Spec - 2019-02 - A00 - WELDING OF METALS BASED ON ISO STANDARDS

DEP SPECIFICATION
WELDING OF METALS, BASED ON ISO STANDARDS

Copyright Shell Group of Companies. No reproduction or networking permitted without license from Shell. Not for resale
DEP 30.10.60.32-Gen.
February 2019
DESIGN AND ENGINEERING PRACTICE
DEM1
© 2019 Shell Group of companies
All rights reserved. No part of this document may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior
written permission of the copyright owner or Shell Global Solutions International BV.
This document has been supplied under license by Shell to:

SAMSUNG ENGINEERING CO., LTD. [email protected] 13/05/2020 03:23:17
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PREFACE
DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions
International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and
maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international,
regional, national and industry standards.
The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and
gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help
achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
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locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
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quality of their work and the attainment of the required design and engineering standards. In particular, for those
requirements not specifically covered, the Principal will typically expect them to follow those design and engineering
practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or
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a Service Agreement or otherwise).
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which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said
users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims
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All administrative queries should be directed to the DEP Administrator in Shell GSI.

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TABLE OF CONTENTS
1. INTRODUCTION ........................................................................................................ 5
1.1 SCOPE ....................................................................................................................... 5
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 5
1.3 DEFINITIONS ............................................................................................................. 5
1.4 CROSS-REFERENCES ............................................................................................. 7
1.5 SUMMARY OF MAIN CHANGES............................................................................... 7
1.6 COMMENTS ON THIS DEP ....................................................................................... 8
1.7 DUAL UNITS............................................................................................................... 8
1.8 NON NORMATIVE TEXT (COMMENTARY) .............................................................. 8
1.9 PRECEDENCE OF DOCUMENTS............................................................................. 8
2. QUALITY PROGRAM ................................................................................................ 9
2.1 GENERAL ................................................................................................................... 9
2.2 PERSONNEL COMPETENCIES ................................................................................ 9
2.3 INSPECTION AND TEST PLAN................................................................................. 9
2.4 DEVIATIONS ............................................................................................................ 10
2.5 FINAL ACCEPTANCE .............................................................................................. 10
3. GENERAL REQUIREMENTS .................................................................................. 10
3.1 WELDING PROCESSES .......................................................................................... 10
3.2 MATERIALS.............................................................................................................. 11
4. WELDING PROCEDURE PREPARATION AND QUALIFICATION ....................... 13
4.1 GENERAL ................................................................................................................. 13
4.2 PREVIOUSLY QUALIFIED PROCEDURES ............................................................ 13
4.3 PROCEDURE DOCUMENTATION .......................................................................... 14
4.4 ESSENTIAL VARIABLES ......................................................................................... 14
4.5 WELDING PROCEDURE QUALIFICATION TESTING............................................ 14
5. WELDER QUALIFICATION ..................................................................................... 18
5.1 GENERAL ................................................................................................................. 18
5.2 WELDER IDENTIFICATION ..................................................................................... 19
5.3 WELDER PRE-QUALIFICATION ............................................................................. 19
5.4 QUALIFICATION DOCUMENTATION ..................................................................... 19
5.5 TIME LIMITATIONS .................................................................................................. 19
6. PREHEATING AND POSTWELD HEAT TREATMENT .......................................... 19
6.1 PREHEATING........................................................................................................... 19
6.2 POSTWELD HEAT TREATMENT ............................................................................ 21
7. WELD INSPECTION ................................................................................................ 27
7.1 METHODS AND EXTENT OF NONDESTRUCTIVE EXAMINATION ..................... 27
7.2 TESTING QUALIFICATIONS ................................................................................... 27
8. WELD REPAIRS ...................................................................................................... 28
8.1 DEFECT REMOVAL ................................................................................................. 28
8.2 RE-WELDING ........................................................................................................... 29
8.3 NONDESTRUCTIVE TESTING ................................................................................ 29
8.4 DEFECT AND REPAIR RATE RECORDS ............................................................... 29
9. HEALTH, SAFETY, SECURITY, AND ENVIRONMENT CONSIDERATIONS ....... 29
9.1 GENERAL ................................................................................................................. 29
9.2 WELDING EQUIPMENT ........................................................................................... 30
9.3 ALIGNMENT ............................................................................................................. 30
10. MATERIAL-SPECIFIC ADDITIONAL REQUIREMENTS ........................................ 30
10.1 GENERAL REQUIREMENTS................................................................................... 30
10.2 WPQR MONITORING .............................................................................................. 30
10.3 WPQR REQUIREMENTS ......................................................................................... 30
10.4 PARAMETER MONITORING ................................................................................... 32
10.5 CMn STEELS NOT INTENDED FOR LOW TEMPERATURE SERVICE ................ 32

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10.6 IMPACT TESTED CMn STEELS (LTCS) ................................................................. 36

10.7 3.5 % NICKEL STEELS ............................................................................................ 41
10.8 LOW ALLOY STEELS .............................................................................................. 44
10.9 AUSTENITIC STAINLESS STEELS ......................................................................... 46
10.10 6 % Mo AND OTHER SUPERAUSTENITIC STAINLESS STEELS ......................... 48
10.11 DUPLEX STAINLESS STEELS ................................................................................ 51
10.12 NICKEL ALLOYS ...................................................................................................... 55
10.13 COPPER ALLOYS .................................................................................................... 57
10.14 TITANIUM ................................................................................................................. 60
10.15 DISSIMILAR WELDING ............................................................................................ 62
11. REFERENCES ......................................................................................................... 67
APPENDICES
APPENDIX A REPORTING REQUIREMENTS FOR WELDING QUALIFICATION ............. 70

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1. INTRODUCTION
1.1 SCOPE
This DEP specifies requirements and gives recommendations for organising and managing
quality assurance (QA) and quality control (QC) for welding of metals, based on ISO
standards.
This DEP is a counterpart to DEP 30.10.60.18-Gen., which is based on API RP 582.
This DEP is written in accordance with the latest regulations in force within the European
economic area including the European Pressure Equipment Directive (PED) 2014/68/EU
and is based on the referenced standards, which cover all aspects of the design and
fabrication of pressure equipment.
This DEP recognises and builds on the expertise and good practices developed in previous
Shell specifications.
The scope of this DEP does not include pipeline or civil structural welding.
DEP 61.40.20.30-Gen., DEP 37.81.40.31-Gen. and DEP 30.10.60.30-Gen. cover pipeline
welding, and DEP 37.81.10.34-Gen. covers civil structural welding.
This DEP contains mandatory requirements to mitigate process safety risks in accordance
with Design Engineering Manual (DEM) 1 - Application of Technical Standards.
This is a revision of the DEP of the same number dated February 2017; see (1.5) regarding
the changes.
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Fabricators nominated by them. Any
authorised access to DEPs does not for that reason constitute an authorisation to any
documents, data or information to which the DEPs may refer.
This DEP is intended for use in facilities related to oil and gas production, gas handling, oil
refining, chemical processing, gasification, distribution and supply/marketing. This DEP
may also be applied in other similar facilities.
When DEPs are applied, a Management of Change (MOC) process shall be implemented;
this is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements could be more
stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable with regards to the safety, environmental, economic and legal aspects. In all
cases, the Contractor shall inform the Principal of any deviation from the requirements of
this DEP which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the Authorities concerned, the objective
being to obtain agreement to follow this DEP as closely as possible.
1.3 DEFINITIONS
1.3.1 General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Fabricator is the party that manufactures or fabricates the equipment and provides
services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.

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The word shall indicates a requirement.

The capitalised term SHALL [PS] indicates a process safety requirement.
The word should indicates a recommendation.
The word may indicates a permitted option.
1.3.2 Abbreviations
Term Definition
ANSI American National Standards Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
AWS American Welding Society
B Maximum nominal pipe wall thickness for “as-welded” application
CI Confidence Interval
CMn Carbon Manganese
CSWIP Certification Scheme of Welding Inspection Personnel
EWF European Federation for Welding, Joining and Cutting
FCAW Flux Core Arc Welding
GMAW Gas Metal Arc Welding
GTAW Gas Tungsten Arc Welding
HAZ Heat Affected Zone
IIW International Institute of Welding
ITP Inspection and Test Plan
IVB Independent Verification Body
MT Magnetic Particle Inspection
NDE Non-destructive Examination (also known as NDT)
NOBO Notified Body
OD Outside Diameter
PED (European)Pressure Equipment Directive
PRE(N) Pitting Resistance Equivalent (including nitrogen)
PT Liquid Penetrant Examination
PWHT Post Weld Heat Treatment

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Term Definition
RT Radiographic Testing
SAW Submerged Arc Welding
SMAW Shielded Metal Arc Welding
t Nominal Pipe Wall Thickness
TMCR Thermo-Mechanically Controlled Rolled
TOFD Time of Flight Diffraction
UT Ultrasonic Testing
VT Visual Testing
WPQR Welding Procedure Qualification Record
WPS Welding Procedure Specification
1.4 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section or
clause number is shown in brackets ( ). Other documents referenced by this DEP are listed
in (11).
1.5 SUMMARY OF MAIN CHANGES

This DEP is a full revision of the DEP of the same number dated February 2017. The
following are the main, non-editorial changes.
Section/Clause Change
All Restructured and clarified requirements, enforced use of
shall/should/may for normative statements.

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1.6 COMMENTS ON THIS DEP

Comments on this DEP may be submitted to the Administrator using one of the following
options:
Shell DEPs Online Enter the Shell DEPs Online system at

https://www.shelldeps.com
(Users with access to
Select a DEP and then go to the details screen for
Shell DEPs Online)
that DEP.
Click on the “Give feedback” link, fill in the online
form and submit.
DEP Feedback System Enter comments directly in the DEP Feedback

System which is accessible from the Technical
(Users with access to
Standards Portal http://sww.shell.com/standards.
Shell Wide Web)
Select “Submit DEP Feedback”, fill in the online form
and submit.
DEP Standard Form Use DEP Standard Form 00.00.05.80-Gen. to record

feedback and email the form to the Administrator at
(other users)
[email protected].
Feedback that has been registered in the DEP Feedback System by using one of the above
options will be reviewed by the DEP Custodian for potential improvements to the DEP.
1.7 DUAL UNITS

This DEP contains both the International System (SI) units, as well as the corresponding
US Customary (USC) units, which are given following the SI units in brackets. When
agreed by the Principal, the indicated USC values/units may be used.
1.8 NON NORMATIVE TEXT (COMMENTARY)

Text shown in italic style in this DEP indicates text that is non-normative and is provided as
explanation or background information only.
Non-normative text is normally indented slightly to the right of the relevant DEP clause.
1.9 PRECEDENCE OF DOCUMENTS

1. In case of conflict between documents the following precedence of documents shall
apply:
a. First level - statutory laws and regulations;
b. Second level - this DEP;
c. Third level - cross-referenced documents;
d. Fourth level - International codes and standards.

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2. QUALITY PROGRAM
2.1 GENERAL
1. Welding QA/QC of equipment and piping components shall be implemented under a
Fabricator quality management system that conforms to ISO 9001 and ISO 3834 and
certified by an IVB.
2. Fabricator shall develop and maintain its quality system for welding activities based on
ISO 3834-6.
3. A welding procedure specification (WPS) shall be considered an engineering
document and is part of the detailed design of a component.
4. The applicable requirements specified in ISO 3834-5 shall be applied.
2.2 PERSONNEL COMPETENCIES

1. The Welding Coordinator, as defined in ISO 3834-2, shall be a EWF / IIW International
Welding Engineer or International Welding Technologist in accordance with ISO
14731.
a. The certified level of active experience of the Welding Coordinator, according to
the International Institute of Welding, shall be a minimum of three years, based
on evidence.
2. Welding inspection personnel shall hold a valid welding inspection qualification and
certificate in accordance with Table 1 or an alternative qualification approved by the
Principal.
Table 1 Competence levels for welding inspection personnel
Competence Country/ Applicable Inspector Position Designation
Level Region Standard
1 UK / Europe ISO 17637 Visual Welding Inspector 3.0
Netherlands / ISO 17637 / International Welding IWI-B
Europe 14731 inspector, Basic
USA AWS Certified Associate Welding CAWI
Inspector
2 UK / Europe ISO 17637 Welding Inspector 3.1
Netherlands / ISO 17637 / International Welding IWI-S
Europe 14731 inspector, Standard
USA AWS Certified Welding Inspector CWI
3 UK / Europe ISO 17637 Senior Welding Inspector 3.2
Netherlands / ISO 17637 / International Welding IWI-C
Europe 14731 inspector, Comprehensive
USA AWS Senior Certified Welding SCWI
Inspector
2.3 INSPECTION AND TEST PLAN

1. The Contractor shall submit to the Principal, for review and approval, an Inspection
and Test Plan (ITP) and related method statements prior to commencement of welding
work.
2. The Contractor shall review and, if deemed acceptable, approve all documents from
the Fabricator prior to submission to the Principal.

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2.4 DEVIATIONS
1. Any conflicts between the requirements of this DEP and other relevant documents
shall be referred to the Principal for resolution.
2.5 FINAL ACCEPTANCE

1. Contractor SHALL [PS] submit the following for approval of the Principal:
a. Fabricator's report and record of monitoring of production welds;
b. Fabricator's welding inspection report.
3. GENERAL REQUIREMENTS
3.1 WELDING PROCESSES

1. All welding shall be performed with one of the processes in Table 2.
Table 2 Acceptable welding processes
Process Name ASME EN/ISO Comment

Designation Designation
gas tungsten arc welding GTAW 141 Refer to (3.1,
Item 2)
shielded metal arc welding SMAW 111
gas shielded flux cored arc welding (GS)FCAW 136 Refer to (3.1,
Item 2)
self-shielded flux cored arc welding (SS)FCAW 114
submerged arc welding – solid wire SAW 121 Refer to (3.1,
Item 3)
submerged arc welding – cored wire SAW 125 Refer to (3.1,
Item 3)
plasma arc welding PAW 15 Refer to (3.1,
Item 2)
gas metal arc welding (active gas) GMAW 135 Refer to (3.1,
Item 2,4)
metal-cored arc welding (active gas) MCAW 138 Refer to (3.1,
Item 2,4)
2. Gas shielded processes (GTAW, GSFCAW, GMAW, MCAW, PAW) shall be used in
the field only if adequate weather shielding that is approved by the Principal is
provided.
3. SAW systems shall be fully mechanised (automated).
GMAW or MCAW might be allowed if the Fabricator can demonstrate to the
Principal’s satisfaction, adequate experience with the processes, ongoing control
over the process, and the continued competence of the welders.
4. The root and second pass of all single-sided welds shall be made using one of the
following methods, in order of preference:
a. GTAW (preferred);
b. Subject to review and approval by the Principal: Controlled droplet transfer
(semi)-automated Pulsed GMAW welding processes such as STT (surface

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tension transfer), RMD (regulated metal deposition), ESAB QSET (optimal short
arc parameters setting), and CMT (cold metal transfer), provided that the
Contractor can demonstrate successful prior experience (e.g., previous project
listing service, material specifications and thickness ranges).
5. All GTAW machines shall be equipped with arc starting devices, e.g., high frequency
starting unit, crater-eliminating, and slope-out control.
a. If regulations do not permit arc starting devices, alternative proposals shall be
subject to the approval of the Principal.
3.2 MATERIALS
3.2.1 Grouping
1. Substrate/parent materials identified under different groupings in ISO/TR 15608 shall
be defined as dissimilar metals to be welded.
2. Similar parent material welded with other grouping weld metal shall be treated as a
dissimilar metal weld.
3.2.2 Parent materials certification
1. Materials used for qualification of WPSs shall be representative of materials to be
used in production welding.
In this context, 'representative' is determined based on the essential variables.
2. Materials used for welding procedure qualification shall be supplied to a recognised
manufacturing specification and as a minimum certified in accordance with EN10204
(ISO 10474), inspection certificate 3.1.
3.2.3 Welding consumables
3.2.3.1 General
1. Welding consumables shall be supplied by a Manufacturer/Supplier accredited in
accordance with ISO 9001 or an equivalent quality specification approved by the
Principal.
2. Welding consumables shall be approved by one of the following organisations or
another organization approved by the Principal:
a. Controlas;
b. Lloyds Register of Shipping;
c. American Bureau of Shipping;
d. Det Norske Veritas;
e. Bureau Veritas.
3. Welding consumables for new WPQRs shall be subject to the approval of Principal via
the proposed WPS prior to qualification.
4. As a minimum, all welding consumables used in production welding shall produce
welds with mechanical properties that are the same or better as those specified for the
base metal, unless otherwise specified.
5. With the following exception, all consumables shall be identified on the WPS by their
AWS or ISO classification and by their Manufacturer/Supplier’s name and designation.
a. For solid wire electrodes (ISO 636, ISO 14171 and ISO 14341), identification
solely by ISO classification may be done.

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3.2.3.2 Consumable certification

1. As a minimum, welding consumables shall be delivered in accordance with their
product datasheet and have certification (including chemical analysis) according to
EN 10204 (ISO 10474), Type 3.1.
2. Each consumable, or consumable batch, shall have individual marking relative to its
certification.
3. If batch testing of welding consumables is done, welding and testing shall be carried
out in accordance with a typical WPS and certification be presented in the format of a
WPQR.
a. Production material or an equivalent parent metal specification shall be used for
such consumable certification.
4. Fluxes for SAW processes shall be delivered with certification according to EN 10204
(ISO 10474), Type 2.2.
3.2.4 Consumable handling/storage
3.2.4.1 General
1. Stored consumables shall be clearly identified with brand name, classification and
batch number.
2. Consumable handling shall be controlled by a procedure subject to approval by the
Principal.
a. Storage shall be in accordance with the Manufacturer/Suppliers’
recommendations for the consumable type.
3. All non-identified, damaged, wet, partially used, rusty or otherwise contaminated
consumables shall be discarded.
4. Records of consumables shall be maintained to ensure an auditable trail from receipt,
through pre-treatment, their issue to operators and their return to stores so that their
identity can be verified at any stage.
5. Consumables that cannot be identified to the satisfaction of the Contractor or Principal
shall be discarded.
a. Any welds made with such consumables shall be cut out and re-welded.
3.2.4.2 Shielded metal arc welding
1. For SMAW, low hydrogen electrodes shall not be stored in heated cabinets containing
electrodes of other types, such as rutile or organic type electrodes.
3.2.4.3 Gas shielding welding process (GTAW/GMAW/FCAW)
1. Each package unit (container or reel) of wire shall be labelled with the information from
the supply container.
2. All bottles containing shielding gases shall have identification as per AWS 5.32.
3. Wire spools for automatic and semi-automatic processes shall be stored in original
packaging.
a. Storage should be done using cabinets or facility with controlled conditions of
temperature and humidity according to the Manufacturer's/Supplier's
recommendation.
4. GTAW filler wires for CRA and non-ferrous welding shall be cleaned with a solvent
immediately prior to their use.

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5. Wire for automatic or semi-automatic welding, remaining coil or spool that is partially
used may be reused in its original container, carefully sealed, and stored in a
controlled storage on the condition that remaining welding consumable is of adequate
quality to be reused.
6. FCAW wires shall be returned to a controlled storage area at the end of each shift.
7. Bare filler wire in coils or spools that have not been kept in sealed containers after use
or wire that has been contaminated with rust, grease or other debris, shall not be re-
used without cleaning in accordance with the wire Manufacturer/Supplier’s
specifications.
8. All wire that cannot be cleaned without damage to the surface, change in size, or other
damage that would adversely affect its use shall be discarded.
3.2.4.4 Submerged arc welding
1. SAW fluxes shall not be left in machine hoppers for extended periods when welding is
not being carried out, e.g., overnight or during non-productive shifts.
2. Recycling of flux shall only be allowed if the procedure is endorsed by the consumable
Manufacturer/Supplier and by the Principal.
3. Each batch of flux and wire shall be labelled with the information from the supply
container.
4. WELDING PROCEDURE PREPARATION AND QUALIFICATION
4.1 GENERAL
1. Welding procedures for all welded joints SHALL [PS] be prepared and qualified in
accordance with ISO 15614, including requirements from the design code, service and
client.
2. The documents described in (4.1, Item 1) shall be subject to review and approval by
the Mechanical, Materials & Integrity (MMI) Technical Authority of the Principal.
3. Each Fabricator shall prepare its own WPSs and qualify its own welding procedures.
a. WPSs shall contain information as specified in ISO 15609 and (Appendix A).
4. The testing results for WPQR/weld test record shall be presented in a detailed format
and with traceable document trail (Appendix A).
5. Unless otherwise specified, multi-pass fillet welds may be qualified by the qualified
procedure for groove welds in accordance with ISO 15614,
6. Separate WPSs shall be provided for groove and fillet welds.
7. Single pass fillet welds shall be separately qualified in accordance with ISO 15614.
4.2 PREVIOUSLY QUALIFIED PROCEDURES

1. WPSs for welding procedures previously qualified by the Fabricator may be submitted
for approval provided the WPSs meet the requirements of this DEP and they are
supported by WPQRs that are approved by an NOBO or a recognised independent
third party.
2. The ownership of WPQRs and WPSs shall be in accordance with ISO 15614-1
Section 8.2 subject to approval of the Principal.

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4.3 PROCEDURE DOCUMENTATION

1. Welding procedure documentation, including the final WPS, and welder instruction
cards (if adopted), shall be submitted to the Principal for final approval.
a. The final WPS may be modified from the original WPS within the allowable
ranges given by ISO 15614 and applicable construction code according to the
parameters actually used during procedure qualification.
2. As a minimum, the WPQR and weld test record documentation shall include the
information specified in (Appendix A).
4.4 ESSENTIAL VARIABLES

1. Any change to a welding procedure outside the allowances to the essential variables
specified in ISO 15614 and applicable construction codes shall require re-qualification
of the procedure.
2. If a welding procedure includes material thicknesses above a threshold such that more
stringent testing is required, the procedure qualification shall be limited to that
threshold, unless the more stringent testing is performed.
3. Weaving (i.e., the width of the final bead) shall be limited to the ranges in Table 3.
Table 3 Weaving ranges
SMAW process Three times the electrode diameter
GTAW process Maximum equal to used cup diameter or 12 mm (1/2 in),

whichever is smaller
GMAW/FCAW Maximum equal to used cup diameter or 15 mm (5/8 in),

process whichever is smaller
Weaving is restricted as quality control in addition to heat input and mitigation

of air ingress to minimize risk of porosity on gas shielding welding processes.
4.5 WELDING PROCEDURE QUALIFICATION TESTING

4.5.1 General
1. Welding procedure qualification testing shall not commence without the presence of
the Principal or its representative and a NOBO or recognised independent third party.
2. The Fabricator shall record all the information required for WPQRs as specified in
(Appendix A).
3. Equipment, such as portable arc monitoring systems, current meters, and temperature
measurement devices, shall have current and valid certificates of calibration.
4. WPQRs, inclusive of all required information and, when deemed acceptable, shall be
signed as witnessed by the Fabricator and approved by the NOBO or a recognised
independent third party.
Rationale: The Principal or its representative will review the final WPS/WPQR/weld
test record combination and give approval to the WPS (or WPS register) before
production welding starts.
5. Mechanical testing shall be performed per ISO 15614 and the additional requirements
in this DEP.
6. Designated testing laboratories shall have a quality system in compliance with
ISO 17025 or equivalent.

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7. When PWHT is specified, it shall be carried out in accordance with (6.2) per the
planned production sequence.
8. Multi-pass fillet welds may be qualified by groove weld performance testing.
9. Production weld testing of multi-pass fillet welds shall be performed to provide
evidence of positive penetration of the root pass only.
4.5.2 Nondestructive testing
1. The NDE shall be performed for welding procedure qualification as per Table 4.
Table 4 NDE Testing
Butt Welds Visual

MT ferrous materials or PT for non-ferrous materials
Radiography, (X-radiography technique)
Ultrasonic, if specified for the material.
Fillet Welds Visual
MT ferrous materials or PT for non-ferrous materials
2. Visual examination of completed welds shall be conducted by both the Fabricator and
the Principal, or its representative.
a. Cutting of a test piece for mechanical testing should not take place until it has
been visually examined and accepted by the NOBO or a recognised independent
third party.
b. If the test piece diameter be too small to allow proper examination of the weld
root, then the test piece shall be cut longitudinally to facilitate examination.
c. For new welding procedure qualifications where alternative or additional NDE
methods are proposed for production welding (e.g., time-of-flight diffraction
(TOFD)), the test piece shall also be subjected to these NDE methods.
3. When NOBO witness is required, this shall be arranged by the Fabricator.
4. When acceptance criteria are not defined in the purchase specifications, the
acceptance criteria shall be defined as “the design code requirements or ISO 5817
quality level B.”
The NDE acceptance criteria are normally covered by the selected design code for
the equipment or piping, for example PD 5500 or EN 13445.
4.5.3 Macro section examination
4.5.3.1 General
1. Macro sections shall be prepared and etched such that the whole cross section of the
weld, inclusive of HAZ, and adjacent parent material and individual weld passes are
visible.
2. Macro sections shall be examined under magnification between 3x and 8x.
3. WPQR documentation shall include original photographs or good quality digital images
of the macro sections with the following:
a. any hardness survey indentations visible on the photographs;
b. photographs marked to indicate the magnification (scale bar).

DEP 30.10.60.32-Gen.
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4. For weld acceptance the examination of the macro section shall not reveal any cracks,
lack of fusion (root, sidewall or inter-run) or volumetric defects (slag, porosity) that are
outside the limits set by the design code or ISO 5817 quality level B.
4.5.3.2 Hardness testing
1. Hardness surveys, as specified in ISO 15614, shall be carried out on macro sections
using Vickers hardness at 10 kg load.
2. Hardness testing shall be in accordance with ISO 6507-1.
3. The hardness requirements for base material, HAZ, and weld metal in Table 5 shall
apply:
Table 5 Hardness requirements - base material, HAZ and weld metals
Application Maximum Hardness
sour environments in oil and gas production Refer to DEP 39.01.10.12-Gen.

facilities
wet H2S environments in petroleum refining Refer to DEP 30.10.02.17-Gen.

and related processing environments
ferritic metals in downstream process 250 HV10 for the entire weld and the HAZ
services, including H2 service conditions
ferritic metals in non-sour service in oil and 300 HV10

gas production
ferritic metals in utility services (steam, air, 300 HV10

water, non-sour service)
9% Ni steels in the as-welded condition 350 HV10
9Cr-1Mo-V steel (P91, T91) in the PWHT 290 HV10

condition
structural steels not directly welded to 325 HV10

pressure containing parts
3.5% Ni steel with base metal thickness ≤ 9.5 250 HV10

mm (3/8 in)
3.5% Ni steel joint thickness > 9.5mm (3/8 in) 275 HV10 in the mid-thickness and cap
when the hardness impression is located
at least 8 mm (5/16 in) from the internal
surface
duplex stainless steels 334 Hv10 for 22Cr DSS

375 HV10 for 25Cr DSS
austenitic stainless steels 250 HV10

DEP 30.10.60.32-Gen.
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4.5.3.3 Low temperature, impact testing

1. For impact testing, refer to ISO/TR 15608, which specifies additional material group-
specific requirements.
The materials within each group have a unique response to low temperature
conditions; therefore, weld qualification impact testing is group specific.
2. Tables 6a and 6b shall be used in lieu of Tables 3 and 4 in ISO 15614-1 for range of
qualification for materials.
Table 6a Range of qualification for steel groups and sub-groups
Material (sub-) group of test pieces Range of qualification

1-1 1a-1
2-2 2a-2
3-3 3c-3c
4-4 4b-4
5-5 5c-5c
6-6 6c-6c
7-7 7c-7c
8c-8c, except that UNS No is
8-8 essential variable where Mo > 4%
9-9 9c-9c
10c-10c, except that UNS No is
10-10 essential variable
a. Covers the equal or lower specified yield strength steels of the same group.
b. Covers steels in the same sub-group and any lower sub-group within the same group.
c. Covers steels in the same sub-group.
Table 6b Range of qualification for nickel alloy and nickel alloy/steel groups
Material group of test pieces Range of qualification

41-41 41-41
42-42 42-42
43-43 43-43
44-44 44-44
45-45 45-45
46-46 46-46
47-47 47-47
48-48 48-48
4.5.4 Tube-to-tubesheet welding

1. Welded tube-to-tubesheet joints shall be full-strength welded and qualified in
accordance with the requirements of ISO 15614-8.

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2. Acceptance criteria shall be all of the following:

a. no cracks;
b. no lack of fusion;
c. no lack of penetration;
d. no porosity.
3. The allowable expansion at tube-to-tubesheet joints shall be agreed between the
Fabricator and the Contractor, with consideration of the tube and tubesheet materials,
hardness, and potential for work hardening during the expansion process.
4. All mechanical testing shall take place after expansion.
5. A minimum of three tensile pull-tests shall be performed on a qualification test coupon.
6. For wet hydrogen sulphide or sour services, a micro-hardness survey for weld metal,
HAZs, and base metals shall be performed in accordance with ISO 15156.
7. Autogenous seal welds shall not be applied as per ISO 16812.
4.5.5 Repair welding procedure
1. Dedicated WPSs, including all of the following, shall be prepared for repair welding:
a. the method of defect excavation;
b. the shape and size of excavation prior to re-welding;
c. all inspections required prior to re-welding;
d. the WPQR, if different from those used for the original weld.
2. Repair welding should be carried out to the same procedure as the original welding.
3. Where a different welding procedure (i.e., a change of process or other essential
variable) is to be used for repair welding, the repair WPS shall be qualified in
accordance with this DEP.
a. Qualification shall require the reproduction of a typical production repair.
4. Full penetration and partial penetration excavations shall be qualified separately.
5. For partial wall excavations, the remaining ligament adopted for the test weld shall be
the smallest allowed in production.
6. Where impact testing is specified for the original weld, impact testing of the repair weld
metal and the adjacent HAZs, both in the parent material and the original weld metal,
shall be carried out at the test temperature of the original weld.
7. When a separate repair WPQR is required by the relevant material specific section,
and where the repair welding is performed using essentially the same procedure as
the original weld, tensile and bend tests are not required for the repair WPQR.
a. All other test requirements shall be met as specified.
5. WELDER QUALIFICATION
5.1 GENERAL
1. All welders shall be qualified in accordance with ISO 9606.
2. All welding operators shall be qualified in accordance with ISO 14732.

DEP 30.10.60.32-Gen.
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5.2 WELDER IDENTIFICATION

1. Whilst on site, the welders and welding operators shall be identifiable.
2. The Fabricator shall maintain a report of welder IDs including name, photograph, and
welder identification number.
3. In the event that a welder leaves the work, the associated welder number shall not be
assigned to another welder employed on the work.
5.3 WELDER PRE-QUALIFICATION

1. Welders qualified on work other than for the Principal may be accepted by the
Contractor provided the following is satisfied:
a. their qualification has been carried out in accordance with ISO 9606 and the
requirements of this DEP;
b. their qualification testing has been witnessed by a NOBO or independent third
party acceptable to the Principal, and the certificate of qualification is endorsed
accordingly;
c. the Fabricator can provide proof that the welder has been continuously employed
by the Fabricator for the previous six months and has been welding with
reasonable continuity during that time, to the same, or similar, procedures with
satisfactory results.
5.4 QUALIFICATION DOCUMENTATION

1. Prior to commencement of work, the Fabricator shall submit the following:
a. a register of the welders to be used on the work,listing the procedures, positions
and thickness ranges in which they are qualified, together with the identity
number for each welder;
b. all weld performance qualification certificates, including relevant back-up
documentation, such as NDE and mechanical test certificates.
5.5 TIME LIMITATIONS

1. Welder and welding operator qualification certificates shall be valid for six months from
the date of approval and revalidated as per ISO 9606 9.3(c).
6. PREHEATING AND POSTWELD HEAT TREATMENT
6.1 PREHEATING
6.1.1 Preheat temperature
1. For carbon-manganese and low alloy steels, the minimum preheat temperature shall
be as calculated in accordance with ISO/TR 17671-2 using the maximum carbon
equivalent allowed for the material to be welded and the weld metal hydrogen level
guaranteed by an approved consumable control procedure.
2. If higher preheat temperatures are necessary to meet the hardness values required by
this DEP, particularly for sour service conditions in accordance with DEP
39.01.10.12-Gen. or DEP 30.10.02.17-Gen., as applicable, the temperature margin
above the minimum required by ISO/TR 17671-2 shall be applied to all thicknesses to
be welded.
3. For reinforced branch fittings, such as olets, that are to be welded, the minimum
preheat temperature shall be 50 °C (90 °F) above that specified by ISO/TR 17671-2.
4. If preheat is not explicitly required by this DEP and ambient temperature is below 5 °C
(41 °F), or if condensation/moisture is apparent on work surfaces, then sufficient

DEP 30.10.60.32-Gen.
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preheat shall be applied to ensure work surfaces are dry and remain warm to the
touch.
5. For 3.5 % nickel steels, a minimum preheat temperature of 100 °C (212 °F) shall be
used for welding all thicknesses.
6.1.2 Preheat application
6.1.2.1 General
1. For materials with wall thickness up to and including 19 mm (3/4 in), preheating shall
be by gas torch or electrical resistance heaters.
a. For wall thickness above 19 mm (3/4 in), electric resistance heating mats shall be
used, unless it is agreed with Principal that access or location makes it
impractical.
2. Electrical resistance elements shall be controlled by thermocouples attached on or
adjacent to the weld preparation.
3. Thermocouple devices shall be regularly calibrated as specified in ISO 17663 and
ISO IEC 60584-1, with a maximum interval of six months.
4. Preheating with oxy/fuel gas should only be by soft flame burners designed for the
purpose.
5. Handheld oxy/fuel gas burners should only be used for welds on pipes less than
168.3 mm OD (DN150 (NPS 6)) or attachment welds less than 300 mm (12 in) long.
This only applies where preheat above 20 °C (68 °F) is required.
6. The temperature of preheat implemented by non-electrical means shall be measured
using contact pyrometers, temperature indicating crayons, or thermocouples.
a. If there is access, temperature measurement shall be taken on the surface
opposite of the one being heated.
i. Measurement shall be taken at a location that is displaced from the source
of heat by a minimum of 25 mm (1 in) in a direction parallel to the vessel,
process piping, or other equipment axis.
ii. Measurement shall be taken after removal of the heat source.
b. If there is no access to the opposite surface, temperature measurement shall be
taken 75 mm (3 in) from both weld toes/edges and delayed for a period not less
than five seconds per mm of material thickness after removal of the heat source.
7. Temperature indicating crayons shall be certified to be free (less than 1 ppm) of lead
and sulphur or any other low melting constituent.
8. Residue from crayons shall be removed from the weld surface before proceeding with
the weld.
9. Thermocouples shall be installed under resistance heater mats, unless test trials prove
the process will not expose the component to temperatures above the lower critical
transformation temperature of the base metal alloy.
6.1.2.2 Welding interruption considerations
1. Interruption of welding with loss of specified preheat temperature shall not be
permitted except for unalloyed steels (Group 1) with UTS of 450 N/mm² (65 ksi) or
lower, or for steels with UTS of 490 N/mm² (70 ksi) when welded with low hydrogen
consumables and with a welded thickness of less than 28 mm (1.1 in).
a. At least 30 % of the weld joint thickness shall have been completed prior to
interrupting welding.
b. After interruption, the joint shall be slow cooled under insulation.

DEP 30.10.60.32-Gen.
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c. Preheating shall be restored to the specified temperature before welding is

recommenced.
2. If welding is interrupted, with associated cooling, and the completed weld ligament
depth is less than 30 % of the total joint thickness, then the appropriate surface
inspection (e.g., MT or PT) shall be performed to ensure freedom from deleterious
defects.
3. For other materials where interruption of welding is permitted by the applicable
welding code the root and second pass as a minimum shall be completed before any
welding interruption
6.1.3 Interpass temperature
1. The maximum welding interpass temperature for production welding shall not exceed
that measured during welding procedure qualification WPQR by more than 50 °C
(90 °F).
6.2 POSTWELD HEAT TREATMENT

6.2.1 General
1. PWHT shall be in accordance with the applicable design codes and as specified in the
appropriate standards included in the purchase order.
Additional guidance is given in tables 7A and 7B.
2. Refer to ISO 17663 for PWHT quality requirements.
3. Refer to DEP 30.10.02.31-Gen. for PWHT requirements in relation to engineering
against low temperature embrittlement.
4. For quenched/normalised and tempered steels, the PWHT temperature shall be such
that it does not cause an unacceptable decrease of mechanical properties of the
parent material.
a. PWHT temperature shall be at least 25 °C (45 °F) below the tempering
temperature used during the manufacture of the base metal component and
recorded on the material certificate.
5. The PWHT cycle shall be designed in such a way as to allow for a minimum of one
additional PWHT cycle in case weld repairs are required.
a. Where conflict between this requirement and the base material temper develops,
it shall be brought to the attention of the Principal for resolution.
6. When production test coupons are requested they shall have the same PWHT
conditions as the actual items in the assembly.
a. Total soak time and cycles for coupons shall be set according to the thickness of
the coupons and equipment thickness.
b. Soak time on the WPQR shall not be less than what is expected for the maximum
thickness range in production welding.
c. If additional PWHT cycles need to be applied on the material, additional
production test coupons exposed to the same heat cycle are required to verify the
mechanical properties stated in the WPQR are maintained.
This includes the heating method either in a furnace or local heat treatment by
resistance mats or induction coils.
7. Refer to (6.2.3, Item 1) for the PHWT of dissimilar welds.
8. No welding or heating shall be carried out after final PWHT.
9. Cooling in still air may be applied below 300 °C (572 °F).

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6.2.2 Piping PWHT

1. If there is no subsequent machining operation, all piping threads and gasket surfaces
shall be protected from oxidation whilst the equipment is subjected to PWHT.
2. PWHT of non-ferrous and austenitic materials shall be subject to the approval by
Principal.
6.2.3 PWHT procedure
1. The PWHT procedure, including all of the following, shall be subject to the approval by
Principal:
a. name of Contractor/Subcontractor;
b. ruling specification;
c. material and item type;
d. method of heating;
e. fuel gas and method of atmosphere control (if gas-fired furnace);
f. size and type of electrical element (if electrical resistance);
g. type, location and number of thermocouples;
h. method of thermocouple attachment and removal;
i. details of loading and supporting arrangements to avoid distortion;
j. provisions to avoid flame impingement (if flame heated)
k. holding time and temperature;
l. heating and cooling rates;
m. type of recording equipment including number of channels;
n. chart speed;
o. calibration documentation.
6.2.4 Furnace PWHT
1. PWHT shall be performed in a fully enclosing furnace.
2. Fuel powered furnaces shall have adequate flame controls to prevent an oxidising
furnace atmosphere or flame impingement onto PWHT items.
3. Unless otherwise specified by the applicable code, the temperature during heating and
cooling shall not vary by more than 150 °C (270 °F) in any 4.5 m (15 ft) length of
piping.
4. The number of thermocouples shall be sufficient to ensure that the temperature and
thermal gradients of the whole of the work are within the required range.
5. One thermocouple shall be attached directly to each spool at the point of greatest wall
thickness.
6. If a large number of small spools are to be treated in one batch, thermocouples may
be attached to a representative number (no less than one in four) of the spools.
6.2.5 Local PWHT
1. Local PWHT may be used if size or installation restrictions prevent furnace PWHT.
2. For local PWHT, heating shall be by electrical resistance heating elements.

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3. For local PWHT the soak temperature shall be achieved and maintained in a band
2.5 times weld thickness either side of the weld centre line.
a. The width of the thermal insulation shall be 7.5 times weld thickness either side of
the weld centre line.
4. Circulation of air in the bore of the process piping or equipment work shall be
prevented.
5. The minimum number and position of thermocouples on pipe shall be as per Table 7.
Table 7 Number and position of thermocouples
Pipe Diameter No. of ‘Clock’ Position

Thermocouples
per Weld
≤ DN 100 (4 NPS) 1 12
>DN 100 to ≤ DN 300 2 6, 12
(4 NPS to 12 NPS)
>DN 300 (12 NPS) 4 3, 6, 9, 12
6. Thermocouples shall be located on the weld centre line and be held in intimate contact
with the surface of the weld by mechanical means or by capacitance discharge
welding.
a. The attachment points of capacitance discharge welded thermocouples shall be
dressed by grinding after removal.
7. For 2G oriented welds the thermocouples shall be placed below the bottom toe of the
weld bevel.
6.2.6 Equipment calibration
1. The calibration procedures for all equipment measuring and recording temperature
shall be subject to approval by the Contractor.
2. Equipment shall be calibrated at least every three months.
6.2.7 Recording and reporting
6.2.7.1 General
1. As a minimum, the heating rate, holding time, temperature and cooling rate data shall
be recorded.
2. The temperature measured by each thermocouple should be recorded by means of a
multi-channel chart recorder.
a. Each chart should be marked with the date of the PWHT, the WPS number, the
weld or spool number(s), channel identification and signature(s) of Subcontractor
personnel.
3. A heat treatment report containing the following information shall be submitted for
review and approval by the Principal:
a. identification of the component being subjected to PWHT;
b. actual heating and soaking rates as recorded on the temperature chart;
c. actual soak and withdrawal temperatures as recorded on the temperature chart;
d. material dimensions and specification;
e. applicable WPS number;

DEP 30.10.60.32-Gen.
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f. project description/code;
g. a signature, from the authorised party, confirming completion of works in
accordance with design requirements.
6.2.7.2 Thermocouples
1. Thermocouple attachments shall be capacitor discharge connections, or nuts and
bolts.
2. If nuts and bolts are used, the materials should be of a composition such that they will
not be adversely affected by the PWHT process.
a. These nuts and bolts shall be treated as temporary attachments.
3. The attachment points of welded thermocouples shall be dressed by grinding after
removal.
4. All thermocouple attachments shall be insulated to prevent temperature misreading
caused by the effect of radiation.
5. The number and positions of thermocouples shall be in accordance with the design
code and the following:
a. as a minimum, three thermocouples to be directly attached on a work piece;
b. for a hollow configuration, one additional thermocouple to be on the inside.
6.2.8 Process service considerations
1. In addition to any code requirements, welds in materials for the following process
services shall be subjected to PWHT:
a. caustic and ammonia service;
b. HF service;
c. rich or lean amine service irrespective of service temperature;
d. sour service conditions as defined in DEP 30.10.02.17-Gen. (for Downstream
applications) or DEP 39.01.10.12-Gen. (for Upstream applications);
e. high pressure, high temperature hydrogen service;
f. carbonates service as defined in DEP 30.10.02.17-Gen.
2. In the services described in (6.2.8, Item 1), all carbon and low alloy steel welds of all
thicknesses shall be given PWHT and be so indicated on the applicable equipment
data sheet or piping/line designation table.
3. Holding times at designated heat-treating temperatures shall be a minimum of one
hour per 25 mm (1 in) of weld thickness.
a. When PWHT is imposed because of environmental cracking concerns,
combinations of longer-than-designated holding times at lower-than-designated
heat-treating temperatures shall not be used.

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Table 7A Guidance on pre-heat and PWHT of weldments when the design is as per EN 13445 /13480
Material Pre-heat Postweld heat treatment

1)
Wall thickness Min. temp. °C Wall thickness Temp. range °C min.- max. Holding time; min.
mm (in) (F) mm (in) (F) per mm (0.04 in) wall
2)
thickness
Carbon Steel All Per ISO TR 17671-2
3)
≤ 32 (1¼ in) Optional
4)
2.5
11)
580°(1076)- 620° (1148)
11)
> 32 (1¼ in) 580°(1076)- 620° (1148)
Fine grained and low nickel ≤ 19 (3/4 in) To ISO 17671-2
4)
≤ 32 (1¼ in) Optional
4)
2.5
alloy steels > 19 (3/4 in) > 32 (1¼ in)
100° (212)-150°(302) 540°(1004)- 580°(1076)
3.5% Ni steels all 100 (212)-150 (302) all 590 (1094)-630 (1166) 2.5
0.3Mo – 0.5Mo steel ≤ 19 (3/4 in) 20°(68) ≤ 20 (0.8 in) Optional
4)
2.5
> 19 (3/4 in) 100°(212)-150°(302) > 20 (0.8 in) 580°(1076)- 620°(1048)
Grade 4130 HSLA steel all 100 (212)-150 (302) all 660(1220)-700(1292) 2.5
5) 8)
1Cr 0.5Mo all 100°(212)-150°(302) all 640°(1184)- 680°(1265) 2.5
1.25Cr 0.5Mo 6) 7)
680°(1265)- 720°(1328)
5)7) 8)
2.25Cr 1Mo all 200°(392)-250°(482) all 630°(1166)- 680°(1265) 5
6) 7)
680°(1265)- 720°(1328)
7)9)
720°(1328)- 750°(1382)
5) 7 8)
5Cr 0.5Mo 9Cr 1Mo all 200°(392)-250°(482) all 680°(1265)- 720°(1328) 5
7) 9)
720°(1328)- 760°(1400)
10)
12-17 Cr martensitic ss all 200°(392)-300°(492) all 700°(1292)- 790°(1454) 2,5

DEP 30.10.60.32-Gen.
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NOTES:
1. If ambient temperature is below 5°C (41 °F) pre-heating at 40 °C (104 °F) is recommended. (See also 6.1.1.)
2. Minimum holding time 1 hour.
3. Low hydrogen filler metals to be used.
4. PWHT is required for Ceq ≥ 0,45 or C ≥ 0,23.
5. For optimum high temperature creep properties in general the lower side of the temperature range to be used.
6. Temperature range in the case of service for hydrogen (H2) or general refinery services.
7. Minimum 10° below refinement temperature.
8. For the larger thickness (>25 mm (>1 in)) components De-Hydrogenation Treatment (DHT) need to be considered when Intermediate Stress Relief (ISR), according to the industry best
practices such as API 934.
9. Temperature range for maximum softening.
10. PWHT temperature selection is based on the original heat treatment temperature of the base metal used.
11. The higher temperature range is specifically for resistance to amine cracking 620° (1148) - 650° (1202) and carbonate cracking 649° (1200) - 663° (1225).

DEP 30.10.60.32-Gen.
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Table 7B Heating and cooling rate requirements during PWHT
Heating and cooling Wall Free range Controlled range

activity thickness
Heating t ≤ 25 mm 0 °C – 300 °C T > 300 °C (572 °F), rate maximum
(1 in) (32 °F – 572 °F) 200 °C (360 °F)/hour.
Heating t > 25 mm 0 °C – 300 °C T > 300 °C (572 °F), rate maximum

(1 in) (32 °F – 572 °F) 5500/t (in mm) in °C/hr (396/t (in inch)
in °F/hr, or 55 °C (100 °F)/hr
(whichever is greater).
Cooling t ≤ 25 mm 400 °C – 0 °C T > 400 °C (752 °F), rate maximum
(1 in) (752 °F – 32 °F), 200 °C/hr (360 °F/hr).
under insulation.
Cooling t > 25 mm 400 °C – 0 °C T > 400 °C, rate maximum 6875/t in
(1 in) (752 °F – 32 °F), °C/hr(495/t (in inch) in F/hr, or 55 °C
under insulation. (100 °F)/hr
(whichever is greater).
7. WELD INSPECTION
7.1 METHODS AND EXTENT OF NONDESTRUCTIVE EXAMINATION

The methods and extent of NDE for pressure vessels or piping are covered by other
applicable DEPs, the respective design code, and relevant design/purchasing
documents.
This DEP does not include complete requirements for testing and NDE for all production
welds. Only the NDE or testing which may be specific to, or resulting from, the use of a
particular welding process (e.g., GMAW, FCAW) or to assure in-service weld
performance (e.g., ferrite tests) are included.
1. Refer to DEP 31.38.01.31-Gen. for piping inspection requirements.
2. Refer to DEP 31.22.00.31-Gen. for pressure vessel inspection associated with the
applicable pressure vessel design code.
7.2 TESTING QUALIFICATIONS

7.2.1 General
1. Mechanical, chemical and electrical testing shall be performed with equipment
calibrated in accordance with applicable ASME, ASTM or ISO standards or in
accordance with a recognised local regulatory agency or third-party agency (e.g.,
TŰV, Lloyds, DNV, EN, CSA).
7.2.2 Inspection personnel
1. Inspection personnel to be used by the Fabricator and Contractor shall individually be
subject to review and approval by the Principal.
2. The minimum qualification requirements for inspection personnel shall be as follows:
a. Visual:
i. MT ASNT, CGSB or ISO 9712, Level 2;
ii. PT ASNT, CGSB or ISO 9712, Level 2;
iii. VT, visual testing in accordance with ISO 9712.

DEP 30.10.60.32-Gen.
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b. Radiography:
i. ASNT, CGSB or ISO 9712, Level 2.
c. Interpretation only:
d. Ultrasonic:
e. Supervisors responsible for overseeing and controlling NDE activities shall be
Level 3 qualified.
7.2.3 General requirements
1. Weld inspection, shall be the responsibility of the Fabricator.
2. The NDE company responsible for the final inspection of welds shall have a quality
system in compliance with ISO/IEC 17020, and be accredited by a nationally
recognised body.
3. NDE procedures shall be subject to approval by the Principal.
4. The Fabricator shall implement a system for uniquely identifying each weld, for the
control and recording of inspections (VT, MT, PT, UT and RT).
a. Isometric drawings, marked with the individual weld numbers, should be
maintained for this purpose.
5. Prior to fabrication start-up, the Fabricator shall submit its identification system for
approval by the Principal.
6. Where PWHT is required, final non-destructive testing shall not take place until final
PWHT has been completed.
7.2.4 Visual Inspection
1. Welders shall perform visual inspection on all prepared joints prior to welding, during
welding (welder self-checks) and upon completed welds before release to inspection
routine.
2. Visual inspections should include the internal surface of the weld wherever possible.
3. The visual acceptance of each weld shall be recorded by the Fabricator as part of the
NDT reporting.
8. WELD REPAIRS
1. The causes for each unacceptable defect shall be immediately investigated, with
corrective action taken to prevent further occurrence.
8.1 DEFECT REMOVAL

1. Surface profile defects or surface porosity on the cap, or root if accessible, may be
removed by disc grinding or burr grinding to a smooth profile subject to the minimum
material thickness being maintained.
2. Unacceptable defects in ferritic steels shall be excavated by mechanical means or
carbon arc gouging to a depth agreed with the Principal as follows:
a. excavation to be followed by grinding;
b. excavation by carbon arc gouging to be applied with a dedicated repair
procedure, subject to approval by the Principal;
c. unacceptable defects in non-ferrous materials be excavated by mechanical
means only;

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d. excavation shall be ground to a smooth boat shape with no sharp edges and
have sufficient slope on the sides to permit access for welding;
e. weld repair excavation depth shall be controlled by gauges to ensure the
minimum amount of material necessary is excavated to completely remove the
defect.
3. MT or PT surface inspection techniques shall be used to confirm removal of weld
defects.
8.2 RE-WELDING
1. If back purging was used on the original weld, the back purge shall be applied if the
repair excavation encroaches closer than 6 mm (1/4 in) to the inside surface of the
vessel, process piping or equipment.
8.3 NONDESTRUCTIVE TESTING

1. All repair welds shall be 100 % re-inspected by the methods specified for the original
weld.
2. Preliminary NDE should be performed before PWHT in case it is required to avoid
having to re-heat treat more than once.
8.4 DEFECT AND REPAIR RATE RECORDS

1. The Fabricator shall implement a system for recording of weld defect and repair rates
on a weekly basis for each production area.
a. The defect rates should be reported together with the accumulated defect rate.
2. Individual welders shall be identified in the defect rate recording system.
3. The Principal shall be informed when repair rates are above 3 % in number of welds,
per individual welder, or length of weld.
For welding activity with long weld lengths and few welds in the construction (such
as tanks) the repair rate is defined by length of weld.
4. The Fabricator shall submit to the Principal a procedure for production welding
parameter monitoring.
a. This procedure shall include details of the method(s) used, the reporting process,
and the frequency of tests related to the number of welders, processes, and shift
patterns.
9. HEALTH, SAFETY, SECURITY, AND ENVIRONMENT CONSIDERATIONS
9.1 GENERAL
1. Unless local regulations are more stringent, the following shall apply:
a. protective clothing for use in welding and allied processes to conform to ISO
11611;
b. equipment for oxygen and acetylene to conform ISO 14114 and ISO 5172;
c. welding equipment to conform IEC 60974-x;
d. ventilation of welding and cutting fumes to conform ANSI Z49.1/AWS Z49.1;

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e. Trichlorethylene, Acetone and other hydrocarbon-based solvents that produce

toxic gases upon welding are not to be used as degreasing agents.
Dedicated cleaning agents are available on the market for degreasing of the
weld bevel and consumable bare wire (GTAW).
There are no ISO/IEC documents available to support a fume or ventilation
specification.
2. HSSE assessment shall be required for confined space entry, ventilation, and welding
as part of the confined space entry and permit-to-work system, with special attention
to the oxygen depletion risks and visual inspection ability/restrictions for the welder.
3. Welding close to live (gas) plant facilities shall require specific safety and risk
assessment, with regard to the use of habitats and specific requirements for gas
detection and power/circuit breakers of the equipment used.
4. Thoriated tungsten electrodes shall not be used in production welding.
The change in the type of tungsten electrode used for GTAW from that qualified
(e.g., move away from thoriated tungsten), is not considered an essential variable
change when made for health and safety reasons provided that there are no other
welding procedure changes.
5. All equipment shall be maintained with records to support its ongoing safe operation.
9.2 WELDING EQUIPMENT

1. For safety in equipment setting, amp meters and volt meters shall be fitted to welding
equipment for the GMAW, FCAW and SAW welding processes.
9.3 ALIGNMENT
1. Equipment used to hold and support process equipment, vessels, piping, shall be
capable of bearing the load whilst maintaining the stability required for working in both
the vertical and horizontal planes.
10. MATERIAL-SPECIFIC ADDITIONAL REQUIREMENTS
10.1 GENERAL REQUIREMENTS

1. Welding requirements vary according to the specific material as specified in (10.5) to
(10.14). Common requirements are specified in (10.2) to (10.4).
2. Material-specific welding requirements include lists of approved welding processes.
10.2 WPQR MONITORING

1. WPQR monitoring shall include the following:
a. WPQR run out lengths (ROLs) and stub lengths for SMAW;
b. WPQR minimum and maximum bead widths for each weld pass;
c. WPQR interpass temperature at start of each pass.
10.3 WPQR REQUIREMENTS

10.3.1 General
WPQR requirements are generally in accordance with the relevant part of
EN ISO 15614, with clarifications and changes as indicated for the specific material.
1. The test piece locations should be in accordance with Figure 5.

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10.3.2 Essential variables

1. In addition to EN ISO 15614, Table 8 shall be applied for all weld procedures.
Table 8 Essential variables to apply to all weld procedures
Direction of Welding A change from vertical up to vertical down or vice versa requires
requalification.
Qualification Position • For GTAW/SMAW welding, qualification in H-L045 (6G)
position can be done instead of PC (2G) + PF (5G) positions.
• Plate: The positions required to qualify are PC (2G), PF
(3Gu), PE (4G).
Single/Double Sided Single-sided welds qualify double-sided welds but not vice-versa.
Bevel/V Compound bevels qualify V-bevels but not vice versa.
Backing Addition or removal of backing strips or gas requires
qualification.
Shielding/Backing Gases Minor constituents of gases do not change by more than 10% of
their nominal value.
Arc Voltage ± 10% of the average measured for the specified weld region.
Current/Wire Feed ± 15% of the average measured for the specified weld region.
Travel Speed ± 20% of the average measured for the specified weld region.
Arc Energy or Heat Input ± 25% of the average measured for the specified weld region.
Arc Type A change in arc characteristics (e.g., dip, globular, spray)
requires requalification.
Electrode/Filler Rod Size SMAW filling & cap passes, Normal practice is one electrode
diameter change is allowed within the consumable manufacturer
recommended optimal parameters settings, max 4mm diameter
use.
PWHT Increase in total PWHT time exceeding 25% requires
requalification.
Automation • Semi-automated and automated welding processes such as
orbital GTAW, Adaptive GMAW such as STT (Surface
Tension Transfer), RMD (Regulated Metal Deposition),
ESAB QSET (optimal short arc parameters settings) and
CMT (Cold Metal Transfer), require additional quality control.
• Full parameter settings reported during qualification,
archived and fully traceable during the fabrication stage.
o One of the following:
§ Automatic weld parameter monitoring to be
used during the qualification process.
§ Automatic welding parameter monitoring
quality control during fabrication.

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Cladding of corrosion • The heat input restricted in reference with the ISO 15614-7
resistant alloys by -10/ +25%.
• The electrode diameter (process 111/SMAW) can be
selected one diameter up/down from the qualified condition.
• The restriction for all changes to the “non-essential”
parameters is that the effect to the dilution of the base
material is minimal to the condition qualified.
For example, for the 111/SMAW process, the normal
recommended amperage and volt ranges are implemented
(not same amperage for lower electrode diameter).
Qualified diameter range 0.5xOD to 2xOD except that pipe diameter 168.3mm OD
for process piping (DN150/NPS 6) qualifies 0.5xOD and over, including plate
10.4 PARAMETER MONITORING

1. Requirements for parameter monitoring should reflect the sensitivity of the mechanical
and corrosion resistance properties of the material to be welded.
2. Parameter monitoring shall be executed per the approved ITP.
3. Records of parameter monitoring shall be reviewed by the Fabricator and Contractor
and any discrepancies with the applicable WPS highlighted to the welder for correction
and subsequently reported to the Principal.
4. Welding sets shall be calibrated or verified at intervals not exceeding 12 months.
5. Parameter monitoring acceptance criteria should meet the Fabricator’s standard
working practices and are intended to ensure repeatability across all machines.
E.g., The Fabricator is able to demonstrate that welders are able to set and
maintain the required parameters using the specified site instructions.
10.5 CMn STEELS NOT INTENDED FOR LOW TEMPERATURE SERVICE

1. In addition to EN ISO 15614 Tables 9 through 13 shall be applied for CMn steels not
intended for low temperature service.

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Table 9 General requirements for CMn Steels not intended for low temperature
service
1. Typical Materials ASTM A285C, A515, A106B, A105, A234-WPB, API 5L Gr B, A516,
A216.
2. Approved Root GTAW (141).
Processes
3. Approved Fill & Cap GTAW (141), SMAW (111), FCAW (136,114), GMAW (135), MCAW
Processes (138), SAW (121,125).
4. Consumable Restrictions SMAW electrodes: Type EXX16 or EXX18.
5. Consumable Chemistry a. Generic applications:
No additional restrictions to the standard.
b. CO2-containing corrosive service limitations:
Root and second pass limited to maximum 0.2 % Ni, 0.6 % Si,
0.5 % Mo to prevent preferential weld corrosion.
c. HF service limitations:
Cr + Cu + Ni < 0.15 % and 0.3 % Mo.
d. Matching type welding consumables:
Type Code Designation
Bare Wire AWS A5.18/A5.18M ER70S-3
ISO 636 W 42 5 W2Si
ISO 14341 G 42 2 M G2Si
Coated AWS A5.1 E7018-1 H4R
Electrode
E7016 H4R
ISO 2560-A E 46 4 B 32 H5
E 42 3 B 12 H5
6. Hydrogen Control ≤ 5ml/100g in accordance with EN ISO 3690.
10.5.2 WPQR requirements

Table 10 WPQR requirements for CMn steels not intended for low temperature
service
1. WPQR Monitoring Automatic monitoring equipment preferred, not mandatory.

2. WPQR Preheat Level If production hardness testing is part of the ITP and carried
out, the WPQR level of preheat is defined as the initial
preheat level of the test piece. Otherwise the WPQR level of
preheat is defined as the initial test piece preheat level or the
initial interpass temperature prior to starting the cap,
whichever is higher.

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10.5.3 WPQR testing requirements

Table 11 WPQR testing for CMn steels not intended for low temperature service
1. WPQR NDE Visual examination, Radiography + MPI as a minimum. Other

techniques, if used in production, included for procedure
qualification.
2. Charpy Impacts, T Specification to be made by reference to design code,
> 5mm (0.2inch) DEP 30.10.02.31-Gen or PED requirements. The standard
PED requirement is 27J minimum average (weld and HAZ) at
the minimum design temperature unless waived by the
appropriate harmonised design standard.
3. Charpy Impacts, T Specification to be made by reference to design code,
> 20mm (0.8inch) DEP 30.10.02.31-Gen. and/or PED requirements. The
standard PED requirement is 27J minimum average (weld and
HAZ) at the minimum design temperature unless waived by the
appropriate harmonised design standard.
4. Macro + Hardness Required as per EN ISO 15614. Photo-macrographs to be
Survey included with indicated magnification not less than 1X and
clearly showing all hardness indentations.
5. Maximum Hardness Refer to (4.5.3.2).

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Table 12 Essential variables for CMn steels not intended for low temperature
service
1. Carbon Equivalent Production CEq max = WPQR CEq +0.03, or 0.38 whichever is
higher.
Relaxation of this variable may be permitted based upon the
Contractor demonstrating QC controls which ensure the
application of suitable preheat for higher CE values and
implementation of appropriate production hardness testing,
approved by the Principal.
2. Thickness Limits As-welded thickness limit is defined in the selected design
(other) code.
3. Bevel Angle Total production weld included angle not to be decreased by
more than 10° from the WPQR.
For weldolets, demonstration that the butt weld welding
parameters can be maintained may be accepted as
justification to waive this requirement.
4. Electrode/Filler Rod Root electrode or filler wire size requires requalification.
Size For SMAW fill and cap, one electrode diameter change may be
allowed within the consumable manufacturer recommended
optimal parameters settings, max 4 mm (5/32 in) diameter use.
5. Preheat No decrease from that qualified.
No deletion or addition except that maximum 50°C (122°F) is
allowed for condensation mitigation.
6. Interpass May be raised by 50 °C (90 °F) above WPQR maximum.
7. Interpass Limit 300 °C (572 °F) maximum.
8. Heat Input or Arc Arc energy maximum recommended is 2.5 kJ/mm (63.5 kJ/in).
Energy
9. Repair Welding Repair WPS to be issued.
Separate WPQR not required unless essential variables
change.
10.5.5 Production controls

Table 13 Production control requirements for CMn steels not intended for low
temperature service
1. Parameter Random ROL or bead width checks are sufficient.

Monitoring
2. Other Tack welding requires preheating to the minimum level
specified on the WPS or 50°C (122°F), whichever is higher.

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10.6 IMPACT TESTED CMn STEELS (LTCS)

1. In addition to EN ISO 15614, Tables 14 through 19 shall be applied for impact tested
CMn steels (LTCS).
Table 14 General requirements for impacted tested CMn steels (LTCS)
1. Typical Materials ASTM A537, A352, A333 Gr6, A350 LF2, A420 Gr WPL6, API
5L X##, A694 F##.
Processes
3. Approved Fill and GTAW (141), SMAW (111), FCAW (136), SAW (121,125).
Cap Processes
4. Consumable SMAW electrodes: Type EXX16 or EXX18.
Restrictions
5. Consumable a. Generic applications:
Chemistry No additional restrictions to the standard.
b. Corrosive service:
For CO2 containing process service, root and second pass
limited to max 0.3% Ni, 0.6% Si, 0.5% Mo to avoid
preferential weld corrosion.
c. For HF service:
The limitation is Cr + Cu + Ni < 0.15% and 0.3% Mo.
d. Typical matching type welding consumables are as follows:
Type Code Designation
Bare Wire AWS A5.18/A5.18M ER70S-3
ISO 636 W 42 5 W2Si
ISO 14341 G 42 2 M G2Si
Coated AWS A5.1 E7018-1 H4R
Electrode
E7016 H4R
ISO 2560-A E 46 4 B 32 H5
E 42 3 B 12 H5
6. Hydrogen Control <= 5ml/100g to EN ISO 3690

Table 15 WPRQ requirements for impacted tested CMn steels (LTCS)
1. WPQR Monitoring Automatic monitoring equipment to be used.

2. WPQR Preheat If production hardness testing is part of the ITP and carried
Level out, the WPQR level of preheat is defined as the initial preheat
level of the test piece. Otherwise, the WPQR level of preheat is
defined as the initial test piece preheat level or the initial
interpass temperature prior to starting the cap, whichever is
higher.

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Table 16 WPQR testing requirements for impacted tested CMn steels (LTCS)
1. WPQR NDE Visual examination, Radiography + MPI as a minimum. If other

techniques are used in production, these to be included for
procedure qualification
2. Charpy Impacts, T > Root : Weld, Fusion Line, FL+2 mm (+0.08 in ) (and FL+5 mm
5mm (0.2 in) when heat input > 2.0 kJ/mm (51 kJ/mm)).
3. Charpy Impacts, T > Root: Weld, Fusion Line, FL+2 mm (+0.08 in) (and FL+5 mm
20mm (0.2 in) when heat input > 2.0 kJ/mm (51 kJ/mm)), including
Cap Weld Centreline
4. Macro + Hardness 5G or 6G: 3 off - 3 or 9 o’c, 6 o'c, 12 o'c positions. Other
Survey positions 1 off. Photo macrographs to be included with
indicated magnification not less than 1X and clearly showing
all hardness indentations.
5. Maximum Hardness Refer to (4.5.3.2).

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Table 17 Essential variables for impacted tested CMn steels (LTCS)
1. Carbon Equivalent Production CEq max = WPQR CEq +0.03, or 0.38 whichever is
higher.
Higher CE values may be permitted subject to review by the
Principal based upon the Contractor demonstrating QC
controls which ensure the application of suitable preheat for
higher CE values and implementation of appropriate
production hardness testing, approved by the Principal.
2. Material Supply Charpy impact and hardness acceptability for normalised,
Condition TMCR, Q&T materials to be qualified or demonstrated in
accordance with low temperature qualification requirements
(4.5.3.3) and Table 5.
3. Thickness For WPQRs with T < 5 mm (0.2 in), impact tests are not
required unless the WPS is to be used on material with
thickness greater than 5mm (0.2in).
4. Thickness Limits As-welded thickness limit is defined in the selected design
(other) code.
5. Simple/Compound Change to/from compound bevel requires approval by the
Principal.
6. Bevel Angle Total included angle not to be decreased by more than 10°
from WPQR.
7. Process The welding process, combination of processes or order of
Combination welding processes not to be changed unless approved by the
Principal.
8. Consumable The consumable brand name is an essential variable.
(The Principal may agree to changes for solid wires).
9. Electrode/Filler Rod Electrode or filler wire size not to be changed at any stage of
Size welding.
10. Polarity/Current Any change in polarity or current type requires requalification.
Type
11. Preheat Decrease from qualified preheat is not permitted.
12. Interpass May be raised by 50°C (122°F) above WPQR maximum.
13. Interpass Limit 250°C (482°F) maximum.
change.

Table 18 Production controls for impacted tested CMn steels (LTCS)
1. Parameter Scheduled, minimum one test per process, per shift.

Monitoring
specified on the WPS or 50°C (122F) whichever is higher.

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10.6.6 Charpy impact testing

1. As a minimum, Charpy impact testing shall demonstrate compliance with the
European Pressure Equipment Directive (97/23/EC).
2. ASTM A105 and A106 grade B materials, shall meet a minimum Charpy impact
resistance of 27J (20 ft-lb) when subjected to Charpy impact testing at a minimum
temperature of 0 °C (32 °F) or the minimum design temperature, whichever is lower.
3. For all other materials Charpy impact testing shall fully comply with the testing
requirements of this DEP and meet the testing temperature and acceptance criteria as
per Table 19.
Table 19 Charpy impact testing temperatures and acceptance criteria
Material Charpy Test Charpy Energy J (ft-lb) (1)

Temp.
°C (°F) Average Individual
Energy Lat. Exp
mm (mils)
A333 Gr 6 -50 (-58) (note 4) 27 (20) 19 (14)
A350 LF2 & A420 WPL6 -50 (-58) 27 (20) 19 (14)
UNS S31803 (2) -50 (-58) 50 (37) 0.38 (15) 40 (30)
UNS S32550 (2) -50 (-58) 50 (37) 0.38 (15) 40 (30)
UNS S32750 (2) -50 (-58) 50 (37) 0.38 (15) 40 (30)
UNS S32760 (2) -50 (-58) 50 (37) 0.38 (15) 40 (30)
A333 Gr 3, A350 LF3, A420 WPL3 -80 (-112) (3) 27 (20) 19 (14)
NOTES 1. The acceptance criteria for sub size specimens shall be reduced to:
7.5mm x 10mm (0.3 x 0.39in) 0.83 x full size values
5mm x 10mm (0.2 x 0.39in) 0.67 x full size values
2.5mm x 10mm (0.1 x 0.39in) 0.5 x full size values
2. The application of duplex stainless steels is limited to -50 °C (-58 °F) and 40 mm (1.5 in) maximum
thickness, unless a fracture mechanics assessment is carried out to justify lower temperatures or greater
thicknesses and is approved by the Principal. (see DEP.30.10.02.31-Gen.)
3. If the design temperature is lower than -80 °C (-112 °F), the test temperature shall be the same as the
minimum design temperature.
4. The Principal might accept pre-qualified procedure that is tested at -46 °C with the same acceptance criteria
depending on actual minimum design temperature and the 1.5J per degree C transition rule.
4. Charpy V-notch specimens shall be prepared and tested in accordance with

ISO 148-1.
5. For welds made with a maximum heat input of 2 kJ/mm (51 kJ/in), a set of three
Charpy impact specimens shall be taken with notches (1) at the weld centre line, (2) at
the fusion line, and (3) at the fusion line + 2 mm (0.08 in), as shown in Figure 3 below.

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Figure 3 Location of impact specimens
(1) RW = Notch at root weld
2mm
(2) RF = Notch at root fusion

line
2mm
(3) R2 = Notch at 2mm from

fusion line (and R5 = at 5mm
for heat inputs over 2kJ/mm)
2mm 2 or 5mm
2mm
(4) CW = Notch at cap weld

centreline
2mm
(5) CF = Notch at cap fusion

line
2mm
(6) C2 = Notch at 2mm from
fusion line (and C5 = at 5mm
for heat inputs over 2kJ/mm)
2 or 5mm
NOTE:
(1), (2) and (3) - All welds
(4) - Additional for ferritic steels with wall thicknesses over 20mm.
(4), (5) and (6) - Additional for duplex stainless steels with wall thickness over 20mm.
6. Where heat inputs greater than 2 kJ/mm (51 kJ/in) have been used during WPQR an
additional set of three specimens shall be taken at the fusion line + 5 mm (0.2 in).
7. For single sided welds, the specimens shall be taken with the lower surface no more
than 2 mm (0.08 in) above the inner surface and the following apply:
a. For material thicknesses greater than 20 mm (0.8 in), a set of three specimens
are also required with their notches at the weld centre line and with their upper
surfaces within 2 mm (0.08 in) of the outer surface.
b. Each specimen to be etched prior to notching and the location of the notch
relative to the fusion or weld centre line individually marked.
c. The notch to be placed in the square face of single sided bevel welds.
d. Pre-existing welding procedure tests performed in accordance with ISO 15614-1
shall be additionally impacted tested on the root area for the materials with the
thickness greater than 19 mm and less than 50 mm according to this DEP.
8. The notch positions for double sided welds shall be agreed with the Principal.

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9. Full size (10 mm x 10 mm (0.39 in x 0.39 in)) impact test specimens shall be used
wherever possible.
Where this is not possible, the larger of three quarter size (7.5 mm x 10 mm (0.3 in
x 0.39 in)) or half size (5 mm x 10 mm (0.2 in x 0.39 in)) specimens may be used.
Reduced acceptance values for reduced size samples are given in Table 8, Note 1.
10. No impact test result shall be less than the specified minimum individual value with not
more than one result less than the minimum average value specified.
a. In the event of failure, the following shall be applied
i. Three additional specimens are required to be tested.
ii. The average of the six specimens is not less than the minimum specified
average.
iii. Only two values to be below the specified minimum average value and only
one of those to be below the specified minimum individual value.
11. Fabrication of impact tested CMn piping and fittings, for process piping service (i.e.,
ASTM A333 gr6 and A350 LF2), shall be subject to PWHT based on the requirements
in the applicable design code and DEP 31.38.01.31-Gen.
10.7 3.5 % NICKEL STEELS

1. In addition to EN ISO 15614, Tables 20 through 24 shall be applied for 3.5% nickel
steels.
Table 20 General requirements for 3.5% nickel steels
1. Typical Materials ASTM A333 Gr3, A350 LF3, A420 Gr WPL3, A765 Gr III, A352
LC3, A203 D.
2. Approved Root GTAW (141)
Processes SMAW (111): Alternating current to be used for root pass
welding, to avoid magnetic arc blow problems and consequent
lack of fusion.
3. Approved Fill & Cap GTAW (141), SMAW (111), SAW (121,125).
Processes
4. Consumable Matching : GTAW : ER80S-Ni2/SMAW electrodes are
Restrictions 7016C2L, 7018C2L, 8016C2 or 8018C2.
5. Consumable Non-Matching : GTAW : ERNiCr-3/SMAW : ENiCrFe-2 or

Restrictions ENiCrFe-3.

Table 21 WPQR Requirements for 3.5% nickel steels
1. WPQR Monitoring Automatic monitoring equipment to be used.

level of the test piece.
Otherwise the WPQR level of preheat is defined as the initial
test piece preheat level or the initial interpass temperature
prior to starting the cap, whichever is higher.

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Table 22 WPQR testing requirements for 3.5% nickel steels

procedure qualification
2. Charpy Impacts, T > Root : Weld, Fusion Line, FL+2mm (and FL+5mm when heat
5mm input > 2.0kJ/mm)
3. Charpy Impacts, T > Root : Weld, Fusion Line, FL+2mm (and FL+5mm when heat
20mm input > 2.0kJ/mm), and Cap Weld Centreline.
4. Macro + Hardness 5G or 6G : 3 off - 3 or 9 o’c, 6 o'c, 12 o'c positions. Other
Survey positions 1 off. Photomacrographs to be included with
indicated magnification not less than 1X and clearly showing
all hardness indentations.
5. Maximum Hardness refer to (4.5.3.2)

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Table 23 Essential variables for 3.5% nickel steels
1. Material Supply Charpy impact and hardness acceptability for Normalised,

Condition TMCR, Q&T materials to be qualified or demonstrated in
accordance with low temperature qualification requirements
(4.4) and Table 3.
2. Thickness For WPQRs with T < 5 mm (0.2 in), impact tests are not
required unless the WPS is to be used on material with
thickness greater than 5 mm (0.2 in)
3. Thickness Limits For service below -80 °C (-112 °F), and/or thickness > 12.5
(other) mm PWHT is required.
The maximum thickness for as-welded applications at a
service temperature of -80 °C (-112 °F) is 12.5 mm (0.5 in).
Principal.
from WPQR.
Principal.
Size welding.
9. Backing gas A back purge with high purity Argon is required for GTAW of
3½ % Nickel steels
10. Heat input Maximum 1.8 kJ/mm (46 kJ/in).
11. Preheat A minimum preheat of 100 °C (212 °F) applies for welding all
thicknesses.
No decrease from that qualified.
12. Interpass No increase is permitted above that used in the WPQR.
change.

Table 24 Production controls for 3.5% nickel steels
1. Parameter Scheduled, minimum 1 test per process per shift.

Monitoring
specified on the WPS or 100 °C (212 °F), whichever is higher.

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10.8 LOW ALLOY STEELS

1. In addition to EN ISO 15614, Tables 25 through 29 shall be applied for low alloy
steels.
Table 25 General requirements for low alloy steels
1. Typical Materials ASTM A 387 types 0.5 Mo, 1 Cr-0.5 Mo, 1.25 Cr- 0.5 Mo, 2.25
Cr-1 Mo steels,5Cr 1Mo, 9Cr 1Mo, P91 (9Cr, 1Mo-V), AISI
4130.
2. Approved Root GTAW (141) and GMAW (1xx) for P3 to P9.
Processes
Processes
4. Hydrogen Control <= 5ml/100g to EN ISO 3690.
5. PWHT Low alloy steels require post weld heat treatment.

Table 26 WPQR requirements for low alloy steels
1. Reference 1.25 and 2.25Cr – API 934s and DEP 30.10.02.32-Gen.,

should be followed whenever applicable.
2. WPQR Monitoring Automatic monitoring equipment preferred but not mandatory.
level of the test piece.
Otherwise the WPQR level of preheat is defined as the initial
test piece preheat level or the initial interpass temperature
prior to starting the cap, whichever is higher.

Table 27 WPQR testing requirements for low alloy steels

procedure qualification.
2. Charpy Impacts, Specification to be made by reference to design code, low
T > 5 mm (0.2 in) temperature DEP 30.10.02.31-Gen. and/or PED requirements.
3. Charpy Impacts, Specification to be made by reference to design code, low
T > 20 mm (0.8 in) temperature DEP 30.10.02.31-Gen. and/or PED requirements.
4. Macro + Hardness 1 Required per EN ISO 15614. Photo-macrographs to be
5. Maximum Refer (4.5.3.2).
Hardness

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Table 28 Essential variables for low alloy steels
1. Material Supply No change.

Condition
Principal.
from WPQR.
Principal.
6. Backing gas A back purge with high purity Argon is required for GTAW of
2.25 Cr steels and higher alloys.
Size welding outside what was qualified in the WPQR.
8. Preheat A minimum preheat of 100 °C (212 °F) applies for welding all
thicknesses.
No decrease from that qualified.
change.

Table 29 Production controls for low alloy steels

Monitoring
specified on the WPS or 100 °C (212 °F) whichever is higher.

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10.9 AUSTENITIC STAINLESS STEELS

1. In addition to EN ISO 15614, Tables 30 through 34 shall be applied for austenitic
stainless steels.
Table 30 General requirements for austenitic stainless steels
1. Typical Materials AISI 300 Series, Grades 304L, 304, 316L, 316, 321, 347.
Processes
3. Approved Fill & Cap GTAW (141), SMAW (111), GMAW (135), SAW (121,125).
Processes FCAW (136): This can be used for design temperatures up to
150 °C (302 °F).
4. Consumable Principal alloying additions should not be made through flux
Chemistry additions.

Table 31 WPQR requirements for austenitic stainless steels

Table 32 WPQR testing requirements for austenitic stainless steels
1. WPQR NDE Visual examination, Radiography + DPI as a minimum. If other

Acceptance criteria for oxidation of stainless steel weldments
DEP 30.10.60.31-Gen.
2. Macro + Hardness Required per EN ISO 15614. Photo-macrographs to be
3. Maximum Hardness Maximum hardness 250 HV10.
4. Micro Examination 5G or 6G: 2 off representing min and max heat input, 1 off for
other positions. Microstructure of weld and HAZ to show
appropriate phase distribution and absence of micro-phases
considered deleterious to mechanical or corrosion properties.
Photomicrographs to be provided of each region (typically
250X) with the WPQR. (ISO 9042, equivalent to ASTM E562)
5. Ferrite Test Ferrite number (FN) 3-8FN in the root, cap and fill (i.e., mid
thickness) passes as per ISO 8249.
Alternative acceptable range may be specified for specific
application, e.g., LNG flare line.

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Table 33 Essential variables for austenitic stainless steels
from WPQR.
For weldolets, demonstration that the butt weld welding
parameters can be maintained may be accepted as
justification to waive this requirement.
Combination welding processes not to be changed.
Size welding outside of what was qualified in WPQR.
4. Polarity/Current Any change in polarity or current type (including pulse
Type characteristics) requires requalification.
7. Repair Welding Repair WPS to be issued. Separate WPQR not required
unless essential variables change.

Table 34 Production controls for austenitic stainless steels

Monitoring
2. Material Segregation Required to separate from other alloys.
3. Other a. Austenitic stainless steels to be cut mechanically or by
plasma arc cutting.
b. All plasma spatters and other debris to be removed from
the vessel, process pipework or other equipment surface by
dedicated disc grinder or emery disc.
c. Acceptance criteria for oxidation of stainless steel
weldments DEP 30.10.60.31-Gen.
4. Ferrite Checks Ferrite check to be done by means of approved ferrite
measurement device on weld metal on the fill (mid thickness)
and cap pass. Acceptance criteria is 3 – 8 ferrite number (FN).

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10.10 6 % Mo AND OTHER SUPERAUSTENITIC STAINLESS STEELS

1. In addition to EN ISO 15614, Tables 35 through 39 shall be applied for 6% Mo and
other superaustenitic stainless steels.
Table 35 General requirements for 6% Mo and other superaustenitic stainless
steels
1. Typical Materials UNS S31254, UNS N08367, UNS N08925, UNS N08926.
Processes
3. Approved Fill & Cap GTAW (141), SMAW (111), FCAW (136), SAW (121,125).
Processes
4. Consumable Type ERNiCrMo-3.
Restrictions
5. Consumable Principal alloying additions not to be made through flux
6. Autogenous Welding Not permitted.

Table 36 WPQR requirements for 6% Mo and other superaustenitic stainless
steels
1. WPQR Monitoring Automatic monitoring equipment required.

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Table 37 WPQR testing requirements for 6% Mo and other superaustenitic
stainless steels
1. WPQR NDE a. Visual examination, Radiography + DPI as a minimum. If

other techniques are used in production, these to be
included for procedure qualification.
b. Acceptance criteria for oxidation of stainless steel
2. Macro + Hardness a. 5G or 6G: 3 off - 3 or 9 o’c, 6 o'c, 12 o'c positions. Other
Survey positions 1 off.
b. Photo-macrographs to be included with indicated
magnification not less than 1x and clearly showing all
hardness indentations.
3. Maximum Hardness 35HRC (335 HV10).
4. Root Chemical All principal alloying additions: minimum C, Si, Mn, P, S, Cr,
Analysis Mo, Ni, Cu, Nb, and Fe.
5. Corrosion Test a. In an as-welded condition by ASTM G48 Method A @
35 °C (95 °F) for 24 hours.
b. The acceptance criteria are: weight loss ≤ 4 g/m² and no
initiation of localised corrosion (e.g., pitting) > 0.025 mm at
the test face.
If the weight loss is > 4 g/m² and it can be identified that this
is only due to corrosion at the cut faces, re-testing may be
carried out on replacement specimens.
c. Previously accepted WPQRs on 6%Mo with corrosion
testing at 30 °C (86 °F) do not require retesting at 35°C
(95 °F).
d. In the pickled and passivated condition, testing by ASTM
G48 Method A @ 40 °C (104 °F) for 24 hours is acceptable
with the same acceptance criterion as item b above.
6. Micro Examination a. 5G or 6G: 2 off representing min and max heat input, 1 off
for other positions.
b. Microstructure of weld and HAZ to show appropriate phase
distribution and absence of micro-phases considered
deleterious to mechanical or corrosion properties.
c. Photomicrographs to be provided of each region (typically
250X and 400X) with the WPQR.

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Table 38 Essential variables for 6% Mo and other superaustenitic stainless
steels
1. Chemistry A change in UNS number requires requalification.

Limitations
2. Position 2G + 5G qualification required for all positional coverage.
3. Joint Type Single and multi-pass fillets require separate qualification.
4. Root Gap Tolerance: - 0 mm / +2 mm (0.08 in) of the WPQR and not
outside the range 2 mm – 5 mm (0.08 in – 0.2 in).
5. Bevel Angle Total included angle not to be changed by more than +10°/ -5°
from WPQR.
7. Consumable The consumable brand name is an essential variable
Size welding outside what was qualified in the WPQR.
10. Interpass No increase above that qualified in the WPQR.
12. Heat Input Limits 1.5 kJ/mm (38 kJ/in) maximum.
13. Repair Welding Separate procedure to be qualified.

Table 39 Production controls for 6% Mo and other superaustenitic stainless
steels
1. Parameter Scheduled, minimum 1 test per process, per shift.

Monitoring
2. Material Segregation Required from other alloys.
3. Other a. 6 Mo stainless steels required to be cut mechanically or by
plasma arc cutting. All plasma spatters and other debris to
be removed by disc grinder or emery disc.

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10.11 DUPLEX STAINLESS STEELS

1. In addition to EN ISO 15614, Tables 40 through 44 shall be applied for duplex
stainless steels.
Table 40 General requirements for duplex stainless steels
1. Typical Materials UNS S31803, UNS32205 (22% Cr) and UNS S32550, UNS
S32750, UNS S32760 (25% Cr), excluding UNS32304.
Processes
3. Approved Fill & Cap GTAW (141), SMAW (111), FCAW (136), SAW (121,125).
Processes
4. Consumable Root and 2nd pass of 22% duplex to be made with 25% duplex
Restrictions consumable unless nitrogen containing shield gas and purge
gas are used.
Overmatched nickel content is required.
(Typically, 2209 type for 22% duplex and 2509 type for 25%
duplex).

8. Back purging Inert back purge of the internal surface to be maintained until
completion of the 3rd pass of the groove weld.
9. Material certification Both base metal and consumable material certification for
qualification to be in accordance with ISO 10474 – 3.2
certificate.

Table 41 WPQR requirements for duplex stainless steels

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Table 42 WPQR testing requirements for duplex stainless steels

Acceptance criteria for oxidation of stainless steel weldments
DEP 30.10.60.31-Gen.
2. Charpy Impacts, T > a. Root: Weld, Fusion Line, FL+2 mm (and FL+5 mm (0.2 in)
5mm when heat input > 1.75 kJ/mm (44 kJ/in)).
b. Criteria for duplex include lateral expansion > 0.38 mm.
See also Table 8.
3. Charpy Impacts, T > Root & Cap: Weld, Fusion Line, FL+2mm (and FL+5mm when
20mm heat input > 1.75kJ/mm (44kJ/in)).
Survey positions 1 off. Photo macrographs to be included with
indicated magnification not less than actual size and clearly
showing all hardness indentations.
5. Maximum Hardness The maximum hardness is 334 HV10 for 22% Cr DSS and
378 HV10 for 25Cr DSS.
There is no direct correlation between hardness of duplex
weldments and corrosion or toughness properties, but higher
values indicate some investigation is required as to the cause.
6. Root Chemical All principal alloying additions: minimum C, Si, Mn, P, S, Cr, Ni,
Analysis Mo, Cu, Al, (W) and N and calculated PREn.
7. Corrosion Test a. In an as-welded condition by ASTM G48 Method A, the test
temperature 22 °C for 22% duplex and 35 °C for 25%
duplex, for 24 hours.
b. The acceptance criteria are: weight loss ≤ 4 g/m² and no
initiation of localised corrosion (e.g., pitting) > 0.025 mm at
the test face.
If the weight loss is > 4 g/m² and it can be identified that this
is only due to corrosion at the cut faces, re-testing may be
carried out on replacement specimens.
c. If pickled and passivated, testing by ASTM G48 Method A
at a test temperature of 25 °C for 22% duplex and 40°C for
25% duplex for 24 hours with the same acceptance criteria
as above is acceptable.
8. Micro Examination a. 5G or 6G: 2 off representing min and max heat input, 1 off
for other positions.
b. Microstructure of weld and HAZ to show appropriate phase
distribution and absence of micro-phases considered
deleterious to mechanical or corrosion properties.
c. Photomicrographs to be provided of each region (typically
250X and 500X) with the WPQR.

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9. Ferrite Test Acceptance criteria: 35% – 60% in parent and 30% – 70% in
weld/HAZ according to ISO 17781 on with measurements to
be made 1 mm from root and cap in weld, HAZ, and parent
metal.

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Table 43 Essential variables for duplex stainless steels
1. Chemistry A change in grade sub group requires requalification.

Limitations
2. Thickness a. Welding procedure tests conducted on impact-tested
materials less than 5 mm thick need not be impact tested.
However, such procedure tests do not qualify for
thicknesses greater than 5 mm.
b. For 22Cr duplex, the thickness ranges qualified are in
accordance with ISO 15614-1.
c. For 25Cr duplex, the thickness ranges qualified are based
on the WPQR thickness (t) as follows:
t < 5 mm (0.2 in) : t - 1.5 t (limit 5 mm if not impact tested)
t >= 5 mm (0.2 in) : 0.75 t - 1.5 t
3. Thickness Limits The following thickness and minimum design temperature

(other) limitation apply:
>= -50 °C : 40 mm
4. Position 2G + 5G qualification required for all positional coverage.
5. Joint Type Multi-pass fillets may be qualified by butt weld fill and cap
parameters.
6. Simple / Compound Change to/from compound bevel requires approval by the
Principal.
from WPQR.
9. Consumable PREn of production consumables should not be more than 0.5
below those used for the WPQR.
The consumable brand name is an essential variable.
(The Principal may agree to changes for solid wires)
10. Electrode / Filler Rod Electrode or filler wire size not to be changed at any stage of
Size welding outside of what was qualified in WPQR.
11. Polarity / Current Any change in polarity or current type (including pulse
12. Interpass May be raised by 25 °C (45 °F) above WPQR maximum but
not above limit below.
13. Interpass Limits 125 °C (257 °F) for 25Cr duplex
150 °C (302 °F) for 22Cr duplex

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14. Heat Input Limits a. The arc energy and interpass temperature to be controlled
to ensure a cooling rate of the weld with respect to the
thickness which avoids detrimental phases or incorrect
ferrite/austenite phase balance.
Typical arc energies are in the range 0.5 kJ/mm – 1.75
kJ/mm.
b. The second pass is normally deposited at lower arc energy
than that of the root pass to achieve satisfactory corrosion
and mechanical properties.
15. Repair Welding Separate procedure to be qualified.

Table 44 Production controls for duplex stainless steels
1. Parameter Scheduled, minimum 1 test per process per shift.

Monitoring
3. Other a. Duplex stainless steels to be cut mechanically or by plasma
arc cutting.
b. All plasma spatter and other debris to be removed from the
vessel, process pipework or other equipment surface by
disc grinder or emery disc.
10.12 NICKEL ALLOYS

1. In addition to EN ISO 15614, Tables 45 through 49 shall be applied for nickel alloys.
Table 45 General requirements for nickel alloys
1. Typical Materials UNS N08825 (Alloy 825), UNS N06625 (Alloy 625), UNS
N04400 (Alloy 400), UNS N06600 (Alloy 600), UNS N0x925
(Alloy 925), UNS N0x718 (alloy 718), UNS N10276 (Alloy
C276).
Processes
Processes
4. Consumable a. The welding consumables to be agreed with Principal.
Restrictions The specific designation can be according ISO 14172, AWS
5.11 or EN 1600 for covered electrodes.
b. For wire the specific designation can be according
ISO 18274 or AWS 5.14.

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Table 46 WPQR requirements for nickel alloys
1. WPQR Monitoring Automatic monitoring equipment should be used.

Table 47 WPQR testing requirements for nickel alloys
1. WPQR NDE a. Visual examination, Radiography + DPI as a minimum. If

other techniques are used in production, these to be
included for procedure qualification.
2. Macro + Hardness Photo-macrographs to be included with indicated magnification
Survey not less than actual size and clearly showing all hardness
indentations.
3. Maximum Hardness Refer to ISO 15156-3 for maximum hardness.

Table 48 Essential variables for nickel alloys
1. Chemistry As per ISO 15614-1.

Limitations
parameters.
from WPQR.
5. Electrode / Filler Rod Electrode or filler wire size not to be changed at any stage of
Size welding.
6. Interpass May be raised by 25 °C above WPQR maximum.
7. Interpass Limit 200 °C maximum.
8. Heat Input 1.5 kJ/mm (39 kJ/in) maximum.

change.

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Table 49 Production controls for nickel alloys

Monitoring
3. Other a. Nickel and its alloys to be cut mechanically or by plasma
arc cutting.
b. All plasma spatter and other debris to be removed from the
10.13 COPPER ALLOYS

1. In addition to EN ISO 15614, Tables 50 through 54 shall be applied for copper alloys.
10.13.1 General requirements – Copper Alloys, expand on materials to be welded and
additional requirements
Table 50 General requirements for copper alloys
1. Typical Materials a. Cu/Ni alloys in the range of 90/10 and 70/30 materials
composition
Al-Brass alloys
Al-Bronze alloys
unalloyed copper
b. With reference to metallic materials DEP 30.10.02.11-Gen.
Processes
3. Approved Fill & Cap GTAW (141), SMAW (111), SAW (121).
Processes
4. Consumable a. The welding consumables to be agreed with Principal.
Restrictions b. The specific designation can be according ISO 14172, AWS
5.11 or EN 1600 for covered electrodes. For wire the
specific designation can be according ISO 18274 or AWS
5.14.
5. Materials condition For the welding of copper materials, the materials’ supply
condition to be reported. (i.e., hardness/strength/deformation
grade/heat treatment, aging).

Table 51 WPQR requirements for copper alloys

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Table 52 WPQR testing requirements for copper alloys

2. Macro + Hardness Photo-macrographs to be included with indicated magnification
Survey not less than 1X and clearly showing all hardness indentations.
3. Maximum Hardness The maximum hardness to be the same as the base material
specification. Normally the annealed condition hardness
requirement is also applicable for the weld area.

Table 53 Essential variables for copper alloys
parameters.
from WPQR.
Size welding.
Type characteristics).
8. Repair Welding a. For new fabrication:
Repair WPS to be issued.
change.
b. Repair/maintenance:
The WPS/WPQR to be reviewed in relation to the process
contaminations for additional requirements in shop and field
repairs on process exposed components.

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Table 54 Production controls for copper alloys

Monitoring
2. Material Segregation Required to separate from other alloys
3. Other a. Copper and its alloys to be cut mechanically or by plasma
arc cutting.
b. Immediately prior to welding the weld preparation and an
area 50 mm (2 in) on each side to be abraded with a
stainless steel brush or stainless wire wool and degreased
with a non-toxic, non-flammable solvent on both external
and internal surfaces.
c. All plasma spatter and other debris to be removed from the
4. Brazing a. Brazing of copper-based alloys shall be qualified according
to ISO 13585 for brazer qualification or EN qualifications via
EN 13134 (procedure), ISO 13585 (brazer) EN 12799
(NDE) and EN 12797 (destructive testing).
b. The qualification is primarily valid for the workshop
performing the welding tests, and other workshops under
the same technical and quality management. It may also be
transferred to and used by a subcontractor, provided the
principles of ISO 3834-2 and ISO 14731 are implemented
and documented.
c. The WPQR/ documentation shall include the material
certificates for the base and filler materials applied in the
weld qualification test.

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10.14 TITANIUM
1. In addition to EN ISO 15614, Tables 55 through 59 shall be applied for titanium alloys.
Table 55 General requirements for titanium alloys
1. Typical Materials a. Ti-alloy grade 2 (R50400) is used specifically and referenced

to DEP 30.10.02.11-Gen.
b. ASTM B265 grade 2 (plate) ASTM B338 Gr2 (tube), ASTM B
861/862 grade 2 (pipe), ASTM B363 Gr.WPT2 (Fittings),
ASTM B381 Gr.F2 (Flanges).
Processes
3. Approved Fill & Cap GTAW (141).
Processes
4. Consumable Same nominal composition as parent metal.
Chemistry
5. Autogenous Not permitted.
Welding
6. Secondary To be maintained until metal temperature falls below 500 °C
Shielding (932 °F) and provided by: glove-box chamber, trailing shield, or
incorporated into the head of orbital welding equipment.

Table 56 WPQR requirements for titanium alloys

Table 57 WPQR testing requirements for titanium alloys

Survey positions 1 off.
Photo-macrographs to be included with indicated magnification
not less than 1X and clearly showing all hardness indentations.
3. Maximum Hardness a. Base metal hardness to be as specified for base materials.
(140 HV10 for annealed plates).
b. The maximum hardness for the weldment (i.e., Weld and
HAZ) is base material hardness + 50 HV10 or 200HV5,
whichever is lower.

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Table 58 Essential variables for titanium alloys
1. Thickness The thickness tested is the maximum thickness qualified.

2. Position 2G + 5G qualification for all positional coverage.
parameters.
4. Simple / Compound Change to/from compound bevel.
5. Root Gap Tolerance: -0 / +2 mm of the WPQR.
6. Bevel Angle Total included angle not to be changed by more than +10°/-5°
from WPQR.
Combination welding processes not to be changed
8. Consumable The consumable brand name is an essential variable
(The Principal may agree to changes for solid wires.
9. Electrode / Filler Electrode or filler wire size not to be changed at any stage of
Rod Size welding.
10. Polarity / Current Any change in polarity or current type (including pulse
Type characteristics).
change.

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Table 59 Production controls for titanium alloys
1 Parameter Scheduled, minimum 1 test per process per shift.

Monitoring
2. Material Required to separate from other alloys.
Segregation
3. Other a. For titanium machining or grinding to be used for weld
preparation.
b. Immediately prior to welding the weld preparation and an
area 50 mm (2 in) on each side to be abraded with a
stainless steel brush or stainless wire wool and degreased
with a non-toxic, non-flammable solvent on both external and
internal surfaces.
c. Periodic checks for iron contamination to be agreed with the
Principal and made by a chemical method (e.g., ferroxyl) on
surfaces to be welded. Any inter-run tarnishing observed to
be removed by wire brushing.
d. As-deposited weld beads and HAZs of titanium welds to be
inspected after each pass for the degree of oxidation. No
dark blue, light blue, grey, and white deposits.
Light and dark straw-coloured oxides may be accepted.
The cause of the unacceptable oxides to be rectified before
production continues.
10.15 DISSIMILAR WELDING

10.15.1 General
1. Approval of Principal shall be obtained before carrying out dissimilar pressure
retaining welds or other dissimilar welds critical to the integrity of the equipment.
Rationale: Dissimilar welding is not a recommended practice and only can be used
as a last engineering option.
2. A list/record of dissimilar welds shall be kept from the beginning of the project and
updated as the project progresses.
3. Suitability of a dissimilar weld design shall be decided after considering the service,
weldment and the weld design together.
4. Welding procedure qualification tests between materials of different hardenability shall
achieve the following:
a. Tensile properties to meet specified minimum tensile properties of the weaker
material.
b. Impact properties to meet specified minima for both materials.
c. Hardness values to comply with the requirements of this DEP and NACE SP0472
for all dissimilar weld WPQRs.

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10.15.2 Groups of dissimilar joints

1. There are two groups of dissimilar joints, equal physical properties joints and different
physical properties joints:
2. Group 1 – Equal physical properties joints.
a. Joints between ferritic materials (carbon, Mo and Cr-Mo steels) – Dissimilar joints
between ferritic low-alloy and carbon steel are normally made using filler material
with a chemical composition matching the lower-grade material.
b. Joints between austenitic materials (AISI 304, 321, 317, 347).
c. Joints between high-nickel alloys (Monel, Alloy 700, Hastelloys B and C, or
equivalents).
3. Group 2 – Different physical properties joints.
a. Joints between ferritic and austenitic materials – This group of joints are normally
made using a buffer filler material.
The selection of weld metal largely depends on the service conditions, such as
temperature, thermal cycling, and possible galvanic corrosion.
10.15.3 Metal combinations of dissimilar joints
10.15.3.1 Welding carbon manganese or 0.5 Mo steels to Cr-Mo steels
1. For welds of carbon manganese or 0.5 Mo steels to Cr-Mo steels the following shall
apply:
a. An intermediate temperature between the PWHT temperature ranges of the two
materials, but lower than the tempering temperature of the lowest grade.
b. The holding time specified for the higher grade increased by 1.5 times.
c. Where the PWHT temperature does l not result in the individual base materials
and weld metal achieving the specified mechanical properties, then a buffering
layer technique to be applied on the higher-grade side.
d. After buffering, PWHT is required at the temperature suitable for the buffered
base material (2.25Cr-1Mo). After this PWHT, the joint will be completed and
PWHT carried out at the temperature suitable for the lower grade base material
(C-Mn steel).
For dissimilar welds in steel operating in the creep range (e.g., 9Cr-1Mo or
9Cr-1Mo modified to 2.25Cr-1Mo steels) carbon depletion in the low Cr base
material or weld can occur (carbon diffusion out of low chromium material into
the neighbouring high chromium steel) and will adversely affect the creep life.
10.15.3.2 Welding C steel to Ni or Cu alloys
1. The following consumables shall be used for welds of C steel to Ni or Cu alloys:
a. C-Mn steel to Ni alloys with AWS A5.11 ENiCrFe-2, Alloy 182 or Alloy 82
consumables.
b. C steels to Ni or Cu alloys with Monel 187/190 (ENiCu7).
c. C steels to Ni-Cr-Fe alloys with AWS A5.11 ENiCrFe-2.
d. C steel to aluminium bronze with special buffer-type electrodes of Cu-8Al or
Cu-10Al-1Fe.

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10.15.3.3 Welding ferritic steel to austenitic steel

1. For hydrogen service, welds shall not be made between ferritic steel and austenitic
steel.
Rationale: Welds between austenitic steel and ferritic steel are potentially sensitive
to cracking. The sensitive area is the local hard zone in the immediate vicinity of the
fusion line in the weld metal.
2. With the following exception, welding of ferritic steel to austenitic steel in hydrogen
service shall be restricted to a maximum operating temperature of 350 °C (660 °F).
a. This restriction does not apply for short-term temperature excursions above
350 °C (660 °F) (e.g., hot hydrogen stripping) because there is an incubation
period necessary before hot hydrogen attack occurs.
Rationale: The risk of cracking increases with temperature for reasons of thermal
fatigue (start-up/shut-down) particularly in the case of AISI 309 type of welds.
3. Dissimilar welding shall not be used for services where hydrogen charging from the
process side can occur.
4. Chemical cleaning or pickling shall not be applied.
5. During weld procedure qualification, a micro-hardness survey on an etched sample
shall be done on the fusion line between the buffer layer and base material.
Rationale: The hard zone on the interface could contain individual hard spots
provided there is not a continuous network (sequence) of hard spots.
6. Where PWHT is required for the ferritic material, the ferritic weld bevel shall be
buttered with a buffer type consumable followed by PWHT and welding with matching
austenitic filler metal.
7. For wall thicknesses below 25 mm (1 in) a stainless steel pup piece/ring may be
welded to the ferritic material with a buffer consumable followed by separate PWHT,
as buttering buffer layer onto thin materials is cumbersome.
10.15.3.4 Welding austenitic stainless steel to Ni-Cr-Fe alloys
1. For high temperature applications, AWS A5.11 ENiCrFe-2 or Alloy 82 filler metal shall
be used.
2. For low temperature applications, Alloy 112/625 or AWS A5.11 ENiCrFe-2 filler metal
shall be used.
10.15.3.5 Welding other metal combinations
1. Welds for other metal combinations, including austenitic stainless steels with design
temperature over 454 °C (850 °F), shall be subject to approval of Principal.
Design concepts used for the above combinations can be utilised on welds for other
metal combinations where applicable.
10.15.4 Nondestructive examination considerations
1. NDE procedures for dissimilar welds shall be subject to approval of the Principal.
Dissimilar welds could require NDE coverage different from that required by the
piping class or standard project NDE schedules.
The weak link of dissimilar welds is the fusion boundary between a base metal and
weld made from the different material.
2. Dissimilar welds shall be designed to allow volumetric examination.

DEP 30.10.60.32-Gen.
February 2019
Page 65
10.15.5 Dissimilar weld register

1. All dissimilar welds shall be recorded in a dissimilar weld register prepared by the
Fabricator and included in the welding plan/map and as a minimum, contain the
following information:
a. Weld identifier;
b. Relevant drawing identifier (P&ID/MEFD/isometric or equipment fabrication
drawings);
c. P numbers of the alloys to be welded and brief description of the weld;
d. Criticality rating of the weld
e. Applicable welding procedure identifier (includes the name of the organisation,
which welded such weld.);
f. Identification of the responsible person who approved the location of the
dissimilar weld;
2. The Contractor shall endorse the Fabricator’s dissimilar weld register and submit to
the Principal.
10.15.6 Final approvals
1. The dissimilar welds register shall be subject to the approval of the designated
technical authority of the Principal.

DEP 30.10.60.32-Gen.
February 2019
Page 66
Figure 5 Position of test specimens
Location Alternative Specimens
1 n/a 12 o’c macro hardness (if required for 5G/6G)
2 2’ 1 Tensile and 2 bend tests
3 3’ Charpy Impacts and 3 or 9 o’c macro hardness (if

required for 5G/6G)
4 4’ 1 Tensile and 2 bend tests
5 n/a 6 o’c macro hardness
1-2 2’-1 Corrosion test specimen A (Duplex and 6%Mo)
4-5 5-4’ Corrosion test specimen B (Duplex and 6%Mo)
NOTES:
1. Locations are based on the upward direction according to EN ISO 15614-1.
2. Specimen location priority: 1st Macros, 2nd Impacts, 3rd Tensiles, 4th Corrosion Coupons, 5th Bends.
3. Additional latitude is acceptable for joints that are not in fixed 5G or 6G positions, but it is
important to ensure that two tensile specimens or two pairs of bend specimens are not adjacent to
each other

DEP 30.10.60.32-Gen.
February 2019
Page 67
11. REFERENCES
In this DEP, reference is made to the following publications:
NOTES: 1. Unless specifically designated by date, the latest edition of each publication is used, together with
any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards/.
SHELL STANDARDS
DEP feedback form DEP 00.00.05.80-Gen.

Metallic materials – Selected standards DEP 30.10.02.11-Gen.
Wet H2S requirements for downstream process equipment and piping DEP 30.10.02.17-Gen.
Metallic materials – prevention of brittle fracture in new assets DEP 30.10.02.31-Gen.
Materials and fabrication requirements for 2¼cr-1mo, 2¼cr-1mo-¼v, DEP 30.10.02.32-Gen.

3cr-1mo & 3cr-1mo-¼v heavy wall pressure vessels
(amendments/supplements to API RP 934-a)
Welding of metals (additional to API RP 582) DEP 30.10.60.18-Gen.
Oxidation of stainless steel weldments DEP 30.10.60.31-Gen.

Unfired pressure vessels DEP 31.22.00.31-Gen.
Shop and field fabrication of piping DEP 31.38.01.31-Gen.
Selection of materials for upstream equipment (amendments and DEP 39.01.10.12-Gen.
supplements to iso 15156:2015)
Shell HSSE & SP Control Framework, Design Engineering Manual DEM1
(DEM) 1 – Application of Technical Standards
https://eu001-
sp.shell.com/sites/AAAAA8432/CF/Web/Design Engineering Manual
1 DEM1.aspx
AMERICAN STANDARDS
Safety in Welding, Cutting and Allied Processes ANSI Z49.1

Qualification Standard for Welding and Brazing Procedures, Welders, ASME/BPVC Sec IX
Brazers, and Welding and Brazing Operators Welding and Brazing
Qualifications
Standard Recommended Practice – Methods and Controls to Prevent NACE SP0472
In-Service Environmental Cracking of Carbon Steel Weldments in
Corrosive Petroleum Refining Environments
EUROPEAN STANDARDS
Metallic products – Types of inspection documents EN 10204

Brazing – Destructive tests of brazed joints EN 12797
Brazing – Non-destructive examination of brazed joints EN 12799
Brazing – Procedure approval EN 13134
Unfired pressure vessels EN 13445

DEP 30.10.60.32-Gen.
February 2019
Page 68
INTERNATIONAL STANDARDS
European pressure equipment directive (PED) 2014/68/EU Directive 2014/68/EU

Arc welding equipment IEC 60974-x
Thermocouples – Part 1: EMF specifications and tolerances IEC 60584-1
Metallic materials – Charpy pendulum impact test – Part 1: Test ISO 148
method
Welding consumables – Rods, wires and deposits for tungsten inert ISO 636
gas welding of non-alloy and fine-grain steels – Classification
Welding consumables – Covered electrodes for manual metal arc ISO 2560
welding of non-alloy and fine grain steels – Classification
Welding and allied processes – Determination of hydrogen content in ISO 3690
ferritic steel arc weld metal
Quality requirements for fusion welding of metallic materials ISO 3834-x
Gas welding equipment – Blowpipes for gas welding, heating and ISO 5172
cutting
Welding. fusion-welded joints in steel, nickel, titanium and their alloys ISO 5817
(beam welding excluded) – Quality levels for imperfections
Metallic materials – Vickers hardness test ISO 6507
Welding – Determination of Ferrite Number (FN) in austenitic and ISO 8249
duplex ferritic-austenitic Cr-Ni stainless steel weld metals
Quality management systems — Requirements ISO 9001
Steels – Manual point counting method for statistically estimating the ISO 9042
volume fraction of a constituent with a point grid
Approval testing of welders – Fusion welding ISO 9606-x
Non-Destructive Testing – Qualification and Certification of Personnel ISO 9712
Steel and steel products – Inspection documents ISO 10474
Protective clothing for use in welding and allied processes ISO 11611
Brazing – Qualification test of brazers and brazing operators ISO 13585
Gas welding equipment – Acetylene manifold systems for welding, ISO 14114
cutting and allied processes – General requirements
Welding consumables – Solid wire electrodes, tubular cored ISO 14171
electrodes and electrode/flux combinations for submerged arc welding
of non-alloy and fine grain steels – Classification
Welding consumables – Covered electrodes for manual metal arc ISO 14172
welding of nickel and nickel alloys – Classification
Welding consumables — Wire electrodes and weld deposits for gas ISO 14341
shielded metal arc welding of non-alloy and fine grain steels —
Classification
Welding coordination – Tasks and responsibilities ISO 14731
Welding personnel — Qualification testing of welding operators and ISO 14732
weld setters for mechanized and automatic welding of metallic
materials
Materials for use in H2S-containing environments in oil and gas ISO 15156
production – Parts 1, 2 and 3

DEP 30.10.60.32-Gen.
February 2019
Page 69
Specification and qualification of welding procedures for metallic ISO 15609

materials
Specification and qualification of welding procedures for metallic ISO 15614-x
materials – Welding procedure test
Petroleum, petrochemical and natural gas industries – Shell-and-tube ISO 16812
heat exchangers
General criteria for the operation of various types of bodies performing ISO 17020
inspection
General requirements for the competence of testing and calibrating ISO 17025
laboratories
Petroleum, petrochemical and natural gas industries — Test methods ISO 17781
for quality control of microstructure of ferritic/austenitic (duplex)
stainless steels
Non-destructive testing of welds – Visual testing of fusion-welded ISO 17637
joints
Welding – Quality requirements for heat treatment in connection with ISO 17663
welding and allied processes
Welding consumables – Solid wire electrodes, solid strip electrodes, ISO 18274
solid wires and solid rods for fusion welding of nickel and nickel alloys
– Classification
Welding – Guidelines for a metallic material grouping system ISO/TR 15608
Recommendations for welding of metallic materials ISO/TR 17671
Specification for Unfired fusion welded pressure vessels PD 5500

DEP 30.10.60.32-Gen.
February 2019
Page 70
APPENDIX A REPORTING REQUIREMENTS FOR WELDING QUALIFICATION
A.1 WELDING PROCEDURE DOCUMENTATION

A.1.1 General
1. The following documentation shall be presented for approval for each welding
procedure qualified:
a. weld Procedure Specification (final version);
b. weld Procedure Qualification Record;
c. parent material certification;
d. consumable batch certification;
e. NDE reports on test weld (including visual examination);
f. post-weld heat treatment record charts (if applicable);
g. mechanical test reports:
h. corrosion testing if applicable.
A.1.2 Welding Procedure Specifications
1. Welding Procedure Specifications (WPSs) shall include the following information, in
addition to the recommendations of ISO 15609 annex A:
a. a unique procedure number including revision number;
b. the parent material(s) range to weld;
c. the thickness and diameter range to weld;
d. the weld preparation or preparations (including sketch with dimensions and
tolerances, backing if applicable)
e. method of clamping or tack welding, including weld parameters;
f. minimum preheat level and method (also condensation mitigation);
g. the maximum interpass temperature allowed;
h. travel speed for each pass or group of passes;
i. bead width or run out length (for SMAW) range for each pass or group of passes;
j. the arc energy in kJ/mm is required to be reported. (NB. If factored to take
account of process thermal efficiency, i.e., a true heat input figure to be clearly
indicated);
k. electrode stick-out for SAW, GMAW and FCAW;
l. gas shroud diameter for GMAW, FCAW (gas shielded) and GTAW;
m. automated welding parameters, such as oscillation, amplitude, frequency, dwell
time and pulse characteristics;
n. any treatment for preparing and welding the second side (gouging, grinding,
machining);
o. signatures by the Fabricator, third party authority and Principal.
A.1.3 Weld procedure qualification records
1. In addition to the recommendations of ISO 15614 Annex A, the weld procedure
qualification records (WPQRs) shall include the weld procedure qualification number,
including revision control.
2. WPQRs shall be endorsed by the third-party inspector(s) or NOBO.

DEP 30.10.60.32-Gen.
February 2019
Page 71
A.1.4 Record of weld test

1. The record of weld test shall include the following information, in addition to the
recommendations of ISO 15614 Annex A:
a. weld procedure number (including revision) and test weld/coupon number;
b. date and time of test;
c. parent material(s) certification details (heat, cast, certificate);
d. welding consumable, batch numbers;
e. welders’ identification number(s);
f. drawing(s) showing actual weld preparation dimensions and weld sequence;
g. method of alignment/tacking;
h. method of preheating;
i. reference to PWHT procedures and record charts if applicable;
j. welding machine(s), type, make and setup.
This is significant for the more automated/sophisticated welding sets.
k. range of bead widths (reference for weld monitoring during production phase).
l. electrode stick-out length (FCAW, GMAW, or SAW).
2. The following information shall be recorded for each, individual weld run:
a. average run out length of electrodes and remaining stub length (for SMAW);
b. welding speed;
c. calculated arc energy;
d. interpass temperature immediately prior to commencement of run;
3. The record of weld test shall be endorsed by the Fabricator and by the third-party
inspector(s) or NOBO.


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DEP SPECIFICATION

WELDING OF METALS, BASED ON ISO STANDARDS

DESIGN AND ENGINEERING PRACTICE

© 2019 Shell Group of companies

This document has been supplied under license by Shell to:

This document has been supplied under license by Shell to:

This document has been supplied under license by Shell to:

10.6 IMPACT TESTED CMn STEELS (LTCS) ................................................................. 36

This document has been supplied under license by Shell to:

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

This document has been supplied under license by Shell to:

The word shall indicates a requirement.

ANSI American National Standards Institute

ASME American Society of Mechanical Engineers

ASTM American Society for Testing and Materials

AWS American Welding Society

B Maximum nominal pipe wall thickness for “as-welded” application

CMn Carbon Manganese

CSWIP Certification Scheme of Welding Inspection Personnel

EWF European Federation for Welding, Joining and Cutting

FCAW Flux Core Arc Welding

GMAW Gas Metal Arc Welding

GTAW Gas Tungsten Arc Welding

HAZ Heat Affected Zone

IIW International Institute of Welding

ITP Inspection and Test Plan

IVB Independent Verification Body

MT Magnetic Particle Inspection

NDE Non-destructive Examination (also known as NDT)

NOBO Notified Body

PED (European)Pressure Equipment Directive

PRE(N) Pitting Resistance Equivalent (including nitrogen)

PT Liquid Penetrant Examination

PWHT Post Weld Heat Treatment

This document has been supplied under license by Shell to:

SAW Submerged Arc Welding

SMAW Shielded Metal Arc Welding

t Nominal Pipe Wall Thickness

TMCR Thermo-Mechanically Controlled Rolled

TOFD Time of Flight Diffraction

WPQR Welding Procedure Qualification Record

WPS Welding Procedure Specification

1.5 SUMMARY OF MAIN CHANGES

This document has been supplied under license by Shell to:

1.6 COMMENTS ON THIS DEP

Shell DEPs Online Enter the Shell DEPs Online system at

DEP Feedback System Enter comments directly in the DEP Feedback

DEP Standard Form Use DEP Standard Form 00.00.05.80-Gen. to record

1.7 DUAL UNITS

1.8 NON NORMATIVE TEXT (COMMENTARY)

1.9 PRECEDENCE OF DOCUMENTS

This document has been supplied under license by Shell to:

2.2 PERSONNEL COMPETENCIES

2.3 INSPECTION AND TEST PLAN

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2.5 FINAL ACCEPTANCE

3.1 WELDING PROCESSES

Process Name ASME EN/ISO Comment

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