MQ SP M 4041

Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Specification MQ-SP-M-4041
Project Name: MARAFIQ SPEC DEVELOPMENT Date: 01 Mar 2011

Contract Number: A5MU Page 1 of 39
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GENERAL WELDING /NDE SPECIFICATION FOR PRESSURE-RETAINING COMPONENTS
This specification has been revised as indicated below and described in the revision record on the
following page. Please destroy all previous revisions.
Revision Date Originator's Reviewed/Checked By Pages

No. Name & Initials Name & Initials
A 7-Jan-11 J. Zlatich T. Wood All
0 10-Jan-11 J. Zlatich T. Wood All
1 1-Mar-11 J. Zlatich T. Wood All
APPROVALS SIGNATURES DATE
Lead Engineer
Engineering Manager:
Client Approval:
ISSUED FOR : Construction X Other Approved

Revision 1
Record of Revisions
Revision Date Description

No.
A 7-Jan-11 Issue Table of Contents for Client Review.
0 10-Jan-11 Issue for Client Review.
1 1-Mar-11 Issued Approved

Revision 1
1.0 GENERAL .....................................................................................................................................................4

1.1 Summary ........................................................................................................................................4
1.2 References .....................................................................................................................................4
1.3 Submittals ......................................................................................................................................5
1.4 QA (Quality Assurance)..............................................................................................................6
2.0 PRODUCTS ..................................................................................................................................................8
2.1 General............................................................................................................................................8
2.2 Welding Procedures ....................................................................................................................8
2.3 Welder/Welding Operator Performance Qualifications ......................................................8
2.4 Materials .........................................................................................................................................9
A. Filler Metal Requirements...............................................................................................9
B. Filler Metal Storage and Handling ...............................................................................11
2.5 Welding .........................................................................................................................................12
A. Acceptable Welding Processes ...................................................................................12
B. Weld Joint Preparation ..................................................................................................13
C. Surface Preparation.......................................................................................................13
D. Joint Backup Requirements..........................................................................................14
E. Workmanship..................................................................................................................14
F. Preheat and Interpass Requirements .........................................................................15
G. PWHT Requirements.....................................................................................................15
H. Shielding /Backing Gas .................................................................................................16
I. Procedure Qualification and Production Testing of Stud Welds .............................16
2.6 Hardness Testing .......................................................................................................................17
2.7 Inspection, NDE and Tests ......................................................................................................21
2.8 Weld Repairs ...............................................................................................................................22
2.9 Weld Overlay and Clad Restoration ......................................................................................22
2.10 Delta Ferrite Testing ..................................................................................................................22
3.0 FIELD WELDING .......................................................................................................................................23
3.1 General..........................................................................................................................................23
4.0 APPENDICES.............................................................................................................................................23
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1.0 GENERAL
1.1 Summary
A. Scope of Specification
This specification covers general welding, heat treatment, NDE and testing
requirements for fabrication of pressure-retaining equipment, piping assemblies,
tankage, attachments welded thereto, piping systems, and any other component
when referenced by an applicable PO (Purchase Order).
See Appendix 01 for specific requirements regarding welding, NDE and

PWHT for amine and wet H2S services.
B. Terminology
Commodity Specification: Specification relating to the design or fabrication of

various types of components such as piping, vessels or rotating equipment.
1.2 References
The publications listed below form part of this specification. Each publication shall be the
latest revision and addendum in effect on the date this specification is issued for
construction unless noted otherwise. Except as modified by the requirements specified
herein or the details of the drawings, Work included in this specification shall conform to
the applicable provisions of these publications.
A. API (American Petroleum Institute)
1. 620, Std Design and Construction of Large, Welded, Low-Pressure

Storage Tanks
2. 650, Std Welded Steel Tanks for Oil Storage
B. ASME (American Society of Mechanical Engineers) Pressure Piping Code
1. B31.3 Process Piping
C. ASME (American Society of Mechanical Engineers) B&PV (Boiler and

Pressure Vessel) Code
1. Section II Part A – Ferrous Material Specifications

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2. Section II Part B – Nonferrous Material Specifications
3. Section II Part C – Specifications for Welding Rods, Electrodes and

Filler Metals
4. Section V Nondestructive Examination
5. Section IX Welding and Brazing Qualifications
6. Section VIII Pressure Vessels, Division 1: Rules for Construction of

Pressure Vessels
7. Section VIII Pressure Vessels, Division 2: Alternative Rules
D. ASNT (American Society of Nondestructive Testing)
1. SNT-TC-1A Recommended Practice for Qualification of Nondestructive

Examination Personnel
E. AWS (American Welding Society)
1. AWS A2.4 Standard Symbols for Welding, Brazing and Nondestructive

Examination
2. AWS A3.0 Standard Welding Terms and Definitions
3. AWS A4.2 Standard Procedures for Calibrating Magnetic Instruments to

Measure the Delta Ferrite Content of Austenitic and Duplex
Ferritic-Austenitic Stainless Steel Weld Metal
1.3 Submittals
Submittals for Buyer review shall be in accordance with the following:
A. Welding
1. WPSs (Welding Procedure Specifications) and PQRs (Procedure

Qualification Records) shall be submitted to the Buyer for review prior to the
start of fabrication. Welding shall not begin until these documents are
returned to the Seller with authorization to proceed.
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2. WPSs shall be clearly identified with the PO and Tag/Item number.
3. WPSs or PQRs that are revised and resubmitted shall indicate a revision
level and revision date change. PQRs that are revised must be re-certified
(re-signed and dated) by the Seller. Documentation to substantiate PQR
revisions in accordance with ASME Section IX, Paragraph QW-200.2(c),
shall be submitted with the revised PQR.
4. Seller must submit for Buyer’s review, along with the initial submittal of the
WPS/PQR, the filler material manufacturer’s chemistry range (i.e., not a
typical or nominal analysis) for each element listed in the SFA specification
as well as mechanical property data for all AWS Classification “G” filler
materials.
5. WPQs (Welder/Welding Operator Performance Qualifications) shall not be

submitted to Buyer for review. WPQs shall be made available upon request
for Buyer’s review in the Seller’s shop for the specific welder/welding
operator to be used in fabrication.
B. NDE (Nondestructive Examination)
1. NDE procedures shall be submitted to the Buyer for review prior to the start
of fabrication.
2. NDE procedures shall contain data required by this specification.
C. PWHT (Postweld Heat Treatment)
PWHT procedures shall be submitted to the Buyer for review, prior to the start of
fabrication.
1.4 QA (Quality Assurance)
A. Requirements of Regulatory Agencies
1. Welding and NDE operations shall be conducted under the Seller’s quality
control system that has been reviewed by the Buyer.
2. WPSs, PQRs, and WPQs shall conform to the requirements of Section IX of

the ASME Code and to the requirements of this specification.
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3. Compliance with this specification and authorization to proceed using

WPSs, PQRs, and other required documentation shall in no way relieve the
Seller’s responsibility to provide welds that are sound and suited for the
services for which they are intended.
4. The control and handling of welding materials shall be addressed in the

Seller’s QA Plan.
5. A system shall be employed to identify and retain the identity of all filler
metals. The Seller shall have available MTRs (Mill Test Reports) for all filler
metals used for production welds.
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2.0 PRODUCTS
2.1 General
A. The Work of this specification is subject to the requirements in the PO or

Contract.
B. Welding symbols shall be in accordance with AWS A2.4.
C. Welding terms and definitions shall be in accordance with AWS A3.0.
D. Welding equipment voltmeters and ammeters shall be in proper working order

and calibrated at least annually. Periodic checking by Buyer's Inspector with
Amp-Tongs or other suitable means may be performed at the Inspector’s
discretion.
2.2 Welding Procedures
A. Welding shall be accomplished with WPSs in accordance with the requirements

of Section IX of the ASME Code and this specification. WPSs shall address the
requirements of this specification and all variables listed in QW-250 of Section IX
for each applicable process. Omission of variable information from the WPS
shall not be interpreted as a negative response to that variable.
B. The Seller shall be responsible for the review of their Sub-Supplier’s WPSs and
PQRs to confirm compliance with code and specification requirements. Sub-
Supplier’s WPSs and PQRs shall be submitted to the Buyer after the Seller has
determined that code and specification requirements have been addressed.
C. Each Seller is responsible for the development, preparation, and qualification of

his own WPSs. Welding procedures prepared and qualified by independent
outside organizations such as the NCPWB (National Certified Pipe Weld Bureau)
and British Columbia Boilers Branch are prohibited.
D. Tube-to-Tubesheet Welding Procedures shall be qualified in accordance with

ASME Code, Section IX, QW-288.
2.3 Welder/Welding Operator Performance Qualifications
A. Welders shall be qualified in accordance with the requirements of ASME

Code, Section IX.
B. The transfer of WPQs between Sellers is not permitted.
C. WPQs shall be made available for Buyer’s review in Seller’s shop upon request.
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D. Additional welder performance qualifications shall be performed whenever the

accessibility, restraint or environment of the code qualifications fail to simulate
the production conditions when these factors are likely to affect the quality of the
production welds.
2.4 Materials
A. Filler Metal Requirements
1. Filler metal shall be as specified in ASME Code, Section II, Part C. The
deposited weld metal principal alloying elements and mechanical properties
shall conform to the ASME requirements of the base metal.
2. Filler metal shall be used only for the primary material and process
applications recommended in the AWS Material Specification or by its
manufacturer (e.g., Filler metals certified for the as-welded condition only,
shall not be used in the PWHT’d condition).
3. Welds deposited by the SAW (Submerged Arc Welding) process shall not
derive principal elements from the flux.
4. Active, alloy and recrushed-slag type SAW fluxes shall not be used.
5. SAW flux used for production welding shall be the same manufacturer's
brand and type as was used for the PQR and shall be specified on both the
WPS and PQR. The SAW wire used for production welding shall be the
same AWS classification as was used for the PQR and shall be specified on
both the WPS and PQR.
6. SMAW (Shielded Metal Arc Welding) electrodes of the non-low hydrogen

classification are not permitted for pressure-retaining welds. Exception:
E6010 or E7010 electrodes may be used for the root pass only in single-
sided full penetration open root groove weld joints in P-No. 1 materials.
7. Only SFA 5.20 AWS Classification E7XT-1/1M, E7XT-5/5M, E7XT-9/9M, or

E7XT-12/12M filler metal shall be used for FCAW (Flux Cored Arc Welding)
of P-1 material. All FCAW filler metals shall be low hydrogen type.
8. AWS Classification "G" filler metal, used for production welding, shall be the
same manufacturer's brand and type as used for the PQR. Both the WPS
and PQR shall specify the manufacturer's brand and type. Seller must
submit for Buyer’s review, along with the initial submittal of the WPS/PQR,
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the filler material manufacturer’s chemistry range (i.e., not a typical or

nominal analysis) for each element listed in the SFA specification as well as
mechanical property data.
9. Slag producing filler metals, such as those used for the FCAW and SMAW
processes, shall not be used for root passes in single-welded full
penetration open root groove weld joints except as allowed by paragraph
2.4 A. 6. above. Root passes in double-welded joints made with slag
producing filler metals shall be back gouged prior to welding the second
side.
10. Carbon-1/2 Moly filler metal shall not be used without PWHT for welding
carbon steel base metal in hydrogen or hydrogen evolving services.
11. Dissimilar metal joints between P-No. 1 through P-No. 7 base metals shall
use low hydrogen type filler metal similar in composition to either base metal
or to an intermediate composition.
12. The following filler metal requirements shall be met in general, however due
consideration must be given regarding filler metal selection based on
specific process applications. Therefore, authorization to proceed with
production welding will be pending the Buyer’s review of the Seller’s
WPS/PQRs for each specific process application. Dissimilar metal joints
between P-No. 1 through P-No. 7 base metals on one side, to P-8 or high
nickel alloys on the other side shall be welded with E/ERNiCrMo-3.
ERNiCr-3 or ENiCrFe-2 may be used for services with less than 1% sulfur.
E/ER309(L) may be used for services with design temperature less than
600°F with prior written permission from the Buyer.
13. Selection of filler metal for other dissimilar metal joints requires review by
the Buyer prior to starting production welding.
14. Dissimilar metal joints between galvanized P-No. 1 base metal (including
those with the galvanized coating “removed”) and P-No. 8 base metal are
not acceptable.
15. WPS requalification is required whenever the chemical composition of the

weld deposit is changed from one A-number to any other A-number in QW-
442 of ASME Code Section IX including a change from A-1 to A-2 and vice
versa.
16. FCAW filler metal used to weld austenitic stainless steel base metal with
operating temperatures greater than 850°F (455°C) or to make welds that
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will be heat treated shall be limited to 0.002wt% Bi (bismuth) maximum.

Actual (not typical) CMTRs (Certified Mill Test Reports) shall be available for
Buyer’s inspector to review and be traceable to all production filler metal to
be used. METRODE brand filler metal or equivalent, based on Buyer’s
evaluation of the CMTR prior to its use in production, shall be used for
welding base metal with operating temperatures above 850°F (455°C).
B. Filler Metal Storage and Handling
The Sellers' procedures for welding consumable storage and handling shall
conform to the following guidelines as a minimum:
1. SMAW Electrodes
a. Low Hydrogen Electrodes shall always be stored in one of the following:
(1) Unopened and undamaged hermetically sealed container.
(2) Electrode storage oven at 250 °F (120 °C) or in accordance with the
filler material manufacturer’s recommendations. The oven may be
stationary or portable (rod caddy).
b. The Seller shall develop and implement filler metal storage and handling
procedures such that filler materials are maintained in a clean, dry
condition up to the time of use. Low hydrogen electrodes shall be
handled and stored in accordance with the Manufacturer's
recommendations to avoid moisture pickup and to retain the low
hydrogen characteristics of the electrode.
c. The Seller's welding materials handling procedure shall specify

maximum exposure limits of electrodes removed from storage, never to
exceed eight hours. Electrodes that exceed exposure limits shall be re-
baked (according to Manufacturers' guidelines) prior to reuse. One re-
bake cycle is permitted. Wet, damaged, or contaminated electrodes shall
be discarded.
d. Electrodes shall be properly identified at all times.
2. SAW Electrodes and Fluxes
a. Submerged arc wire shall be stored with Supplier's wrapper intact. Coils
that have been partly used shall be protected and identified before being
returned to storage. Contaminated or unidentified wire shall not be used.
b. Flux used for SAW shall be dry and free from contamination. Flux shall
be stored in factory packaging until time of use. Flux from opened or
damaged packages shall be dried at 300 °F (150 °C) for 1 hour minimum
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before use or in accordance with the filler material manufacturer’s

recommendations.
3. GMAW and GTAW Electrodes and Gases
a. Wires shall be stored with Supplier's identification wrapper intact. Coils

or straight lengths of filler material that have been partly used shall be
protected and identified before being returned to storage. Contaminated
or unidentified wire shall not be used.
b. Gas used for shielding shall be welding grade and shall have a dew point
of minus 40 °F (minus 40 °C) or lower.
2.5 Welding
Welding shall conform to the requirements of the ASME Code and this specification.
A. Acceptable Welding Processes
The following welding processes, or combinations thereof, are permitted for

welding pressure-retaining components within the limits specified below. Use of
processes other than those listed below, including but not limited to the STT and
RMD modifications of the GMAW process, requires written permission from the
Buyer during bid evaluation proceedings. Welding process limitations in addition
to those specified below, based on service conditions, may be specified in
Commodity Specifications. See Appendix 01, attached to this specification, for
specific welding process limitations for amine/wet H2S service. Note: WPSs for
automated welding processes (e.g., orbital welding ) as well as pulsed-current
processes shall specify applicable equipment settings (e.g., background and
peak amperage and voltage settings) to ensure consistent quality welds.
1. SMAW
2. GTAW - Manual (With high frequency current start, or equal) or Automatic
3. SAW - Machine
4. GMAW - Short circuiting mode of transfer is acceptable for root pass only in
material of any thickness and for welding the total joint thickness when base
material does not exceed 3/8 of an inch (10 mm) for Pressure-Retaining
Parts and Non-Pressure-Retaining Parts. Note: Short circuiting mode of
metal transfer is permitted for only the root pass in branch connections (e.g.,
Figure 328.5.4D of ASME B31.3).
GMAW - Globular mode of transfer is acceptable for welding fill and cap
passes only (not root pass) in open-root, full penetration, single-welded
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groove welds and for all passes in single-welded groove welds with backing,
fillet welds and double-welded full penetration groove welds in Pressure-
Retaining Parts and Non-Pressure-Retaining Parts up to and including 1/2
of an inch (13 mm).
GMAW - Spray / Pulsed Spray mode of transfer is acceptable for all passes
in all thickness of material for Pressure-Retaining Parts and Non-Pressure-
Retaining Parts except for root pass in open-root, full penetration, single-
welded groove welds.
5. FCAW with external shielding gas is acceptable for all passes in all
thickness’ of material for Pressure-Retaining Parts and Non-Pressure-
Retaining Parts except for the root pass in open-root, full penetration,
single-welded groove welds. When impact testing is required, the same
manufacturer's brand and type filler metal shall be used in production as
was used on the PQR. Both the WPS and PQR shall specify the filler metal
manufacturer's brand and type.
6. SW (Stud Welding) – Arc and Resistance
B. Weld Joint Preparation
1. Weld joint preparation for carbon, alloy steel and stainless steel may be
made by machining, grinding, or thermal cutting. When thermal cutting or
beveling is permitted for stainless steel, the cut surfaces shall be ground to
bright metal.
2. Double-welded groove weld joints are preferred and shall be used wherever
feasible. The second side of double-welded groove weld joints shall be
back gouged prior to welding the second side. Pressure boundary groove
weld joints shall be full penetration.
3. Tack welds that are to be incorporated into the final weld shall be feathered
by grinding to achieve a profile that can be welded over without adversely
affecting the weld quality.
4. Tack welds that are not incorporated into the weld shall be removed
completely after their need has been fulfilled.
C. Surface Preparation
1. Weld bevel surfaces to be joined shall be clean and free from paint, oil, dirt,
scale, oxides, and other foreign material detrimental to welding, including
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the adjacent base metal surfaces on both the inside and outside of the joint
for at least 1 inch (25 mm) from weld bevel surfaces.
2. The WPS shall specify solvent wiping to remove low melting temperature
contaminants, such as sulfur contained in cutting fluids, from the surfaces of
high nickel alloys that will be heated due to welding or postweld heat
treating operations.
3. Flux, weld spatter, and slag shall be removed from weld beads by chipping,
grinding, or both, and wire brushing before starting to deposit a succeeding
pass.
4. Surfaces and edges to be welded shall be smooth, uniform, and free from
fins, tears, cracks, or other defects that would adversely affect the quality or
strength of the weld.
D. Joint Backup Requirements
1. Permanent backing rings/bars are not permitted without specific written

permission from the Buyer.
2. The WPS shall specify the P-No. or material designation for backing
material, whether it is temporary or permanent. For joints between similar
materials, the backing material chemistry shall match the base metal
chemistry.
3. Consumable inserts are not considered backing rings and may be used for
appropriate applications.
E. Workmanship
1. Weld joints shall be aligned as accurately as practical and alignment

preserved during welding.
2. Tack welds shall be made by qualified welders, using a procedure reviewed

by the Buyer.
3. Temporary attachments, such as hold-down fixtures or alignment bars, shall

be removed by cutting to within 1/8 of an inch (3 mm) from the surface and
then ground flush. The attachment material shall be of the same chemical
composition as the base material.
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4. Arc strikes, in areas not to be covered by the finished weld, shall be ground
and PT or MT examined to ensure that the material surface is not cracked.
5. Welding defects shall be removed before welding resumes. Weld craters

shall be completely filled before depositing subsequent weld beads.
6. The use of pneumatic cleaning tools for scaling slag from welds is
acceptable and is not considered peening.
7. Grinding wheels, rotary burrs, and austenitic stainless steel wire brushes,
used on austenitic stainless steel, high nickel and nonferrous alloys, shall
not have been used previously on ferrous materials. Metal removal and
abrasive tools used on the above materials, as well as galvanized steel,
shall be segregated from other tools and suitably marked for use on that
specific material only.
8. When NDE is required, as-welded surfaces are permitted, however, the

surfaces of welds shall be sufficiently free from coarse ripples, grooves,
overlaps, abrupt ridges, and valleys to allow proper interpretation. When an
as-welded surface interferes with an examination, the surface shall be
ground to permit proper interpretation, taking care not to infringe on the
minimum design metal thickness.
9. Weld metal shall be deposited for the full thickness of the joint preparation,
regardless of minimum wall thickness. Underfill shall not be permitted.
F. Preheat and Interpass Requirements
1. The mandatory minimum preheating temperature for thermal cutting, tack

welding, and welding shall be in accordance with the applicable Commodity
Specification or the recommended or required code requirement, whichever
is greater. Additionally, whenever material is wet or contains surface
moisture, it shall be dried by heating.
2. The maximum interpass temperature for austenitic stainless steel and high
nickel alloys shall be 350 °F (175 °C).
G. PWHT Requirements
1. PWHT shall be performed in accordance with the applicable code and

Commodity Specification.
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2. PQRs for welding P-No. 8 to P-No. 1 through P-No. 6 materials shall use
the highest PWHT temperature specified on the WPS when the WPS
specifies a PWHT temperature range that exceeds 1300°F (704°C) {e.g., if
the WPS PWHT temperature range is 1250 °F - 1350 °F (677°C – 732°C),
then 1350 °F (732°C) must be used for the PQR PWHT}.
3. Attachment of clips, brackets, or other devices requiring welding directly to

the inside or outside surface of pressure containing components after
PWHT is not permitted without prior written permission from the Buyer.
H. Shielding /Backing Gas
1. Shielding gas for welding low carbon grades of P-No. 8 material with the
GMAW or GTAW processes shall not contain more than 2 ½ % carbon
dioxide (CO2).
2. Single-welded joints in pressure-retaining components, except those

fabricated from P-No. 1, 3 & 4, shall be made with a back purge. Double-
welded joints, joints with backing rings/bars, and fillet welds are exempt
from purge gas requirements. Back purge requirements shall be as follows:
a. Welding grade argon shall be used as the purging gas. The use of
nitrogen for a purge gas requires written permission from the Buyer prior
to starting production welding.
b. Purge gas flow shall continue until a minimum of 3/8 of an inch (10 mm)
of weld metal has been deposited.
c. The materials used for pipe purging dams and the methods employed in
their placement, use, and subsequent removal shall not damage the
piping or related components.
d. The purge gas shall be verified to contain less than 1 percent (1%)
oxygen (measured by an oxygen analyzer), or flow for a sufficient
amount of time to allow at least 6 purge volume changes, prior to the
initiation of welding.
I. Procedure Qualification and Production Testing of Stud Welds
1. Arc and resistance stud welding for attaching non-load-carrying studs (such
as extended heat transfer surfaces and insulation attachment pins) shall be
qualified in accordance with ASME Section IX on base materials at least as
thick and having the same nominal chemical compostion as the production
base material. The PQR shall include a record of all welding variables and
equipment settings used during qualification.
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2. A production test sample of at least 5 consecutively welded studs shall be

tested at the beginning of each shift and after performing maintenance
operations on automatic equipment.
3. Production welds shall be inspected by hammer testing [2 lb (1 kg) hammer

and 20 to 30 in. (50 to 75 cm) stroke] or 15 degree bend tests as agreed
between the Buyer's Engineer and the Seller.
2.6 Hardness Testing
A. Personnel Qualification
Personnel performing hardness testing shall demonstrate their capabilities to the

satisfaction of the Buyer’s Inspector. Qualification of the hardness testing
personnel, including training and experience, shall be made available to the
Buyer’s Inspector.
B. Definition of “Hardness Test”
Unless otherwise specified, a hardness test shall be 1 reading in the deposited

weld metal for welds or 1 reading in the base metal for bent or formed piping
components.
C. Testing Equipment
The following is a list of acceptable hardness testers. The Buyer shall approve
the hardness tester if it is not listed below.
DYNAMIC / REBOUND AND UCI

BRINELL TYPE HARDNESS TESTERS
TYPE HARDNESS TESTERS
Telebrineller Newage Calibrated Pin Tester Equotip (DYNAMIC/REBOUND)
Teleweld, Inc. Newage Ind., Inc. Equotip Associates
416 North Park 2300 Maryland Rd. 140 Industry Drive
St. Willow Grove, PA 19090 Pittsburgh, PA 15275
Streator, IL
61364
Minibrineller L.C. Eitzen Brinell Meter Microdur (MIC 10) (UCI)
Electromechanic L.C. Eitzen Co. Inc. Krautkramer
al Components P.O. Box 1210 50 Industrial Park Rd.
P.O. Box 159 Glenwood Springs, CO P.O. Box 350
Gillette, NJ 81601 Lewistown, PA 17044
07933
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D. Brinell Hardness Testing Procedure
1. Brinell hardness test methods shall be in accordance with ASTM A 833 and
Manufacturer’s recommendations.
2. The diameter of the indention ball shall not be smaller than 7 mm and not
larger than 10 mm.
3. If a hardness reference bar is used, the bar hardness shall be within + 15

BHN of the hardness of material being measured.
4. The surface to be hardness tested shall be ground or sanded so that the

edge of the impression can be clearly defined to permit the measurement of
the diameter to  0.02 mm. When rebound hardness testers are used, the
area to be tested shall be ground or sanded approximately 0.010 of an inch
(0.25 mm) below the “mill” or heat treated surface prior to testing to remove
the decarburized layer.
5. Grinding or sanding shall be conducted in such a manner that overheating

of the material is prevented.
6. Adjacent readings shall be a least 0.25 of an inch (6.4 mm) apart, edge to
edge.
E. Dynamic/Rebound and UCI Hardness Testing Procedure
Testing procedures using the Dynamic / Rebound and UCI Type Hardness
Testers shall be as follows:
1. The hardness test method shall be in accordance with ASTM A 956 for
Dynamic/Rebound testers and ASTM A 1038 for UCI (Ultrasonic Contact
Impedance) testers and the manufacturer’s recommendations.
2. Five hardness readings constitute one hardness test. The five readings and
their average shall be reported. If there is a variation in readings greater
than  15%, testing with a Brinell-type hardness tester is required.
3. The hardness test instrument shall be calibrated in the same position as

intended for production testing.
4. The minimum wall thickness shall be ½ of an inch (12 mm).

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5. The surface to be tested shall be prepared in accordance with the ASTM

references given in item 1 above.
F. Hardness Limits
The hardness of hot-formed bends and weld metal shall meet the limits given
below:
(2)
MATERIAL P-NUMBER BRINELL HARDNESS
P-1 200
P-3, P-4 225
P-5(1), P-6, P-7 235
P-10A, B, C & F 225
P-11 225
Notes:
1. The Buyer’s Engineer shall designate hardness requirements for P91 and
F91 materials.
2. Hardness testing shall be performed after any required PWHT.
G. Hardness Testing Exemptions for Welds in P-1 material
Hardness testing of welds in P-1 material is not required if any of the following
filler metals are used:
1. Shielded Metal Arc Welding (SMAW) process with AWS A5.1 Class E60XX
and/or E70XX electrodes
2. Gas Tungsten Arc Welding (GTAW) process or Gas Metal Arc Welding
(GMAW) process with AWS A5.18 Class ER70S-2 through ER70S-5 filler
metal
3. Flux Cored Arc Welding (FCAW) process using filler metal E7XT-1, -5, -9, -
12 with CO2 or E7XT-1M, -5M, -9M, -12M with either CO2 or Ar/CO2
mixture
4. Submerged Arc Welding (SAW) process using filler metal combinations of

ELXX or EMXX wires in accordance with AWS A 5.17 and a neutral flux
approved by the Buyer
Revision 1
H. Hardness Testing Frequency
1. Pressure Vessels (Including Heat Exchangers except air-cooled heat

exchangers), Pressure Storage Spheres And Storage Tanks.
Unless otherwise exempted by Par. 2.6 G., the Seller shall check the weld
hardness of each category A, B, C and D joint.
2. Air-Cooled Heat Exchangers
The minimum number of welded joints tested shall be as specified in API

Standard 661.
I. Piping
PWHT’d welds and HAZs and hot bent or hot formed piping components in P No.
3, 4, 5, 6 and 10A materials shall be hardness tested in accordance with
paragraph 331.1.7 of ASME B31.3. Additionally, 5% of all welds and HAZs not
requiring PWHT in P No. 3, 4, 5, 6 and 10A materials shall be hardness tested.
Dynamic/Rebound type hardness testers shall be used for testing all HAZs and
any weld where accessibility restricts the use of Brinell type testers.
a. Unless exempted by Par. 2.6 G., the Seller shall check the hardness of
5% of both PWHT’d and non-PWHT’d piping welds (not HAZs) in P No.
1 material.
2. If the clearance will not permit hardness testing, a production weld mockup
with similar conditions (i.e., material type, thickness and joint geometry)
shall be made using the applicable WPS and tested to represent the
production weld.
J. Remedial Measures / Documentation
1. When hardness readings exceed the maximum values, the Buyer shall be
notified before the Seller takes any corrective action.
2. For each vessel/heat exchanger weld found to exceed the specified

hardness, two additional welds in similar components, selected by the
Buyer’s Inspector, shall be tested. For each piping weld found to exceed the
specified hardness, when less than 100% hardness testing is required,
progressive testing in accordance with paragraph 341.3.4 of ASME B31.3
shall be performed.
3. A hardness test report shall be prepared by the Seller and submitted to the
Buyer.
Revision 1
4. The hardness test report shall indicate the type of hardness tester,
personnel conducting hardness tests, type of material, last equipment
calibration date, test location (e.g., weld I.D.) and reading of each point
tested.
K. PQR Hardness Testing
PQR hardness testing of P-No. 3, 4, 5, 6 and 10A material shall be performed in

accordance with paragraph 2.6.
2.7 Inspection, NDE and Tests
A. General
1. Welds that are deposited by procedures differing from those properly

qualified and reviewed by the Buyer are subjected to rejection and complete
removal.
2. Cleanliness shall be maintained after completion of welding. Stubs, rods,

flux, slag, or other foreign material shall be removed from inside the
equipment or piping. Weld spatter and slag shall be removed from the
surface of finished welds.
3. Defective welds shall be repaired according to Section 2.8 of this

specification.
4. The Buyer’s Inspector or his authorized representative shall have free

access to the Seller's work place and the right to reject workmanship that
does not meet this specification. At the discretion of the Inspector,
additional testing of welds shall be done if the Inspector deems it essential
to maintain quality.
5. The Buyer’s Inspector shall have the option of selecting locations for any
spot or random NDE.
B. Inspection and NDE Requirements
Inspection and NDE shall be performed as specified in the P.O. As a minimum,

NDE shall be as specified in the applicable code or standard. NDE shall be
performed by personnel certified in accordance with ASNT recommended
practice SNT-TC-1A. Personnel responsible for interpreting examination results
shall be certified to Level II or III. Other types of certification require written
permission from the Buyer. NDE and inspection records shall be made available
to the Buyer’s Inspector.
Revision 1
2.8 Weld Repairs
Welds that do not comply with the specified acceptance criteria shall be repaired and re-
examined in accordance with the following:
A. The defect shall be excavated and examined to ensure removal of defects to an

acceptable condition. The repaired areas shall be re-examined using the same
examination procedures by which the defect was originally detected.
B. Repairs to correct weld defects shall be made using the same procedure used for
the original weld or other weld procedure reviewed by the Buyer. A second
repair attempt of a given defect requires written permission to proceed with such
repairs from the Buyer prior to proceeding.
C. Weld repairing PWHT’d components without subsequent PWHT requires Buyer’s

written permission and shall meet all the requirements in paragraph UCS-56(f) of
ASME VIII, Div. 1. All carbon steel repair procedures shall employ the temper
bead technique.
2.9 Weld Overlay and Clad Restoration
Weld overlay and clad restoration is assumed to be not applicable to the Marafiq facilities.
2.10 Delta Ferrite Testing
Delta ferrite shall be determined as required below for pressure-retaining welds when the
weldment is in cryogenic service or will be PWHT’d or has a design temperature greater than
1000°F.
A. Five percent (5%) of category A, B, C, and D welds in austenitic stainless steel
vessels/heat exchangers shall be tested for delta ferrite in the weld deposit and
results recorded.
B. Five percent (5%) of pressure-retaining welds in austenitic stainless steel piping

shall be tested for delta ferrite in the weld deposit and the results recorded.
C. Delta ferrite determinations made using magnetic instruments shall be performed

before PWHT when PWHT is required.
D. Delta ferrite content shall be 3 - 10 FN for operating temperatures of 800 °F (425

°C) and above or for components that are PWHT’d. For components with
operating temperatures below 800 °F (425 °C) not requiring PWHT the delta
ferrite content shall be 3 - 12 FN.
E. Delta ferrite shall be determined by a magnetic instrument calibrated in

accordance with AWS A4.2 (e.g., Severn gage or Ferrite scope), or calculated
using the WRC-1988 (preferred) or DeLong Constitution Diagrams.
Revision 1
3.0 FIELD WELDING
3.1 General
A. Field fabrication and erection shall be performed in accordance with Section 2.0
of this specification, except for the addition or deletion of items detailed in this
section.
B. Welding shall not be done when the ambient air temperature is lower than 0°F
(minus 18°C) or when surfaces are wet, exposed to rain, snow, sleet, or high
wind. The ambient air temperature may be below 0°F (minus 18°C) during
welding, however a heated structure or shelter around the area being welded
must maintain the air temperature adjacent to the weldment at 0°F (minus 18°C)
or higher.
4.0 APPENDICES
APPENDIX 01: WELDING, NDE AND PWHT REQUIREMENTS FOR AMINE AND WET H2S
SERVICE
APPENDIX 02: SUPPLEMENTARY MATERIAL AND FABRICATION REQUIREMENTS FOR

DUPLEX STAINLESS STEEL (UNS S32205, S31803 AND S32750)
APPENDIX 03: WELDING REQUIREMENTS FOR CRYOGENIC SERVICE

Revision 1
APPENDIX 01
WELDING, NDE AND PWHT REQUIREMENTS FOR AMINE AND WET H2S SERVICE
1.0 SCOPE
This Appendix defines welding, NDE and PWHT requirements for pressure-retaining equipment
and piping in Amine and Wet H2S service.
2.0 WELDING PROCESSES
The following welding processes or combinations thereof, are permitted for welding equipment
and piping in Amine and Wet H2S Services. The welding process limitations in paragraph 2.5 A.
of the main body of this specification apply in addition to the following.
2.1 FCAW
2.2 GMAW
2.3 GTAW
2.4 SAW
2.5 SMAW
The maximum single-pass weld thickness for any welding process shall be ¼ of an inch (6.5
mm).
3.0 FILLER MATERIAL
Filler material requirements of paragraph 2.4 A. in the main body of this specification apply in
addition to the following.
3.1 Only solid wire conforming to AWS ER70S-2 through 5 may be used for GMAW or
GTAW welding of P-1 material in the non PWHT'd condition.
4.0 SURFACE CONDITIONS
Arc gouged and thermally cut surfaces of pressure retaining parts exposed to process fluids shall
be ground to bright metal. Punch marks or scribed work lines shall not be allowed on surfaces
exposed to process fluids.
Revision 1
APPENDIX 01
5.0 PRODUCTION HARDNESS TESTING
See the body of this specification (MQ-SP-M-4041) for personnel qualification, equipment and
production hardness testing frequency requirements for welds in fabricated components (except
as noted below for air coolers) and piping. Hardness testing frequency for base metal
components shall include at least one item from each heat treat lot of all pressure-retaining
material. For air coolers, one seam of each type (i.e., header box long seam, end plate to header
box, nozzle attachment seam, and nozzle girth seam) shall be tested on each header box.
5.1 Definition of “Hardness Test”
Unless otherwise specified, for welds, a hardness test shall be one reading in the
deposited weld metal using a Brinell type tester plus five readings using a Dynamic /
Rebound or UCI type tester in the HAZ on each side of the weld. For hot formed
components, a hardness test shall be one reading using a Brinell type tester in the base
metal in center of the area that was heated. For base metal components, a hardness test
shall be one reading using a Brinell type tester.
5.2 Hardness Limits
The hardness of carbon steel hot-formed pressure parts, base metal, weld metal, and the
related HAZ of all welds shall meet NACE RP0472. Base metal and weld hardness for
materials other than carbon steel shall not exceed the limits given below:
MATERIAL P-NUMBER BRINELL HARDNESS(1)

P-1 200
P-3, P-4 225
P-5, P-6, P-7 235
P-10A, B, C & F 225
P-11 225
Notes:
1. For piping base metal, use the lower of the value shown, or the value given
in the specific ASTM standard. For weld metal, use the lower of the value
shown or the value in ASME B31.3.
HAZ hardness for the above P-Number materials listed shall not exceed Rc 22 or 248
Hv10 equivalent using a Dynamic / Rebound or UCI type tester.
Revision 1
APPENDIX 01
5.3 Hardness Testing Exemptions for Welds in P-1 Materials
A. Hardness testing on welds in P-1 material is not required if any of the following
conditions are met:
1. Shielded Metal Arc Welding (SMAW) process with AWS A5.1 Class E60XX
and/or E70XX electrode is used.
2. Gas Tungsten Arc Welding (GTAW) process or Gas Metal Arc Welding
(GMAW) process with AWS A5.18 Class ER70S-2 through ER70S-5 filler
metal is used. Filler metal shall not have a combined Mn (manganese) plus
Si (silicon) content that exceeds 2.00 wt %. Mn and Si content of each heat
of filler metal to be used in production shall be verified via a CMTR (Certified
Mill Test Report) that specifies actual deposited weld metal chemistry (i.e.,
CMTRs specifying “typical” weld metal chemistry are not acceptable).
Alternatively, the Seller may perform the chemical analysis of Mn and Si for a
heat of filler metal. A CMTR or the Seller’s chemical analysis report for each
heat of production filler metal shall be submitted along with the WPS/PQR for
review.
3. FCAW filler metal shall not have a combined Mn (manganese) plus Si

(silicon) content that exceeds 2.00 wt %. Mn and Si content of each heat of
filler metal to be used in production shall be verified via a CMTR (Certified
Mill Test Report) specifying actual deposited weld metal chemistry (i.e.,
CMTRs specifying “typical” weld metal chemistry are not acceptable).
Alternatively, the Seller may perform the chemical analysis of Mn and Si for a
heat of filler metal. A CMTR or the Seller’s chemical analysis report for each
heat of production filler metal shall be submitted along with the WPS/PQR for
review.
4. SAW filler metal ELXX or EMXX wires, in accordance with AWS A-5.17, used
with a neutral flux approved by the Buyer shall have a maximum Mn+Si
content of 2.00 wt %. Each wire heat/flux lot combination to be used in
production shall be analyzed. The chemical analysis report shall be
submitted along with the WPS/PQR for review. The test plate welded for
chemical analysis of the weld deposit for Mn and Si shall be made using the
highest voltage specified on the WPS.
B. Hardness testing of the weld HAZ in P-1 material is not required for non-micro
alloyed steel (i.e., steel having a Columbium plus Vanadium content less than 0.015
wt %).
Revision 1
APPENDIX 01
6.0 PROCEDURE QUALIFICATION HARDNESS TESTING
Hardness testing shall be performed on all PQRs (Procedure Qualification Records) supporting
WPSs for welding pressure retaining joints and attachments to pressure retaining parts in both
the as-welded and PWHT’d conditions. A hardness traverse including the base metal, HAZ and
weld metal shall be performed in accordance with Figure 2 or 3 (as applicable) in NACE Standard
RP0472 to demonstrate compliance of hardness values of as-welded joints. PWHT’d joints shall
also be hardness tested to demonstrate the ability of the PWHT time and temperature to produce
weldments of acceptable hardness. The hardness limits for the base metal, HAZ and weld metal
shall meet the acceptance criteria given in paragraph 5.2 above. When micro-alloyed carbon
steel production base material (i.e., material having Cb+V content greater than 0.015 wt %) is
used, the PQR coupon used for the above hardness traverse shall have a Cb+V content equal to
or greater than the highest one to be used in production. The PQR coupon used for the hardness
traverse shall be at least 1-1/2 inches thick or equal to the thickest production part to be welded,
whichever is greater, and use a preheat temperature and heat input no greater than the minimum
specified on the associated WPS.
7.0 PWHT
The minimum PWHT temperature shall be in accordance with the requirements of the applicable
Code except that 1150°F (621°C) minimum shall be used for P-1 material and 1275°F (690°C)
minimum shall be used for P-4 and P-5 material. Use of reduced PWHT temperatures, allowed
by Code, requires prior written permission from the Buyer.
7.1 Piping Specific Requirements
PWHT requirements outlined in ASME B31.3, paragraph 331.1 shall be followed however
the exceptions provided in Table 331.1.1, based on nominal wall thickness, and the
exceptions provided in paragraph 331.1.3, based on governing thickness, are not
permitted.
The specific types of welds listed in A. through D. below are exempt from the special
PWHT requirements of this appendix.
A. Multi-pass girth welds in Wet H2S Service only (not Amine) seamless piping welded
from the outside only.
B. Multi-pass external attachment welds in Wet H2S Service only (not Amine), when the
weld metal is not in contact with the process fluid. Multi-pass external attachment
welds in Amine Service when the pipe wall thickness is 1 inch thick or greater.
C. Multi-pass seal and socket welds in Wet H2S Service only (not Amine).
Revision 1
D. Multi-pass welds for set on branch connections in Wet H2S Service only (not Amine)
{e.g., see ASME B31.3, Figure 328.4.4 (a)}, provided all welding is performed from
the outside.
8.0 NONDESTRUCTIVE EXAMINATION
NDE shall be performed in accordance with specification MQ-SP-M-4011 for pressure vessels,
including heat exchangers, and the body of this specification (MQ-SP-M-4041) for shop and field
fabricated piping with the following additional requirements.
8.1 Ultrasonic Examination
Pressure retaining plates in Amine or Wet H2S service shall be ultrasonically examined
as follows:
A. All pressure retaining plates over 1-1/2 inches (38 mm) in thickness shall be
ultrasonically examined in accordance with the requirements of ASME SA-578 Level
1. Scanning shall be along continuous perpendicular grid lines on nominal 9-inch
(22.9 cm) centers. All detonation (explosion) clad or roll clad plate material shall be
ultrasonically examined according to the procedure outlined in this paragraph.
Repair by welding of laminations in plates or clad backing plates in excess of those
outlined in ASME SA-578 Level 1 is not permitted unless written permission to
proceed with such repairs is received from the Buyer.
Revision 1
APPENDIX 02
SUPPPLEMENTARY MATERIAL AND FABRICATION REQUIREMENTS FOR

DUPLEX STAINLESS STEEL (UNS S32205, S31803 AND S32750)
1.0 GENERAL
1.1 These requirements pertaining to duplex stainless steels (DSS) supplement the
requirements of the equipment data sheet, Project Welding and Material Specifications
and API Technical Report 938-C.
1.2 OWNER shall authorize any exceptions to these requirements.
1.3 The hardness limits of NACE MR0103 shall be met for UNS S32205, S31803 and UNS
S32750 base metal and weldments in wet H2S service.
2.0 MATERIALS
Plate materials shall be supplied in accordance with ASME SA-240. Fittings shall be
supplied in accordance with ASME SA-182. Seamless pipe material shall be supplied in
accordance with ASME SA-790. Tubing shall be supplied in accordance with ASME SA-
789 and as modified in this specification. In addition, the materials shall satisfy the
following requirements:
2.1 Nitrogen shall be 0.14% minimum for UNS S31803.
2.2 Materials shall be water quenched or rapidly cooled in air after the final anneal.
2.3 DSS material shall be solution annealed to ensure adequate corrosion resistance, and
each heat of material shall be tested per Test Method B or C in ASTM A 923, and meet
the given criteria. The Rapid Screening Test included in ASTM A 923 shall not be used to
accept material.
2.4 Marking materials shall be suitable for stainless steels and contain less than 200 ppm
halogens and 200 ppm sulfur. When requested, composition certificates of marking
materials shall be provided. Dye stamping of final products is prohibited.
2.5 Tubing
2.5.1 Tubing shall be seamless, unless welded tubing is approved by OWNER. If

welded tubing is approved, it shall receive both hydrostatic testing and
nondestructive electric testing in accordance with ASME SA-789.
Revision 1
2.5.2 One specimen representing each heat lot shall receive a microstructural
examination per the requirements of ASTM A 923 Test Method A. The presence
of Affected or Centerline Structures shall be grounds for rejection of the solution
anneal batch represented by the specimen, and the batch shall require reheat
treatment and retesting.
2.5.3 No weld repairs to tubes are permitted. Repair of dents is not permitted.
2.5.4 Tubes and tube bends shall be solution annealed after bending or straightening if
cold work is in excess of 15%.
2.5.5 After heat treating, other than bright anneal procedures, all tubing shall receive a
descaling treatment followed by a neutralizing and appropriate rinsing treatment.
Other descaling, pickling and final surface treatments require prior approval by
OWNER.
3.0 WELDING AND FABRICATION
3.1 Joint Preparation
3.1.1 DSS may be cut using the plasma-arc process, a machine cutter, or grinding disc
dedicated solely for the use on DSS. Carbon-arc shall not be used for cutting or
back gouging. If plasma-arc cutting is used, a minimum of 1/16 of an inch of
base metal shall be removed by grinding or machining, back from the cut surface
during the beveling process to remove any heat affected zone (HAZ). The inside
and outside surfaces of plasma-arc cut base metal shall be thoroughly cleaned of
all spatter. During machining operations, only cutting fluids compatible with
stainless steel shall be used.
3.1.2 Any small burrs, nicks, or other irregularities on the weld bevel shall be repaired,
if possible, by light grinding. Any suspected edge defects or laminations shall be
reported to OWNER before proceeding with investigation or repairs. Repairs by
welding shall not proceed without prior approval of OWNER.
3.1.3 Each beveled edge and internal and external surfaces over a distance of at least
2 inches back from the bevel shall be cleaned immediately prior to welding.
.Cleaning shall include brushing with a stainless steel wire brush and wiping with
clean cloths and acetone, or other OWNER-approved solvent followed by drying
with clean cloths or dry filtered air.
Revision 1
3.2 General Welding Requirements
3.2.1 All welds, including tack welds shall be made with filler metal. Filler metal for
welding dissimilar metal joints shall be approved by OWNER on a case by case
basis.
3.2.2 The welding procedure specification (WPS) shall restrict the heat input during
welding to the Procedure Qualification Record (PQR) heat input values + or –
10%. In order to establish this + or – 10% range on the WPS, the amperage,
voltage, travel speed and resultant heat input must be recorded for each weld
pass used to weld the PQR coupon. The heat input ranges specified on the
WPS shall be no lower than 10% below the lowest value used on the PQR and
no higher than 10% above the highest value used on the PQR. Additionally, the
heat input specified on the WPS for UNS S31803 and UNS S32205 shall in all
cases be between 0.5 kJ/mm (12.7 kJ/in) and 2.5 kJ/mm (63.5 kJ/in), inclusively,
and between 0.2 kJ/mm (5.1 kJ/in) and 1.5 kJ/mm 38.1 kJ/in), (inclusively, for
UNS S32750. It is Suggested that a welding heat input matrix be prepared and
made part of the WPS to be used by the welder and Q.C. inspector to control the
production welding heat input. The welding heat input matrix in Table 1 is
provided as an example. The Seller is responsible for developing his own matrix
for each WPS based on the specific variables used to weld its supporting PQR.
3.2.3 The maximum interpass temperature shall not exceed 350°F for UNS S32205
and S31803 and 300°F for UNS S32750.
3.2.4 All single-welded, open root, full penetration groove weld joints {i.e., corner welds
(branch or nozzle attachments) and butt welds} as well as fillet welds joining pipe
nipples to socket-weld fittings shall be made with a GTAW root and “cold”
(second) pass. The joint shall be back purged until at least ¼ inch of weld metal
thickness has been deposited or until the weld is completed, whichever is less.
The cold pass should use a heat input no greater than 75% of the heat input
used for the root pass to avoid overheating the root pass. Backing gas shall be
an argon/nitrogen mixture with 5% nitrogen, preferably, or 100% argon or 100%
nitrogen. All backing gases shall be welding grade gases. Caution must be
exercised when using 100% nitrogen to avoid joint designs and welding
techniques that will cause the effective nitrogen content of the shielding gas to
increase which may result in a corrosion test coupon failure. The oxygen content
of the back-purged volume shall be less than 0.25% (2500 ppm). The Seller
shall submit details of the method and equipment to be used for monitoring
oxygen content as part of the welding procedure specification.
3.2.5 Under no circumstances shall the welding arc be struck outside the weld bevels.
If this occurs, the arc strike shall be removed by grinding. The ground area shall
be examined with liquid penetrant, and any relevant indications will require
repairs.
Revision 1
3.2.6 During production welding, calibrated equipment for measuring the following
variables shall be available at any time:
Welding current (amperage).

Arc voltage.
Interpass temperatures (digital).
Oxygen content of backing gas.
Wire Feed Speed.
Travel speed.
Shielding and backing gas flow rate.
3.2.7 Welds that are back gouged prior to welding the second side shall have liquid
penetrant examination performed on the back gouged surface. All back gouging
shall be accomplished with approved procedures.
3.2.8 All welds with access to the process side shall be cleaned after welding by hand
wire brushing of the as-welded surfaces.
3.2.9 All welds made, including those for tacking and fitup, shall be made with
approved weld procedures, materials and qualified welders.
3.2.10 Weld maps shall be submitted with applicable weld procedures, for review and
authorization to proceed prior to starting production welding.
3.3 Welding Procedure Specification (WPS) Requirements
WPSs shall be qualified in accordance with ASME Section IX and the requirements of
this specification. Existing WPS are acceptable provided they meet the requirements of
this specification.
3.3.1 Each WPS shall contain the information required by ASME Section IX, QW-250,
and the following:
a. The specific welding process or combination of processes to be used in

production.
b. Heat input range (maximum and minimum permitted). Refer to paragraph

3.2.2
c. 30-65% ferrite limit for deposited weld metal

Revision 1
3.4 Procedure Qualification Record (PQR) Requirements
3.4.1 Essential Variables
Essential variables for procedure qualification shall be in accordance with ASME Section
IX, QW-250 including supplementary essential variables for notch toughness, and those
listed below. Any changes in the essential variables of an approved WPS shall require
requalification.
For manual and machine welding:
a. Base metal thickness A change in base metal thickness more than

+ or – 20% from the PQR coupon thickness
b. Filler metal size: A change in diameter of the filler metal.
c. Shielding gas flow rate: A change in flow rate beyond -20% or

+10%.
d. Backing gas composition: A change in the gas composition.
e. Electrical characteristics: A change in type of current, polarity, or

pulse range.
f. Tube to tube sheet welding: Must be qualified per QW-288.
g. Heat input: A deviation from max. or min. Refer to

paragraph 3.2.2
For machine welding only:
h. Joint configuration: A change in joint configuration outside

tolerances specified in the procedure.
i. Weld position: A change in the weld position (e.g. vertical

to horizontal).
j. Filler metal: For SAW, a change in the brand name and

type of wire and flux.
3.4.2 PQR Test Specimens
The minimum number of mechanical test specimens required for a welding

procedure qualification test shall be in accordance with ASME Section IX, with
the addition of the following:
Revision 1
a. ASTM A923 Testing
Test Quantity of Specimens
ASTM A 923 Test Method B or C with:
Test Method B: Charpy V-notch at -40°C:
Weld centerline 2
Fusion line 2
Fusion line + 2.5 mm 2
Fusion line + 4.75 mm 2
Test Method C: Ferric Chloride
Corrosion Test 2
Cross-section for macro-examination, photo-micrographs 1
and ferrite measurements
Cross-section for Hardness Test Surveys 1

Impact testing per Test Method B may be waived if the specimen thickness is less than
0.098 inch. In such a case Test Method C must be used.
b. Ferrite Determinations
A cross-section of the PQR coupon shall be polished and etched to clearly

reveal the two-phase austenite/ferrite microstructure in preparation for making
the photo-micrographs required in paragraph 3.4.5. A Ferritescope shall be
used to determine the ferrite content of the base metal (unaffected by the heat of
welding) and the deposited weld metal on the prepared cross-section. The
Ferritescope shall be calibrated per AWS A4.2, using a set of “high” (typically
ranging from approximately 15% to 85%) ferrite weld-metal-like secondary
calibration standards. A ferrite determination shall be performed at each location
described below. All ferrite determinations made including individual readings
and their average shall be recorded on the PQR and identified in relationship to
the specific location examined.
Ferrite determinations shall be performed at the following locations. Each

determination shall be comprised of at least five readings. The average of the
five readings shall be within the percentages specified below.
 In the base metal unaffected by the heat of welding (i.e., at least ¼ of an

inch away from the weld fusion line), one determination shall be made on
each side of the weld at mid thickness of the PQR coupon (total of 2).
Revision 1
 In the weld deposit, 3 determinations shall be made near the vertical center
line of the weld, one in the cap, one in the root, and one at mid thickness of
the PQR coupon (total of 3).
Ferrite content at these locations shall be 35-65% for the base metal and 30-
65% for the weld deposit. Any deviation from these ranges must be approved
by OWNER/Buyer.
c. Photo-micrographs and Macro-examination
 Photo-micrographs at approximately x400 shall be provided to OWNER for

each of the locations where a ferrite determination is performed as
described above.
 Photo-micrographs shall show a typical austenite/ferrite microstructure.
 The macro-examination shall provide evidence that the weld is sound and
free from cracks and other defects with full penetration and fusion between
weld passes and base metal. Results of the macro-examination shall be
reported on the PQR.
d. Hardness Testing
PQR hardness testing of the base metal, weld and HAZ on a polished and
etched weld cross-section shall be performed per NACE RP0472, Figure 2 or 3,
as applicable, using the Vickers Hv10 method. No individual reading shall
exceed 320 Hv10 in any area. The average of the readings in any area (i.e.,
base metal, weld or HAZ) shall not exceed 310 Hv10.
3.4.3 Testing Laboratories
Third party laboratories performing testing (for both procedure qualification and
production) shall be experienced in the methods used for DSS testing. When
requested, SELLER shall submit to OWNER, the laboratory name and
qualifications.
3.5 Dissimilar Metal Welds
Dissimilar metal joints, e.g., carbon steel to DSS or austenitic stainless steel to DSS shall
require qualification and testing to all the requirements of this specification except that the
non-DSS HAZ need not be subjected to corrosion testing or impact testing beyond the
requirements of the applicable code.
Revision 1
4.0 PRODUCTION NDE AND TESTING
4.1 Liquid Penetrant Examination (PT)
All accessible completed production welds shall be PT examined. Procedures and

acceptance criteria shall be in accordance with Section VIII, Division 1, Appendix 8. The
examination shall include a band of base metal at least one inch wide on each side of the
weld and on both faces of the joint (if accessible).
4.2 Ferrite Checks
The ferrite content of all accessible completed production welds shall be determined
using a Fischer Feritescope in the deposited weld metal only. A minimum of 1
determination shall be made on each 5 feet of weld or part thereof. Each determination
shall be comprised of at least five readings. The average value of the Feritescope
readings on each weld shall be 30-65%. Where accessible, the ferrite determination
shall be made on the weld metal exposed to the service product. The Feritescope shall
be calibrated as given in paragraph 3.4.2 b. above.
4.3 Hardness Testing
Vickers Hv10 hardness tests using a Krautkramer MIC 10 instrument with a MIC #2010
(10kg) probe shall be performed in accordance with ASTM A1038 on all completed
pressure-retaining welds. The hardness test calibration standard used to calibrate the
production hardness tester shall be the same UNS number material as the production
part to be tested. The hardness of the calibration standard shall be tested per paragraph
6. of ASTM A 1038 using a Vickers “workbench” hardness tester with a 10 kgf load.
The laboratory report of hardness test readings for the calibration standard verification
shall be available for review by the client’s inspection representative upon request. One
hardness test comprised of five (5) readings per test shall be taken on the center of the
weld. The average of the five readings shall not exceed 310 Hv10, and no individual
reading shall exceed 320 Hv10. Hardness tests shall be on the surface exposed to the
service product, where possible.
5.0 PRODUCTION WELDING CONTROL
Along with the Seller’s submittal of WPS/PQRs for review, he shall also submit his Q.C.
procedure to be used to verify that the welding variables of the WPS are being followed
for production welding. The procedure shall specify the frequency of checking each
welder’s work (e.g., once at the beginning of each shift and once at mid-shift, as a
minimum). The Q.C. procedure shall include an example form to be used to record the
checking of at least the following variables: preheat and interpass temperature,
amperage, voltage, travel speed and resultant heat input. The production joint welded
and the WPS used shall also be recorded on the form for information.
Revision 1
Process: FCAW
Material: UNS S31803/UNS S32205
Consumable: Manufacturer: XXXX Brand: XXXX
AWS No.: E2209T1-4 Diameter: 0.045"
Heat Input: Minimum 15 KJ/in.
Maximum 59 KJ/in.
Table 1
Voltage Travel Speed Range (min/max)

(Volts) (in./min)
20.0 2.8/11.2 2.9/11.6 3.1/12.0 3.2/12.4 3.3/12.8 3.4/13.2

21.0 3.0/11.8 31/12.2 3.2/12.6 3.3/13.0 3.4/13.4 3.5/13.9
22.0 3.1/12.3 3.2/12.8 3.4/13.2 3.5/13.6 3.6/14.1 3.7/14.5
23.0 3.3/12.9 3.4/13.3 3.5/13.8 3.6/14.3 3.7/14.7 3.9/15.2
24.0 3.4/13.4 3.5/13.9 3.7/14.4 3.8/14.9 3.9/15.4 4.0/15.8
25.0 3.6/14.0 3.7/14.5 3.8/15.0 3.9/15.5 4.1/16.0 4.2/16.5
26.0 3.7/14.6 3.8/15.1 4.0/15.6 4.1/16.1 4.2/16.6 4.4/17.2
27.0 3.8/15.1 4.0/15.7 4.1/16.2 4.3/16.7 4.4/17.3 4.5/17.8
28.0 4.0/15.7 4.1/16.2 4.3/16.8 4.4/17.4 4.6/17.9 4.7/18.5
29.0 4.1/16.2 4.3/16.8 4.4/17.4 4.6/18.0 4.7/18.6 4.9/19.1
30.0 4.3/16.8 4.4/17.4 4.6/18.0 4.7/18.6 4.9/19.2 5.0/19.8
Current
140.0 145.0 150.0 155.0 160.0 165.0
(Amps)
Comments: Usage Example: If 150 Amps and 22 Volts used then the travel speed must be between 3.4 and 13.2 inches per minute.
The seller is responsible for developing his own matrix, similar to the example above, for each WPS based on the
variables used to weld its supporting PQR. See paragraph 3.2.2 for guidance on how to establish the qualified heat input
range. The minimum and maximum heat input value shall be specified on the matrix sheet as shown in the above
example. A “Usage Example”, as shown above in the Comments section, should be given for each matrix to help ensure
the welder understands how to use the matrix.
Revision 1
APPENDIX 03: WELDING REQUIEMENTS FOR cryogenic service
1.0 SCOPE
This Appendix addresses welding requirements for austenitic stainless steel equipment and
piping in cryogenic service. For the purpose of this Appendix, cryogenic service is defined
as a service with a MDMT (minimum design metal temperature) of -155°F (-104°C) or
colder.
2.0 WELDING PROCESSES
The GTAW process is the preferred process to be used. The GMAW-Spray/Pulsed Spray,
SAW and SMAW processes are not to be considered acceptable during bidding and
requires submittal of a summary of the Seller’s experience in welding cryogenic stainless
steel, including copies of their WPS/PQRs when applying for approval to use processes
other than GTAW. Use of the FCAW and GMAW-S processes is strictly prohibited.
3.0 FILLER METALS
3.1 Type 316L filler metal should be used instead of type 308L filler metal when
welding type 304L base metal.
3.2 Filler metal carbon content shall be as low as possible; ELC “Extra Low Carbon”
grades are preferred.
3.3 Filler metal delta ferrite content shall be as low as possible; preferably not greater
than 3% in general and not greater than 2% for MDMTs of -320°F (-196°C) and
colder.
3.4 Filler metal nitrogen content should be as low as possible, preferably not greater
than 0.05%.
3.5 Filler metal nickel content should be as high as possible within the range allowed
by the filler metal specification.
3.6 Lime type coating for SMAW electrodes is required (e.g., E316L-15).
Revision 1
4.0 INTERPASS TEMPERATURE MEASUREMENT
The interpass temperature shall not exceed 350°F (177°C) and shall be measured on the
deposited weld metal in the weld joint with a contact thermometer, not on the base metal
adjacent to the joint.
5.0 PRODUCTION FILLER METAL TESTING
5.1 Filler metal qualification tests shall be performed using the applicable WPS and
each heat/lot/batch of filler metal that will be used in production.
5.2 Each filler metal qualification test shall be conducted in accordance with ASME
Section IX, for impact testing only, with testing at the MDMT or colder. The
acceptance criteria shall be in accordance with the requirements for the base
metal.
5.3 A filler metal qualification test report, listing the test results, essential and
supplementary-essential variables and the applicable filler metal heat/lot/batch
numbers, must be recorded and attached to the Supplier’s standard PQR.
5.4 The applicable WPS shall specify the same heat/lot/batch numbers that were
used in the corresponding filler metal qualification test report.
5.5 The filler metals used for production welding shall be from the same
heat/lot/batch numbers that are specified on the WPS.
End of Specification

MQ SP M 4041

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Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Specification MQ-SP-M-4041

Project Name: MARAFIQ SPEC DEVELOPMENT Date: 01 Mar 2011

GENERAL WELDING /NDE SPECIFICATION FOR PRESSURE-RETAINING COMPONENTS

Revision Date Originator's Reviewed/Checked By Pages

APPROVALS SIGNATURES DATE

ISSUED FOR : Construction X Other Approved

GENERAL WELDING /NDE SPECIFICATION FOR PRESSURE-RETAINING COMPONENTS

Revision Date Description

A 7-Jan-11 Issue Table of Contents for Client Review.

0 10-Jan-11 Issue for Client Review.

1 1-Mar-11 Issued Approved

GENERAL WELDING /NDE SPECIFICATION FOR PRESSURE-RETAINING COMPONENTS

1.0 GENERAL .....................................................................................................................................................4

GENERAL WELDING /NDE SPECIFICATION FOR PRESSURE-RETAINING COMPONENTS

See Appendix 01 for specific requirements regarding welding, NDE and

Commodity Specification: Specification relating to the design or fabrication of

A. API (American Petroleum Institute)

1. 620, Std Design and Construction of Large, Welded, Low-Pressure

2. 650, Std Welded Steel Tanks for Oil Storage

B. ASME (American Society of Mechanical Engineers) Pressure Piping Code

1. B31.3 Process Piping

C. ASME (American Society of Mechanical Engineers) B&PV (Boiler and

1. Section II Part A – Ferrous Material Specifications

GENERAL WELDING /NDE SPECIFICATION FOR PRESSURE-RETAINING COMPONENTS

2. Section II Part B – Nonferrous Material Specifications

3. Section II Part C – Specifications for Welding Rods, Electrodes and

4. Section V Nondestructive Examination

5. Section IX Welding and Brazing Qualifications

6. Section VIII Pressure Vessels, Division 1: Rules for Construction of

7. Section VIII Pressure Vessels, Division 2: Alternative Rules

D. ASNT (American Society of Nondestructive Testing)

1. SNT-TC-1A Recommended Practice for Qualification of Nondestructive

E. AWS (American Welding Society)

1. AWS A2.4 Standard Symbols for Welding, Brazing and Nondestructive

2. AWS A3.0 Standard Welding Terms and Definitions

3. AWS A4.2 Standard Procedures for Calibrating Magnetic Instruments to

Submittals for Buyer review shall be in accordance with the following:

1. WPSs (Welding Procedure Specifications) and PQRs (Procedure

GENERAL WELDING /NDE SPECIFICATION FOR PRESSURE-RETAINING COMPONENTS

2. WPSs shall be clearly identified with the PO and Tag/Item number.

5. WPQs (Welder/Welding Operator Performance Qualifications) shall not be

B. NDE (Nondestructive Examination)

2. NDE procedures shall contain data required by this specification.

C. PWHT (Postweld Heat Treatment)

1.4 QA (Quality Assurance)

A. Requirements of Regulatory Agencies

2. WPSs, PQRs, and WPQs shall conform to the requirements of Section IX of

GENERAL WELDING /NDE SPECIFICATION FOR PRESSURE-RETAINING COMPONENTS

3. Compliance with this specification and authorization to proceed using

4. The control and handling of welding materials shall be addressed in the

GENERAL WELDING /NDE SPECIFICATION FOR PRESSURE-RETAINING COMPONENTS

A. The Work of this specification is subject to the requirements in the PO or

B. Welding symbols shall be in accordance with AWS A2.4.

C. Welding terms and definitions shall be in accordance with AWS A3.0.

D. Welding equipment voltmeters and ammeters shall be in proper working order

2.2 Welding Procedures

A. Welding shall be accomplished with WPSs in accordance with the requirements

C. Each Seller is responsible for the development, preparation, and qualification of

D. Tube-to-Tubesheet Welding Procedures shall be qualified in accordance with

2.3 Welder/Welding Operator Performance Qualifications

A. Welders shall be qualified in accordance with the requirements of ASME

B. The transfer of WPQs between Sellers is not permitted.

GENERAL WELDING /NDE SPECIFICATION FOR PRESSURE-RETAINING COMPONENTS