SP-90-02 Rev 4 - Welding of Metallic Piping

SASOL SPECIFICATION SP-90-02
REVISION 4
WELDING OF METALLIC PROCESS AND POWER PIPING
Originator SIGNED Reviewer : SIGNED

: H Froneman AR Benade
Approved by Date :
SIGNED 24 MAY 2012
:
JPG Wykes
EFFECTIVE DATE: JUNE 2012
For interpretation of Specification, the following person(s) can be contacted:

A.R Benade, J.J Kruger, H Froneman, 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
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 © 2012. SASOL. All rights reserved.
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WELDING OF METALLIC PIPING
TECHNICAL COMMITTEE OF SPECIFICATION SP-90-02, Revision 4
NAME COMPANY AND DEPARTMENT
BENADE A.R. (Arnold) Sasol Technology Welding
DE KLERK W. (Willem) Sasol Technology QA
KRUGER J.J. (Johan) Sasol Technology Welding
BOTHA P.J. (Pieter) Sasol Technology Welding
FRONEMAN H. (Hanre) Sasol Technology Welding
BRADLEY R. (Ronald) Sasol Synfuels Metallurgical Engineering
SWART A.P. (Abe) Sasol Technology Mechanical
SMIT P.P.J. (Paulus) Sasol Technology Mechanical
MAARTENS P. (Pieter) Sasol Synfuels Inspection
WENHOLD O. (Otto) Infrachem Equipment Integrity
DORFLING C. (Charl) Sasol Synfuels Weldtech
FISHER D. (Dennis) Infrachem Site Serv OES
ODELL G. (Greg) Sasol Synfuels Mechanical Engineering and

Governance
ACKNOWLEDGED PERSONS:
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REVISION DESCRIPTION SHEET
REVISION 4
Specification SP-90-02, Revision 4 has been reviewed and brought in line with the latest revisions of
ASME B31.1, ASME B31.3 and SP-50-03A. In addition, requirements for welder qualifications has
been amended and requirements for PWHT and the extent of non-destructive testing (previously
specified in SP-90-02A) were revised and included in this specification. SP-90-02A as a standalone
specification has been discontinued.
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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
2 REFERENCED AND RELATED DOCUMENTS ............................................................. 4

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

5.1 COMPLIANCE TO CODES AND SPECIFICATIONS ......................................... 7
5.2 WELDING PROCEDURE QUALIFICATION ....................................................... 7
5.3 WELDING PROCEDURE QUALIFICATIONS REQUIRING IMPACT
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TESTING ................................................................................................................. 8
5.4 WELDING PROCEDURE QUALIFICATION HARDNESS TESTS .................. 10
5.5 QUALIFICATION OF REPAIR WELDING PROCEDURES ............................. 11
5.6 WELDER QUALIFICATIONS ............................................................................. 12
6 WELDING PROCESSES ................................................................................................... 14
7 WELDING CONSUMABLE REQUIREMENTS ............................................................ 14
8 WELD JOINT PREPARATION ........................................................................................ 14
9 CLEANING REQUIREMENTS ........................................................................................ 15
10 WELDING REQUIREMENTS .......................................................................................... 16
11 WELD CONTOUR .............................................................................................................. 17
12 PREHEATING..................................................................................................................... 19
13 POST WELD HEAT TREATMENT (PWHT) ................................................................. 19
14 REPAIRS .............................................................................................................................. 20
15 NON-DESTRUCTIVE EXAMINATIONS........................................................................ 21
15.1 GENERAL REQUIREMENTS.............................................................................. 21
15.2 VISUAL EXAMINATION .................................................................................... 22
15.3 MAGNETIC PARTICLE TESTING (MT) AND PENETRANT TESTING (PT) 22
15.4 RADIOGRAPHIC EXAMINATION (RT) ............................................................ 24
15.5 ULTRASONIC EXAMINATION (UT) ................................................................ 26
16 HARDNESS TESTING ....................................................................................................... 27
APPENDIX A: LINE CLASS REQUIREMENTS ......................................................................... 1
NOTES FOR TABLE 1 ...................................................................................................................... 20
APPENDIX B: DIRECTIONS FOR COMPLETING THE WELDING PROCEDURE

SUMMARY .......................................................................................................................... 27
APPENDIX C: REQUIREMENTS FOR DUPLEX STAINLESS STEEL WELDING,

FABRICATION AND QUALIFICATION ....................................................................... 30
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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.
1.2 LEGAL REQUIREMENTS
This specification is governed by the law of contract.
1.3 PRECEDENCE
When special requirements are clearly specified in the SASOL contractual requirements,
those requirements shall govern and supplement this Specification.
In the event of any conflict between the various relevant documents, the order of precedence
shall be:
a. The purchase order, including terms, conditions and legal requirements

b. Drawings as approved by SASOL
c. This specification
d. Other referenced documents
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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)
MT Magnetic Particle Testing
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
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1.5 DEFINITIONS
1.5.1 APPROVAL / APPROVED BY - Written agreement or authorization by SASOL or

SASOL’s Representative. Note: Such approval does not relieve the contractor of any of his
contractual responsibilities
1.5.2 MANUFACTURER OR FABRICATOR OF PIPING - the company responsible for welding

during fabrication of piping. The same meaning applies to construction contractor where this
is part of his scope of work.
1.5.3 NEW FABRICATION – Any system fabricated to a new design as a complete or partial
replacement of an existing line or as a new system.
1.5.4 PIPING - assemblies of piping components used to convey, distribute, mix, separate,
discharge, meter, control, or snub fluid flows. Piping also includes pipe-supporting elements,
but does not include support structures, such as building frames, bents and foundations.
1.5.5 PIPING COMPONENTS - mechanical elements suitable for joining or assembly into
pressure-tight fluid-containing piping systems. Components include pipe, tubing, fittings,
flanges, gaskets, bolting, valves and devices such as expansion joints, flexible joints,
pressure hoses, traps, strainers, in-line portions of instruments, and separators.
1.5.6 QUALIFICATION – in welding, this means welded and tested in accordance with
contractual requirements.
1.5.7 SASOL - SASOL Limited or any of its affiliates, or their employees with the designated
authority to ensure compliance with this specification.
1.5.8 SASOL’S Representative - The duly authorized legal entity sighted in the contract
representing the Sasol business unit or SASOL when no such entity is appointed.
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2 REFERENCED AND RELATED DOCUMENTS
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
2.2 AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) BOILER AND

PRESSURE VESSEL 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 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
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ANSI Z49.1 Safety in Welding, Cutting and Allied Processes
2.6 AMERICAN WELDING SOCIETY (AWS) SPECIFICATIONS
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-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-90-32 Minimum Requirements for Sasol Engineering Drawings
SP-110-06 Impact Testing of Metallic Materials
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3 GENERAL REQUIREMENTS
3.1 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.
3.2 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.
3.3 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.
4 DOCUMENTATION SUBMITTAL, APPROVAL AND RECORDS
4.1 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.
4.2 A welding procedure summary shall be submitted to SASOL’s representative and AIA
itemising all Welding Procedure Specifications (WPS) and Procedure Qualification Records
(PQR) to be used in fabrication. Typical sample forms and instructions for their completion
are contained in Appendix B. Manufacturers to submit their formats for SASOL’s approval
if these differ from the sample.
4.3 Welding procedures and fabrication documents submitted for approval shall comply with the
requirements of specification SP-90-32. 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.
4.4 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).
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4.5 Welders’ performance qualification records shall be made available to SASOL’s

representative and AIA for review upon request.
4.6 Welder production records shall be maintained in accordance with the requirements of
Appendix A, Notes 5, 7 and 8.
4.7 Production welding shall only commence after the applicable manufacturer’s documentation
has been approved by SASOL’s Representative and AIA.
4.8 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.
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.
5.2 WELDING PROCEDURE QUALIFICATION
5.2.1 Each manufacturer shall qualify all welding procedures prior to any production
welding. These qualifications are to be certified by an AIA. SASOL reserves the
right to witness the testing.
5.2.2 Procedure qualification tests shall be made on base metal having the same
P-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 2
qualifies welding on P-Number 1 Group- Numbers 2 and 1 material.
5.2.3 All essential and non-essential variables in accordance with ASME IX shall be
addressed in the PQR and WPS. In addition, the following non essential variables
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shall be included in the PQR and WPS:
a. Method of groove preparation and root gap.

b. Specification and grade of electrode, wire and flux used.
c. Base metal specification(s).
d. Pipe diameter.
e. Welding method - manual, semi-automatic, machine or automatic welding.
5.2.4 For non-ASME base materials (unassigned materials), the type, grade and code
designation of material used shall be given.
5.2.5 The PWHT requirements for procedure qualification tests shall be in accordance
with the applicable code and SP-90-17.
5.3 WELDING PROCEDURE QUALIFICATIONS REQUIRING IMPACT TESTING
5.3.1 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.
5.3.2 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.
5.3.3 Impact tests shall be conducted in accordance with, and meet the impact values
specified in, specification SP-110-06. Impact test results shall be submitted as part
of the PQR.
5.3.4 Impact testing of austenitic weld metal and HAZ may be waived if solution heat
treatment is carried out after welding.
5.3.5 Number, sequence and distribution of passes shall be recorded on the PQR, in
order to correlate Charpy impact test locations with its actual heat input value.
𝐻𝐼𝑚𝑎𝑥 𝑞𝑢𝑎𝑙𝑖𝑓𝑖𝑒𝑑 = 𝑙𝑜𝑤𝑒𝑟 𝑜𝑓 [𝑊𝑒𝑙𝑑 𝑀𝑒𝑡𝑎𝑙 𝐻𝐼max 𝑡𝑒𝑠𝑡𝑒𝑑 𝑜𝑟 𝐻𝐴𝑍 𝐻𝐼max 𝑡𝑒𝑠𝑡𝑒𝑑 ]
5.3.6 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
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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.
5.3.7 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.
5.3.8 When impact testing is required by code or contract, but it is not specified in
Table 1 of Appendix A, the thickness ranges qualified shall be in accordance with
the relevant Piping Code (i.e ASME B31.1, ASME B31.3). In addition to code
requirements, the base materials used in the qualification test shall belong to the
same code exemption curve and heat treated condition as the production base
materials.
5.3.9 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:
a. Each type of filler metal.

b. Each type welding process.
c. On the same base material specifications which will be used in production even when the
base metal is exempted from impact testing according to specification SP-90-18. When
the base material is exempted of impact testing, the acceptance criteria 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 of the base material.
Where it is impractical to do a PQR on a material specification due to its product form
(e.g. elbow) a more suitable product form may be used provided it is from the same
P-Number, Group-Number, same exemption curve if applicable, same nominal chemical
composition, same mechanical properties and heat-treated condition.
d. The thickness ranges qualified shall be in accordance with Table 5.3.9.
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TABLE 5.3.9 RANGE OF BASE METAL THICKNESS QUALIFIED WHEN IMPACT

TESTING IS REQUIRED
MATERIAL THICKNESS LIMITS OF QUALIFICATIONS (mm)

TESTED
Lower Upper
(mm)
3 to 6 T/2 6
Over 6 to 16 T T+6
Over 16 Larger of 16 or T/2 T+6
5.4 WELDING PROCEDURE QUALIFICATION HARDNESS TESTS
5.4.1 All welding procedure qualification tests for P1, P4, P5 and P10H materials 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.
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 16.7. of
this specification. Transverse Vickers hardness survey tests of procedure
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.
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FIGURE 5.4.2 REQUIRED HARDNESS INDENTATION LOCATION FOR

PERFORMING A VICKERS HARDNESS SURVEY ON CROSS
SECTION BUTT AND FILLET WELD SAMPLES
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 requires 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.
5.5.2 Repair welding procedure qualification welds shall be made on welds identical to
those used to qualify the original welding procedure. When repair procedure
qualification is called for, SASOL will specify whether a full thickness, mid-
thickness or cap repair qualification is required.
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5.6 WELDER QUALIFICATIONS
5.6.1 Each manufacturer shall qualify all welders and operators on his approved welding
procedures prior to production welding
5.6.2 Requirements for welders and welding operators shall be in accordance with
ASME IX. The additional requirements for fabricators with a proven butt weld
rejection rate of 5% or less, recorded over the previous 12 months, are as follows:
5.6.2.1 Qualifications where impact testing is required:
a. The performance qualification tests of each welder shall include heat input control and
documented proof thereof (e.g. parameter record sheet). SASOL reserves the right to
accept or reject the qualification.
b. When welders were previously qualified in accordance with the above paragraph, re-
qualification is not required provided that:
i) initial qualification is available; and
ii) evidence is provided that welding with heat input control as specified in
paragraph 5.3.6 was performed successfully during the previous three months.
5.6.2.2 Welders for GMAW and FCAW shall be qualified as follows unless otherwise
agreed between SASOL and the fabricator:
a. For groove welds-butt joints: radiography and bend tests.

b. For branch connections: four macros at stops /starts of the corner joint, in addition to the
groove weld requirements.
c. For fillet welds: two macros at stops /starts.
d. The minimum outside diameter qualified is the diameter tested.
e. 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.
5.6.2.3 Manufacturer shall re-test individual welders or welding operators when their
repair rates consistently exceed 5% over a period of three weeks in accordance
with the requirements stated above as well as the requirements listed in Table 5.6.3.
Repair rates shall be calculated on the number of butt welds tested.
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5.6.3 Fabricators with a butt weld rejection rate exceeding 5%, recorded over the
previous 12 months, or that does not have a formal system for recording rejection
rates, shall perform welder qualification, in addition to the above, as follows:
a. Qualification on Ferritic material does NOT qualify Austenitic material.

b. In addition to ASME IX diameter limits are further restricted as follow:
TABLE 5.6.3 DIAMETER QUALIFICATION RANGE RESTRICTIONS
Test Coupon Dia Diameter Range Qualified

inch (mm) inch (mm)
D ≤ 1 (25) D to 6 (168.3)
6 (168.3) ≤ D D/2 to Unlimited
c. Time allowed for the Welder qualification test shall be limited to 1.5 x estimated time
allowed to complete a similar production weld. This estimated time as well as the actual
time taken to complete the test coupon shall be shown on the welder performance
certificate. Actual time = time taken to weld root, filler and cap, including all associated
inter-run cleaning activities.
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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 (Automatic only) SAW
Gas Metal Arc Welding (*)(Pulse and Spray transfer only) GMAW
Flux Cored Arc Welding - Gas assisted FCAW-G
(*) GMAW short circuit with pulsating arc is also acceptable provided that thickness range
qualified remains with ASME IX and the specific power source, make and settings used for
PQR are used and specified for production welding. 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.
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.
8 WELD JOINT PREPARATION
8.1 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.
8.2 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
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applicable welding procedure, shall not be built up by welding without the approval of
SASOL.
8.3 Surface defects that infringe on the minimum material wall thickness shall not be repaired by
welding without prior approval by SASOL.
8.4 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.
8.5 The shop welding preparations of piping manufactured in sections for assembly on site shall
be suitably protected and adequate care shall be taken to prevent damage of the sections
during transport and erection.
8.6 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.
9 CLEANING REQUIREMENTS
9.1 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.
9.2 Peening is not permitted.
9.3 Cleanliness shall be maintained during fabrication welding. All stubs, rods, flux, slag, burrs,
shavings and other foreign material shall be removed from pipe assemblies.
9.4 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.
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9.5 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.
10 WELDING REQUIREMENTS
10.1 Permanent backing rings shall not be permitted unless specifically approved by SASOL.
10.2 Consumable inserts may not be used without prior SASOL approval.
10.3 Gas purging is required for single sided welds of P5 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.
10.4 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).
10.5 All tack welds and temporary attachment welds shall be performed by qualified welders
using a qualified WPS.
10.6 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.
10.7 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
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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.
10.8 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.
10.9 Heat input control in production shall be the same method as used during procedure
qualification for each respective welding process (See Par 5.3.6). 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.
10.10 Weld Toe-to-Toe clearance of 2T or 50mm whichever is less where T is the governing
thickness.
11 WELD CONTOUR
11.1 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 11.2 for acceptable weld profiles.
11.2 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.
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FIGURE 11.2. FILLET AND GROOVE WELD PROFILE REQUIREMENTS
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12 PREHEATING
12.1 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.
12.2 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.
12.3 Interpass temperature shall not exceed 175°C for austenitic stainless steel and high nickel
alloy welds.
13 POST WELD HEAT TREATMENT (PWHT)
13.1 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.
13.2 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

b. Extent of insulation used
c. Prescribed valve closure position
d. Functionality test after heat treatment
13.3 The following PWHT methods are acceptable:
a. Furnace method
b. Local resistance method
c. Local induction method
The use of other PWHT methods shall require prior approval by SASOL.
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14 REPAIRS
14.1. For pipe diameters of NPS 2 and smaller any unacceptable sub-surface discontinuities
detected by RT shall constitute a cut out and re-weld.
14.2. For pipe diameters larger than NPS 2, any unacceptable sub-surface discontinuities detected
by RT or UT methods shall be completely removed by chipping, 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. 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.
14.3. 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.
14.4. All repaired welds shall be examined by the same NDE methods as were specified for the
original weld.
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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.
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.
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.
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.
15.1.5 Results of all NDEs shall be reported on a form approved by the SASOL’s representative.
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.
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
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hardness tests on every weld in the stated category or class.

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.
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.
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.
15.2 VISUAL EXAMINATION
15.2.1 Visual examination procedures shall be in accordance with ASME Code Section V, Article 9
and this specification.
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.
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.
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.
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
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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.
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. 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.
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.
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.
15.3.5 The following relevant indications are unacceptable:
a. Any crack, lack of fusion or incomplete penetration.

b. Any linear indication longer than -
i) 1,5 mm for material up to 15 mm thick,
ii) 3 mm for material over 15 mm up to 30 mm thick,
iii) 4,5 mm long for material over 30 mm thick.
c. 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.
d. Any group of four or more indications in any line if not separated from each other by the
longer of 1.5 mm or the major dimension of the longest adjacent indication.
e. Ten or more indications occurring in any 80 mm diameter area or any 5000 mm2
rectangular area whose major dimension is not greater than 150 mm when it is taken in
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the most unfavourable orientation relative to the indications being evaluated.

f. 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
chipping, 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.
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.
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.
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.
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.
15.3.10 All welds requiring PWHT shall be re-examined 100% after PWHT by MT as per Table 1
Appendix A or PT where MT is not practical.
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.
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.
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
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B31.1 or ASME B31.3, shall be in accordance with the code requirements, except that:
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.
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 0,1 0,13
6 to 8 0,13 0,16
8 to 10 0,16 0,2
10 to 16 0,2 0,25
16 to 25 0,25 0,33
25 to 32 0,33 0,4
32 to 40 0,4 0,51
40 to 50 0,51 0,64
50 to 80 0,64 0,81
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.
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.
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.
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.
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.
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.
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.
15.5.5 Branch welds requiring UT shall be scanned on both inside and outside pipe surfaces when
possible.
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16 HARDNESS TESTING
16.1 Production hardness testing shall be performed by the Brinell method and procedures in
accordance with ASTM Method E10 and E110 as applicable or any other proposed method
approved by SASOL that does not introduce a sharp indentation.
16.2 Portable dynamic or rebound type hardness testing shall be performed in accordance with
ASTM A956 and the equipment manufacturer’s recommendations. Poldi testing equipment
is not acceptable. The accuracy of portable equipment shall be verified by tests made on a
master block of known hardness. The hardness of master blocks shall be determined by a
calibrated laboratory hardness-testing machine or alternatively standard hardness blocks may
be purchased.
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.
16.3 Production hardness tests shall be performed when specified in Table 1 of Appendix A. A
hardness test shall constitute a set of impressions as specified in ASTM Methods A956 or
E10 as applicable, both the weld metal and HAZ. The HAZ shall be located by etching after
preparation of the area to be tested.
16.4 For production Brinell 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 instrument shall be calibrated at the start and end of each batch of tests in the same
position as that for production testing.
16.5 Hardness test results and locations shall be recorded and made a part of the manufacturer’s
code data book. SASOL’s authorised representatives shall be permitted to witness hardness
testing.
16.6 SASOL’s authorised representative shall, at his discretion, witness hardness testing and the
calibration of test equipment.
16.7 Hardness values shall comply with the maximum allowable values given in Table 16.7 of
this specification.
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TABLE 16.7 – VICKERS AND BRINELL HARDNESS REQUIREMENTS
HARDNESS (HV10) HARDNESS (HB)

MATERIAL
MAXIMUM MAXIMUM
P-1* 240 200
P-1, 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.
16.8 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.
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
16.7 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.
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16.9 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.
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WELDING OF METALLIC PIPING APPENDIX A
APPENDIX A: LINE CLASS REQUIREMENTS
TABLE 1
MATERIAL DESCRIPTION AND SERVICE HEAT TREATMENT
QUALIFICATION
IMPACT TEST
NON-DESTRUCTIVE EXAMINATION REQUIREMENTS
PRE-HEAT
NON-
LINE CLASS
NON-PRESS
(GENERAL NOTES:1, 2, 5, 8, 9 and 81)
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
SERVICE PRESSURE/ ATTACH-
FILLET
PWHT
SEAL
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, Fuel CS, (P-1) C-Steel 11 x x 21 100% 100% 5% 5% 41, 42, 41, 42, 71, 72 71, 72
Gas, Fuel Oil, HC, Inert Gas, Tar Class 150 (P-1) 7 7 31 31 44 44
0 to 400°C
A1D Amine (61ºC -93ºC) CS, (P-1) C-Steel 11, 12 x x x 22 100% 100% 5% 5% 41, 42, 41, 42, 74 74
Carbonate (61ºC -93ºC) Class 150 (P-1) 7 7 31 31 44 44
Wet CO/CO2 (0ºC-49ºC) 0 to 93°C
(depending on
commodity)
A2D Isopropyl Ether CS, (P-1) C-Steel 11, 12 x x x 22 100% 100% 5% 5% 41, 42, 41, 42 74 74
Class 150 (P-1) 7 7 31 31 44 ,44
0 to 400°C
A3D Dilute Chemical Sewer CS, (P-1) C-Steel 11, 12 x x x 21, 23 100% 100% 5% 5% 41, 42, 41, 42, 72, 73, 72, 73,
Sour Water Class 150 (P-1) 7 7 31 31 44 44 74 74
Stripped Gas Liquor 0 to 105°C
AA Hydrocarbon CS, (P-1) C-Steel 11 x x 21 100% 100% 5% 5% 41, 42, 41, 42, 71, 72 71, 72
Corrosive Process Class 150 (P-1) 7 7 31 31 44 44
0 to 370°C
AAA Salty Water CS, (P-1) C Steel 11 x x 21 100% 100% 5% 5% 41, 42, 41, 42, 71, 72 71, 72
Class150 (P-1) 7 7 31 31 44 44
0 to 110°C
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QUALIFICATION
IMPACT TEST
PRE-HEAT
NON-
LINE CLASS
NON-PRESS
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
FILLET
PWHT
SEAL
P-NUMBER
AAB Amine, (0ºC -60ºC) CS, (P-1) Class C Steel 11 x x 21 100% 100% 5% 5% 41, 42, 41, 42, 71, 72 71, 72
Ammonia Water, (0ºC -175ºC) 150 (P-1) 7 7 31 31 44 44
Carbonate (0ºC -60ºC) 0 to 400°C
Caustic Soda (SP50-3A Appendix D (depending on
Zone A) commodity)
Isopropyl Ether, (0ºC - 400ºC)
Methanol, (0ºC - 400ºC)
Process Water (0ºC - 400ºC)
AAE Sulphuric Acid (93% - 98%) CS, (P-1) C Steel 11 x x 21 100% 100% 5% 5% 41, 42, 41, 42, 71, 72 71, 72
Class 150 (P-1) 7 7 31 31 44, 92 44, 92
0 to 40°C
Alloy 20 (P-45) 51, 52 51, 52

AAH Catalyst Transport Air CS, (P-1) Class C Steel 11 x x 21 100% 100% 5% 5% 41, 42, 41, 42, 71, 72 71, 72
Note 6 150 (P-1) 7 7 31 31 44 44
0 to 260°C
AAJ Boiler Return H20, Gassifier Return CS, (P-1) Class C Steel 11 100% 100% 0% 0% 41, 42 41, 42 72 72
water, Thickener Feed 125 (P-1) 7 7
16 to 65°C
AAK Boiler Bottom Ash, Boiler Fly Ash, CS, (P-1) Class C Steel 11 100% 100% 0% 0% 41, 42 41, 42 72 72
Pond Reclaim, Spent Catalyst Slurry, 125 (P-1) 7 7
Thickener Underflow 16 to 65°C
AAM Decoking CS, (P-1) Class C Steel 11 x x 21 100% 100% 100% 100% 41, 42 41, 42, 71, 72 71, 72
150 (P-1) 7 7 82 82 44 44
401 to 593°C
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QUALIFICATION
IMPACT TEST
PRE-HEAT
NON-
LINE CLASS
NON-PRESS
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
FILLET
PWHT
SEAL
P-NUMBER
AAV Hydrocarbons – Vacuum Service CS, (P-1) C-Steel 11 x x 21 100% 100% 5% 5% 41, 42, 41, 42, 71, 72 71, 72
Class 150 (P-1) 7 7 31 31 44 44
0 to 250°C
AC Hydrocarbons with Hydrogen Service CS, (P-1) Class C Steel 11 x x 21 100% 100% 5% 5% 41, 42 41, 42, 71, 72 71, 72
150 (P-1) 7 7 31 31 44 44
0 to 400°C
ADM Hydrocarbons, Methanol CS, (P-1, LT15) C Steel, -15°C 11, 12 x x x 21 100% 100% 5% 10% 41, 43 41, 43, 72, 73, 72, 73,
Normalized (P-1, LT15) 61 7 7 31 31 44 44 74 74
Class 150
-15 to 175°C
ADN Hydrocarbons, Methanol CS, (P-1, LT45) C Steel, -46°C 11, 12 x x x 21, 24 100% 100% 25% 100% 41, 43 41, 43, 72, 73, 72, 73,
Normalized (P-1, LT45) 61 7 7 31 82 44 44 74 74
Class 150
-45 to 175°C
AEM NH3 Anhydrous with less than CS, (P-1, LT45) C Steel, -46°C 11, 12 x x x 22 100% 100% 25% 100% 41, 43 41, 43, 74 74
0,2 wt % H20 Normalized (P-1, L45) 61 7 7 31 82 44 44
Class 150
-45 to 175°C
AG Hydrocarbons 5 Chrome 1¼ Chrome 13 x x x 27 100% 100% 10% 10% 41, 43 41, 43, 74 74
(P-5B) (P-4) 7 7 4, 31 4, 31 44 44
Class 150 Note 3 34 34
0 to 538°C
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QUALIFICATION
IMPACT TEST
PRE-HEAT
NON-
LINE CLASS
NON-PRESS
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
FILLET
PWHT
SEAL
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 - 427ºC) Class 150
Isopropyl Ether, (0ºC - 427ºC) 0 to 427°C
Nitric Acid (40 per cent maximum) (depending on
(0ºC - 100ºC) commodity)
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
ALA Concentrated Brine Solution Duplex Stainless Duplex 16 100% 100% 5% 10% 51, 52 51,52 72 72
Note 91 Comprising of Na2SO4, Mg(OH)2, Steel UNS Stainless Steel 91 7 7 31 31
CaSO4, NaCl 31803 (P-10H) UNS 31803
Class 150 (P-10H)
0 to 300°C
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QUALIFICATION
IMPACT TEST
PRE-HEAT
NON-
LINE CLASS
NON-PRESS
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
FILLET
PWHT
SEAL
P-NUMBER
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 Dual 16 100% 100% 5% 10% 51, 52 51, 52
Certified Certified 7 7 31 31
(P-8) (P-8)
Class 150
170°C Max.
AX Oxygen CS (P-1), C Steel 11, 16 x x 21 100% 100% 10% 10% 41, 42 41, 42, 71, 72 71, 72
Note 6 304/304L Dual (P-1) 7 7 31 31 44, 92 44, 92
Certified
51, 52 51, 52
(P-8),
Monel
(P-42)
Class 150
0 to 150°C
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NON-
LINE CLASS
NON-PRESS
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
FILLET
PWHT
SEAL
P-NUMBER
AYB Process Fluids 316/316L Dual 304/304L Dual 16 100% 100% 5% 10% 51, 52 51, 52
Phenol Certified (P-8) 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 x x 21 100% 100% 25% 100% 41, 43, 41, 43, 71, 72 71, 72
Class 150 (P-1) 7 7 31, 83 83 44 44
0 to 400°C
AZT Phenol CS (P-1) C Steel 11 x x 21 100% 100% 25% 100% 41, 43, 41, 43, 71, 72 71, 72
Class 150 (P-1) 7 7 31, 83 83 44 44
0 to 80°C
C Process Air, (0 to 400°C) CS (P-1) C Steel 11 x x 21 100% 100% 10% 10% 41,42 41, 42, 71,72 71, 72
Amine (0 to 60°C) Class 300 (P-1) 7 7 31 31 44 44
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
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PRE-HEAT
NON-
LINE CLASS
NON-PRESS
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
FILLET
PWHT
SEAL
P-NUMBER
C1D Amine: 61 to 93°C CS (P-1) C Steel 11, 12 x x x 22 100% 100% 10% 10% 41, 42 41, 42, 74 74
Carbonate : 61 to 93°C Class 300 (P-1) 7 7 31 31 44 44
Wet CO/CO2 : 0 to 93°C 0 to 93°C
(depending on
commodity)
C2D Isopropyl Ether CS (P-1) C Steel 11, 12 x x x 22 100% 100% 10% 10% 41, 42 41, 42, 74 74
Class 300 (P-1) 7 7 31 31 44 44
0 to 400°C
C3D Dilute Chemical Sewer CS (P-1) C Steel 11, 12 x x x 21, 23 100% 100% 10% 10% 41, 42 41, 42, 72, 73, 72, 73,
Sour Water Class 300 (P-1) 7 7 31 31 44 44 74 74
Stripped Gas Liquor 0 to 105°C
C4D Phenol CS (P-1) C Steel 11, 12 x x x 22 100% 100% 25% 100% 41, 43, 41, 43, 74 74
Class 300 (P-1) 7 7 31, 83 83 44 44
0 to 400°C
CA Hydrocarbons (Corrosive) CS (P-1) C Steel 11 x x 21 100% 100% 10% 10% 41, 42, 41, 42, 71, 72 71, 72
Class 300 (P-1) 7 7 31 31 44 44
0 to 400°C
CAF Caustic Soda (Zone B) CS (P-1) C Steel 11, 12 x x x 22 100% 100% 10% 10% 41, 42, 41, 42, 74 74
Class 300 (P-1) 7 7 31 31 44 44
CAH Catalyst CS (P-1) C Steel 11 x x 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
0 to 400°C
CAL Thickener Underflow CS (P-1) C Steel 11 x x 21 100% 100% 10% 10% 41, 42, 41, 42, 71, 72 71, 72
Class 300 (P-1) 7 7 31 31 44 44
0 to 85°C
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NON-
LINE CLASS
NON-PRESS
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
FILLET
PWHT
SEAL
P-NUMBER
CBA Hydrocarbons CS (P-1) C Steel 11 x x 21 100% 100% 10% 10% 41, 42, 41, 42, 71, 72 71, 72
Class 300 (P-1) 7 7 31 31 44 44
0 to 400°C
CDM Hydrocarbons, Methanol CS (P-1) (LT15) C Steel (LT15) -15°C 11, 12 x x x 21 100% 100% 10% 10% 41, 43, 41, 43, 72, 73, 72, 73,
Normalized (P-1) 61 7 7 31 31 44 44 74 74
Class 300
-15 to 0°C
CDN Hydrocarbons, Methanol CS (P-1) (LT45) C Steel (LT45) -46°C 11, 12 x x x 21, 24 100% 100% 25% 100% 41, 43, 41, 43, 72, 73, 72, 73,
Normalized (P-1) 61 7 7 31 82 44 44 74 74
Class 300
-45 to 16°C
CEM NH3, (Anhydrous with less than CS (P-1) (LT45) C Steel (LT45) -46°C 11, 12 x x x 22, 24 100% 100% 25% 100% 41, 43, 41, 43, 74 74
0,2 wt % Water) Normalized (P-1) 61 7 7 31 82 44 44
Class 300
-45 to 175°C
CFC Hydrocarbons with Hydrogen, 1¼ Chrome 1¼ Chrome 13 x x x 26 100% 100% 10% 100% 41, 43, 41, 43, 72, 73, 72, 73,
Hydrogen (P-4) (P-4) 7 7 4, 31, 34 4, 82 44 44 74 74
Class 300
0 to 538°C
CFD Catalyst with Hydrogen 1¼ Chrome 1¼ Chrome 13 x x x 26 100% 100% 10% 100% 41, 43, 41, 43, 72, 73, 72, 73,
(P-4) (P-4) 7 7 4, 31, 34 4, 82 44 44 74 74
Class 300
0 to 485°C
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PRE-HEAT
NON-
LINE CLASS
NON-PRESS
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
FILLET
PWHT
SEAL
P-NUMBER
CG Hydrocarbons with Hydrogen 5 Chrome 1¼ Chrome 13 x x x 27 100% 100% 10% 100% 41, 43 41, 43, 74 74
Hydrocarbons and Hydrogen (P-5B) (P-4) 7 7 4, 31, 4, 82 44 44
Sulphide Class 300 Note 3 34
0 to 530°C
CGD Hydrocarbons 5 Chrome 1¼ Chrome 13 x x x 27 100% 100% 10% 100% 41, 43 41, 43, 74 74
Hydrogen Sulphide (Wet) (P-5B) (P-4) 7 7 4, 31, 4, 82 44 44
Class 300 Note 3 34
0 to 500°C
C IA Polypropylene Powder 304/304L SS 304/304L SS 16 x x 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 x x 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
CIR Hydrocarbons 304/304L SS 304/304L SS -195°C 61 16 x x 100% 100% 10% 10% 51, 52 51, 52
Methanol Dual Certified Dual Certified 7 7 31 31
Ethylene (P-8) (P-8)
Class 300
-195 to 175°C
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PRE-HEAT
NON-
LINE CLASS
NON-PRESS
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
FILLET
PWHT
SEAL
P-NUMBER
CIW Alkyl 304/304L SS 304/304L SS 16 x x 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 x x 100% 100% 10% 100% 51, 52 100%
Note 6 (P-8) (P-8) Note 3 7 7 31 82
Class 300
0 to 275°C
CRC Hydrocarbons with Hydrogen 304/304L SS 304/304L SS 16 x x 100% 100% 10% 100% 100% 100%
(Corrosive) Dual Certified Dual Certified 7 7 31 82
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 x x 100% 100% 5% 10% 51, 52 51, 52
(P-8) (P-8) 7 7 31 31
Class 300
170°C Max
CTC Raw Gas (H2 Rich), Steam-Oxygen 321 SS 304 SS 16 x x 100% 100% 10% 100% 51, 52 51, 52
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 x x 29 100% 100% 25% 100% 100% 100%
C4 and Lighter Fluids (P-8) (P-8) 7 7 31, 34 82
Class 300
0 to 675°C
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QUALIFICATION
IMPACT TEST
PRE-HEAT
NON-
LINE CLASS
NON-PRESS
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
FILLET
PWHT
SEAL
P-NUMBER
CX Oxygen CS (P-1) C Steel 11 x x 21 100% 100% 10% 100% 41, 42 41, 42, 71, 72 71, 72
Note 6 (P-1) 7 7 44, 92 44, 92
304/304L Dual 100% 100%
Certified (P-8)
and Monel
(P-42)
Class 300
0 to 150°C
CYB Process Fluids 316/316L 304/304L 16 x x 100% 100% 10% 10% 51, 52 51, 52
Phenol Stainless Steel Stainless Steel 7 7 31, 34 31, 34
Dual Certified Dual Certified For For
Corrosive Water
(P-8) (P-8) Note 3 Phenol: Phenol:
Class 300
25% 100%
0 to 525°C 31, 34 82
CZC Benzene CS (P-1) C Steel 11 x x 21 100% 100% 25% 100% 41, 43 41, 43, 71, 72 71, 72
Class 300 (P-1) 7 7 31, 83 83 44 44
0 to 400°C
F Hydrocarbons CS (P-1) C Steel 11 x x 21 100% 100% 10% 100% 41, 42 41, 42, 71, 72 71, 72
Class 600 (P-1) 7 7 31 82 44 44
FAF Caustic Soda CS (P-1) CS(P-1) 11, 12 x x x 22 100% 100% 100% 100% 41, 42 41, 42, 74 74
(Appendix D, Area B) Class 600 7 7 82 82 44 44
FC Hydrocarbons w/Hydrogen, Hydrogen CS (P-1) C Steel 11 x x 21 100% 100% 25% 100% 41, 42 41, 42, 71, 72 71, 72
Class 600 (P-1) 7 7 31 82 44 44
0 to 400°C
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QUALIFICATION
IMPACT TEST
PRE-HEAT
NON-
LINE CLASS
NON-PRESS
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
FILLET
PWHT
SEAL
P-NUMBER
FCA Hydrocarbons with Hydrogen CS (P-1) C Steel 11 x x 21 100% 100% 25% 100% 41, 42 41, 42, 71, 72 71, 72
(Corrosive) Class 600 (P-1) 7 7 31 82 44 44
0 to 400°C
FEM Ammonia (Anhydrous with less than CS (P-1) (LT45) C Steel (LT45) -46°C 11, 12 x x x 22, 24 100% 100% 25% 100% 41, 43 41, 43, 74 74
0,2 wt % water) Normalized (P-1) 61 7 7 31, 82 44 44
Class 600
-45°C to 175 °C
FFC Hydrocarbons with Carbon Hydrogen 1¼ Chrome 1¼ Chrome 13 x x x 26 100% 100% 25% 100% 41, 43 41, 43, 72 73, 72, 73,
(P-4) (P-4) 7 7 4, 31, 34 4, 82 44 44 74 74
Class 600
0 to 538°C
FFD Hydrocarbons with Hydrogen 1¼ Chrome 1¼ Chrome 13 x x x 26 100% 100% 25% 100% 41, 43 41, 43, 72 73, 72, 73,
(Corrosive) (P-4) (P-4) 7 7 4, 31, 34 4, 82 44 44 74 74
Class 600
0 to 485°C
FIR Hydrocarbons 304/304L SS 304/304L SS -195°C 61 16 x x 100% 100% 25% 100% 51, 52 51, 52
Methanol Dual Certified Dual Certified 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 x x 100% 100% 25% 100% 100% 100%
Note 6 Class 600 7 7 31, 34 82
0 to 460°C
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QUALIFICATION
IMPACT TEST
PRE-HEAT
NON-
LINE CLASS
NON-PRESS
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
FILLET
PWHT
SEAL
P-NUMBER
FMB Process Fluids 304/304L SS 304/304L SS 16 x x 100% 100% 25% 100% 100% 100%
Dual Certified Dual Certified 7 7 31, 34 82
(P-8) (P-8)
Class 600
0 to 525°C
FNH Catalyst (CAT) 304/304L SS 304/304L SS 16 x x 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 x x 100% 100% 25% 100% 100% 100%
Mixtures (P-8) (P-8) 7 7 31, 34 82
Class 600 Note 3
0 to 538°C
FUC Heater Effluent – Delayed Coker 321H SS 321 SS 16 x x 29 100% 100% 25% 100% 100% 100%
(P-8) (P-8) 7 7 31, 34 82
Class 600 Note 3
0 to 675°C
FYB Process Fluids 316/316L 304/304L 16 x x 100% 100% 10% 25% 51, 52 51, 52
Stainless Steel Stainless Steel 7 7 31, 34 31, 34
Dual Certified Dual Certified
(P-8) (P-8 )
Class 600 Note 3
0 to 450°C
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QUALIFICATION
IMPACT TEST
PRE-HEAT
NON-
LINE CLASS
NON-PRESS
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
FILLET
PWHT
SEAL
P-NUMBER
G Hydrocarbons, Hydrocarbons CS (P-1) C Steel 11 x x 21 100% 100% 100% 100% 41, 42 41, 42, 71, 72 71, 72
With Hydrogen, Hydrogen Class 900 (P-1) 7 7 82 82 44 44
0 to 400°C
GFD Hydrocarbons with Hydrogen 1¼ Chrome 1¼ Chrome 13 x x x 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 74
Class 900
0 to 485°C
GYC Hydrocarbons with Hydrogen 316/316L SS 304/304L SS 16 x x 100% 100% 100% 100% 100% 100%
(P-8) (P-8)
Class 900 Note 3
0 to 425°C
H Hydrocarbons, Hydrocarbons with CS (P-1) C Steel 11 x x 21 100% 100% 100% 100% 41, 42 41, 42, 71, 72 71, 72
Hydrogen, Hydrogen Class 1500 (P-1) 7 7 82 82 44 44
0 to 400°C
HUC Process Fluids 321H SS 321 SS 16 x x 29 100% 100% 100% 100% 100% 100%
(P-8) (P-8) 7 7 82 82
Class 1500 Note 3
0 to 675°C
HYC Hydrocarbons with Hydrogen 316/316L SS 304/304L SS 16 x x 100% 100% 100% 100% 100% 100%
(P-8) (P-8)
Class 1500 Note 3
0 to 425°C
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QUALIFICATION
IMPACT TEST
PRE-HEAT
NON-
LINE CLASS
NON-PRESS
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
FILLET
PWHT
SEAL
P-NUMBER
J Hydrocarbons, Hydrocarbons with CS (P-1) C Steel 11 x x 21 100% 100% 100% 100% 41, 42 41, 42, 71, 72 71, 72
Hydrogen, Hydrogen Class 2500 (P-1) 7 7 82 82 44 44
0 to 400°C
JTC Hydrocarbons with Hydrogen 321 SS 304/304L SS 16 x x 100% 100% 100% 100% 100% 100%
Note 93 (P-8) Dual Certified 7 7 82 82
Class 2500 (P-8)
0 to 490°C Note 3
JYB Hydrocarbons with Hydrogen 316/316L SS 304/304L 16 x x 100% 100% 100% 100% 100% 100%
Note 93 Dual Certified Dual Certified 7 7 82 82
(P-8) (P-8)
Class 2500 Note 3
0 to 455°C
KH Gravity Sewers, Process Conservation CS (P-1) C Steel 11 x x 100% 100% 0% 0% 41, 42 41, 42
Sewers Atmos Pres. (P-1) 7 7
5 to 150°C
KJ Gravity Sewers, Process Conservation 304/304L SS 304/304L SS x x 100% 100% 0% 0% 51, 52 51, 52
Sewers Dual Certified Dual Certified 7 7
(P-8) Atmos (P-8)
Pressure
5 to 150°C
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QUALIFICATION
IMPACT TEST
PRE-HEAT
NON-
LINE CLASS
NON-PRESS
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
FILLET
PWHT
SEAL
P-NUMBER
L Instrument air, Utility Air, Water CS (P-1) C Steel 11 x x 21 100% 100% 0% 0% 41, 42 41, 42 72 72
(Cooling), Water (Utility – Clarified Class 150 (P-1) 7 7
Ash Water), Water (General Factory),
1030 kPa Max
Foam
0 to 60°C
LA Underground: CS (P-1) C Steel 11 x x 21 100% 100% 0% 0% 41, 42 41, 42 72 72
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 x x 21 100% 100% 0% 0%
Underground - NPS ½ to NPS 4, Class 150 (P-1) 7 7
Threaded and Galvanized, 6” and
0 to 50°C
Larger – Galvanized after Fabrication
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QUALIFICATION
IMPACT TEST
PRE-HEAT
NON-
LINE CLASS
NON-PRESS
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
FILLET
PWHT
SEAL
P-NUMBER
LF Aboveground Fire Water (Wet CS (P-1) C Steel 11 x x 21 100% 100% 5% 5% 41, 42 41, 42 72 72
Systems) Class 150 (P-1) 7 7
1800 kPa Max
16 to 50°C
LFA Aboveground Fire Water CS (P-1) C Steel 11 x x 21 100% 100% 5% 5% 41, 42 41, 42 72 72
(Unpressurized Systems) - NPS ½ to Class 150 (P-1) 7 7
NPS 4, Threaded and Galvanized, 6”
1800 kPa Max
and Larger – Galvanized after
Fabrication 16 to 50°C
N Boiler Feed Water CS (P-1) C Steel 11 x x 21 100% 100% 5% 10% 41, 42 41, 42, 71, 72 71, 72
Condensate Class 150 (P-1) 7 7 31 31 44 44
Steam 0 to 400°C
R Boiler Feed Water CS (P-1) C Steel 11 x x 21 100% 100% 10% 10% 41, 42 41, 42, 71, 72 71, 72
Condensate Class 300 (P-1) 7 7 31 31 44 44
Steam 0 to 400°C
RA Boiler Feed Water CS (P-1) C Steel 11 x x 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 44
Steam 0 to 400°C
S Boiler Feed Water CS (P-1) C Steel 11 x x 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
Steam 0 to 427°C
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QUALIFICATION
IMPACT TEST
PRE-HEAT
NON-
LINE CLASS
NON-PRESS
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
FILLET
PWHT
SEAL
P-NUMBER
SA Boiler Feed Water CS (P-1) C Steel 11 x x 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 44
Steam 0 to 427°C 35
SF HP Steam, 1¼ Chrome 1¼ Chrome 13 x x 26 100% 100% 25% 100% 41, 43, 41, 43, 72, 73, 72, 73,
Condensate (P-4) (P-4) 7 7 4, 31, 34 4, 82 44 44 74 74
Saturated Steam Class 600
0 to 482°C
VA Lube Oil 304/304L SS 304/304L SS 16 x x 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 x x 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 x x 100% 100% 10% 10% 51, 52 51, 52
(P-8) (P-8)
Class 600
0 to 205°C
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QUALIFICATION
IMPACT TEST
PRE-HEAT
NON-
LINE CLASS
NON-PRESS
PRE-
SOCKET &
MATERIAL/ PRESSURE
SP-50-3A
ATTACH
BUTT &
FILLET
PWHT
SEAL
P-NUMBER
VD Lube Oil 304/304L SS 304/304L SS 16 x x 100% 100% 10% 10% 51, 52 100%
(P-8) (P-8)
Class 900
0 to 205°C
VE Lube Oil 304/304L SS 304/304L SS 16 x x 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 x x 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 x x 100% 100% 0% 0%
Class 150 (P-1) 7 7
0 to 320°C
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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. The weld
material shall be the same as that used for the pipe pressure weld. Welding procedures and performance
qualifications shall be 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.
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.
Page 20 of 36
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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.
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.
7 Each completed weld shall be visually examined 100% in accordance with this Specification Section
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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.
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 RT is not required on welds in piping that is open to atmosphere or for drains; except that for flare lines,
the extent of radiography specified for the line class shall be done.
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
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temperature does not exceed 38°C. Heat input shall be 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 of all carbon steel welds shall be performed in accordance with 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 19mm
22 All pressure retaining welds and welds attaching internal non-pressure parts to pressure retaining parts
shall be PWHT, regardless of thickness.
23 For nominal wall thickness less than 19mm, in sour fluid and sour gas services, PWHT shall be required
if the as welded Brinell hardness values exceed the maximum values specified in Table 16.7 of this
Specification. Therefore PQRs shall be dual qualified with and without PWHT.
24 Repairs shall be PWHT or cut and re-welded regardless of thickness.
25 Deleted
CHROME-MOLY PIPING
26 PWHT of P4 piping welds shall be performed in accordance with ASME B31.1, ASME B31.3,
supports welded to piping shall be PWHT (fillet welds and full penetration welds) when the thickness of
the weld exceeds 13mm.
27 PWHT of P5 piping welds shall be performed in accordance with ASME B31.1, ASME B31.3,
supports welded to piping shall be PWHT (fillet welds and full penetration welds) regardless.
28 Deleted
HIGH TEMPERATURE AUSTENITIC PIPING
29 PWHT might be required to mitigate ductility dip or more suitable filler material such as Type 16-8-2
shall be used. Proposal to be approved by SASOL.
30 RADIOGRAPHY
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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 under this Specification shall be
radiographed 100%.
c. Selection of welds to be examined shall include girth butt, butt welds, socket welds and applicable
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)
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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 MT method unless Note 44 applies.
44 After PWHT all welds shall be subjected to 100% MT on all accessible surfaces.
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.
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.
70 HARDNESS TESTING
71 Butt welds which require PWHT shall be subject to hardness test after PWHT, 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.
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.
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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.
80 ULTRASONIC EXAMINATION (UT)
81 Girth butt welds produced by the automatic or semi-automatic GMAW (MIG-MAG) welding processes
shall be subjected to random UT, using an ultrasonic procedure approved 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 on 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 Appendix C for the requirements for Duplex stainless steel welding, fabrication and qualification.
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.
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WELDING OF METALLIC PIPING APPENDIX B
APPENDIX B: DIRECTIONS FOR COMPLETING THE WELDING PROCEDURE SUMMARY
SPACE NO. ACTION TO BE TAKEN
1. Enter SASOL’s purchase order number. A separate summary must be completed for
each purchase order and suborder.
2. Enter manufacturer’s name.
3. Enter manufacturer’s shop location where work will be performed.
4. Enter the date when the summary is compiled.
5. Enter Welding Procedure Specification number.
6. Enter Procedure Qualification Record number(s) supporting the Welding Procedure

Specification.
7. Enter the welding process(es) qualified in the procedure.
8. Enter the ASME/ASTM materials used when qualifying the procedure.
9. Enter the ASME/ASTM materials used when qualifying the procedure.
10. Enter whether procedure requires impact testing.
11. Enter thickness of material used for qualification.
12. Enter thickness range qualified by the Procedure Qualification Record
13. Enter other requirements, e.g. Procedure requiring impact tests; enter lowest
temperature procedure is qualified for.
14. Enter any special design or process information regarding the item of construction or
welding procedures in this box.
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WELDING PROCEDURE SUMMARY, PIPE
SHEET ___________ OF _____________ REVISION ________________________________
PO ORDER NUMBER: __________________________________________________________
ITEM TAG NUMBER: __________________________________________________________
BY: __________________________________________________________________________
WELDING PROCEDURE SUMMARY PIPE
CHARGE NUMBER: ____________________ DATE: __________________________
DATA SHEET PROCESS: ____________________________ DATE: __________________________
MECHANICAL: _______________________ DATE: __________________________
INSTRUMENTS: _______________________ DATE: __________________________
ELECTRICAL: _________________________ DATE: __________________________
THICKNESS THICKNESS
ISO / APPROVAL
Line SUPPORTING PROCESS SPECIFICATION OF PWHT IMPACT TEST OF QUALI- RANGE
Sheet WPS No. OTHER STATUS (1)
Class PQR (S) (ES) PIPE MATERIAL FICATION QUALIFIED mm)
No.
YES NO YES NO (mm) MIN MAX STATUS DATE
5 6 7 8 9 10 11 12 13
REMARKS:
(1) LEGEND. A-APPROVED, COMMENCE FABRICATION. B-APPROVED, COMMENCE FABRICATION, SUBMIT WITH CORRECTIONS. C-NOT APPROVED, DO NOT FABRICATE
MANUFACTURER: 2 LOCATION: 3 . DATE: 4 _______________________________

Project description 1 . Engineering Contractor, test pack (to top) Revision at date
Page 28 of 36
SP-90-02
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SHEET ___________ OF _____________ REVISION ________________________________
PO ORDER NUMBER: __________________________________________________________
ITEM TAG NUMBER: __________________________________________________________
BY: __________________________________________________________________________
WELDING PROCEDURE SUMMARY PIPE
CHARGE NUMBER: ____________________ DATE: __________________________
DATA SHEET (EXAMPLE) PROCESS: ____________________________ DATE: __________________________
MECHANICAL: _______________________ DATE: __________________________
INSTRUMENTS: _______________________ DATE: __________________________
ELECTRICAL: _________________________ DATE: __________________________
THICKNESS THICKNESS
ISO / SPECIFICATION APPROVAL
Line SUPPORTING PWHT IMPACT TEST OF QUALI- RANGE
Sheet WPS No. PROCESS (ES) OF PIPE OTHER STATUS (1)
Number PQR (S) FICATION QUALIFIED mm)
No. MATERIAL
YES NO YES NO (mm) MIN MAX STATUS DATE
516 1-1-B3M SMAW 11-01 SMAW 5L Gr B x x 7 1,6 14 A
520 1-1-AB-3M GMAW 11-21 GMAW A
SMAW 11-24 SMAW 5L Gr B x x 12,5 4,8 25 B
524 1-1-AB-1H GMAW 11-67 GMAW A
SMAW 11-63 SMAW SA 106 Gr B x x 10 4,8 20 B31,1 A
634 1-1-A –3L GMAW 11-42 GMAW A 333 Gr6 x x 4 3 6 LT45 B
652 8-8-A –3L GMAW 88-92 GMAW A 312 Gr 304L x x 7 3,5 11 LT195 A
719 9-9 B-3L SMAW 99-83 SMAW A 333 Gr 3 x x x 8 4 12 LT85 C
REMARKS:
Requalify SMAW 99-83 in PWHT condition. As welded also marginal
(1) LEGEND. A-APPROVED, COMMENCE FABRICATION. B-APPROVED, COMMENCE FABRICATION, SUBMIT WITH CORRECTIONS. C-NOT APPROVED, DO NOT FABRICATE
MANUFACTURER: ABC MANUFACTURERS LOCATION: INDUSTRIA MANUFACTURIA DATE: 1986-04-02
P.O. 4571204-005102 .
Engineering Contractor, test pack (to top) Revision at date
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SP-90-2
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WELDING OF METALLIC PIPING APPENDIX C
APPENDIX C: REQUIREMENTS FOR DUPLEX STAINLESS STEEL WELDING,

FABRICATION AND QUALIFICATION
1. Joint Preparation
1.1 Duplex stainless steel may be cut using the plasma-arc process, a machine cutter, or grinding
disc dedicated solely for the use on duplex stainless steel. Carbon-arc shall not be used for
cutting or back gouging. If plasma-arc cutting is used, the inside surface must be thoroughly
cleaned of all spatter. Sufficient metal shall be removed in the bevelling process to remove
any heat affected zone (HAZ) that occurred as a result of the plasma-arc cutting. Once used
for cutting duplex stainless steel, grinding discs shall be used exclusively for that purpose.
The final surface preparation and configuration shall be obtained by machining. During
machining operations, only a cutting fluid compatible with stainless steel shall be used.
1.2 Before any welding takes place, all weld bevels shall be visual inspected internally and
externally for nicks, dents, general damage, or other surface defects. Defects shall be dealt
with as stated below, after which, the final cleaning prior to welding shall take place.
1.3 Any small burrs, nicks, or other irregularities on the weld bevel shall be repaired, if possible,
by light grinding. Any suspected edge defects or laminations shall be reported to the
Purchaser before proceeding with investigation or repairs. Repairs by welding shall not
proceed without prior approval of the Purchaser.
1.4 Each bevelled edge, internal and external surfaces over a distance of at least 50mm back
from the bevel shall, immediately prior to welding, be thoroughly dried, and shall be cleaned
with a stainless steel wire brush. The bevelled edge shall then be wiped clean with acetone,
or other Purchaser approved solvent.
2. General Welding Requirements
2.1 All welds, including tack welds, shall be made with filler metal. Welding processes and
consumables as specified in Table C2.1 shall be used unless otherwise authorized by the
Purchaser:
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TABLE C2.1 ACCEPTABLE WELD PROCESSES

Process Standard 22% Cr Super 25% Cr
SMAW SFA 5.4 E2209 SFA 5.4 E2553
GTAW SFA 5.9 ER2209 SFA 5.9 ER2553
SAW SFA 5.9 ER2209 with a flux SFA 5.9 ER2553 with a flux
designated for duplex SS designated for duplex SS
The use of GMAW, when approved, shall be by the spray transfer mode and shall use the
shielding gas recommended by the alloy manufacturer. The process shall not be used for
non-backgouged root passes.
The fabricator may propose the use of 25% Cr filler materials for 22% Cr base metals to
Purchaser for approval, especially if needed to pass corrosion resistance testing. This table
also does not cover some of the 25% Cr alloys with additional alloying elements such as
tungsten. The alloy manufacturer’s recommendations on filler metals shall be followed.
2.2 The maximum heat input shall be the heat input qualified and the minimum heat input shall
be as recorded during the PQR qualification. Heat inputs shall be within the range of 0.5
KJ/mm to 2.5 KJ/mm for standard 22% Cr alloys. Limits for 25% Cr super alloys shall be
based on the alloy manufacturer’s recommendations (which typically involve a lower, tighter
range).
2.3 The maximum interpass temperature shall not exceed 150 ºC for 2209 or 100 ºC for 25% Cr
filler metals. Measurements shall be taken on the parent metal surface, directly adjacent to
the weld groove. Temperature indicating crayons shall not be used, unless approved by
Purchaser, and if allowed, shall have a maximum halogen content of 200 ppm and a
maximum sulphur content of 200 ppm.
2.4 All single sided welds shall be made with a GTAW root pass and back purged until at least 6
mm of weld metal thickness has been deposited. Backing gas shall be welding grade 90%
nitrogen/10% hydrogen mixture, pure nitrogen or argon/nitrogen mixture with not less than
5% nitrogen. The oxygen content of the back-purged volume shall be less than 0.25% (2500
ppm). The manufacturer shall submit details of the method and equipment to be used for
monitoring oxygen content as part of the welding procedure specification. Shielding gasses
can be argon or argon with 2% maximum nitrogen. Signs of sugaring/oxidation of the weld
shall constitute rejection and repair.
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2.5 Under no circumstances shall the welding arc be struck outside the weld bevels. If this
occurs, the arc strike shall be removed by grinding. The ground area shall be inspected with
liquid penetrant, and any relevant indications shall require repairs.
2.6 During production welding, calibrated equipment for measuring the following variables shall
be available at all times:
a. Welding current (amperage)

b. Arc voltage
c. Interpass temperatures
d. Oxygen content of backing gas
e. Wire feed speed (for machine welding)
f. Welding head travel speed
g. Shielding and backing gas flow rate (using floating ball type flow meter).
h. Ferrite scope for ferrite determination.
2.7 Welds that are back-gouged for welding on the opposite side shall be liquid penetrant
inspected after cleaning prior to back-welding. All back-gouging shall be accomplished with
approved procedures, insuring complete removal of oxides from plasma-cut surfaces.
Carbon-arc gouging shall not be used.
2.8 All accessible welds exposed to the process side shall be cleaned after welding by a stainless
steel hand wire brush on the as-welded surfaces.
2.9 All welds made, including tack and fit up, shall be done with approved procedures, materials
and certified welders / welding operators.
2.10 On 10% of production welds ferrite determination shall be performed and meet the
requirement of 30% to 65% ferrite.
3. Welding Procedure Specifications and Qualification Requirements
3.1 The WPS/PQRs shall be qualified in accordance with ASME Section IX and the
requirements of this specification. Existing WPS/PQRs, or parts of existing WPS/PQRs may
be acceptable provided all of the following requirements are satisfied.
3.2 Each WPS shall contain the information required by ASME Section IX, QW-250, and the
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following:
a. For filler metal(s), the specific manufacturer(s) and trade name(s) to be used in
production.
b. Details of tack welding technique (where applicable).
3.3 Essential variables for procedure qualification shall be in accordance with ASME Section
IX, QW-250 (including supplementary essential variables for notch toughness) and those
listed below. Any changes in the essential variables of an approved WPS shall require re-
qualification.
3.3.1 For manual and machine welding the following are additional essential variables:
a. Any change in filler metal specification and tradename.

b. Any change in filler metal diameter.
c. Any change in shielding gas flow rate beyond -20% / +10%.
d. Any change in type of current, polarity, or pulse range.
e. Any increase in the maximum interpass temperature.
f. Any change in the heat input greater than the maximum qualified or below the
minimum recorded
g. In addition to ASME Section IX requirements given in QW-403.6 for minimum
qualified thickness requirements, the maximum qualified thickness shall not exceed
1.2T.
3.3.2 For machine welding only. The following are additional essential variables:
a. For SAW, any change in the brand name and type of flux.
b. Any change in joint configuration outside tolerances specified in the procedure.
c. Any change in the weld orientation (e.g. vertical to horizontal or from 1G, 2G or 4G to
3G).
3.4 The minimum number of mechanical test specimens required for a welding procedure
qualification test weld shall be in accordance with ASME B31.3, Section IX, and SP-110-6
with the addition of tests stipulated in Table C3.4.
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SP-90-2
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TABLE C3.4 ADDITIONAL TESTING REQUIREMENTS

Quantity of
Test Specimens
ASTM A-923 Test Method B or C with:
Test Method B: Charpy V-notch (-40 deg F / -40 deg C):
Weld centerline 2
Fusion line 2
Fusion line + 2.5 mm 2
Fusion line + 4.75 mm 2
Or
Test Method C: Ferric Chloride Corrosion Test 2
Cross section for macro-examination, photo-micrographs and 1
ferrite measurements
Transverse Hardness Test Surveys 2
3.5 Test procedures and acceptance standards for supplementary welding procedure qualification
tests shall be as follows:
3.5.1 ASTM A 923 Charpy Test (Method B) and Ferric Chloride Corrosion Test (Method C)
a. Charpy impact testing shall be in accordance with ASTM A 923 Test Method B with test
results reported. The number of specimens shall be increased in accordance with
Paragraph 3.4. Specimens shall be removed from the thru-thickness locations specified
by SP 110-6. Lateral expansion measurements shall be reported for information.
b. Ferric chloride corrosion tests shall be in accordance with ASTM A 923, Method C with
test results reported. The test specimens shall include weld HAZ and base metal.
c. The rapid screening test (ASTM A 923 Test Method A) shall not be used to approve
procedures.
3.5.2 Ferrite Tests (Modified ASTM E 562)
a. For ferrite assessment during procedure qualification tests, metallurgical sections shall
be polished and etched to clearly reveal the two-phase austenite/ferrite microstructure.
The area being point counted, either parent material, weld metal or HAZ, shall be
examined and photographed under a microscope at a sufficient magnification to fill the
field of view and to be able to clearly discriminate between the constituent phases. (For
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SP-90-2
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parent plate and weld metal, a magnification of approximately 400X is required, and for
HAZ, about 700X to 1000X is recommended.)
b. The photographs shall be overlaid with a grid of at least 100 points and the percentage
ferrite shall be calculated from the number of points that fall on the ferrite phase and the
total number of points used. Automated counting methods using quantitative
metallographic equipment can also be used.
c. The ferrite content shall be measured on one of the metallurgical sections using the point
counting technique at the following locations:
i) In the parent metal, one measurement on each side of the weld at mid thickness
(total of 2).
ii) In the heat affected zone on each side of the weld, in the region of the root pass
(total of 2).
iii) In the weld metal near to the vertical center line of the weld, one in the cap, one
in the root, and one at mid thickness (total of 3).
d. Ferrite content at these locations shall be 30-65% in base and weld metal, and 30-70% in
the HAZ.
e. Experienced laboratories shall be used.
3.5.3 Photomicrographs and Macro-Examination
a. Photomicrographs at approximately 400X shall be provided for each of the locations

where a phase balance assessment is performed.
b. Photomicrographs shall show a typical austenite/ferrite microstructure.
c. The macro-examination shall provide evidence that the weld is sound and free from
cracks and other defects with full penetration and fusion between weld passes and parent
metal.
3.5.4 Hardness Testing
a. Hardness testing is required on all weld procedure qualification records. Hardness

readings shall be taken Vickers with a 10 Kg load.
b. Hardness testing shall be performed in accordance with Section 16.
3.6 Dissimilar metal welds, i.e., carbon steel to duplex stainless steel or austenitic stainless steel
to duplex stainless steel shall require qualification and testing to the requirements of this
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specification except that the non-duplex HAZ need not be subject to Charpy or corrosion
testing.
Page 36 of 36

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SASOL SPECIFICATION SP-90-02

WELDING OF METALLIC PROCESS AND POWER PIPING

Originator SIGNED Reviewer : SIGNED

EFFECTIVE DATE: JUNE 2012

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

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

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

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

SASOL SPECIFICATION SP-90-02

WELDING OF METALLIC PIPING

TECHNICAL COMMITTEE OF SPECIFICATION SP-90-02, Revision 4

NAME COMPANY AND DEPARTMENT

BENADE A.R. (Arnold) Sasol Technology Welding

DE KLERK W. (Willem) Sasol Technology QA

KRUGER J.J. (Johan) Sasol Technology Welding

BOTHA P.J. (Pieter) Sasol Technology Welding

FRONEMAN H. (Hanre) Sasol Technology Welding

BRADLEY R. (Ronald) Sasol Synfuels Metallurgical Engineering

SWART A.P. (Abe) Sasol Technology Mechanical

SMIT P.P.J. (Paulus) Sasol Technology Mechanical

MAARTENS P. (Pieter) Sasol Synfuels Inspection

WENHOLD O. (Otto) Infrachem Equipment Integrity

DORFLING C. (Charl) Sasol Synfuels Weldtech

FISHER D. (Dennis) Infrachem Site Serv OES

ODELL G. (Greg) Sasol Synfuels Mechanical Engineering and

SASOL SPECIFICATION SP-90-02

WELDING OF METALLIC PIPING

REVISION DESCRIPTION SHEET

SASOL SPECIFICATION SP-90-02

WELDING OF METALLIC PIPING

2 REFERENCED AND RELATED DOCUMENTS ............................................................. 4

3 GENERAL REQUIREMENTS ............................................................................................ 6

4 DOCUMENTATION SUBMITTAL, APPROVAL AND RECORDS ............................. 6

5 PROCEDURE QUALIFICATION AND WELDER QUALIFICATION ........................ 7

SASOL SPECIFICATION SP-90-02

WELDING OF METALLIC PIPING

6 WELDING PROCESSES ................................................................................................... 14

7 WELDING CONSUMABLE REQUIREMENTS ............................................................ 14

8 WELD JOINT PREPARATION ........................................................................................ 14

9 CLEANING REQUIREMENTS ........................................................................................ 15

10 WELDING REQUIREMENTS .......................................................................................... 16

11 WELD CONTOUR .............................................................................................................. 17

13 POST WELD HEAT TREATMENT (PWHT) ................................................................. 19

16 HARDNESS TESTING ....................................................................................................... 27

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

NOTES FOR TABLE 1 ...................................................................................................................... 20

APPENDIX B: DIRECTIONS FOR COMPLETING THE WELDING PROCEDURE

APPENDIX C: REQUIREMENTS FOR DUPLEX STAINLESS STEEL WELDING,

SASOL SPECIFICATION SP-90-02

WELDING OF METALLIC PIPING

1.2 LEGAL REQUIREMENTS

This specification is governed by the law of contract.

a. The purchase order, including terms, conditions and legal requirements

AFC Approved for Construction

AIA Approved Inspection Authority

FCAW Flux Cored Arc Welding

FCAW-G Flux Cored Arc Welding - Gas Assisted

GMAW Gas Metal Arc Welding

GTAW Gas Tungsten Arc Welding