Document No.

GIS 42-102
Applicability Group
Date 3 May 2005

Guidance on Industry Standard for

Fabrication, Assembly, Erection, and
Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy,
Titanium, and Zirconium Pipework (ASME
B31.3)

GIS 42-102

DO NOT COPY
BP GROUP
ENGINEERING TECHNICAL PRACTICES
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

Foreword

This is the first issue of Engineering Technical Practice (ETP) BP GIS 42-102. This Guidance on
Industry Standard (GIS) is based on parts of heritage documents from the merged BP companies as
follows:

British Petroleum
GS 118-7 The Fabrication, Assembly, Erection and Inspection of Austenitic and
Duplex Stainless Steel, Cupro-Nickel, Nickel Base Alloy, Titanium and
Zirconium Pipework to ASME B31.3.

Amoco
A PN-PLT-31.3-C Piping—Plant—ASME B31.3—Construction Specification.
A PN-PLT-31.3-CG Piping—Plant—ASME B31.3—Construction and Fabrication Guide.
A PN-PLT-31.3-P Piping—Plant—ASME B31.3—Fabrication Specification.

ARCO
Std 200 Piping Design.

DO NOT COPY
Copyright © 2005, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipient’s organisation. None of the information
contained in this document shall be disclosed outside the recipient’s own organisation
without the prior written permission of Director of Engineering, BP Group, unless the
terms of such agreement or contract expressly allow.

Page 2 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

Table of Contents
Page
Foreword............................................................................................................................................2
Introduction ........................................................................................................................................5
Chapter I Scope and definitions........................................................................................................6
300 General statements ..................................................................................................................6
300.1 Scope ............................................................................................................................6
300.4 Status of appendices .....................................................................................................6
Chapter V Fabrication, assembly, and erection ................................................................................7
327 General .....................................................................................................................................7
327.1 Quality assurance and positive material identification ...................................................7
327.2 Material control ..............................................................................................................8
327.3 Pipework marking ..........................................................................................................8
327.4 Fabrication facilities .......................................................................................................8
328 Welding.....................................................................................................................................9
328.2 Welding qualifications....................................................................................................9
328.3 Welding materials ........................................................................................................11
328.4 Preparation for welding................................................................................................12
328.5 Welding requirements..................................................................................................13
330 Preheating ..............................................................................................................................16
330.1 General........................................................................................................................16
331 Heat treatment ........................................................................................................................17
331.1 General........................................................................................................................17
331.2 Specific requirements ..................................................................................................18
332 Bending and forming...............................................................................................................19
332.1 General........................................................................................................................19
332.2 Bending .......................................................................................................................19
335 Assembly and erection ...........................................................................................................20

DO NOT COPY
335.1 General........................................................................................................................20
Chapter VI Inspection, examination, and testing ............................................................................21
341 Examination ............................................................................................................................21
341.3 Examination requirements...........................................................................................21
341.4 Extent of required examination ....................................................................................21
342 Examination personnel ...........................................................................................................21
342.1 Personnel qualification and certification ......................................................................21
343 Examination procedures .........................................................................................................21
344 Types of examination..............................................................................................................22
344.2 Visual examination ......................................................................................................22

Page 3 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

344.5 Radiographic examination ...........................................................................................22

344.6 Ultrasonic examination ................................................................................................22
345 Testing ....................................................................................................................................23
345.4 Hydrostatic leak test ....................................................................................................23
347 Weld repairs............................................................................................................................23
Appendix E Reference standards ...................................................................................................30
Appendix N Additional requirements for 22%Cr and 25%Cr duplex stainless steel materials........31
N1. Introduction..................................................................................................................31
N2. Welding........................................................................................................................31
N3. Welding procedure qualification ..................................................................................32
N4. Welder qualification .....................................................................................................34
N5. Production welding ......................................................................................................34
Appendix O Additional requirements for titanium and zirconium ....................................................35
O1. Introduction..................................................................................................................35
O2. Cleaning and preparation for welding ..........................................................................35
O3. Welding........................................................................................................................35
O4. Welding procedure qualification ..................................................................................37
O5. Welder qualification .....................................................................................................37
O6. Production welding ......................................................................................................37
Bibliography .....................................................................................................................................38

List of Tables

Table 1 – Acceptance criteria for welds (to be read in conjunction with Table 341.3.2 of
ASME B31.3) ..........................................................................................................................24
Table 2 – Acceptable radiographic sensitivity levels (using wire type IQI to ASTM E747 or BS
EN 462-1) ...............................................................................................................................25

List of Figures

Figure 1 – Charpy notch locations ...................................................................................................26

Figure 2 – Dimensional tolerances for fabricated pipework .............................................................27
Figure 3 – Local heat treatment for branch connections..................................................................28

DO NOT COPY
Figure 4 – Segmental bends............................................................................................................29

Page 4 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

Introduction

a. Guidance for fabrication, assembly, erection, and inspection of austenitic and duplex
stainless steel, cupro-nickel, nickel base alloy, titanium, and zirconium pipework is based
on American Society of Mechanical Engineers (ASME) B31.3, Process Piping, 2002:
1. Chapter I Scope and definitions.
2. Chapter V Fabrication, assembly, and erection.
3. Chapter VI Inspection, examination, and testing.
b. Guidance statements of this GIS are modifications to ASME B31.3.
c. Modifications to ASME B31.3 are identified as Add, Modify to Read, or Delete.
d. Paragraph numbers in this ETP correspond to ASME B31.3.
e. Paragraphs of ASME B31.3 that are not revised remain applicable.

DO NOT COPY

Page 5 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

Chapter I Scope and definitions

300 General statements

300.1 Scope

300.1.3 Exclusions
Add
(e) Sea transport.
(f) Transmission pipelines in land or subsea locations, including risers.
(g) Pipelines of significant length and diameter, e.g., transfer lines between processing units,
storages, and jetties that are specified by BP to be engineered as main pipelines.
(h) Production piping systems, as designated by BP.
Production piping is covered by BS EN 14161 and ASME B31.4.
(i) Underground drainage systems.
(j) Steam piping systems within plot limits of power stations and steam generating stations
outside process areas.
Steam piping is covered by ASME B31.1 and BS EN 13480.
There is no ETP currently available to cover this category. However, guidance on
these systems can be found in ACES A PN-BLR-31.1-E and BP OUS RP 5-5-4.
(k) Heating, ventilating, and domestic water systems within buildings, including offshore
accommodation modules.
(l) Hydraulic systems.

300.4 Status of appendices

Table 300.4 Status of appendices in B31.3

Add
N Fabrication requirements for 22%Cr and 25%Cr duplex stainless steel pipework Requirements
O Fabrication requirements for titanium and zirconium Requirements

DO NOT COPY

Page 6 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

Chapter V Fabrication, assembly, and erection

327 General

Add

327.1 Quality assurance and positive material identification

327.1.1 Initial documentation

a. Before commencing fabrication of pipework, fabricator shall prepare:
1. Quality plan.
2. Set of design documents.
b. Both documents shall be subject to BP approval.
c. These documents should normally include:
1. Procedures for:
a) Storage and control of materials and welding consumables (Refer to GP 18-02).
b) Welding and nondestructive testing.
c) Mechanical working, heat treatment, and leak testing.
2. Supporting qualification records.
3. Illustration of proposed areas of application.
d. Previously qualified welding procedures may be considered for use if they comply with
this GIS document and are appropriate to proposed scope of work.
e. Simplified welder instruction cards based on qualified welding procedures should be
prepared for each welding process/material combination and issued to each welder.
f. Quality plan shall include brief details and sequence of examinations that will be
performed for fabricator.
g. Names of individuals responsible for implementation of quality assurance and quality
control functions shall be included.
Fabricators involved in simultaneous fabrication of carbon steel and alloy piping

DO NOT COPY
should submit positive material identification (PMI) document setting out how they
maintain and verify identification of materials during fabrication. GIS 36-103 sets
out requirements for a PMI system.

327.1.2 Production documentation

a. Fabricator shall maintain production records using recording system approved by BP.
b. Production records shall include:
1. Material and welding consumable certificates.
2. Post weld heat treatment records.
3. Visual and dimensional inspection.
4. NDT and pressure test records.

Page 7 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

5. Isometric drawings marked up with weld numbers.

6. Welder and welding operator qualification test records.
7. Authenticated copies of NDT operators’ certificates.
8. Records of agreed concessions to fabrication standards.
c. Upon completion of fabrication programme, records shall either be passed to BP or stored
by fabricator, as directed by engineering design or fabrication contract.

327.2 Material control

a. Fabricator shall inspect materials upon receipt and ensure that correct grade of material has
been supplied and that identification, dimensions, material quality, and end preparation are
in accordance with the requisite standards and specifications.
b. Different materials shall be kept in discrete sections of storage area, and material shall be
marked in a manner that allows it to be related to original manufacturer’s certification.
c. Procedures for transfer of material identification marks shall be agreed with BP prior to
commencement of fabrication.
d. Materials shall be stored above ground and kept free from dirt, grease, and other
contaminants.
e. Material that is not readily identifiable shall be removed from worksite and quarantined
until material grade and source can be confirmed.
Positive identification and segregation of materials is an important issue.

327.3 Pipework marking

a. Pipework shall be identified by indelible marking that is free from sulphur, chloride, and
other halogens.
b. If spools are subject to postweld heat treatment, suitable heat resisting paint shall be used.
c. Vibroetching techniques may be used for identification transfer, but adhesive tapes or hard
stamping, other than that with low stress stamps, shall not be used.
d. Marking shall have minimum life of 1 year in covered, unheated, storage.
e. Marking shall identify material and fabricator and include item number, enabling spool to
be traced to relevant isometric drawing.
Guidance on suitable colours for identification of piping materials is in BS 5383.

327.4 Fabrication facilities

DO NOT COPY
a. Area used for fabrication shall be totally separate from that used for carbon and low alloy
steel.
1. Each alloy type shall be segregated during fabrication.
2. Precautions shall be taken to prevent surface contamination by contact with jigs and
fixtures manufactured in non compatible materials.
3. Separate sets of clearly identified cleaning and grinding equipment shall be provided
for each material.
b. Shop layout, equipment, and production procedures shall be subject to BP approval,
particularly if fabrication of titanium or zirconium is involved.

Page 8 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

328 Welding

328.2 Welding qualifications

328.2.1 Qualification requirements

(a) Add
1. Welding procedure specifications and procedure qualification test results shall be
subject to BP approval before commencement of fabrication.
2. Each procedure qualification record (PQR) shall be certified by recognised
independent inspectorate.
SMAW, GTAW, and SAW processes are frequently employed for pipework
fabrication and are considered to be acceptable welding techniques if used in
accordance with this ETP. GMAW and FCAW processes are also often applied to
piping fabrication. However, there are many variants of these two processes. In
addition to ensuring adequate procedure qualification, it is important to ensure that
the particular welding technique proposed for a given application is well proven
and will only be used by qualified and experienced welders.
(d) Add
1. Unless specified otherwise by engineering design, duplex stainless steel piping
materials, fittings, and weldments for design temperatures below 0°C (32°F) shall be
subject to Charpy V notch impact testing, as detailed in Appendix N.
2. Minimum design temperature for duplex stainless steels shall be –50°C (–58°F).
3. Austenitic stainless steels shall not generally require Charpy V notch impact testing if
minimum design temperatures greater than –196°C (–320°F).
4. If the possibility of toughness degradation as a result of post weld heat treatment
exists (see 331.1.1), Charpy V notch impact testing is required for austenitic stainless
steels.
5. Required impact energy for austenitic stainless steels is 40 J (30 ft-lb) at minimum
design temperature.
6. If impact testing is required weld metal, fusion line, and HAZ shall be tested.
7. Charpy specimens shall be cut transverse to weld with axis of notch perpendicular to
surface of test piece.
8. Specimen and notch locations shall be as shown in Figure 1.
9. If only subsize charpy specimens can be taken, the following standard energy
reduction factors shall be applied:

DO NOT COPY
Specimen Size (mm) Specimen Size (in) Reduction Factor
10 x 7.5 0.394 x 0.295 0.833
10 x 5 0.394 x 0.197 0.667

10. If welding procedure requiring impact testing is to be used in all positions, separate
2G and 5G qualifications shall be performed.
(e) Modify to Read
Backing rings are not permitted.
(f) Add
P-Numbers (also F-Numbers)

Page 9 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

1. Extension of welding procedure qualification from material on PQR to material of

different specification, even if it has same P-Number, shall be subject to BP approval.
2. New welding procedure qualification is required for nonimpact tested procedures, if
there is a change of consumable classification.
3. Unless agreed otherwise, new welding procedure qualification is required for impact
tested procedures if there is a change of consumable brand name.
3. New welder performance test is required if there is a change of SMAW electrode
brand name, unless brand characteristics do not differ sufficiently to affect
performance. Such change shall be subject to BP approval.
Add
(g) Welding procedure specification (WPS) shall require requalification if any of the following
changes are made:
1. Change outside welding parameter tolerance ranges specified in qualified welding
procedure specification.
2. Increase of more than 1 gage number in electrode size from that used in qualified
welding procedure.
3. Change in type of current, e.g., ac to dc or, in dc welding, change in electrode
polarity, except where these changes are within electrode manufacturer
recommendations.
4. For impact tested procedures, increase in either maximum electrode diameter or
weave width or if maximum interpass temperature is raised above that originally
qualified (refer to 330.1.5).
5. For critical applications, as directed by the engineering design.
(h) If a limitation on weldment hardness is specified in engineering design, macrographic
examination and hardness measurements shall also form part of welding procedure
qualification (WPQ).
Service conditions requiring restrictions to hardness levels are identified in
GP 06-20.
(i) In addition to mechanical testing, welding procedure test samples shall be subjected to dye
penetrant and radiographic examination.
(j) Nondestructive examination shall be completed prior to machining of test pieces.
(k) Ideally, welder performance tests for positional welding should be performed in both 2G
and 5G positions. However, subject to agreement of BP, welder performance test may be
undertaken in 6G position. In that case, each welder shall also demonstrate his ability to

DO NOT COPY
deposit acceptable root runs in both 2G and 5G positions. With the agreement of BP, this
may be achieved by radiography of welder’s first production welds in 2G and 5G
positions.
(l) Welders and welding operators shall be qualified by visual examination and radiography,
except in case of titanium or zirconium, which also require mechanical testing in
accordance with Appendix O. In the case of 25% Cr duplex stainless steels (Appendix N)
corrosion testing may be required.
Subject to provision of authenticated CV and with agreement of BP, welders and
welding operators may be qualified on their initial production welds for materials
other than 25% Cr duplex stainless steels, titanium and zirconium.
(m) Welder and welding operator qualification tests shall be witnessed by inspector.

Page 10 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

The above additions and modifications to qualification requirements have been

made on basis of fabrication experience and allow welding to proceed with
improved level of confidence in both procedural qualification and welder skill.
Ultrasonics may be used in lieu of radiography if material thickness restricts
suitability of radiography due to decreased sensitivity or extended exposure time.

Add

328.2.5 Test joints

a. Welding procedure qualification tests shall be performed on pipe.
b. On sizes greater than DN 20 (NPS 8), plate qualified welding procedures may be approved
by BP.
c. Welder performance tests shall be performed on pipe.
d. Performance testing shall utilise pipes of nominally same chemical analysis as production
material, unless agreed otherwise by BP.
e. The test shall use filler metal of the same chemical composition and manufacturer as those
to be used in production.
Change in type or even manufacturer of filler metal can alter fluidity of weld pool
and affect ability of welder to successfully complete a weld. This must be recognised
in extent of qualification testing required.

328.3 Welding materials

328.3.1 Filler metal

Add
a. GTAW filler wires shall be degreased prior to use and shall subsequently be handled with
clean gloves.
b. Degreasing agents shall leave no chloride or sulphide containing residues on the surface.
Filler metals will be selected with due regard to need for weld metal to, as a
minimum, match physical properties and corrosion resistance of parent material.
In the case of the 300 series austenitic stainless steels, ferrite content of deposited
weld metal should normally lie in range 3%-8%. However, under certain service
conditions, it may be necessary to further limit ferrite content. In critical
applications, it may also be necessary to measure ferrite content.
Stress relieving heat treatments in range 900°C/950°C (1650°F/1740°F) usually

DO NOT COPY
result in a reduction of notch toughness in 300 series austenitic stainless steel weld
metals. If PWHT is specified for pipework in low temperature service or if the piping
design code includes notch toughness requirements, welding procedure tests should
ensure that PWHT does not result in unacceptable embrittlement. This is especially
relevant for filler metals containing niobium or molybdenum.
Higher alloy austenitic stainless steels, such as those containing 20% or greater Ni
and/or 4% or greater Mo often require use of nickel base weld metals to ensure
sound weld metal of adequate corrosion resistance.
Some specific guidance on filler metal selection is provided in the appendices. Final
guidance concerning any special requirements, including selection of filler metal
composition for dissimilar metal joints or fabrication of corrosion resistant alloy
clad components, should be provided by engineering design.

Page 11 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

328.3.2 Weld backing material

Modify to Read
As stated in 328.2.1(e), backing rings shall not be used.

328.3.3 Consumable inserts

Modify to Read
Consumable inserts may only be used with BP approval.

328.4 Preparation for welding

328.4.1 Cleaning
Add
a. Working practices shall be designed to minimise contamination.
b. Before welding, internal and external surfaces shall be cleaned for distance of at least
50 mm (2 in) from fusion face.
c. Surfaces to be joined by welding shall be stainless steel wire brushed and degreased
immediately prior to welding.
d. On small pipes, for which it is not possible to wire brush internal surface, an approved
chemical cleaning material shall be used.
e. Degreasing agents shall leave no chloride or sulphide containing residues on the surface.

328.4.2 End preparation

(a) General
(1) Add
(a) Except for zirconium and titanium, materials shall be cut to size and bevelled by
plasma arc cutting, cold cutting, machining, or an appropriate grinding
technique. Zirconium and titanium shall be subject to requirements of
Appendix O.
(b) If plasma arc cutting is used, surfaces adjacent to cut shall be cleaned before
cutting by light grinding or wire brushing to bright metal.
(c) Immediately prior to cutting, prepared surfaces shall be further cleaned by
suitable degreasing agent.
(d) After plasma arc cutting, surfaces shall be ground smooth and returned to bright
metal finish.

DO NOT COPY
(b) Circumferential welds
(4) Modify to Read
Weld metal buttering shall not be deposited to assist alignment or provide sufficient
material for machining without BP approval.
Add
(6) Prior to fitup, weld bevels shall be visually inspected, supplemented by dye penetrant
or, if appropriate, magnetic particle examination, if considered necessary by
fabricator or BP inspection or welding personnel.

Page 12 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

328.4.3 Alignment
(a) Circumferential welds
Add
(3) Bore misalignment in circumferential butt joints shall not exceed 1.5 mm (1/16 in)
without BP approval.
(c) Branch connection welds
(3) Add
Weld metal shall not be deposited to correct contour, shape, or tolerances without
permission of BP.
Add
(e) Fabrication tolerances
1. Unless approved otherwise, fabrication tolerances shall comply with Figure 2.
2. Category M tolerances shall be used:
a) For service temperatures greater than 460°C (850°F).
b) PN 150 (Class 900) ratings and above.
c) If specified by engineering design.
3. If, when welding austenitic steels, design changes are necessary to comply with
defined tolerances, such changes shall be approved by BP.
Weldments in austenitic steels are prone to distortion due to their high coefficients
of thermal expansion and low thermal conductivity. Fabricators should consider this
before beginning to weld. In some cases, changes to design details will mitigate risk
of distortion.

328.5 Welding requirements

328.5.1 General
(b) Modify to Read
Welds shall be marked with welder/welding operator identification symbol using marker
pencils or paints that comply with 327.3.
(c) Modify to Read
(1) Preference shall be given to use of lineup clamps or bridge tacks that do not interfere
with deposition of a continuous root run.

DO NOT COPY
(2) Root tack welding, if approved, shall not commence until bore purging has been
established.
(3) Tacks, if they are to be incorporated in final weld, shall be cleaned prior to the root
pass and the ends feathered by grinding.
(4) Interval between tack welding and deposition of root pass shall be minimised to
reduce contamination.
(5) Removal of bridge tacks shall be by mechanical grinding only.
To reduce the risk of contamination of the weld zone clamp, face and bridge tack
materials should be of the same material as or be compatible with that being
welded.

Page 13 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

(d) Modify to Read

Peening shall not be permitted on any pass.
Add
(g) Unless otherwise stated in manufacturer installation instructions, welding adjacent to inline
valves shall be performed with valve in fully opened position.
Soft seated valves (e.g., butt welded or socket welded ball valves) should not be
welded inline unless a weld procedure has been qualified to demonstrate that soft
seats are undamaged or unless soft seat has been removed prior to welding.
(h) GTAW or PAW shall be used for root pass of materials covered by this GIS. GTAW or
PAW are also the preferred techniques for the second (hot) pass.
(i) If appropriate, SMAW may be used for hot pass, provided electrode size does not exceed
2.5 mm (3/32 in).
(j) SMAW shall not be used on piping less than DN 65 (NPS 2 1/2), except if welders have
demonstrated their ability to use SMAW on pipe of these diameters.
(k) Butt welds and pressure containment fillet welds in DN 40 (NPS 1 1/2) and smaller pipes
shall be performed using GTAW or PAW for all passes.
(l) GTAW and PAW equipment shall use either high frequency starting unit or alternative
programmed touch starting unit. A current decay device should also be fitted, together with
a gas lens, to improve gas shielding of weld pool.
(m) GTAW and PAW shall only be used under enclosed shop conditions, unless adequate
weather protection is provided at each outdoor location where these techniques are to be
used.
If gas shielded processes are being used, moderate air currents can result in loss of
shielding gas leading to weld defects. Thus, sufficient screening must be used under
such circumstances to keep winds and draughts away from welding area.
(n) The composition of shielding gas used for welding shall be compatible with the alloy being
welded and the weld properties required.
(o) The bore of materials covered by this ETP shall be purged during deposition of the weld to
ensure that no oxidation or coking of root run and internal surface occurs.
In general, high purity argon or argon based gas mixtures should be used for bore
purging. However, in the case of austenitic stainless steels, nitrogen or nitrogen
based gas mixtures may be considered for use. Argon based gas mixtures containing
a percentage of nitrogen may be beneficial for use with duplex stainless steels
(Appendix O).

DO NOT COPY
If erecting pipe spools, particularly in large diameter pipework, forethought should
be given to installation of internal dams to minimise use of purge gas.
If initiating flow of purge gas, a general rule of thumb that may be used is that 'all
air may be removed by admission of a volume of purge gas at least six times the
volume of air being displaced.' However, if welding more reactive materials, such as
titanium and zirconium, dew point measurements are desirable to establish the
quality of the purge. In general, oxygen meters are valuable for monitoring
purposes.
It is often adequate for austenitic steels to ensure a flow of purge gas during the
deposition of the root and the first/second fill passes, provided that the bore is
subsequently sealed to prevent atmospheric ingress. However, in the case of higher
alloy stainless steels, nickel alloys, and the more reactive materials, such as

Page 14 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

titanium and zirconium, a positive purge flow should be maintained throughout the
welding operation.
Guidance on the need for extended purge times is provided in the appendices and
will be supplemented as necessary by the engineering design.
(p) Unless approved otherwise, SAW, FCAW, and GMAW shall not be performed on pipes
smaller than DN 150 (NPS 6).
(q) Root welds should be completed without interruption other than to allow the welder to take
a new length of filler wire or to reposition himself.
(r) Vertical down welding is not permitted.
(s) Temporary attachments
1. Temporary attachments to outside surface of pipe shall be minimised and shall not be
made without BP approval.
2. Attachments that are permitted shall be made in controlled manner to avoid oxidation
of internal surface of pipework.
3. Fabricator shall advise what precautions he proposes to take with regard to fixing and
removing temporary attachments to and from such materials.
(t) If practical, fillet welded joints for pressure containment should have minimum of three
weld passes, two of which should be showing for visual inspection.
The above additions and modifications to welding requirements have been made on
the basis of fabrication experience and allow welding to proceed with improved
level of confidence in workmanship and practice.

328.5.3 Seal welds

Modify to Read
a. Threaded joints should be assembled in such a manner that a maximum of three threads are
exposed prior to welding.
b. Joints to be seal welded shall be made up clean and without use of tape or compound.
c. Welding shall be performed in accordance with qualified procedure by qualified welder.
d. Welding shall not cause damage to threaded fitting.
e. Exposed threads shall be covered by seal weld.

328.5.4 Welded branch connections

Add

DO NOT COPY
If designing angled branch connections, in addition to considering stress concentration effects,
sufficient access shall be provided for welding in acute angle section.
If set on integrally reinforced branch connections are used, it should be noted that
the wall thickness of the connection may well be in excess of that necessary to
provide the required level of reinforcement. Consequently, no reinforcement
contribution is necessary from the weld metal, and the deposition of a branch weld
with an excessive throat thickness may lead to unacceptable distortion of the main
run pipe. The engineering design should provide guidance on the sizing of branch
welds if using this type of fitting and on the need for controlled weld profiles if the
branch is on severe cyclic duty.
If set in integrally reinforced branch connections are used, fit up, jigging, and
developing an overall welding sequence, should minimise the extent of any
"sinking".

Page 15 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

The use of integrally reinforced branch connections on thin wall pipes, sch. 10 and
below, should be avoided.

328.5.5 Fabricated laps

Add
Fabricated laps shall not be used without agreement of BP.

328.5.6 Welding for severe cyclic conditions

Add
a. Weld reinforcement shall be smooth and regular.
b. Weld reinforcement shall blend smoothly with external surface of pipe to minimise
possible stress concentration effects.
The engineering design should provide specific guidance considered necessary for
weld profiles in severe cyclic duty.

Add

328.5.7 Proximity of welds

a. Toes of adjacent circumferential butt welds shall be no closer than four times nominal
thickness of pipe.
b. For pipe sizes of DN 300 (NPS 12) and below, minimum acceptable separation shall be
50 mm (2 in).
c. For pipe sizes greater than DN 300 (NPS 12), minimum acceptable separation shall be
100 mm (4 in).
d. Branch and non pressure part attachment welds shall not cross longitudinal seams or
circumferential butt welds and shall be subject to toe to toe separation distance specified
for circumferential butt welds. If such intersections are unavoidable, the main weld shall be
subject to nondestructive examination prior to making attachment weld.
e. Joints involving intersection of more than two welds shall be avoided.

330 Preheating

330.1 General
In general, materials covered by this GIS do not require preheating for welding
except to drive off moisture or raise component temperature above 0°C (32°F).

DO NOT COPY
330.1.1 Requirements and recommendations
Add
a. Cupro-nickel alloys may be preheated to a maximum temperature of 50°C (120°F).
b. Oxy-fuel gas welding or cutting torches may only be used for preheating if fitted with
proprietary preheating nozzles.
Preheating of cupro-nickel is not normally necessary. However, for high heat sink
welds, i.e., tee butt welds or if one of the members being fabricated is relatively
thick, preheats of up to 50°C (120°F) may be applied to aid fusion.

Page 16 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

330.1.3 Temperature verification

(b) Add
Thermocouples may not be directly attached to pressure parts without agreement of BP.

330.1.4 Preheat zone

Modify to Read
The preheat zone shall extend 75 mm (3 in) or a distance equal to four times the material
thickness, whichever is greater, beyond each edge of weld.

Add

330.1.5 Interpass temperature

Maximum interpass temperature shall not exceed stated limits for the following materials:
Max. Interpass Temp. Allowed
Materials °C °F
Cupro-nickel, High alloy austenitic stainless steels containing ≥20% 100 212
Ni and/or ≥4% Mo
Nickel based alloys containing ≥10% Mo 100 212
Nickel based alloys containing ≤10% Mo 150 300
300 series austenitic stainless steels 200 390
Guidance concerning interpass temperatures for duplex stainless steels and titanium/zirconium
is given in Appendices N and O.
If 300 series austenitic stainless steels are utilised in critical applications, interpass
temperature may be restricted to 150°C (300°F) by the engineering design.
Particular requirements for special or proprietary alloys shall also be detailed in
the engineering design.

331 Heat treatment

331.1 General

331.1.1 Heat treatment requirements

Add
(e) Heat treatment is not normally considered necessary for materials covered by this GIS.
(f) Austenitic stainless steels may require some reduction in residual stress level after welding
or cold bending.

DO NOT COPY
(g) Specific applications for which heat treatment is required shall be identified by the
engineering design.
If austenitic stainless steels are exposed to process environments containing
chlorides or polythionic acids, the presence of residual stresses generated by either
welding or mechanical working may lead to stress corrosion cracking. Stress relief
heat treatment may consequently be necessary prior to service.
(h) If stress relief heat treatment of austenitic steels is specified by the engineering design,
welds shall be heated to temperature in range of 900°C - 950°C (1650°F - 1740°F) and
held for 1 hour per 25 mm (1 in) of thickness. Minimum soaking period shall be 1 hour.
(i) Low melting point metals, such as aluminium, lead, tin, copper, zinc, cadmium, and
mercury, and their alloys, shall not be permitted to contact surfaces that will undergo hot
forming, welding, or post weld heat treatment.

Page 17 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

Possible sources of such contamination include solder, galvanised components

clamps and fixtures, and certain types of paint.

331.1.4 Heating and cooling

Add
a. If furnace heat treatment is applied to austenitic steels, furnace temperature shall not
exceed 300°C (600°F) if pipework is loaded.
b. For austenitic stainless steels, maximum heating rate above 300°C (600°F) shall not
exceed 200°C (400°F) per hour.
c. Following elevated temperature soaking, austenitic pipework shall be removed from the
furnace and rapidly cooled in air.
Should heat treatment be necessary during fabrication of other alloys covered by
this ETP, full details of soaking temperature and time, along with applicable heating
and cooling rates will be provided by engineering design.

331.1.6 Temperature verification

Add
a. If practical, thermocouples shall be attached to spool pieces at minimum of six equally
spaced locations, adjacent to welds, prior to heat treatment.
b. Procedures for attachment of thermocouples by capacitor discharge welding shall be
subject to BP approval. Use of this technique shall be carefully monitored.

331.1.7 Hardness tests

Add
Additional requirement for hardness testing may be specified by engineering design.

331.2 Specific requirements

331.2.6 Local heat treatment

Modify to Read
a. If local heat treatment is applied, weld shall be sufficiently heated and insulated to ensure
that (for a pipe of DN (NPS) ‘D’ and wall thickness ‘t’):
1. Specified heat treatment temperature is achieved at weld.
2. Within distance of 1.8 Dt on both sides of the weld, temperature of not less than
half of specified heat treatment temperature is attained.

DO NOT COPY
b. In the case of branch attachments, temperature gradient shall be such that length of
material from each crotch heated to temperature equalling half heat treatment temperature
shall be 1.8 Dt (where ‘D’ and ‘t’ are the nominal diameter and thickness of the main
pipe and branch as appropriate) (Figure 3).
c. In a. and b., ‘D’ is expressed as DN (NPS), ‘t’ is expressed in mm (in), and temperature is
expressed in °C.
The above modification is made to clarify the requirements for local post weld heat
treatment.

Page 18 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

332 Bending and forming

Bend manufacturer procedures must be reviewed to confirm that adequate control is

being exercised in heating, cooling, and inspection of bends. Typical tolerances on
completed bends should be as follows:
• Ovality at any cross section of bend should not exceed 5%.
• Wall thickness after bending should not be less than nominal design thickness.
• Angle of bend should be within 0.009 radians (0.5 degrees) of nominal.

332.1 General
Add
a. Bending of stainless steel and nickel alloy pipe should be done cold.
b. If size and schedule of pipe is such that cold bending becomes impractical, hot bending
may be used.
c. Unless specified otherwise, factory manufactured piping fittings shall be solution heat
treated in temperature range specified by alloy manufacturer.
For some highly corrosive applications the use of pulled bends is not permitted. For
such applications, the engineering design will define the appropriate bend
manufacturing processes.

332.2 Bending

332.2.2 Bending temperature

(a) Modify to Read
1. Cold bending of austenitic stainless steel shall be performed at temperatures below
425°C (800°F).
2. Cold bending of duplex stainless steels shall be performed at temperatures below
300°C (570°F).
3. Cold bends in austenitic or duplex stainless steels shall be heat treated in applications
if there is a likelihood of stress corrosion cracking due to chlorides or polythionic acid
in service.
Heat treatment of duplex stainless steels must produce a microstructure appropriate
to intended service conditions. It is recommended that heat treatment procedure
qualification is performed to demonstrate adequacy of any heat treatment that is to
be applied to duplex stainless steels.

DO NOT COPY
If cold bending of alloy pipe produces local strain in excess of 10% consideration
should be given to application of post forming heat treatment and any specific
requirements should be stated in engineering design.

332.2.3 Corrugated and other bends

Add
a. Fabricated mitre (segmented) bends are not generally permitted.
b. Subject to agreement of BP, limited use of mitred bends in accordance with Figure 4 may
be proposed.
c. ‘Cut and shut’ design shall not be used.
Further guidance or restrictions that may be necessary for bending and forming
materials covered by this ETP will be detailed by engineering design.

Page 19 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

335 Assembly and erection

335.1 General

335.1.1 Alignment
(a) Piping distortions
Add
Piping distortions. Application of heat for correction of minor distortions shall only be
undertaken with BP approval.

Add

335.1.2 Bolting procedures

a. Bolting procedures should be provided for each joint or group of joints to be assembled.
b. As a minimum, these procedures shall contain the following information:
1. Required bolt load or stress.
2. Tightening method.
3. Tightening sequence.
4. Elongation measurement requirements.

DO NOT COPY

Page 20 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

Chapter VI Inspection, examination, and testing

341 Examination

341.3 Examination requirements

341.3.1 General
(a) Modify to Read
Final examination shall be performed after completion of heat treatment.

341.3.2 Acceptance criteria

(a) Modify to Read
Acceptance criteria for welds is stated in ASME B31.3, Table 341.3.2, and Table 1 of this
GIS.

341.4 Extent of required examination

Add
a. For all fluid categories, extent of required examination and inspection method employed
shall depend on criticality rating of individual piping system.
b. Method of determining criticality rating shall be specified by engineering design. Assigned
values shall be recorded in piping line lists.

342 Examination personnel

342.1 Personnel qualification and certification

Add
a. Only personnel certified in accordance with PCN, CSWIP, AWS QC1, ASNT CP-189, or
ASNT recommended practice SNT-TC-1A shall be allowed to undertake examinations.
b. In the case of ASNT SNT-TC-1A, assessment of operator competence should have been
undertaken by an external authority.
c. Other equivalent certification may be accepted at discretion of BP.

DO NOT COPY
d. Personnel qualifications shall be subject to BP approval.
Under most circumstances, ‘equivalent certification’ will only be considered if the
body issuing certification meets the requirements of ISO 9712 or EN 473.

343 Examination procedures

Add
Examination procedures shall comply with 327.1.1.

Page 21 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

344 Types of examination

344.2 Visual examination

344.2.1 Definition
Add
Visual examination shall include examination of internal surface of weld, if possible, using
suitable optical instruments.

344.5 Radiographic examination

344.5.1 Method
Modify to Read
a. X-ray techniques are preferred for shop radiography of pipework up to 25 mm (1 in) wall
thickness.
b. If use of X-rays is impractical, gamma ray isotopes may be used, subject to BP approval.
c. In each case, prior to production radiography the technique shall be qualified using source
side image quality indicator (IQI) of wire type to ASTM E747 or BS EN 462-1, whichever
is applicable.
d. Single wall, single image technique should be used if possible.
e. Lead intensifying screens and fine grain high contrast film shall be used.
f. Film density shall be 2.0-3.0 through thickest portion of weld.
g. IQI specified in accordance with BS EN 462 1 shall have radiographic sensitivity that
complies with Table 2.
h. If complete joint circumference is radiographed in a single exposure, four IQIs placed at
π/2 radian (90 degree) intervals shall be used.
i. Set on branch connections if permitted by engineering design, should be subject to
intermediate radiography.
2. Film shall be on bore side of joint.
3. Radiography shall be performed when weld depth is similar to wall thickness and
before reinforcing fillet is applied.

344.5.2 Extent of radiography

(c) Spot radiography

DO NOT COPY
Modify to Read
Spot radiography shall not be used for girth, mitre, or branch welds.

344.6 Ultrasonic examination

Add
a. If ultrasonic examination is required, procedures for each joint configuration and thickness
shall be subject to BP approval.
b. Such examination will normally be restricted to wall thicknesses greater than 10 mm
(3/8 in).
If fabricating pipework having wall thickness in excess of 25 mm (1 in),
consideration should be given to examination of root region if welding is partially

Page 22 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

complete to depth of approximately 30% of wall thickness. This minimises the need
for through wall repairs.
Following repairs to the root and reexamination, the weld should be completed and
subjected to final examination.

345 Testing

345.4 Hydrostatic leak test

Add
a. Fabricator hydrostatic test procedure shall include:
1. Details of test fluid.
2. Minimum temperature.
3. Test pressure.
4. Pressure recording.
5. Control method and holding time.
b. Hydrostatic test procedure shall be reviewed by BP.
c. After hydrostatic testing, pipe spools that are to be stored prior to installation shall have
ends sealed to prevent ingress of dirt, moisture, or other contaminants.
d. Flange faces shall be coated with suitable corrosion preventive.
Hydrotesting should be performed after completion of heat treatment.
If piping spools are to be stored prior to installation, consideration should be given
to the need for the introduction of a suitable vapour phase inhibitor/biocide.

345.4.1 Test fluid

Add
a. Water shall be clean and potable.
b. Water shall not have chloride content above 100 ppm except for zirconium, titanium,
copper, and nickel based alloys.
c. On austenitic and duplex stainless steel piping, water with chloride content of less than
30 ppm should be used for hydrostatic testing. If it is necessary to use water within range
of 30 to 100 ppm, lines shall be flushed with water having chloride content of less than
30 ppm within short period of testing.

DO NOT COPY
Add

347 Weld repairs

a. Before starting fabrication, the fabricator and BP shall agree which types of welding
defects are to be regarded as notifiable prior to rectification.
b. Fabricator shall subsequently advise BP of need to perform such repair, which shall be
subject to approval prior to commencement of further work on defective welds.
c. Detailed records of repairs shall be retained by fabricator.
d. Repair welding shall comply with approved repair procedures, unless use of original
procedure has been agreed with BP.

Page 23 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

e. As a minimum, repair welds shall be inspected to their full extent using techniques used
for inspection of initial weld.
f. If cracking has occurred in either weld metal or heat affected zone and a repair has been
agreed:
1. The full extent of the original weld shall be re-examined on completion of the repair .
2. BP may require that additional inspection technique to be applied to the joint
following repair.
g. Weld repairs shall, if practical, be performed prior to post weld heat treatment. If a second
heat treatment is necessary, details of procedure qualification requirements shall be agreed
with BP.
Application of a second heat treatment may have adverse effects on the properties of
weld metal and some base materials. Thus, it may be necessary to consider a
qualification test using previously welded and heat treated material for qualification
of repair techniques. In such cases, additional testing of parent material should be
performed.

Table 1 – Acceptance criteria for welds (to be read in conjunction with Table 341.3.2 of ASME B31.3)

Type of Imperfection Acceptance Criteria for the Specified Service Condition

Lack of fusion 'A' for all welds.
Incomplete penetration (1) 'A' shall apply to all welds in severe cyclic or normal fluid service.
Internal porosity 'D' shall apply to all welds in severe cyclic or normal fluid service.
'E' shall be applicable to category D fluid service.
Slag inclusion, tungsten inclusion, or 'F' shall apply to all welds irrespective of service condition.
elongated indication (1)
Undercutting 'H' shall apply to girth and, if approved, mitre groove welds in category D
fluid service.
Concave root surface (suck back) (1) Not permitted in severe cyclic or normal fluid service unless a specific
limit is set by the engineering design. A maximum of 1.6 mm (1/16 in)
shall apply to welds in category D fluid service.
Reinforcement or internal protrusion For all welds irrespective of service conditions external weld
reinforcement shall be uniform, 1.6 mm (1/16 in) to 3 mm (1/8 in) in
height and shall merge smoothly into the pipe surface.
Positive root penetration shall not exceed 1.6 mm (1/16 in) for DN 50
(NPS 2) and smaller or 3 mm (1/8 in) for larger pipe.
Note:
1. If these defects are permitted, total cumulative length of lack of root penetration, slag inclusions, or concave root shall
not exceed 10% of weld joint circumference.

DO NOT COPY

Page 24 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

Table 2 – Acceptable radiographic sensitivity levels

(using wire type IQI to ASTM E747 or BS EN 462-1)

1
Thickness X-Radiography Gamma Radiography
mm in SWSI DWSI DWDI SWSI DWSI DWDI
≤ 4.5 ≤ 0.177 Note 3 Note 3 Note 3 Note 3 Note 3 Note 3
4.5 – 6.0 0.177 – 0.236 2.0% 2.5% 3.2% 2.6% 2.7% 3.5%
6.0 – 9.0 0.236 – 0.354 1.7% 2.0% 3.0% 2.4% 2.5% 3.2%
9.0 – 14.0 0.354 – 0.551 1.5% 1.8% Note 3 2.4% 2.5% Note 3
14.0 – 18.5 0.551 – 0.728 1.4% 1.7% NA 2.0% 2.2% NA
18.5 – 26.0 0.728 – 1.024 1.3% 1.7% NA 1.7% 2.0% NA
26.0 – 40.0 1.024 – 1.574 1.1% 1.7% NA 1.5% 1.8% NA
>40.0 >1.574 Note 3 Note 3 Note 3 Note 3 Note 3 Note 3
1. Thickness for SWSI and DWSI is estimated single weld thickness. Thickness for DWDI is one wall thickness plus one
estimated weld thickness.
2. Sensitivity shall be no worse than the values given in this Table. Sensitivity values are based on IQI placed on film side
for SWSI and DWSI exposures and IQI on source side for DWDI exposures. Sensitivity shall be calculated using the
formula:
Thickness of thinnest wire visible in weld area
Sensitivity = Thickness 1
3. Sensitivity requirement to be agreed with BP following production of test radiographs.

DO NOT COPY

Page 25 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

Figure 1 – Charpy notch locations

2mm MAX

WELD CENTRE 2mm MAX

LINE NOTCHES FL

FL + 1mm
FL + 2mm

FL + 5mm

FUSION LINE (FL) AND HAZ

DO NOT COPY
NOTCH POSITIONS

Weld metal centre line, FL and FL+2 mm testing is mandatory. The need for other notch locations to be tested shall be identified
by the engineering design.
<25 mm (1 in) wall thickness = charpy specimens to be taken from weld cap.
≥25 mm (1 in) wall thickness = charpy specimens to be taken from the root and cap regions.

Page 26 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

Figure 2 – Dimensional tolerances for fabricated pipework

CL

A B

CL

C/L FLANGE OR BRANCH

CL D
A

A
A

CL

A
E

Maximum Allowable Dimensional Tolerance

Category M and Severe Cyclic Temperature
Item Category D and Normal Service Conditions >450°C (850°F) Rating ≥PN 150 (Class 900)
A ± 3 mm (1/8 in) maximum from indicated dimension: from face to face, centre to face, location of
attachments, etc.
B 8% maximum (for internal pressure) 2% maximum
3% maximum (for external pressure)
Flattening measured as difference between maximum and minimum O.D. at any cross section
C ± 3 mm (1/8 in) maximum lateral translation of ± 1.5 mm (1/16 in) maximum lateral translation
branches or connections of branches or connections
D ± 1.5 mm (1/16 in) maximum rotation from the indicated position, of flanges measured as shown
E 0.75 mm (0.03 in) maximum out of alignment of 0.4 mm (0.016 in) maximum out of alignment of
flanges from the indicated position, measured flanges from the indicated position, measured
across any diameter across any diameter

DO NOT COPY

Page 27 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

Figure 3 – Local heat treatment for branch connections

1.8 D1 t 1

1.8 D2t 2

SHADED AREAS TO BE HEAT TREATED

D NOMINAL O.D OF MAIN PIPE

1
D NOMINAL O.D OF BRANCH PIPE
2
t THICKNESS OF MAIN PIPE
1
t THICKNESS OF BRANCH PIPE
2

DO NOT COPY

Page 28 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

Figure 4 – Segmental bends

DO NOT COPY

Page 29 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

Appendix E Reference standards

ASNT
Add
CP-189 Qualification and Certification of Nondestructive Testing Personnel.

ASTM
Add
E 562 Standard Test Method for Determining Volume Fraction by Systematic
Manual Point Count.
E 747 Standard Practice for Design, Manufacture and Material Grouping
Classification of Wire Image Quality Indicators (IQI) Used for
Radiology.

AWS
Add
QC1 Standard for AWS Certification of Welding Inspectors (1996 or later
edition).

Add

BP
GP 18-02 Guidance on Practice for Storage and Control of Welding Consumables.

BSI Standards
BS EN 462-1 Non-destructive testing - Image quality of radiographs - Part 1: Image
quality indicators (wire type) - Determination of image quality value.

EEMUA standards
EEMUA 153 Process Piping-Supplement to ASME B31.3.

DO NOT COPY

Page 30 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

Add

Appendix N Additional requirements for 22%Cr and 25%Cr duplex stainless steel
materials

N1. Introduction
a. This appendix lists significant differences and additional precautions required for
fabrication of duplex stainless steels.
b. This appendix shall be read in conjunction with main body of this GIS.

N2. Welding

N2.1 Welding processes

a. Welding processes shall generally be restricted to GTAW and SMAW.
b. GTAW shall be employed for root and second (hot) pass that shall both be completed with
addition of filler metal.
c. SMAW shall be restricted to fill and capping passes in pipe with wall thickness greater
than 5 mm (3/16 in).
d. Alternative gas shielded welding processes may be employed, subject to BP approval and
with documented evidence of previous successful use.
e. Duplex stainless steels are potentially susceptible to delayed hydrogen cracking.
Consequently, all possible steps should be taken to minimise hydrogen potential of
welding technique, including:
1. Adequately drying SMAW consumables.
2. Use of low temperature preheat to remove moisture.
3. Avoidance of hydrogen containing shielding gases.

N2.2 Filler metal

a. Generally, filler metal compositions should be selected from the following list:
1. 22Cr/9Ni/3Mo.L.
2. 25Cr/7Ni/2Mo.
3. 25Cr/9Ni/3Mo.Cu.L.
4. 25Cr/9Ni/4Mo.L.

DO NOT COPY
b. Other proprietary compositions specifically manufactured for duplex steels may be
appropriate.
c. Selection shall be made to meet ferrite level of 35% - 65% in all regions of weld metal and
minimum PREn value of 34 for 22%Cr duplex and 40 for 25%Cr duplex.
d. Additional guidance on filler metal selection may be provided by engineering design.
The corrosion resistance of duplex stainless steel weldments is totally dependent on
the two criteria above, ferrite level and PREn, and they must not be relaxed without
specialist consideration.

N2.3 Shielding gas

a. Shielding gases shall be argon based.

Page 31 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

b. Shielding gases shall not contain hydrogen.

In the case of GTAW, nitrogen may be added to the shield to preclude loss of
nitrogen from the weld pool. Nominally 1% and 2% nitrogen additions have been
reported to be sufficient to prevent loss of nitrogen, an important alloying element in
the case of duplex steels, from 22%Cr and 25%Cr materials, respectively.
Proprietary gas mixtures may be employed if the fabricator can demonstrate its
successful use to the satisfaction of BP.

N2.4 Backing gas

a. Positive flow of backing gas shall be maintained during tacking and welding, including
capping passes if pipe wall thickness is less than 10 mm (3/8 in).
b. If pipe wall thickness is less than 10 mm (3/8 in), positive flow may be terminated and
bore sealed if weld throat thickness is greater than 10 mm (3/8 in).
c. Argon shall generally be employed for back purge.
d. For duplex alloys containing relatively high levels of nitrogen, BP may approve use of
argon/nitrogen mixtures.
e. Oxygen content of purge gas shall be measured and shall be less than 0.5%.
f. Hydrogen containing backing gases shall not be used in any application if possibility of
mixing with shielding gas exists.

N2.5 Joint geometry

a. Weld root gaps below 2 mm (5/64 in) are not permitted, unless fabricator can prove that
his production method does not adversely affect the microstructural balance of root bead.
b. Fabricator shall also ensure that qualified root gap is achieved consistently during
production welding.
Weld root gap is critically important in achieving root weld metal microstructures
containing specified austenitic ferrite balance.

N2.6 Heat input

a. Heat input during welding procedure qualification shall not exceed range of 0.8 kJ/mm –
2.5 kJ/mm (20 kJ/in – 62.5 kJ/in).
b. In the case of 25%Cr duplex steels, upper limit shall be 1.5 kJ/mm (37.5 kJ/in).
c. Subject to these limitations, heat input during production welding shall not deviate from
that qualified by more than ±10%.

DO NOT COPY
N2.7 Preheat and interpass temperature
a. Preheating shall not generally be used except to remove moisture from joint.
b. Maximum interpass temperature for 22%Cr duplex steels shall be 150°C (300°F).
c. Maximum interpass temperature for 25%Cr duplex steels shall be 125°C (257°F).

N3. Welding procedure qualification

N3.1 P-Numbers
a. P-Numbers shall not apply to duplex stainless steels.
b. Each alloy designation shall be separately qualified.

Page 32 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

N3.2 Positional welding

a. Unless specified otherwise, qualification for positional welding shall require test pieces
welded in both the 2G and 5G positions.
b. Sections for hardness and microstructural qualification shall be taken from 3 o’clock and
6 o’clock positions of 5G test piece.

N3.3 Metallurgical qualification

a. Metallurgical qualification is required for all welding procedures.
b. A transverse section taken across weldment shall be prepared for metallographic
examination.
c. Etchant used shall enable ferrite, austenitic, and any sigma phase present to be clearly
identified.
d. Ferrite austenitic balance shall be determined by a systematic point counting procedure as
detailed in ASTM E562.
e. Phase balance shall, as a minimum, be measured in root HAZ and root weld metal.
f. Engineering design may call for measurements in other regions of weldment.
g. Acceptable ferrite levels shall be in range of 35% - 65%.

N3.4 Charpy V notch impact testing

a. For procedures requiring Charpy V notch impact testing, impact tests shall be performed at
minimum design temperature.
b. Test locations shall be as detailed in 328.2.1(d) and Figure 1.
c. Acceptance criteria shall be 45 J (33 ft-lb) minimum average, 35 J (26 ft-lb) minimum
individual.

N3.5 Hardness determination

a. Hardness measurements shall be performed in accordance with duplex stainless steel
procedures.
b. Hardness traverses shall sample HAZ and weld metal in root and cap regions.
c. Maximum hardness shall be 334 HV10 (28 Rc) for 22% Cr and 378 HV10 (32 Rc) for
25% Cr.

The above HV/Rc conversions are specific to duplex

stainless steels.

DO NOT COPY
N3.6 Essential variables
The following additional essential variables shall apply to duplex stainless steels:
a. Tolerance of minus 0, plus 2 mm (5/64 in) shall apply to qualified procedure root gap.
b. Each pipe wall thickness less than or equal to 5 mm (3/16 in) shall be separately qualified.
c. For thicknesses greater than 5 mm (3/16 in), the following qualified thickness range shall
apply to each thickness (t) tested:
22%Cr 0.5t (but not less than 5 mm (3/16 in))
–1.5t (subject to a maximum thickness of 25 mm (1 in)).
22%Cr > 25 mm (1 in) and 25%Cr 0.75t (but not less than 5 mm (3/16 in))
–1.0t.

Page 33 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

These thickness limitations reflect the need for control over the thermal cycle
applied to duplex steels during welding in order to maintain the ferrite/austenitic
balance and prevent the formation of intermetallic phases.
d. No change shall be made in type of groove or in basic groove design from that used in
qualified welding procedure specification. If welding in pipe bore is to be applied, an
appropriate welding procedure shall be qualified.
e. Electrode size used in qualified welding procedure may be reduced by no more than one
size. No increase in maximum size of electrode is allowed.

N3.7 Corrosion testing

Need for corrosion testing and acceptance criteria shall be as defined in the engineering design.
ASTM G48 corrosion testing may be required as an integral part of welding
procedure qualification. In many instances, this requirement is imposed solely as an
additional means of quality control, depending on the grade of duplex stainless steel
and the specific application. However, it is strongly recommended that such tests
should be implemented particularly when welding 25% Cr duplex steels.

N4. Welder qualification

a. Welders shall be qualified on duplex stainless steel.
b. Unless specified otherwise, both 2G and 5G qualification is required at maximum root gap
specified by relevant welding procedure.
The engineering design shall specify if additional ASTM G48 corrosion testing and
metallography is required for welder qualification. However, it is strongly
recommended that the additional corrosion testing requirement is implemented if
welding 25% Cr duplex alloys and the welders have:
• No previous experience of 25% Cr duplex.
• Have not welded 25% Cr duplex within the last six months.
or if detailed parameter monitoring of heat input during both pipe spool fabrication
and erection is not implemented.
c. Welders shall not be qualified on initial production welds.

N5. Production welding

N5.1 General
a. Welding instruction card shall include details of root gap and heat inputs to be used.
b. Bridge tacking shall be used for butt welds.

DO NOT COPY
c. Each temporary attachment shall be subject to BP approval.

N5.2 Repair welding

a. Fabricator shall qualify procedures for both deep penetration and shallow repairs.
b. Extent of testing shall be subject to BP approval.
c. No local through the wall repairs are permitted. Joints shall be cut out and re-welded.

Page 34 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

Add

Appendix O Additional requirements for titanium and zirconium

O1. Introduction
a. This appendix lists significant differences and additional precautions required for
fabrication of titanium and zirconium.
b. This appendix shall be read in conjunction with the main body of this GIS.

O2. Cleaning and preparation for welding

a. Weld preparation shall be performed by machining, sawing, or manually using metal burr,
followed by draw filing or wire brushing with stainless steel brush. Thermal cutting
techniques are unacceptable.
b. Working practices shall be designed to minimise contamination. Before welding, internal
and external surfaces shall be cleaned for at least 75 mm (3 in) from fusion face.
c. Surfaces to be joined by welding shall be stainless steel wire brushed and degreased
immediately prior to welding.
d. Degreasing agent shall leave no chloride or sulphide containing residues on surface.
e. On small pipes, where it is not possible to wire brush internal surface, approved chemical
cleaning agent shall be used.
f. New files and stainless steel brushes strictly reserved for use on only titanium or zirconium
shall be used.
The need for cleanliness during fabrication of titanium and zirconium cannot be
overemphasised. Strict segregation from other materials must be implemented, and
this may be assisted by construction of restricted access tented area or clean room
facility. Guidance on cleaning of titanium and zirconium is given in ASTM B600 and
B614, respectively.

O3. Welding

O3.1 Welding process

a. Welding shall be performed by gas shielded welding process.
b. GTAW or PAW may be used.

O3.2 Filler metal

DO NOT COPY
a. Filler metals shall:
1. Have same nominal composition as base material.
2. Comply with AWS A5.16/A.16M (titanium) and A5.24 (zirconium).
b. Filler wires shall be thoroughly cleaned and degreased. Degreasing agent shall leave no
chloride and sulphide residues on surface.
c. After cleaning, wires shall be handled with clean gloves specifically issued for either
titanium or zirconium fabrication.
d. Welder shall ensure that end of filler wire is kept within gas shield at all times during
welding by restricting weaving of welding wire to a minimum.
e. Prior to each weld pass, end of filler wire shall be cut to expose clean wire using chromium
plated wire cutters.

Page 35 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

O3.3 Shielding gases

a. Shielding gases shall only be high purity (99.998%) argon, helium, or argon helium
mixtures.
b. Welding torch nozzle size and the associated gas lens shall be selected to ensure adequate
primary shielding.
c. Trailing secondary shield shall be used to protect the weld and HAZs while they are
cooling to temperatures less than 180°C (350°F).
d. The dew point of shielding gas shall be:
1. Less than –50°C (–58°F).
2. Measured at torch immediately prior to welding and at each cylinder change.
3. Measured at the beginning of each shift for bulk supply systems.
e. As an alternative, but less preferable option to dew point measurement, test weld meeting
silver coloration requirements of O6.2 shall be produced at intervals specified in d.

O3.4 Backing gas

a. Positive flow of high purity (99.998%) argon backing gas shall be maintained throughout
welding operation and during cooling to 180°C (350°F).
b. System shall be purged prior to commencement of welding.
c. The dew point of the backing gas shall be assessed as per the shield gas (See O3.3.d
above).
Titanium and zirconium readily absorb carbon, oxygen, nitrogen, and hydrogen at
high temperatures with consequence that weldments can become embrittled. Thus,
the importance of preweld cleaning and degreasing of joint area and filler metal
cannot be over emphasised. The efficiency of the primary and secondary shielding
together with purge is of paramount importance. Gas shielding and purging
methods used during the successful qualification of welding procedures must be
strictly enforced during production welding.
If relatively small components are being fabricated, welding within a controlled
atmosphere chamber may be a cost effective production technique.

O3.5 Preheat and interpass temperature

a. Although preheating is not required, minimum temperature for welding shall be 15°C
(60°F).
b. Interpass temperatures shall be:

DO NOT COPY
1. Restricted to 100°C (212°F).
2. Measured by contact thermometer.

O3.6 Interpass cleaning

a. No interpass cleaning shall be performed until colour test detailed in O6.2 has been
completed.
b. Craters shall be lightly ground using metal burr.
c. Each pass shall be cleaned with stainless steel wire brush.

Page 36 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

O4. Welding procedure qualification

O4.1 Hardness determination

a. Hardness measurements shall be performed on titanium welding procedure qualifications.
b. Hardness traverses shall sample all regions of weldment.
c. Acceptance limit shall be 200 HV5 (200 Brinell).
d. Unless specified by BP, hardness measurements are not required for zirconium.
If hardness testing is required for zirconium piping, testing will be performed using
Brinell hardness testing. The maximum difference in hardness value across the
weldment should not exceed 30 points on Brinell hardness scale.

O5. Welder qualification

a. Welders or welding operators shall be requalified prior to start of production welding
unless they have been welding titanium or zirconium immediately prior to contract.
b. Qualification shall be by radiography and by root and face bend testing.
c. Additionally, welders and welding operators shall weld agreed quality control test piece at
frequency specified by BP.
d. Bend test coupons shall be taken from test piece and shall pass transverse root bend and
face bend tests (bend radius 5T) meeting procedure qualification acceptance criteria.
Normal practice is for welders working on zirconium to produce a separate test
piece for every tenth weld produced.

O6. Production welding

O6.1 General
a. Welding instruction card shall emphasise need to strictly adhere to cleaning and gas
shielding/purging procedures.
b. Preference shall be given to use of lineup clamps. Bridge tacks may be used with
agreement of BP.
c. Temporary welded attachments are not allowed.

O6.2 Weld bead discolouration

a. Each weld bead, including every pass in multipass weldments, shall be examined for
discoloration.
b. Colours shall be judged against the table below.

DO NOT COPY
c. Quality plan and welder instruction card shall clearly define procedure and individual
responsibilities associated with this examination.
Weld Colour Significance Shielding Action
Silver Generally a Good Clean with stainless steel wire brush, proceed to
good weld NDT or next weld pass.
Pale straw Acceptable Fair Discoloration should be removed with stainless steel
weld brush before next pass.
Light Poor weld Poor Remove weld bead and adjacent metal completely;
blue/purple improve shielding before rewelding.
Grey or yellow Very poor weld Extremely Remove weld bead and heat affected zone
powder poor completely. Examine shielding equipment for leaks,
gas supply, etc. Make test welds before re-welding.

Page 37 of 38
3 May 2005 GIS 42-102
Guidance on Industry Standard for Fabrication, Assembly, Erection, and Inspection of Austenitic and Duplex Stainless
Steel, Cupro-Nickel, Nickel Base Alloy, Titanium, and Zirconium Pipework (ASME B31.3)

Bibliography

American Society of Mechanical Engineers (ASME)

[1] ASME B31.1 Power Piping.

[2] ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids.

BP
[3] GIS 36-103 Guidance on Industry Standard for Positive Material Identification (PMI).

[4] GP 06-20 Guidance on Practice for Materials for Sour Service.

British Standards Institute (BSI)

[5] BS EN 473 Non-destructive testing - Qualification and certification of NDT personnel - General
principles.

[6] BS 5383 Material identification of steel, nickel alloy and titanium alloy tubes by continuous
character marking and colour coding of steel tubes.

[7] BS EN 13480 Metallic industrial piping.

[8] BS EN 14161 Petroleum and natural gas industries – Pipeline transportation systems.

International Organization for Standardization (ISO)

[9] ISO 9712 Non-destructive testing - Qualification and certification of personnel.

DO NOT COPY

Page 38 of 38