolers, shop and field fabricated piping, fired heater tubes, storage tanks, stacks and their attachments. Equipment or piping containing toxic or corrosive materials. Structural Steel Other fabrications where specified.

2. 3. 4. B.

This Standard modifies the requirements of applicable ASME, AWS, API and ANSI codes and standards in effect at the revision date. Conflicts between requirements of this Standard, related specifications, standards, codes, purchase orders or drawings shall be clarified with Client or Client's Engineer (designated Contractor) prior to proceeding with the fabrication of the affected parts. Regarding conflicts, the Client reserves the right of final decision. Where conflicts exist between this Engineering Standard and other POLARIS Engineering Standards and/or applicable codes or regulations, the more stringent requirement shall govern. All conflicts shall be brought to the Clients attention for resolution. The Client shall be the sole arbiter of any conflicts.

C.

D.

II.

REFERENCES This POLARIS Standard is to be used in conjunction with the latest revision of the standards and codes listed below, unless specifically noted. The terminology "latest revision" shall be interpreted as the revision in effect at the time of contract award. This POLARIS Standard may reference specific sections of some of these codes and standards. The revision of the codes and standards being referenced is noted below in parenthesis. This information is provided to identify the subject matter being referenced. Changes or exceptions made to the referenced code or standard shall apply to later revisions as applicable. A. POLARIS Engineering Standards

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3.

840.1

General Requirements For Pipe Fabrication

B.

National Codes and Standards 1. 2. 3. 4. 5. 6. 7. API AWS American Petroleum Institute Standards American Welding Society Standards

ASME B16.5 Pipe Flanges and Fittings (1998) ASME B31.1 Power Piping (2001) ASME B31.3 Process Piping (2001) National Board Inspection Code (NBIC) ASME Boiler and Pressure Vessel Code (2001)

III.

WELDING PROCEDURES A. Welding procedure specifications (WPS) and procedure qualification test records (PQR) for Vendor welding covered by this Standard shall be submitted to the Client or the Client's Engineer for review and acceptance prior to the start of any welding. No welding shall commence until welding procedure specifications and qualification records have been accepted by Client or Clients representative. Welding performed by Subvendors is also required to go through the same review and acceptance procedures described in III.A above. Vendors are required to provide copies of this and all other relevant standards to their Subvendors and to review their Subvendors welding procedures for conformance to this Standard prior to submitting to the Client or Client's Engineer for acceptance. The information contained in the welding procedure specifications and procedure qualification test records shall include, but not be limited to the information contained in ASME Code, Section IX and AWS D1.1. Welding procedure specifications shall conform to ASME Section IX, Form QW-482 or equivalent. Procedure qualification records shall conform to ASME Section IX, Form QW483 or equivalent. Structural steel welding procedures may conform to AWS Prequalified or AWS Recommended Procedure formats.

B.

C.

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D.

This Standard includes additional requirements and restrictions, which may not be listed in the Vendor's submitted welding procedures. They shall be listed, when required by this Standard, either in the welding procedure or on the weld map. The main additional requirements are summarized in Section XII below. Vendor shall prepare a Weld Map Form" as illustrated in Appendix I of this Standard which must be completed and submitted at the same time as welding procedures for Client's acceptance. Vendor may submit this information in other formats provided all information required in Appendix I is included. All welders shall be qualified by means of welding performance testing. Welding performance qualification test records shall be made available for review by the Client or Client's Representative upon request. Welding performance tests shall be in accordance with ASME Section IX or AWS D1.1 as applicable, under conditions of restraint and accessibility as demanding as those to be experienced in production by the welder. Welding performance test records shall conform to ASME Section IX, Form QW-484 or equivalent. Welding performance testing records for structural steel shall conform to the recommended AWS format. Weld overlay or clad back-welding shall be qualified in accordance with ASME Section IX. Weld overlaying or clad restoring (back-cladding) shall be applied with a minimum of two passes and capable of controlling dilution as evidenced by a chemical analysis. Depth of chemical analysis shall be three-quarters of the required overlay thickness unless specified otherwise and approved by Client. When impact testing is required by the code or POLARIS Standards, impact test results for weld and heat affected zone shall be reported with the welding procedure qualifications. When maximum Brinell hardness is specified by code, POLARIS Engineering Standards, or Section X.D.8 of this Standard, they shall be reported with the welding procedure qualification record and they shall not exceed the maximum specified limits.

E.

F.

G.

H.

I.

J.

IV.

WELDING PROCESSES (GENERAL) A. The following welding processes are permitted, subject to the limitations set forth in Section V below, providing that satisfactory evidence is submitted showing that the procedures qualified are in accordance with applicable codes, standards, and this Standard. 1. 2. Manual shielded metal arc with covered electrode (SMAW) Gas tungsten arc: manual or automatic (GTAW)

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3. 4. 5. 6. 7. B.

Automatic or machine submerged arc (SAW) Oxy acetylene cutting (OFC-A) Gas metal arc (GMAW) Flux Core Arc Welding (FCAW) Plasma Arc Welding (PAW); manual, automatic or machine

Welding processes other than those listed above require specific approval by the Client or Client's Engineer and shall not be assumed as acceptable by the Vendor during bid preparation. Fabricators and welders shall be capable of demonstrating satisfactory experience with the selected acceptable welding processes listed in this standard. First time use of a welding process requires specific written approval by Client prior to welding. Client and Client's Engineer reserve the right to disallow the use of any welding process or welder based on excessive rates of repair.

C.

D.

V.

WELDING PROCESS LIMITATIONS A. GMAW and FCAW processes shall have stated in the WPS, and on the required weld map (see Appendix I), whether the current is in the short circuiting arc or spray transfer range. The shop and the welding personnel shall have demonstrated production welding experience with each process to the satisfaction of the Client and Client's Engineer. GMAW is acceptable for root passes and completion of welds up to 3/8 inch deposited weld metal thickness for groove welds and 3/8 fillet weld size. When specific Client permission is obtained to exceed this maximum deposited thickness; all such welds shall be 100% ultrasonically shear-wave examined throughout their entire length. FCAW, in the short circuiting arc mode, is unacceptable. FCAW, spray transfer, without shielding gas, is acceptable with specific Client approval for structural steel welding fabrication only. FCAW, spray transfer, with shielding gas is acceptable for welding shop fabricated pipe and for welding pressure retaining parts of pressure vessels provided the following conditions are met: 1. The procedure qualification record shall include results of micro hardness testing for both as-welded and stress relieved conditions as applicable for

B.

C. D.

E.

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weld, heat affected zone, and base. 2. Production NDE shall include 100% hardness testing on all FCAW weldments per Section X, Paragraph C.

F. G.

GMAW and FCAW for field fabrication must have the Client's specific approval. Automatic or machine type SAW is preferred. The SAW process shall have stated on the WPS that the procedure is automatic or machine type welding in order to be acceptable. Manual or semi-automatic SAW is prohibited. Automatic or machine type SAW of P-1 materials shall be limited to 1/2 inch maximum thickness per layer of deposit for material of 1-1/4 inch thickness or greater and 3/8 inch maximum thickness per layer of deposit for material less than 1-1/4 inch thick. The maximum deposit for alloy and stainless steel shall be limited to 0.4 inches per pass. GTAW shall be utilized for pipe fabrication on first two layers for ferrous alloy, and non-ferrous alloys on single welded groove joints accessible for one side only and on other equipment as defined in the POLARIS Engineering Standards. GTAW shall be used on all piping buttwelds on P-1 materials 2 NPS and smaller.

H.

I.

VI.

FILLER MATERIALS AND FLUXES A. Filler materials and fluxes shall be as specified in ASME, Section II, Part C., Filler Materials and Fluxes, other than those specified in the above code and which meet other requirements of this Standard, shall not be assumed as acceptable by the Vendor during bid preparation. All welding shall employ a filler metal unless approved by the Client in writing. Welding employing no filler metal shall not be assumed as acceptable by the Vendor during bid preparation. Friction welding is prohibited. The specific AWS grade, ASME specifications, Manufacturer and trade name for filler metals and fluxes to be used on the project shall be indicated on the welding procedure specification and weld map (Appendix I). Use of filler metals and fluxes for other than the Manufacturer's primary recommended application is prohibited. For example: Filler wire intended for OFW shall not be used for GTAW. Filler wire intended for certain welding positions specified by the Manufacturer shall not be utilized in other welding positions. Fluxes recommended for single pass shall not be utilized on multi-pass welds. Automatic or machine submerged arc welding fluxes are subject to the following limitations:

B.

C.

D.

E.

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1.

Fluxes used for welding carbon or low alloy steels shall not contribute alloying elements to the weld. The use of Lincoln 780 flux is prohibited. A separate welding procedure qualification shall be required for each brand and grade of flux and electrode combination. Welding procedures employing "active" fluxes for carbon steel shall demonstrate that hardness does not exceed 200 BHN. Hardness shall be reported with the procedure qualification record. Alloy steel shall be welded using an alloy wire and a "neutral" flux. Fluxes shall not contribute alloying elements to the weld deposit.

2. 3.

4.

5.

F.

Fluxes shall be reconditioned prior to re-use in accordance with Manufacturer's recommendations. The use of re-crushed slag is prohibited. Carbon steels of group P-1 shall be welded with A-1 analysis weld metal only. Use of other weld metal analysis numbers requires the Client's approval. For welding 70 KSI tensile strength P-1 material subject to a PWHT, filler metals containing 1/2% Mo are permitted in order to meet the minimum tensile strength requirement. Similar base materials shall be joined with a weld metal deposit that matches the base metal in both chemistry and mechanical properties. In cases where this cannot be accomplished, the Vendor shall propose a choice of filler together with the reasons for the choice for the Client's review and approval. Welds joining pressure containing parts of two different ferric steels shall have a weld metal deposit conforming to the nominal composition of the higher alloy base materials unless otherwise approved by the Client. Welds joining two different ferric steels, only one of which is a pressure retaining part, shall have a weld metal deposit conforming to the nominal composition of the pressure retaining part unless the engineering design specifies otherwise and written approval is given by the Client. When joining two different austenitic stainless steels, the (A-8) filler metal may match either and must result in a ferrite number range of 3-12. Delta ferrite shall be determined from the certified chemical analysis and the "WRC Delta Ferrite Diagram." Welds joining austenitic stainless steels to ferritic steels shall be made with filler metal as follows:

G.

H.

I.

J.

K.

L.

M.

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1. 2.

Type 309 for design temperatures not exceeding 650oF. Coated electrodes of SFA 5.11 AWS classes ENiCrFe-2 (comparable to Huntington Alloy's INCO A) and ENiCrFe-3 (comparable to Huntington Alloy's INCO 182) or bare electrodes of SFA 5.14 of AWS Classes ERNiCrFe-5 (comparable to Huntington Alloy's INCO 62) and ERNiCr-3 (comparable to Huntington Alloy's INCO 82) except where process conditions do not permit. TP 310 fillers are acceptable only for welding of Type 310 base materials to themselves.

3.

N.

For GMAW and GTAW welding of P-1 materials exceeding 65 KSI minimum tensile strength, only AWS classification ER70-S2 or ER70-S3, filler metals of SFA 5.18 shall be used. The use of ER70-SG & GS, ER-70C-G & GS of SFA 5.18 is prohibited without prior submittal and approval of the filler metal material test reports (MTRs) for each lot. Their utilization shall not be assumed as acceptable by the Vendor during bid preparation. When use of this material is approved by Client the material shall be marked and segregated for the job. For FCAW of carbon steels exceeding 65 KSI minimum tensile strength, only AWS Classification E7X-T1 or E7X-T5 filler metals of SFA 5.20 shall be used. Use of SMAW electrode groups F-1, F-2, and F-3 as specified in ASME Section IX, Table QW-432, are limited as follows: 1. To fillet welds or butt welds on material not exceeding 65 KSI minimum tensile strength, in material thickness not exceeding 1/2 inch thickness. F-1, F-2, and F-3 electrodes are not permitted on materials requiring impact tests. F-1 or F-2 electrodes shall not be used for pressure retaining parts or nonpressure attachments to pressure retaining parts. F-3 electrodes may be used for root passes of butt welds regardless of base metal thickness.

O.

P.

2.

3.

4.

Q.

The receipt, use, dispersal and retrieval of welding filler materials shall be maintained under strict control, with storage, baking and drying as recommended by the Manufacturer to assure that completed welds conform to the approved welding procedure specification requirements for welding materials.

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VII.

WELD JOINT PREPARATION AND WELDING FABRICATION A. Joint designs shall be in accordance with applicable code or POLARIS Engineering Standard requirements. Weld joints shall be prepared by machining, grinding or thermal cutting. When thermal cutting is performed, the joint surfaces shall be ground to sound metal prior to welding. Materials shall be subjected to the same preheat requirements for thermal cutting as required by the applicable welding procedure. For austenitic material 2 inches and thicker, plate edges, including weld bevels shall be liquid penetrated tested. Welded butt joints shall meet the minimum requirements for penetration or fusion in accordance with the applicable code or POLARIS Engineering Standard requirements. The addition of permanent backing such as rings, bars, or strips are unacceptable and shall not be used without the Client's written approval. Their utilization shall not be assumed as acceptable by the Vendor during bid preparation. The additional backing referenced in this Standard is not defined by this Standard as the weld installed on the first side of a butt weld welded from both sides. Temporary (removable) backing rings, bars, or strips shall not be used without the Client's written approval. Their utilization shall not be assumed as acceptable by the Vendor during bid preparation. If approved by the Client, the weld area exposed when backing is removed shall be dressed and examined for cracks or defects by visual and liquid penetrated or magnetic particle examination methods, whichever is applicable. All backing material and unacceptable indications shall be removed completely and repaired utilizing a weld procedure which has been accepted by the Client. Materials of temporary backing rings, if approved by the Client, shall conform to the nominal chemistry of the weld filler metal as defined in Section VI of this Standard. When Client's approval is given for use of backing rings, the Vendor welding procedure and the weld map (Appendix I) submitted for review shall either indicate that welding was qualified with backing ring (state on PQR) or that backing ring will be added (stated on WPS and the weld map, Appendix I). Consumable inserts require written approval by the Client. Their utilization shall not be assumed as acceptable by the Vendor during bid preparation. If approved by Client, they shall in all cases conform to the nominal chemistry of the weld filler metal as defined in Section VI of this Standard. In all cases, they shall require root shielding with inert gas.

B.

C.

D.

E.

F.

G.

H.

I.

J.

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K.

The materials used for pipe purging dams and methods employed in their placement, use, and subsequent removal shall be as required to ensure that no damage results to the piping or related components. The method that is proposed by the Vendor to obtain and maintain adequate root shielding shall be included either as part of the submitted welding procedure or as a separate standard for review. The procedure for root shielding by inert gas shall contain the following: 1. 2. 3. The composition and purity of shielding gas to be used. Flow rates and time required to obtain adequate purging. Pipe dam details materials to be used, type of construction, method of placement and removal.

L.

M.

Unless otherwise specified, back-purging (root shielding), when required, shall be maintained until completion of 2 weld layers. Weld joint tolerances for root opening and alignment shall meet the requirements of applicable codes and POLARIS Engineering Standards, and also the weld joint sketches contained in the submitted welding procedures to ensure against lack of penetration and lack of fusion. For shop and field fabrication, when poorly fitted joints occur with excessive joint gap or excessive offset, the Vendor shall submit a separate weld repair procedure indicating with a sketch the method proposed to bring the joint back to original design requirements in conformance as close as possible to the original Client accepted welding procedure. The Vendor cannot assume that backing rings or strips, permanent or temporary, are acceptable without the Client's review. Any weld joints of this nature found to be slugged with supplementary filler metal are unacceptable. The weld build up of beveled ends to close excessive gap is unacceptable unless a Vendor welding procedure is submitted for doing so and is accepted by the Client. Grinding and cleaning of stainless steels and nonferrous material shall be done only with tools that will not leave detrimental deposits on the base metal; aluminum oxide or silicone carbide grinding wheels and austenitic stainless steel wire brushes shall be used. These tools shall not have been previously used on other than the material to be cleaned. Surfaces to be welded shall be clean and free of paint, oil, dirt, scale and other foreign materials, which may contain lead, sulfur, and other low melting point elements detrimental to welding. Beveled edges are to be cleaned and coated with deoxaluminate paint prior to shipment. Preparation of the bevel just prior to welding shall be as specified on the applicable welding procedure specification.

N.

O.

P.

Q.

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R. S.

Penning of welds to enhance mechanical properties is prohibited. Tack welds which are to be incorporated into the final weld shall be subject to all the same requirements as the applicable welding procedure, including preheat, and are to be performed by welders qualified to perform the welding procedure accepted for that joint. If separate tackers are used other than the welder performing the joint weld, they shall be qualified for performance on all the same welding variables for the portion of the weld they perform as stated in the applicable accepted welding procedure or else the tack welds shall be completely removed. Tack welds shall be made with filler metal of the same composition as will be used for the first pass of the weld as stated in the applicable accepted welding procedure for the joint. All slag shall be thoroughly removed from tack welds and the leading and trailing edges shall be blend ground to a feather edge prior to welding the root pass or covering pass. Tack welds that violate any of the above requirements shall be completely removed. Completed welds having tack welds found to violate any of the above shall be subject to complete removal. Removable start-up and run-off tabs shall be used for longitudinal welds. Materials used for these tabs shall be of the same composition as the base weld. For alloy clad plate and material, the following limitations shall apply for preparation at the joint prior to back-cladding: 1. Cladding shall be stripped back to a minimum of 1/4 inch from the edge of base material bevels by machining, grinding or arc gouging. Removal of the cladding shall not reduce the base material thickness below the design thickness. A minimum radius of 1/16 inches shall be used at the limit of cladding removal unless the clad material is beveled at least 30o. Preparation of local repair cavities in overlay welds that penetrate into the base material more than 10% of its thickness, or 3/16 inch, whichever is less, shall have the base material rewelded with the appropriate Client accepted welding procedure consistent with the base material prior to completing the overlay repair. Copper sulfate test to ensure complete cladding removal.

T.

U.

V.

W.

X.

2.

3.

4.

5.

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Y.

Strip type lining shall be attached to the shell circumferentially and shall be designed so that the distance between attachment welds does not exceed that shown below. The weld between the strips shall be at least 1/4 inch and not more than 1/2 inch in width. Strip lining shall be a multi-pass fillet-butt weld of three (3) weld minimum design with 100% dye penetrant testing of final weld. See Figure A below.

Figure A Strip Welding Linings Vessel Operating Temperature 650 F and Under Over 650 oF Z. Distance Between Welds 4 inches Not permitted (See VII.Z)

Vessels with integrally clad type linings shall be made of explosion bonded plate or plate clad with the required lining material in the steel mill in accordance with the mills standards. These standards are to be approved by Client. Weld overlays shall consist of at least two layers so that the required depth of the top layer will have the alloy composition required for the service. The first layer may be made with electrodes of higher alloy content to compensate for dilution effects. The finished surface shall be 100% examined by the liquid penetrant method of examination. All stubs, rods, flux, slag or foreign material shall be removed from the equipment or piping after completion of welding and prior to postweld heat treatment or hydrostatic test. The use of temporary welded attachments shall be avoided where possible. All locations of removed temporary attachments shall be examined visually after removal of the attachment. 1. Temporary attachments shall be removed by flame cutting, arc gouging or grinding. Hammering off is not permitted. (This paragraph does not apply to atmospheric storage tanks within the scope of Standard 1115.1 and API 650.) Defects discovered in the base metal such as gouges, cracks or undercuts

AA.

BB.

CC.

2.

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shall be removed and repaired and the area re-examined using the same method of NDT that revealed the original defect. DD. Vertical welding shall be performed vertical up. permitted except for the GMAW root pass only. Downhill welding is not

EE.

For field erection of API storage tanks, the weld seams of sketch plates for tank bottoms and floating roofs shall contain a minimum of two weld passes. Single pass seams are not acceptable. Branch Connections 1. Branch connections such as weldolets, threadolets, sockolets, and stub-ins shall be joined to the header by full penetration welds. Incomplete penetration as defined by Table 341.3.2, Note B of ASME B31.3, is not acceptable. Start and stop welds on root pass shall be feathered in. Branch connections shall be prepared in accordance with Figure 328.4.4 (A), (B) or (C) of ASME B31.3. A minimum root gap of 1/16 inches shall be maintained during welding. The root gap shall be stated in the welding procedure specification.

FF.

2. 3.

VIII.

PREHEAT AND INTERPASS TEMPERATURES A. Preheat shall be at least sufficient to dry surfaces to be welded but not less than 50oF. Higher temperatures may be required for highly restrained joints such as closely spaced nozzles. Carbon steel plates 1.25 inch thick or more, shall be preheated to 200oF minimum and ferritic alloy plates to 300oF minimum prior to flame cutting and ground smooth prior to welding. All such prepared edges including holes cut for nozzles or manways, shall be liquid penetrant examined or magnetic particle inspected for cracks or laminations. Minimum preheat temperatures shall not be less than that stated in ASME, Section VIII, Division 1, Appendix R and Paragraph UCS 56; ASME B31.1, Paragraph 131; or ASME B31.3, Table 330.1.1, as applicable. Minimum preheat temperatures are required to be stated on the welding procedure specification. Preheat maintenance shall be applied when required by the Client for the conditions stated below. Preheat maintenance is the maintenance of the stated minimum preheat temperature, without interruption, from start to completion of welding. Vendor must either state on the WPS or weld map that preheat is to be maintained when so required by Section VIII of this Standard. Loss of preheat maintenance will require complete liquid penetrant or magnetic particle inspection of the uncompleted seam prior to any further welding. Any defects found must be reported to the Client's Inspector for his review.

B.

C.

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D.

Preheat maintenance is required for the following: 1. Equipment and piping, regardless of service or wall thickness, of the P-5B, C, and D material groups (where chrome content exceeds 4%) and of P-6 and P-7 materials. Modifications to existing equipment and piping, regardless of material or wall thickness in hydrogen service. Hydrogen service is defined as: Any service in which the partial pressure of hydrogen in the fluid handled is 50 psia or more. This work requires a hydrogen bake-out, pre-heat maintenance and PWHT. Pressure vessel and exchanger seams, nozzle and attachment welds of P-1, P-3, P-4 and P-5 group materials, regardless of service, if shell or head thickness is equal to or greater than 1-1/2 inch. Piping fabrication, regardless of material or service, if thickness is equal to or greater than 3/4 inch.

2.

3.

4.

E.

The same preheat requirements shall be met as are required on the Client accepted welding procedures for thermal cutting, gouging, tack welding and welding repairs. The maximum preheat and interpass temperature for P-8 materials shall be 350 oF. The maximum preheat and interpass temperature shall be specified on the WPS for all materials of material group P-7 and higher.

F.

IX.

POSTWELD HEAT TREATMENT A. Postweld heat treatment (PWHT) shall be performed in accordance with the ASME Code and/or POLARIS Engineering Standard 840.4, as applicable. The applicable code or Standard for PWHT shall be referenced on the weld map (Appendix I). The maximum and minimum holding temperature and holding time shall also be stated on the WPS. POLARIS requires a two (2) hour minimum holding time for all equipment and piping to be heat treated. 1. For all equipment, except field fabricated tanks and piping, the post weld heat treatment procedure outlined in the ASME Code, Section VIII, Paragraphs UW-40, UW-49, and UCS-56, shall be followed. The exemptions provided for in the notes to Table UCS-56 are permitted with Client approval. Complete temperature cycle of heating, soaking and cooling shall be recorded on a chart and a copy of the continuously temperatures shall be provided to the Client for record. Cooling rate and heating rate shall be recorded on the WPS.

2.

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3.

Minimum and maximum PWHT temperatures and minimum holding time shall be as specified in the appropriate code and/or POLARIS Engineering Standard, except as specifically noted below: a. All carbon steel vessels, exchangers, and piping requiring PWHT are to be postweld heat treated at 1150 oF maximum ( 25 oF) for a minimum of two (2) hours. All 1-1/4% Cr - 1/2% Mo vessels, exchangers and piping are to be postweld heat treated at 1325 oF maximum ( 25 oF) for a minimum of two (2) hours. All 5% Cr - 1/2% Mo and 9% Cr 1% Mo vessels, exchangers and piping are to be postweld heat treated at 1350 oF maximum ( 25 o F) for a minimum of two (2) hours. All carbon steel and low chrome piping shall be postweld heat treated in accordance with POLARIS Engineering Standard 840.4.

b.

c.

d.

B.

Postweld heat treatment may be required for carbon steel equipment and piping for certain service conditions even when not mandatory per the applicable code or standard. Postweld heat treatment for these services will be indicated by the POLARIS Engineering Standards. At a minimum the following items shall be post weld heat treated: 1. Unless otherwise specified, welds in amine equipment and piping shall be postweld heat treated regardless of operating temperature or concentration. This also includes piping and equipment, which may be at risk of amine contamination as defined by the project P & ID's. Unless otherwise specified, welds in caustic equipment and piping shall be postweld heat treated regardless of the operating temperature or caustic concentration. This also includes piping and equipment, which may be at risk of caustic contamination as defined by the project P & ID's. Postweld heat treatment is required for equipment as well as shop and field fabricated piping of 1-1/4 Cr and higher ferritic steel weldments regardless of thickness. Postweld heat treatment is required for equipment as well as shop and field fabricated piping of carbon steel weldments regardless of thickness when design operating conditions are within 200 oF of the Nelson Curve for that material. All carbon steel equipment and piping in sour service with a fluid pressure

2.

3.

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of 65 psia or greater and containing hydrogen sulfide (H2S) at a partial pressure in excess of 0.05 psia (mol-fraction multiplied by total system pressure) with, or without, water present. 6. 7. All deaerators require post weld heat treatment. All equipment in these services above shall have welds ground, smooth, and wet fluorescent magnetic particle tested.

C.

Postweld heat treatment temperatures will be in accordance with ASME B31.3, Table 331.1.1 and POLARIS Engineering Standards 840.1 and 840.4. Acceptable methods for postweld heat treatment are: 1. 2. 3. Furnace method Local resistance method Local induction method

D.

Other methods for postweld heat treatment require Client's written approval. E. For piping, postweld heat treatment performed by exothermic methods requires Client's written approval and shall not be assumed as acceptable by the Vendor during bid preparation. When approved by Client, welding procedures submitted for review using postweld heat treatment by exothermic methods shall be qualified as using the exothermic method proposed for heat treatment. All weld joints postweld heat treated by exothermic methods, when approved, require 100% radiography. Postweld heat treatment for stainless steels of Material Group P-8, nonferrous materials or dissimilar materials requires approval by the Client. Direct impingement by torch or furnace burner is not acceptable. Threads and gasket surfaces shall be protected from excessive oxidation during heat treatment. Equipment and piping postweld heat treated for any reason, code or process, shall not be subjected to any further welding, hammering, pressing or forming after postweld heat treatment without Client approval. Postweld heat treatment procedures describing cleaning requirements, heating and cooling rates, thermocouple locations, type of heating, equipment, etc., shall be submitted to the Client for review and approval to proceed. For local postweld heat treatment of thicknesses greater than 2 inches, the Vendor shall verify that the minimum code required PWHT temperature is attained on the unheated side of the joint. Verification may be established either by the

F.

G.

H.

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attachment of thermocouples or by the submittal of test data. K. PWHT is always required for all piping in which the wall thickness is 3/4 or greater.

X.

NON-DESTRUCTIVE EXAMINATION, TESTING AND INSPECTION A. Non-destructive examination (NDE) shall be performed and results evaluated in accordance with the requirements of the applicable ASME code, ANSI standard, or API standard. Any additional NDE required above and beyond the above mentioned codes and standards shall be as specified in this Standard and other POLARIS Engineering Standards. As a minimum, or when non-destructive examination is not specified, all welds shall be visually examined. Plate 2 inches and thicker and clad material shall be 100% ultrasonically tested at the mill with acceptance to SA-578, Level B. Brinell Hardness Tests 1. Hardness tests shall be performed when PWHT is specified, and when required by codes, standards or POLARIS Engineering Standards. Hardness test results shall be given in equivalent Brinell values regardless of test method utilized. A test shall include one (1) examination in the weld and one (1) in each heat affected zone at the toe of the weld. Hardness tests on piping shall be taken as specified in POLARIS Engineering Standards 840.1 and 840.4. Hardness tests on pressure vessels, exchangers, and other equipment where required shall be taken as follows: a. One test for one longitudinal seam per course section, on the inside surface where practical. One test for each circumferential seam per 50 linear feet of weld, on the inside surface where practicable. One test for each major joint weld for box-type headers on air coolers. One test for each size nozzle 4 inches and over in size, if accessible.

B.

C.

D.

2.

3.

b.

c.

d.

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140.10 Rev.: 5 Page: 18 of 24

e.

As a minimum, one test shall be taken for each welding process employed on pressure containing welds and also one test per welder or welding machine operator. As required in the applicable code or standard.

f. 4. 5.

When PWHT is required, hardness tests shall be performed after PWHT. Where NACE MR-0175 and/or RP-0472 are specified the hardness testing requirements of those standards shall apply where more stringent than this Standard. Results of hardness tests shall be documented by the Vendor for review by the Client's Inspector. The Client's Inspector shall be consulted on choice of location for tests. Hardness tests exceeding the maximum Brinell Hardness Number (BHN) allowed shall have two more tests taken near each failed location and both are required to be within the maximum acceptable hardness requirements. Hardness test results shall be reported with the procedure qualification record by the Vendor with submittal of welding procedure review by the Client for the following: a. b. c. Whenever hardness tests are required by codes or standards. Whenever equipment or piping is to be postweld heat treated. Whenever automatic or machine type welding processes are employed, or whenever FCAW is to be utilized. Hardness for carbon steel shall not exceed 200 BHN; hardness for low alloy shall be in accordance with applicable codes or standards. For other materials requiring hardness testing, acceptance values shall be as stated in the applicable codes and standards.

6.

7.

8.

d.

E.

Production test requirements on weld overlay and back-cladding on vessels and exchangers are as follows: 1. One chemical analysis of overlay from each girth section and component (such as head, tubesheet, etc.) and from each back-cladded longitudinal and circumferential seam. Also, back-cladded manway attachment and a representative number of nozzles, at least one of each size. Production tests shall include a minimum of one test per welding process utilized and one test per welder or welding operator employed.

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2.

For austenitic stainless steel, the overlay or back-clad for TP 347 stainless, when specified, shall have elements Cr, Ni, Mn, Si, C and Cb reported. For others, the overlay or back-clad shall meet the minimum requirements of the specified alloy. Ferrite content of austenitic stainless steel overlay and back-cladding shall be checked by using a magnetic gage or other method approved by the Client. Range of ferrite shall be 3-12 FN per magnetic meter.

3.

4.

F.

Weld overlays and back-cladding for vessels and towers shall be examined by a standard copper sulfate test prior to hydrostatic test and by liquid penetrant examination following hydrostatic test. Overlay clad tubesheets shall be liquid penetrant examined prior to hydro static test. The Client's Inspector shall be authorized to reject work or materials and require repair or corrections where the applicable specifications or acceptance levels have not been met. The Client's Inspector may require additional examination over and above the minimum specified. If the weld proves to be acceptable, the cost of examination shall be borne by the Client. If the weld proves to be unacceptable, the cost of the examination, and all required repairs and re-examination shall be borne by the Vendor. Root and final welds in vessels, air cooler box headers, exchangers and piping larger than 24 inches shall be magnetic particle examined when the material thickness is equal to or greater than the following: MATERIAL GROUP P-1 P-3 P-4 P-5 P-6 P-7 THICKNESS (INCH) 1-1/4 3/4 5/8 All All All

G.

H.

I.

J.

Welds in all non-magnetic materials, either of solid alloy or alloy clad plate shall be examined by liquid penetrant methods. Where strength welds for tube to tubesheet joints are required, Vendor shall submit a cut-off sample before fabrication.

K.

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L.

Pressure retaining butt welds in shell or heads over 1.80 inches thick may be manual arc process welded and shall be radiographed 100%. Heads fabricated from more than one piece shall have welds radiographed 100% prior to forming. For equipment and piping requiring PWHT all required NDE of completed welds shall be performed after the postweld heat treatment.

M.

N.

XI.

REPAIRS A. Welding repairs shall be performed utilizing Client approved welding procedures under conditions and requirements as stringent as those imposed by the welding procedure originally accepted for the particular weld. The repair procedures, using welding, shall be submitted for review and shall include the following: 1. 2. The method of defining the type and the extent of the defect. Methods used for removing the defect, and testing conducted to ensure that the defect has been removed. Welding procedures employed for re-welding and NDE methods used to inspect weld repair area after completion of the welding.

B.

3.

C.

Unacceptable discontinuities shall be completely removed by chipping, gouging, grinding or other Client authorized methods (for the type of material being repaired) to clean to sound metal and the excavated area shall be examined by magnetic particle or liquid penetrant methods to assure complete removal of defects. Excavation for repairs by flame or arc gouging shall have the same preheat requirements imposed as the welding procedures used to perform the weld. Preheat to be used for repair welding (such as attachments, undercutting, and other defects which do not penetrate the full weld thickness) shall be the same as required for the original weld for the full base metal thickness. Undercutting shall be repaired by blend grinding provided the required base metal thickness by design is not reduced. Otherwise, weld metal buildup will be required. Defective work or materials that have been weld repaired shall, as a minimum, be re-examined by the same non-destructive test method by which the defect was originally located.

D.

E.

F.

G.

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H.

Only two repair attempts shall be allowed on any one defective area. No further attempts to repair shall be carried out without authorization of the Client.

XII.

SUMMARY OF WELDING VARIABLE LIMITATIONS, RESTRICTIONS, AND OTHER REQUIREMENTS Limitations, restrictions and other requirements of this Standard, whether required by ASME Section IX or not, are required to be stated in the Vendor's WPS, PQR and weld map (Appendix I), on welding procedures submitted by the Vendor for review. The main requirements are summarized as follows: A. B. C. Impact test results on PQR. Brinell hardness test results on PQR. Mode of transfer for GMAW and FCAW to be stated on WPS and weld map of Appendix I. GMAW: Limitations and requirements. FCAW: Limitations and requirements. Automatic or machine type SAW to be specified in WPS. Filler metals and fluxes. To have stated in the WPS and/or weld map (Appendix I) the AWS grades ASME specifications, Manufacturers, and trade names of filler metals and fluxes. When backing is approved for use, it is required to be stated on PQR, WPS and weld map (Appendix I). Root shielding (back purge) method to be stated on WPS or separate procedure submitted. Minimum preheat temperature to be stated in WPS. Preheat maintenance when required to be stated in WPS. Maximum preheat and interpass temperature to be stated on WPS for P-7 group materials and higher. Postweld heat treatment holding temperature and holding time to be specified on weld map (Appendix I) and in WPS. Additional welding variables to be stated in the WPS whether essential or nonessential per ASME Section IX are:

D. E. F. G.

H.

I.

J. K. L.

M.

N.

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1.

Electrical characteristics: current and voltage ranges, and polarity, for all welding processes. AWS specification for non-consumable electrode for GTAW. Travel speed and whether single or multiple arc for automatic processes of GTAW, GMAW, SAW, FCAW/CO2 and for overlay and back-clad welding. Amount of bead overlap, extent of oscillation and wire size for overlay and back-clad welding.

2. 3.

4.

O.

Block welding is prohibited. However, The Temper Bead Welding Technique per NBIC is allowable with Clients written approval. When welding titanium, each bead and adjacent base metal shall be cleaned to remove all surface discoloration prior to deposition of the next bead. The final weld surface may have intermittent, iridescent straw-colored oxides. The root pass of butt welds in lube oil piping, accessible from one side only, shall be welded with the GTAW process.

P.

Q.

XIII.

PROCEDURE FOR REVIEW AND ACCEPTANCE OF VENDOR WELDING PROCEDURES A. The Client requires Vendors and their Subvendors, if applicable, to submit a copy of each welding procedure appropriate for fabrication. A copy of the weld map (Appendix I) shall also be filled out and attached to the submittal. Procedures cannot be reviewed unless accompanied by the weld map. Submittals of welding procedures for review shall be directly to the Client and/or Client's Engineer. No portion of this Standard shall be waived without written approval. Vendors shall review the welding procedures of their own Subvendors for compliance to this Standard prior to submitting for review and acceptance. The Client and/or Client's Engineer will review the submitted welding procedures and weld map and make comments back to the Vendor in writing. Comments are either (1) Acceptable without comment, (2) Acceptable with comments, (3) Revise and resubmit per comments or (4) Unacceptable with comments. All comments, if possible, will make reference the paragraph number of this Standard with which the procedure must comply.

B.

C.

D.

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E.

Upon receiving the marked up welding procedure from the Client and/or Client's Engineer, the Vendor must comply with the comments. The Vendor shall submit corrected documents. The Surveillance Inspector assigned by the Client is to verify that welding will be performed to the accepted and corrected welding procedures, which incorporate the comments. Items in dispute shall be resolved prior to fabrication being stated on the affected parts.

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APPENDIX I WELD MAP

Supplier Name Supplier Shop Order # POLARIS PO # Item/Tag # Pressure Vessel Heat Exchanger Storage Tank Fabricated Pipe Spools Other

Design Temperature Design Pressure Min. Design Metal Temp. Postweld Heat Treatment Yes No Required by Code Service Time and Temperature Impact Testing Yes No Required by Code Service Temperature Applicable Code or Standard Draw a single-line sketch of the apparatus. For pipe spools, only show typical weld joints, i.e., butt, branch, and attachments, by P-No. Locate an example of all types of typical weld joints, dissimilar welds & attachments Identify each different welding procedure by separate letter or number.

This form completed by Email Address Telephone Revision Date This space for POLARIS Identification

This space for POLARIS Review Stamp