SP-90-02 - Rev 5 - Welding of Metallic Piping

SASOL SPECIFICATION SP-90-02
REVISION 5
WELDING OF METALLIC PROCESS AND POWER PIPING
Niel Swanepoel Johan Kruger

2020-04-17 15:29:25 +02:00 2020-04-22 10:52:51 +02:00
I approve this document
Originator : Reviewer I approve this document
DB SWANEPOEL : JJ KRUGER
Andrew Dacre
2020-04-17 10:59:20 +02:00
Approved by : I approve this document
A DACRE
For interpretation of Specification, the following person(s) can be contacted:
D.B Swanepoel, J.J Kruger, P.J Botha, W.P De Klerk
PREVIOUS REVISIONS
A Revision Description Sheet is included to assist in identifying the changes

in the latest revision.
ISSUE
REV No PROPOSED BY REVIEWED BY APPROVED BY DATE
DATE
2 June 2000 JP Nell APdeGavino Dias C Thirion 5 June 2000
3 Nov 2003 AR Benadé APdeGavino Dias C Thirion 11 Dec 2003
4 May 2012 H. Froneman AR Benade JPG Wykes 24 May 2012

Any questions, queries, comments and proposals for revisions or additions can be
directed in writing to the Sasol Specification Coordinator at
specifications@sasol.com
VALIDATION This Specification is only regarded as controlled in the electronic format on the official SASOL Livelink/Intranet
website. When printed, this document is deemed as uncontrolled and thus for information only. It is the responsibility of the
user of a printed copy of the document to ensure validity before use. When issued on a CD to a registered user, it is a
controlled document and users will be notified and issued with the latest revision. If it is issued for a specific project, it is valid
for the duration of the project, unless agreed otherwise.
COPYRIGHT This Specification is protected by copyright and is the sole property of SASOL. The information is proprietary
to SASOL and is for the sole use of the identified project or defined scope of work. Any unauthorised use, disclosure or copying
or any other means of duplication or reproduction, is prohibited.
Copyright © 2020. SASOL. All rights reserved.
Revision 5
April 2020
WELDING OF METALLIC PIPING
TECHNICAL COMMITTEE OF SPECIFICATION SP-90-02, Revision 5
NAME COMPANY AND DEPARTMENT
BOTHA PJ (Pieter) Group Technology
DE KLERK W (Willem) Group Technology
FISHER D (Dennis) Sasolburg Operations, Technical

Services
HORN, JW (JW) Sasol Synfuels Mechanical Engineering

and Governance
KRUGER JJ (Johan) Group Technology
RABIE M (Marcel) Group Technology
NEL HJ (Hugh Jean) Sasol Synfuels Mechanical Engineering

and Governance
ORSMOND C (Charl) Sasol Synfuels Metallurgical

Engineering
SWANEPOEL DB (Niel) Sasol Synfuels Metallurgical

Engineering
SMIT GF (Deon) Synfuels Weldtech
VAN HEERDEN R (Ruan) Group Technology
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REVISION DESCRIPTION SHEET
REVISION 5
Specification SP-90-02, Revision 5 was given a general update. The update entails the
acknowledgement of advances in welding technology and means to ensure controlled
implementation is included. Several line classes were modified to duly capture and clarify
some severe service requirements. Changes in heat treatment requirements of ASME B31.1
and B31.3 were evaluated and incorporated in some of the line classes. General
requirements and guidelines have been added to address some of the lessons learnt in
piping fabrication
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FOREWORD
In the following sections of the specification, each requirement is categorized into a CORE,
SITE SPECIFIC or NEGOTIABLE requirement. The categorization is placed immediately
after each paragraph in “Bold”.
Example:
1.1.1 Paragraph ends. Core
The definitions of CORE, SITE SPECIFIC and NEGOTIABLE are shown below. The
colour associated with each categorization is also used.
Classification Tag Colour Definition
Core Core Red Non-NEGOTIABLE requirements that are

applicable to all Sasol sites, including
international sites, taking into consideration:
<0000> Safety
World best practice
Site Specific RSA Blue Non-NEGOTIABLE requirements applicable to all
South African based sites, taking into
(RSA)
consideration:
Legal requirements of the country
Standardization issues
Environmental implications
Site Specific Secunda Blue Non-NEGOTIABLE requirements applicable to
the Secunda site only, taking into consideration:
(Secunda)
Site Specific Sasolburg Blue Non-NEGOTIABLE requirements applicable to
the Sasolburg site only, taking into consideration:
(Sasolburg)
Site Specific Natref Blue Non-NEGOTIABLE requirements applicable to
the Natref site only, taking into consideration:
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Classification Tag Colour Definition
(Natref) Legal requirements of the country

Site Specific International Blue Non-NEGOTIABLE requirements applicable to all
non-South African based sites only, taking into
(International)
consideration:
NEGOTIABLE NEGOTIABLE Green Requirements that must be agreed by both the
project team and client at an appropriate time.
Once agreed, this requirement becomes
mandatory for the specific job.
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TABLE OF CONTENTS
PAGE
1 GENERAL ..................................................................................................................1
1.1 SCOPE .........................................................................................................1
1.2 LEGAL REQUIREMENTS ............................................................................1
1.3 PRECEDENCE .............................................................................................1
1.4 ABBREVIATIONS .........................................................................................2
1.5 DEFINITIONS ...............................................................................................3
1.6 DEVIATIONS ................................................................................................4
2 REFERENCED CODES AND STANDARDS.............................................................4

2.1 AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) CODE
FOR PRESSURE PIPING ............................................................................4
2.2 AMERICAN SOCIETY OF MECHANICAL ENGINEERS BOILER AND
PRESSURE VESSEL CODE (ASME BPV CODE).......................................5
2.3 AMERICAN SOCIETY FOR TESTING OF MATERIALS (ASTM)
STANDARDS................................................................................................5
2.4 INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)
STANDARDS................................................................................................5
2.5 AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) STANDARDS ..5
2.6 AMERICAN WELDING SOCIETY (AWS) SPECIFICATIONS......................5
2.7 AMERICAN SOCIETY FOR NON-DESTRUCTIVE TESTING (ASNT)
STANDARDS................................................................................................6
2.8 SASOL SPECIFICATIONS ...........................................................................6
3 GENERAL REQUIREMENTS ....................................................................................7
4 DOCUMENTATION SUBMITTAL, APPROVAL AND RECORDS ............................7
5 PROCEDURE QUALIFICATION AND WELDER QUALIFICATION .........................9

5.1 COMPLIANCE TO CODES AND SPECIFICATIONS...................................9
5.2 WELDING PROCEDURE QUALIFICATION...............................................10
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5.3 WELDING PROCEDURE QUALIFICATIONS REQUIRING IMPACT

TESTING ....................................................................................................14
5.4 WELDING PROCEDURE QUALIFICATION HARDNESS TESTS .............17
5.5 QUALIFICATION OF REPAIR WELDING PROCEDURES........................19
5.6 WELDER AND WELDING OPERATOR QUALIFICATIONS AND
CONTROL ..................................................................................................19
6 WELDING PROCESSES .........................................................................................28
8 WELD JOINT PREPARATION ................................................................................31
9 CLEANING REQUIREMENTS .................................................................................32
10 WELDING REQUIREMENTS...................................................................................33
11 WELD CONTOUR ....................................................................................................35
12 PREHEATING ..........................................................................................................36
13 POST WELD HEAT TREATMENT (PWHT) ............................................................36
14 REPAIRS..................................................................................................................38
15 NON-DESTRUCTIVE EXAMINATIONS...................................................................39
15.1 GENERAL REQUIREMENTS.....................................................................39
15.2 VISUAL EXAMINATION .............................................................................41
15.3 MAGNETIC PARTICLE TESTING (MT) AND PENETRANT TESTING
(PT) .............................................................................................................41
15.4 RADIOGRAPHIC EXAMINATION (RT) ......................................................43
15.5 ULTRASONIC EXAMINATION (UT)...........................................................45
16 HARDNESS TESTING .............................................................................................46
APPENDIX A: LINE CLASS REQUIREMENTS...................................................................1
NOTES FOR TABLE 1.............................................................................................................1
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APPENDIX B: DIRECTIONS FOR COMPLETING THE WELDING PROCEDURE

SUMMARY .................................................................................................................1
APPENDIX C: REQUIREMENTS FOR DUPLEX STAINLESS STEEL WELDING,

FABRICATION AND QUALIFICATION .....................................................................1
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1 GENERAL
1.1 SCOPE
This specification covers shop and field welding and welding related heat treatment,
examination and testing requirements for newly fabricated metallic piping. This
specification applies to SASOL Plants located in Secunda and Sasolburg, South
Africa. This specification can be used for other locations, provided that specific
requirements are added to provide for local conditions and regulations. These
typically include differences in statutes, quality of available work force and in
environmental and climatic factors. The practices in this specification also find
application in the maintenance of running plants unless specifically agreed to
otherwise (except for line classes which are not contained herein or cases wherein it
may not be feasible to fully comply).
This specification is written for the codes of construction referenced herein, namely
ASME B31.1 and ASME B31.3. For other codes of construction the requirements of
this specification may require modification and supplementation as agreed with
Sasol’s Representative. CORE
1.2 LEGAL REQUIREMENTS
This specification is governed by the law of contract. CORE
1.3 PRECEDENCE
When special requirements are clearly specified in the SASOL contractual

requirements, those requirements shall govern and supplement this Specification.
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In the event of any conflict between the various relevant documents, the order of
precedence shall be:
1. The purchase order, including terms, conditions and legal requirements
2. Drawings as approved by SASOL
3. This specification
4. Other referenced documents. CORE
1.4 ABBREVIATIONS
AFC Approved for Construction
AIA Approved Inspection Authority
HB Brinell Hardness
FCAW Flux Cored Arc Welding
FCAW-G Flux Cored Arc Welding - Gas Assisted
GMAW Gas Metal Arc Welding
GTAW Gas Tungsten Arc Welding
HAZ Heat affected Zone
HI Heat Input
HV10 Vickers Hardness (10kg Load)
MCAW Metal Cored Arc Welding
MT Magnetic Particle Testing
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NDE Non Destructive Examination
NPS Nominal Pipe Size
PQR Procedure Qualification Record
PT Penetrant Testing
PWHT Post Weld Heat Treatment
RT Radiographic Testing
SAW Submerged Arc Welding
SMAW Shielded Metal Arc Welding
UT Ultrasonic Testing
WPS Welding Procedure Specification
1.5 DEFINITIONS
Refer to SP-00-03 for the definitions of the following terms:
1.5.1 Approval / approved by
1.5.2 Automatic process
1.5.3 Manufacturer or fabricator of piping
1.5.4 Mechanised process
1.5.5 New fabrication
1.5.6 Piping
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1.5.7 Piping components
1.5.8 Qualification
1.5.9 Sasol
1.5.10 Sasol’s representative
1.5.11 Welder/s
1.6 DEVIATIONS
Any proposed deviation from this specification, including modifications deemed

necessary in particular applications, shall be submitted to Sasol for approval, using
Form F019 “Application for Concession”, providing a full description of the deviation,
its motivation, supporting documents and proposed actions. Deviations from
statutory codes and other legal requirements are not allowed. CORE
2 REFERENCED CODES AND STANDARDS
Where reference is made to a code, specification or standard, the reference shall be

taken to mean the latest edition of the code, specification or standard, including
addenda, supplements and revisions thereto at the time of contract award.
2.1 AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) CODE FOR

PRESSURE PIPING
ASME B31.1 Power Piping
ASME B31.3 Process Piping
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2.2 AMERICAN SOCIETY OF MECHANICAL ENGINEERS BOILER AND PRESSURE

VESSEL CODE (ASME BPV CODE)
Section II Materials
Section V Non-destructive Examination
Section IX Welding and Brazing Qualifications
2.3 AMERICAN SOCIETY FOR TESTING OF MATERIALS (ASTM) STANDARDS
ASTM A956 Standard Test Method for Leeb Hardness Testing of Steel Products
ASTM A1038 Standard Test Method for Portable Hardness Testing by the
Ultrasonic Contact Impedance Method
ASTM E10 Brinell Hardness of Metallic Materials
ASTM E110 Standard Test Method for Indentation Hardness of Metallic Materials
by Portable Hardness Testers
2.4 INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO) STANDARDS
ISO 1027 Radiographic Image Quality Indicators for Non-Destructive Testing -

Principles and Identification
2.5 AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) STANDARDS
ANSI Z49.1 Safety in Welding, Cutting and Allied Processes
2.6 AMERICAN WELDING SOCIETY (AWS) SPECIFICATIONS
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AWS A2.4 Standard Symbols for Welding, Brazing, and Non-Destructive

Examination
AWS A3.0 Standard Welding Terms and Definitions
2.7 AMERICAN SOCIETY FOR NON-DESTRUCTIVE TESTING (ASNT) STANDARDS
SNT-TC-1A Recommended Practice for Non-Destructive Testing Personnel

Qualification and Certification
2.8 SASOL SPECIFICATIONS
SP-00-03 Definitions Specification
SP-40-05A Mandatory Requirements for Pressurised Systems-
SP-50-03 Piping Design and Fabrication
SP-50-03A Piping Material Specification
SP-50-05 Internal Cleaning and Protection of Piping
SP-50-09 General Piping: Process and Utility - Leak Testing
SP-90-01A Welding Consumables
SP-90-17 Heat Treatment
SP-90-18 Selection of Materials for Low Temperature Service
SP-90-23 Positive Material Identification
SP-90-31 Units of Measurement
SP-90-37 Requirements for Sasol Owner Documentation
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SP-110-06 Impact Testing of Metallic Materials
SP-110-07 General Specification for Austenitic Materials for Elevated

Temperature Service
SP-110-08 Duplex Stainless Steel Fabrication
3 GENERAL REQUIREMENTS
3.1.1 Fabrication, assembly, inspection, examination, testing and erection of piping shall
conform to the requirements of ASME B31.1 or B31.3, whichever is applicable, and
to the requirements of this specification. CORE
3.1.2 Welding terms and definitions shall be in accordance with AWS A3.0. Symbols for
welding and non-destructive examination (NDE) shall be in accordance with AWS
A2.4. CORE
3.1.3 Safety measures for the protection of welders and operators involved in welding and
cutting shall be in accordance with the practices specified in ANSI Z49.1 when not
so regulated by local ordinances or laws. CORE
4 DOCUMENTATION SUBMITTAL, APPROVAL AND RECORDS
4.1.1 The manufacturer shall in all instances comply with all the relevant contractual
requirements. Approval by others does not validate non-compliance or relieve the
manufacturer of his legal responsibilities and liabilities to contractual requirements.
CORE
4.1.2 In order to maintain control, the manufacturer shall maintain an updated list of all
welding procedures (WPS) and supporting procedure qualifications (PQR) utilised in
a project. The manufacturer may use his own format. This list may be requested by
Sasol or Sasol’s representative. CORE
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4.1.3 Welding procedures and fabrication documents submitted for approval shall comply
with the requirements of specification SP-90-37. All technical documentation shall
be clear, legible and suitable for further duplication / reproduction. All submitted
procedures and reports shall be checked, and signed by the manufacturer as
checked for accuracy, clarity, completeness and conformance with the reference
documents. CORE
4.1.4 Fabrication inspection and test / quality control plans shall be developed detailing all
the principal stages of preparation, forming, welding, heat treatment, NDE and
testing and submitted to SASOL’s representative and AIA for approval before
starting fabrication. (See specification SP-40-05A for description of responsibilities).
CORE
4.1.5 Each individual WPS/ PQR submitted shall be accompanied by a WPS Approval
Request Sheet as detailed form F1118. The Approval Request Sheet shall be
prepared by the Manufacturer and detail all relevant information regarding intended
application of the WPS which is relevant to its review. This document shall uniquely
reference the WPS number and revision and shall be approved by both SASOL’s
representative and the AIA. If approved, the WPS itself shall be initialled to ensure it
is the same version as that submitted with the Approval Request. This Approval
Request Sheet shall accompany the WPS at all stages (including the shop floor). A
WPS which is not accompanied by this sheet shall be considered as unapproved.
CORE
4.1.6 All second and subsequent submission of documents to Sasol shall incorporate the
following: CORE
a. Each change shall be marked with an indicator adjacent to the change

referring to the revision number where the change occurred. CORE
b. The document shall be accompanied by a comment resolution sheet which

lists all comments made by SASOLs representative and/or AIA in the previous
revision. The manufacturer’s response/resolution to each comment shall be
added in answer to each comment. NEGOTIABLE
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4.1.7 Welders’ performance qualification records, accompanied by a project welder’s list

(refer section 5.6.1), shall be made available to SASOL’s representative for review
upon request. The AIA shall have reviewed the individual performance qualification
records for the welders proposed on the list and shall accordingly sign the list if in
agreement. CORE
4.1.8 Production welding shall only commence after the applicable manufacturer’s
documentation has been approved by SASOL’s Representative and AIA. CORE
4.1.9 Units and measurements shall be according to specification SP-90-31.The fabricator

shall show the location of all welded joints on the AFC ISO drawings. Distinction
shall be made between shop and field welds. CORE
5 PROCEDURE QUALIFICATION AND WELDER QUALIFICATION
5.1 COMPLIANCE TO CODES AND SPECIFICATIONS
5.1.1 Welding procedure qualifications and welder’s performance qualifications shall

comply with ASME Code Section IX, with the additional requirements of ASME
B31.1 or ASME B31.3, whichever is applicable, as well as with the requirements of
this Specification. CORE
5.1.2 Each manufacturer shall qualify all welding procedures prior to any production
welding. The manufacturer shall perform a gap analysis as soon as information on
the scope of work is available. CORE
5.1.3 Sasol reserves the right to request additional supporting documentation for a
submitted PQR such as:
a. Base metal and filler metal certificates;
b. parameter record sheets (signed by both manufacturer and the witnessing
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independent third party);
c. heat treatment graphs,
d. laboratory reports; NDE certificates, gas certificates.
Failure to supply such documentation may result in non-acceptance of the PQR.

CORE
5.1.4 Addendums may be added to existing PQR’s in cases such as where additional
tests are required which were not performed in the original PQR. The coupons for
such addendums must be made within the same parameter ranges and variables as
the original PQR. The final package shall contain all relevant documentation and
records (as in section 5.1.3 above) for both the original PQR and the addendum as
proof of the addendum representing the original PQR. CORE
5.1.5 All welding procedure qualifications (PQR) shall be witnessed or endorsed by

independent third parties in accordance with the requirements of the local
legislation. Sasol or its representative may specify additional witnessing or
certification requirements based on consideration of the application and the
requirements of the local legislation.
The PQR shall, however, clearly indicate whether the welding and/or testing was
witnessed or merely endorsed. CORE
5.2 WELDING PROCEDURE QUALIFICATION
The requirements in this section apply to all cases but, where more stringent
requirements are provided in sections 5.3 and 5.4, they shall also apply for
applications with impact testing or hardness testing requirements respectively.
CORE
5.2.1 Procedure qualification tests shall be made on base metal having the same P-
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number and Group-Number or higher Group-Number as the base metal to be used

in production welding. Example: A PQR on P-Number 1 Group-Number 3 qualifies
welding on P-Number 1 Group- Numbers 3 to 1 material.
This does not apply for P1 (Group 1 and 2) and P3 (Group 1 and 2) materials which
do not have impact testing or hardness testing requirements and whose nominal
thickness does not exceed 19mm. In such cases, the procedure qualification tests
shall be made on base metal having the same P-number only. The measured tensile
strength of the PQR shall, however, be sufficient to support production welding of
the base materials with higher tensile strength in the higher Group numbers also.
CORE
5.2.2 Additional Essential Variables and limitations as specified in Section 6 for the
respective processes shall also apply. CORE
5.2.3 All production welds involving single sided root welds shall be qualified by PQR’s
wherein:
a. The same process is used on the root as intended on the production weld
b. The PQR is welded in the absence of backing, backwelding or backgrinding.

(Unless the proposal is to use backing in production welding in which case the
PQR shall replicate the backing)
c. No root repairs are performed during or after welding the PQR.
d. The actual root gap and root face dimensions are recorded in the PQR.
e. The WPS accordingly specify realistic ranges for all parameters required to
replicate the same root quality. As a minimum this shall be:
i. ±20% of the welding current employed in the PQR
ii. ±1mm in the root gap from that recorded in the PQR
iii. ±0.5mm in the root face dimensions from that recorded in the PQR
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f. The PQR is performed in the same position as that intended in production

welding with the exception that 6G or a combination of 5G and 2G shall qualify
for all positions.
Such PQR’s shall include Radiographic Testing of the PQR test piece. Failure of the
PQR to meet the criteria specified for the production welds shall result in rejection of
the PQR. CORE
5.2.4 All essential and non-essential variables in accordance with ASME IX shall be
addressed in the PQR and WPS. In addition, the following information shall be
recorded in the PQR and specified in the WPS:
a. Method of groove preparation and root gap.
b. Specification and grade of electrode, wire and flux used.
c. Base metal specification(s) and grade(s) (incl. heat treated condition where it
is an essential variable)
d. Pipe diameter when below 500mm for production. This is to consider the
suitability of the process and electrode/wire diameter for the intended pipe
schedule and diameter specified in the WPS.
e. Bevel design including bevel angle.
f. Sequence of processes and passes. E.g. Root pass process, Hot pass
process, Fill and Cap processes. Also include the electrode/wire diameters for
each intended process. (It is not necessary to indicate the number of passes
as these will vary)
g. Electrode or wire diameter(s). Current and voltage range to be specified for

each diameter.
h. Welding method - manual, semi-automatic, machine or automatic welding.
i. Method of tacking as well as process and parameters to be employed. CORE
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5.2.5 Detailed procedure qualification testing is required for all automatic/ mechanised/
machine type welding processes. PQR and WPS shall list all variables required to
set up the automatic/mechanised/machine welding equipment including the detailed
weld preparation and tolerances.
The following shall be deemed to be essential variables and shall apply for all
automatic/ mechanised/ machine type and specialised equipment (excludes SAW
without pulsing on thickness less than 60mm with included bevel angles greater than
45˚, but includes orbital welding):
a. Equipment make and model to be specified on the PQR (for the manipulator,
the power source and its ancillary equipment). This need not be an essential
variable for simple mechanised GMAW (non-pulsed) and FCAW processes
manipulated by the welder (e.g. a torch fixed to a column and boom).
b. Weld joint configuration (special emphasis on the root gaps, root face, land,
bevel angle, radii etc.). Realistic ranges to be specified on the WPS for which
a representative joint can still be produced.
c. Critical parameter settings (e.g. weave width, dwell time, weave speed, current
pulse settings, feedback control parameters, travel speed, arc angle, contact-
to-work distance and height control settings).
d. Tracking method
e. Welding head design
f. Where these processes are employed to weld out of position (e.g. not rotated),
the position as well as the pipe diameter shall be an essential variable. CORE
Where a fabricator proposes to use such specialised equipment, the details of it

shall be provided to Sasol for review and approval. Depending on the degree of
specialisation and the process details, Sasol may request specific essential
variables to be added.
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Each of these PQR’s shall also have macro’s taken as close as possible to the top
(0˚), vertical (90˚) and bottom (180˚) positions. Photographic quality images of the
macro’s shall be included in the PQR package. CORE
5.2.6 For non-ASME base materials (unassigned materials), the type, grade and code
designation of material used shall be given. CORE
5.2.7 The PWHT requirements for procedure qualification tests shall be in accordance
with the applicable code and SP-90-17.CORE
5.3 WELDING PROCEDURE QUALIFICATIONS REQUIRING IMPACT TESTING
The following requirements apply when impact testing of welding procedures is

required by code, as specified in Table 1 of Appendix A or by contractual
requirement.
5.3.1 Unless otherwise specified, impact tests shall be performed at or below the
temperature specified in Table 1 of Appendix A for line classes requiring impact
testing. CORE
5.3.2 Impact tests shall be conducted in accordance with specification SP-110-06 and
meet the impact values specified therein. Impact test results shall be submitted as
part of the PQR. CORE
5.3.3 The number, sequence and distribution of passes shall be recorded on the PQR.
The corresponding parameters and heat inputs shall be recorded for each pass. The
heat input employed in the areas subjected to impact testing shall be used to
establish the allowable WPS heat input ranges as follows:
The heat input ranges shall be established based on the typical ranges utilised in
welding of the PQR. Passes with outlier heat input values shall be discarded. Outlier
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passes are defined herein as a single or small selection of passes with values
uncharacteristically high compared to the general range of values (if a dispute arise
the following definition shall be used: values which fall outside of 75% to 125% of
the average heat input per wire diameter are considered outliers). If it can be proven
that such uncharacteristically high heat inputs were used in a localised area, it shall
be proven that it was indeed included in the material being impact tested and that
the full thickness of the impact test sample is covered by such passes by means of
macro preparation. CORE
5.3.4 The heat input for SMAW shall be recorded and controlled by measuring the length
of weld bead per unit length of electrode consumed (run-out ratio) ASME IX
QW409.1b. For SAW and GTAW the formula as per ASME IX QW409.1a shall be
used. For semi-automatic processes the heat input shall be recorded and controlled
by volume [maximum bead width, amps and volts] for the same wire diameter used
during qualification. Real time instantaneous energy can be used in lieu of
calculation for advanced microprocessor controlled power sources, ASME IX
QW409.1c. For all processes, calculation as per the formula in ASME IX QW409.1a
may be used as alternative to the run-out length or weld volume methods, provided
it is recorded as such in the PQR and the same method is employed in production
control. CORE
5.3.5 For manual and semi-automatic welding processes without backing the actual root
gap used during procedure qualification shall be a supplementary essential variable
not to be exceeded during production welding. CORE
5.3.6 When impact testing is required by code or contract, but it is not specified in Table 1
of Appendix A, the qualified thickness ranges shall be in accordance with the
relevant Piping Code (i.e ASME B31.3). In addition to code requirements, the base
materials used in the qualification test shall belong to the same code exemption
curve (or impact test exemption temperature in ASME B31.3) and be in the same
heat treated condition as the production base materials. CORE
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5.3.7 Welding procedures requiring impact testing according to Table 1 of Appendix A,

shall include impact testing of the weld metal and the heat affected zone (HAZ) on
the following: (i.e. the following supplementary essential variables shall apply)
a. Each type of filler metal.

b. Each type of welding process.
c. Representative base material which is defined as all of the following:
i. Same P-Number and Group Number
ii. Same base material heat treated condition (e.g. Normalised vs

Quenched and tempered)
iii. Same impact test exemption curve or impact testing exemption

temperature in ASME B31.3
iv. For carbon steels, carbon equivalent or Pcm of production material

not more than 0.02 greater than that of the PQR.
(In the absence of the Carbon Equivalent or Pcm being captured on the
PQR for historic PQR’s, the grade and product form of the base material
shall be an essential variable. All new PQR’s must have the Carbon
Equivalent or Pcm values recorded for future reference.)
v. Carbon Equivalent and Pcm shall be calculated as:
*For C content ≥0.11%
**For C content <0.11%
When the base material is exempted of impact testing, the acceptance criteria
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for impact testing of filler materials, weld metal and HAZ, shall be in accordance
with SP-110-06 and based on the minimum specified Yield Strength of the base
material.
d. The thickness ranges qualified shall be in accordance with Table 5.3.7. CORE
TABLE 5.3.7 RANGE OF BASE METAL THICKNESS QUALIFIED WHEN IMPACT

TESTING IS REQUIRED
MATERIAL THICKNESS LIMITS OF QUALIFICATIONS (mm)

TESTED
Lower Upper
(mm)
T< 6 T/2 6
6 ≤ T ≤ 16 T T+6
T > 16 Larger of 16 or T/2 T+6
5.4 WELDING PROCEDURE QUALIFICATION HARDNESS TESTS
5.4.1 Welding procedure qualification tests require hardness testing when any of the
following applies:
a. When note 76 is specified for the applicable lineclass in Appendix A.

b. For all P4, P5 and P10H materials irrespective of service
c. All materials subjected to PWHT
d. Welds deposited by semi-automatic and automatic processes (except for P8 and
P41 to P45 materials)
The hardness testing shall include cross section Vickers hardness (HV10) and
surface Brinell hardness (HB) tests of the weld metal and HAZ. The surface
preparation for the Brinell hardness qualification test shall be representative of the
production welds. CORE
5.4.2 For welding procedure qualifications, Vickers (HV10) indentation locations shall be as
per Figure 5.4.2. Hardness values shall meet the requirements in Table 16.1.12. of
this specification. Transverse Vickers hardness survey tests of procedure
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qualifications shall be performed on one sectioned and polished face along a line
parallel to, and within 1 mm of, the inner and outer surfaces, and in the centre of the
cross section, with the indents spaced not greater than 0.75 mm apart in the HAZ
and fusion zone and unaffected base material. The first indent for the HAZ
measurements shall be located close as possible to the fusion line but shall not
include any weld metal. CORE
FIGURE 5.4.2 REQUIRED HARDNESS INDENTATION LOCATION FOR

PERFORMING A VICKERS HARDNESS SURVEY ON CROSS
SECTION BUTT AND FILLET WELD SAMPLES
5.4.3 Procedure qualifications requiring hardness testing shall be submitted with a

macrograph of the sample in the etched condition illustrating the hardness indent
locations. For applications where note 75 is not specified in Appendix A, this may be
omitted if the accompanying laboratory report contain a schematic drawing of the
hardness indent locations confirming compliance with 5.4.2. NEGOTIABLE
5.4.4 Hardness tests shall be taken from a portion of the circumference welded in the
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vertical position (e.g., the 90˚ or 180˚ position if the top is at 0˚). CORE
5.4.5 For large diameter pipes, Sasol may specify that hardness tests additionally be
taken from the top (0˚) and bottom (180˚) positions as well as at the intersection with
the pipe longitudinal weld. NEGOTIABLE
5.4.6 For orbital mechanised or automatic positional welds, hardness tests shall be taken
from the top, vertical and bottom positions. Additionally, when note 75 is specified in
Appendix A for the lineclass, hardness tests shall be taken from each programmed
segment of the circumference whose heat input or wire feed speed differs more than
10% from that tested. CORE
5.5 QUALIFICATION OF REPAIR WELDING PROCEDURES
5.5.1 SASOL reserves the right to call for the qualification of repair welding procedures for
completed welds that require repair after NDEs, when impact testing is required by
Table 1 of Appendix A as well as for services where hardness limitations are
specified for sour service and other stress corrosion services. This requirement shall
be agreed upon during bid clarification or specified in the technical scope of supply.
NEGOTIABLE
5.5.2 Repair welding procedure qualification welds shall be made on welds identical to
those used to qualify the original welding procedure (i.e. the WPS being repaired
shall then be an essential variable). When repair procedure qualification is called for,
SASOL will specify whether a full thickness, mid-thickness or cap repair qualification
is required. NEGOTIABLE
5.6 WELDER AND WELDING OPERATOR QUALIFICATIONS AND CONTROL
5.6.1 The manufacturer shall implement and maintain a formal system for the tracking of
welders’ qualifications as well as their production performance and rejection rates.
The system shall be available for auditing by Sasol or its representative. It shall, as a
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minimum, comply with the following:
a. The system shall demonstrate compliance with the requirements of Appendix

A notes 5, 7 and 8.
b. It may be generated from a dedicated software package. As an alternative it

may be generated from a documented and implemented process of manual
data capturing and processing.
c. A welders list shall be prepared at the start of the project and periodically
updated. It shall list the identification details of each welder as well as all
qualification information (such as processes, materials and diameters qualified
for). This list shall be a controlled document and be available with the direct
supervision at all times. Only welders listed shall be utilised.
d. The manufacturer shall maintain a list with records of all welder qualification
tests performed by each welder. This shall list all historic qualifications
(performed under the manufacturer), lapsed qualifications as well as dates of
failed qualification tests.
e. The reject rate per welder shall be available and accurately tracked. The time
between welding of a production weld, its testing and subsequent capturing
and reporting shall be minimised. Reject rates shall strictly be reported on as
follows:
i. Expressed only on a butt rate as follows:
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐵𝑢𝑡𝑡𝑠 𝑓𝑎𝑖𝑙𝑒𝑑

% 𝑅𝑒𝑗𝑒𝑐𝑡𝑖𝑜𝑛 = 100 ×
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐵𝑢𝑡𝑡𝑠 𝑅𝑇'𝑒𝑑
ii. The reject rate to be indicated for each welder. Both the reject rate for
the period of reporting as well as for the project to date shall be
reported.
iii. The period of reporting shall be as agreed with the project
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management team but shall not exceed once per month for shop
fabrication and once per week for field fabrication and installation.
f. It is also desired that the manufacturer be able to provide evidence of the

performance of each welder in past projects executed under the same
manufacturer. CORE
5.6.2 Each manufacturer shall qualify all welders and operators on his approved welding
procedures prior to production welding. Qualification on production welds is strictly
prohibited. CORE
5.6.3 The premise of the qualification requirements provided herein is that the
manufacturer shall only use trained competent welders (and supervision) on
production welds. In the interest of skills development, the manufacturer may recruit
novices provided that such personnel undergo a rigorous welder training program of
at least several weeks. Novices may not undergo any official performance
qualification test prior to completion of abovementioned program. The test criteria for
failed qualification tests in subsequent sections of this document shall be followed
and compliance demonstrated by the record keeping specified in section 5.6.1 (c)
and (d).CORE
5.6.4 Test requirements for welders and welding operators shall be in accordance with
ASME IX.
a. All qualification tests shall be examined by radiography as a minimum. Where

QW-304 and QW-305 of ASME IX does not allow for radiography to be used
in lieu of bend testing, both tests shall be performed.
b. Visual examination shall be performed on both the internal and external

surfaces of test coupons and shall meet the criteria specified in both ASME IX
and section 15.2 of this specification.
Visual examination and witnessing of bend testing shall be performed and witnessed
by Level 2 QC inspector as minimum. A Level 2 RT Technician with RT Interpreters
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shall evaluate the RT results. All relevant reports to be included in the pack. CORE
5.6.5 The qualification requirements in addition to code are as follows:
a. Qualifications where impact testing is required:
i. The performance qualification tests of each welder shall include heat

input control and documented proof thereof. This proof shall be in the
form of a parameter record sheet of actual parameters measured and
duly signed by a welding inspector or other suitably competent person.
The original WPS (on which heat input ranges are specified) shall also
be available and the heat inputs recorded shall match that specified.
SASOL reserves the right to accept or reject the qualification.
ii. When welders were previously qualified in accordance with the above
paragraph, re-qualification is not required provided that:
The initial qualification is available; and
evidence is provided that welding with heat input control as

specified in paragraph 5.6.5(a)(i) was performed successfully
during the previous three months. CORE
b. Welders for GMAW (incl MCAW) and FCAW shall be qualified as follows
unless otherwise agreed between SASOL and the fabricator:
i. For groove weld-butt joints: radiography and bend tests.

ii. For branch connections: four macros at stops /starts of the corner joint,
in addition to the groove weld requirements.
iii. For fillet welds: two macros at stops /starts.
iv. The minimum outside diameter qualified is the diameter tested.
v. The filler material AWS classification shall be a welder’s essential
variable for FCAW-G. For stainless steel the AISI designation is not a
variable, e.g. Type 316L.
vi. The filler material brand name shall be an essential variable for
MCAW.
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vii. For GMAW processes with proprietary or complex pulsed waveforms,

such as controlled short circuiting (STT®, RMD®, CMT® ), the welder
shall qualify with the same equipment (model and brand) as well as
essentially same settings (e.g. program number) as that to be used in
production welding. The WPS on which he qualified shall duly capture
all such settings and variables and shall accordingly be appended to
the welder qualification record. The root specific parameters shall be
essential variables for all pulsed GMAW processes to be employed on
single sided roots. CORE
c. Welding operators to be used on orbital welding or any similar mechanised or

automatic welding processes shall be qualified in accordance with the relevant
sections in ASME IX. The following shall additionally apply:
i. The welding operator shall be able to do all necessary setups and

equipment settings to perform the production welds. Where this
involves writing of programs, the program shall not be altered by the
welding operator (this is only to be loaded or altered by the original
developer of the program – such as welding engineer).
ii. The welding operator shall only be afforded limited ranges on basic
parameters (such as current, position, height and travel speed) which
have been pre-programmed and proven to be valid during the PQR
qualification stages.
iii. Welding operators shall be requalified for each make and model of
equipment. Where a make and model of equipment utilises multiple
heads for various diameters (but of the same operating principle), the
welding operators need not qualify with each head, but only within the
diameter ranges imposed on manual welders. CORE
d. Welders and welding operators who are to produce production welds with
complex bevels are to be qualified on bevels simulating the production
conditions. For bevels with included bevel angle less than 30˚ (i.e. 15˚ per
side) the minimum qualified bevel angle for welders or welding operators shall
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be equal to that tested. The actual measured bevel angle and qualified range
are to be recorded on the welder test certificate. CORE
e. Welders who are to be utilised for producing field welds are to be qualified
under conditions simulating those anticipated in production. Such field welds
to be made under particularly difficult conditions are to be identified at the start
of the project by Sasol or its representative and the construction contractor.
The following are deemed to be conditions warranting additional welder
training and testing:
i. Restrictive access to the full joint circumference due to proximity of

adjacent obstacles (Typically defined as any obstacle within 150mm for
pipe diameters of 4” and smaller, within 2x the pipe diameter up to 12”
and within 600mm for larger sizes; also defined as any restriction
closer than 75mm measured along the pipe length from any of the
weld bevels)
ii. Obstacles not allowing for direct visual access around the full
circumference of the joint.
iii. Odd welding positions such as where the welder needs to weld
overhead for extended periods of time
iv. Restricted access
v. Uncomfortable conditions (e.g. extreme temperature conditions,
confined spaces, heights)
The details of the production welds and conditions are to be provided to Sasol
for approval along with the manufacturer’s proposal of how the welders will be
trained and tested to perform under the conditions. Sasol reserves the right to
impose specific tests simulating the field conditions where manufacturer
oversight did not identify it prematurely. NEGOTIABLE
f. Welders who are to be utilised for producing field welds shall, in addition to
qualifying to ASME IX and other tests specified herein, weld test coupons
which conform to the following:
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i. Contain welds in the 2G and 5G positions (the 6G position may be

used in lieu of 2G and 5G)
ii. ID’s of matching ends are specifically sized to induce a root hi-lo of at
least 2mm (1.5mm for pipes of diameters 2” and smaller)
iii. Diameters for which the welders are qualified shall meet the ranges of
table 5.6.5.(f)
iv. Contain a means of restriction such as pipes adjacent to the pipe being
welded or in the form of a retaining ring adjacent to the weld.
Where the above requirement is enforced, the manufacturer shall provide to

Sasol or its representative a proposal, for approval, on the test setup to which
welders will be qualified. The materials type and sizes are to be selected to
logically cover the ranges anticipated in production. NEGOTIABLE
TABLE 5.6.5 (f) DIAMETER QUALIFICATION RANGE RESTRICTIONS
Test Coupon Diameter Diameter Range Qualified

inch (mm) inch (mm)
D ≤ 1 (25) D to 6 (168.3)
If pipe rotated: D/2 to Unlimited
If pipe welded out of position: D/2
6 (168.3) ≤ D to 36”
D/2 to Unlimited
24 (600) ≤ D (all positions)
NEGOTIABLE
g. Welders shall have their qualifications revoked when any of the following
apply:
i. The welder repair rate exceeds the limits specified in table 5.6.5.(g)
ii. The welder fails 2 or more of his first 3 production welds
iii. The welder fails 3 consecutive welds at any time
iv. Upon evaluation by an inspector from Sasol, Sasol’s representative or
the AIA, the weld deposited by the welder is of such poor quality that
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the welder is deemed to lack the necessary skill.
The above is not to be limited per lineclass and applies to all production welds
made by the welder.
A welder with revoked qualifications shall not be allowed to continue any

further production welding until such time as he is retrained and requalified in
accordance with subsequent sections. Sasol and/or Sasol’s representative
shall be notified of all revoked qualifications within 48hours along with the
proposed remedial action. CORE
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TABLE 5.6.5.(g) MAXIMUM ALLOWABLE RT REJECTIONS
Maximum allowable
RT rejections-
Mechanised/
Orbital, Automatic
processes or
Number of Welds Maximum allowable RT Maximum allowable RT processes with a
RT’ed: rejections per welder: rejections per welder: GMAW roots:
(Note 1) (Note 2) (Note 3)
≤ 30 3 butts 3 butts 2 butts
31 to 50 3 butts 4 butts 2 butts

51 to 80 4 butts 5 butts 5%
≥ 81 5% 6% 3%
Note 1: This is the maximum allowable RT rejections per welder beyond which the welder’s
qualifications shall be revoked. It is the value for the period of reporting only (sampling period
agreed upon).
Note 2: This is the maximum allowable RT rejections per welder beyond which the welder’s
qualifications shall be revoked. It is the cumulative rate maintained since the start of the
project.
Note 3: This is the maximum allowable RT rejections for the listed specialized processes
beyond which the WPS shall be revoked and only reinstated pending a root cause
investigation. It is not the rate per welder/ welding operator but the rate maintained for the
specific process by the welder/ welding operator.
General Notes:
Where reference is made to number of welds it shall refer to number of welds RT tested (not
welded)
Where a rate is specified is shall mean the butt weld rate as defined in section 5.6.1(e)(i)
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h. Welders who fail a qualification test may be allowed for immediate retest
provided it complies with ASME IX QW-320 and all of the following conditions
are met:
i. The failure is not deemed to be the result of gross incompetence (as

evaluated by Sasol, Sasol’s representative or AIA).
ii. The welder can verbally describe the possible cause of the defect
causing the rejection and the technique that will be implemented to
avoid its recurrence.
iii. The welder has not failed any of his last 2 qualification tests.
Welders who do not meet the requirements above shall be exposed to a minimum
training period of 1 week prior to being allowed to retest. CORE
6 WELDING PROCESSES
Acceptable welding processes are given in Table 6:
TABLE 6 ACCEPTABLE WELDING PROCESSES
AWS LETTER
WELDING PROCESS
DESIGNATION
Shielded Metal Arc Welding SMAW
Gas Tungsten Arc Welding GTAW
Submerged Arc Welding (Mechanised/Automatic only) SAW
Gas Metal Arc Welding (Pulse and Spray transfer GMAW

only) (*) (**)
Flux Cored Arc Welding (Gas assisted only) FCAW-G
(*) GMAW short circuit with pulsating arc (or controlled short circuit) is also
acceptable provided that it complies with specifications of this section.
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(**) MCAW shall be treated as a form of GMAW with unique wire form. It is
acceptable for use, subject to it meeting the requirements specified for GMAW.
Refer to additional notes and restrictions in this section which shall apply in addition
to that listed in this table.
Other welding processes may be used only upon specific written approval by
SASOL. The fabricator shall submit pertinent data and application of the proposed
for evaluation. CORE
6.1.1 Welding without the addition of filler metal (autogenous welding) shall have prior
approval by Sasol. CORE
6.1.2 GMAW using the short circuiting transfer mode is not permitted unless it is used as
temporary backing (e.g. for SAW in which case it shall be completely removed by
subsequent backgrinding or backgouging). Proprietary controlled pulsed short
circuiting processes (such as STT®, CMT® and RMD®) may be proposed for
welding of root passes only subject to Sasol’s review and approval. Essential
variables as defined for Pulsed GMAW shall apply in such cases. CORE
6.1.3 FCAW-G, GMAW (normal and pulsed) and MCAW may be used provided the
following conditions are met:
a. Welders are qualified in accordance with section 5 of this specification.
b. Not allowed on any piping with diameter smaller than NPS 6 or wall thickness
less than 11mm. (Wall thickness limit does not apply for roots deposited by
controlled short circuiting GMAW)
c. It shall not be used for the root pass of pressure retaining single-sided welds
without backing and backwelding, except for duly approved proprietary
controlled short circuiting processes.
d. Notes 8 and 81 shall specifically be followed. CORE
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6.1.4 The following additional essential variables apply for FCAW-G, GMAW, pulsed
GMAW (normal pulse and proprietary controlled short circuiting) and MCAW:
a. An increase in wire diameter from that qualified in the PQR. For proprietary
processes (see section 6.1.2), a reduction in wire diameter also constitutes an
essential variable.
b. For FCAW-G and MCAW, any change in the consumable brand name.
c. A change in the groove design (e.g. from V to U) and a reduction in the bevel
angle of more than 5˚.
d. For pulsed GMAW specifically (includes all controlled short circuiting

processes and those of pulsed waveforms):
i. Equipment make and model

ii. Program number and all other essential settings (which can be
program numbers for Synergic power sources but can also be specific
pulse parameters such as pulse time, peak- and background currents,
tail-out, feedback control and arc correction parameters etc.)
Where conventional short circuiting GMAW is applied as root for temporary

backing, only a single layer may be used and the PQR shall indicate the depth
of backgrind to completely remove this weld metal. The depth of backgrinding
shall constitute an essential variable which may not be reduced. CORE
6.1.5 Specialised welding processes (mechanised, automatic or orbital welding or welding

of root by controlled short circuiting pulsed GMAW) whose weld rejection rate
exceeds the limits of table 5.6.5.(g) at any stage shall have the WPS revoked. The
manufacturer shall identify the root cause of the defect and institute corrective
actions, for Sasol’s approval, prior to re-commencing work with the process. CORE
6.1.6 The NDE requirements of note 81 shall also be followed for narrow groove welding
(defined as welds with included angle equal to or less than 30˚ (i.e. 15˚ per side)).
CORE
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6.1.7 The use of flux cored or flux coated GTAW wires shall be subject to approval from
Sasol. If approved by Sasol in writing, the brand name shall be an essential variable
for both the PQR and the welder qualification. Core
7 WELDING CONSUMABLE REQUIREMENTS
The requirements for welding consumables used (filler material, shielding and
purging gases) shall be in accordance with the requirements of Specification SP-90-
01A. CORE
8 WELD JOINT PREPARATION
8.1.1 Weld joint preparation may be made by machining, grinding or thermal cutting. The
surfaces shall be smooth and true. When thermal cutting or gouging is performed,
the joint surfaces shall be ground to bright metal. CORE
8.1.2 Material such as plate, pipe, forgings, castings or any other product form that is cut
too short dimensionally or when fit up at a joint, produces a root gap in excess of
that qualified by the applicable welding procedure, shall not be built up by welding
without the approval of SASOL. CORE
8.1.3 Surface defects that infringe on the minimum material wall thickness shall not be
repaired by welding without prior approval by SASOL. CORE
8.1.4 When thermal cutting is used on stainless steel or other high alloy materials the
carrier gas (when applicable) shall be inert. Grinding wheels and stainless steel
wire brushes used on high alloy materials shall not previously have been used on
carbon or low alloy steels. Carbon air arc gouging is not allowed on stainless steel
or other high alloy materials. CORE
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8.1.5 The welding preparations of piping shall be suitably protected and adequate care
shall be taken to prevent damage of the sections during transport and erection.
There shall be no ingress of any moisture, dust or foreign materials and no
contamination on the bevel itself, or adjacent surfaces on both the pipe internal and
external surfaces. The bevels shall be free of rust. This also applies to instances
where pipes are tacked up well in advance of welding taking place. The joint shall as
a minimum be protected by tape around the full circumference. CORE
8.1.6 For butt welds in pipe NPS 24 and larger that are not welded from both sides, fit-up
inspection shall be a hold point for fabricator quality control with 100% internal visual
inspection of the root pass. When internal visual inspection cannot be performed,
the weld shall be inspected by 100% RT (UT may be used in lieu of RT with prior
approval of SASOL). The root area of double-sided welded joints shall be back
gouged and/or ground and examined by MT or PT prior to welding. CORE
8.1.7 Complex bevels (such as compound or J-groove bevels) or bevels of weld joints
with stringent fit-up requirements (such as for orbital or automatic welding
applications) shall only be prepared by means of machining or with dedicated
mechanical end-prep rotary equipment. Preparing such bevels by manual grinding is
not allowed. CORE
9 CLEANING REQUIREMENTS
9.1.1 Flux, weld spatter and slag shall be removed from each weld bead prior to
depositing the succeeding pass as well as from the completed weld. CORE
9.1.2 Peening is not permitted. CORE
9.1.3 Cleanliness shall be maintained during fabrication welding. All stubs, rods, flux,
slag, burrs, shavings and other foreign material shall be removed from pipe
assemblies. CORE
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9.1.4 Weld slag residue shall be completely removed from all stainless steel and high
nickel alloy piping. When weld slag residue cannot be removed from the inside
surface, the root pass shall be deposited by the GTAW or GMAW process with solid
wire. CORE
9.1.5 Piping systems requiring special cleaning as per isometric drawings or for gaseous
oxygen lines shall require the root pass to be deposited by the GTAW or GMAW
processes as applicable with solid wire. The back side of the root pass shall be
purged with inert gas when the pipe diameter is too small to allow mechanical
cleaning or back welding of the root pass. CORE
10 WELDING REQUIREMENTS
10.1.1 Permanent backing rings shall not be permitted unless specifically approved by
SASOL. CORE
10.1.2 Consumable inserts may not be used without prior SASOL approval. CORE
10.1.3 Gas purging is required for single sided welds of low alloy steels with a Cr content
higher than 3% and for all stainless steel and high nickel alloy piping, with a suitable
backing gas in accordance with SP 90-01A. The use of alternative methods in lieu of
such purging is not allowed without prior SASOL approval. If approved for specific
non-critical, non-corrosive services, additional requirements on the consumables,
welders and welding procedure qualification may be imposed. CORE
10.1.4 All attachment welds directly to pressure containing parts shall conform to the
requirements applicable to the pressure containing welds of the specific line class.
Attachments welded directly to a pressure containing components shall be of the
same type of material as that of the pressure component (type or grade are
materials of the same nominal chemical analysis and mechanical property range,
even though of different product form). CORE
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10.1.5 All tack welds and temporary attachment welds shall be performed by qualified
welders using a qualified WPS. CORE
10.1.6 All temporary attachment welds, where permitted, shall be removed and the affected
surfaces properly conditioned to eliminate surface stress raisers. Such surfaces
shall be examined by the magnetic particle (MT) or liquid penetrant (PT) method and
supplemented with hardness testing on all locations when required by Table 1 of
Appendix A. Temporary attachments shall be removed by methods which will not
damage the base material i.e. no hammering, excessive grinding. Temporary
attachments such as carbon steel welded directly to stainless steel components
shall not be permitted. CORE
10.1.7 Reinforcing pads shall follow the curvature of the pipe and shall be continuously
welded. Maximum allowable gap between the edges of the reinforcing pad and the
pipe shall nowhere be greater than 1.5 mm. When fitting reinforcing pads to welded
pipe and the reinforcing pad would cover any of the weld seams, the pipe weld
seam reinforcement shall be ground flush and 100 % RT examined prior to fitting the
reinforcing pad. CORE
10.1.8 No arc strikes are permitted outside the weld joint preparation. Wherever arc strikes
occur on the pipe outside the weld joint, the surface shall be examined by the MT or
PT method and supplemented with hardness testing and conditioned to eliminate
stress raisers. CORE
10.1.9 Heat input control in production shall be the same method as used during procedure
qualification for each respective welding process (See Par 5.3.4). Prior to fabrication
the fabricator shall submit a Heat Input Control Procedure to SASOL for approval.
Welders shall set the heat input control variables, as per applicable approved WPS,
on a separate piece of pipe at the beginning of each shift. CORE
10.1.10 Weld Toe-to-Toe clearance of 2T or 50mm whichever is less where T is the

governing thickness (as defined in ASME B31.1 or B31.3 as applicable). CORE
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10.1.11 The mismatch on the internal diameters of roots for two abutting pipe ends shall not
exceed 1.5mm unless more stringent requirements are specified by code, the WPS
or mandated by the service. CORE
11 WELD CONTOUR
11.1.1 Weld beads shall have a convex contour with complete fusion at the sides of the
bevel and without cold lap or trapped slag. See Figure 11.1.2 for acceptable weld
profiles. CORE
11.1.2 The finish of welds shall be such that surface irregularities will not interfere with the
application of the specified NDE or the interpretation of the test results. CORE
FIGURE 11.1.2. FILLET AND GROOVE WELD PROFILE REQUIREMENTS
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12 PREHEATING
12.1.1 Preheat shall be in accordance with the applicable Code and this specification and
as supplemented by specification SP-90-17. Preheat as required in SP-90-17 shall
apply on all fillets where base material is 10mm thick or more. CORE
12.1.2 The preheat temperature shall be maintained during any interruption of the welding
when the specified preheat temperature for the material is 150°C or higher. CORE
12.1.3 Interpass temperature shall not exceed 175°C for austenitic stainless steel and high
nickel alloy welds. CORE
13 POST WELD HEAT TREATMENT (PWHT)
13.1.1 PWHT requirements are specified in Table 1 of Appendix A and shall be performed
in accordance with the applicable Code as supplemented by specification SP-90-17.
CORE
13.1.2 It is cautioned that the services indicated for the respective line classes are the
typical services and may not capture the presence of all trace elements or all service
conditions which could dictate the need for PWHT. The full stream composition
(including trace elements, hydrogen partial pressure etc) shall be evaluated to SP-
50-03A and its referenced appendices for PWHT due to service reasons. Where
PWHT is not necessarily specified by code or line class but is confirmed to be
required due to service reasons, it shall be clearly specified on the ISO. Line classes
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which may be at risk of service related PWHT requirements are indicated by note
22a Appendix A (although it is cautioned that some other line classes may also be
covered). This list is not exhaustive and the severe service definitions of SP50-3A
shall always apply.
PWHT would typically be required for the following severe services applications:
a. Carbon steel and low alloy steel piping exposed to wet hydrocyanic acid, wet
carbon monoxide/carbon dioxide mixtures, gas liquor and mixtures of such
solutions when the operating temperature is below 100°C.
b. Carbon steel and low alloy steel piping exposed to carbonate solutions and
mixtures of carbonates and hydrocarbons (unless exempted under the
conditions of the line classes for carbonates in Appendix A)
c. Carbon steel and low alloy steels used in sour water service (subjects to
exemptions provided in notes in Appendix A)
d. Carbon steel and low alloy steels in caustic service as defined in SP50-3A
Appendix D.
e. Carbon and low alloy steels in high temperature hydrogen service as defined
in SP50-3A Appendix E.
f. Services in which carbon and low alloy steels are exposed to an environment
which can cause stress corrosion cracking e.g. rectisol wash plant, sulfinol,
vetrocoke, ammonium nitrate, anhydrous ammonia with water content of less
than 0.2%.
g. Equipment made from ferritic steels for the Rectisol wash plant. CORE
13.1.3 PWHT procedures shall be submitted to SASOL’s representative for review and
approval and the contents shall be in accordance with the requirements of
specification SP-90-17. For PWHT of valves where internals are not removed, the
procedure shall address measures to ensure that non-metallic materials and trim will
not be damaged during the heat treatment. These measures include, but are not
limited to the following:
a. Thermocouple locations during preheating and PWHT
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b. Extent of insulation used

c. Prescribed valve closure position
d. Functionality test after heat treatment CORE
13.1.4 The following PWHT methods are acceptable:
a. Furnace method
b. Local resistance method
The use of other PWHT methods (such as local induction methods) shall require
prior approval by SASOL. CORE
14 REPAIRS
14.1.1 For pipe diameters of NPS 2 and smaller any unacceptable sub-surface
discontinuities detected by RT shall constitute a cut out and re-weld. CORE
14.1.2 For pipe diameters larger than NPS 2, any unacceptable sub-surface discontinuities
detected by RT or UT methods shall be completely removed by gouging, grinding or
other approved methods to clean sound metal. Thermal gouging methods shall not
be used for removal of the weld root. This shall be done by grinding with a slitting
disc such that a configuration as near as possible to the original weld bevel is
achieved. The resultant cavity shall be examined by a suitable NDE method that will
verify that the defect was completely removed. The following restriction apply:
a. Minimum excavation length shall be 75mm.

b. Maximum accumulated excavated length shall not exceed 40% of the
circumference. An excavated length of more than 40% of the circumference
shall constitute a cut out and re-weld.
c. The distance between two adjacent excavations shall be 50mm minimum. The
excavation shall be continuous in the event that this distance is less than
50mm.
d. Two attempts to repair a defect on the same area of a weld will be permitted.
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If the second repair attempt is unsuccessful, the complete weld shall be cut
out and re-welded unless further repairs are authorized by SASOL.
e. Where impact testing is required for Carbon steel, at temperatures below
minus 15ºC, in accordance with Table 1 of Appendix A, a repair shall be
PWHT or cut and re-welded regardless of thickness. CORE
14.1.3 Weld repairs shall be performed using an approved repair procedure or the
procedure used for the original weld. If PWHT was originally required, the weld
repair shall be PWHT. CORE
14.1.4 All repaired welds shall be examined by the same NDE methods as were specified
for the original weld. CORE
15 NON-DESTRUCTIVE EXAMINATIONS
15.1 GENERAL REQUIREMENTS
15.1.1 The NDE requirements of welds shall be in accordance with Table 1 of Appendix A.
CORE
15.1.2 The fabricator shall use a quality control system that provides traceability of
production welds and weld repairs to individual welders or welder operators and
date of production. When random or sampling NDE are involved, the system shall
provide for the sampling of each welder’s production in a timely and periodic manner
that includes all pipe diameters, wall thickness, material types and welding
processes used. CORE
15.1.3 All NDEs shall be performed in accordance with written procedures that conform to
the stated and referenced requirements of this specification and which have been
submitted to, and approved by SASOL’s representative and AIA. CORE
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15.1.4 All NDEs shall be performed by qualified personnel (ASNT Recommended Practice
SNT-TC-1A or a SASOL approved equivalent). All evaluators shall be Level II as a
minimum. UT operators shall be Level II as a minimum. CORE
15.1.5 Results of all NDEs shall be reported on a form approved by SASOL’s

representative. CORE
15.1.6 When examination requirements state that either MT or PT methods may be used,
the following rules shall apply:
a. MT method shall be used on all ferromagnetic materials if the surfaces

requiring examination are accessible for this method.
b. PT method shall be used on non-magnetic test materials, on ferromagnetic
surfaces not accessible to MT (piping NPS 2 or smaller) and on surfaces that
might be damaged by MT. CORE
15.1.7 When complete or 100% examination is carried out the following shall apply:
a. Complete or 100 % examination by the RT, UT, PT or MT methods is defined

as the examination, by the specified method, of the entire length or
circumference of every weld of the stated category or class.
b. Complete or 100 % hardness testing is defined as making the required
number of hardness tests on every weld in the stated category or class.
CORE
15.1.8 Sampling or random examinations shall be done as follows:
a. Sampling or random examinations by the RT, UT, PT or MT methods is

defined as the examination, by the specified method, of the entire
circumference of each selected weld in the specified percentage of the total
number of welds in a stated category or class.
b. Sampling or random hardness tests is defined as making the required number
of hardness tests on each selected weld in the specified percentage of the
total number of welds in a stated category or class.
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c. If unacceptable welds are found in random MT, PT, RT or UT examinations,

additional examinations of welds produced by the same welder and/or welding
operator shall be implemented in accordance with ASME B31.3. CORE
15.1.9 The examination of branches and other attachments containing full penetration
welds may be examined by UT if SASOL agrees that the required RT examination is
impracticable. In the event that UT and RT are not practical, as a minimum, the root
pass shall be visually examined from the root side and PT/MT from the cap side to
ensure that complete penetration of the root was obtained. CORE
15.2 VISUAL EXAMINATION
15.2.1 Visual examination procedures shall be in accordance with ASME Code Section V,
Article 9 and this specification. CORE
15.2.2 The fabricator shall visually inspect all fit-ups and weld surfaces prior to welding and
during welding to ensure that the requirements of this specification are met. CORE
15.2.3 All completed welds shall be visually examined and the acceptance criteria shall be
in accordance with ASME B31.1 or ASME B31.3 whichever is applicable. CORE
15.2.4 Visual examination of weld roots shall be so timed that the maximum length of the
inside weld surface can be examined during fabrication. NEGOTIABLE
15.3 MAGNETIC PARTICLE TESTING (MT) AND PENETRANT TESTING (PT)
15.3.1 For MT examination, alternating current (AC) shall be used in accordance with the
requirements and methods specified in Article 7 of the Code, Section V. Direct
current (DC) or half wave rectified current examination shall be carried out when
further results clarification is required. CORE
15.3.2 PT procedures shall be in accordance with the requirements and methods specified
in the ASME Code Section V, Article 6 and the requirements of this Specification.
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Penetrant materials shall meet the requirements of Paragraph T-641 of Article 6,

Section V of the ASME Code for sulphur and halogen content regardless of the type
of material to be examined. CORE
15.3.3 All PT and MT indications are not necessarily defects but may be produced by
machining marks, surface conditioning, magnetic permeability variations or other
indications which are not relevant unacceptable discontinuities. Any indication,
which is believed to be non-relevant, shall be regarded as a defect, unless
evaluation by re-examination by other NDE or surface conditioning verifies that no
actual defects are present. CORE
15.3.4 Linear indications are those indications in which the length is more than three times
the width. Indications shall be classified as rounded when indications are circular or
elliptical with the length less than three times the width. CORE
15.3.5 MT/PT examination of completed welds shall meet the acceptance criteria of ASME
B31.1 or ASME B31.3 whichever is applicable. Additionally, the following relevant
indications are unacceptable: (relevant indications defined as per ASME B31.1 or
B31.3 whichever is applicable)
a. Any crack, lack of fusion or incomplete penetration.

b. Any single rounded indication:
i. None permitted for material up to 5 mm thick
ii. 3 mm for material over 5 mm up to 12.7 mm thick
iii. 4.5 mm for material over 12.7 mm thick.
c. Defects revealed by PT and MT methods of examinations shall be explored
for depth. Cracks detected, irrespective of depth or orientation shall be
completely removed by gouging or grinding. The edges of cavities where
defects are removed, shall be rounded and merge smoothly into the parent
metal. When the depth of the defect encroaches on the minimum nominal
wall thickness of the pipe, the cavity shall be repaired by welding, using
qualified welding procedures and welders and be re-examined after welding.
CORE
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15.3.6 MT and PT of welds shall include a band of base metal at least 25 mm wide on each
side of the weld. CORE
15.3.7 If arc burns occur during MT, the arc burns shall be ground out and the area
examined by the magnetic yoke method. The area shall also have its hardness
tested when hardness testing is specified for the line class. CORE
15.3.8 All welds in piping systems subjected to pneumatic testing, except welds in carbon
steel piping systems subject to 100 % RT, shall be examined completely by the MT
or PT method prior to pneumatic testing. CORE
15.3.9 Branch pipe welds shall be fully examined before being covered by the reinforcing.
The branch pipe to reinforcing pad and reinforcing pad to header pipe welds shall
also be completely examined. CORE
15.3.10 All welds requiring PWHT shall be RT’ed prior to PWHT and re-examined 100%
after PWHT by MT as per Table 1 Appendix A or PT where MT is not practical,
except when note 4 is specified. CORE
15.3.11 When sampling examination is employed, the welds selected for examination by MT
or PT shall not include welds already selected for RT. CORE
15.3.12 When examinations by MT or PT are required on welds in piping of NPS 24 and

larger, both inside and outside surfaces shall be examined (when access permits).
NEGOTIABLE
15.4 RADIOGRAPHIC EXAMINATION (RT)
15.4.1 RT procedures and techniques shall be in accordance with the ASME Code, Section
V, Article 2 and the supplementary requirements of this specification. The
acceptance criteria applicable for 100% radiography or random radiography for
piping controlled by ASME B31.1 or ASME B31.3, shall be in accordance with the
code requirements, except that:
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a. Incomplete penetration shall not be acceptable,

b. The acceptance criteria for welds in line classes for which 25% radiography is
specified, shall be the same as for 100% radiography. CORE
15.4.2 At least one image quality indicator shall appear on each separate radiographic film.
Image quality indicators shall be of the wire type in conformance with ASME V,
EN462 or ISO 1027. The required image quality of radiographs submitted for
interpretation shall be the visibility of the designated wire size as specified in Table
15.4.2 for the weld thickness examined.
TABLE 15.4.2 - REQUIRED IMAGE QUALITY
IQI WIRE DIAMETER (mm)

WELD THICKNESS
(mm) H2/H2S SERVICE OTHER SERVICE
- to 6.4 0.16
6.4 to 9.5 0.20
9.5 to 12.7 0.25
12.7 to 19 0.33
As per ASME V
19 to 25.4 0.41
Article 2
25.4 to 38.1 0.51
38.1 to 50.8 0.64
50.8 to 63.5 0.81
63.5 to 101.6 1.02
CORE
15.4.3 When welds in pipe less than 4 inch NPS are radiographed by the double wall
exposure double wall view, or the double wall exposure super-imposed welds
technique, the image quality indicator shall be placed on the source side of the pipe.
When this technique is used, the projected images shall be at least one weld width
apart. The weld shall be radiographed twice, at angles 90° to each other.
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Where there is evidence of over penetration on the double wall double image film,
the actual wall thickness shall be measured and the amount of over penetration
shall be calculated using the ratio between the actual wall thickness and the wall
thickness measured on the film. The acceptance criteria for visual inspection given
in ASME B31.3 and this Specification shall then be used. In case of a dispute on
the calculated thickness or measured over penetration, UT with a compression
probe shall be used to verify the amount of over penetration. CORE
15.4.4 Radiographs of pipe welds exposed for single wall viewing shall require one image
quality indicator on each end of the exposed film. CORE
15.4.5 Weld identification (drawing and weld number), position markers, repair identification
and welder's symbol shall be in radiographic images of lead letters or numbers and
shall be fastened to the pipe and not the cassette. Other required film identification
may be placed on the film by other methods with SASOL’s approval. Location of
position markers shall be marked on pipe and shall remain on the pipe until the weld
has been accepted. Radiographs of repaired welds shall be identified by images of
R-1, R-2 progressively. CORE
15.4.6 Radiographic film shall meet the following minimum requirements unless ASME
B31.1 or B31.3 requires more stringent limits:
a. Subject to achieving acceptable sensitivity, radiographic film shall be in

accordance with EN 584-1 Class C4 or ASTM E1815 Type I.
b. For gamma radiography the radiographic film shall be in accordance with EN
584-1 Class C3 or ASTM E1815 Type I. CORE
15.5 ULTRASONIC EXAMINATION (UT)
15.5.1 The procedures, calibrations and techniques for UT of welds shall be in accordance
with the ASME Code Section V, Article 4 and the supplementary requirements of
this Specification. CORE
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15.5.2 The UT acceptance criteria shall be in accordance with the relevant design code,
except that for ASME B31.3 in addition all discontinuities evaluated as being cracks,
lack of fusion or incomplete penetration are unacceptable regardless of length.
CORE
15.5.3 UT equipment, procedure, calibration, extent and modes of scanning and technique
shall be documented in the procedure that will be submitted to SASOL’s
representative and AIA for approval. CORE
15.5.4 Girth welds shall be scanned from both sides of the weld, scanning on either inside
or outside or both as necessary to achieve the coverage from both sides of welds.
CORE
15.5.5 Branch welds requiring UT shall be scanned on both inside and outside pipe
surfaces when possible. CORE
16 HARDNESS TESTING
16.1.1 Production hardness testing shall be performed when so specified in Appendix A,

elsewhere in this document or in project requirements. CORE
16.1.2 Production hardness tests shall only be done in accordance with a written and
approved procedure. The procedure shall, as minimum, address the following
details:
a. Testing equipment make and model (Equipment Manufacturer datasheet

indicating areas of application to also be appended)
b. Ranges of application (e.g. hardness ranges, measurement positions, material
thickness limits etc.). These shall be within the limits stated by the Equipment
Manufacturer in the datasheet.
c. Surface preparation (incl grinding and etching)
d. Calibration requirements
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e. Equipment operating instructions

f. Results evaluation and reporting CORE
16.1.3 When production testing is only required to be performed on the weld metal, the
following production hardness testing methods may be used:
a. Brinell Method
b. Portable dynamic rebound type (Leeb). This is limited to a minimum base
material thickness of 20mm unless otherwise recommend by the Equipment
Manufacturer in the datasheet for the same make and model of equipment.
c. Ultrasonic Contact Impedance (UCI) Method. This shall be limited to loads of
5kgf or 10kgf. CORE
16.1.4 When production hardness testing is required on both the weld metal and the heat
affected zone, only the Ultrasonic Contact Impedance (UCI) Method may be used.
For such measurements, the weld cap shall be ground flush with the pipe surface.
The pipe and weld surface shall be ground to a bright metal finish of 240grit or finer.
The HAZ shall be identified by means of etching with a 5%Nital solution. Hardness
measurements shall be placed within the darkened area of the HAZ as close as
practically possible to the fusion line but in no instance more than 2mm from the
fusion line.
The minimum number of measurements specified in section 16.1.14 (as well as
16.1.7 to 16.1.10 as is applicable) shall be taken in each of the following 3
respective areas: Weld Metal and HAZ either side of the weld. CORE
16.1.5 The accuracy of portable equipment shall be verified by tests made on master
blocks of known hardness which shall cover the range of hardness spanning from
acceptable to rejectable. The hardness of master blocks shall be determined by a
calibrated laboratory hardness-testing machine or alternatively standard hardness
blocks may be purchased. As a minimum, equipment shall be calibrated at the start
and end of each batch of measurements, or shift whichever is less.
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The approved testing procedures for portable hardness testing equipment shall be
demonstrated to the satisfaction of the authorised inspector or SASOL inspector, for
each operator prior to production hardness testing. CORE
16.1.6 For all production hardness tests, the area under test shall be ground or machined
flat and shall have a surface finish (Ra) as specified by the portable hardness
tester’s manual. The fabricator shall implement necessary controls to ensure metal
removal is not excessive or encroaches on the minimum thickness. CORE
16.1.7 For production tests using the UCI Method, testing shall comply with ASTM A1038
and the following requirements:
a. At least 7 measurements shall be taken in each specified location. The

locations for each measurement shall be at least 3 indent diameters from
other indents. The lowest and highest values shall be omitted and the average
value calculated.
b. If a scatter in individual measurements are noted, the standard deviation shall
be calculated. If it exceeds 15HV, the test shall be declared invalid and
investigation performed to establish the cause of the scatter. (This does not
apply to HAZ measurements)
c. The probe shall be seated flat on the surface to be measured. During the
entire test, it shall be held as steady as possible and as close to perpendicular
to the surface as possible. CORE
16.1.8 For production tests using the Portable Dynamic or Rebound testing method, testing
shall comply with ASTM A956 and the following requirements:
a. At least 7 measurements shall be taken in each specified location. The

locations for each measurement shall be at least 2 indent diameters from
other indents. The lowest and highest values shall be omitted and the average
value calculated.
b. The equipment shall be duly calibrated for exact position in which the test is
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performed. For equipment with automatic compensation for changes in

position, the position shall be duly captured.
c. The probe shall be seated flat on the surface to be measured. During the
to the surface as possible. The position shall be as close as possible to that
calibrated for.
d. Hardness measurements shall be taken from the centre of the weld. CORE
16.1.9 For production tests using the Brinell Method, testing shall comply to the following
requirements:
a. Take at least 2 indents (indents to be separated by at least 12mm) on each

location to be measured.
b. If the difference between the 2 values do not exceed 15%, they may be
averaged. If the difference exceeds this value, more indents would be needed
and the cause for the scatter shall be evaluated.
c. If the measurement technique utilises a reference bar of fixed hardness, it
shall be selected such that its hardness is within 15% of the hardness being
measured. As the hardness is not known at the start of the test, it is
recommended to utilise a starting hardness bar of around 200HB. Hardness
values may then need to be repeated with lower or higher reference hardness
bars to establish the true hardness.
d. The weld surface to be measured shall be suitably prepared. An area of at
least 1inch diameter shall be ground to a smooth metal finish free of oxides,
scale or any coating to a surface finish of no coarser than 120grit.
e. The probe shall be seated flat on the surface to be measured. During the
to the surface as possible. The location of the weld shall allow sufficient
access to the measuring equipment, accurate load application (by whatever
means) and indent evaluation.
f. Each hardness impression shall be evaluated to establish validity of the result
(in terms of indent size, roundness etc). CORE
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16.1.10 Hardness test results and locations shall be recorded and made a part of the
manufacturer’s code data book. All measured values shall be reported and no
values may simply be omitted (unless the operator can confirm it to be a false
reading due to indent location or technique employed). Hardness values which fail to
meet the criteria shall be marked as such. Where retesting is allowed for in section
16.1.13, the results shall be separately reported and duly marked as retest results in
the report. CORE
16.1.11 SASOL’s authorised representative shall, at his discretion, witness hardness testing
and the calibration of test equipment. CORE
16.1.12 Hardness values shall comply with the maximum allowable values given in
Table 16.1.12 of this specification. CORE
TABLE 16.1.12 – VICKERS AND BRINELL HARDNESS REQUIREMENTS
HARDNESS (HV10) HARDNESS (HB)

MATERIAL
MAXIMUM MAXIMUM
P-1* 240 200
P-1, P-4, P-4* 250 220
P-5 270 240
P-10H 310 290
P-10H * 290 260
*For sour water service and other stress corrosion services.
NOTE: Conversions between the two types of hardness testing methods are not
permitted. CORE
16.1.13 Production hardness tests shall be performed progressively throughout fabrication to

the extent specified in Table 1 of Appendix A, and the following:
a. The welds to be tested randomly shall be selected by the fabricators

inspector.
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b. If any hardness values exceed the maximum allowable value, a second

impression, and if required, additional impressions shall be made on the same
weld as near to the original impression as practical (at least one indentation
apart) to verify the excessive hardness and its extent. The average of the
readings shall meet the values of the Table 16.1.12 with one reading within
+5% of the average value. If the additional test(s) indicate excessive
hardness, the weld shall be rejected.
c. If a condition of excessive hardness is confirmed, at least two additional welds
made by the same welder or welding station, shall be tested to determine the
extent of deviation.
d. If consistent excessive hardness is confirmed, the welder and/or the welding
procedure, whichever is applicable, shall be re-qualified, after re-evaluation of
welding variables such as filler material and pre-heat. Sasol shall be notified
of this within 48hours of the discovery and prior to any further work being
performed. CORE
16.1.14 The location and number of hardness tests on each weld requiring hardness tests
shall be as follows:
a. Circumferential welds - two tests, the second test shall be located about 90°
from the first location.
b. Longitudinal welds - two tests, one test at each end of the weld. CORE
16.1.15 Operators performing hardness tests shall have proper training and experience with
the specific hardness test method being used for each case (this includes the
measurement equipment make and model). CORE
16.1.16 The contractor performing the hardness testing shall ensure that operators have
proper training and experience with the particular hardness test method employed in
each case. The contractor shall maintain records of training (which shall be limited
each measurement equipment make and model) as well as induction into the
hardness testing procedure for each method. The contractor shall ensure operators
only execute work within their areas of qualification. CORE
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16.1.17 SASOL’s authorised representative reserves the right to evaluate the competence of
operators and/or to audit the controls implemented by the contractor to ensure
operator competence. CORE
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APPENDIX A
APPENDIX A: LINE CLASS REQUIREMENTS
TABLE 1
MATERIAL DESCRIPTION AND SERVICE HEAT TREATMENT
PQR IMPACT
NON-DESTRUCTIVE EXAMINATION REQUIREMENTS
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
(GENERAL NOTES:1, 2, 5, 8, 9 and 81)
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A
SERVICE PRESSURE/ ATTACH-

TEMP MENT AND VISUAL RT (36) MT PT BHN
P-NUMBER
SHOP FIELD SHOP FIELD SHOP FIELD SHOP FIELD SHOP FIELD
A Process Air, Dry CO2, Flare Gas, CS, (P-1) C-Steel 11 21 22a 100% 100% 5% 5% 41, 42, 41, 42, 71, 72 71, 72
Fuel Gas, Fuel Oil, HC, Inert Gas, Class 150 (P-1) 7 7 31 31 44 44
Tar, LP Nitrogen
0 to 400°C
A1D Amine (DEA only) (61ºC -93ºC) CS, (P-1) C-Steel 11, 12 22 100% 100% 5% 5% 41, 42, 41, 42, 74, 76 74, 76
Amine (MEA only) (0ºC -93ºC) Class 150 (P-1) 7 7 31 31 44 44
Carbonate (61ºC -93ºC) 0 to 93°C
Wet CO/CO2 (0ºC-49ºC) (depending on
commodity)
A2D Isopropyl Ether CS, (P-1) C-Steel 11, 12 22 100% 100% 5% 5% 41, 42, 41, 42 74, 74,
Class 150 (P-1) 7 7 31 31 44 ,44 72, 76 72, 76
0 to 400°C
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APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
A3D Dilute Chemical Sewer CS, (P-1) C-Steel 11, 12 21, 23 22a 100% 100% 5% 5% 41, 42, 41, 42, 72, 73, 72, 73,
Sour Water Class 150 (P-1) 7 7 31 31 44 44 75, 76 75, 76
Stripped Gas Liquor 0 to 105°C 22
(For
Strip
Gas
Liquor
only)
AA Hydrocarbon CS, (P-1) C-Steel 11 21 22a 100% 100% 5% 5% 41, 42, 41, 42, 71, 72, 71, 72,
Corrosive Process Class 150 (P-1) 7 7 31 31 44 44 76 76
0 to 370°C
AAA Salty Water CS, (P-1) C Steel 11 21 100% 100% 5% 5% 41, 42, 41, 42, 71, 72, 71, 72,
Class150 (P-1) 7 7 31 31 44 44 76 76
0 to 110<0000>C
AAB Amine (DEA only), (0ºC -60ºC) CS, (P-1) C Steel 11 21 22a 100% 100% 5% 5% 41, 42, 41, 42, 71, 72, 71, 72,
Ammonia Water, (0ºC -175ºC) Class 150 (P-1) 7 7 31 31 44 44 76 76
Carbonate (0ºC -60ºC) 0 to 400 C
(depending on
Caustic Soda (SP50-3A Appendix commodity)
D Zone A)
Isopropyl Ether, (0ºC - 400ºC)
Methanol, (0ºC - 400ºC)
Process Water (0ºC - 400ºC)
Page 2 of 22
SP-90-02
Revision 5
April 2020
APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
AAE Sulphuric Acid (93% - 98%) CS, (P-1) C Steel 11 21 41, 42, 41, 42, 71, 72, 71, 72,
Class 150 (P-1) 44, 92 44, 92 76 76
100% 100% 5% 5%
0 to 40 C
7 7 31 31
Alloy 20 (P-45) 51, 52 51, 52

AAH Catalyst Transport Air CS, (P-1) C Steel 11 21 100% 100% 5% 5% 41, 42, 41, 42,
Note 6 Class 150 (P-1) 7 7 31 31 44 44
0 to 260 C
AAJ Boiler Return H20, Gasifier Return CS, (P-1) C Steel 11 100% 100% 0% 0% 41, 42 41, 42
water, Thickener Feed Class 125 (P-1) 7 7
16 to 65 C
AAK Boiler Bottom Ash, Boiler Fly Ash, CS, (P-1) C Steel 11 100% 100% 0% 0% 41, 42 41, 42
Pond Reclaim, Spent Catalyst Class 125 (P-1) 7 7
Slurry, Thickener Underflow 16 to 65 C
AAM Decoking CS, (P-1) C Steel 11 21 100% 100% 100% 100% 41, 42 41, 42, 71 71
Class 150 (P-1) 7 7 82 82 44 44
401 to 593 C
AAV Hydrocarbons – Vacuum Service CS, (P-1) C-Steel 11 21 100% 100% 5% 5% 41, 42, 41, 42, 71, 72, 71, 72,
Class 150 (P-1) 7 7 31 31 44 44 76 76
0 to 250°C
Page 3 of 22
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Revision 5
April 2020
APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
AC Hydrocarbons with Hydrogen CS, (P-1) C Steel 11 21 22a 100% 100% 5% 5% 41, 42 41, 42, 71, 72, 71, 72,
Service Class 150 (P-1) 7 7 31 31 44 44 76 76
0 to 400 C
ADM Hydrocarbons, Methanol CS, (P-1, C Steel, -15 C 11, 12 21 100% 100% 5% 10% 41, 43 41, 43, 72, 74, 72, 74,
LT15) (P-1, LT15) 61 7 7 31 31 44 44 76 76
Normalized
Class 150
-15 to 175 C
ADN Hydrocarbons, Methanol CS, (P-1, C Steel, -46 C 11, 12 21, 24 100% 100% 25% 100% 41, 43 41, 43, 72, 73, 72, 73,
LT45) (P-1, LT45) 61 7 7 31 82 44 44 74, 75, 74, 75,
Normalized 76 76
Class 150
-45 to 175 C
AEM NH3 Anhydrous with less than CS, (P-1, C Steel, -46 C 11, 12 22 100% 100% 25% 100% 41, 43 41, 43, 74, 76 74, 76
0,2 wt % H20 LT45) (P-1, L45) 61 7 7 31 82 44 44
Normalized
Class 150
-45 to 175 C
AG Hydrocarbons and Hydrogen 5 Chrome 1¼ Chrome 13 27 100% 100% 10% 10% 41, 43 41, 43, 74, 75, 74, 75,
Sulphide (P-5B) (P-4) 7 7 4, 31 4, 31 44 44 76 76
Class 150 Note 3 34 34
0 to 538 C
Page 4 of 22
SP-90-02
Revision 5
April 2020
APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
AIB Process Fluids, (0ºC - 425ºC) 304/304L SS 304/304L SS 16 100% 100% 5% 10% 51, 52 51, 52
CO2 (wet), (50ºC - 427ºC) Dual Certified Dual Certified 7 7 31, 34 31, 34
Conc Chem Sewer, (0ºC - 105ºC) (P-8) (P-8) Note 3
Demineralized Water, (0ºC - Class 150
427ºC) 0 to 427 C
Isopropyl Ether, (0ºC - 427ºC) (depending on
Nitric Acid (40 per cent maximum) commodity)
(0ºC - 100ºC)
AIR Hydrocarbons, Methanol, Liquid 304/304L SS 304/304L SS -195 C 16 100% 100% 5% 10% 51, 52 51, 52
Nitrogen Dual Certified Dual Certified 61 7 7 31 31
(P-8) (P-8) Note 3
Class 150
-195 to 175 C
AIV Hydrocarbons – Vacuum Service 304/304L SS 304/304L SS 16 100% 100% 5% 10% 51, 52 51, 52
Dual Certified Dual Certified 7 7 31 31
(P-8) (P-8) Note 3
Class 150
0 to 250 C
Page 5 of 22
SP-90-02
Revision 5
April 2020
APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
ALA Concentrated Brine Solution Duplex Duplex 16 100% 100% 5% 10% 51, 52 51,52 73, 76, 73, 76,
Note 91 Comprising of Na2SO4, Mg(OH)2, Stainless Steel Stainless 91 7 7 31 31 91 91
CaSO4, NaCl UNS 31803 (P- Steel UNS
10H) 31803
Class 150 (P-10H)
0 to 300 C
ANC 10% Dilute Sulphuric Acid, Alloy 20 304/304L SS 16 100% 100% 5% 10% 51, 52 51, 52
(P-45) Dual Certified 7 7 31 31
Class 150 (P-8)
0 to 60 C
AOA Organic Acid UNS 31254 304/304L SS 17 100% 100% 5% 10% 51, 52 51, 52
(P-8) Dual Certified 7 7 31 31
Class 150 (P-8)
0 to 230 C
AP Chlorination Gas Inconel 600 Inconel 600 16 100% 100% 5% 10% 51, 52 51, 52
(P-43) (P-43) 7 7 31, 34 31, 34
Class 150
0 to 565 C
ASJ Liquid Sulphur (Stretford Solution) 316/316L Dual 316/316L 16 100% 100% 5% 10% 51, 52 51, 52
Certified Dual Certified 7 7 31 31
(P-8) (P-8)
Class 150
170 C Max.
Page 6 of 22
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Revision 5
April 2020
APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
AX Oxygen CS (P-1), C Steel 11, 16 21 100% 100% 10% 10% 41, 42 41, 42, 51, 52 51, 52 71, 72, 71, 72,
Note 6 304/304L Dual (P-1) 7 7 31 31 44, 92 44, 92 76 76
Certified (For CS (For CS
(P-8), only) only)
Monel
(P-42)
Class 150
0 to 150 C
Page 7 of 22
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April 2020
APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
AXR Liquid Oxygen 304/304L Dual 304/304L -195 C 16 100% 100% 10% 10% 51, 52 51, 52
Certified (P-8) Dual Certified 61 7 7 31 31
Class 150 (P-8)
-196 to 175°C
AYB Process Fluids 316/316L Dual 304/304L 16 100% 100% 5% 10% 51, 52 51, 52
Phenol Certified (P-8) Dual Certified 7 7 31, 34 31, 34
Class 150 (P-8) For For
0 to 450°C Phenol: Phenol:
10% 25%
31, 34 31, 34
AZC Benzene CS (P-1) C Steel 11 21 100% 100% 100% 100% 41, 43, 41, 43, 71, 72, 71, 72,
Class 150 (P-1) 7 7 83 83 44 44 76 76
0 to 400°C
AZT Phenol CS (P-1) C Steel 11 21 100% 100% 100% 100% 41, 43, 41, 43, 71, 72, 71, 72,
Class 150 (P-1) 7 7 83 83 44 44 76 76
0 to 80°C
Page 8 of 22
SP-90-02
Revision 5
April 2020
APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
C Process Air, (0 to 400°C) CS (P-1) C Steel 11 21 22a 100% 100% 10% 10% 41,42 41, 42, 71,72, 71, 72,
Amine (DEA only) (0 to 60°C) Class 300 (P-1) 7 7 31 31 44 44 76 76
Carbonates (0 to 60°C) 0 to 400°C
Caustic Soda, (SP50-3A Appendix
D Zone A )
Hydrocarbons, (0 to 400°C)
Nitrogen (0 to 230°C),
Methanol, (0 to 400°C)
Tar, (0 to 180°C)
Process Water(0 to 400°C)
Hydrogen
C1D Amine (DEA only) (61 to 93°C) CS (P-1) C Steel 11, 12 22 100% 100% 10% 10% 41, 42 41, 42, 74, 76 74, 76
Amine (MEA only) (0 to 93ºC) Class 300 (P-1) 7 7 31 31 44 44
Carbonate (61 to 93°C) 0 to 93°C
Wet CO/CO2 (0 to 93°C) (depending on
commodity)
C2D Isopropyl Ether CS (P-1) C Steel 11, 12 22 100% 100% 10% 10% 41, 42 41, 42, 74, 76 74, 76
Class 300 (P-1) 7 7 31 31 44 44
0 to 400°C
Page 9 of 22
SP-90-02
Revision 5
April 2020
APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
C3D Dilute Chemical Sewer CS (P-1) C Steel 11, 12 21, 23 22a 100% 100% 10% 10% 41, 42 41, 42, 72, 73, 72, 73,
Sour Water Class 300 (P-1) 7 7 31 31 44 44 75, 76 75, 76
Stripped Gas Liquor 0 to 105°C 22
(For
Strip
Gas
Liquor
only)
C4D Phenol CS (P-1) C Steel 11, 12 22 100% 100% 25% 100% 41, 43, 41, 43, 74, 76 74, 76
Class 300 (P-1) 7 7 31, 83 83 44 44
0 to 400°C
CA Hydrocarbons (Corrosive) CS (P-1) C Steel 11 21 22a 100% 100% 10% 10% 41, 42, 41, 42, 71, 72, 71, 72,
Class 300 (P-1) 7 7 31 31 44 44 76 76
0 to 400°C
CAF Caustic Soda (Zone B) CS (P-1) C Steel 11, 12 22 100% 100% 10% 10% 41, 42, 41, 42, 74, 76 74, 76
Class 300 (P-1) 7 7 31 31 44 44
CAH Catalyst CS (P-1) C Steel 11 21 100% 100% 10% 10% 41, 42, 41, 42, 71,72, 71, 72,
Hot Quench Tower Slurry Class 300 (P-1) 7 7 31 31 44 44 76 76
0 to 400°C
CAL Thickener Underflow CS (P-1) C Steel 11 21 100% 100% 10% 10% 41, 42, 41, 42, 71, 72 , 71, 72,
Class 300 (P-1) 7 7 31 31 44 44 76 76
0 to 85°C
Page 10 of 22
SP-90-02
Revision 5
April 2020
APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
CBA Hydrocarbons CS (P-1) C Steel 11 21 100% 100% 10% 10% 41, 42, 41, 42, 71, 72 , 71, 72,
Class 300 (P-1) 7 7 31 31 44 44 76 76
0 to 400°C
CDM Hydrocarbons, Methanol CS (P-1) C Steel -15°C 11, 12 21 100% 100% 10% 10% 41, 43, 41, 43, 72, 74, 72, 74,
(LT15) (LT15) 61 7 7 31 31 44 44 76 76
Normalized (P-1)
Class 300
-15 to 0°C
CDN Hydrocarbons, Methanol CS (P-1) C Steel -46°C 11, 12 21, 24 100% 100% 25% 100% 41, 43, 41, 43, 72, 73, 72, 73,
(LT45) (LT45) 61 7 7 31 82 44 44 75, 76 75, 76
Normalized (P-1)
Class 300
-45 to 16°C
CEM NH3, (Anhydrous with less than CS (P-1) C Steel -46°C 11, 12 22, 24 100% 100% 25% 100% 41, 43, 41, 43, 74, 76 74, 76
0,2 wt % Water) (LT45) (LT45) 61 7 7 31 82 44 44
Normalized (P-1)
Class 300
-45 to 175°C
CFC Hydrocarbons with Hydrogen, 1¼ Chrome 1¼ Chrome 13 26 100% 100% 10% 100% 41, 43, 41, 43, 72, 73, 72, 73,
Hydrogen (P-4) (P-4) 7 7 4, 31, 4, 82 44 44 74, 75, 74, 75,
34 76 76
Class 300
0 to 538°C
Page 11 of 22
SP-90-02
Revision 5
April 2020
APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
CFD Catalyst with Hydrogen 1¼ Chrome 1¼ Chrome 13 26 100% 100% 10% 100% 41, 43, 41, 43, 72, 73, 72, 73,
(P-4) (P-4) 7 7 4, 31, 4, 82 44 44 74, 75, 74, 75,
34 76 76
Class 300
0 to 485°C
CG Hydrocarbons with Hydrogen 5 Chrome 1¼ Chrome 13 27 100% 100% 10% 100% 41, 43 41, 43, 74, 75, 74 75,
Hydrocarbons and Hydrogen (P-5B) (P-4) 7 7 4, 31, 4, 82 44 44 76 76
Sulphide Class 300 Note 3 34
0 to 530°C
CGD Hydrocarbons 5 Chrome 1¼ Chrome 13 27 100% 100% 10% 100% 41, 43 41, 43, 74, 75, 74, 75,
Hydrogen Sulphide (Wet) (P-5B) (P-4) 7 7 4, 31, 4, 82 44 44 76 76
Class 300 Note 3 34
0 to 500°C
C IA Polypropylene Powder 304/304L SS 304/304L SS 16 100% 100% 5% 10% 51, 52 51, 52
Note 6 Dual Certified Dual Certified 7 7 31 31
(P-8) (P-8)
Class 300
0 to 110°C
CIB Hydrocarbons with Hydrogen 304/304L SS 304/304L SS 16 100% 100% 5% 10% 51, 52 51, 52
(Corrosive) Dual Certified Dual Certified 7 7 31, 34 31, 34
(P-8) (P-8)
Class 300
0 to 525°C
Page 12 of 22
SP-90-02
Revision 5
April 2020
APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
CIR Hydrocarbons 304/304L SS 304/304L SS -195 C 16 100% 100% 10% 10% 51, 52 51, 52
Methanol Dual Certified Dual Certified 61 7 7 31 31
Ethylene (P-8) (P-8)
Class 300
-195 to 175 C
CIW Alkyl 304/304L SS 304/304L SS 16 100% 100% 5% 10% 51, 52 51, 52
Waste Alkyl Dual Certified Dual Certified 7 7 31, 34 31, 34
Waste Catalyst (P-8) (P-8)
Class 300
0 to 525°C
CMX Oxygen 321 SS 304 SS 16 100% 100% 10% 100% 51, 52 100%
Note 6 (P-8) (P-8) Note 3 7 7 31 82 53
Class 300
0 to 275°C
CRC Hydrocarbons with Hydrogen 304/304L SS 304/304L SS 16 100% 100% 10% 100% 100% 100%
(Corrosive) Dual Certified Dual Certified 7 7 31 82 53 53
Catalyst Slurry (Has 321 SS (P-8)
Pump Around Systems Components)
0 to 250°C
CSJ Liquid Sulphur (Stretford Solution) 316L SS 316 SS 16 100% 100% 5% 10% 51, 52 51, 52
(P-8) (P-8) 7 7 31 31
Class 300 316 SS 16 100% 100% 5% 10% 51, 52 51, 52
170°C Max (P-8) 16 7 7 31 31 51, 52 51, 52
Page 13 of 22
SP-90-02
Revision 5
April 2020
APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
CTC Raw Gas (H2 Rich), Steam- 321 SS 304 SS 100% 100% 10% 100%
Oxygen Mixture (P-8) (P-8) 7 7 31, 34 82
Class 300 Note 3
0 to 538°C
CUC Hydrocarbons 321H SS 321 SS 16 29 100% 100% 25% 100% 100% 100%
C4 and Lighter Fluids (P-8) (P-8) 7 7 31, 34 82 53 53
Class 300
0 to 675°C
CX Oxygen CS (P-1) C Steel 11 21 100% 100% 10% 100% 41, 42 41, 42, 100% 100% 71, 72, 71, 72,
Note 6 (P-1) 7 7 44, 92 44, 92 53 53 76 76
304/304L Dual
Certified (P-8)
and Monel
(P-42)
Class 300
0 to 150 C
CYB Process Fluids 316/316L 304/304L 16 100% 100% 10% 10% 51, 52 51, 52
Phenol Stainless Steel Stainless 7 7 31, 34 31, 34
Dual Certified Steel Dual
Corrosive Water (P-8) Certified For For
Phenol: Phenol:
Class 300 (P-8) Note 3
25% 100%
0 to 525°C
31, 34 82
Page 14 of 22
SP-90-02
Revision 5
April 2020
APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
CZC Benzene CS (P-1) C Steel 11 21 100% 100% 100% 100% 41, 43 41, 43, 71, 72, 71, 72,
Class 300 (P-1) 7 7 83 83 44 44 76 76
0 to 400°C
F Hydrocarbons CS (P-1) C Steel 11 21 22a 100% 100% 10% 100% 41, 42 41, 42, 71, 72, 71, 72,
Class 600 (P-1) 7 7 31 82 44 44 76 76
FAF Caustic Soda CS (P-1) CS(P-1) 11, 12 22 100% 100% 100% 100% 41, 42 41, 42, 74, 76 74, 76
(SP50-03A Appendix D, Area B) Class 600 7 7 82 82 44 44
FAL Thickener Underflow CS (P-1) C Steel 11 21 100% 100% 10% 10% 41, 43 41, 43 72 72
Class 600 (P-1) 7 7 31 31
0 to 85˚C
FC Hydrocarbons w/Hydrogen, CS (P-1) C Steel 11 21 22a 100% 100% 25% 100% 41, 42 41, 42, 71, 72, 71, 72,
Hydrogen Class 600 (P-1) 7 7 31 82 44 44 75, 76 75, 76
0 to 400°C
FCA Hydrocarbons with Hydrogen CS (P-1) C Steel 11 21 22a 100% 100% 25% 100% 41, 42 41, 42, 71, 72, 71, 72,
(Corrosive) Class 600 (P-1) 7 7 31 82 44 44 75, 76 75, 76
0 to 400°C
FEM Ammonia (Anhydrous with less CS (P-1) C Steel -46°C 11, 12 22, 24 100% 100% 25% 100% 41, 43 41, 43, 74, 76 74, 76
than 0,2 wt % water) (LT45) (LT45) 61 7 7 31, 82 44 44
Normalized (P-1)
Class 600
-45°C to 175
°C
Page 15 of 22
SP-90-02
Revision 5
April 2020
APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
FFC Hydrocarbons with Carbon 1¼ Chrome 1¼ Chrome 13 26 100% 100% 25% 100% 41, 43 41, 43, 72 73, 72, 73,
Hydrogen (P-4) (P-4) 7 7 4, 31, 4, 82 44 44 74, 75, 74, 75,
34 76 76
Class 600
0 to 538°C
FFD Hydrocarbons with Hydrogen 1¼ Chrome 1¼ Chrome 13 26 100% 100% 25% 100% 41, 43 41, 43, 72 73, 72, 73,
(Corrosive) (P-4) (P-4) 7 7 4, 31, 4, 82 44 44 74, 75, 74, 75,
34 76 76
Class 600
0 to 485°C
FIR Hydrocarbons 304/304L SS 304/304L SS -195 C 16 100% 100% 25% 100% 51, 52 51, 52
Methanol Dual Certified Dual Certified 61 7 7 31 31, 82
Ethylene (P-8) (P-8)
Class 600
-195 to 175 C
FKX Oxygen Monel (P-42) Monel (P-42) 16 100% 100% 25% 100% 100% 100%
Note 6 Class 600 7 7 31, 34 82 53 53
0 to 460 C
FLA Hydrocarbons with Hydrogen Duplex S/S (P- Duplex S/S 91 91 100% 100% 25% 100% 100% 100% 73, 76, 73, 76,
Note 91 (Corrosive) 10H) (P-10H) 7 7 31 82 53 53 91 91
Page 16 of 22
SP-90-02
Revision 5
April 2020
APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
FMB Process Fluids 304/304L SS 304/304L SS 16 100% 100% 25% 100% 100% 100%
Dual Certified Dual Certified 7 7 31, 34 82 53 53
(P-8) (P-8)
Class 600
0 to 525°C
FNH Catalyst (CAT) 304/304L SS 304/304L SS 16 100% 100% 5% 10% 51, 52 51, 52
Note 6 Polypropylene + Catalyst (CAT) Dual Certified Dual Certified 7 7 31, 34 31, 34
(P-8) (P-8)
Class 600
0 to 70°C
FTC Raw Gas (H2 Rich) Steam-Oxygen 321 SS 304 SS 16 100% 100% 25% 100% 100% 100%
Mixtures (P-8) (P-8) 7 7 31, 34 82 53 53
Class 600 Note 3
0 to 538°C
FUC Heater Effluent – Delayed Coker 321H SS 321 SS 16 29 100% 100% 25% 100% 100% 100%
(P-8) (P-8) 7 7 31, 34 82 53 53
Class 600 Note 3
0 to 675°C
Page 17 of 22
SP-90-02
Revision 5
April 2020
APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
FYB Process Fluids 316/316L 304/304L 16 100% 100% 10% 25% 51, 52 51, 52
Stainless Steel Stainless 7 7 31, 34 31, 34
Dual Certified Steel Dual
(P-8) Certified
Class 600 (P-8 )
0 to 450°C Note 3
G Hydrocarbons, Hydrocarbons CS (P-1) C Steel 11 21 22a 100% 100% 100% 100% 41, 42 41, 42, 71, 72, 71, 72,
With Hydrogen, Hydrogen Class 900 (P-1) 7 7 82 82 44 44 76 76
0 to 400°C
GFD Hydrocarbons with Hydrogen 1¼ Chrome 1¼ Chrome 13 26 100% 100% 100% 100% 41, 43 41, 43, 72, 73, 72, 73,
(Corrosive) (P-4) (P-4) 7 7 4, 82 4, 82 44 44 74, 75, 74, 75,
76 76
Class 900
0 to 485°C
GYC Hydrocarbons with Hydrogen 316/316L SS 304/304L SS 16 100% 100% 100% 100% 100% 100%
Dual Certified Dual Certified 7 7 82 82 53 53
(P-8) (P-8)
Class 900 Note 3
0 to 425°C
H Hydrocarbons, Hydrocarbons with CS (P-1) C Steel 11 21 22a 100% 100% 100% 100% 41, 42 41, 42, 71, 72, 71, 72,
Hydrogen, Hydrogen Class 1500 (P-1) 7 7 82 82 44 44 75, 76 75, 76
0 to 400°C
Page 18 of 22
SP-90-02
Revision 5
April 2020
APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
HUC Process Fluids 321H SS 321 SS 16 29 100% 100% 100% 100% 100% 100%
(P-8) (P-8) 7 7 82 82 53 53
Class 1500 Note 3
0 to 675°C
HYC Hydrocarbons with Hydrogen 316/316L SS 304/304L SS 16 100% 100% 100% 100% 100% 100%
Dual Certified Dual Certified 7 7 82 82 53 53
(P-8) (P-8)
Class 1500 Note 3
0 to 425°C
J Hydrocarbons, Hydrocarbons with CS (P-1) C Steel 11 21 22a 100% 100% 100% 100% 41, 42 41, 42, 72, 74, 72, 74,
Hydrogen, Hydrogen Class 2500 (P-1) 7 7 82 82 44 44 75, 76 75, 76
0 to 400°C
JTC Hydrocarbons with Hydrogen 321 SS 304/304L SS 16 100% 100% 100% 100% 100% 100%
Note 93 (P-8) Dual Certified 7 7 82 82 53 53
Class 2500 (P-8)
0 to 490°C Note 3
JYB Hydrocarbons with Hydrogen 316/316L SS 304/304L 16 100% 100% 100% 100% 100% 100%
Note 93 Dual Certified Dual Certified 7 7 82 82 53 53
(P-8) (P-8)
Class 2500 Note 3
0 to 455°C
Page 19 of 22
SP-90-02
Revision 5
April 2020
APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
KH Gravity Sewers, Process CS (P-1) C Steel 11 100% 100% 0% 0% 41, 42 41, 42
Conservation Sewers Atmos Pres. (P-1) 7 7
5 to 150°C
KJ Gravity Sewers, Process 304/304L SS 304/304L SS 100% 100% 0% 0% 51, 52 51, 52
Conservation Sewers Dual Certified Dual Certified 7 7
(P-8) Atmos (P-8)
Pressure
5 to 150°C
L Instrument air, Utility Air, Water CS (P-1) C Steel 11 21 100% 100% 0% 0% 41, 42 41, 42
(Cooling), Water (Utility – Clarified Class 150 (P-1) 7 7
Ash Water), Water (General
Factory), Foam 1030 kPa Max
0 to 60°C
LA Underground: CS (P-1) C Steel 11 21 100% 100% 0% 0% 41, 42 41, 42
Water (Cooling), Water (Utility – Class 150 (P-1) 7 7
Clarified Ash Water), Water (Utility 1030 kPa Max
–General Factory)
0 to 60°C
LC Potable Water Above Ground and CS (P-1) C Steel 11 21 100% 100% 0% 0%
Underground - NPS ½ to NPS 4, Class 150 (P-1) 7 7
Threaded and Galvanized, 6” and
Larger – Galvanized after 0 to 50°C
Fabrication
Page 20 of 22
SP-90-02
Revision 5
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APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
LF Aboveground Fire Water (Wet CS (P-1) C Steel 11 21 100% 100% 5% 5% 41, 42 41, 42
Systems) Class 150 (P-1) 7 7
1800 kPa Max
16 to 50°C
LFA Aboveground Fire Water CS (P-1) C Steel 11 21 100% 100% 5% 5% 41, 42 41, 42
(Unpressurized Systems) - NPS ½ Class 150 (P-1) 7 7
to NPS 4, Threaded and
Galvanized, 6” and Larger – 1800 kPa Max
Galvanized after Fabrication 16 to 50°C
N Boiler Feed Water CS (P-1) C Steel 11 21 100% 100% 5% 10% 41, 42 41, 42, 71, 72, 71, 72,
Condensate Class 150 (P-1) 7 7 31 31 44 44 76 76
Steam 0 to 400°C
R Boiler Feed Water CS (P-1) C Steel 11 21 100% 100% 10% 10% 41, 42 41, 42, 71, 72, 71, 72,
Condensate Class 300 (P-1) 7 7 31 31 44 44 76 76
Steam 0 to 400°C
RA Boiler Feed Water CS (P-1) C Steel 11 21 100% 100% 10% 10% 41, 42 41, 42, 71, 72, 71, 72,
Condensate Class 300 (P-1) 7 7 31, 35 31, 35 44, 45 44, 45 76 76
Steam 0 to 400°C
S Boiler Feed Water CS (P-1) C Steel 11 21 100% 100% 25% 100% 41, 43, 41, 43, 71, 72, 71, 72,
Condensate Class 600 (P-1) 7 7 31, 34 82 44 44 76 76
Steam 0 to 427°C
Page 21 of 22
SP-90-02
Revision 5
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APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
SA Boiler Feed Water CS (P-1) C Steel 11 21 100% 100% 25% 100% 41, 43, 41, 43, 71, 72, 71, 72,
Condensate Class 600 (P-1) 7 7 31, 34, 35, 82 44, 45 44, 45 76 76
Steam 0 to 427°C 35
SF HP Steam, 1¼ Chrome 1¼ Chrome 13 26 100% 100% 25% 100% 41, 43, 41, 43, 72, 73, 72, 73,
Condensate (P-4) (P-4) 7 7 4, 31, 4, 82 44 44 76 76
Saturated Steam Class 600 34
0 to 482°C
VA Lube Oil 304/304L SS 304/304L SS 16 100% 100% 5% 5% 51, 52 51, 52
Seal Oil Dual Certified Dual Certified 7 7 31 31
(P-8) (P-8)
Class 150
0 to 200°C
VB Lube Oil 304/304L SS 304/304L SS 16 100% 100% 5% 5% 51, 52 51, 52
(P-8) (P-8)
Class 300
0 to 200°C
VC Lube Oil 304/304L SS 304/304L SS 16 100% 100% 10% 10% 51, 52 51, 52
(P-8) (P-8)
Class 600
0 to 205°C
Page 22 of 22
SP-90-02
Revision 5
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APPENDIX A
PQR IMPACT
PRE-HEAT
(Refer 13.1.2)
NON-
REQUIRED
LINE CLASS
SERVICE
TEST
SEVERE
CHECK
MATERIAL/ PRESSURE
PWHT
SP-50-3A

P-NUMBER
VD Lube Oil 304/304L SS 304/304L SS 16 100% 100% 10% 10% 51, 52 100%
Seal Oil Dual Certified Dual Certified 7 7 31 31 53
(P-8) (P-8)
Class 900
0 to 205°C
VE Lube Oil 304/304L SS 304/304L SS 16 100% 100% 25% 25% 51, 52 100%
(P-8) (P-8)
Class 1500
0 to 205°C
VF Lube Oil 304/304L SS 304/304L SS 16 100% 100% 25% 25% 51, 52 100%
(P-8) (P-8)
Class 2500
25 500 kPa
Max
0 to 205°C
Y Steam Tracing CS (P-1) C Steel 11 100% 100% 0% 0%
Class 150 (P-1) 7 7
0 to 320°C
Page 23 of 22
SP-90-02
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WELDING OF METALLIC PIPING APPENDIX A
NOTES for Table 1
1 “Branch Welds” as referred to in general notes and in the welding requirements

tables of this specification shall be defined as “set on” and “set in” branches as
shown in ASME B31.1 and ASME B31.3. Welding and other requirements for self
reinforced branch connections shall follow the requirements of this specification.
2 Requirements of NDE procedures, acceptance criteria and documentation shall be

in accordance with the requirements of this Specification.
3 Non-pressure attachments of the material specified may be welded directly to the

pipe provided the weld material is the same as that used for the pipe pressure weld
and welding procedures and performance qualifications are the same as for
pressure-containing welds in the piping material.
4 RT shall be performed before and after PWHT.
5 Where random NDE of welds are specified, the following requirements shall be met:
a. NDE of welds shall be performed as soon as possible after the welds are
completed and the sampling shall be distributed proportionately and uniformly
over the types of welds, the number of welds, the welding processes used, the
welders and the welding stations involved in the production. The required
extent of random examinations shall be applied to the welding production of
each shift, day, week and/or established sample period.
b. Records shall be kept of the number of welds produced and the number of
welds examined on a daily basis to confirm the uniform and timely
examination of the required number of welds specified in this Appendix. For
RT, these records shall be evaluated for compliance with required line class
percentages at time intervals of no longer than one week.
Page 1 of 10
Copyright © 2020 SASOL. All rights reserved.
SP-90-02
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c. It shall not be acceptable to meet the required extent of radiography for a line
class by radiographing the required number of welds in a short period of time
(relative to the time period in which the welds are made). Radiographing a
disproportionately large number of welds in only a few piping pieces or,
radiographing the required number of welds from the work of only a small
proportion of the number of welders working on a particular piping line class is
unacceptable.
d. If unacceptable welds are found by spot or random NDE, the requirements of

progressive sampling for examination as per ASME B31.3 shall be met,
regardless of the code of construction. Such additional examinations shall be
in addition to the specified extent of examination and shall not be credited
towards meeting the specification required extent of examination.
The requirements to perform additional RT with respect to welds in piping

controlled by ASME B31.3, are as follows:
- Line Classes Requiring 100% Radiography:

Welds shall not be considered in the progressive sampling lot of line
classes requiring spot or random RT.
- Line Classes Requiring 25% Radiography

Two additional welds shall be radiographed for each individual weld
rejected regardless of the type of radiographic rejection. Additional
radiographs shall be taken on welds in the same piping line class and
welded during the same established sample period, by the same welder
and WPS.
- Line Classes Requiring 5% or 10% Radiography:

Two additional welds shall be radiographed, for each individual weld
rejected regardless of the type of radiographic rejection. Additional
radiographs shall be taken on welds in line classes of the same type of
material and welded during the same established sample period, by the
same welder and WPS.
Page 2 of 10
SP-90-02
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April 2020
6 All lines shall be fabricated in accordance with the following:
a. The root run shall be performed using the manual GTAW process.
b. The root side of butt weld joints shall be purged with welding grade argon in
sufficient flow in order to provide a smooth, clean and flat root surface.
c. All flange to pipe welds, branch connections and other welds which are
accessible from the inside shall have the root surfaces ground smooth. This
grinding operation shall be performed in a manner that provides a uniform
transition from one piece to another. Gouges, rough grind marks, weld spatter
and arc strikes are not acceptable.
d. Root welds shall be 100% visually inspected. Acceptance of the root condition
of welds shall be documented.
e. Where visual inspection of the root cannot be performed each weld shall be
100% RT inspected.
f. The PQR shall include photographic quality macro images containing the root
in the in the as-welded condition. This shall at least be taken from top and
vertical position for positional welds.
7 Each completed weld shall be visually examined 100% in accordance with this
Specification Section 15.2. Random in process visual examinations of welds shall
be performed. Results of visual examinations shall be documented.
8 Examinations and tests specified in notes 31(c), 41, 51, 72 and 81 which are
intended to sample the quality of the welding performed by a welder or automatic
welding station in the specified time interval, the sample examined shall be selected
from all of the welds in any line class made in that sampling interval by the welder or
welding station being sampled. The sampling for these examinations and tests on
pressure-containing welds shall include girth butt welds, branch connection welds,
socket welds and seal welds in approximate proportion to the number of these type
of welds in the sample lot.
Page 3 of 10
SP-90-02
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April 2020
None of these types of welds may be neglected in the sample selection. These
sampling requirements shall be met for every line class and every welder or
automatic welding station related to each specific welding procedure used and
represented in the sampling lot.
9 For piping that is open to atmosphere or for drains; except that for flare lines, RT
may be waived provided a design spec break is included beyond the isolation valve
which confirms the pressure to be less than 50kPa.
10 PREHEAT
CARBON STEEL PIPING
11 Carbon steel piping shall require a preheat in accordance with SP 90-17.
12 For carbon steel piping subject to impact testing, and/or hardness limits due to
process reasons, the minimum qualified preheat, is the minimum preheat recorded
and the maximum interpass temperature is the maximum recorded during the
procedure qualification.
CHROME-MOLY PIPING
13 For Cr-Mo (P-4 and P-5) piping, preheat and preheat maintenance shall be
performed as specified in SP-90-17.
14 Deleted
15 Deleted
AUSTENITIC STAINLESS STEEL AND MONEL
16 Preheat will not normally be required. Removal of moisture by heating may be

permissible provided the temperature does not exceed 38°C. Interpass temperature
shall not exceed 175°C.
17 Preheat will not normally be required. Removal of moisture by heating may be

permissible provided the temperature does not exceed 38°C. Heat input shall be
Page 4 of 10
SP-90-02
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April 2020
restricted to 1.5kJ/mm and interpass temperature shall not exceed 100°C.
20 POST WELD HEAT TREATMENT (PWHT) (See also SP-90-17)
CARBON STEEL PIPING
21 PWHT all carbon steel circumferential butt welds when nominal wall thickness is
equal to or greater than 19mm. When required, PWHT shall be performed in
accordance with ASME B31.1, ASME B31.3 and as supplemented by SP 90-17.
Non-pressure attachments and supports welded to piping shall be PWHT (fillet
welds and full penetration welds) when the thickness of the weld exceeds 19mm.
22 All pressure retaining welds and welds attaching internal non-pressure parts to
pressure retaining parts shall be PWHT, regardless of thickness.
22a Some lines in these line classes may operate in severe service (such as high
temperature hydrogen service and/or wet sour service) depending on the
composition of the medium and operating temperature. The necessary evaluation to
the appendices of SP-50-03A shall be done for each to establish whether such
services are applicable. The presence of such services may invoke additional
hardness testing and/or PWHT. The finding shall be signed off by a Metallurgical
Engineer or Materials Specialist.
23 For nominal wall thickness less than 19mm, in sour fluid and sour gas services,
weldments shall conform to either of the following:
100% of field welds shall be hardness tested in accordance with note 75

and section 16 of this document. If a hardness value exceeds the limits of
table 16.1.12, the weld shall be subject to PWHT.
All welds to be subjected to PWHT in lieu of the abovementioned hardness

testing. The extent of hardness testing shall then be in accordance with the
notes specified for the lineclass.
PQR’s shall therefore be dual qualified with and without PWHT.
24 Repairs shall be PWHT or cut and re-welded regardless of thickness.
Page 5 of 10
SP-90-02
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April 2020
25 Deleted
CHROME-MOLY PIPING
26 PWHT of P4 piping welds shall be performed when required by ASME B31.1, ASME
B31.3, whichever is applicable and as supplemented by SP 90-17. However, non-
pressure attachments and supports welded to piping shall be PWHT (fillet welds and
full penetration welds) when the thickness of the weld exceeds 13mm. Welds
exempted from PWHT due to their thickness shall be subjected to PWHT when the
production hardness limit specified in table 16.1.12 is exceeded.
27 PWHT of P5 piping welds shall be performed on all welds within the ranges
specified in ASME B31.1, ASME B31.3, whichever is applicable and as
supplemented by SP 90-17. However, non-pressure attachments and supports
welded to piping shall be PWHT (fillet welds and full penetration welds) regardless.
28 Deleted
HIGH TEMPERATURE AUSTENITIC PIPING
29 Refer to SP-110-07. Proposal to be approved by SASOL.
30 RADIOGRAPHY
31 Random radiography of original welds is required to the minimum percentage extent

noted for all girth butt welds regardless of size. All branch connection welds in
which the branch pipe or fitting is NPS 8 or larger shall be included in the sampling.
For branch connections NPS ½ up to and including NPS 6 see Note 82.
a. Examinations shall include the work of all welders welding in the line class and
shall be performed in a timely manner as the work progresses so that the
welds selected for examination are uniformly spread over the total number of
welds made and that no portion of the piping welds in the line class is not
sampled. (See Note 5).
b. The first three girth butt welds or 2000 mm of weld length, whichever is less,
and the first branch connection weld made by each welder beginning to work
Page 6 of 10
SP-90-02
Revision 5
April 2020
under this Specification shall be radiographed 100%.
c. Selection of welds to be examined shall include girth butt, butt welds, socket
welds and applicable (when possible) branch connection welds in the
approximate proportions of these welds in the line being welded. (See Note
8).
d. The acceptance criteria for all 25% radiography shall be the same as the
acceptance criteria used for 100% radiography.
e. RT that results in weld rejections shall have additional examinations carried

out in accordance with Note 5(d).
32 Deleted
33 Deleted
34 All girth butt welds regardless of size, and all branch connection welds shall be RT
examined 100% when the design temperature exceeds 400°C. (See Note 82).
35 Welds in piping in this line class shall be radiographed to the extent required by
Table 136.4 ASME B31.1 and as required by this Specification. The more severe
requirement between this specification and ASME B31.1 shall govern.
36 Unless Note 4 is referenced and when PWHT is required, the required RT

examination shall be performed before PWHT.
40. MAGNETIC PARTICLE (MT)
41 Welds made by automatic or semi-automatic procedures shall be subjected to

random MT to an extent of at least one weld examined per welding station per shift.
(See Note 8).
42 At least 5% of the pressure containing welds, made by manual welding processes,

shall be examined by the MT method unless Note 44 applies.
43 At least 10% of the pressure containing welds and 5% of the non-pressure

attachment welds, made by manual welding processes, shall be examined by the
Page 7 of 10
SP-90-02
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April 2020
MT method unless Note 44 applies.
44 After PWHT all welds shall be subjected to 100% MT on all accessible surfaces.
45 All branch welds where the thickness of the weld exceeds 19mm shall be examined
by the MT method unless Note 44 applies. For design temperatures in excess of
400°C, in addition to Note 42 and 43, the following welds will be subjected to MT
(unless deemed impractical by the AIA in which case the inspections will be done
with PT)
a. All butt welds (longitudinal and circumferential) for NPS 2 and smaller
b. All welded branch connections for NPS 4 and smaller
c. All fillet, socket, attachment and seal welds
50 LIQUID PENETRANT (PT)
51 Welds made by automatic or semi-automatic welding processes shall be subjected

to random PT to an extent of at least one weld examination per welding station per
shift. (See Note 8).
52 At least 10% of the pressure containing welds and 5% of the non-pressure

containing attachment welds, deposited by manual processes, shall be examined by
PT.
53 Butt welds and branch connection welds, regardless of size, and non-pressure
external attachment welds shall be examined 100% by the PT method.
60 IMPACT TESTING (See also SP-110-6)
61 Only tested and certified filler materials shall be issued for production welding. Filler
materials shall be tested for the applicable PWHT condition to meet Charpy V-notch
impact requirements at:
a. Minus 46°C for Carbon steel piping
b. Minus 196°C for Austenitic stainless steel.
Page 8 of 10
SP-90-02
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April 2020
70 HARDNESS TESTING
71 Where PWHT is only performed due to it being specified in ASME B31.1 or ASME
B31.3 (as is applicable), hardness testing is not mandatory (unless hardness testing
is specifically required by ASME B31.1 or ASME B31.3 as is applicable).
Comprehensive heat treatment records shall be available to prove PWHT being
performed on each respective weld.
72 For machine, automatic and semi-automatic processes, the first weld produced at
each welding station per shift shall be hardness tested. In addition, if a change is
made from one welding procedure to another welding procedure, the first weld made
after such a change shall be hardness tested.
73 Hardness test shall be performed on at least 10% of the pressure containing butt
welds produced by manual welding for each welder and welding procedure (unless
note 23 is applicable and specifies a higher % based on service).
74 Butt welds which require PWHT shall be subject to hardness test after PWHT for
each welder and welding procedure, to the following extent:
a. At least two welds, randomly selected shall be hardness tested, from each
furnace load of piping subject to furnace PWHT.
b. At least one weld, randomly selected, shall be hardness tested, from each P-
number grouping in the daily heat treatment production of each localised
PWHT equipment operator.
75 Hardness tests shall be performed on both the Weld Metal and Heat Affected Zone.
76 Hardness testing is required for PQR qualification in accordance with section 5.4 of
this document.
80 ULTRASONIC EXAMINATION (UT)
81 Girth butt welds produced by the automatic or semi-automatic GMAW (MIG-MAG)

welding processes and applications where a groove with included angle smaller
than 30˚ shall be subjected to random UT, using an ultrasonic procedure approved
Page 9 of 10
SP-90-02
Revision 5
April 2020
by SASOL to the following extent:
a. The first weld produced at each welding station per shift shall be UT.
b. The first weld produced after a change from one welding procedure to another
welding procedure or after a change in welding operator shall be UT.
c. At least two additional welds, randomly selected, shall be UT from the

production of each welding operator on each shift.
d. If interpass lack of fusion defects are found, all welds, made at that welding
station or by that operator after the last acceptable weld UT examination, shall
be UT examined.
e. See also Note 8 for specific requirements.
82 When RT of welds are impractical, or when so directed by SASOL, UT of welds shall

be conducted. The UT procedure and standards of acceptance shall be approved
by SASOL prior to conducting any UT examinations.
83 UT shall be performed in addition to RT. The UT procedure and standards of

acceptance shall be approved by SASOL prior to conducting any UT examinations.
90. MISCELLANEOUS REQUIREMENTS
91 See SP-110-08 for the requirements for Duplex stainless steel welding
92 All dissimilar welds shall be subject to the same NDE requirements as other welds
of the specified line class, except that PT might be required in lieu of MT.
93 Delta ferrite measurements shall be performed for welding procedure qualifications

and each production weld. Ferrite number values shall be from 4 to 10.
Page 10 of 10
SP-90-02
Revision 5
April 2020
WELDING OF METALLIC PIPING APPENDIX B
APPENDIX B: DIRECTIONS FOR COMPLETING THE WELDING PROCEDURE

SUMMARY
Section was deleted in Rev. 5

Partially replaced with form F1118. As good practice and ensuring control, fabricator may still
need to keep a list of project approved WPS and PQR’s
Page 1 of 1
SP-90-02
Revision 5
April 2020
WELDING OF METALLIC PIPING APPENDIX C
APPENDIX C: REQUIREMENTS FOR DUPLEX STAINLESS STEEL WELDING,

FABRICATION AND QUALIFICATION
This section is deleted and replaced by SP-110-08
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SASOL SPECIFICATION SP-90-02

WELDING OF METALLIC PROCESS AND POWER PIPING

Niel Swanepoel Johan Kruger

For interpretation of Specification, the following person(s) can be contacted:

D.B Swanepoel, J.J Kruger, P.J Botha, W.P De Klerk

A Revision Description Sheet is included to assist in identifying the changes

2 June 2000 JP Nell APdeGavino Dias C Thirion 5 June 2000

3 Nov 2003 AR Benadé APdeGavino Dias C Thirion 11 Dec 2003

4 May 2012 H. Froneman AR Benade JPG Wykes 24 May 2012

SASOL SPECIFICATION SP-90-02

WELDING OF METALLIC PIPING

TECHNICAL COMMITTEE OF SPECIFICATION SP-90-02, Revision 5

NAME COMPANY AND DEPARTMENT

BOTHA PJ (Pieter) Group Technology

DE KLERK W (Willem) Group Technology

FISHER D (Dennis) Sasolburg Operations, Technical

HORN, JW (JW) Sasol Synfuels Mechanical Engineering

KRUGER JJ (Johan) Group Technology

RABIE M (Marcel) Group Technology

NEL HJ (Hugh Jean) Sasol Synfuels Mechanical Engineering

ORSMOND C (Charl) Sasol Synfuels Metallurgical

SWANEPOEL DB (Niel) Sasol Synfuels Metallurgical

SMIT GF (Deon) Synfuels Weldtech

VAN HEERDEN R (Ruan) Group Technology

SASOL SPECIFICATION SP-90-02

WELDING OF METALLIC PIPING

REVISION DESCRIPTION SHEET

SASOL SPECIFICATION SP-90-02

WELDING OF METALLIC PIPING

1.1.1 Paragraph ends. Core

Classification Tag Colour Definition

Core Core Red Non-NEGOTIABLE requirements that are

Page iii of vii

SASOL SPECIFICATION SP-90-02

WELDING OF METALLIC PIPING

Classification Tag Colour Definition

(Natref) Legal requirements of the country

SASOL SPECIFICATION SP-90-02

WELDING OF METALLIC PIPING

2 REFERENCED CODES AND STANDARDS.............................................................4

3 GENERAL REQUIREMENTS ....................................................................................7

4 DOCUMENTATION SUBMITTAL, APPROVAL AND RECORDS ............................7

5 PROCEDURE QUALIFICATION AND WELDER QUALIFICATION .........................9

SASOL SPECIFICATION SP-90-02

WELDING OF METALLIC PIPING

5.3 WELDING PROCEDURE QUALIFICATIONS REQUIRING IMPACT

6 WELDING PROCESSES .........................................................................................28

8 WELD JOINT PREPARATION ................................................................................31

9 CLEANING REQUIREMENTS .................................................................................32

11 WELD CONTOUR ....................................................................................................35

13 POST WELD HEAT TREATMENT (PWHT) ............................................................36

16 HARDNESS TESTING .............................................................................................46

APPENDIX A: LINE CLASS REQUIREMENTS...................................................................1

NOTES FOR TABLE 1.............................................................................................................1

SASOL SPECIFICATION SP-90-02

WELDING OF METALLIC PIPING

APPENDIX B: DIRECTIONS FOR COMPLETING THE WELDING PROCEDURE

APPENDIX C: REQUIREMENTS FOR DUPLEX STAINLESS STEEL WELDING,

Page vii of vii