Reg.

360
Joints

a) These Regulations provide for ordinary bolted flange joints. Special types of joints may be used, subject to
the approval of the Chief Inspector.
b Arc welded butt joints of pipes or socket welded joints for pipes, valves and fitting
shall be made by metallic shielded arc process and post weld heat treated effectively
except in the following cases. 

For Carbon steel -

(i)                  The nominal wall thickness in case of butt joints does not exceed 20 mm
or carbon content does not exceed 0.25%;

(ii)                  The throat thickness of fillet weld for socket welded joints or other types
of joints does not exceed 20 mm or carbon content does not exceed 0.25%.

Note.- In case of carbon content for above cases lies between 0.25% < C � 0.30%, the
PWHT is not required for maximum thickness of 9mm.

For Alloy steel: -

(i)                   In case of 0.5 Molybdenum steel, if the thickness does not exceed 13mm and
outside diameter does not exceed 127mm and for any fillet welds, the throat
thickness does not exceed 13mm.

(ii)                 In case of 1 Chromium and 1/2 Molybdenum steel, if the thickness does not
exceed 13mm and outside diameter does not exceed 127mm and pre-heated to
125oC and for any fillet welds if the throat thickness does not exceed 13mm.

(iii)                In case of 2-1/4 Chromium 1 Molybdenum steel, post weld heat treatment is
not mandatory under the following conditions.

(1)           a maximum specified Chromium content of 3.0%.

(2)           a maximum nominal outside diameter of 102mm.

(3)           a maximum thickness of 13mm.

(4)           a maximum specified carbon content of  0.15%.

(5)           a minimum pre-heat temperature of 150oC.

(6)           a maximum throat thickness of 13mm in case fillet weld.

Method of Heat Treatment: -

(1)      For carbon steel, a stress relieving heat treatment shall be performed by heating the
part to at least 600�20oC. 

When required by the characteristics of the material, different temperatures may

be necessary to obtain proper stress relieving.  The part to be stress relieved shall be
brought slowly up to the specified temperature and held at that temperature for a period
proportionate on the basis of at least 2-1/2 minutes per millimetre of the maximum
thickness of the part (approximately one hour per twenty five millimetres of thickness)
and shall be left to cool in the furnace to a temperature which, for parts with thickness
greater than 20 millimetres, does not exceed 400 oC.  After withdrawal from the furnace,
the part shall be allowed to cool in a still atmosphere.

A temperature-time diagram of the stress relieving process shall be provided when

the Inspecting Authority requires it.

(2)      For alloy steel a stress relieving heat treatment shall be carried out on the basis of
the composition of the alloy as shown in the table below: -

Table

________________________________________________________________________
_____

Type of steel                                         Range of temperature                        Time at the

temperature

                                                                                                                                per 25mm
of thickness

                                                                                                                                of the
plate.__________

1 Cr 1/2 Mo                                           620oC   -  650oC                                    1 hour (1 hr.

min.)

1/2 Cr  1/2 Mo

------------------------------------------------------------------------------------------------------------
----

1 Cr 1/2 Mo                                           620oC  -  660oC                                       1 hour (1

hr. min.)

1.1/4 Cr 1/2 Mo

------------------------------------------------------------------------------------------------------------
----
 2.1/4 Cr 1 Mo                                        625oC -  750oC                                         1 hour (1
hr. min.)

________________________________________________________________________
___

Note.- This wide range for the post weld heat treatment temperature is necessary because
of the marked dependence of the mechanical properties of this steel on the tempering
temperature.  In production a definite temperature with a tolerance of �20oC would be
selected to ensure that the mechanical properties upon which the design was based are in
fact achieved.

Heat treatment shall be carried out by one of the following methods: -

(i) Local heating using portable muffle induction coil or other suitable heating
appliance. Particular care shall be taken to apply heat uniformly over the area to be
treated.  The use of procedure that does not provide adequate control for this purpose,
such as manual operation of gas torches, is not permissible.  The temperature shall be
maintained symmetrically over peripheral band of metal of a minimum width of three
times the width of the butt-welded preparation.  The temperature shall be measured by
thermocouples pinned, welded or otherwise suitably attached to the surface of the pipe
and, where necessary, protected from flame impingement.

(ii) Heating in stationary furnace:-  The temperature of the joint shall be measured by the
thermocouples so disposed within the furnace as to give a true measure of the joint
temperature.

In case the materials made to the foreign codes or standards are accepted under regulation 3(2)
(i), the method of heat treatment shall conform to that specified in the codes or standards.
Reg. 360
Joints

(c) Such Butt-welded joints conform to Fig 28.

(d) Tests on completed welds on pipelines:

(1) Classification

For the purpose of tests, pipelines shall be divided into two classes:-

Class II. - Pipelines for service conditions in which any one of the following limits is exceeded:-

Design temperature 218°C (425°F)

Design Pressure 17.6 kg/cm² (250 lbs/sq in)
Feed water 24.6 kg/cm² (350 lbs/sq in)
Class II. -Pipelines for service conditions in which none of the foregoing limits is exceeded.

2) Identification of Welds

The Welders’ identification mark shall be stamped without indentation, or stencilled adjacent to each
completed weld.
 (3) Tests for Class I pipelines

(i) Where the completed pipelines are not subjected to hydraulic test:

Where the completed pipelines are not tested by the application of hydraulic pressure, the welds shall be
subjected to the following inspection procedure:-

Piping over 102 mm. (4 in.) bore.-All butt-welds shall be subjected to non-destructive examination by
radiographic or other approved methods. The entire circumference of the first five welds made by each
welder shall be non-destructively examined. If these are found to be satisfactory and the Inspecting
Officer or Inspector is in other respects satisfied with the welding technique, methods of control and
supervision employed, relaxation in the extent of non-destructive examination may be considered, but
this relaxation shall in no case permit the non-destructive examination of less than one-third of the
circumference of each of the remaining welds made by the Welder concerned.

Piping 102 mm. (4 in.) bore and under, but not less than 38 mm. (1 ½ in.) bore.-Five percent of the
butt-welds made by each welder with a minimum of two welds per welder, selected at random shall be
subjected to non-destructive examination by either radiographic or other approved methods or may be
cut out for visual examination and bend tests.
Reg. 360
Joints

  Piping less than 38 mm. (1 ½ in.) bore.- Special tests are not normally required but two per cent of the
welds by each welder on a pipeline may be cut out from the pipeline for visual examination and bend
tests.

(ii) Where the completed pipelines are subjected to hydraulic test-

Where the completed pipelines are tested by the application of hydraulic pressure, the welds shall be
subjected to the following inspection procedure:-

Piping over 102 mm. (4 in.) bore.-Ten per cent of the welds made by each Welder on a pipeline with a
minimum of two welds per welder, selected at random, shall be subjected to non-destructive examination
by radiographic or other approved methods.

Piping 102 mm. (4 in.) bore and under, but not less than 38 mm. (1 ½ in.) bore.-Two per cent of the
welds made by each welder on a pipeline with a minimum of one weld per welder, selected at random,
shall be subjected to non-destructive examination by radiographic or other approved methods or may be
cut out for visual examination and bend tests.

Piping less than 38 mm. (1 ½ in.) bore.- Special tests are not normally required, but two per cent of the
welds by each welder on a pipeline may be cut out from the pipeline for visual examination and bend
tests.
4)Tests for Class II pipelines

(i) All pipelines under this classification shall be subjected to hydraulic test on completion of erection.
(ii) On completion of the first ten production welds made by each welder, one of the welds shall be cut
out for test purposes or alternatively, the welder shall prepare a test specimen made up of two similar
lengths of piping welded in a position as closely representative of a selected production weld as is
practicable. The test specimen shall be subjected to visual examination and bend tests.
(iii) Two per cent of the remainder of the welds made by each welder shall be selected at random and
cut out for test purposes, or, alternatively, the welders shall prepare a test specimen made up of two
similar lengths of piping welded in a position as closely representative of a selected production weld as
is practicable. The test specimen shall be subjected to visual examination and bend tests.
(iv) Notwithstanding anything contain in sub-clause (ii) and (iii), the bend tests shall be dispensed with in
case the welds have been non-destructively tested in the following manner:-

A. Piping over 102mm (4 in.) bore:-Five per cent of the welds made by each welder     on a pipeline
with a minimum of two welds per welder, selected at random shall     be subjected to a non-destructive
examination by radiographic or other approved     methods.
 B. Piping 102mm (4 in.) bore and under – One per cent of the welds made by each     welder on a
pipeline with a minimum of one weld per welder, selected at random     shall be subjected to non-
destructive examination by radiographic or other     approved techniques.”
  5) Re-tests

  If any test specimen is unsatisfactory, two further weld specimen for re-test shall be selected from the
production welds and subjected to tests. In the event of failure of any of the re-test specimens, the
production welds carried out by this welder subsequent to the previous test shall be subject of special
(e) consideration.

   Socket weld joints:-Socket weld joins may be used with carbon and low alloy steel pipes not
exceeding 60.3 mm outside diameter. Such welds shall not be used where fatigue, severe erosion or
  crevice corrosion is expected to occur. The working pressure of the socket weld fittings shall be
determined in accordance with equation 91 (regulation 350). The thickness of the socket weld fittings
shall not be less than 1 ¼ times the nominal thickness of pipe. The material shall be compatible with the
  associated piping.

(f)
All butt welded joints shall be subjected to non-destructive examination by
radiographic, radioscopy or other approved methods such as ultrasonic testing,
magnetic particle inspection or liquid dye penetrant inspection.  When radioscopic
examination is to be performed in lieu of radiography on welded components, the
following requirements shall be met:

(1)     A written procedure shall be submitted for approval to the Inspecting Authority
which shall contain the following:-

(i)       material and the thickness range;

                    (ii)      equipment qualifications;

(iii)     test object scan plan;

(iv)      radioscopic parameters;

(v)             image processing parameters;

(vi)                 image display parameters;

(vii)               image archiving requirements;

(viii)               accept-reject criteria (Code reference);

(ix)                performance evaluation;

(x)               Operator identification.

(2)     The system shall be aided with an image processor to enhance the quality of the
radioscopic images and system performance quality shall exhibit-

(i)                  a thin section contrast sensitivity of 3%;

(ii)                 a thick section contrast sensitivity of 2%;

 (iii)               a spatial resolution of 3 line pairs per mm;.

(iv)               IQI sensitivity - 2% of the joint thickness when wire IQI's are to be

used, the wire diameter axis shall be oriented along the axis of the least
sensitivity of the system.

(3)     Radioscopes are to be properly marked to co-relate with particular part of joint

represented.

(4)     The radioscopic examination data shall be recorded and stored on videotape,

magnetic disk or optical disk at the maker's plant for a sufficient period after the
date of radioscopic examination as specified by the Inspecting Authority, Efficient
radioscopic examination record recall shall be made available at any time over the
record retention period and shall be traceable to the test objects.

(5)     When repair has been performed as a result of radioscopic examination, the

repaired areas shall be re-examined using the same radioscopic technique to
evaluate the effectiveness of the repair.

(6)     To aid in proper interpretation of the radioscopic examination data, the details of
the technique used shall accompany the data.  As a minimum, the information shall
include the approved procedure requirements and system performance test data