JERES W 016 Welding Special Corrosion Resistant Materials

JERES-W-016 Welding of Special Corrosion

Resistant Materials

Revision 0

Responsibility JER Engineering Division

29 April 2008

Jubail Export Refinery Engineering Standards


JERES-W-016 Rev. 0

Welding of Special Corrosion –Resistant Materials 29 April 2008

This document is the property of Jubail Export Refinery and no parts of this document shall be reproduced by

any means without prior approval by the Company.

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Revision Tracking

Revision Revision Date Scope of Revision

0 29 April 2008 Issued for bid package.

04 21 April 2008 Revised to incorporate technical audit team comments.

03 31 March 2008 Issued for bid package for review.

02 18 February 2008 Updated as indicated.

01 25 May 2007 The first official JERES-W-016 is issued.

00 12 April 2007 Revised as per JER comments

00 30 January 2007 First draft issued is based on Saudi Aramco SAES-W-016 “Welding of Special Corrosion – Resistant Materials” issue date 30 March, 2005. Document was modified to incorporate amendments and modifications.


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Table of Contents

Section Contents Page

1 Scope 4

2 Conflicts, Deviations and Clarifications 5

3 References 5

4 Definitions 6

5 General 8

6 High Temperature Applications 8

7 Corrosive Services 8

8 Special Requirements for Duplex Stainless Steels 11

Appendixes

A Filler Metal and Electrode Selection 20

B Recommended Welding Consumable for Duplex 21

C Minimum requirements for DSS Base Metal 22


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1 Scope

1.1 This standard specifies the requirements for welding and testing of special corrosion-resistant piping materials. This is defined as stainless steel and nickel-based alloys for piping in severe corrosion service and high temperature service, as defined below. Severe corrosion service is defined as:

a) Any service listed in JERES-L-132 which specifies the use of either austenitic stainless steel, excluding types 304/304L/316/316L, or nickel-based alloys.

b) Any service that uses duplex stainless steels.

Commentary Note:

Use of stainless steel or nickel-based alloys for product cleanliness (e.g., lube oil piping or aircraft refueling facilities) or mechanical properties (e.g., low temperature service requiring impact toughness) are not included.

High temperature service is defined as any application with a design temperature above 427°C.

1.2 Other applications (e.g., pressure vessels) may also be subject to this standard if the application standard or any other document makes reference to this standard.

Commentary Note:

This standard is also applicable to pressure vessels

1.3 These requirements are in addition to the requirements of AMSME B31.3, ASME SEC VIII and ASME SEC IX.

1.4 This standard is to be considered as a supplement to JERES-W-011 and/or JERES-W-010.

1.5 This entire standard may be attached to and made part of purchase orders.

1.6 Additional requirements may be contained in Scopes of Work, Drawings, or other Instructions or Specifications pertaining to specific items of work.

1.7 Strip lining and weld overlay applications are excluded from this document.

Commentary Note:

Refer to JERES-W-014 for welding requirements for overlays.


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1.8 Any reference to COMPANY shall be interpreted as the COMPANY Welding Specialist or a representative designated by COMPANY. Any reference to "approval" shall be interpreted as written approval.

2 Conflicts, Deviations and Clarifications

2.1 Any conflicts between this standard and other applicable Company Engineering Standards (JERES), Material Specifications (JERMS), Standard Drawings (JERSD), Engineering Procedures (JEREP), Company Forms or Industry standards, specifications, Codes and forms shall be brought to the attention of Company Representative by the Contractor for resolution.

Until the resolution is officially made by the Company Representative, the most stringent requirement shall govern.

2.2 Where a licensor specification is more stringent than those of this standard, the Licensor’s specific requirement shall apply.

2.3 Where applicable Codes or Standards are not called by this standard or its requirements are not clear, it shall be brought to attention of Company Representative by Contractor for resolution.

2.4 Direct all requests for deviations or clarifications in writing to the Company or its Representative who shall follow internal Company procedure and provide final resolution.

3 References

The selection of material and equipment, and the design, construction, maintenance, and repair of equipment and facilities covered by this standard shall comply with the latest edition of the references listed below as of the CUT-OFF DATE as specified in the Contract unless otherwise noted.

3.1 Company References

Company Engineering Procedure

Company Engineering Standards

JERES-A-301 Materials in Wet H2S Services

JERES-L-132 Velocity Criteria and Basic Material Selection for Process Piping


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JERES-W-011 Welding Requirements for On-Plot Piping

JERES-W-010 Welding Requirements for Pressure Vessels

JERES-W-014 Weld Overlays and Welding of Clad Materials

3.2 Industry Codes and Standards

American Society of Mechanical Engineers

ASME SEC IIC Welding Rods, Electrodes and Filler Metals

ASME SEC VIII Rules for Construction of Pressure Vessels

ASME SEC IX Welding and Brazing Qualifications

ASME B31.3 Chemical Plant and Petroleum Refinery Piping

American Society for Testing and Materials

ASTM A833 Indentation Hardness of Metallic Materials by Comparison Hardness Testers

ASTM E140 Hardness Conversion Tables for Metals

ASTM E562 Standard Test Method for Determining Volume Fraction by Systematic Manual Point Count

ASTM G48 Standard Test Methods for Pitting and Crevice Corrosion Resistance of Stainless Steels and Related Alloys by the Use of Ferric Chloride Solution

American Welding Society

AWS A4.2 Standard Procedures for Calibrating Magnetic Instruments to Measure the Delta Ferrite Content of Austenitic and Duplex Austenitic-Ferritic Stainless Steel Weld Metal

AWS D18.2 Guide to weld discoloration levels on inside of austenitic stainless steel tube.

American Petroleum Institute

API Technical Report 938C Use of duplex stainless steels in the oil refinery industry

British Standards Institution

BS EN 1043-1 Destructive tests on welds in metallic materials. Hardness testing – Hardness test on arc welded joints.


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4 Definitions

4.1 Definitions presented in this Standard and other JER documents have precedence over other definitions. Conflicts between various definitions shall be brought to the attention of Company Representative by the Contractor for resolution.

Company: Jubail Export Refinery.

Company Representative: A designated person from the Company or an assigned third party representative.

Company Inspector: A designated person or an agency responsible for conducting inspection activities on behalf of the Company.

4.2 List of Definitions

Atmospheric Pressure: An internal pressure that results in total uplift force not exceeding the weight of the tank roof.

Auto-Refrigeration Temperature: Auto-refrigeration temperature is the temperature resulting from adiabatic vaporization at atmospheric pressure of the process fluid. The value of this temperature shall result from a process simulation.

Design Engineer: The Engineering Company responsible for specifying, on the design data sheet, the design requirements for equipments and/or piping.

Low-Flash Liquids: Hydrocarbon liquids with a flash point below 54°C (129°F) or within 8°C (14.4°F) of their flash point. Crude oils are not included in this category.

Low-Pressure: An internal pressure that exceeds the weight of the tank roof but does not exceed 103 kPa gauge (15 psig).

Reid Vapor Pressure: The vapor pressure of hydrocarbon liquids at 38°C (129°F) as measured in accordance with ASTM D323.

Manufacturer: The Company responsible for the design and fabrication of equipments and/or piping.

5 General

5.1 All WPS/PQR and also fabrication shall be in accordance with ASME SEC IX plus the additional requirements of JERES-W-011, JERES-W-010 and this standard.


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5.2 Ferrite measurements shall be performed in accordance with AWS A4.2.

5.3 Abrasive tooling and/or grinding disks shall not have been used on either carbon steel or any other grade of stainless steel material. The selection of grinding and cleaning tools shall be appropriate for the base material, e.g., carbon steel brushes shall not be used on stainless steel material.

5.4 All filler materials should be individually and clearly stamped, flagged or stenciled to ensure traceability and correct usage on site and/or at plant.

6 High Temperature Applications

6.1 The welding procedure qualification for austenitic stainless steels, except type 310, shall include a determination of the Ferrite Number in the as-welded condition. The Ferrite Number shall be between 3 and 10 FN.

6.2 For production welds, the ferrite content shall be checked in the as-welded condition. The Ferrite Number shall be between 3 and 10 FN.

6.3 Any welding on high carbon grades of austenitic stainless steel material (e.g., 304H or HK40) after service times exceeding 1 year shall require a re-solution heat treatment prior to welding.

7 Corrosive Services

7.1 The GTAW process shall be used for the following applications:

1) The root pass of single-sided groove welds without backing.

2) For all passes for piping, tubes, and nozzles of 2 inch nominal diameter or less.

3) For all passes for wall thickness less than 9.5 mm for duplex stainless steel or for wall thickness less than 6.5 mm for other Corrosion Resistant Alloys (CRA).

7.2 All manual GTAW shall use a high frequency start and post-purge gas flow for the torch. A remote contractor and current control (pedal or torch mounted) is required. Pre-set power source current start/rise and decay/stop controls triggered by a foot switch or torch mounted control is an acceptable alternative for the remote control.

7.3 For all GTAW welding, filler metal shall be added. Autogenous welding of any pass is not permitted.


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The filler metal shall be selected as shown in appendix A, in JERES-W-010 and JERES-W-011, as applicable.

7.4 The maximum interpass temperature shall not exceed 100°C.

7.5 Backing Gas and Purging

7.5.1 The purge times for the backing gas shall be calculated to give a theoretical volume change of 6 times the enclosed pipe volume. Table 2 is shown for information and can be used for the standard conditions as listed in the table. Extra purging time is necessary if the purge gas inlet and outlet (vent) cannot be placed at opposite ends of the enclosed volume in order to insure complete displacement of the original air.

7.5.2 The purge shall achieve actual oxygen levels inside or exiting the joint (via the vent) no greater than 1% prior to and during welding, as measured using an oxygen analyzer. The actual oxygen levels achieved in production shall be measured periodically (i.e., on a random basis for the number of joints to be performed). Analyzers shall be used for all joints if excessive internal oxidation is observed on any joints based on the visual appearance of the oxide tint. Oxyde tint shall be referred to AWS D 18.2

7.5.3 During pre-weld purging, the joint area shall be adequately sealed at all openings to maintain the purge and prevent any air ingress.

If purge dams are to be used but cannot be retrieved after welding, then proprietary dissolvable (water soluble) dams shall be used (Only in case of final hydraulic test). For golden welds/closure welds that may not be tested by hydraulic tests, special considerations such as specific nozzles for installation and removing of purge dams shall be considered by Manufacturer.

7.6 Joint Design

For GTAW, the root gaps must be specified and maintained during welding at equal to or larger than the root pass filler wire diameter.

Maximum internal misalignment between pipe or tube sections shall not exceed 1.6 mm.

7.7 Joint preparation

7.7.1 Cutting and beveling


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CRA may be cut using the plasma-arc process, a machine cutter, or grinding disc dedicated solely for the use on CRA. Carbon-arc shall not be used for cutting or backgouging.

If plasma-arc cutting is used, the inside surface must be thoroughly cleaned of all spatter. Sufficient metal shall be removed in the beveling process to remove any HAZ that occurred as a result of the plasma-arc cutting. Once used for cutting CRA, grinding discs shall be used exclusively for that purpose, and contamination with carbon steel should be avoided during all steps. The final surface preparation and configuration shall be obtained by machining. During machining operations, only a cutting fluid compatible with stainless steel shall be used.

7.7.2 Imperfections

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 the purchaser prior to proceeding with investigation or repairs. Repairs by welding shall not proceed without prior approval of the Company Representative.

7.7.3 Cleaning

Each beveled edge, and internal and external surfaces over a distance of at least 50 mm back from the bevel shall, immediately prior to welding, be thoroughly dried, and shall be cleaned with a stainless steel wire brush. The beveled edge shall then be wiped clean with acetone, or other approved solvent.

7.7 Tacking

A minimum of 4 equi-spaced tacks around a pipe circumference shall be used.

Either root tacks or bridge tacks are permitted. Root tacks must be either feathered or ground out prior to making the root pass.

7.8 Technique

Either high frequency (HF) or high voltage (HV) arc initiation shall be used.

Commentary Note:

HF may be used (but is not required) continuously.

The continuous feed technique shall be used for the root pass (i.e., the filler wire is positioned between the root faces and fed continuously into the weld pool).

Commentary Note:


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The welder must avoid narrow root gaps and improper travel speeds in order to achieve the proper root bead deposit chemistry.

Stringer beads shall be used. Minor arc oscillation to ensure sidewall fusion is permitted.

ForAvesta 254 SMO, heat input shall be kept to a minimum, and if possible not over 10 kJ/cm (15 kJ/cm maximum).

Whenever the welder stops welding, the welding current shall be gradually decreased by use of the remote current control. The torch shall be held in position close to the weld pool until the gas shielding post-purge flow is completed.

Grinding of all start/stops is required. Commentary Note:

The maximum interpass temperature needs to be monitored regularly by the welder.

7.9 Inspection

7.9.1 Visual Inspection

All weld surfaces and heat affected zones must be free of dark colored and heavy 'sugary' oxidization, pinholes, cracks, crevices, undercut, lack of penetration and incomplete fusion.

If the root ID surface can be visually inspected, the stop/starts shall be examined. No crater defects, such as cracks, "suck-back," or shrinkage, are permitted. The general criteria listed above shall also be met

7.9.2 Penetrant Testing

Dye penetrant testing is to be carried out after repair excavations and completion of all root passes on both production and repair welds. Dye penetrant testing must also be carried out on any surface where attachment welds have been removed.

7.9.3 Radiographic Examination

Radiography is required on all production and repair welds (ultrasonic testing may be used if RT is not practical). The acceptance criterion shall be in accordance with the ASME B31.3 'Normal Fluid Service' category and ASME VIII requirements with the additional requirements of

a) Zero lack of root penetration.

b) Zero lack of root fusion

7.10 PWHT


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Monel shall be PWHTed whatever the thickness. Recommended temperature range is 620/675°C. Recommended duration is 1h per 25 mm thickness with a minimum of 1 hour.

8 Special Requirements for Duplex Stainless Steels The following requirements are in addition to all requirements previously specified in this standard.

The requirements of this paragraph are in addition to API TR 938C that is fully applicable. Additional requirements for base metal are defined in Appendix C.

8.1 Welding

8.1.1 Welding Procedure Specification

In addition to paragraph 5.1, JERES-W-010 and JERES-W-011 the WPS shall include :

− The specific welding process or combination of processes to be used in production.

− For filler metal(s), the specific manufacturer(s) and trade name(s) to be used in production.

− Details of tack welding technique (where applicable).

− Electrical characteristics of welding, i.e., current and voltage range and polarity for each size (diameter) of filler metal.

− Heat input range.

− Welding travel speed.

− Maximum interpass temperature.

8.1.2 Welding Repair

For repair welding, details of technique for removing and verifying removal of defects shall be supplied to Company representative for approval before any repairs are done.

8.1.3 Welding Procedure Qualification

8.1.3.1 Essential variables for procedure qualification shall be in accordance with ASME Section IX, ( and project specifications JERES-W-010 and JERES-W-011), including supplementary essential variables for notch toughness, and those listed below. Any changes in the essential variables of an approved WPS shall require re-qualification.


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8.1.3.2 Additional essential variables :

− Thickness: In addition to ASME Section IX requirements given in QW-403.6, the maximum qualified thickness shall not exceed 1.2T.

− base metal : any change in UNS designation or numerical. For superduplex (25% Cr) any change of manufacturer

− Filler metal type: Any change in manufacturer trade name shall be approved by the Company.

− For SAW process any change in the brand name of the wire or the flux (or any change in the couple wire/flux)

− Filler metal size: Any change in diameter of the filler metal.

− Shielding gas flow rate: Any change in flow rate beyond – 20/+ 20%.

− Backing gas composition: Any change in the gas composition.

− Electrical characteristics: Any change in type of current, polarity, or pulse range.

− Interpass temperature: Any increase in the maximum interpass temperature.

− Heat input: Any change greater than ±10%

− Welding direction: any change in welding direction (ie, change from uphill to downhill or vice versa)

− Welding process : any change in welding Combination as defined in ASME IX QW 200.4

− Automatic welding : Joint preparation : Any change in dimentional tolerances specified in WPS (maximum acceptable change for root gap is -0/+2 mm)

8.1.3.3 Mechanical tests

The minimum number of mechanical test specimens required for a welding procedure qualification test weld shall be in accordance with ASME Section IX, project welding specifications and the following table :


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Tests Specimen Quantity

ASTM A 923 Test Method B and C with:

Test Method B: Charpy V-notch (– 40°C):

Weld centerline

Fusion line

Fusion line + 2 mm

Fusion line + 5 mm

Test Method C:

Ferric Chloride Corrosion Test

1 set

1 set

1 set

1 set

2

Cross section for macro-examination, photo-micrographs and ferrite measurements 1

Transverse Hardness Test Surveys 1

Root pass chemical analysis 1

8.1.3.4 Test methods

Test procedures and acceptance standards for supplementary welding procedure qualification tests shall be as follows:

8.1.3.4.1 ASTM A 923 TESTS

a) Charpy impact testing : shall be in accordance with ASTM A 923, Test Method B, with test results reported. The number of specimens shall be increased in accordance with B.5. Specimens shall be removed from the locations specified by ASME Section IX.

Complementary notes:

− Charpy tests shall be done with one set (3 specimens). Acceptance criteria shall be according to ASTM A923-Table 2 for each specimens. Average value shall be reported for information.

− If MDMT/Design Temperature is lower than the temperature defined in ASTM A923, then tests shall be conducted at the MDMT/Design


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temperature with the same acceptance criteria. [For SMAW process lower values could be accepted at the sole discretion of the Company]

− Lateral expansion values shall be reported for information

− Charpy V-Notch location (FL, FL+2 & FL+5) shall be based on the intersection of the specimen longitudinal axis and the dedicated fusion line at the center of the notch.

b) Ferric chloride corrosion tests : shall be in accordance with ASTM A 923, Method C with test results reported. The test specimens shall include weld, HAZ and base metal.

c) The rapid screening test (ASTM A 923 Test Method A) shall not be used to approve procedures.

8.1.3.4.2 Ferrite measurement (ASTM E562 modified)

a) Ferrite study

For ferrite assessment during procedure qualification tests, metallurgical sections shall be polished and etched to clearly reveal the two-phase austenite/ferrite microstructure.

The area being point counted, either parent material, weld metal or HAZ, should be examined and photographed under a microscope at a sufficient magnification to fill the field of view and to be able to clearly discriminate between the constituent phases. (For parent plate and weld metal, a magnification of approximately X400 is required, and for HAZ, about X700 to X1000 is recommended.)

b) Ferrite calculation

The photographs shall be overlaid with a grid of at least 100 points and the percentage ferrite shall be calculated from the number of points that fall on the ferrite phase and the total number of points used. Automated counting methods using quantitative metallography equipment can also be used.

For HAZ, the grid shall be positioned along the fusion line

c) Localisation

The ferrite content shall be measured on one of the metallurgical sections using the point counting technique at the following locations:

1) In the parent metal, one measurement on each side of the weld at mid thickness (total of 2).

2) In the HAZ on each side of the weld, in the region of the root pass, under the skin surface and at mid-thickness (total of 6).


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3) In the weld metal, three measurements near to the vertical center line of the weld, one in the cap, one in the root, and one at mid thickness (total of 3).

d) Acceptance criteria

Ferrite content at these locations shall be 35% – 65%.

e) Laboratory selection

Experience within the refining industry indicates that this is a difficult test (especially on HAZ) and results are often not accurate. Experienced laboratories shall be used.

Laboratory shall be approved by Company Representative

8.1.3.4.3 Photo – Micrographs and Macroexamination

a) Photo-micrographs with magnification applied shall be provided to the Company Representative for each of the locations where a phase balance assessment is performed.

b) Photo-micrographs shall show a typical austenite/ferrite microstructure.

c) 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 parent metal.

8.1.3.4.4 Hardness tests

Hardness testing is required on all weld procedure qualification records (PQR). Hardness readings shall be taken in Vickers with a 10 kg load. Localisation and number of readings shall be in accordance with EN 1043-1 and the following:

At least eight readings at a depth of 2.5 mm below the inside and below the outside surfaces shall be recorded for both base metals, HAZ and weld deposit.

Hardness shall not be above 310 Hv10 average, with no reading over 320 Hv10 for 22% Cr DSS grades.

Hardness shall not be above 325 Hv10 average, with no reading over 335 Hv10 for 25% Cr DSS grades.

For severe sour service it shall be referred to JERES-A-301.

8.1.3.4.5 Root pass Chemical analysis

A chemical analysis of the root pass shall be realized when in contact with process fluid.

PREN shall not be less than the one of the base metal.


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8.1.3.5 Dissimilar Weld metals

Dissimilar metal welds, i.e., carbon steel to DSS or austenitic stainless steel to DSS shall require qualification and testing to the requirements of this specification except that the non-duplex HAZ need not be subject to Charpy or corrosion testing.

8.1.3.6 Tube-to-tubesheet Welding Procedure Qualification Requirements

Tube-to-tubesheet welding procedures shall be qualified using a qualification test in accordance with JERES-W-010 and the following requirements:

8.1.3.6.1 The test assembly shall simulate all steps of the production joint including both rolling and welding.

8.1.3.6.2 In addition, if production welding is to be performed through the plug sheet, this should be simulated in the test assembly. (Access hole diameter and distance from hole to tubesheet shall be equal to production distances ± 10%.)

8.1.3.6.3 In addition to the macro-examination required by AF-334, the microstructure and ferrite content of one randomly selected weld section shall be assessed using the procedures detailed in 8.1.3.4.2 and 8.1.4.3.

Examination shall be done at three locations spaced of 120°. One of this location shall include arc extinction area.

8.1.3.6.4 Hardness (Hv10) readings shall be taken in the HAZ, weld deposit and tubesheet base metal. A minimum of 6 readings shall be taken on each of the tube-to-tubesheet joints prepared for metallography. Hardness shall be in accordance with 8.1.3.4.4.

8.1.3.6.5 A quadrant section of a tube-to-tubesheet weld shall be subject to corrosion testing in accordance with 8.1.1.4.1c). No pitting is allowed

8.2 Tube-to-Tubesheet Rolled Joints (Expanded Joint)

Rolling shall be prequalified by a mock up and hardness testing. The mockup test assembly shall be in accordance with JERES-W-010 appendix B with a minimum of ten rolled-in tube samples. The rolling procedure should be the same as the procedure that will be used during production.

Hardness readings shall be taken in Vickers with a 10 kg load. Measured shall be performed along the expanded area at mid thickness and with 2 mm steps (min 8 measures). Hardness values shall not exceed 310 Hv10 average, with no readings above 320 Hv10. Rolled surfaces shall not extend past the tubesheet or into weld areas.

Rolled and welded joints shall be prequalified in accordance with the requirement of this specification


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8.3 Heat Input

Maximum and minimum heat inputs shall not exceed the values qualified in accordance with 8.1.3, with no value exceeding 2.5 kJ/mm or being below 0.8 kJ/mm for 22% Cr alloys.

Heat input for tube-to-tubesheet welding may be as high as 3.5 kJ/mm, assuming that when the ferrite is checked during the procedure qualification, it is found to be within the limits specified for the weld deposit and HAZ.

Limits for 25% Cr alloys shall be based on the manufacturers’ recommendations but should be with 0.5 and 2 Kj/mm.

8.4 Position welding

SMAW process with diameter greater than 3.2 shall be used only for 1G and 2F position.

8.5 Interpass temperature

8.5.1 The maximum interpass temperature shall not exceed the value qualified in accordance with 8.1.3 and this temperature shall not exceed 177°C for 22% Cr alloys and 150°C for 25% Cr alloys.

8.5.2 Measurements shall be taken on the parent metal surface, directly adjacent to the weld groove, using a contact thermometer with an instant digital display. Temperature-indicating crayons can be used with Company representative approval. If the crayons are used, certificates from the crayon manufacturer shall be available for review by the Company Representative, which certify a maximum halogen content of 200 ppm and maximum sulfur content of 200 ppm

8.6 Shielding and backing gas

8.6.1 Backing gas shall be nitrogen or a mix Nitrogen/Argon but with minimum 5% Nitrogen

8.6.2 Oxygen content in the protected area shall be less than 2500 ppm. Methods and equipment used to control this O2 level shall be part of the WPS.

8.6.3 Shielding gas could be Ar or a mix Ar/N2 but with maximum 3% N2

8.6.4 Gas with hydrogen, oxygen or carbon dioxide are not accepted.

8.7 Welding tubes to tubesheets


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8.7.1 Tube-to-tubesheet welds shall be made using GTAW process with the addition of filler metal.

8.7.2 The weld throats (minimum leak paths) shall not be less than the thickness of the tube wall.

8.7.3 Welds shall be made with a shielding gas containing 2% – 3% nitrogen.

8.7.4 For strength welded joints, no rolling shall be used, except that a light roll solely to maintain fitup for welding is acceptable (< 3%). Any additional rolling requires approval from Company. Rolled surfaces shall not extend past the tubesheet or into the weld area.

8.7.5 For rolled joints or rolled and welded joints, rolled surfaces shall not extend past the tubesheet or into weld areas.

8.7.6 A fabrication plan shall be submitted for approval, and shall include cleaning prior to assembly, welding and rolling sequences, and inspections as a minimum.

8.8 NDE and Testing in Addition to Applicable Fabrication Codes and specifications

8.8.1 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 25mm wide on each side of the weld and both faces of the joint (if accessible).

8.8.2 Ferrite checks

The ferrite content of all accessible completed production welds shall be checked using a ferritescope. A minimum of three tests shall be made on each 1.5 m of weld. The average value of the ferritescope readings on each weld shall be 35% – 65%. For calibrating the ferritescope, the volume percent ferrite shall be determined using a ferritescope at similar locations as those tested using the point counting technique

8.8.3 Production Harness Tests

Weld deposit hardnesses shall be obtained on 100% of welds with a Telebrineller that comply with ASTM A833. The hardness of the reference bar shall be within ±10% of the maximum specified hardness.

At each test location, three readings shall be obtained and averaged.

The average result shall meet 255 HBN max., and the individual readings shall meet 270 HBW max.


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Appendix A - Table 1 – Filler Metal and Electrode Selection (1)

Base Metal (4) GTAW Filler Metal SMAW Electrode

Avesta 254 SMO ERNiCrMo-3 (2) EniCrMo-3 (2)

Monel ERNiCu-7 ENiCu-7

Alloy 20 ERNiCrMo-3 (2) ENiCrMo-3 (2)

Hastelloy C22/C276 ERNiCrMo-4 ENiCrMo-4

Hastelloy B2 ERNiMo-1 ENiMo-1

Alloy 600 ERNiCr-3 (3) ENiCrFe-3 (3)

Notes:

1) Contact Company for base metals not listed or for approval of alternative consumables. 2) Acceptable substitutes are ERNiCrMo-4 and ENiCrMo-4, respectively, for GTAW and SMAW. As well as Avesta

P12. 3) Acceptable substitutes are ERNiCrMo-3 and ENiCrMo-3, respectively, for GTAW and SMAW. 4) (See JERES-L-132) 5) Common trade names are:

ERNiCrMo-3 (GTAW) Inconel 625 ENiCrMo-3 (SMAW) Inconel 112 ERNiCr-3 (GTAW) Inconel 82 ENiCrFe-3 (SMAW) Inconel 182 ERNiCu-7 (GTAW) Monel 60 ENiCu-7 (SMAW) Monel 190

Table 2 – Backing Gas Purge Times for Stainless Steel Pipe

Assumes use of argon gas at a flow rate of 20 CFH (9 lpm).

Listed times are for each 300 mm of pipe length to be purged (multiply by actual length). Use the values for 300 mm for any shorter length.

Nominal Pipe Size Purge Time (minimum)

2 inch NS 0.5 minutes

4 2 minutes

6 4 minutes

8 7 minutes

10 10 minutes

12 15 minutes

16 25 minutes


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Appendix B: Table 3 – Recommended welding consumable for duplex

This include welding of temporary attachment and tacking

Process 22%Cr 25% Cr

SMAW SFA 5.4 E 2209 SFA 5.4 E 2553

GTAW SFA 5.9 E 2209 SFA 5.9 ER 2553

SAW SFA 5.9 ER 2209 with flux dedicated to DSS

SFA 5.9 ER 2553 with flux dedicated to DSS

Special DSS with additional elements such as tungsten are not covered. Plate suppliers’ recommendation shall be followed.

25% Cr welding consumable for welding 22% Cr may be approved by Company if this is proven necessary to meet the corrosion requirements of this specification.

Welding consumables shall be selected in order to have a PREN greater than the one of the base metal (min one PREN more than base metal)

Table 4 – Recommended Welding consumable for duplex DMW

Grade 22% Cr 25% Cr 22% Cr Table 3 Type 2553 25% Cr Type 2553 Table 3

304 E309MoL E2209 E309LMo

316 E309MoL E2209

E309MoL E2209

Steel and low alloy steel E309L E309MoL

E309L E309MoL

(E designation is used for SMAW but could be replaced by ER for GTAW and PAW.


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Appendix C: Minimum requirements for DSS Base Metal

The following requirements are in addition to API TR 938C that is fully applicable.

1 Specification for the supply of duplex stainless steel material

1.1 Plates, tubes, forgings, fittings, bars 1.1.1 Acceptable grades

22% Cr duplex stainless steels shall be specified as UNS S32202, UNS S31803 or equivalent European standard, grade 1.4462 (x2CrNiMoN22-5).

25% Cr super-duplex stainless steel shall be specified as UNS S31260, S32520, S32550, S32750, S39274, S39277 or equivalent European standard, grade 1.4501 (X2CrNiMoCuN25-7-4) or 1.4410 (X2CrNiMoN25-7-4).

1.1.2 Steel making process

Duplex steel shall be produced by the electric furnace process, and subsequently vacuum oxygen decarburized (VOD) or argon oxygen decarburized (AOD). Secondary melting processes such as vacuum arc re-melt (VAR) and electro-slag re-melt (ESR) are permitted.

1.1.3 Chemical composition

Chemical composition of 22% Cr and 25% Cr duplex stainless steel shall be in accordance with its relevant UNS number (and/or standard) and the following limits:

Grade Minimum Nitrogen content - % minimum PREN (1) 22% Cr 0,14 34

25% Cr 0,20 40

(1) : PREN = %Cr + 3.3%Mo + 16%N

All the following chemical elements shall be reported on the certified materials test reports: C, Mn, Si, S, P, Ni, Cr, Mo, Cu, N and any others elements deliberately added.

1.1.4 Delivery condition

Materials shall be water quenched after the final anneal. A special care shall be given at the quench start temperature that shall be at least 980°C.


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22% Cr and 25% Cr duplex stainless steel shall be delivered cleaned and passivated. HF/HNO solutions are recommended. A passivation procedure (including element concentration, immersion time and temperature) shall be approved by TOTAL. Flush water shall have a chloride content less than 200ppm.

All mill scale shall be removed.

1.1.5 Corrosion

To ensure adequate corrosion resistance, each heat of material of 22% Cr grades (except for tubing) shall be tested per Test Method B and C in ASTM A 923, and meet the given criteria.

The Rapid Screening Test included in ASTM A 923 (method A) shall not be used to accept material.

For method B, impact test shall be performed with a set of 3 specimens and not 1 as mentioned in ASTM A 923. The average energy shall be 54J as a minimum and the minimum value for each specimen shall be 43J.

For 25% Cr grades, both Test Methods B and C shall be done with the criteria as proposed by supplier and approved by Company:

Notes : For test method B (22% Cr and 25% Cr), if the MDMT is lower than the test temperature define in ASTM A923, then the test shall be conducted at the MDMT with the same acceptance criteria.

For test method B (22% Cr and 25% Cr), lateral expansion value shall be reported for information.

1.1.6 Base metal repair

Repair by means of welding is not permitted

1.1.7 Marking

Marking materials shall be suitable for stainless steels and contain less than 200ppm halogens and 200ppm sulfur. Composition certificates of marking materials shall be provided to Company at request.

Dye stamping, when used, shall be applied by low stress hard-die stamping. (The low stress stamps shall be round nosed with a radius of 0.25mm minimum.)

1.2 Additional requirements for heat exchangers and air cooler tubing 1.2.1 Fabrication

Tubes shall be seamless except otherwise agreed in writing by Company


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Tubing shall be solution annealed at the minimum temperature or in the temperature range listed for the particular grade in ASME SA-789 standard (or EN 10216-5) for sufficient time to eliminate intermetallic precipitates and then rapid cooled by water quenching, or air or inert gas cooling to below 315°C. Other heat treatments or quenching media must be approved by Company representative.

1.2.2 Hardness test

Maximum Vickers hardness (Hv10) shall be 270 and shall be checked for each heat/lot of tubes.

Hardness shall not be performed on the surface where potential surface local hardening may mislead the results but shall be performed at mid-thickness between skin and center line (i.e. ¼ or ¾ t where t is the thickness).

1.2.3 Microstructural examination

For heat exchangers and air-coolers tubing, test method A and method C according to ASTM A 923 shall be performed with the following requirements (i.e. method B not required):

- 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 lead to grind the tube for rejection of the solution anneal batch represented by the specimen. The batch shall require reheat treatment and retesting,

- the sample size shall be a 25 mm long tube specimen for each heat lot,

- in addition, ASTM A 923 Test Method C shall also be done and meet the given criteria.

1.2.4 Bending

Tubes and tube bends shall be heat treated (annealed) per § 1.2.1 after bending or straightening if cold work (hardening) is in excess of 15% or if the hardness requirement given in § 1.2.2 is exceeded.

Lubricants shall be removed from tube surfaces prior to heat treatment. The Vessel manufacturer shall submit heat treatment plans for approval, which will include precautions to minimize exposure of any sections to 700°C - 950°C (1300°F - 1750°F) as this could cause unacceptable intermetallic precipitation.

The preferred heat treatment method is electric resistance, which is done for only seconds.


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After heat treating, other than bright anneal procedures, all tubing shall receive a descaling treatment of pickling followed by a neutralizing and appropriate rinsing treatment. All mill scale shall be removed.

JERES W 016 Welding Special Corrosion Resistant Materials

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