Hindustan Urvarak and Rasayan Limited Barauni & Sindri: Job Specification For Supply Pipe and Piping Components
Hindustan Urvarak and Rasayan Limited Barauni & Sindri: Job Specification For Supply Pipe and Piping Components
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DOCUMENT CATEGORY
܆ INFORMATION – Class 1
܈ REVIEW – Class 2
ISSUED FOR
܈ OWNER
܆ INTERNAL- CONSORTIUM
܆ INTERNAL-TECHNIP-FMC
܆ INTERNAL - LTHE
Arunkumar Jayapal
2018.08.27 19:40:56
Bruno Martin Venkataraman
Krishnamoorthy
+02'00' 2018.08.27 2018.08.28 08:40:30 +02'00'
19:43:34 +02'00'
A 28/08/18 IFQ – ISSUED FOR QUOTATION J ARUNKUMAR B. MARTIN K VENKATARAMAN
Rev Date STATUS WRITTEN BY CHECKED BY APPROVED BY
DD/MM/YY (name & visa) (name & visa) (name & visa)
DOCUMENT REVISIONS
Sections changed in last revision are identified by a vertical line in the margin
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HOLDs
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CONTENTS
1. INTRODUCTION 5
4. PURPOSE 7
6. MATERIALS 8
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1. INTRODUCTION
Government of India has formed a joint venture company of M/s NTPC Ltd., M/s Coal India Limited
(CIL), M/s Indian Oil Corporation (IOCL) & FCIL/HFCL by name M/s Hindustan Urvarak &
Rasayan Ltd. (“HURL”) hereinafter also referred to as “OWNER”, for setting up Ammonia Urea
Fertilizer Complex along with its associated offsite & utility facilities at the 2 following locations:
• Barauni, Bihar, India.
• Sindri, Jharkhand, India.
The 2 Ammonia & Urea Plants will each be having a capacity of 2200 MTPD & 3850 MTPD
respectively (“PROJECT”).
The consortium of TECHNIP France and TECHNIP India limited, India (Collectively “TECHNIP),
and LARSEN & TOUBRO Hydrocarbon Engineering Limited, has been awarded contracts for the
PROJECT covering the following activities:
• Process Licenses;
• Basic Design and Detailed Engineering;
• Procurement, Catalyst Supply;
• Construction;
• Pre-Commissioning, Commissioning, Start up;
• Sustained load test, Performance Guarantees test.
• VENDOR means a Company/Agency with whom CONTRACTOR has entered any Purchase
Orders to supply equipment or material for the Project
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• SUBCONTRACTOR means any party with whom CONTRACTOR has entered any
subcontract.
3. REFERENCE DOCUMENTS
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4. PURPOSE
The specification covers minimum technical requirements for procurement of pipe and piping
components be used for 077625C - HURL project BARAUNI and SINDRI.
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5. ORDER OF PRECEDENCE
In case of conflict between requirements specified herein and the requirements of any other
referenced document, the order of precedence shall be:
Material requisition,
Ident/Commodity code description (if any),
This specification,
Referenced codes and standards
6. MATERIALS
Materials shall be according to the requirements indicated in the ITEM DESCRIPTION shown in the
Material Requisition, in the relevant "DETAILED SUPPLY SPECIFICATIONS’’ and in any
reference document. In any case, the SUPPLIER shall notify PURCHASER of all conflicts among the
aforesaid documents.
Post weld heat treatment (PWHT)
Unless otherwise heat treatment is specified all welds shall, as a minimum, be PWHT in accordance
with the material groupings and thickness ranges defined in ASME B31.3. Any required NDE
examinations shall be executed after the final PWHT.
Indian Boiler Regulation (IBR)
For all materials specified as IBR (Indian Boiler Regulation) in the ITEM Description, the
requirements of Indian Boiler Regulation shall be followed.
Piping systems for Steam and Boiler Feed Water are subject to the requirements of the Indian Boiler
Regulation (IBR).
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IBR piping components, irrespective whether fabricated inside or outside India, shall be fully in
compliance with the requirements of the IBR code (latest edition) in design, inspection, erection and
certification. It is SUPPLIER’s responsibility to comply in full with the requirements of the IBR and
to obtain all the required approvals and certification.
For carbon steel Pipes, Fittings and Flanges under IBR the chemical composition shall conform to
the following:
Carbon (Max) 0.25 %
Others (S, P, Mn) As prescribed in IBR regulation
The chemical composition as indicated in this clause is not applicable for pipes other than IBR
services.
• Pipes under purview of IBR shall be accompanied with IBR certificates in form IIIA, duly
approved and countersigned by IBR authority/local authority empowered by central boiler
board of India.
• Flanges and Fittings under purview of IBR shall be accompanied with IBR certificates in
form III-C, duly approved and countersigned by IBR authority/local authority empowered
by central boiler board of India
Alloy piping components with weld ends (i.e. socket ends and bevel ends) shall have the following
final minimum mill tempering temperature:
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For all alloy steel welded piping components, the required carbon content of the weld filler metal
shall be equal or greater than 0,05 C wt.
Dual Grade or Dual Marked Stainless Steel (e.g. 316/316L) shall be supplied provided that the chemical
and mechanical properties comply with the requirements of both grades.
For austenitic stainless steel 300 series “H Grade” (with min carbon content 0,04%), high carbon
electrodes /wires with 0.04 to 0.08% Carbon shall be used. Filler metal shall be selected to produce weld
deposit that fall within the ferrite number (FN) range of 4-8 as determined by the WRC (Welding
Research Council) diagram which is included in AWS A-5.4
For all items of stabilized SS grades, resolution annealing shall be done. lt shall be carried out subsequent
to normal resolution annealing. Soaking temperature and holding time for stabilizing heat treatment
shall be 900 deg. Celsius and four hours
All stainless-steel fittings shall undergo Inter-Granular Corrosion (IGC) test to ASTM A262 practice
“B” & acceptance criteria shall be that the corrosion rate shall not exceed 48 mils/year. Two sets of
samples shall be drawn from each heat treatment lot, one set corresponding to highest carbon content
and other set corresponding to highest wall thickness of the fittings.
Austenitic stainless steel flanges shall undergo Inter Granular Corrosion (IGC) test to ASTM A 262
practice 'B' and acceptance criteria shall be that the, corrosion rate shall not exceed 48 mils per year.
Two sets of samples shall be drawn from each heat treatment lot, one set corresponding to highest carbon
content and other set corresponding to highest rating / thk.
Urea grade stainless steel.
For all stainless-steel material specified as “Modified Urea Grade Material” in the item description
requirements shall be as per the Technical notes – Urea Grade Piping Material (Refer Attachment
1).
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6.2 Pipes
6.2.1 General
The material type, specification and grade shall be strictly in accordance with the standards referred
to this specification. All materials shall be new materials with all surfaces clean and free from defects,
weld spatter, arc strike, rust, dirt, sand, scale, paint or any other foreign substance.
• For carbon and alloy steels, diameters and wall thicknesses shall conform to ASME
B36.10M where applicable.
• For austenitic stainless steels, duplex stainless steels and nickel alloys diameters and wall
thicknesses shall conform to ASME B36.19M where applicable, otherwise ASME B36.10M
is applicable.
Dimensional tolerances shall be within the limit specified in the applicable material
standards(ASTM/API).
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Stainless Steel Welded Pipes which refer to ASTM A358 shall be Class 1, as indicated in the relative
ITEM DESCRIPTION.
However, Class 3 (single welded) is acceptable instead of Class 1 (double welded) only for thickness
thinner than 10 mm. In this case, Supplier will precise at bid stage, if the pipe is Class 3 instead of
the required Class 1.
Film of examination is mandatory. Radioscopy is not accepted in lieu of Radiographic examination.
Welded Pipe not referenced in ASME B31.3 or ASME Div. II part D (e.g. ASTM A358 Grade
317/317L) shall have the same mechanical properties (yield strength and tensile strength) of
applicable plate specification (e.g. ASTM A240 Grade 317/317L) at room temperature and at the
maximum design temperature. If SUPPLIER has not data relevant to the required mechanical
properties, a hot tensile test at the maximum design temperature is required. The hot tensile test shall
be performed with a procedure that shall be agreed with Purchaser.
6.3 Fittings
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All welded fittings shall be normalised for CS, normalised & tempered for AS; and 100%
radiographed by X-ray for all welds made by fitting manufacturer as well as for welds on the parent
material. Bevel ends of all BW fittings shall undergo 100% MP/DP test
At the exception of miter bends, fabricated tees, elbows and other fittings employing circumferential
or intersection welds are considered pipe fabrications, and are not acceptable.
All pipes employed for manufacturing of fittings shall be required to have undergone Hydro test to
ASTM A530 to the extent so as to produce wall stress of 75% of SMYS of the material.
Fittings with diameter over 60":
Large diameter fittings that the material standards(ASME) do not cover in size or shape shall be
designed in accordance with ASME B31.3 and be manufactured to have the same quality as the
requirements of the applicable material standards. Design of fittings should be established according
to ASME B16.9 paragraph 2.2 (mathematical analysis or proof test).
Tolerances shall be the same as those specified for fittings of 48” diameter. Cross sectional drawing
or catalogue drawings shall be supplied for all these items.
For intermediate diameters not covered by MSS-SP-75, SUPPLIER shall guarantee the end-to-end
dimension of the next larger fittings.
Concentric and eccentric reducers produced as a conical shape are permitted only for sizes larger
than 48”.
Welded fittings
Welded stainless steel and nickel alloy fittings shall be Electric Fusion Welded according to ASME
B31.3 unless otherwise specified.
Welded tees
Welded tees made by joining sections of pipe are not acceptable. When tees are fabricated from plate
the weld seams shall be parallel to the axes of both the run and the branch.
Wall thickness of elbows:
Wall thickness of elbows shall not be in excess of more than 15 % of the specified wall thickness.
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The threaded portion of the galvanized fitting shall be protected from the galvanizing process.
No welding as weld repair is acceptable.
6.4 Flanges
All flanges shall be of forged one piece material (seamless), and plate may not be substituted without
written approval from the Purchaser.
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6.5 Gaskets
All gaskets material shall be asbestos free.
Non-metallic Flat gasket:
Dimensions shall be in accordance with ASME B16.21
Diameters 26” to 60” shall conform to ASME B16.47 B or ASME/AWWA C207 – Class D (only
for water service) according to Item description
Thickness shall be 2 mm, all diameters
Full faced gasket shall have bolt hole punched out.
All gaskets shall be treated antistic both sides for the full range of temperature they are designed
to be used
Large flat gaskets made with several bonded segments are allowed only after Purchaser approval
6.6 Bolting
Stud bolts shall be threaded full length and chamfered both ends. Length tolerance shall be in
accordance with the requirement of table F2 of Annexure 6 of ASME B16.5
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The nuts shall be double chamfered, semi-finished, heavy hexagonal type and shall be made by
the hot forged process.
Heads of jack screws and M/C bolts shall be heavy hexagonal type. Jack screw end shall be
rounded.
Threads shall be unified (UNC for; 1" dia and 8UN for> 1" dia) as per ASME B1.1 with class 2A
fit for Studs, M/C Bolts and jack screws, and class 2B fit for nuts.
Length for standard flange assembly shall be in accordance with ASME B16.5 (length of stud-
bolt does not include the height of the points, whatever is the thread).
Length for special flange assembly (eg. Wafer valve, spectacle blind, …) is specified in the
Material Requisition
Stud bolts shall be supplied with 2 Heavy Hex nuts.
Machine bolts shall conform to ASME B18.2.1 Heavy Hex head and shall be supplied with 1
Heavy Hex nut and Nuts shall conform to ASME B18.2.2
Tops and Bearing Surface of Nuts in size 5/8-inch nominal size and smaller shall be double
chamfered. Larger size nuts shall be double chamfered or have washer faced bearing surface and
chamfered top.
When an external coating is required (galvanisation, ceramic, …) coating thickness must be
included in the final dimensions such as defined in the applicable standard.
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Transverse tension test shall be carried out on pipes of nominal size 8” and above and thickness of
Sch.120 and above as per supplementary requirements of respective standards.
Check analysis shall be carried out as per ASTM-A-530 for pipes as per ASTM-A-312 and pipe size
> 8” and thickness > Sch.120, Check analysis shall also be carried out as per supplementary
requirement S1 of ASTM-A-312.
For seamless pipes, each length of pipe with following specifications shall be ultrasonically tested as
per ASTM E 213 or ASTM A 388.
(a) Size up to 4 inches and Sch. > 120
(b) Size > 5 inches and thk. > 12 mm.
Any defects producing signal greater than the appropriate reference groove shall be unacceptable.
The allowable defect shall be longitudinal flat bottom groove on the outside or inside surface of the
pipes and length not greater than 25 mm, width not greater than 1.6 mm and depth not greater than
the smaller of 1 mm or 5% of the wall thickness.
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- thickness
- diameters
- bevel threaded dimensions
- roundness
- straightness
- end to end dimensions
- flange facing
- bolt hole
- diameter of bolt circle and number of holes
These Documents shall be supplied for ALL welded materials, also if not required in the others
referenced Detailed Supply Specification.
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8. DOCUMENTATION
The Material Requisition defines the documentation to be delivered by the SUPPLIER.
Documentation will clearly mention SUPPLIER’s name, Project identification and Material
Requisition number.
MATERIAL DOCUMENTATION SHALL BE CONSIDERED AS AN INTEGRAL PART OF
THE SUPPLY.
Material Certificates:
Traceability and proper identification of all materials is required.
All materials shall be supplied with their relevant original certification covering mechanical and
chemical properties.
Certification shall include the certificate of the raw material.
All certificates shall be issued in English language.
Certificates shall represent the material in the final condition, or at least in a condition after operations
which can affect any of the properties being reported.
Type of inspection documents shall conform to EN 10204:
Material certificates
3.1 For all metallic components including bolting materials, RTJ gaskets and
Galvanised piping
2.2 For other metallic gaskets
2.1 for all non-metallic components and malleable iron threaded fittings
Test certificates
3.1 Pressure tests and non-destructive tests.
Mill test certificates indicating the following and duly signed by the inspecting authority along
with supply of materials
- Purchase order no.
- Material test certificates (Material specification, grade, physical property, chemical
composition & heat treatment report) shall also be furnished for the flanges supplied.
- Size and Sch. No. /thickness
- Quantity
- Heat and lot no.
- Results of Chemical analysis
- Mechanical test results (as per applicable Clause).
- Results of impact test where applicable.
- Non-destructive test results (as per applicable clause)
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IBR Documentation
Pipes: Pipes meant for steam service shall be supplied with 3 copies of I.B.R. certificates in Form
IIIA duly signed by IBR inspecting authority along with supply of materials. In addition 8 copies
shall be sent to Owner / Contractor for final compilation.
Fittings: Fittings meant for steam service shall be supplied with 3 copies of I.B.R. certificates in
Form IIIC duly signed by IBR inspecting authority along with supply of materials. In addition 8
copies shall be sent to Owner / Contractor for final compilation.
Flanges: Flanges meant for steam service shall be supplied with 3 copies of I.B.R. certificates in
Form IIIC duly signed by IBR inspecting authority along with supply of materials. In addition 8
copies shall be sent to Owner / Contractor for final compilation.
9. MARKING
9.1 General
Marking shall conform to requirements of the Material Requisition
Marking may be applied by stencilling on ferrous materials with a thickness less than 5 mm,
austenitic stainless steel below 10 mm, and all nonferrous materials.
When stencilling is not used, marking shall be applied by low-stress hard-die stamping on a painted
background, unless otherwise approved by Purchaser.
Low-stress stamps shall be round nosed with a radius of 0.25 mm minimum. Casting shall have the
charge or heat number cast in the material. The other required markings also to be cast-in, in an order
of preference.
As a minimum, marking shall be in accordance with:
Requirements of the applicable standard,
MSS SP 25 for other materials than pipe,
Purchaser Ident Code
Purchaser Ident code can be omitted for components of nominal size 1 ½” and smaller provided
marking is transferred on the packing box
Colour code for piping identification shall be confirm to 077625-C00-JSD-2310-0001_RevA for
TechnipFMC and confirm to 077625-C00-PP-0000-5505 for LTHE.
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Carbon and alloy steel pipes (excluding stainless steel or higher alloys and galvanized steel) shall be
protected by mill finish products.
SUPPLIER shall use an easily removable rust preventive compound, that can guarantee the shipment
and 1 year of outdoor storage without detrimental effect, taking into account the type of transport
and site climatic conditions.
Stainless steel and nickel alloy pipes shall be protected from ferritic contamination and chloride
attack such as might occur from exposure to sea water or sea water spray by means of jute, plastics,
etc.
Protection for bevel ends shall be agreed with the Purchase Order. Rust preventive shall not
detrimental to welding.
Rust preventive on machined surfaces to be welded shall be easily removable with a petroleum
solvent, and the same shall not be harmful to welding.
After inspection and before dispatch, flanges and fittings shall be thoroughly dried and cleaned. All
flanges except SS flanges shall be coated with hard film type of rust preventive to protect against
rusting during transit and storage
10.1 Pipe
Threaded or beveled ends of pipes shall be protected with plastic, metal or wood covers.
SUPPLIER shall ensure adequate protection from damage during shipment to any coating and
wrapping on pipes.
For large diameter pipes, in particular when thin wall manufactured, SUPPLIER shall provide
suitable reinforcements to avoid buckling and ends ovalization.
The smaller pipes may be bundled together but limited to the same item code number.
10.2 Fittings
Arrangement will avoid water retention (particularly for elbows).
10.3 Flanges
Machined surfaces shall be protected with an easy removable rust preventive compound, or by
strippable products. In addition, flange facings shall be duly protected from damage during shipping
and storage, using suitable packing and heavy-duty plastic or wood flange facing protectors.
Each couple of orifice flanges shall be shipped complete with bolts and plugs, and assembled with
gasket contact surface protected by suitable packing.
10.4 Gasket
Packed in closed box
10.5 Bolting
Packed in closed box and protected by a non-corrosive oil or grease
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11. ATTACHMENTS
1. TECHNICAL NOTES – UREA GRADE PIPING MATERIAL.
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ATTACHMENT – I
TECHNICAL NOTES – UREA GRADE PIPING MATERIAL
1.0 GENERAL
This specification covers the requirements for austenitic stainless steel materials and
relevant welds in contact with the process fluid in the high-pressure section of urea
plants. These requirements shall be considered in addition to the ones of the codes and
standards applicable to the product in question (equipment, piping components, plates,
materials, testing, etc.). In case of conflict with any of the above standards, this document
prevails.
1.1.2 This specification takes into consideration both the 316L UG stainless steel (UNS
S31603) and the 25Cr-22Ni-2Mo type stainless alloy (UNS S31050).
1.2 Definitions
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1.3 ABBREVIATIONS
ASME Sect. VIII Boiler and pressure vessel code - Pressure Vessel
ASME Sect. IX Boiler and pressure vessel code- Welding
and Brazing qualifications
ASME Sect.V Non Destructive Examination.
ASME Sect. II Part C Specification for welding rods, electrodes and filler
metals
EN 10204 Metallic materials - Types of inspection documents
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2.0 MATERIALS
2.1 General
2.1.1 The list of suppliers and sub-vendors of plates, forgings, bars, piping and tubes for High
Pressure Urea equipment and piping to be operated in contact with the urea process
fluid shall be submitted to OWENER/PMC for acceptance.
2.1.2 All semi-finished products shall be supplied in the solution annealed condition. No
heating over 400 °C shall be allowed during machining or any other manufacturing
activity, except welding. If heating above 400 °C cannot be avoided, a new solution
annealing heat treatment shall then be performed and new samples shall be taken and
tested as described in para 4.
2.1.3 If, after solution annealing heat treatment, forgings or bars are submitted to machining
and more than 5 mm depth is removed from the side in contact with the process fluid, then
a new solution annealing heat treatment is required except for the 25Cr-22Ni-2Mo alloy
provided that the samples taken after machining satisfy the test requirements as per para
4.
2.1.4 All tubes and pipes shall be seamless type. For welded fittings, special requirements
of welding have to be pre-approved by OWNER/PMC.
2.1.5 Cast parts and rod bars are not permitted unless approved by OWENER/PMC.
2.1.6 When 316L UG material is required, the use of 25Cr-22Ni-2Mo material is allowed as
an alternative.
2.2.1 Stainless steel 316L UG type shall be in accordance with the ASME-(SA) specifications
applicable to the relevant semi- finished products; it shall also meet the additional
requirements detailed in para 3 and 4.
2.3 25Cr-22Ni-2Mo alloy (UNS S31050)
2.3.1 Stainless steel 25Cr-22Ni-2Mo type shall be in accordance with the ASME-(SA)
specifications applicable to the relevant semi- finished products; it shall also meet the
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In the following paragraphs the chemical or additional chemical requirements for 316
UG stainless steel and 25Cr-22Ni-2Mo alloy are reported. Any deviation from these
requirements shall be subject to OWNER / PMC acceptance.
The 316L UG stainless steel base material shall have the following additional
chemical requirements:
C = 0.020 % max.
P = 0.015 %max.
S = 0.010 % max.
Ni > 13%
N = 0.10 % max.
The carbon content restriction above does not apply to forgings provided no
welding is performed after the solution annealing heat treatment, not even for installation
purposes.
The 25Cr-22Ni-2Mo stainless steel base material shall have the following chemical
Composition:
Cr = 24 ÷ 26 % C = 0.020 % max.
Ni = 21 ÷ 23.5 % P = 0.020 % max.
Mo = 2 ÷ 2.6 % S = 0.010 % max.
Mn = 1.5 ÷ 2.0 % Si = 0.40 % max.
N = 0.10 ÷ 0.15 % B = 0.0015 % max.
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3.1.3 W.O. deposit shall meet the following requirements for a depth of at least 3 mm from
the ʊas welded ۅor machined surface:
Cr eq = % Cr +% Mo +1. 5 % Si
Ni eq = % Ni +30 % C +0. 5 % Mn
3.1.4 Chemical analysis at depth of 1 mm and 2 mm shall also be performed and reported
for information.
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3.2.1 Short Time Tensile Test shall be performed/ certified at the design temperature for each
heat of Urea Stripper heat exchanger tubes.
3.2.2 If the design is carried out in accordance with ASME code BPVC section VIII, for
forgings the code itself shall be applicable with reference to CODE CASE 2038.
3.2.3 For other requirements, the relevant material/ product SA (ASME) specification shall
be applied.
PLATES One sample for each heat One sample for each plate
One sample form each lot of One sample form each lot of no more than
PIPING, FORGING no more than 50 pieces of 50 pieces of each heat and same heat
each heat and same heat treatment (1)
treatment (1)
One sample form each lot even if of no
BOLTS, NUTS, One sample for each heat more than 50 pieces of each heat and
SMALL-SIZE same heat treatment (1) for bolts, nuts, and
FORGING forgings of small size (Dia.219.1mm )
One sample form each lot of 200 pieces of
EXCHANGER TUBES One sample for each heat
each heat and same heat treatment (1)
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4.2.1 Samples for corrosion tests and micro structural examination shall be taken as per
the above table (base material) and from each weld test during the welding procedure
qualification. Overheating shall be avoided when cutting the specimens (thermal-cutting
is not allowed). Each sample shall be marked, by stamping, with proper identification
traceability number.
4.2.2 The area of each sample shall be of 180 cm2 as a minimum (if not otherwise specified
in this document) and shall permit to take out with sufficient allowance the following
specimens:
4.2.3 Each specimen shall include the side that will be in contact with the process fluid if
known (consequently liner plates shall then be installed by exposing to the process fluid
the side that has been actually tested with positive results). Specimens for the corrosion
test shall have an area of approximately 30 - 32 cm2, weight of 40 g minimum (100 g
maximum) and, when feasible, an approximately rectangular shape with dimensions of
about 50 x 25 x 5 mm.
4.2.4 In the case of plates with thickness over 7 mm, the specimen shall be reduced to 5 mm
by machining material in excess on the opposite side from that (those) in contact
with the process fluid (avoiding overheating).
4.2.5 In the case of tubes with outside diameter less than 30 mm, the sample shall have
a cylindrical shape. In the case of tubes or pipes with outside diameter 30 mm, the
sample shall be taken with length "a" approximately equal to arc "b".
4.2.6 If the pipe or tube thickness is over 7 mm, the specimen thickness shall be reduced to
5 mm by machining material in excess on the opposite side from that (those) in contact
with the process fluid (avoiding overheating).
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4.2.7 In the case of forgings or bars, if it is not possible to take a sample with the surface to be
in contact with the process fluid, the sample shall be taken from the core of the forging
bar. Test specimens shall be taken from the forging extension or by a representative
specimen with the same heat and heat treatment having maximum treated thickness
size of those forgings.
4.2.8 In the case of special pieces (valves, thermocouples, fittings, instrument separators, etc.)
the supplier shall submit to OWNER / PMC for acceptance an overall drawing showing
the location of the sample(s).
4.2.9 In the case of welding procedure qualification tests for SAW / ESW / SMAW weld
overlay (see Attachment 1) three samples shall be taken:
- sample S1 (Attachment 2) which shall include at least 2 bead overlap of adjacent beads
- sample S2 (Attachment 3) which shall include stop and restart point of a bead
- sample S3 (Attachment 4) which shall include beads deposited by manual welding
with SMAW and/ or GTAW on the automatic overlay, simulating repair if any.
4.2.10 The specimens obtained from each of the above samples shall be used as follows:
- specimen(s) labeled “A” are to be used for metallographic analysis (one is for re-
testing if required)
- specimen(s) labeled “B” are to be used for corrosion test
- specimen labeled “B1” is to be used for corrosion re-testing if required
- specimen labeled “C” is to be used for macro graphic examination
- specimen labeled “D” is for chemical check analysis.
4.2.11 In the case of welding procedure qualification tests for additional automatic GTAW weld
overlay on liner plates or SAW / ESW / SMAW weld overlay, a sample of S1 type including
at least 2 bead overlap of adjacent beads (see Attachment 2) shall be taken out.
4.2.12 In the case of welding procedure qualification test for butt joints, the sample shall be as
wide as the face of weld in contact with the process fluid plus 12 mm (6 mm each side)
and 5 mm thick (see Attachment 6).
4.2.13 In the case of procedure qualification tests for welds between tube and tube-sheet, no. 2 mock-
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up shall be prepared. From the first one the specimens for corrosion test and
metallographic examination shall be obtained and they shall include 3 tubes in central position.
One central tube shall be used for the corrosion test, one shall be used for the metallographic
examination, one is for re-testing, if required (see Attachment 7 for details). The second mock-
up shall be prepared following Attachment 9 and it will be subject only to the flaw assessment
test as detailed in para 4.5.
4.2.14 The metallographic examination of the first mock-up shall be performed on the central
tube assembly previously longitudinally sectioned following 4 perpendicular directions
starting from the second weld pass stop as follows:
a) on 4 of the 8 surfaces obtained from the sectioning a macro graphic examination shall
be performed in order to determine the extension of weld fusion (which shall not exceed
at any point 75 % of wall tube thickness), weld throat thickness (minimum weld throats of
all sections shall be not less than the specified tube wall thickness) and penetration.
b) the 4 remaining surfaces shall be used for the microstructural examination (one surface
for each of the 3 required etchings plus one for re-testing if required).
4.2.15 The surface to be in contact with the process fluid and the opposite one if not machined
shall remain in the "as received" condition.
4.2.16 The specimens shall not be subjected to any heat treatment before the test.
4.2.17 The remaining part of each sample after taking out the specimens, with the identification
number, shall be made available for five years (ex-work delivery) at Supplier‘s care for further
OWNER / PMC investigation.
4.2.18 All tests described below (macro graphic and micrographic examination, corrosion test,
flaw assessment, etc.) shall be performed and certified by a laboratory approved by OWNER
/ PMC. Laboratory shall officially inform OWNER / PMC about any inconvenience (e.g.
deviations from the material requirements etc.) encountered during the tests as well as in case
of re-testing.
4.3 MICROSTRUCTURE EXAMINATION
4.3.1 The material (base, welds and weld overlay) used in contact with the process fluid shall
be subject to metallographic analysis following the methods detailed below. 3 (three)
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metallographic specimens, each for any required etching, shall be obtained from each of
the sample(s) as detailed in para. 4.2.2 and 4.2.10. A fourth specimen shall be retained for
retesting (if required). The re-use of the same metallographic specimen for two or more
different etchings is not allowed.
4.3.4 The material microstructure shall be determined following ASTM A262 Practice A. Only a
fully austenitic step structure as defined in the above standard shall be considered
acceptable. The presence of any structure other than the step structure (e.g. ditch
structure, interdendritic ditches, end-grain pitting type I or II) is not allowed.
4.3.5 Presence of sigma phase shall be checked at 100x and 500x after electrolytic etching
with NaOH 10N at 3 V and 0.5 to 1 A/cm2 for 2 to 5 sec. Sigma phase shall be absent.
4.3.6 An etching with oxalic acid (10%, 6 V DC, 0.5 - 1 A/cm2, 15 sec.) shall be performed and
the specimen shall be examined at 100x and 500x. Presence of any intergranular or
intragranular compounds or phases other than the austenitic phase is not allowed
whatever their composition might be and irrespective of their quantity, with the exception of
the ferrite phase within the limits stated in para. 4.3.3.
4.3.7 The material not in compliance with the above requirements shall be rejected.
4.4.1 The corrosion test, Huey type, shall be performed on the sample material that already resulted
acceptable after the microstructure examination detailed in para 4.3.
4.4.2 AISI 316L UG specimens shall be subjected to 5 test periods and the acid shall be renewed
each time. Each period shall last 48 hours actual boiling. 25Cr-22Ni-2Mo alloy shall be
subjected to 10 test periods at the same conditions as above.
4.4.3 The corrosion test shall follow the ASTM A262 Practice C with the following additions:
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4.4.6 The ratio of the solution volume to the sample area shall be 20 ml/cm² as a minimum.
4.4.7 The flasks for Huey test shall be used only for this purpose.
4.4.8 The flask, refrigerator and specimen shall be carefully rinsed after each test cycle to remove all
the corrosion products (by means of a nonmetallic brush).
4.4.9 Before corrosion testing, the specimens shall be first degreased in acetone (chlorinated agents
are not allowed), pickled in boiling nitric acid (65%) for thirty minutes, and then rinsed;
the corrosion products shall be removed by nonmetallic brush.
4.4.10 After each test cycle and after rinsing, the specimens shall be dipped in acetone, dried by
hot air, and weighed (when cold).
4.4.11 The time between two cycles shall be as short as possible.
4.4.12 Besides the determination of the corrosion rate (for each cycle and for the overall periods)
obtained by weighting, it is also required to determine the maximum depth of attack by
examining under a microscope the edges of a specimen section (for details see note 5 of
table in para. 4.4.13)
4.4.13 The following table shows both the maximum corrosion rate and depth of attack allowed in
each test cycle and for the average of the results of all cycles, calculated according to ASTM
A262 Practice C:
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NOTES:
General: the above limits are valid for each test cycle and for the average of the result of all
cycles.
1. If the corrosion rate exceeds the rate specified in the table or if the corrosion rate in cycle
5 (cycle 10 for 25Cr-22Ni-2Mo alloy) exceeds the one in cycle 4 (cycle 9 for 25Cr-22Ni-
2Mo alloy) by more than 50%, a second specimen taken from the same sample under
examination shall be re-tested with the same procedure. Only the result of re-testing shall
be taken into consideration. Further re-testings are not allowed.
2. No deviations allowed.
3. The heat affected zone and the bead overlap zone (for W.O.) shall also be examined.
4. Any deviation shall be subject to OWNER / PMC acceptance.
5. Depth of attack shall be determined after completion of the corrosion test by taking a
metallographic sample from the most corroded area, if visible. The value shall be referred
to the deepest attack observed on both the transverse and the longitudinal directions of
the specimen
4.5.2 The tube protrusion shall be machined down until the contact between tube face and the
upper weld toe. This surface shall be recorded as starting test level. The examination shall
proceed on repeated plane at 1 mm distance from each other till the tube gets lose.
4.5.3 Each level shall be prepared for etching and examined under a binocular microscope
with magnification from x15 to x25.
4.5.4 The following table gives the number and extension of the allowable defects
4.5.5
Defect type Max. allowed number of defects (1) Max. dimensions allowed
Cracks (2) 0 -
Pores 5 0.6
Wormholes 0 -
Slag inclusions 2 0.6
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Fusion defects 2 2
Crater cracks 0 -
Burn through 0 -
Note 1: It is the sum of all defects found on 7 tube welds at all levels
Note 2: Any deviation shall be subject to OWNER / PMC acceptance
4.5.6 The weld fusion depth shall have a regular profile and its extension shall never exceed the
75% of the wall tube thickness at any point
4.5.7 No more than 1 defect per tube and per level is allowed. Any deviation shall be subject
to OWNER / PMC acceptance.
4.5.9 A photograph shall be taken on each surface (scale 1:1) showing defects location, type
and extension.
4.5.10 Certification of the flaw assessment test shall be in accordance with para. 4.6.
4.6 CERTIFICATION
4.6.1 The laboratory shall certify that the test results are in compliance or not in compliance with
the requirements of the present specification. The certification shall be made available
to OWNER / PMC as soon as the certificate is issued. Certification shall include the following:
4.6.2 A photograph(s) showing the samples as received; the identification stamping on the
sample(s) shall be clearly visible and readable.
4.6.3 The photomicrographs showing the material ‘s microstructure after each etching. The
photos shall be of high quality and fully readable (e.g. laser prints on photographic quality
paper, prints from photo negatives etc.). B/W or color photocopies are not acceptable.
4.6.4 The etching details, the magnifications employed and a short but comprehensive comment by
a metallurgy specialist shall be reported in each caption. The result of the ferrite check on
each specimen shall also be reported.
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4.6.5 The corrosion rates after each testing cycle and the average corrosion rate values shall
be reported.
4.6.6 As an option the testing certificate can be supplied in electronic (PDF) format provided
the above requirements are fully met.
4.6.7 OWNER / PMC reserves the right to require to the Supplier further testing or investigation
whenever OWNER / PMC acceptance is required or the laboratory results are controversial.
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