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Welding Procedures IP 18-7-1

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(This practice is appropriate for attachment to Inquiry or Purchase Document) Rev. 0 June 1997

THIS INFORMATION FORAUTHORIZED COMPANY USE ONLYEXXON RESEARCH AND ENGINEERING COMPANY FLORHAM PARK, N.J.

INTERNATIONAL

PRACTICE

SCOPE

I 1.1 This practice governs welding qualifications for the welding of:

a. Materials used in the construction of tankage, piping assemblies, pressure containing equipment,and attachments welded thereto.

b. Internals for pressure vessels and piping systems.

c. Static castings and centrifugal castings for fired heaters.

d. Structural items built in accordance with AISC or AWS Structural specifications.

e. Support structures, platforms, stairs, handrails, etc.

f. Any other component when referenced by an applicable purchase document.

I 1.2 An asterisk (V) indicates that a decision by the purchaser is required or that additional information isfurnished by the purchaser.

I 1.3 The following references are synonymous: BP and IP.

SUMMARY OF ADDITIONAL REQUIREMENTS

I V 2.1 Table 1 lists the practice, codes and specifications which shall be used with this practice as specified bythe purchaser.

TABLE 1

PRACTICE

IP 19-2-1 Weld Overlay and Integrally Bonded Cladding

CODES AND SPECIFICATIONS

ASME Codes

Section II Material Specifications, Part C - Welding Rods, Electrodes and Filler Metal

Section VIII Pressure Vessels, Division 1

Section VIII Pressure Vessels, Alternative Rules, Division 2

Section IX Welding and Brazing Qualifications

B31.3 Chemical Plant & Petroleum Refinery Piping

ANSI / AWS Specifications

A5.XX Series Filler Metal Specifications

D1.1 Structural Welding Code - Steel

I 2.2 The requirements of this practiceaugment those in:

a. ASME Code Section IX for pressure vessels and piping built in accordance with ASME Codes

listed in Table 1.

b. ANSI/AWS D1.1 for carbon and low alloy steel structures built in accordance with AWS D1.1 orAISC specifications.

c. Either ASME Section IX or ANSI/AWS D1.1 for noncode structures and components.

I V 2.3 All Welding Procedure Specifications (WPSs) and Procedure Qualification Records (PQRs) shall be

submitted to purchaser for approval prior to the start of fabrication or construction. Weld maps orsimilar guides indicating where and how these WPSs will be used shall be included in the submittal. Basisfor rejection shall be noncompliance with this practice, failure to meet applicable codes, or violation ofindustry practice.

I 2.4 The Supplementary Essential Variables in ASME Code Section IX shall apply to all impact testedwelding procedure specifications (even if impact testing is not a code requirement).

I 2.5 Weld overlay and back cladding operations shall also meet the requirements ofIP 19-2-1.

I 2.6 The concept of prequalified procedures provided in ANSI/AWS D1.1 is acceptable for structuralcomponents and nonpressure items unless otherwise specified by the purchaser. In this case, no PQRmust be submitted.

Changes shown by
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IP 18-7-1 Welding Procedures

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Rev. 0 June 1997 (This practice is appropriate for attachment to Inquiry or Purchase Document)


INTERNATIONALPRACTICE

DEFINITIONS

I 3.1 A Welding Procedure Specification (WPS) is a document prepared for each weld or group of weldspresenting:

a. Instructions to the welders including both essential and nonessential variables.

b. Sketches with bead sequence, electrical variables, gas flow requirements, etc.c. Procedure Qualification Record(s) (PQR) (however, these shall not constitute a substitute for

subpar. a. and b. above).

I 3.2 The term Inspector, used in this practice, refers to the Owner's representative.

BASE METAL

I V 4.1 Base metals not listed in ASME Section IX, QW-422 or Appendix C but having equivalent chemical and

mechanical properties as listed materials may be classified in a listed P-Number or S-Number and, whereapplicable, Group Number subject to the approval of the Owner's Engineer.

R 4.2 Each base metal within a given P-Number or Group Number having nominally different chemical or

mechanical properties (as designated in QW-422 of ASME Code Section IX) requires:

a. A separate WPS. This requirement does not apply to different grades of P-No. 8, Groups 1 and 2,

base metal provided the WPS specifies the filler metal required for each different base metal type.b. Separate PQRs whenever a welding related operation satisfactory for one base metal is, in the

opinion of the Owner's Engineer, unsatisfactory for another base metal within the same P or GroupNumber.

R 4.3 Backing strip material specification or its nominal chemistry must be recorded in the WPS or theapplicable fabrication drawing. For joints between similar materials, the backing strip chemistry shallmatch the base metal chemistry.

WELDING PROCESSES

R 5.1 Fusion welding processes may be used with the following limitations:

a. Short circuiting gas metal arc welding (GMAW-S or short arc) shall be limited to any of thefollowing conditions:

1. The root pass for any material thickness and complete butt or fillet welds provided the wallthickness ofno member exceeds 3/8 in. (10 mm).

2. Complete butt or fillet welds provided the wall thickness of no member exceeds 1 in. (25mm) and either of the following conditions is met:

(a) Welding is done in any position except vertical-down and the current is not lessthan 170 A.

(b) Welding is done in the vertical-up position (3G) and the heat input is not less than35,000 Joules/inch (14,000 Joules/cm). Heat input is defined as:

amperage voltage 60

travel speed (inches or cm per minute)

3. This process shall not be used for branch connections (e.g., Figure 327.3.3 of B31.3).

b. Flux cored arc welding (FCAW) either with or without external gas shielding may be used for

either groove or fillet welds. For pressure boundary welds and welds with impact testrequirements, only electrode classifications or types which are identified as multipass and whichhave specified minimum impact test requirements shall be used.

c. Single pass butt welding of pressure containing joints in ferritic steel exceeding 1/4 in. (6 mm)thickness is acceptable only when the joint receives a subsequent grain refining (austenitizing) heattreatment.

d. Manual GTAW (TIG) welding must be used with the addition of filler metal and high frequencystarting equipment or equal.

e. For GTAW (TIG), the addition or deletion of consumable inserts for single welded butt joints(without backing devices) requires separate WPS(s) and PQR(s).

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INTERNATIONAL

PRACTICE

R 5.2 Welding processes using coatings or fluxes shall not be used for austenitic stainless steel, nickel or

aluminum alloy root passes unless the slag is removed from the underside of the root passes and thearea inspected.

R V 5.3 Each combination of welding processes, or WPS, or both, requires qualification as a combinationunless specifically approved by the purchaser. Any process or WPS used solely for the root passes may

be eliminated without requalification for double welded butt joints or for joints using backing strips.R 5.4 For each automatic welding process, the WPS or supplementary document shall specify all applicable

equipment settings to assure consistent performance by all welding operators.

R 5.5 Automatic welding (e.g., orbital welding) requires separate WPSs and PQRs for all welding variables

spelled out in ASME IX, Para. QW-250 for the process, and for specific joint geometry, diameter, wallthickness and welding position.

FILLER METALS

R 6.1 Filler metals shall be specified in each WPS by AWS specification and classification. However, fillermetals which do not conform to a standard AWS specification and classification, or which have specialrequirements, shall be identified by manufacturer and type. For submerged arc and electroslag welding

the AWS electrode-flux classification, and the flux manufacturer and trade name shall be specified.

R 6.2 A system shall be employed to identify and retain the identity of all filler metals.R V 6.3 Unless specifically authorized by the purchaser, a fillermetal shall be used only for the primary material

and process applications recommended in the AWS filler metal specification or by its manufacturer, e.g.,filler metals designed for single pass welding" shall not be used for multipass joints.

R 6.4 When joining similar metals, the deposited weld metal shall match the chemistry and the mechanicalproperties of the base metal as closely as possible.

V Whenever the minimum mechanical properties of the deposited weld metal fail to meet the minimummechanical properties of the base metal, or whenever the nominal chemistry of the deposited weld metal

differs from the nominal chemistry of the base metal, the vendor's proposal to use such weld metal mustbe submitted to the purchaser for approval by the Owner's Engineer.

R 6.5 When joining two different ferritic steels, or when joining ferritic to martensitic steels, the filler metalshall conform to the nominal chemistry of either base metal or an intermediate composition, except asfollows:

a. For attaching nonpressure parts to pressure parts, the filler metal chemistry shall match thenominal chemical composition of the pressure part.

b. For welding Type 405 or 410S hexmesh, anchors, etc., to carbon and low alloy steel, the fillermetal shall be:

1. Inconel (except ANSI/AWS A5.14, Class ERNiCrFe-6), provided the welds are not exposed

to sulfur above 700F (370C), or

2. Type 309 (25 Cr -12 Ni), for design temperatures not exceeding 600F (316C).

3. For service conditions exceeding the limits stated in 1. and 2. above, the filler metalselection shall be reviewed with Owner's Engineer.

R 6.6 For welding austenitic stainless steels, the following requirements shall be met:

a. When joining ASME P-8, Group 1 austenitic stainless steels, the filler metal must contain at least 1FN (Ferrite Number) or 1% ferrite. However, 347 electrodes shall contain at least 4 FN.

b. When joining two different austenitic stainless steels, the filler metal may match either.c. When joining 310 or 330 stainless steels and for cryogenic and special corrosive service, 0 FN

filler metal may be used.

R 6.7 When joining austenitic stainless to ferritic steels, filler metal types shall be selected as follows:

a. Inconel (except ANSI/AWS A5.14 Class ERNiCrFe-6), provided the welds are not exposed to

sulfur above 700F (370C).

b. Type 309 (25 Cr-12 Ni) for design temperatures not exceeding 600F (316C).

c. Type 310 (25 Cr-20 Ni) stainless steel shall not be used.

d. For service conditions exceeding the limits stated in a. and b. above, the filler metal selection shallbe reviewed with Owner's Engineer.

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R 6.8 When the thickness of carbon or low alloy steel base metal exceeds 1/2 in. (13 mm), groove or fillet

welds shall be made with filler metals producing low hydrogen deposits. However, cellulose or futile-typecoated electrodes may be used for the root pass of a groove weld regardless of the base metal thickness.

R 6.9 Active submerged arc fluxes may be used for carbon steel (P-1 Material) welding within all the followinglimitations:

a. Material wall thickness shall not exceed 1 in. (25 mm).

b. Voltage ranges are established and equipment is available to monitor that these limits will not beexceeded.

c. Welding procedure qualification results indicate that the impact and hardness requirements havebeen met.

R 6.10 Alloyed submerged arc fluxes shall not be used for welding low alloy steels.

R 6.11 Reprocessed flux or recrushed slag shall not be used for submerged arc welding of pressure-containingparts such as pressure vessels, piping and storage tanks. Use of such materials is permitted forsubmerged arc welding of structural and noncode components provided all of the following requirementsare met:

a. Approval by Owner's engineer.

b. Separate and distinct markings identifying the recrusher and his trade designation.

c. Separate WPS(s) and PQR(s).d. Testing per AWS A5.17, AWS A5.23 or equivalent specification.

R 6.12 WPS shall be requalified whenever:

a. Wire chemistry for ferritic steels is changed from one AWS classification to any otherclassification or to a chemical composition not covered by the AWS fil ler metal specifications.

b. Filler metal is changed from one specific make and type designated underAWS Classification

G" to any other manufacturer or manufacturer's designation.

c. Submerged arc welding flux is changed from one manufacturer to another or from onemanufacturer's grade to another grade (equivalency on the basis of ANSI/AWS A5.17 or A5.23 isnot acceptable). The manufacturer and the manufacturer's grade of flux shall be stated in both theWPS and the PQR.

d. Flux cored electrodes are changed from one AWS classification to another, electrodes are not

classified by AWS or electrodes are specified with supplementary requirements. Requalification isnot required for a change in the position designator from EX0T -X to EX1T-X and vice versa.

e. 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.

R 6.13 All-weld-metal tensile tests with any applicable production type PWHT to determine ultimate strength,

yield strength, elongation, and reduction of area shall be conducted whenever:

a. The deposited filler metal does not fall within any of the ANSI/AWS filler metal specifications,A5.XX Series.

b. Satisfactory mill test reports or other supplier certifications are not available.

SHIELDING AND PURGING GASES

R 7.1 When shielding gases are used, the WPS shall indicate the gas composition, its purity, and its flow rate.

R 7.2 When back purging is used, the WPSshall indicate:a. Type of gas and flow rate.

b. Amount of gas injected into the area prior to welding to insure removal of oxygen.

c. Method of venting to prevent excessive pressure buildup and to permit oxygen to escape.

R 7.3 Whenever a back purging gas is selected to prevent oxidation or scale formation on the underside ofthe weld, such purge shall be maintained until at least 3/8 in. (10 mm) depth of weld metal has beendeposited.

R 7.4 Deletion of a back purging gas for a single welded butt joint without backing strip shall require aseparate PQR.

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INTERNATIONAL

PRACTICE

WELDING POSITIONS AND APPLICATIONS

R 8.1 Additional procedure and performance qualifications shall be performed whenever the accessibility, the

restraint or the environment of the code qualifications fails to simulate production conditions.

PREHEATINGR 9.1 Whenever material is wet or contains surface moisture or condensate, it shall be dried by heating.

R 9.2 The minimum preheat temperatures shall not be less than those shown in Appendix R and Table UCS-56

of ASME Code Section VIII-1. Higher temperatures may be required for highly restrained joints (such as

closely spaced nozzles). For P-No. 9 Group Materials, the guidance provided in the NonmandatoryAppendix R will remain nonmandatory.

R 9.3 Maximum interpass temperature limits shall be specified for austenitic and duplex stainless steels and fornonferrous alloys.

POSTWELD HEAT TREATING (PWHT)

R 10.1 The WPS shall specify whetherPWHT must be performed. (A statement such as PWHT, if required byASME code" is not acceptable.)

I 10.2 PWHT cycle. All welding WPSs specifying PWHT must indicate the following:a. Heating rate (maximum)

b. Holding temperature (maximum and minimum)

c. Holding time

d. Cooling rate (maximum)

For special heat treating methods such as exothermics, the process and specific heat treating packagemay be specified in lieu of the above.

R 10.3 The adequacy of heat treatments required to reduce or limit hardness shall be checked by hardnessmeasurements.

I V 10.4 PWHT of austenitic stainless steel or nonferrous alloys requires approval by the Owner's Engineer.

R 10.5 Welding procedure qualification tests for austenitic stainless steel to ferritic steel welds shall employ

the maximum PWHT temperature limit specified in the welding procedure whenever stainless steel is

heated above 1300F or 700C [e.g., if PWHT range is 1250-1350F (675-730C) use 1350F (730C)].I 10.6 Repairing PWHTd components without PWHT may be proposed provided the repair meets all

requirements in Para. UCS-56(f) of ASME VIII-1 and:

a. All carbon steel repair procedures employ temper beading.

b. All P-No. 3, 4 and 5A materials shall be MT or PT inspected after the material has been at ambienttemperature for not less than 48 hours.

CLEANING

R 11.1 Methods for cleaning (i.e., power grinding or solvent cleaning) the surfaces to be welded shall be detailedin the WPS and tailored for the beveling and welding processes.

R 11.2 For double welded joints the backside of the joint shall be cleaned to sound metal unless it can bedemonstrated that an acceptable weld can be made without this operation.

I 11.3 All slag shall be removed from the outside of each completed weld.

SPECIAL APPLICATIONS AND TESTING

I V 12.1 PQRs shall include results of additional tests when these tests are specified for the welded product suchas:

a. Hardness: Such data shall be based upon a qualification test or if approved by the purchaser maybe obtained on a production weld. These tests shall be conducted on the weld surface (not thecross section).

b. Impact values.

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R 12.2 Arc and resistance stud welding for attaching non-load-carrying studs (such as extended heat transfersurfaces and insulation attachment pins) shall be qualified on materials having the same thicknesses andnominal chemistries as the production welds. Destructive tests of at least 10 consecutively welded studsshall be used to demonstrate the suitability of the WPS including the specified percent fusion. The PQRshall include a record of all welding variables and equipment settings used during qualification. A

production test sample of at least 5 consecutively welded studs shall be tested at the beginning of eachshift and after performing maintenance operations on automatic equipment.V Production welds shall be inspected by hammer testing [2 lb (1 kg) hammer and 20 to 30 in. (500 to 750

mm) stroke] or 15 bend tests as agreed between the Owner's Engineer and the fabricator.

I V 12.3 All tube-to-tubesheet WPS shall be qualified and tested in accordance with ASME Code Section VIII,

Division 2, Article F-3. The vendor shall submit a complete fabrication plan (including assembly, cleaning,weld preparation and testing) to purchaser for approval by the Owner's Engineer.

R 12.4 For tube-to-tubesheet welding, tubesheet surfaces require a weld overlay if either of the followingconditions exist:

a. The root pass is deposited by GTAW (TIG) welding without filler metal.

b. The tubesheet material requires PWHT according to the applicable code.

Revision Memo

6/71 Original Issue of Basic Practice

1/73 Revision 1

6/76 Revision 2

1/81 Revision 3

6/88 Revision 4

6/93 Revision 5

6/97 Revision 0 - Original Issue of International Practice

Extensive technical and editorial revision of formerBP 18-7-1 and initial issue of this IP. Significant revisions include:Par. 2.1 deleted reference to BP 18-1-1, Par. 2.2 modified mandatory requirements. Deleted Old Par. 2.4 on slagremoval since covered in Par. 5.2. Deleted OldPar. 4.4 on backing strip qualification data. Par. 5.1 deleted oxyfuelwelding, electroslag, and electrogas from fusion welding processes. Old Par. 6.13 and 6.14 deleted to simplifyacceptance of low hydrogen electrodes. Deleted all weld overlay details as they will become part ofIP 19-2-1. DeletedSubsection and Old Par. 9.1 covering welding variable details. Deleted Old Par. 13.4 stud welding requirements nowcovered by the ASME Code.

Exxon Research and Engineering Company, 1993, 1997

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