G3ir 1000 50 SP 9015 - R3

IFC Issued for Construction
Jan 03, 2013
Client Name : BASF India Limited Project Name : Project GIR Project Number : G3IR
Document No. G3IR-1000-50-SP-9015 Date 31-Dec-12 Page 2 of 20
WELDING / NDE SPECIFICATION FOR SHOP/FIELD FABRICATED PIPING.
Record of Revisions
This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions. Revision No. 0 Date Description
23-APR-12
Issued for Review/RFQ
29-May-12
Issued for Construction (IFC)
26-Nov-12
Re-Issued for Construction (IFC) Clause 1.1A revised to include requirements for welding of pipes & fittings. Clause 2.2D Submittals defined. Clause 2.3B PWHT requirement are defined. Clause 2.5 Delta Ferrite Testing requirement for Austenitic Stainless Steel is detailed. Appendix 03 revised to include RT requirement in AFA1E & NA1G spec.
31-Dec-12
Re-Issued for Construction (IFC) Appendix-03 revised to include 100% RT for Butt weld joints for Natural Gas service.
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DISCLAIMER: THIS SPECIFICATION DEVELOPED BY FLUOR DANIEL INDIA PRIVATE LIMITED, IS THE PROPERTY OF BASF INDIA LIMITED AND THIS SPECIFICATION CANNOT BE REPRODUCED, COPIED, DISTRIBUTED DIRECTLY OR INDIRECTLY OR OTHERWISE USED WITHOUT EXPRESS WRITTEN PERMISSION OF BASF INDIA LIMITED FOR ANY PURPOSE OTHER THAN FOR THE PROJECT FOR WHICH IT IS FURNISHED.
Table of Contents 1.0 2.0 3.0 4.0 GENERAL .....................................................................................................................................................5 PRODUCTS...................................................................................................................................................6 EXECUTION.................................................................................................................................................9 ATTACHMENTS....................................................................................................................................... 10
1.0
GENERAL
1.1
Summary A. Scope of Specification This specification prescribes requirements for welding of pressure-retaining piping and fittings, including non-pressure attachments thereto. B. Related Specifications Work in this specification shall be coordinated with Project specification as listed below.
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 on the drawings, Work included in this specification shall conform to the applicable provisions of these publications.
A.
ASME (American Society of Mechanical Engineers) 1. 2. 3. ASME B31.3 ASME Section V ASME Section IX Process Piping Nondestructive Examination Welding and Brazing Qualifications
B.
API (American Petroleum Institute) 1. API-582 Welding Guidelines for Chemical & Oil Industry.
C.
NACE (National Association of Corrosion Engineers) 1. NACE SP0403 Avoiding Caustic Stress Corrosion Cracking of Carbon Steel Refinery Equipment and Piping.
1.3
Submittals Submittals shall be made to the Buyer or their designated representative in accordance with the PO or Project Scope of Work and the following: A. Welding Submit WPSs (Welding Procedure Specifications) and PQRs (Procedure Qualification Records)
B.
NDE & Heat Treatment Procedure Submit the required documents.
1.4
IBR Piping Welding IBR code- 1950, Regulation No.-360.
2.0
PRODUCTS 2.1 General General design and fabrication requirements shall be in accordance with ASME B31.3. 2.2 Welding A. Acceptable Welding Processes See Appendix 03 for list of acceptable welding processes and associated limitations. B. Selection Selection of the proper welding consumables for welding process cannot be made without adhering to the following steps: Filler metal shall be used as per ASME Sec II Part C. Determine the base metal chemistry and minimum tensile strength after heat Treatment, if required. Determine the welding process and position to be used. Select filler metal and flux by closely matching the general base metal chemistry, minimum tensile and impact properties with the deposited filler metal. Refer the (American Welding Society) specifications listed on Appendix 04 for the required information. If required by the welding process to be used, a shielding gas compatible with the base metal and weld metal must be chosen. Because weld metal performance is affected by shielding gases, the next section contains a brief discussion of the subject.
SMAW electrodes of non-low hydrogen classification shall not be used for pressure retaining welds, with the exception of E6010 and E7010 maybe used for root pass welding of single sided welds. Low hydrogen SMAW electrodes shall always be stored in one of the following manner :1. Unopened and undamaged hermetically sealed container. 2. Electrode storage oven at 120 C or in accordance with filler material manufacturers recommendations.
For GTAW process, gas used for shielding shall be welding grade and shall have a dew point of minus 40 C or lower. Dissimilar metal joints between galvanized P No-1 base metal and P No 8 base metal are not acceptable.
C.
Weld Joint Fit-up The WPS or engineering design document shall specify maximum pipe wall offset (hilow) for single-welded butt joints.
D.
Submittals Following vendor documents shall be submitted to Fluor for review / approval before shop/ field fabricated starts :a) WPS/ PQR b) Procedure of Non-destructive examinations (including Hydrostatic Test)
2.3
Thermal Treatment A. Preheat and Interpass Requirements The minimum preheating temperatures for welding, thermal cutting, and tack welding, including bridge tacks, shall be as specified in the WPS, or the applicable Code, whichever is greater. B. PWHT (Postweld Heat Treatment) Requirements
1. 2.
PWHT of piping of various metallurgy shall be in accordance with ASME B31.3 PWHT, if required, shall be performed in an enclosed furnace or by electrical resistance heating methods. Buyer permission is required to use other PWHT methods.
3.
For caustic service, for CS welds, postweld heat treatment shall NOT be carried out in this project. For PQR testing, max permissible hardness of weld of P1 to P7 material shall be as per API 582. Material & Welding Specialist of Fluor will evaluate PQR of specific WPS for hardness requirement stated therein by the contractor. For production welds in P-1 material, the max permissible hardness of weld shall be 200 BHN after PWHT for Caustic service.
4.
5.
2.4
NDE (Nondestructive Examination) Requirements The extent of NDE for each piping line class is specified in Appendix 03. A. Visual Examination Visual examination and evaluation of indications shall be in accordance with ASME B31.3, Paragraph 344.2 and ASME Code, Section V, Article 9. B. Liquid Penetrant Examination 1. Liquid penetrant examination and evaluation of indications shall be in accordance with the requirements and methods specified in ASME B31.3, Paragraph 344.4 and ASME Code Section V, Article 6. Liquid penetrant examination of welds shall include a band of base metal at least 1 inch (25 mm) wide on each side of the weld. In-process liquid penetrant examination. When liquid penetrant examination is substituted for ultrasonic examination, the root pass, intermediate passes (if specified by the Buyer) and the finished weld shall be examined by the liquid penetrant method.
2.
3.
C.
Magnetic Particle Examination 1. Magnetic particle examination and evaluation of indications shall be in accordance with the requirements and methods specified ASME B31.3, Paragraph 344.3 and ASME Code, Section V, Article 7. Magnetic particle examination of welds shall include a band of base metal at least 1 inch (25 mm) wide on each side of the weld. The AC magnetic yoke method shall be used. In-process magnetic particle examination. When magnetic particle examination is substituted for ultrasonic examination, the root pass, intermediate passes (if specified
2.
3.
by the Buyer), and the finished weld shall be examined by the magnetic particle method. D. Ultrasonic Examination Ultrasonic examination and evaluation of indications shall be in accordance with the requirements and methods specified in ASME B31.3, and paragraph 344.6 and ASME Code Section V Article 5. 1. Ultrasonic examination may be substituted for radiographic examination when permitted by the Buyer. When a single-wall radiographic technique cannot be used on weld joints requiring radiography and the pipe wall thickness exceeds 1-1/4 inches (32 mm), the welds shall be 100% ultrasonically examined in lieu of radiographic examination.
2.
E.
Radiographic Examination 1. Radiographic examination procedures, techniques, and evaluation of indications shall be in accordance with ASME B31.3, and ASME Code Section V, Article 2. Additional requirements for radiographic examination shall be as follows: a. Radiographs shall be made using industrial radiographic film of optical density of 2.0. Lead screens shall be used. Approval from the Buyer or their designated representative is required for use of penetrameters other than those specified in the applicable Code. Whenever less than 100% radiography is specified, the following rule shall apply: The percent of welds specified on Appendix 03 shall be radiographed around their entire circumference. A record shall be kept of the quality and extent of each welder's work. Each welders work shall be represented in the percentage of welds examined. e. Wire type image quality indicators (IQIs) equal to those meeting EN462-1, DIN 54109 or JIS-Z3104 requirements may be substituted for those specified in ASME Section V provided an equivalent sensitivity is met.
2.
b. c.
d.
2.5
Delta Ferrite Testing Following shall be the procedure for the requirement of delta ferrite testing in welds of austenitic stainless steel piping during shop and field fabrication :A. Delta ferrite testing of austenitic stainless welds is required irrespective of service fluid being handled. Minimum Five percent (5%) of pressure-retaining welds in austenitic stainless steel shall be tested for delta ferrite content in the weld deposit. Delta ferrite determinations made using magnetic instruments shall be performed before PWHT. Delta ferrite content shall be 3 - 10 FN for welds operating temperatures of 800 F (425C) and above, or for welds planned to be subjected to thermal treatment. For welds with operating temperatures below 800 F (425 C), the delta ferrite content shall be 3 12 FN. Delta ferrite shall be determined by a portable magnetic instrument calibrated in accordance with AWS A4.2 /4.2M
B.
C.
D.
E.
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. Welding shall not be done when the ambient air temperature is lower than 0F (minus 18C) or when surfaces are wet, exposed to rain, snow, sleet, or high wind. The ambient air temperature may be below 0F (minus 18C) during welding, however a heated structure or shelter around the area being welded must maintain the air temperature adjacent to the weldment at 0F (minus 18C) or higher.
B.
4.0
APPENDICES APPENDIX 01 STANDARD WELD JOINT SYMBOLS APPENDIX 02 STANDARD NDE/HEAT TREAT/TEST SYMBOLS APPENDIX 03 SUMMARY OF HEAT TREATMENT, EXAMINATION & WELDING REQUIREMENTS FOR WELDED PIPING. APPENDIX 04 AWS FILLER METAL SPECIFICATIONS
APPENDIX 01 STANDARD WELD JOINT SYMBOLS
ABBR BW SBR SW OL FW PFW TC TC/S
JOINT TYPE Butt Weld Branch Weld Socket Weld O'lets Fillet Weld Pressure Fillet Weld Threaded Threaded/Seal Welded
DESCRIPTION OF APPLICABLE JOINTS Pipe-to-pipe, including miters or any combination of Pipe/Fitting/ Valves. Includes branch butt welds (i.e., Sweep-o-lets) Branch pipe attachment to run pipe, includes Set-in or Set-on Pipe to Socket connections O'let attachment to run pipe Non-pressure attachments (e.g., guides, supports, etc.) Slip-on flanges or Reinforcing Pads Threaded connection (Non-Seal Welded) Threaded connection (Seal Welded)
APPENDIX 02 STANDARD NDE/HEAT TREAT/TEST SYMBOLS
ABBR RT MT PT UT VT HT PMI FN CVN PWHT
TYPE OF OPERATION Radiography Magnetic Particle Examination Liquid Penetrant Examination Ultrasonic Examination Visual Examination Hardness Test Positive Material Identification Delta Ferrite Determination Impact Testing Postweld Heat Treatment
REMARKS All types, nil, 10% and Full 100% All methods, Wet or Dry All methods All methods, excluding thickness testing Dimensional checks, etc. All methods All methods All methods Charpy V-Notch If Required
Document No. : G3IR-1000-50-SP-9015 Date 19-Nov-12 Page 13 of 20
WELDING /NDE SPECIFICATION FOR SHOP / FIELD FABRICATION APPENDIX 03 SUMMARY OF HEAT TREATMENT, EXAMINATION & WELDING PROCEDURE REQUIREMENTS FOR WELDED PIPING. HEAT TREATMENT L I N E C L A S S C PIPE O MATERI D AL AND E PNUMBE C R OR A ST NUMBE E R G O R Y S O C K E & T B U T T F & I L S L E E A T L N O N P R E S B E N D S NOTES R A N D O M E X A M I N E DESTRUCTIVE & NONDESTRUCTIVE EXAMINATION WELDING PROCEDURES
Numbers listed in this column are applicable note numbers. Post weld treatment when required will be noted on the isometric drawing.
1 0 0 % V I S U A L
NOTES
NOTES
Numbers listed in this column are applicable note numbers.
Authorized welding procedures.
AFA1E RT.% CASB 5% NA1
A T T A C H W W M E E E L L N D D T S S S N A312 304 - - SS P-8 N A106B/A 53B P-1 N A106B P-1 -
1a
2a, 3b
1a
2a, 3b
NA1F
1a
2e, 3b
ROOT PASS GTAW FILLER PASS SMAW ROOT PASS SMAW FILLER PASS SMAW ROOT PASS GTAW FILLER PASS SMAW
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WELDING /NDE SPECIFICATION FOR SHOP / FIELD FABRICATION HEAT TREATMENT L I N E C L A S S C PIPE O MATERI D AL AND E PNUMBE C R OR A ST NUMBE E R G O R Y S O C K E & T B U T T F & I L S L E E A T L N O N P R E S B E N D S NOTES R A N D O M E X A M I N E DESTRUCTIVE & NONDESTRUCTIVE EXAMINATION WELDING PROCEDURES
1 0 0 % V I S U A L
NOTES
NOTES
NA1G RT. % CASA-10% NA1T RT. % NG-100% NAB1
A106B P-1
A T T A C H W W M E E E L L N D D T S S S - - -
1a
2a, 3b
A106B P-1
1a
2e, 3b
A106 IBR P-1
1a
2c, 3b
ROOT PASS GTAW FILLER PASS SMAW ROOT PASS SMAW FILLER PASS SMAW ROOT PASS SMAW FILLER PASS SMAW
1 0 0 % V I S U A L
NOTES
NOTES
NAN1 (SERVICES) RT. % PW- 10% RW-NIL CHWS-10% CHWR-10% STS- NIL TWW-NIL CWS-10% CWR-10% TWS/TWR10% (Note : 6a)
A T T A C H W W M E E E L L N D D T S S S IS-1239/ - - IS-3589 P-1
1a
2a, 3a
ROOT PASS SMAW FILLER PASS SMAW
1 0 0 % V I S U A L
NOTES
NOTES
NAN1F
A T T A C H W W M E E E L L N D D T S S S IS-1239/ - - IS-3589 P-1 IS-1239 P-1 -
1a , UG/AG
2a, 3a
NAN1N
1a
2a, 3a
NANG1 (SERVICES) RT.% PW- 10% IA-10% PA-NIL ( Note: 6a)
IS-1239/ IS-3589 P-1
1a
2a, 3a
ROOT PASS SMAW FILLER PASS SMAW ROOT PASS SMAW FILLER PASS SMAW ROOT PASS SMAW FILLER PASS SMAW
1 0 0 % V I S U A L
NOTES
NOTES
NFA1
ASTM A312 304 SS P-8 ASTM A312 316L SS P-8 PP LINED FRP HDPE PIPE
A T T A C H W W M E E E L L N D D T S S S - - -
1a
2a, 3b
NGB1P
1a
2a, 3b
NTP1
AG/UG
N/A
ROOT PASS GTAW FILLER PASS SMAW, Note- 4a. ROOT PASS GTAW FILLER PASS SMAW , Note- 4a. PLASTIC PIPES
NUH1
U/G
N/A HDPE PIPE
1 0 0 % V I S U A L
NOTES
NOTES
NUH1S
RAB1
A T T A C H W W M E E E L L N D D T S S S - SPECIAL - - GRADE PE N A106 IBR - - P-1
N/A
N/A PLASTIC PIPE
1a
2c, 3b,
RFA1
ASTM A312 304 SS P-8 A106 IBR P-1 -
1a
2a, 3b
SAB1
1a
2c, 3b
ROOT PASS SMAW FILLER PASS SMAW ROOT PASS GTAW FILLER PASS SMAW, Note 4a ROOT PASS SMAW FILLER PASS SMAW
WELDING /NDE SPECIFICATION FOR SHOP / FIELD FABRICATION Explanation of Notes used in Table SMAW - Shielded Metal Arc Welding GTAW Gas Tungsten Arc Welding
1a
Preheat of base metal shall be in accordance with the "Recommended" or "Required" temperature specified in ASME B31.3 Table 330.1.1, whichever is higher. The minimum interpass temperature shall not be less than the minimum preheat temperature. Radiograph (RT) testing shall be Ten percent of the total number of buttwelds, randomly selected, in accordance with ASME B31.3, Paragraph 341.4.1 (a), (b) &(c). For fillet & socket welds 10% MPI/ DPT on inner surface is preferable, otherwise on outer surface. Deleted As per IBR Regulation no. 360. Deleted Radiograph (RT) testing shall be hundred percent of the total number of buttwelds, in accordance with ASME B31.3, Paragraph 341.4.1 modified to include hundred percent. For fillet & socket welds 100% MPI/ DPT on inner surface is preferable, otherwise on outer surface. Visual examination for Category "D" Fluid Service shall be performed in accordance with ASME B31.3, Paragraph 341.4.2 (Paragraph A341.4.2 for Nonmetallic Pipe and Piping Lined with Nonmetals) to the extent necessary to satisfy the examiner that all requirements are met. Visual examination for Normal Fluid Service shall be performed in accordance with ASME B31.3, Paragraph 341.4.1(a). (Paragraph A341.4.1 for Nonmetallic Pipe and Piping Lined with Non metals). Based on the thickness of the filler pass GTAW welding can be used in lieu of SMAW .This will be identified in WPS and PQR and will be authorized by Buyer. In case of caustic and acid services, for single side welds, root run shall be carried out as per GTAW method. PW RW CHWS/CHWR STS TWW CWS/CWR TWS/TWR IA PA CASA CASB - Process Water - Raw Water - Chilled Water Supply/Return - Storm Water (A/G) - Treated Waste Water (A/G & U/G) - Cooling Water Supply/Return (A/G & U/G) - Tempered Water Supply/Return - Instrument Air - Plant Air - CAUSTIC (INFRA) - CAUSTIC (EM)
2a
2b 2c 2d 2e
3a
3b
4a
5a 6a.
WELDING /NDE SPECIFICATION FOR SHOP / FIELD FABRICATION
APPENDIX 04 AWS FILLER METAL SPECIFICATIONS
Number A5.1 A5.2 A5.4 A5.5 A5.9
Title Carbon Steel Electrodes for Shielded Metal Arc Welding Carbon and Low Alloy Steel Rods for Oxy fuel Gas Welding Stainless Steel Electrodes for Shielded Metal Arc Welding Low Alloy Steel Covered Arc Welding Electrodes Corrosion - Resisting Chromium and Chromium - Nickel Steel Bare and Composite Metal Cored and Stranded Welding Electrodes and Welding Rods Solid Surfacing Welding Rods and Electrodes Welding Electrodes and Rods for Cast Iron Carbon Steel Electrodes and Fluxes for Submerged Arc Welding Carbon Steel Filler Metals for Gas Shielded Arc Welding Low Alloy Steel Electrodes and Fluxes for Submerged Arc Welding Carbon and Low Alloy Steel Electrodes and Fluxes for Electro slag Welding Carbon and Low Alloy Steel Electrodes for Electro gas Welding Copper and Copper Alloy Gas Welding Rods Low Alloy Steel Filler Metals for Gas Shielded Arc Welding Low Alloy Steel Electrodes for Flux Cored Arc Welding Consumable Inserts
A5.13 A5.15 A5.17 A5.18 A5.23 A5.25 A5.26 A5.27 A5.28 A5.29 A5.30

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IFC Issued for Construction

Jan 03, 2013

Document No. G3IR-1000-50-SP-9015 Date 31-Dec-12 Page 2 of 20

WELDING / NDE SPECIFICATION FOR SHOP/FIELD FABRICATED PIPING.

Issued for Review/RFQ

Issued for Construction (IFC)

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Document No. G3IR-1000-50-SP-9015 Date 31-Dec-12 Page 3 of 20

WELDING / NDE SPECIFICATION FOR SHOP/FIELD FABRICATED PIPING.

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Document No. G3IR-1000-50-SP-9015 Date 31-Dec-12 Page 4 of 20

WELDING / NDE SPECIFICATION FOR SHOP/FIELD FABRICATED PIPING.

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Document No. G3IR-1000-50-SP-9015 Date 31-Dec-12 Page 5 of 20

WELDING / NDE SPECIFICATION FOR SHOP/FIELD FABRICATED PIPING.

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Document No. G3IR-1000-50-SP-9015 Date 31-Dec-12 Page 6 of 20

WELDING / NDE SPECIFICATION FOR SHOP/FIELD FABRICATED PIPING.

NDE & Heat Treatment Procedure Submit the required documents.

IBR Piping Welding IBR code- 1950, Regulation No.-360.

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Document No. G3IR-1000-50-SP-9015 Date 31-Dec-12 Page 7 of 20

WELDING / NDE SPECIFICATION FOR SHOP/FIELD FABRICATED PIPING.

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Document No. G3IR-1000-50-SP-9015 Date 31-Dec-12 Page 8 of 20

WELDING / NDE SPECIFICATION FOR SHOP/FIELD FABRICATED PIPING.

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Document No. G3IR-1000-50-SP-9015 Date 31-Dec-12 Page 9 of 20

WELDING / NDE SPECIFICATION FOR SHOP/FIELD FABRICATED PIPING.

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Document No. G3IR-1000-50-SP-9015 Date 31-Dec-12 Page 10 of 20

WELDING / NDE SPECIFICATION FOR SHOP/FIELD FABRICATED PIPING.

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Document No. G3IR-1000-50-SP-9015 Date 31-Dec-12 Page 11 of 20

WELDING / NDE SPECIFICATION FOR SHOP/FIELD FABRICATED PIPING.

APPENDIX 01 STANDARD WELD JOINT SYMBOLS

ABBR BW SBR SW OL FW PFW TC TC/S

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Document No. G3IR-1000-50-SP-9015 Date 31-Dec-12 Page 12 of 20

WELDING / NDE SPECIFICATION FOR SHOP/FIELD FABRICATED PIPING.

APPENDIX 02 STANDARD NDE/HEAT TREAT/TEST SYMBOLS

ABBR RT MT PT UT VT HT PMI FN CVN PWHT

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Document No. : G3IR-1000-50-SP-9015 Date 19-Nov-12 Page 13 of 20

Numbers listed in this column are applicable note numbers.

Authorized welding procedures.

AFA1E RT.% CASB 5% NA1

A T T A C H W W M E E E L L N D D T S S S N A312 304 - - SS P-8 N A106B/A 53B P-1 N A106B P-1 -

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Document No. : G3IR-1000-50-SP-9015 Date 19-Nov-12 Page 14 of 20

Numbers listed in this column are applicable note numbers.

Authorized welding procedures.

NA1G RT. % CASA-10% NA1T RT. % NG-100% NAB1

A106 IBR P-1

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Document No. : G3IR-1000-50-SP-9015 Date 19-Nov-12 Page 15 of 20

Numbers listed in this column are applicable note numbers.

Authorized welding procedures.

A T T A C H W W M E E E L L N D D T S S S IS-1239/ - - IS-3589 P-1