BOILER AND PRESSURE VESSEL CODE

SECTIONS

USE FOR

Rules for Construction of Power Boilers

II

Materials
Part A

Ferrous Material Specifications

Part B

Nonferrous Material Specifications

Part C

Specifications for Welding Rods, Electrodes, and Filler Metals

Part D

Properties

IV

Rules for Construction of Heating Boilers

Nondestructive Examination

VI

Recommended Rules for the Care and Operation of Heating Boilers

VII

Recommended Guidelines for the Care of Power Boilers

VIII

Rules for Construction of Pressure Vessels

Div 1
Div 2

Alternative Rules

Div 3

Alternative Rules for Construction of High Pressure Vessels

IX

Welding and Brazing Qualifications

Fiber-Reinforced Plastic Pressure Vessels

XI

Rules for Inservice Inspection of Nuclear Power Plant Components

XII

Rules for Construction and Continued Service of Transport Tanks

For NDT Ref. Code

Ref. Code
for Methods
RT

Ref. Code
for Acceptence Standard

Sec 5 article 2

Sec 8 Div 1 Appendix 4

UT

Sec 5 article 4

Sec 8 Div 1 Appendix 12

DPT

Sec 5 article 6

Sec 8 Div 1 Appendix 8

MPT

Sec 5 article 7

Sec 8 Div 1 Appendix 6

ESSENTIAL VARIABLES FOR WELDER QUALIFICATION AS PER SEC IX

WELDER QUALIFIED WITH

WELDER QUALIFIED FOR

SIZE
OD
THK
(groove)
THK
(fillet)

Less then 1"OD

1" to 2 7/8" OD
2 7/8"OD & Above

Size Welded & Above

1"OD & Above
2 7/8"OD & Above

Less then 13mm

13mm & Above
Less then 5mm
5 to 10mm

2T
Max. to be welded
T to 2T
Max. to be welded
POSITION

Groove
for
plate
Fillet
for
plate
Groove
for
pipe
Fillet
for
pipe

1G

1G & 1F

2G
3G
4G
1F
2F
3F
4F
1G
2G
5G
6G
1F
2F
4F
5F

1G, 2G & 1F, 2F

1G, 3G & 1F, 2F, 3F
1G, 4G & 1F, 2F, 4F
1F
1F & 2F
1F, 2F & 3F
1F, 2F & 4F
1G & 1F
1G, 2G & 1F, 2F
1G, 5G & All Fillet
All groove & Fillat
1F
1F & 2F
1F, 2F & 4F
All Fillet
P-NUMBER

Any P-no 1 to 11 or 34 & 41 to 49

Any P-no 21 to25
Any P-no 51 to 53 or 61, 62

All P-no 1 to 11 or 34 & 41 to 49

All P-no 21 to25
All P-no 51 to 53 or 61, 62

F-NUMBER
F-no 1 with backing
F-no 1 without backing
F-no 2 with backing
F-no 2 without backing
F-no 3 with backing
F-no 3 without backing
F-no 4 with backing
F-no 4 without backing
F-no 5 with backing
F-no 5 without backing
Any F-no 6
Any F-no 21 to 25
F-no 34 or Any F-no 41 to 45
Any F-no 51 to 55
Any F-no 61
Any F-no 31,32,33,35,36,37,71,72
NOTE :
1- Flat
2- Horizontal

F-no 1 with backing

F-no 1 with & without backing
F-no 1 & 2 with backing
F-no 1 with backing &
F-no 2 with & without backing
F-no 1, 2 & 3 with backing
F-no 1 & 2 with backing & F-no 3 with
& without backing
F-no 1, 2, 3 &4 with backing
F-no 1, 2 & 3 with backing &
Fno 4 with & without backing
F-no 1 & 5 with backing
F-no 1 with backing &
F-no 5 with & without backing
All F-no 6
All F-no 21 to 25
F-no 34 & All F-no 41 to 45
All F-no 51 to 55
All F-no 61
same F-no used during the tast

POSITION
4- Overhead
5- Vertical (only for pipe)

3- Vertical

6- Inclined (only for pipe )

For WPS Qualification

Thickness Qualification Range &
Tension & Bend Tests for Groove Weld
Thickness T of
Test Coupon
IN mm

Qualified Thickness
of Wps

Tests Required

Min.

Max.

Tension

Side
Bend

Face
Bend

Root
Bend

Less Than 1.5

2T

NA

1.5 to 10.0

1.5mm

2T

NA

Above 10.0 to
Less Than 19.0

5.0mm

2T

NA

19.0 to
Less Than 38.0

5.0mm

2T

NA

NA

38.0 & Above

5.0mm

200mm

NA

NA

Height of reinforcement or
internal protrusion
Thkiness of material
T

Acc. Reiforcemant
Height in mm

6mm

1.5

> 6 to 13 mm

> 13 to 25 mm

> 25 mm

NOTE :- for Category D Fluid Service internal

protrusion Limit is twice

List of WPS of various materials in different conditions

Sl.
WPS. No
NO

Material

11223

C.S (A106 Gr-B)

11122

C.S (A106 Gr-B)

11185

C.S (A106 Gr-B)

11110

C.S (A106 Gr-B)

11111

C.S (A106 Gr-B)

14118

C.S (A106 Gr-B)

14221

C.S (A106 Gr-B)

14215

C.S (A106 Gr-B)

11413

C.S (A106 Gr-B)

10

41398

A.S (A335)

11

41478

Dissimilar

12

51135

A.S (A335)

13

51153

A.S (A 335)

14

51235

Dissimilar

15

51262

A.S (A 335)

16

51140

A.S (A 335)

17

81124

18

81131

19

81183

20

11294

21

11143

22

11360

P1 Gr1,2 P1 Gr1,2
P1 Gr1,2 P1 Gr1,2
P1 Gr1,2 P1 Gr1,2
P1 Gr1,2 P1 Gr1,2
P1 Gr1,2 P1 Gr1,2

24

11363

C.S (A106 Gr-B)

Welding
Process

Filler wire/
Elecrode

F - No

Thk
Range(mm)

6G

SMAW

E6010 + E7018

3+4

1.6 - 19.0

6G

SMAW

E6010 + E7018

3+4

2.5 - 46.0

6G

SMAW

E6010 + E7018

3+4

4.8 - 19.0

GTAW
+SMAW
GTAW
+SMAW

ER70S-2 +
E7018
ER70S-2 +
E7018

6+4

1.6 - 19.0

for the combination of TIG + ARC upto 19mm

6+4

4.8 - 46.0

for TIG + ARC above 19mm PWHT* Req.

& Preheat Req. 80 Deg.C for thk >=25mm

Remarks

PWHT* Req. (Above 19.02 Thk )

& Preheat Req. 80 Deg.C for thk
>=25mm
Hardness
( for services of FS,WX,BE,PE & NACE )

6G

6G

GTAW

ER70S-2

2.5 - 17.0

for the (C.S.) pipes which are less than 2" dia

All Fillet
Only

GTAW

ER70S-2

2.75 - 6.0

for the (C.S.) pipes which are less than 1.5" dia

P1 Gr1,2 P1 Gr1,2

6G

GTAW

ER70S-2

2.75 - 21.94

P1 Gr1,2 P1 Gr1,2

6G

SMAW

E7018

4.8 - 70.0

1.25 Cr - 0.5 Mo

6G

GTAW
+SMAW

ER80S-B2 +
E8018-B2

6+4

2.77 - 36.0

PWHT & Hardness Req.

1.25 Cr - 0.5 Mo

All Fillet
Only

SMAW

E7018

Up to 32

Preheat Req. 177 Deg.C for P4 by Torch or Coil

5 Cr 0.5 Mo

6G

GTAW
+SMAW

ER80S-B6 +
E8018-B6

6+4

4.8 - 50.8

Purging shall be maintained

PWHT** & Hardness Req.

5 Cr 0.5 Mo

6G

GTAW
+SMAW

ER80S-B6 +
E8018-B6

6+4

1.6-18

Below 13 mm Throat PWHT not required

( Preheating / post heating required )

All Fillet
Only

SMAW

E8018-B6

All

P5B Gr1
-P5B Gr1

5Cr-0.5Mo

All Fillet
Only

SMAW

E8018-B6

above 3 mm

P5B Gr1
-P5B Gr1

9Cr-1Mo

6G

GTAW
+SMAW

ER80S-B8 +
E8018-B8

6+4

4.8 - 50.8

18Cr-10Ni-Ti/Cd

6G

4.8 - 46

Purging shall be maintained during Root & Hot pass

6G

ER347 +
E347
ER316L +
E316L

6+5

16Cr-12Ni-2Mo

GTAW
+SMAW
GTAW
+SMAW

6+5

4.8 - 46.0

Purging shall be maintained during Root & Hot pass

6G

SMAW

E309L

1.6 - 12.0

All fillet

SMAW

E6013

3.0 - 19.0

3G

SMAW

E7018

4.8 - 32.0

5F

SMAW

E7018

3.0 - 75.0

SMAW

E6013

3.0 - 75.0

SMAW

E7018

4.8 -100.0

P1 Gr1,2 P1 Gr1,2
P1 Gr1,2 P1 Gr1,2

P4 Gr1 P4 Gr1
P4 Gr1 P1 Gr1,2
P5B Gr1
-P5B Gr1
P5B Gr1
-P5B Gr1
P5B Gr1
-P1 Gr1,2

C.S
C.S ( A 36)

position

6G

P8 Gr1 - P8
Gr1
P8 Gr1 - P8
S.S (A312 TP 316/316L)
Gr1
P8 Gr1 Dissimilar
P1 Gr1
P1 Gr1 G.I
P1 Gr1
P1 Gr1,2 C.S
P1 Gr1,2

11361

Composition of
base material

S.S (A312 TP 321/347)

23

NOTE :-

Grade

P1 Gr1,2 P1 Gr1,2

All grove /
All fillet
All grove /
All fillet

Soaking 600 - 640 C for 1 hour,Heating & Cooling Rate 150 C/Hr

PWHT* Req.
For Amine line less than 2" dia
PWHT* & Hardness Req.
for Amine line Support

for trunion to pipe/base plate, PWHT not Req.

preheating and post heating required by Torch or Coil
Below 13 mm Throat PWHT not required
for trunion to pipe/base plate
Preheating / post heating required

Purging shall be maintained

PWHT** & Hardness Req.

Structural only ,
Preheat Req. 65 Deg.C for thk >38 - 65mm
Preheat Req. 110 Deg.C for thk >=65 - 75mm

** Preheating : 250 ; Interpass :350 ;post heating :300 Soaking 704 - 760 C for 2 hour,Heating & Cooling Rate 100 C/Hr

CHEMICAL COMPOSITION % AS PER SEC II DIV 1

Material P - NO

Carbon
steel

Stainlees
steel

Alloy
steel

Specification &
Carbon
Grade

Manganese
Mn

Chromium
Cr

Molybdenum
Mo

Nickel
Ni

Silicon
Si

Phosphorus
P

Sulfur
S

SA-106 Gr A

0.25

0.27 - 0.93

0.40

0.15

0.40

0.10

0.035

0.035

SA-106 Gr B

0.30

0.29 - 1.06

0.40

0.15

0.40

0.10

0.035

0.035

SA-106 Gr C

0.35

0.29 - 1.06

0.40

0.15

0.40

0.10

0.035

0.035

SA-312 Gr 304*

0.08

2.00

18.0 - 20.0

NA

8.0 - 11.0

1.00

0.045

0.03

SA-312 Gr 309S**

0.08

2.00

22.0 - 24.0

0.75

12.0 - 15.0

1.00

0.045

0.03

SA-312 Gr 310S**

0.08

2.00

24.0 - 26.0

0.75

19.0 - 22.0

1.00

0.045

0.03

SA-312 Gr 316*

0.08

2.00

16.0 - 18.0

2.0 - 3.0

10.0 - 14.0

1.00

0.045

0.03

SA-312 Gr 321**

0.08

2.00

17.0 - 19.0

NA

9.0 - 12.0

1.00

0.045

0.03

SA-312 Gr 347**

0.08

2.00

17.0 - 19.0

NA

9.0 - 13.0

1.00

0.045

0.03

5B

SA-335 Gr P5

0.15 max.

0.30 - 0.60

4.0 - 6.0

0.45 - 0.65

NA

0.50 max.

0.025

0.025

5B

SA-335 Gr P9

0.15 max.

0.30 - 0.60

8.0 - 10.0

0.9 - 1.10

NA

0.25 - 1.0

0.025

0.025

SA-335 Gr P11

0.05 - 0.15

0.30 - 0.60

1.0 - 1.50

0.44 - 0.65

NA

0.50 - 1.0

0.025

0.025

SA-335 Gr P12

0.05 - 0.15

0.30 - 0.61

0.8 - 1.25

0.44 - 0.65

NA

0.50 max.

0.025

0.025

SA-335 Gr P15

0.05 - 0.15

0.30 - 0.60

NA

0.44 - 0.65

NA

1.15 - 1.65

0.025

0.025

5A

SA-335 Gr P21

0.05 - 0.15

0.30 - 0.60

2.65 - 3.35

0.8 - 1.06

NA

0.50 max.

0.025

0.025

5A

SA-335 Gr P22

0.05 - 0.15

0.30 - 0.60

1.90 - 2.60

0.87 - 1.13

NA

0.50 max.

0.025

0.025

5B

SA-335 Gr P91

0.08 - 0.12

0.30 - 0.60

8.0 - 9.50

0.85 - 1.05

0.40 max.

0.20 - 0.50

0.02

0.01

NOTE :-

*
**

L = C - 0.035 & H = C - 0.04 - 0.10

H = C - 0.04 - 0.10

Other

RADIOGRAPHY ACCEPTANCE CRITERIA AS PER B 31.3

CATEGORY M & NORMAL FLUID ( ALL OTHER FLUID)

CRACK , LOF

LOP

UNDERCUT

SLAG / TUNGSTEN
INCLUSION / ELONGATED
INDICATION

Length <= 38 mm
of 150 mm RT

Depth<=1mm
and Tw/4

INTERNAL
POROSITY

Thickness of weld
inclusive reinforcement
>= Tw

Depth <= 1mm

and 0.2 Tw
Not Acceptable

ROOT
CONCAVITY

SINGLE
INCLUSION

MORE THAN
ONE
INCLUSION
THICKNESS
(Tw) <= 6mm

Length <= 2Tw

Width <= 3 mm
and Tw/2

Cumulative Length
<= 4Tw up to
150mm RT

ISOLATED

RANDOM

Major dimension
<= t/3 or 6mm

Major dimension
<= t/4 or 4mm

THICKNESS
(Tw) > 6mm

ISOLATED
Major dimension
<= 1.5 X
( t/3 or 6mm)

Note : For Alligned Indication Total Sum of Demension <= t up to 12t length
: For Cluster Porosity length of Cluster shall not exceed 2T or 25mm
: For more then one Cluster the sum of length of the Cluster shall not exceed 25mm in 150mm length
: For Welder Qualifiaction - As per Sec IX- Rounded indication is t/5 or 3 mm which ever is less

RANDOM
Major dimension
<= 1.5 X
( t/4 or 4mm)

CATEGORY D FLUID ( STORM & COOLING WATER )

CRACK

LOF; LOP

UNDERCUT

INTERNAL POROSITY / SLAG / ELONGATED

INCLUSION / TUNGSTUN INCLUSION

ROOT
CONCAVITY

N/A

Thickness of weld
inclusive
reinforcement
>= Tw

Depth <= 0.2 Tw

Not Acceptable

Depth <=1.5 mm
and
Length <= 38 mm [Tw/4 or 1mm]
of 150 mm RT

Notes :
Tw

Thickness of Base Metal

Isolated

Distance between two relevent indication is more than 25 mm

Random

Distance between two relevent indication <= 25 mm

" and "

" or "

The Lesser values is acceptance

The Larger value is acceptable.

Sensitivity of Film by wire Type IQI (ASTM)

Material Thk.
In mm
up to 6.4
over 6.4 to 9.5
over 9.5 to 12.7
over 12.7 to 19.0
over 19.0 to 25.4
over 25.4 to 38.1
over 38.1 to 50.8

X-ray

Source Side
essential wire
5
6
7
8
9
10
11

Density limitation
mim
1.8

Film Side
essential wire
4
5
6
7
8
9
10

IQI Set A
wire dia
in MM
0.08
0.10
0.13
0.16
0.20
0.25

IQI Set B

wire
identity

wire dia
in MM

wire
identity

1
2
3
4
5
6

0.25
0.33
0.41
0.51
0.64
0.81

6
7
8
9
10
11

Density variation
max
4.00

minus 15 % and plus 30 % from the density

at designated wire of wire IQI

gamma ray

2.00

4.00

minus 15 % and plus 30 % from the density

at designated wire of wire IQI

Acceptance Criteria for Welder & Welding operator qualification as per ASME Sec. IX - 2004
A

Linear Indications:

01

Crack, LF & LP

Extent of Imperfection

Zero

(No
Evident Imperfection)
3 mm for T upto 10 mm

02

Elongated Slag

T/3 for T over 10 mm to 57 mm

Cum. Length

T in a length of 12T weld

Max. Dimention

20% of T or 3mm whichever is smaller

19 mm for T over 57mm

Rounded Indication:

01
02

Length

Rounded Indication

No. of Indication

12 in 150 mm weld length for T < 3mm

for T > 3mm ref. chart

004