MASS

PIPE SCHEDULE CHART

SIZE IN
LENGTH VOLUME

CS: ANSI/ASME B36.10; Sch./ wall Thk.in mm; density = 7.85 kg/dm3SS: ANSI/ASME ch./Wall Thk. In mm; d =B36.19; Aus. Steel 7.93 kg/dm3Wt / m = π x (OD-t) x t x density
INCH OD (mm) STD
1 Pound = 0.454 Kg. 1 Inch = 25.4 mm 1 UK gal = 4.5461 L 1 33.40 3.38
1 Metric Ton = 1000 Kg. 1 mil = 0.0254 mm 5 mL = 5 cc = 1 tsp. 2 60.30 3.91
1 Ton = 1016.05 Kg. 1 mm = 1000 micron PRESSURE
3 88.90 5.49
FORCE WORK / ENERGY 1 Pa = 1N/m2
1 Kgf = 9.81 N 1 ft-lb = 1.3558 J 1 Mpa = 1 N/mm2 4 114.30 6.02
1 lb (Pound) = 4.45 N POWER 1 Mpa = 10 bar 141.30 6.55
5
1 N = 105 Dyne 1 Watt = 1 J/s 1 bar = 14.5 PSI
6 168.30 7.11
1 Watt= 1 Amp x 1 volt 1 bar = 0.9869 atm
DENSITY 1 ppm =1 mg/l = 1 mg/kg 1KSI = 6.90 Mpa 8 219.10 8.18
Density of steel = 484 to 503 Pcf, or 7.75 to 8.05 g/cm3 1 Kgf /cm2 = 14.22 PSI 273.00 9.27
10
Density of Water at 4oC = 1 gm / cm3 1 bar = 750.06 mm Hg at 0oC
Density of Hg at 0OC = 13.5951 g/cm3 1 bar = 10197.44 mm H2O at 4oC

323.80 9.53

PRESSURE PIPING CODE
ASME B 31.1 – Power
ASME B 31.2 – Fuel
ASME B 31.3 – Process
ASME B 31.4 – Transportation of HC /LPG
ASME B 31.5 – Refrigeration
ASME B 31.8 – Gas transportation & distribution
ASME B 31.9 – Building service
ASME B 31.11 – Slurry transportation
Socket & Threaded fittings :
I. ASME B16.11:
CODES
Flanges :-
ASME B16.1 : - CI PF & FF.
ASME B16.5 : -CS PF & FF
ASME B16.47 : - steel flanges. (Above
24”)
Butt welded fittings :-
ASME B16.9 : - Steel BW F
ASME B16.28 : - BW SR elbows &
returns bends.
Gasket :-
ASME B16.20 / API -601: - Metal
ASME B16.21 : - Non metallic.
12
ASME section I : - ROC of power boiler.
ASME Section II : - Materials.
Part A – Ferrous.
Part B – Non-Ferrous materials.
Part C – Spec.- Electrodes & filler wire.
Part D – Properties.
ASME Section IV : - ROC of Heating Boiler.
ASME Section V : - NDE.
ASME Section VI : - RRCO of heating boiler.
ASME Section VII : - RGC of power boiler.
ASME Section VIII : - ROC of pressure vessels. (Division I & II)
ASME Section IX : - Welding & Brazing qualification.
Valves :- Pipes :-
ASME B16.10: - F to F & E to E dim. ASME B36.10 : - Welded & Seamless
II. ASME B16.34 : - Flanged & butt-welded ends wrought iron pipes.
steel valves (Pressure &Temperature ratings) ASME B36.19 : - SS pipes.
Materials
P No. / Steel designation Forgings Wrought Fitting Pipe Plate Stud & Nut Remark
Group No.
SA-516, Gr.70
SA-193, B7 SA-193, B7M (NACE)
Carbon Steel SA-105 SA-234, WPB SA-106 GR.B SA-36,(Non pr.
SA-194, 2H SA-194, 2HM (NACE)
1/1 Prat)
SA-320-7
SA-350, LF2 SA-420, WPL6 SA-333 GR.6 Low. Temp.
SA-194, 4
1Cr-0.5Mo SA-182, F12 SA-234, WP12 SA335, P12 SA-387-12 A/Steel
4/1
1.25Cr-0.5Mo SA-182, F11 SA-234, WP11 SA335, P11 SA-387-11
5A / 1 2.25Cr-0.5Mo SA-182, F22 SA-234, WP22 SA335, P22 SA-387-22 A/Steel
5Cr-0.5Mo SA-182, F5 SA-234, WP5 SA335, P5 SA-387-5 A/Steel
5B / 1
9Cr-1Mo SA-182, F9 SA-234, WP9 SA335, P9 SA-387-9
18Cr-8Ni SA-182, F304 SA-403, WP304 SA-312, TP304 SA-240, 304 SS
SA-193, B8
18Cr-8Ni SA-182, F304H SA-403, WP304H SA-312, TP304H SA-240, 304H SS
SA-194, 8
18Cr-8Ni SA-182, F304L SA-403, WP304L SA-312, TP304L SA-240, 304L Low C SS
8/1
16Cr-12Ni-2Mo SA-182, F316 SA-403, WP316 SA-312, TP316 SA-240, 316 SS
SA-193, B8M
16Cr-12Ni-2Mo SA-182, F316H SA-403, WP316H SA-312, TP316H SA-240, 316H SS
SA-194, 8M
16Cr-12Ni-2Mo SA-182, F316L SA-403, WP316L SA-312, TP316L SA-240, 316L Low C SS
43 67Ni-30Cu SB-164 SB-165 SB-127 Monel
45 35Ni-35Fe-20Cr-Cb SB-462 SB-366 SB-729 SB-463 Alloy 20
Materials
CS: 235 TP, MDT ≥
Product CS: 235LT TP CS: 360LT TP SS: 316 TP SS: 316 TP SS: 316 TP
15⁰C & Thk. < 16
Imp. Test Imp. Test 22 Cr Duplex 25 Cr Duplex
mm
Pipes SMLS A106 Gr.B A333 Gr. 6 API 5L Gr. X52 A312 Gr. TP316 A790 UNS S31803 A790, UNS S32550
Pipes ASTM A672 CC60/70, A671 Gr. CC60/70, Cl. A671 Gr.CC70, Cl.
A358 Gr. 316 A928 A928
Welded Cl. 12,22; API 5L Gr.B 12,22 12,22
Fittings A234 Gr. WPB A420, Gr. WPL 6 A860 Gr.WPHY52 A403 Gr.WP316 A815 UNS S31803 A815,UNS S32550
A182
Forgings A105 A350 Gr. LF2 A694 Gr.F52 A182 Gr. F316 A182 Gr. F51 / F60
F53/F55/F61
Plate A 516 Gr. 60/70 A 516 Gr. 60/70 A 516 Gr. 70 A240 Gr.316 A240 A240
A351 Gr.CF8M or A995 UNS Gr. A995,A5 (UNS
Castings A216 Gr. WCB A352 Gr. LCC A352 Gr. LCC
CF3M 4(J92205) J93404)
Bar A276 UNSS31600 A276 UNS S31803 A276, UNS S32550
Tube A269 Gr.316 A789 UNS S31803 A789, UNS S32550
Product SS: Cu/Ni 90/10 Ni-alloy Ti-alloy, Gr.2 High Strength Low
06 Mo TP & Cu-alloys Alloy Steel
Pipes SMLS A312,UNS S31354 B466,UNS C70600 B705,UNS N06625 B861,Gr.2 A519 AISI 4130
Pipes
A358 B467 B705 B862,Gr.2
Welded
Fittings A403,WP S31254 UNS C70600 B366 B363,Gr.WPT2 A234 AISI 4130
ASTM A788,AISI
A182,Gr.F44,UNS
Forgings UNS C70600 B564,UNS N06625 B381,Gr.F2 4140,API 6A
N08367
60K,A182 F22
Plate A 240 B171 B443 B265,Gr.2
ASTM A 487,Gr.
Castings B148,UNS C95800 A494,Gr.CW-6MC B367,Gr.C2
A 351,CK-3MCuN 2B/2C
Bar A276,UNS S31254 B446 B348,Gr.2
Tube A269,UNS S31254 B444 B338,Gr.2
As per BSEN 10225:
ADMA Spec: Fixed Offshore Steel Structure SP 1030 => Rm = Tensile Strength
ReH = Yield Strength
Primary members( Category-I) are those which are essential to the
IPE - I beams
overall structural
integrity of the structure. Examples of these are as follows: IPN - standard beams
For Jackets: Legs, piles, horizontal & vertical bracing. HE - wide flange beams, A- Light,
For decks or modules: Legs, main trusses or frames including bracings and main B – Normal, M – Heavy.
floor girders and crane pedestals.
For Masts/Bridges: Main chords and bracings in main faces
HLZ - extra wide flange beams
HL - extra wide flange beams
Special members (Category-S) are parts of primary members
located in critical load
HD - Wide flange columns
transmission areas. Typically these are the, HP - Wide flange bearing piles
a. areas subject to in-service through-thickness stress. UPE - Channels with parallel flanges
b. areas of highly constrained welding during fabrication. UPN - standard channels
c. areas containing high concentrations of welding.
d. main leg node shell plates, overlapped joints, pad eyes and through plates at
U - Channels with taper flanges
cruciform’s.
For Jackets: Nodes on main legs including cans, brace stubs if used, main plates
for
padeyes.
For Decks/modules: Nodes of deck legs, main plate for pad eyes, primary
structure, which exceeds 50 mm thickness.
Secondary members ( Category-II) are those whose contribution
to the overall
structural integrity is not essential, but which are significantly loaded, (e.g. floor
plate, stringers, major equipment supports, stairs and walkways, conductors or
risers
support members).
Ancillary (Tertiary)( Category-A) steel members are defined as
members and
attachments which do not fall in the above categories and are not essential to
the
main stability and strength of the structure (e.g. handrails, ladders, access
platforms,
minor equipment supports, temporary steelwork such as sling lay down
platforms,
bumpers and guides).

ZADCO >> Technip FMC >> SLB (SCHULMBERGE) >> ADYARD

Consumable:
1) BSEN 10204 – 31. Cert, 2) LR Approved, 3) PMI for SS, DSS, SDSS & CuNi, 4)
Storage 20 to 40˚, Max. 60% Humidity. 5) Low Hydrogen / Basic Electrode like E7018
– Max. 2 time Re-dry at 300 to 350 ̊C for 2 Hrs., Holding 150˚ C min., in Quiver - 70˚C.

TEST Cert. Type AWS code for EEMUA

2.1: Declaration of Compliance with PO/without test/by Mfg. SMAW : AWS A5.1, A5.5
2.2: Declaration of Compliance with PO / With Test result (non- GMAW: AWS A 5.18
GTAW: AWS A5.18
specific inspection) /by Mfg.
SS FCAW: AWS A5.20
3.1. Cert. compliance with PO/ issued by Mfg./ with Specific Test GS FCAW: AWS A5.20
result / validated by Mfg. Authorised Inspector (Before 2004 3.1B) SAW Wire & Flux: BSEN 756 & 760
3.2. Cert. compliance with PO/ issued by Mfg./ with Specific Test Shielding gas: BSEN 439
result / validated by Purchaser Authorised Inspector (Before 2004 3.1A)
LAB Test Corrosion analysis - ASTM G28-02, G48A
Mechanical- ASTM A370 Liner pipe grip test – API 5LD Para 8.3 (b)
Charpy Impact –ASTM A370, E23 Eddy Current Test – ASTM E426
Flattening – ASTM A530 UT Test – ASTM E213
Hardness – ASTM E384 UT Test Cladding – ASTM A578 S7
Chemical – ASTM E350 DPT – ASTM E165
Micro Examination – ASTM E112 (100X), E45 Inter Granular Corrosion – ASTM A262 Practice E
HIC Cracking Test – NACE TM 0284 / ISO 15156-2 Ferrite Content – ASTM E562
Impact Test Detrimental Phases – ASTM A923
Izode Test ASTM D256 Charpy Test ASTM E23 Ferroxyl Test for free Iron pickling & passivated surface – ASTM A 380
V-notch Hole, V, U-notch lateral expansion ASME Sec VIII, UHA 51, a) > 2) > –a) Page
Cantilever Manner Two support 270: at opposite the notch ≥ 0.38 mm
Struck exposed Cantilever front Struck behind the notch
side of notch
75 x 10 x 10 55 x 10 x 10
Cladding Material Pickling as per ASM A380 (Water Chloride Content < 25 ppm)
UNS N08826 (Alloy 825) => ASTM B424 Incoloy Corrosion Test Requirement for CRA
Ni 38-46, Cr 19.5-23.5, Mo 2.5-3.5, C 0.5 Max. Fe 22 Min. material Test Method Acc. Criteria
Alloy 825 ASTM G28 Method A G 28: Max. Corr.
UNS N06625 (Alloy 625) => ASTM B443 Inconel Plate Rate 0.08
ASTM G48 Method A (pitting) mm/Month
Ni 58 min., Cr 20-23, Mo 08-10, C 0.1, Max. Fe 5 Max.

Alloy 625 ASTM G28 Method A For G48, No.

UNS S31254 (6Mo) => ASTM A240 (Austenite SS) Pitting at 20X,
Ni 17.5-18.5, Cr 19.5-20.5, Mo 6-6.5, C 0.02, Max. Fe NA. Max. Weight
ASTM G48 Method A (Clad
Pate) Loss ≤1.5 (4)
Higher cost, higher = Alloy 625 (UNS N06625) = PREN 50. 6 Moly ASTM A262 Practice E IGC Test g/m2
Base Alloy = 6 Mo (UNS S31254) = PREN 43. for SS
Lower cost, lower alloy = (316L) (UNS S31603) =PREN 25. ASTM G48 Method A (pitting) For A262, No
for DSS Crack ao 20 X
A923 to detect intermetallic phases
G48 determine the Ω to the initiation of chloride pitting.

Material Mn Si Ni Cr Mo Cu Fe Ti Al Co Cb Ferrite No (FN) cannot be converted directly in to volume % Ferrite

SS 316 L X X X unless saturation ferrite Magnetization of the ferrite level is taken into
DSS / SDSS X X X the account of these alloys. With various calculations, an approximate
ALLOY 625 X X X X relationship has been developed using formula.
UNS N08926 X X X X X
ALLOY 718 X X X X Volume F% of Ferrite = 0.7 (FN) + 0.54, where ‘F’ is residual ferrite and
ALLOY 925 X X X X FN is ferrite content.
UNS 31254 X X X

Pressure Vessels Materials Fe Ni Cr Mo C Mn Si P S C

Type SS 316 0.08 2 0.045 0.030
Type 316L 65 12 17 2.5
Alloy 400, Monel 1.2 66
Alloy 625 Gr. 1, Inconel 625, Gr. 1 5 58 20- 8-10 0.1
Max 23
Alloy C-276, Hastelloy 276 6.5 53 15.5 16

17-4HP SS / ASTM A693 Typ.630/UNS S17400 =>Precipitation Hardening Stainless Parts Material
Steel (UNS S17400)(Page 497 / 2013) Body ASTM-A105N; A350, Gr. LF2; A216, WCB
ASTM A564 Gr. 630: Hot Rolled, Cold Finished Age-Hardening SS Bar/Shape (Page Bonnet ASTM-A105N; A350, Gr. LF2; A216, WCB
296 / 2013) Ball ASTM-A182,Gr. F44 (UNS S31254), B564 (UNS N06625)
ASTM A216, WCB: Steel Casting and carbon suitable for fusion welding for ↑ Temp. Seat ASTM-A182,Gr. F44 (UNS S31254),
Service (UNS J03002) (Page 388 / 2013). Stem ASTM-A182,Gr. F44 (UNS S31254); 17-4HP SS; A564 Gr.630;
ASTM A193, Gr.B7M:AS and SS Bolting Materials for ↑ Tempr or ↑ Pr. Service and
ASTM B637 (Inconel 718)
other special applications. Cr-Mo (Page 314 / 2013).
Stem Key AISI 4140 / ASTM A29 Gr. 4140
ASTM A194, Gr.2HM: CS & AS Nut for bolt for ↑Pr. or ↑Temp. service or both (Page
332 / 2013). Wedge ASTM-A182,Gr. F44 (UNS S31254), A351Gr.CF8M
ASTM B637: Precipitation-Hardening Ni-Alloy bar, forging and forging stock for ↑Temp. Bolt /Stud ASTM A193, Gr.B7M; A320 Gr. L7M
Service Inconel 718 (UNS N07718) (Page 979 / 2013). Nut ASTM A194, Gr.2HM;
ASTM B564: Precipitation-Hardening Ni-Alloy bar, forging and forging stock for ↑Temp. ASTM-A105N: CS forging for piping application, N= Normalised, A= Annealed, NT=
Service Inconel 625 (UNS N06625) (Page 862 / 2013). Normalised + Tempered, QT= Quench + Tempered (Page 240-2013)
A320 Gr. L7M:AS and SS Bolting materials for ↓Temp. services (Page 562 / 2013). ASTM-A350, Gr. LF2: Specialized CS /Low AS Forging ,Notch Toughness Reqd. Pipe
AISI 4140 / ASTM A29 Gr. 4140 : Carbon and Alloy steel Bar, Hot Wrought (Page 170 Component (Page 636 / 2013)
/ 2013) ASTM-A182, Gr. F44:Forged/Rolled Alloy and SS pipe flanges, Forged fittings, Valves &
valves parts for ↑Tempr UNS S31254 (Page 291-2013)
A351Gr.CF8M:Casting Austenitic. Duplex for pressure
containing Parts. (Page 648 / 2013).
GRE Items Inspection RAW material test GRE Items Inspection Production test
WA Test of resin-ASTM D 570: 1Hr@105ºC cured sample=> in water Specific Tangential Initial Stiffness (STIS) & Structural Hoop
@ 24 hrs.=> Accp. ≤ 0.03% Flexural Modulus of pipe: TM-002 & ASTM D 2412. Stiffness ≥ 5000
RI of epoxy resin hardener mix - RMT-011 & ASTM D 1045=> ABBE Pa and Structural hoop flexural modulus ≥ 20500 MPa. 5% Deflection
in Dia.
Refractometer => Accp. 1.5530 to 1.5865
Axial Tensile Strength of Pipe TM-003 & ASTM D 638 ≥ 55 Mpa.
Viscosity of Epoxy Resin- RMT-001A & ISO 2555 => conditioning @ Hoop Tensile Strength of Pipe TM-004 & ASTM D 2290 ≥ 210 Mpa.
25ºC=>Brookfield Viscometer => Accp. 10000 - 12000 Cps Degree of Curing (Tg Value) of Pipes and Fittings – (DSC /
Resin Gel Time, Cure Time and Peak Temperature- RMT-002 & (Differential Scanning Calorimeter)Method-Glass transition
ASTM D 2471 => conditioning @ 25ºC + mix hardener => Gel-Time : temperature) Tg ≥ 95% of minimum Tg value measured for qualifying
90 ± 30 Min. Gel-to-peak : 10 ± 5 Min. Peak Temp. : 200 ± 40 °C . component in 1000 hours survival test.
Glass Fibers: - M/C, Size/ Binder content & Tex properties - Tg ≥ 135% for Pipes, Fittings, Flanges & Lamination Joints
RMT-003, RMT-004 & RMT-005. Tg ≥ 110% for Cement Joints
Moisture Content : < 0.15 % [105ºC@3hrs] WA Test, Boil Resistance of Pipes, Fittings & Flanges-ASTM D
Binder content: Nom. ± 30 % [LOI 600ºC@30 min.] 570: 1Hr@105ºC cured sample=> in water @ 3 hrs.=> Accp. ≤ 1% and
Tex Number : Nom. ± 15 % [weight in grams of 1000 m] no detoriation or delamination after boiling.
C-Glass Veil & W/R Mat: - Moisture content, Size/Binder content LOI Test TM-005 & ASTM D 2584– Structural Glass content of
& Density- RMT-003, RMT-004 & RMT-005. Pipes and Fittings
Moisture Content : < 0.15 % [105ºC@3hrs] The glass content in the structural wall shall be,
Binder content : Nom. ± 30 % [LOI 600ºC@30 min.] For pipes, 70-82%,
Tex Number : Nom. ± 15 % [1m2 of the W/R mat / glass veil.] For Molded fittings, 65-75%
For Hand Lay-up fittings, 50-65%.
Conductivity Test (Determination of Electrical Resistance)
ONTW-42
The electrical resistance value shall be less than 10 X 106 Ohm.
Barcol Hardness Test of Pipes and Fittings ≥40.

ELEMENT
C (Carbon): Strength & hardening in steel
Mn( Manganese ): Toughness & Hardening second to carbon
Si (Silicon): Deoxidizer, moderate strengthener <0.3%
Al (Aluminium) : <0.008%Deoxidizer ↑mech. prop.+ toughness, Grain Refiner
Cr (Chromium): Hardness (low) - corrosion resistance (high)
Mo (Molybdenum): Hardenability - high temp tensile - creep Ω
V (Vanadium): Strength - Improves mechanical properties
Ni(Nickel): Hardening - cold toughness-low Temp. Application
Cu (Copper): Corr. Ω(low) - cracking (high), weathering (Corten)
P (Phosphorus): Causes cracking if too high
S (Sulfur): Aids in machining - Cracking problems like P
B (Boron): Very small amounts increase hardness
Ti (Titanium): Removes: Oxygen, S, N, and C, Grain Refiner
N (Nitrogen): Improves strength - lowers toughness
Nb (Columbium): Grain Refiner - ↑ mech.Prop. Strength+toughness
 Ferrite number FN) is a measure of = Chromium & Nickel equivalent in
an Austenitic stainless steel material. It should be between 3-7% max.

P-no. Reducing 41 Pure Ni P No. EN288 Base Metal

WPS 42 Ni-Cu:- Monel 500 ASS, 4-SG
Steel => 1 to 43 Ni-Cr Ferrite:- Inconel G-1, Gr.304, 316, 347
15F 44 Ni-Mo:- Hastelloy C22, C276 8 9 G-2,Gr.309, 310
Al => 21 to 45 Ni-Cr :- Incoloy 800, 825 G-3, Gr.↑Mn
26 46 Ni-Cr-Si G-4, Gr.254 SMO
Cu => 31 to 10 H 10 D&SD, Gr. 31803, 32750
35 MONEL: nickel-copper alloy R-405 (UNS N04405)
Ni => 41 to Nickel (plus Cobalt) 63.0 min, Copper .28.0 - 34.0
49
Ti => 51 to Inconel 625 : Nickel-Chromium-Molybdenum Alloy (UNS N06625)
53
Zr => 61 to
62 47
Ni-Cr-Tungstone
P No. EN288 Base Metal
1 1 C-Mn Steels, 4-SG-65,70, 80,? Ksi
3 4 0.5Mo-.5Cr,3-SG
4 5 1.25Cr-0.5Mo,2-SG
5A 5 2.25Cr-Mo
5B 5 5Cr-0.5Mo, 9Cr-Mo,2-SG
5C 6 Cr-V,5-SG

Material Root run / Filler Wire / Filling Base Metal / AWS Electrode Specification / Electrodes
Electrode Carbon Steel (AISI 1018,ASTM A36, A516)

304 SS on carbon steel / overlaying CS with SS. ER 309L

SA106, Gr. B (CS, Pipe Smls, ↑Temp.) E 6010 / ER 70-S2 / E 7018 A5.1=> E6010, E6013,E7018, E7024
SS, Gr. 310 (SA569, ↑Duct, ↑Weld, ↑Temp.) - / ER 310 Low-Alloy Steel (AISI 4140, 8620, ASTM A514, A519)
/ E 310 A5.5=> E8018-C1, E9018-B2
SA312, TP304 (Aus. SS,smls & wld Pipe, ↑temp. ) -/ Stainless Steel (AISI 304, 316,410, ASTM A240)
ER308L-16 / E 308L-16 A5.4=>E308L, E316L,E410NiMo
SA312, TP304L E 308L-16 - / ER308L / E 308L-16 Cast Iron (Ductile Iron, Grey Iron)
SA312, TP304H - / ER308H / E 308H A5.15=> ENi-CI, EniCu-A
SA312, TP347 - / ER 347 / E 347 Aluminium (A356, 5052,3003, 6061-T6)
SA312,TP316 - / ER 316 / E 316 A5.3=> E1100,E4043
SS, Gr. 410 (SA268, smls. & wld. Tube, Matc /Frtc ) - / ER 410 / E 410 Copper Alloys (B505 UNS C95400,Brass, Bronze)
SA 333 Gr.6 (smls. & wld. Pipe, ↓ temp.) E 6013 / ER 80S- A5.6=> E CuAl-A2, E CuMnNiAl
Ni-1 / E 7018-1 Nickel Alloys (Inconel 625,Hastelloy C22)
SA335, Gr. P5 (smls. Frtc AS pipe, ↑Temp.) - / ER 80S-B6 / ER502 /E A5.11=> ERNiCrMo-3, ERNiFe-1
8018-B6 / E502
Monel: A5.14=> ERNiCu-7 (UNS N04060)
SA335, Gr. P22 E6013 / ER 90S-B3/E 9018-B3
DSS: A5.4=> E2209, A5.9=>ER2209, A5.22=> E2209 T1-1
SA335, Gr. P11 E6013 / ER 80S-B2 /E 8018-B2
SA516, Gr. 70 E 6013 / ER 70-S2 / E 7018 -1
CS to SS - / ER 309L / E309L-16
AS to SS - / ER NiCr-3 / E NiCrFe-2
UNS N08825 - / ER NiCrMo-3 / E NiCrMo-3

Welding Variables WPS as per ASME Sec IX Details Welding Variables WPS as per ASME Sec IX
QW SMAW SAW QW GMAW / MIG/ MAG and FCAW GTAW /TIG
No. No. QW No. 255 QW.255.1 QW 256 QW 256.1
QW No. 253 QW. 253.1 254 QW.254.1 Details HFO CRO HFO CRO
Details HFO CRO HFO CRO 402 Joints E E E E
402 Joints E E E E
403 B/ Metals E SE E E E SE E E
403 B/ Metals E SE E E E SE E E
404 F/ Metals E SE E E E SE E E 404 F/Metals E SE E E E SE E E
405 Positions SE E E E E 405 Positions SE E E SE E E
406 Preheat E SE E E E SE E E 406 Preheat E SE E E E SE E E
407 PWHT E SE E E E SE E E 407 PWHT E SE E E E SE E E
408 Gas 408 Gas E E E E E E
409 E/Char. SE E E SE E E 409 E/Char. E SE E E SE E E
410 Tech E SE E E E SE E E
410 Tech E SE E E E SE E E

Welding Position NACE MR – 0175 : Sulphide Stress Cracking Resistant Metallic

ASME Sec IX BS EN Materials for Oilfield Equipment. Max. hardness of CS and low AS
Groove Fillet exposed to sour service - 250 BHN. Main requirement in NACE
Not mentioned about 3F/5F
Pi Plt Pi Plt Sd MR0175 -PWHT
1GR 1G 1FR 1F 1S PA F and down head = 1G/1F NACE MR – 0284 : Evaluation of Pipeline and Pressure Vessel
2F PB H-V = 2F Steel for Resistance to Hydrogen Induced Cracking.
2G 2G 2F 2S NACE TM – 0177 : Laboratory Testing of Metals for Resistance to
2FR PC H = 2G
 PF V-up = 3G/5G Sulfide Stress Cracking in H2S Environment
x 3G x 3F x
PG V-down = 3G/5G Raised face finish – AARH (Arithmetic Average Roughness Height)
PD H-V (OH) = 4F Low Temp. Service additional Mechanical Test – Impact
x 4G 4F 4F 4S
PE O = 4G Attribute of Tensile Test – YS, UTS, % Elongation
PF V-up = 3G/5G SS 316L contain less carbon than standard grade SS
5G x 5F x
PG V-down = 3G/5G To have a better corrosion resistant property ( Less carbon means less
Inclined pipe (upwards) =
H-LO45 Chromium carbide formation and hence less depletion of Chromium,
6G
6G x x x
Inclined pipe (downwards)= which enhance the Corrosion Resistance.)
J-LO45
6G

Long Radius Elbow Short Radius Elbow
C enter-to-Face dimension
1.5 D D It is calculated as : Static head + surface pressure head - the vapour
used typically where space is a constraint
fluid flow is also restricted
Eccentric Reducer:
Horizontal liquid reducers are always eccentric, top flat which
prevents the build up of air bubbles in the system.
Horizontal gas reducers are always eccentric, bottom flat, which
allows condensed water or oil to drain at low points.
To maintain elevation (BOP) in rack.
At the suction side of pumps to ensure air does not accumulate
Source of supply below pump => Top Flat
Source of supply above pump => Bottom Flat
Concentric reducers:
Used at Pump discharge, vertical pipeline etc.
NPSH: Net Positive Suction Head = is the pressure available at the
pump suction after vapour pressure is subtracted.
pressure of your product - the friction losses in the piping, valves and
fittings. It thus reflects the amount of head loss that the pump can
sustain internally before vapour pressure is reached.
Base Metal / AWS Electrode Specification / Electrodes
Cast iron to mild Steel => Lincoln. NI 55 or NI 99
Mild steel to Stainless steel =>
Electrode selection is determined from the base metal chemistries and
the percent weld admixture. The electrode should produce a weld
deposit with a small amount of ferrite (3-5 FN) needed to prevent
cracking. When the chemistries are not known, our Blue Max® 2100
electrode, which produces a high ferrite number, is commonly used.
Dissimilar Metals: Welding Stainless Steel to Mild Steel

Thumb Rule: What is standard?

Spanner size for given bolt =1.5 x diameter of Bolt
Current (Amp) = [Diameter of Electrode (mm) X 40] + 20
Undercut allow => 0.8 mm / 5 %
Tungsten electrode Tip =>a length = approx. 2 to 2.5 times E dia.
stickout length = 2 to 3 times the electrode dia.
Constant current (drooping characteristic) power source:
 MMA and manual TIG
 Large Δ in arc volt. = small Δ in welding amp. ± 10v = ± 5 amps
Constant voltage (flat characteristic) power source:
 MIG/MAG, FCAW and SAW
 Small Δ in arc volt. = Large Δ in welding amp. ± 10v = ± 5 amps
A Standard can be defined as a set of technical definitions and
guidelines that function as instructions for designers, manufacturers,
operators, or users of equipment. Ex ASME 31.3 is a standard for
process piping.
What is code?
A standard becomes a Code when it has been adopted by one or more
governmental bodies and is enforceable by law, or when it has been
incorporated into a business contract.
What is specification?
Specifications clearly and accurately describe the technical
requirements of any given product or process and are used heavily by
purchasing departments for controlling the quality of incoming materials.
Ex API 5L

Hardness: => Ω to plastic deformation Quality Control Quality Assurance

• Vickers hardness test - uses a square-base diamond pyramid indenter. Product Process
• Rockwell hardness test - uses a diamond cone indenter or steel ball. Reactive Pro-active
• Brinell hardness test - uses a ball indenter Staff Function
Line Function
240HV10 = hardness 240, Vickers method, 10kg indenter load
Find the defects Prevent the defects
22HRC = hardness 22, Rockwell method, diamond cone indenter (scale C)
Walk through Quality Audit
238HBW = hardness 238, Brinell method, tungsten ball indenter
22 HRC = 248 HV10 Testing Defining Process
2
UTS (N/mm or MPa) = 3.39 x Brinell Hardness Number Inspection Selection of tools

(HB) Checkpoint Review Training

C% ↑=>↑ harder and stronger through heat treating, ISO 9000
=> ↓ ductile / Regardless of the HT weldability /melting point
Proj.: UMM LULU
Aus. SS welds and CS ≤ 22 HRC (237 BHN / 250 Hv10).
≤ 200 BHN, NACE MR 0175/ISO 15156
NI- Alloy 625/825 Weld ≤ 40 HRC (370 BHN / 392 Hv10), 200 BHN,
NACE MR 0175/ISO 15156
WPQ: Welder Ability to deposit sound weld metal.
Min acceptable mechanical test in a WPQ
Root Bend – 1 No; Face Bend – 1 No Or Side Bend – 2 Nos.
Pipeline Welding & Welder => ASME SEC IX
Structural Steel Welding & Welder => AWS D1.1
6G Qualified Welder => Qualified for all position
2G+5G = 6G, for welder test
Essential Variables- in the WPS:
affect the Mechanical Properties (other than Notch toughness) of the
weldment. ( P No, Welding Process, A No, Filler metal, electrode,
preheat, PWHT etc)
PQR Required => when Essential variable Changed.
Preheat: Slow down the cooling rate in weld area.
Avoid cracking of the weld metal or heat affected zone.
Remove entrap hydrogen gas.
Prevent formation of harden-able microstructure => brittleness
Help to produce more ductile metallurgical structure => Prevent Cracking
reduces the shrinkage stresses
Notch toughness properties ensured
The area be measured to insure proper preheating:
at least equal to the thickness of the thickest member, but not less than
3 in. (75 mm) in all directions from the point of welding.
Min. reqd tensile value of an E7018 Electrode => 70000 PSI
Transfer modes in GMAW => globular, short-circuiting, and spray
DCRP = DCEP and DCSP = DCEN
What extra precaution must be taken with low hydrogen electrodes
Holding the electrode in oven at 250-300⁰C
FCAW –S => SELF-SHIELDED FLUX CORED ARC WELDING
FCAW –G => GAS-SHIELDED FLUX CORED ARC WELDING
MMAW => Manual Metal Arc welding OR SMAW => Shielded Metal Arc Welding
GMAW => Gas Metal Arc Welding
a) MIG =>Metal Inert Gas
b) MAG=> Metal Active Gas
SAW => Submerged Arc Welding
OFW => Oxy-Fuel Welding
GTAW => gas tungsten arc welding , OR TIG => Tungsten Inert Gas welding,
PAW=> Plasma Arc Welding

Interpass Temp.: The yield and ultimate tensile strengths of the weld
metal are both a function of the interpass temp. High values of
interpass temp. tend to reduce the weld metal strength.
Temperature Indicating Sticks
PWHT: To relieve the stress developed during welding.
Care of Base Materials before cladding
Care and preservation of solid CRA, CRA-clad or -lined materials is very
important during fabrication and welding and should begin as materials are
received. CRAs should not be stored outside without adequate protection.
Plate clamps and other hard metallic devices should not be used in handling,
unless the CRA surfaces are protected from marring. When stacking these
materials, new, clean wood blocks should be used to separate each piece.
Chemical elements such as sulphur, phosphorous, lead, zinc and copper can
contaminate CRA and cause embrittlement if not completely removed before
welding and heat treating. These contaminants may be present in cutting
fluids, grease, oil, waxes, household detergents and soaps, primers, marking
crayons and temperature-indicating crayons. They must be removed by
swabbing the affected area with a nonchlorinated solvent such as toluene,
methyl-ethyl-ketone (MEK), acetone or isopropyl alcohol. In addition, the
chemical content of the hydrotest water, cleaners, paints and inks must be
carefully selected to avoid the contaminants

CE = C + + +

(CE) Weld ability (CE) Preheat

Up to 0.35 Excellent Up to < 0.4 No
0.36–0.40 Very good 0.4 to ≤ 0.6 Yes
0.41–0.45 Good > 0.6 Yes + post-heat
0.46–0.50 Fair
Over 0.50 Poor

Mild Steel (covered )/ SMAW Process / AWS A5.1-91 Low Alloy (covered )/ SMAW Process / AWS A5.5-96
E 60 1 0 E 80 1 8 -
Electrode 60 ksi position Coating & current B1
Position: 1 – F, H, V, O; 2 – F, H; 3 – F, H, HD,O Electrode 60 ksi position Coating & current Chem. Comp.
Coating & current:
Digit Type of Coating Welding Current
0 Cellulose Solution DCEP Arc Energy = KJ/mm [TS = Travel Speed
1 Cellulose Potassium AC, DCEP/N
2 Titania Sodium AC, DCEN
3 Titania potassium AC, DCEP/N
(mm/Minuit)]
4 Iron Powder Titania AC, DCEP/N
5 Low Hydrogen Sodium DCEP Heat Input = KJ/mm
6 Low Hydrogen Potassium AC, DCEP
7 Iron Powder Iron oxide AC, DCEP/N [TS = Travel Speed (mm/Minuit)
8 Iron Powder Low Hydrogen AC, DCEP
K = thermal efficiency factor = 1.0 for SAW, 0.8 for MMA, SMAW,
9 Iron oxide Sodium AC, DCEP
GMAW (MIG/MAG), FCAW-S, FCAW-G, 0.6 – TIG, Plasma]
SAW Wire / Flux: Carbon steel electrode and flux
Specification AWS 5.17
F 7 A 6 – E M 12 K or F 6 A 4 – EC 1
Flux
Min. UTS 7 x 10 ksi
A= For welded, P =For PWHT
X 10 ˚F Charpy 27Jule
E=Solid electrode, EC – Composite Electrode
l- Low, M – Medium, H – Mn content
/ 100 % C content, here 0.12%
Made form semi-killed steel
ADMA: CP-108 => Min. Spacing between weld toes.
1. Weld joint of Non pressure part to pressure weld joint => 2t or 40 mm
whichever is the smaller.
2. Branch connection Weld joint to Longitudinal / circumferential seam => 75
mm at least.
3. circumferential seam to circumferential seam
=> at least 4t for Category “B” Service
=> at least OD or 150mm whichever is the larger for Category “A” Service
4. Longitudinal seam to Longitudinal seam OFFSET
=> at least 15º for Long seam
=> at least 90º for Spiral seam
5. Miter weld joint => 50 mm or 6 x Pipe wall Thk. whichever is the greater.
6. For other type joint see the CP 108.
7. Category “A” Service =>all Hazardous, sour or corrosive service. Other
Category “B”.

ADMA: STD-128 (Standard for pipe fittings) ADMA: STD-121 (Relief Valve)

ADMA: STD-119 (Glob Valve) ADMA: STD-118 (butterfly Valve)

ADMA: STD-117 (Check Valve)
ADMA: STD-116 (Ball Valve)

141 – TIG, 13 - SMAW

Positive Material Identification(PMI):
The X-ray alloy analyzer technology is hand held and portable allowing
analysis to be performed on-site on materials that are difficult to
transport to a laboratory environment.
Detecting fine surface cracks => Shear wave ultrasonic X False
=> Upto 3 mm depth MPI √
True
Detecting side wall lack of fusion in GMAW => RT X False
Dry powder overhead MPI => False
CSWIP: Type of Joint: Autogeous Weld: Fusion Weld without Filler metal –Plasma, OFW
BS EN 970 (Visual Butt => 135 -180⁰, Homogeneous: no significant diff. Mech. Prop & Chem. Comp.
Inspection): T => 5 upto and 90⁰ Betw Weld Metal & Parent Metal
=> Every 1 yr. vision Check Corner => 30 - 135⁰ CS plates welding with matching CS electrode.
=> Illumination 350 Lux / Edge => 0 - 30⁰ Heterogeneous: Have significant diff. Mech. Prop & Chem.
Recommended 500 Lux
=> 600 mm Distance Cruciform => + Comp.
=> not < 30⁰ Lap => 0 - 5⁰
Betw Weld Metal & Parent Metal.
=> x2 to X5 Type of Weld: Butt & Fillet
Root Face: 1-2mm (CS Com. WP) Repair of cast Iron with Ni-based alloy electrode.
Welding Position: ISO 6947
PA(1G/2FR), PB(2F/2FR), Root Gap: 1- 3mm Dissimilar: Have significant diff. Mech. Prop & Chem. Comp.
PC(2G), PD(4F), PE(4G), Land: Straight Portion of fusion face Betw both Parent Metals to be weld
PF(3G/3F↑) & PG (3G/3F↓), btw. Root face and curved part of J or CS Lug weld to Aus. Steel Pr. Vessels.
PH (5F/5G↑), PJ(5F/5G↓) U weld Heat Effected Zone: Part of Parent metal Metallurgically effected
H-LO45(6G↑), J-LO45 (6G↓) by
a (Throat)= 0.707 x z (leg length)
heat by Thermal Cutting / welding but not melted.
PE PD
Toe: Boundary btw. Weld face & Parent metal / Btw. Runs.
PF PG PC High tress concentration,=> Fatigue crack, cold crack.
PA PB

Dim Tolerance AWS D 1.1 : 5.23.4 Beam and Girder Camber (without Designed

5.23.2 Straightness of Columns and Trusses: Concrete Haunch):
           at mid span => ± 40 mm  ≥ 30 m
  1mm/m   [10m]   10mm  [15m] 10mm+ 3mmx
                             => ± 20 mm  < 30 m
5.23.3 Beam and Girder Camber (Typical Girder):            at supports => 0 for end supports
           at mid span => ­0, +40 mm  ≥ 30 m                              => ±  3 mm for interior supports
                             => ­0, + 20 mm  < 30 m
           at supports => 0 for end supports           at intermediate points=>  ± 
                             => ±  3 mm for interior supports
5.23.5 Beam and Girder Sweep: ±1 mm x No. of meters of total length

          at intermediate points=>  – 0, +  AWS D1.1 gives requirements for stud welding. FALSE

Does AWS D1.1 require a welder to be qualified when pre-qualified

weld procedures are used? YES

AS => Australian; DIN => Germany; BS => Great Britain; ISO =>
International; JIS => Japanese; AISI / ASTM / ASME / SAE => Dissimilar Metal Welding:
United State of America
AISI /SAE => American Iron and Steel Institute-Society of
Automotive Engineers.
ASME => American Society of Mechanical Engineers
/Code
ASTM => American Society of Testing Materials / Not
code
Soluble Paper dam is a water-soluble material used for restricting the
purging gas within the pipe.
. service; (b) for High-Temp service or where Tress

The tell-tale hole can be used for two purposes:

1. During the welding the trapped gases can escape easily without
causing a problem to the welds.
2. Testing the weld for leak as indicated above.
relief on ferrite side required
Piping: Ref. (Related ARAMCO Question) Difference between Pipe and Tube:
Dimensional inspection of Raised Face Weld Neck Pipe – NB : Tube – OD
flange =>a) No. of Hole , b) Rating, c) Internal Diameter, Nominal Size, OD & Schedule :
Schedule = Wall Thickness
d) soundness of bevel edge, e) raised face roughness, f)
Round Shape : Round, Square, Rectangular, Oval, Octagon Shape
thickness of hub. Refer by ID : Refer by OD
ASME Code for piping: General Product : Specific Product , Tighter Tolerance
ASME B31.1 = > Power Piping, ASME B31.3 = > Process Piping Measure OD (inch) & search in pipe chart
Stub In or Stub On Connection: Does appear : Dose not appear
Stub-in is used when the Branch is more than one size smaller than
main pipe. For a given NPS, the OD stays fixed and the wall thickness increases with schedule .
Stub-on is to be used when the Branch is equal to or one size For NPS ⅛ to 12 inches, the NPS ≠ OD
smaller than main Pipe For the size 14” and onwards NB = OD
ASME B36.10M and B36.19M
Equivalence Nominal Pipe Size (NPS) to Nominal Diameter (DN)
Nominal Pipe Size (NPS) is based on inches, and DN (diamètre
nominal/nominal diameter) in millimetres.
ISO 6708 norm defines Nomimal Diameter for pipe components.
NPS [INCH] NB DN [mm] NPS [INCH] NB DN [mm]
1/2 15 2 50
3/4 20 3 80
1 25 4 100
1.1/2 40 5 125
Piping Test Pack content before Hydro test.
P & ID Drawing with limits =>Spool List=> ISO with
Mark-up=> Weld summary sheet with NDT report=> Weld
visual report=> final dimensional report=> Calibration cert.
(Gauges & Chart recorder)=> Water quality certificate=>
Pressure test report & Chart:
- Flange Pressure Rating.
- Flange Jack Screw have or not.
- Support welding have or not
- Spool identification / Tagging.
- Two Pressure Gauge Location.
-

Ref: UAE Collection => metal and non-metal => Engineering materials
Engineering Materials Metallurgy:
↓ a) Physical Metallurgy b) Extraction Metallurgy a) Process Metallurgy
For selecting the materials:
↓ ↓ ↓ a) Commercial factors such as: Cost, availability, ease of manufacture.
Metals Non-metals Metalloid b) Engineering properties of materials such as:
↓ ↓ ↓ Electrical conductivity, strength, toughness, ease of forming by
↓ ↓ Synthetics Naturals extrusion, forging and casting, machinability and corrosion Ω.
Ferrous Non-Ferrous Ferrous Metals:
↓ S = Steel, CI = Cast Iron, WI = Wrought Iron,
LCS = Low Carbon Steel, MCS = Medium Carbon Steel, HCS = High
Metal------ Alloy
Carbon Steel, AS = Alloy Steel.
S---CI---WI ↓
GCI = Gray Cast Iron, WCI = White Cast Iron, MCI = Malleable Cast Iron,
Al-Cd-Cr-Co-Cu-Au-Pb-Mg-Mn-Mo-Ni-Pl-Ag-Sn-Ti-W-V-Zn
HDCI = High-dity Cast Iron, ACI = Alloy Cast Iron
GCI---WCI---MCI---HDCI---ACI
Alloy => Brass(Cu+Zn)-Tin Bronze(Cu+Sn)-Al Bronze(Cu+Al)-Cu Ni
LCS---MCS---HCS---AS see next page
Alloy-Al Alloy-Mg Alloy-Zn Based Die-casting Alloy-Sn Pb alloy
Al -Aluminium, Cd – Cadmium, Cr – Chromium, Co – Cobalt, Synthetics Materials →Acrylic
Cu- Copper, Au – Gold, Pb – Lead, Mg- M agnesium, →Plastics →Thermoplastic →PTFE
Mn – Manganese, Mo – Molybdenum, Ni – Nickel , Pt –Platinum,
Ag – Silver, Sn – Tin, Ti – Titanium, W – Tungsten, →Thermosetting →Polythene
V – Vanadium, Zn – Zinc. →Ceramics →Glass →Polyvinyl Chloride (PVC)
Tin Bronze (Cu + Sn) Aluminium Alloy → Porcelain →Nylon
→Phosphor Bronze → Heat Treatable (wrought) →Polystyrene
→Gun Metal → Heat Treatable (cast)
Tin-lead Alloy → Non-Heat Treatable (wrought) → Cemented Carbides
→Soft Solder → Non-Heat Treatable (cast) →Composites → Carbon Fibre
→Bearing Metal Naturals Materials → Concrete
Asbestos – Colourants – Coal – Cotton – diamond – Emery – → Glass Reinforced Plastics (GRP)
Gases (air Derivatives) – Glues ( Animal Derivatives) – Gums
(Vegetable Derivatives) – Granite – Mica – Oil – Quartz – Rubber Epoxides - Alkyed – Phenol formaldehyde
–Sapphire – Wood – Wool (Bakelite) – Melamine formaldehyde - Urea formaldehyde

Metal Structure and Bounding in Materials:

Colourants – Dyes - Pigments Nucleus [Proton (+ve) + Neutron] + Electron(-ve) => Atom
The number of electrons => atomic number / element of the atom
Gases (air Derivatives) Two or more atoms => molecule.
Argon – Methane (natural) – Neon – Nitrogen – Oxygen –Helium [Two or more atoms, either of one type or of different
types, are joined together chemically, the unit which is produced is
Factors affecting materials properties: called a molecule.]
1. Heat treatment, 2. Processing, 3. E nvironmental Reactions Maximum number of electrons in an orbit = 2 n2 [n = Orbit Number]
Quenching Hot-working Rusting Steel Atom ± Electron = Ions, Atom + Electron = (-ve)Ions, Atom - Electron
Annealed Rolled Steel Beam Dezincification of Brass = (+ve) Ions,
Work hardened Forging Degradation of plastic The outer shell electrons are called valence electrons.
Normalized Extruded Sections Bonding in Materials:
in non ferrous metal 1. Ionic Bond => the transfer of electrons between the atoms, sodium
Cold-working and chlorine ions are formed as shown in this reaction :
Wire Drawing, Rivet Heading, Sheet metal Pressing Na + + Cl ‾ → Na +Cl ‾

Metal ion (+) Non-metal ion (-) Outer orbit

Outer orbit e
+ e + + II +
3. Metallic Bond =>
e Metallic bonds are found in metals like zinc.
Transferred electron Shared electrons 4. Van der Waal’s Force => include attractions and repulsions between
atoms, molecules, and surfaces, as well as other intermolecular forces.
2. Covalent bond => electrons are shared (as opposed to They differ from covalent and ionic bonding in that they are caused by
transfer) between atoms in their outermost shells to achieve a stable correlations in the fluctuating polarizations of nearby particles.
set of eight.
Methane => H H Attractive interactions resulting from dipole-
I dipole interaction of two hydrogen chloride molecules
H C H => H--C—H Crystalline Structures :
1. BCC, 2. FCC, 3. HCP
I
H
H
1. Body-Centered-Cubic [BCC]: Cr, Mo, Nb, W, Fe The crystalline state :
N = 8* 1/8 + 1 = 2 the metals and its alloys have crystalline structure where the atoms are
2. Face-Centered-Cubic [FCC]: Al, Cu, Pb, Ni, Fe, Au, Ag rearranged in an organized shapes which it is called as the crystal lattice.
N = 8 * 1/8 + 6 * 1/2 = 4 This lattice consisted of another smallest grouping of atoms each one is
3. Hexagonal-Closed-Packed [HCP]: Be, Cd, Mg, Zn called the unit cell.
N = 12 * 1/6 + 3 + 2 * 1/2 = 6 N = NC + NI + NF
N : Nos. of the basic atoms in the unit cell.
N C : Nos. of the atoms in the corner.
N I : Nos. of the atoms in side the cube.
N F : Nos. of the atoms in the center of the face.
The atomic packing factor [A.P.F]:
For, BCC => 0.68, FCC => 0.74, HCP => 0.74
Mechanical properties of materials:
Iron (Fe) Metal at Room Temperature => BCC 1. Strength => ability to withstand forces (tensile, compressive or
Iron (Fe) Metal at > 910⁰C => FCC shear) acting upon it without fracture occurring. A material's strength is
Iron (Fe) Metal at > 1400⁰C=> BCC usually given by its tensile strength – the force required to pull it apart.
2. Toughness => Toughness can be expressed as a material's
ability to withstand shock loads without fracture.
Most tools need toughness especially hammers, spanners, chisels,
punches and Links of chains. Impact Test
3. Malleability => ability to be shaped by hammering, rolling or
pressing , without fracture occurring.
All ductile materials => malleable but not all malleable materials => ductile
Malleability ↑=> Temp.↑; Malleable materials =>Au, Ag, Pb, Al & Cu
Heating a material in a forge before hammering or pressing into shape.
4. Hardness => ability of a material to resist indentation or wear .
Ex. cutting tools
5. Ductility => ability of a material to be drawn out in tension
without fracture. Ex. Copper Wire. Bend Test
0.2% or 0.002
Ferrous materials: => 1) Steel, 2) Cast Iron, 3) Wrought Iron
Steel : =>
1) Plain Carbon Steel => C% = < 0.3 to 1.5
a) Low < 0.3 C%, Commonly used
Low Carbon steel = often called Mild Steel
b) 0.3 < Medium < 0.6 , ↑hardness & TS, ↓Ductility & Machinability
c) 0.6 < High < 1.0, challenging to weld
d) 1.25 < Very High ≤ 2, metal cutting tools and truck springs
2) Low Allow Steel => C% < 0.25 (Often < 0.15)
Add Alloying Element – Ni, Cr, Mn, Si etc.
+ve influence of Alloying element ↑Low Temp. Notch
Toughness, Strength at room temp. and Corr. Ω
-Ve influence of Alloying element crack susceptibility
Low Hydrogen welding Process
3) High allow Steel => Stainless Steel => Cr% ≥ 12 and Ni
crystalline structure a) Austenitic, b) Ferritic and c) Martensitic
a) Austenitic => 18-20% Cr and 8-10% Ni
=> MPT not possible
=> not hardenable by heat treatment
=> “L” denotes C% < 0.03% [316L]
=> FCC
=> 316 and 304 SS non magnetic
b) Ferritic => 12 - 27 % Cr. And Ni
=> Mild steel (carbon steel with up to about 0.2 wt% C)
consist mostly of ferrite
=> ↑ductility and formability
=> BCC
=> highly resistant to chlorides.
Gr. 400 Serise =>high permeabilities / attract a magnet / MPT possible
and c) Martensitic => 12 % Cr and 0.12% C
Gr. 400 Serise =>high permeabilities / attract a magnet / MPT possible
=> Body Centre Tetragonal (BCT)
=> Can be tempered and hardened
=>Tempered ↑hardness and ↑ toughness
6. Stiffness => A stiff material requires high loads to elastically
deform. A stiff material has a high Young's modulus.
7. Brittleness => A material is brittle if it fractures without appreciable
deformation under an applied load , particularly a suddenly applied load.
Brittleness = opposite of ductility, ↑ hardness = ↑ brittleness
The glass covers on fire alarm systems. Weak in tension strong in compression. Grey cast
iron is a good example of this
8. Elasticity => the ability of a material to return to its original shape and
size after a load causing it to deform has been removed
9. Plasticity => the ability of a material to remain deformed after the load which
is causing the deformation has been removed. Plasticity needs to be shaped by bending,
drawing or pressing.
CREEP TEST => Even at constant stress, materials continue to deform
for an indefinite period of time. This time – dependent deformation is
called creep. creep test is commonly thought of as a high-temperature
test.
Nominal stress – Strain OR Conventional Stress – Strain diagrams:
Law of proportionality is valid up to a point [A] (the limit of
proportionality or the proportionality limit.).
The limiting point [B] is termed as Elastic Limit.
[A ]– [B] => Elastic but not Law of Proportionality
[C] and [D]- Beyond the elastic limit [B] plastic deformation occurs and
strains are not totally recoverable. [C]= upper yield points and [D] = lower
yield points. The stress at the yield point is called the Yield Strength (Proof
Stress). the yield point is so near the proportional limit => offset method is
applied => drawn parallel to the straight line portion of initial stress diagram by
offsetting (2%).=> especially for the low carbon steel
[E] = The maximum load which the specimen can with stand without
failure is called the load at the ultimate strength.
[F] Beyond point E, the bar begins to forms neck. The load falling from
the maximum until fracture occurs at F.
https://www.youtube.com/watch?v=9hG38JnM4nA
Duplex Stainless Steel :
=> 50% Austenitic + 50% Ferrite (ratio may be 40/60)
=> 22-25% Cr and 5% Ni (with Mo and N)
=> ↑ YS and ↑ stress Corr. Cracking Ω to chloride than Austenitic
=> UNS S31803/S32205
Super Duplex Stainless Steel :
 Duplex steel, Pitting Resistance Equivalent Number (PREN) > 40,
where PREN = %Cr + 3.3x(%Mo + 0.5x%W) + 16x%N.
 Cr%≥25
 UNS S32760
 ADMA Requirement given below. Need Original MTC or Wet TRUE
COPY stamp of first purchaser.
 Hardness 318 HV10
 NORSOK M650
 Rp0.2≥550MPa; Rm ≥ 750Mps, A≥40.0
 Impact 45J Avg./35J Single, at -46˚C for ≥ 6mm Thk. ASTM A370
Sub-size Factor 7.5mm - 5/6, 5 mm – 2/3.
 ASTM G48 Method A: 50˚C, 24 Hrs, No pitting 20x Magnification,
 Wt. Loss < 4.0 g/m2.
Stainless steels are grades of steel with a mass fraction of
chromium of at least 10.5 % and a maximum of 1,2 % of
carbon.
UNS S31803 or S32205 weld samples (22% Cr duplex)
UNS S32550, S32750, UNS S32760 weld samples (25%
chromium "super"

AD197-473-G-00503 ADMA Spec

7.4 ACCEPTANCE CRITERIA PMI
Material - tolerance of +/- 10%.
Welds - tolerance of +/-12.5%.

NDT RADIOGRAPHY

Set of IQI: ASME Sec V-2015, T-276, Page No. 30

Selection of IQI: ASME Sec V-2015, T-276, Page No. 32

Set of IQI: ASME Sec V-2015, T-276, Page No. 32

https://www.youtube.com/watch?v=1UQ40agA8Aw
Metallurgy of Iron
https://www.youtube.com/watch?v=Bmd7T6SLKSE
https://www.youtube.com/watch?v=uh4obOPltpw
Iron crystal structures
Magnetic Particle Testing 9) Lifting Capacity: 10 lbs (4.5 Kgs)- AC Yoke
1) Applicable only for FERROMAGNETIC materials. Iron, nickel and 40 lbs (18 kgs)- Permanent magnet
cobalt alloys 10) Magnetic Field Strength: Shims Gages (Indicators)
2) Heated e Material to temp. Curie Point => Demagnetise Pie Gages
Iron => 770⁰C, Steel => 880⁰C, Nickel => 380⁰C, Cobalt => 1121⁰C Gauss/Tesla Meter (Field Strength Meter)
3) Good Lighting > 500 Lux. A light intensity of at least 1000 lux (100 Slotted strips, also known as Burmah-Castrol Strips
fc) is recommended /( 1076 lux (100 fc) is recommended
ASTM E709 MPI or E165 LPT)
4) Surface Temp: Dry powder for hot surface 316˚C
Wet Particle 50˚C
5) Dark area UV lamp
6) White background lacquer in order to contrast with magnetic particle.
7) A.C. Yoke 1-2 mm depth from surface
8) D.C. / Permanent magnate 4-7 mm depth from surface.

Magnetic Field = describes a volume of space where there is a
change in energy within that volume = a magnetic field is a change
in energy within a volume of space.
Magnetic poles = never been detected in isolation = a dipole is an
object that has a magnetic pole on one end and a second, equal but
opposite, magnetic pole on the other.
A magnetic field is produced whenever an electrical charge is in
motion. The strength of this field is called the magnetic moment.
All materials are affected in some way by a magnetic field.
Ferromagnetic = a large, positive (attracted) susceptibility to magnetic
fields = able to retain the magnetic properties = Iron, nickel, and cobalt
Magnetic properties (Ferromagnetic) = atoms carry a magnetic
moment + the material is made up of small regions known as magnetic
domains.
Magnetic domains can be detected using Magnetic Force Microscopy (MFM)
Magnetized = the magnetic domains within the material are aligned.
Magnetically saturated = all of the domains are aligned.

Diamagnetic = a weak, negative (repelled) susceptibility to magnetic

Magnetic Lines of Force :
fields = does not retain the magnetic properties = copper, silver, and gold
Paramagnetic = a small, positive (attracted) susceptibility to magnetic => the exit poles = North, the entrance poles = South
fields = does not retain the magnetic properties = magnesium, molybdenum, => seek the path of least resistance
lithium, and tantalum.
Magnetic Lines of Force :
=> never cross one another The hysteresis loop
Wider - narrower
=> all have the same strength ↓ Permeability ↑
=> Density decreases, higher permeability to lower ↑permeability.
Retentivity ↓
=> Density decreases, increasing distance from the↑poles.
Coercivity ↓
↑ Reluctance ↓
=> north to south in air and south to north in materials
↑ Residual
Magnetism ↓
When a material is placed within a magnetic field, the magnetic
forces of the material's electrons will be affected. This effect is
known as Faraday's Law of Magnetic Induction Retentivity : ability to retain a certain amount of residual magnetic field
right-hand clasp rule = If a person grasps a conductor in one's when the magnetizing force is removed after achieving saturation.
right hand with the thumb pointing in the direction of the current, the Residual Magnetism or Residual Flux - the magnetic flux density that
fingers will circle the conductor in the direction of the magnetic field remains in a material when the magnetizing force is zero.

Coercive Force - The amount of reverse magnetic field which must

be applied to a magnetic material to make the magnetic flux return to zero.
Permeability, m - A property of a material that describes the ease
with which a magnetic flux is established in the component.
Reluctance - Is the opposition that a ferromagnetic material shows
to the establishment of a magnetic field. Reluctance is analogous to
the resistance in an electrical circuit.
m = B/H
SI Units SI Units CGS Units
Quantity
(Sommerfeld) (Kennelly) (Gaussian)
Field H A/m A/m oersteds
Flux Density
B tesla tesla gauss
(Magnetic Induction)
Flux f weber weber maxwell
Magnetization M A/m - erg/Oe-cm3

Painting & Coating Holiday Voltage Calculation :

http://www.technical- V=525√T where “T” is the coating thickness in mils as per NACE
avenue.com/Portals/0/datasheet/Fischer/PMP10%20Duplex_Phasco http://tinker-rasor.com/wp-content/uploads/2013/09/Electrical-
pe.pdf
Inspection-of-Coatings-on-Concrete.pdf
Coating Thk. Measuring Method
• Magnetic induction method (MI): DIN EN ISO 2178. High Voltage Detector (in excess of 500 V), coating film exceeds 0.5
• Amplitude-sensitive eddy current method (AEC): DIN EN ISO 2360. mm = 20 mil = 508 micron
• Phase-sensitive eddy current method (PEC):ISO/DIS 21968 (draft)
Low Voltage Holiday Detector (5 to 90 V dc)
AEC Lacquer http://compass.astm.org/EDIT/html_annot.cgi?D5162+08
MI

PEC Zinc As per MNL 01 ADMA Spec. Clause No. 10.2

Holiday volt => 100 Volts per 25 µm (1 mil), Thumb rule
Iron / Steel

Paints = Pigments + Binder + Solvents

Coating An alternative to Table 1, the test Pigment – fine solid particle /Protection Opacity & Colour
Coating M voltage is represented by the
Thick. Binder – Oil & Resin / Film Former & Cohesion
Thick. Units Value
Range expression: V = M √Tc, Pigment – Organic & water / Reduce viscosity
mm <1 3294 Where, V = Testing voltage, Tc =
mm >1 7843 coating thickness, and M = a
constant dependent on the
Substrate (Steel)
mil < 40 525
thickness range and the units of Surface preparation
mil > 40 1250 thickness as follows: Primer – Wets & adheres to substrate / Inhibitor
Intermediate – Built film thickness
Final - Ω to environments / aesthetics
 Ultrasonic Test Wave type in solid : Particle vibration
Ref: C→Removel HD → 1_Impt DOC SERVIEC LIFE →UAE COLLECTION →UT Level III study → Ultrasonic
Testing
Longitudinal : Parallel to wave direction
Sonic Range Ultrasonic Range / Bats Transverse (Shear):Perpendicular to wave direction
Infrasonic Musical Range 0.25 x 106 to 20 x 106
Surface (Rayleigh): Elliptical orbit - symmetrical mode
Dogs Voice Testing Plate Wave – Lamb: Component perpendicular to surface (extensional wave)
Human Plate Wave – Love: Parallel to plane layer, perpendicular to wave directio
Stoneley (Leaky Rayleigh Waves): Wave guided along interface
101 102 103 104 105 106 107 108 Sezawa : Ant symmetric mode
I I I Angle in degree Trigonometric function Value
Hertz Kilohertz Megahertz Sin Cos tan sec
35 0.57 0.82 0.70 1.22
Wavelength: The distance between any point on a wave and the
45 0.71 0.71 1.00 1.41
equivalent point on the next phase. 60 0.87 0.50 1.73 2.00
Frequency: The number of times the wavelength occurs in one second. 70 0.94 0.34 2.75 2.92
Amplitude: The strength or power of a wave signal. The "height" of 80 0.98 0.17 5.67 5.76
a wave when viewed as a graph.

V=fx -----1 Acoustic impedance: V = Velocity [ mm/s] Z = Acoustic impedance [g/m2s]

Z=Vx -------- VR = Thin rod Velocity [ mm/s] Z1 = Z of Incident Wave mat.
Thin rod velocity VL = Longitudinal Velocity [ mm/s] Z2 = Z of Transmitted Wave mat.
- 5 VT = Transverse Velocity [ mm/s] R = Co-eff. Of Energy reflection
VR = ------2 f = Frequency [Hz] for normal incidence
R= ------ = wavelength [mm] T= Co-eff. Of Energy Transmission
Longitudinal wave velocity r & i = angle of refraction & angle
E = Young’s Modulus of elasticity of incidence
6
[dynes/mm2] Vi & Vr = Velocity in incident
VL = ----3 T+R=1 ----
G = Share Modulus of elasticity medium & Refracted medium
- -7
[dynes/mm2] ni & nr = Refractive index incident
Transverse wave velocity Snell's Law:
= Material density [g/mm3] medium & Refracted medium
N = Near Zone
-- = Poisson’s ratio
VT = = ----

-8 Ф = half beam angle [Red.]

4
D = Transducer Dia. [mm]

i Cirt = Sin -1(V i/V r) - - - -10

Ф = Sin-1 --

-9
= Sin-1 - - - -11
N=

= (

= ---

-12

S = Skip distance
B = Beam Path - - - - - - 13
d 1 = Depth of defect
Ѳ
S 1 = Surface Distance
- - - - - - 14
S
b 1 = Beam Path <
S/2 d1 = b1 cos Ѳ - - -15
d 2 = Depth of defect
Ѳ B/2 B/2S1 = b1 sin Ѳ - - t- 16
S 2 = Surface Distance d2 = 2t – b2 cos Ѳ--17
b 2 = Beam Path > S2 = b2 sin Ѳ -- - - 18

b2 = +x

S1
S2
t Ѳ B/2 xѲ b1 d2 td1

VT VL VT Z (g.cm -2.S -1 ) ρ(g/cm 3)

VL (m/s -2
Z (g.cm .S ) -1 3
ρ(g/cm ) Material (m/s) (m/s) x 10 5 x10 3
Material (m/s) ) x 10 5 x10 3
Tungstan 5180 2870 99.80 19.27
Aluminium 6320 3080 17.00 2.69
Glass 5770 3430 14.40 2.50
steel (Iron) 5900 3230 46.50 7.88
Lucite 2670 1120 3.20 1.20
S. Steel(302) 5660 3120 45.50 8.04
Teflon 1350 - 3.00 2.22
S. Steel(410) 7390 2990 56.70 7.67 Nylon 1800 - 2200 1.80 - 2.20 1.00 - 1.00
Cast Iron: from 3500 2200 25.00 7.14
Quartz 5730 - 15.20 2.65
Cast Iron: to 5600 3200 40.00 7.14
Perspex 2730 1430 3.20 1.17
Copper 4700 2260 42.00 8.94
Glycerin 1920 - 2.40 1.25
Brass 3830 2050 33.00 8.62
Water 1483 - 1.48 1.00
Nickel 5630 2960 42.00 7.46
Oil 1410 - 1.12 0.79
Lead (Pure) 2160 700 24.50 11.34 Rubber 2300 - 2.50 – 3.70 1.09 - 1.61
Titanium 6100 3120 27.50 4.51
Attenuation:
Intensity diminishes with distance travels through a medium. 1.22 → null →% peak
scattering + absorption => attenuation 1.08 → 20 dB →10% peak
Attenuation α f 2
Scattering => Reflection other than original direction.
Absorption => Conversion of sound energy to other energy.

A = A0 e-αz - - - - - - 19
A = Amplitude changed, A0 = Initial Amplitude, α = 0.88 → 10 dB →32% peak
Attenuation Co-eff.[Np/m], Z = Travel Distance [m] 0.70→ 6 dB →50% peak
Np = Neper; Np / 0.1151= dB Gain dB Echo Height %
dB = Decibel = Log of ratio of two measurement. 42 80 %
36 -6 dB 40%
ΔI(dB) = 10 log = 10 log 30 - 6 dB 20%

I = Sound Intensity, P = S Pressure using transducers, V = Voltage.

CALIBRATION CHECKING:
Longitudinal Wave Probe:
A time base in terms of steel thickness:
A. Calibration of the
25 b)
a) 25 thk. of IIW Block V1, mm If the echoes will not
coincide
25mm with appropriate
/ scale divisions, the time base A&B
is not linear and aBgraphical calibration required., c)
<10mm, C 4-5MHz probe gives better accuracy. d) Higher
f => Lower Dead Zone, 10mm&5mm Perspex side
B. Check on linearity of amplifier: C
The amplification is linear when the ratio of
the height of any two consecutive echoes remains
D when the degree of sensitivity is altered.
constant
C. Assessment of (a) Relative sensitivity:
Echo from the 1.5 mm diameter hole D

D. Assessment of (b) Penetrating power:

The sensitivity control is set at a minimum and
the probe placed on the metallized surface of the
Plexiglass block. A measure of the penetrating power
D1
can then be obtained by slowly increasing the sensitivity
E E
control to a maximum and noting the number
of bottom echoes which appear. 2 - 4 nos. echo less
penetrating power.
E. Check of the dead zone:
The distance from the probe to the Plexiglass F
at positions D1 and E is 10 mm and 5 mm,
F
F. Check on the resolving power:
The probe is moved in order to obtain 3 bottom
echoes at 85, 91 and 100 divisions.
Transverse Wave Probe:
G. Determination of probe5 index 10 G
15
M3 from
Move the probe until Max. Amplitude received M2100M1
mm curved
surface. The central mark on the graduated scale will be the position
at which the beam leaves the Plexiglass and enters the steel, i.e. the
probe index.
H. Determination of the angle of refraction
G J
Move the probe until maximum signal amplitude
is obtained from the Plexiglass cylinder.the relevant angle of refraction
marked on the probe should coincide with the correct scale position.
I. Correction of the zero point H
Obtain an echo at a maximum amplitude on the screen from 100 mm
radius. Adjust the echo by movement of the horizontal shift and the
40⁰ in45⁰
fine time base control 50⁰
order to obtain two echoes on the screen at
50 subdivisions and 100 subdivisions.
Obtain an echo on the screen by placing the 45° probe H
at distance e 25 mm. Rotate the probe from one side to the other and
note the echo amplitude at various angles of probe position. A
horizontal polar diagram can be plotted,
J. Assessment of sensitivity
The sensitivity of the equipment can now be specified in terms of echo I
height and distance from the 1.5 mm hole.
I
V1 Block Dimension: V2 Block Dimension

http://www.inspection-for-industry.com/ultrasonic-
F= Frequency testing.html3.
P = Penetration ↑ ↓ ↑ ↓ ↑ ↓ ↑ ↓ ↑ General:
A = Attenuation F P A D S C R Y N 3.1-Basic Requirements and Terms
D = Divergence ↓ ↑ ↓ ↑ ↓ ↑ ↓ ↑ ↓ ASME V-article 1 (General Requirement), 4 (Weld) & 5
S = Sensitivity (Material) ASME SEC.VIII, DIV.1.
C = Crystal Thickness 3.2-Examination coverage: Scan Overlap ≤ 10% of the
R = Resolution transducer (piezo-electric element) dimension ┴ to the
Y – λ = Wave Length direction of the scan.
N = Near Field 3.3- Rate of search unit movements < 150 mm/s.
4. Personnel Qualification: Level II, ASNT-SNT-TC-1A.
AWS D1.1
Step 1: Selection of probe:
Table 6.2