FIELD WELDING ENGINEER’S MANUAL

2008 Edition

WELDING AND NDE SERVICES

BECHTEL CONSTRUCTION OPERATIONS
INCORPORATED
 Copyright 2000-2008 Bechtel Corporation
2008 Edition. All Rights Reserved.

Contains confidential information proprietary to Bechtel and may not be disclosed to a third-party without
Bechtel’s prior written permission.

Electronic documents, once printed, are uncontrolled and may become outdated.

Printed in the United States of America.

Field Welding Engineer’s Manual Revision 1

FOREWORD

This handbook is not under controlled distribution. It is intended to provide information to those individuals
who wish to obtain general information regarding the subject matter herein. This handbook has been
developed to assist in the training and development of Bechtel personnel and is intended to be part of
Bechtel’s overall technical training program. The handbook is also intended to provide useful guidelines,
information and data to assist personnel in making effective decisions, and is based on conventional or non-
nuclear appllications. The appropriate Bechtel technical specialist(s) should be consulted whenever questions
or concerns arise regarding the subject matter herein. All materials included in this handbook are for
reference purposes only and shall not be used for work execution. The handbook is not intended to replace or
supercede codes, standards, procedures, or engineering specifications.

Manual Approvals

Foreword Page iii

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permission. All rights reserved.
Revision 1 Field Welding Engineer’s Manual

1.0 CHAPTER 1 – THE FIELD WELDING ENGINEER & CE&T WELDING & NDE SERVICES ... 1–1

1.1 SCOPE ...................................................................................................................................................... 1–1

1.2 DIRECT HIRE PROJECTS ....................................................................................................................... 1–1

1.2.1 Project Technical References................................................................................................................ 1–1
1.2.2 Duties of the Field Welding Engineer .................................................................................................... 1–1
1.2.3 Construction Duties ............................................................................................................................... 1–2

1.3 MANAGEMENT PROJECTS .................................................................................................................... 1–3

1.3.1 Project References ................................................................................................................................ 1–3
1.3.2 Field Welding Engineers Duties ............................................................................................................ 1–3

1.4 CE&T WELDING AND NDE SERVICES SUPPORT................................................................................ 1–4

1.4.1 Problem Solving and Consultation ........................................................................................................ 1–4
1.4.2 Recruiting of Site Welding Engineers .................................................................................................... 1–4
1.4.3 Off-Site Welder Testing ......................................................................................................................... 1–5
1.4.4 On-site Welder Testing .......................................................................................................................... 1–5
1.4.5 Welder Training ..................................................................................................................................... 1–5
1.4.6 Welding Control Manual (WCM) ............................................................................................................ 1–5
1.4.7 Welding, Brazing, Soldering, and Bonding Procedure Qualifications ................................................... 1–5
1.4.8 ASME Quality Control Manuals ............................................................................................................. 1–5
1.4.9 ASME Code Symbol Stamps ................................................................................................................. 1–5
1.4.10 Authorized Inspectors (AIs) ............................................................................................................... 1–6
1.4.11 Qualification and Training of NDE Personnel .................................................................................... 1–6

1.5 REVIEW OF SUBCONTRACTOR PROCEDURES ................................................................................. 1–6

1.6 Standard Work Process Procedures (SWPP) ....................................................................................... 1–6

2.0 CHAPTER 2 – WELDING CONTROL MANUAL & FROM 167 .................................................2-1

2.1 SCOPE ....................................................................................................................................................... 2-1

2.2 WELDING CONTROL MANUAL ............................................................................................................... 2-1

2.3 FORM 167 .................................................................................................................................................. 2-1

2.3.1 Function of the Form 167 ....................................................................................................................... 2-1
2.3.2 Site Use of the Form 167 ........................................................................................................................ 2-1
2.3.3 Request for Change to the Form 167 ..................................................................................................... 2-2

2.4 DESIGNATION CODES FOR WELDING PROCEDURES ....................................................................... 2-2

2.5 WELDING PROCESS AND VARIABLE DESIGNATIONS ....................................................................... 2-3

2.6 IDENTIFYING MATERIAL COMMONLY USED ON FOSSIL FUEL PROJECTS .................................... 2-4

2.7 FIELD WELDING OF BOILER PROPER AND BOILER EXTERNAL ...................................................... 2-5

Page iv Contents
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Field Welding Engineer’s Manual Revision 1

2.8 FIELD WELDING OF ASME B31.3 PIPING .............................................................................................. 2-5

3.0 CHAPTER 3 – WELDER AND BRAZER QUALIFICATION TESTS ......................................... 3–1

3.1 SCOPE ...................................................................................................................................................... 3–1

3.2 GENERAL INFORMATION....................................................................................................................... 3–1

3.3 CODES AND STANDARDS ..................................................................................................................... 3–2

3.4 QUESTIONS AND ANSWERS ON PERFORMANCE QUALIFICATION ................................................ 3–2

3.5 WELDER QUALIFICATION LOG ............................................................................................................. 3–3

3.6 BRAZER QUALIFICATIONS .................................................................................................................... 3–4

3.7 SOLDERING QUALIFICATIONS.............................................................................................................. 3–4

3.8 WELDER SYMBOLS & STAMPING......................................................................................................... 3–4

3.8.1 Numbering ............................................................................................................................................. 3–4
3.8.2 Application ............................................................................................................................................. 3–5
3.8.3 Code Requirements ............................................................................................................................... 3–6
3.8.4 Hard Stamping Limitations .................................................................................................................... 3–6

3.9 SAMPLE DOCUMENTS ........................................................................................................................... 3–7

4.0 CHAPTER 4 – WELDING FILLER MATERIAL CONTROL ...................................................... 4–1

4.1 SCOPE ...................................................................................................................................................... 4–1

4.2 FILLER METAL SUPPLIERS ................................................................................................................... 4–1

4.3 FILLER MATERIALS REQUISITIONS ..................................................................................................... 4–1

4.4 FILLER MATERIAL COLOR CODE ......................................................................................................... 4–2

4.5 ELECTRODE CLASSIFICATION SYSTEM ............................................................................................. 4–2

4.6 STORAGE AND ISSUE ............................................................................................................................ 4–5

4.7 FILLER METAL INVENTORY................................................................................................................... 4–5

4.8 Delta Ferrite .............................................................................................................................................. 4–5

4.9 Impact Tested Consumables for Low Temperature Service ............................................................... 4–6
4.9.1 Carbon Steel .......................................................................................................................................... 4–6
4.9.2 Stainless Steel ....................................................................................................................................... 4–6

4.10 FORMS ...................................................................................................................................................... 4–6

Contents Page v
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Revision 1 Field Welding Engineer’s Manual

5.0 CHAPTER 5 – NDE & WELD REPAIRS ................................................................................... 5–1

5.1 SCOPE ...................................................................................................................................................... 5–1

5.2 NDE CONTRACTS ................................................................................................................................... 5–1

5.3 NDE REQUIREMENTS ............................................................................................................................. 5–1

5.4 EXAMINATION RESULTS ........................................................................................................................ 5–1

5.5 RADIOGRAPHY (RT) GENERAL REQUIREMENTS .............................................................................. 5–2

5.5.1 White ...................................................................................................................................................... 5–2
5.5.2 Red ........................................................................................................................................................ 5–2
5.5.3 Orange ................................................................................................................................................... 5–3
5.5.4 Blue ........................................................................................................................................................ 5–3

5.6 MAGNETIC PARTICLE (MT) / LIQUID PENETRANT (PT) ..................................................................... 5–4

5.7 NDE PERSONNEL QUALIFICATION ...................................................................................................... 5–4

5.8 REPAIRS TO WELDS ............................................................................................................................... 5–5

5.8.1 Repairs to Boiler Code Welds ............................................................................................................... 5–5
5.8.2 Repairs to Other Welds ......................................................................................................................... 5–6
5.8.3 Welder Performance .............................................................................................................................. 5–6
5.8.4 Reject Rates .......................................................................................................................................... 5–6

5.9 Weekly or Monthly Report on Welding, NDE and Documentation ..................................................... 5–7

6.0 CHAPTER 6 – POSTWELD HEAT TREATMENT (PWHT)....................................................... 6–1

6.1 SCOPE ...................................................................................................................................................... 6–1

6.2 DOCUMENTATION ................................................................................................................................... 6–1

6.3 BECHTEL-PERFORMED PWHT .............................................................................................................. 6–2

6.4 WHEN PWHT IS SUBCONTRACTED ...................................................................................................... 6–2

6.5 ADDITIONAL REQUIREMENTS .............................................................................................................. 6–2

6.6 POTENTIAL PROBLEMS AND CORRECTIVE ACTION FOR PWHT .................................................... 6–3

7.0 CHAPTER 7 – PIPING............................................................................................................... 7–1

7.1 SCOPE ...................................................................................................................................................... 7–1

7.2 INFORMATION STAMP SYSTEM ............................................................................................................ 7–1

7.2.1 Drawings ................................................................................................................................................ 7–1
7.2.2 Weld Numbers ....................................................................................................................................... 7–1
7.2.3 Drawing Control (Welding) .................................................................................................................... 7–1

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Field Welding Engineer’s Manual Revision 1

7.3 Information Stamp ................................................................................................................................... 7–2

7.4 CONTROL USING “TeamWorks” or “Max Trax” .................................................................................. 7–3

7.5 FIELD WELDING CHECKLIST ASME, FORM WR-4 .............................................................................. 7–3

8.0 CHAPTER 8 – FIELD ERECTED STORAGE TANKS .............................................................. 8–1

8.1 SCOPE ...................................................................................................................................................... 8–1

8.2 BASIC REQUIREMENTS ......................................................................................................................... 8–1

8.3 FINAL DOCUMENTATION ....................................................................................................................... 8–2

8.3.1 TANK TEST VERIFICATION ................................................................................................................. 8–3
8.3.2 TANK TEST VERIFICATION ................................................................................................................. 8–4
8.3.3 TANK MONTHLY WELDING REPORT ................................................................................................ 8–5
8.3.4 SAMPLE TANK MONTHLY WELDING REPORT ................................................................................. 8–6
8.3.5 FINAL TANK CONFORMANCE ............................................................................................................ 8–7
8.3.6 FINAL TANK CONFORMANCE ............................................................................................................ 8–8

9.0 CHAPTER 9 – INSPECTION, CODE STAMPS, NAMEPLATES AND CODE DATA REPORTS
9–1

9.1 SCOPE ...................................................................................................................................................... 9–1

9.2 ORDERING REQUIRED CODE BOOKS ................................................................................................. 9–1

9.3 APPLICABLE CODES AND STANDARDS ............................................................................................. 9–1

9.3.1 ASME Section I – Power Boilers ........................................................................................................... 9–1
9.3.2 ASME Section IX – Welding and Brazing Qualifications ....................................................................... 9–1
9.3.3 ASME B31.1 – Power Piping ................................................................................................................. 9–1
9.3.4 ASME B31.3 – Chemical Plant and Petroleum Refinery Piping............................................................ 9–1
9.3.5 AWS D1.1 – Structural Welding Code ................................................................................................... 9–1
9.3.6 AWS D1.3 – Structural Welding Code for Sheet Steel .......................................................................... 9–2
9.3.7 AWS D1.4 – Structural Code - Reinforcing Steel .................................................................................. 9–2
9.3.8 AWS D9.1 – Sheet Metal Welding Code ............................................................................................... 9–2
9.3.9 API Standard 650 – Welded Steel Tanks for Oil Storage ..................................................................... 9–2
9.3.10 AWWA Standard C-206 – Field Welding of Steel Water Pipe .......................................................... 9–2

9.4 CODE-EFFECTIVE DATES ...................................................................................................................... 9–2

9.4.1 ASME Section IX ................................................................................................................................... 9–2
9.4.2 ASME B31.1 .......................................................................................................................................... 9–3
9.4.3 AWS, API AND AWWA CODES ............................................................................................................ 9–3

9.5 AUTHORIZED INSPECTOR (AI) .............................................................................................................. 9–3

9.6 CODE SYMBOL STAMPS ........................................................................................................................ 9–4

9.6.1 “A” Stamp – Boiler assembly ................................................................................................................. 9–4
9.6.2 “S” Stamp – Power Boilers (Manufacturer of boiler) ............................................................................. 9–4
9.6.3 “PP” Stamp – Pressure Piping............................................................................................................... 9–5

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Revision 1 Field Welding Engineer’s Manual

9.6.4 “R” -Stamp – Repairs ............................................................................................................................. 9–5

9.7 LOCATION OF STAMPS, NAMEPLATES AND ATTACHMENTS ......................................................... 9–5

9.7.1 Boilers .................................................................................................................................................... 9–5
9.7.2 Sample Nameplate (ASME Section I) ................................................................................................... 9–5

9.8 Boiler External Piping ............................................................................................................................. 9–7

9.8.1 API 650 Tanks ....................................................................................................................................... 9–7

API 650 Nameplate .............................................................................................................................................. 9–7

9.9 CODE DATA REPORTS -- ASME Section I Forms ................................................................................ 9–8

9.9.1 Form P-2 – Manufacturer’s Data Report ............................................................................................... 9–8
9.9.2 Form P-3 – Manufacturer’s Data Report for Watertube Boilers, Superheaters, Waterwalls, and
Economizers ...................................................................................................................................................... 9–8
9.9.3 Form P-3A – Engineering / Contractor Date Report for a Compete Boiler ........................................... 9–8
9.9.4 Form P-4 – Manufacturer’s Partial Date Report .................................................................................... 9–8
9.9.5 Form P-4A – Manufacturer’s Data Report for Fabricated Piping .......................................................... 9–8
9.9.6 Form P-5 – Summary Data Report for Process Steam Generators ...................................................... 9–8
9.9.7 Form P-6 – Manufacturer’s Data Report Supplementary Sheet ........................................................... 9–8
9.9.8 Form A-357 – Guide to Data Report Forms Distribution ....................................................................... 9–8
9.9.9 Form R-1 – Report of Welded Repair .................................................................................................... 9–9
9.9.10 Form R-2 – Report of Alteration ........................................................................................................ 9–9
9.9.11 Form R-3 – Report of Parts Fabricated by Welding .......................................................................... 9–9
9.9.12 Form R-4 – Report Supplementary Sheet ......................................................................................... 9–9

10.0 CHAPTER 10 – JOB RECORDS & HISTORY .................................................................... 10–1

10.1 SCOPE .................................................................................................................................................... 10–1

10.2 MAINTENANCE OF RECORDS DURING CONSTRUCTION ............................................................... 10–1

10.3 RETENTION OF RECORDS AT COMPLETION OF CONSTRUCTION ............................................... 10–2

10.4 WELDING HISTORICAL REPORT (CE&T Welding & NDE Services Use) ........................................ 10–2

11.0 CHAPTER 11 – USEFUL INFORMATION........................................................................... 11–1

11.1 Scope ...................................................................................................................................................... 11–1

A. APPENDIX A ............................................................................................................................ A–1

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Field Welding Engineer’s Manual Revision 1

1.0 CHAPTER 1 – THE FIELD WELDING ENGINEER AND CE&T WELDING & NDE SERVICES
1.1 SCOPE

The Field Welding Engineer’s (FWE) primary duty on any project is to be a contributing member of the
site construction team as part of the field engineering group reporting to the Project Field Engineer (PFE).
The primary function of that team is to deliver a quality product to the customer in accordance with the
contractual requirements, within schedule and budget.

The FWE is responsible for working in accordance with the project approved corporate Standard Work
Process Procedures (SWPP’s) and within the Division of Responsibilities (DOR) when applicable. Many
of the documents and requirements that an FWE is associated with are beyond their direct control in
terms of making changes. The FWE’s ability and willingness to communicate positive suggestions and
comments related to the work will be very beneficial to the project and Construction Engineering &
Technologies (CE&T) Welding & NDE Services.

1.2 DIRECT HIRE PROJECTS

On a direct hire project the FWE performs inspections, quality related functions, and directs efforts at
ways of improving quality, efficiency, and cost-effectiveness in all areas related to their assignment. The
FWE prepares the project welding historical and the lessons learned reports. These reports are essential
and have positive effect on our long-term profitability.

1.2.1 Project Technical References

The references listed below define the project technical requirements. It is the FWE’s responsibility
to become familiar with them. The FWE uses items 1 and 2 on a daily basis, and is the primary
person responsible to the PFE for implementing these requirement(s).
1. Welding Control Manual (WCM). CE&T Welding & NDE services shall issue the project WCM.
The WCM contains applicable welding procedure specifications for each piping class, NDE
standards, PWHT standards, General Welding Standards, Welding & NDE Matrix (Form 167) and
any special requirements for the project. It also defines code classes. (See the Form 167 in
Chapter 2)
2. Bechtel Quality Control Manual (BQCM for ASME VIII & I). Bechtel Construction QC issues
BQCM. The welding engineer shall assure that the BQCM is on site prior to any ASME Section I,
VIII or ASME B31.1 work. The Form 167 will define any ASME work that will be required. If the
FWE has any concerns or questions about the BQCM, he shall contact CE&T Welding & NDE
Services.
3. Design Drawings, Vendor Drawings.
4. Prime & Sub-contract Documents (which may address record retention, invoke specific
requirements such as customer involvement in welder testing and review of radiographs etc.).
5. Applicable Codes (B31.1, B31.3, ASME I, AWS D1.1, API, etc.) - PFE shall assure all current and
required code books are available at site.
1.2.2 Duties of the Field Welding Engineer

The following highlight the primary duties of the FWE on a direct hire project:
a. Monitor that Safety and Environmental requirements are being met

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Revision 1 Field Welding Engineer’s Manual

b. Generate Field Material Requisitions (FMR’s) for welding related equipment, consumables, and
tools according to site welding requirements
c. Train welders and Welder Training Instructors in accordance with site standards and Standard
Work Process Procedure 4MP-T81-03702, Welder Training.
d. Identify any need for welder upgrading or training, and when required, request assistance from
Welding & NDE services for such upgrading or training when required.
e. Prepare and file all documentation in accordance with Standard Work Process Procedure 4MP-
T81-03705, Welding and NDE Documentation and Records Management.
f. Assure that all field welding is done in accordance with the current revision of the Welding
Control Manual and relevant Codes.
g. Generate Form 84Q for additional welding procedures or documents.
h. Monitor Sub-contractors welding procedure specifications (WPS), NDE standards, and welder
qualification records for compliance to applicable contract requirements. CE&T Welding & NDE
Services shall approve all subcontractors’ WPS’s & NDE procedures.
i. Interface with the Authorized Inspector (AI) concerning BQCM requirements. Review WD-2
standard(s) with AI prior to making any ASME I welds or B31.1 boiler proper welds.
j. Assure that radiography, magnetic particle and liquid penetrant examinations comply with Code
and project requirements.
k. Generate NDE requests
l. Review all PWHT charts for acceptance to applicable Code and project requirements.
m. Assure that the correct filler metal is being used for any given weld.
n. Evaluate all NDE results.
o. Maintain visual surveillance of field fit-up and welding operations.
p. Alert the PFE to all conflicts between specifications and welding procedures.
q. Be responsible for surveillance of all welding being performed by subcontractors.
r. Issue weekly reports in accordance with the applicable project SWPP and send copy to the
Manager of CE&T Welding & NDE Services.
s. Prepare a project welding history at the completion of the project and submit copy to Manager of
CE&T Welding & NDE Services. This report should include topics such as historical numbers of
welders, reject rates, subcontractor performance, consumable and NDE/ PWHT costs, and
lessons learned.
1.2.3 Construction Duties

The FWE also assists the project by carrying out work, evaluating situations, and getting answers
when needed to support construction. Construction duties shall include:
a. Select appropriate welding equipment and consumables.
b. Provide training and technical direction for post weld heat treat operations performed by direct
hires.
c. Recommend the use of alternate methods of welding where appropriate (Manager of CE&T
Welding & NDE Services approval is required).
d. Improve work processes related to welding by suggesting more cost-effective alternatives. This
includes suggestions to eliminate work or documentation that is not required by the project
SWPP’s.

Page 1–2 Ch. 1 – The Field Welding Engineer and CE&T Welding & NDE Services
Welding & NDE Services
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© Bechtel Corporation 2008, 2004, 2001, 2000. Contains confidential and/or proprietary information to Bechtel and its affiliated companies
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Field Welding Engineer’s Manual Revision 1

1.3 MANAGEMENT PROJECTS

Projects within the scope of this guide normally use indirect hire craft to perform work. When a FWE is
assigned to a site where our role is construction management, the following are primary duties of the
FWE.

1.3.1 Project References

The FWE responsibility is to become familiar with the project technical requirements listed below
(contact the PFE if help is required):
a. Job Specifications& Procedures
b. Design Drawings
c. Prime or Sub-contract Documents
d. Applicable Codes (Including local country Codes when applicable for International Projects)
e. Contractor's Quality & Welding Program
f. *TEAMWorksTM (All large piping systems, hangers, valves etc and weld information)
g. *InfoWORKS® (All site documents can be found)
h. *BPS (Bechtel Procurement System and FMR’s)
i. BCOI Operating Instructions

* When application is used by the Project, if the Contractor uses different applications for
these functions the FWE shall become familiar with Contractors system.

1.3.2 Field Welding Engineers Duties

The FWE does not take direct responsibility for Contractor activities. The FWE assures that the
Contractor performs the agreed scope-of-work, maintains their welding & quality control program, and
completes the work in accordance with project requirements. The FWE shall perform surveillance of
Contractor’s welding and welding related activities, and audit the Contractors document control
system and reports on a regular basis.

Each contractor or subcontractor is responsible for preparation and maintenance of records and
documentation required in providing verification of compliance to the applicable Code(s). The FWE
monitors the documentation to assure all requirements are met.

The FWE is responsible to verify that subcontract welders are qualified and are using WPSs. The
FWE is also responsible for monitoring qualifications of NDE personnel examining the Contractors
work. The CE&T NDE Level III shall review and approve the qualifications of NDE personnel.

There are variations in control from one management project to another. The scope of work under a
management contract varies in accordance with customer participation and contractual respon-
sibilities. The specific responsibilities and degree of control to be exercised by the FWE will be as
defined in the project DOR and as directed by the PFE.

The FWE should not attempt to “force” Contractors to do things the Bechtel way. The Contractor
shall take full responsibility for their own work and are expected to work to their own approved
standards and procedures. Imposing requirements that go beyond the scope of the contract could
adversely affect the project schedule, and in many cases result in “extras” and “claims”. If a

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Revision 1 Field Welding Engineer’s Manual

Contractor can deliver the desired quality, documentation, and reports within the agreed schedule,
then it is not appropriate to make them change their system to suit a method more familiar to the
Bechtel FWE.

The FWE shall ensure that Sub-contractors welding and NDE procedures have been approved by
MET or CE&T Welding & NDE Services prior to commencing work.

The FWE shall issue weekly or monthly reports as required in Standard Work Process Procedure
4MP-T81-03705, Welding and NDE Documentation and Records Management.

1.4 CE&T WELDING AND NDE SERVICES SUPPORT

This section outlines the services provided by CE&T Welding & NDE Services to a project and to the
FWE on that project.

1.4.1 Problem Solving and Consultation

Site welding-related problems or inquiries are routed to CE&T Welding & NDE Services. The contact
information as follows:
Houston 713-235-5575 Mike Kirkes [email protected]
Houston 713-235-3433 Walt Spier [email protected]
Frederick 301-228-8181 Henry Lehman [email protected]
San Francisco 415-768-4353 Stan Yee [email protected]

All requests for information or problem solving should be as explicit and brief as possible. Clearly
defining the problem and providing all pertinent supplementary data will help assure an expeditious
and correct solution. Welding related problems might include the following kinds of information:
a. A brief problem description, including any actions taken to date to solve the problem.
b. Base metal type and thickness (e.g., A106, Grade C, etc.).
c. Welding process and filler metal type.
d. Weld joint configuration.
e. Digital photographs.
f. Governing Code (year), including appropriate revisions or addenda. It is also important to
indicate any project specification that might have more stringent requirements than the Code.
g. Identification of any cognizant home office project personnel, drawings or other data that might
be available from Engineering.
h. General site conclusions or observations that might assist in solving the problem.
i. Cost, legal (claims, back charges), or Code considerations, if any.
1.4.2 Recruiting of Site Welding Engineers

CE&T Welding & NDE Services evaluates welding staff candidates to assure they meet technical
requirements including certifications for NDE or visual inspections and experience criteria (i.e. fossil
fuel, pipeline, petrochemical background, welding experience etc). CE&T Welding & NDE Services
also provides assistance in finding new assignments for welding staff personnel at project
completion. The FWE should keep CE&T Welding & NDE Services updated on any new certifications
acquired by team or personnel.

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All rights reserved.
Field Welding Engineer’s Manual Revision 1

1.4.3 Off-Site Welder Testing

CE&T Welding & NDE Services provides procedures and personnel for upgrading, training, and
qualifying welders at off-site welding test facilities. Construction management makes final decision
on need for off-site welder testing, and is responsible for contacting CE&T Welding & NDE Services
when off-site testing is required.

1.4.4 On-site Welder Testing

Welder testing conducted at the jobsite or nearby facilities such as a local union hall that the FWE
can witness without creating difficulties due to a temporary absence from the jobsite is conducted by
the FWE assigned to the job site.

1.4.5 Welder Training

Where training programs are required to fill welding manpower needs, or upgrade welders to new
qualifications, CE&T Welding and NDE Services will provide assistance to the project on request,
including equipment requirements, consumable needs, and cost estimates.

1.4.6 Welding Control Manual (WCM)

The WCM is the manual issued to each project; the enclosed Form 167 is the controlling document
for application of field welding, PWHT and nondestructive examination (NDE). CE&T Welding & NDE
Services originates the document, maintains the procedures and standards referenced therein, and
makes distribution to jobsites.

1.4.7 Welding, Brazing, Soldering, and Bonding Procedure Qualifications

CE&T Welding & NDE Services shall conduct all procedure qualifications. CE&T Welding & NDE
Services may authorize the qualification be done at the jobsite locations. When permitted, such
testing is performed at the jobsite under the direct supervision of a Welding & NDE Services
representative. All completed weld coupons shall be shipped to Welding & NDE Services in Houston
for mechanical testing.

1.4.8 ASME Quality Control Manuals

Whenever work is governed by ASME Section I, Section VIII (Div 1), B31.1 (Boiler External Piping),
or the National Board Code, a Corporate ASME Quality Control Manual (BQCM) is required. BCOI
CE&T is responsible for distribution and maintaining of the BQCM. The Site Manager (SM) or PFE
requests the BQCM and the applicable ASME Certificates of Authorization for the project from BCOI
CE&T. The site has the responsibility to assure control and return of the QC Manual when the project
is finished. If the FWE is not sure the job site requires a BQCM, contact Welding & NDE Services for
guidance.

1.4.9 ASME Code Symbol Stamps

The SM or the PFE requests code symbol stamps. The site has the responsibility to assure the
control and return of Code symbol stamps when the project is finished. This responsibility is
extremely important. Loss of Code symbol stamps could affect corporate status in terms of
maintaining Certificates of Authorization. (The PFE will usually ask the FWE to assist in ordering the
Code Stamps and Name Plates).

Ch. 1 – The Field Welding Engineer and CE&T Welding & NDE Services Page 1–5
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Revision 1 Field Welding Engineer’s Manual

1.4.10 Authorized Inspectors (AIs)

For work within the U.S. and Canada, services of an AI are mandatory for ASME Code work. It is the
responsibility of the job site to arrange for such services. CE&T Welding & NDE Services will assist if
requested. For International Projects outside of North America, AI services are not normally
mandatory, but may be a contractual requirement by the customer; the prime contract should be
checked in this regard.

1.4.11 Qualification and Training of NDE Personnel

CE&T Welding & NDE Services qualifies and certifies Bechtel personnel involved in the radiographic,
dye penetrant, magnetic particle, vacuum box, leak testing, visual, and ultrasonic examination
methods. Certification is provided to all entities worldwide through the Houston and London offices of
CE&T Welding & NDE Services.

1.5 REVIEW OF SUBCONTRACTOR PROCEDURES

Site subcontractor's welding procedure specifications, NDE, and PWHT procedures shall be given
“permission to proceed with work”. For site-let contracts, CE&T Welding & NDE Services shall
perform this task unless otherwise defined in the project DOR. Procedures for ultrasonic flaw detection
and all NDE procedures that are used on work under the administrative jurisdiction of ASME Section I
must be reviewed by a Bechtel NDE Level III.

Bechtel’s NDE and PWHT procedures are normally used as technical attachments to bid documents, and
upon submission of a subcontractor’s procedures, are used by the FWE as the technical reference for
reviewing those procedures.

On direct hire jobs, Bechtel normally performs most of the welding on-site, with the exception of tank and
boiler erection, which may be subcontracted to others. Welding procedures for site contractors
performing work under a direct contract to Bechtel, which are used on ASME I Boiler proper or Boiler
External piping, must be reviewed and accepted for conformance to Code requirements. Material
Engineering Technology (MET) shall make such review and acceptance for Engineering issued contracts.
For site issued contracts, review and acceptance shall be by Welding & NDE Services. It is the
responsibility of the FWE to be familiar with these procedures and monitor them through out the duration
of the project.

1.6 STANDARD WORK PROCESS PROCEDURES (SWPP)

All work performed on Bechtel projects shall be in accordance with the latest revision of the relevant
SWPP’s, instructions relating to Joint Ventures (JV) and/or Sub-contracted work are contained within the
SWPP’s.

For specific actions and documents to be utilized for field construction, field construction controls,
installation, welding, PWHT, and Positive Material Identification (PMI), in congruence with applicable
codes, standards, specifications, procedures, and contractual customer requirements, refer to the
Standard Work Process Procedures at the ends of Chapter 2 (4MP-T81-03701, Welding Program),
Chapter 3 (4MP-T81-03702 Welder Training and Upgrading), Chapter 4 (4MP-T81-03703, Positive
Material Identification), and Chapter 10 (4MP-T81-03705, Welding & NDE Documentation and Records
Management).

Page 1–6 Ch. 1 – The Field Welding Engineer and CE&T Welding & NDE Services
Welding & NDE Services
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Field Welding Engineer’s Manual Revision 1

2.0 CHAPTER 2 – WELDING CONTROL MANUAL & FROM 167

2.1 SCOPE

This chapter describes the contents of a Welding Control Manual (WCM) and the use of the Form 167,
which is the job-specific specification for Welding, Postweld Heat Treating (PWHT), and Nondestructive
Testing (NDE).

2.2 WELDING CONTROL MANUAL

The WCM contains the standards, specifications, and procedures to be used for field welding.

The job-specific Form 167 will cover the project defined work scope for ASME piping, boilers (HRSG),
and/or pressure vessels, NFPA piping, storage tanks, and structural field welding applications.

Standard Work Process Procedure 4MP-T81-03701, Welding Program gives an overview of what is
issued in a project WCM.

2.3 FORM 167

For direct hire work, indirect hire and JV work, the Form 167 denotes the applicable Code, base metal
type, thickness and/or pipe diameter for each component, or pipe class to be welded.

For direct hire work, the corporate welding procedure(s) to be used for each application are designated,
as well as any required NDE or PWHT.

General and Specific notes are also included, as appropriate, to cover unique or additional requirements
and guidance. The Form 167 is prepared by CE&T Welding and NDE services and is the controlling
document for all welding, NDE, and PWHT performed in the field by Bechtel.

On direct hire jobs where structural components, storage tank erection, or boiler (HRSG) Code work is
carried-out by others, the work will be in accordance with the project drawings and specifications
applicable to that Contractor's scope-of-work.

2.3.1 Function of the Form 167

Welding, PWHT and NDE standards are specified in the Form 167 and it is exclusively issued to a
specific job. It specifies the procedures to be used in the site fabrication of all components to be
welded by direct hire personnel. It also contains notes and comments, which reflect requirements,
based upon company practice, applicable Codes, and customer requirements. Only the procedures
specified on the latest revision of Form 167 are applicable for use by the job site.

For JV work, the partner responsible for adding the appropriate welding procedures to the Form 167
shall be defined in the project DOR.

On subcontracted work where a Form 167 has been issued for the scope-of-work, it is the Sub-
contractors responsibility to add their appropriate approved welding procedures. On completion of
entry the Form 167 shall be transmitted to CE&T Welding & NDE services for approval and revision
issue.

2.3.2 Site Use of the Form 167

The FWE is responsible for the implementation of the Form 167 and the WCM on-site.

Ch. 2 – Welding Control Manual & From 167 Page 2-1

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Revision 1 Field Welding Engineer’s Manual

The Form 167 is used by the FWE, for required information when marking isometrics and other
drawings to designate weld related requirements. It is the primary reference used by FWE and
construction to determine welding, PWHT, and NDE requirements.

A sample Form 167 is attached at the end of this Chapter. Requirements in addition to those listed
for each line item on the Form 167 are contained in notes which are applicable to all work covered in
the Form 167, or where so stated, applicable only to specific line items. All notes on the Form 167
must be read as they contain important information and mandatory requirements. Where the notes
refer to specific Code requirements, the applicable Code governs in all cases.

2.3.3 Request for Change to the Form 167

Any change to requirements specified on the Form 167 requires approval from CE&T Welding & NDE
Services. The CE&T Welding & NDE Services contact will be the job assigned corporate home
office-welding specialist. If the requested change requires a procedure or specification that has not
been transmitted to the job site, CE&T Welding & NDE Services will transmit it with a revised Form
167.

For items not listed on the Form 167, a Form 84Q shall be prepared by the site FWE and sent to
CE&T Welding & NDE Services for approval. The job site-FWE shall insert the approved copy of
Form 84Q into the Welding Control Manual. Fax approval can usually be obtained directly from
Welding & NDE Services. A blank Form 84Q is at the end of this chapter.

2.4 DESIGNATION CODES FOR WELDING PROCEDURES

ASME Section IX P-number designations commonly used on Bechtel projects and the alloys commonly
used under each P-number are shown in Table 2-1.

TABLE 2-1 – ASME IX P-NUMBER DESIGNATIONS

P-Number Material Common Product Form
P-1 C-Si Pipe

P-3 C-1/2Mo Plate/Smls.Tube

P-4 1-1/4 Cr-1/2 Mo Forging/Fitting/Smls.Pipe

P-5A 2-1/4 Cr-1 Mo Forging/Fitting/Smls.Pipe

P-5B 9Cr-1Mo-V Forging/Fitting/Smls.Pipe
P-5C 3.0Cr-1Mo-0.25V Forging/Plate/Casting

P-6 SS (Ferritic & Martensitic) Smls./Welded/Tube/Forging

P-7 12 percent Chrome (Ferrite) Liner Plate

P-8 300 Series Austenitic SS Pipe & Liner Plate

P-21, 22, 23 Aluminum Bus Bar

P42, 43, 45 Monels, Inconels and Incoloys Piping/Tubing/Liner Plate

*** Other material classifications are referenced in ASME Section IX.

Page 2-2 Ch. 2 – Welding Control Manual & From 167

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Field Welding Engineer’s Manual Revision 1

When material does not have an ASME assigned P-number, a designation indicative of the specific
material to be welded will be used to identify the procedure. For example, company procedures for
structural welding under D1.1 use the ASME P-number designations to communicate the materials, which
can be welded. Example: ASTM A514 has not been given a P-number designation by ASME Section IX,
the welding procedure for joining this material to a P-1 carbon steel is designated A514, P1-A-Lh.

2.5 WELDING PROCESS AND VARIABLE DESIGNATIONS

Designations used to identify welding procedures are provided in the following tables:

TABLE 2-2 – WELDING PROCESS DESIGNATIONS

DESIGNATION WELDING PROCEDURE

A Shielded Metal-Arc Welding (SMAW)

AT GTAW root pass with SMAW fill and cap

F Flux Cored Arc Welding (FCAW)

T Gas Tungsten-Arc Welding (GTAW)

M Gas Metal Arc Welding (GMAW)

H101 Torch Brazing

TABLE 2-3 – DESIGNATIONS DENOTING PROCESS VARIABLES ON PROCEDURES

DESIGNATION WELDING PROCEDURE

Ag Argon gas purging

B Backing Strips or Tape

C Cellulosic electrodes (EXX10)

Clad Cladding or overlay welding

D Downhill progression for vertical position welding

Combination downhill root pass and uphill filler pass progression for
Du
vertical position welding
Lh Low-hydrogen electrodes (EXX15, 16 or 18)

Ng Nitrogen gas purging

Ch. 2 – Welding Control Manual & From 167 Page 2-3

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Revision 1 Field Welding Engineer’s Manual

Table 2-4 – Typical Designations For Supplemental Information

DESIGNATION WELDING PROCEDURE

XX indicates an F grouping number (i.e. F-42 would indicate that the

(F-XX)
welding would be performed using an Inconel filler metal such as Inco 182.

A procedure for use on AWS D1.1 components. In addition, procedures

(Structural) used only with specific Codes or product forms have that information in
the procedure title (i.e. Sheet Metal AWS D1.3 or Sheet Metal AWS D9.1)

(Rebar) Rebar welding

(A-C02) Argon and carbon dioxide mixture shielding gas

Table 2-5 – Example of procedure Designations

DESIGNATION WELDING PROCEDURE

P1-A-c For carbon steel using E6010 electrodes

P1-A-c-Lh For carbon steel using E6010 for root pass welding and E7018 for the fill
and cap
P8-AT-Ag For stainless steel using a GTA root with an argon purge and SMA fill.

P1-A-Lh (Structural) For carbon steel using E7018. Limited to structural components.

2.6 IDENTIFYING MATERIAL COMMONLY USED ON FOSSIL FUEL PROJECTS

TABLE 2-6
ASME MATERIAL PIPE FLANGE FITTING
P NUMBER TYPE GRADE * MARKING MARKING
P-1 Carbon Steel 1 WPB Grade II

P-3 Carbon - 0.5 Mo WC1

P-4 1 Cr, 1/2 Mo P-12 WP-12

P-4 1-1/4 Cr, 1/2 Mo P-11 WP-11

P-5A 2-1/4 Cr, 1 Mo P-22 WP-22

P-5B 9 Cr, 1 Mo, V P91 F91

304, 316 Flange and fittings designations are the
P-8 Austenitic SS
347, etc. same as the stainless grade
P-45 Alloy 20Cb-3
*The manufacturer must mark pipe with the ASME or ASTM Specification number plus a grade
designation.

Page 2-4 Ch. 2 – Welding Control Manual & From 167

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Field Welding Engineer’s Manual Revision 1

2.7 FIELD WELDING OF BOILER PROPER AND BOILER EXTERNAL

Where direct hire work is performed, the welding, NDE and PWHT requirements are found on the Form
167. The FWE must follow requirements stated in WD-2 and transfer the requirements shown on Form
167 to WR-4 "Field Welding Check Lists".

For boilers assembled by others; welding, NDE and PWHT requirements shall be in accordance with their
approved quality control program. If the manufacturer assembles the boiler, they will use their own quality
system to control welding and welding-related activities. If the manufacturer does not assemble the
boiler, the boiler manufacturer will be requested to supply weld maps for use by the erector. The erection
contractor (assembler) will designate their welding procedures they intend to use on assembly of the
border and shall initiate a reliable system for designating requirements, and for assuring that all ASME
requirements are met.

Work within the scope (jurisdiction administration) of ASME Section I includes ASME B31.1 piping which
is designated as "Boiler External Piping".

Boiler External Piping requires the same quality control measures and involvement of an AI as is required
for ASME Section I Boiler Proper. However, welding and NDE requirements for fabrication and
examination are from ASME B31.1, instead of ASME Section I.

2.8 FIELD WELDING OF ASME B31.3 PIPING

Where random radiography is specified on a Form 167, the designated LOT for welders shall be
agreed with the Customer before the start of work in accordance with ASME B31.3 Section 344.1.3
Definitions ”random” examination.

Ch. 2 – Welding Control Manual & From 167 Page 2-5

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Revision 1 Field Welding Engineer’s Manual

Sample form 167 (ATTACHMENT A)

a. For general requirements see Bechtel Specifications:
4MP-T11-W-201 Welding Engineering Guide, Code Stamping PT(SR) ASME Penetrant Examination
BQ-1 ASME-IX Brazer Performance Qualification RT-ASME IX Radiographic Examination
GBS/GSS Brazing/Soldering Standard RT-ASME/API Radiographic Examination
GNMS-2 General Non-metallic Standard UT-TM Ultrasonic Thickness Measurement
GWS Structural General Welding Standard – Structural VT-ASME/API Nondestructive Examination, Visual Examination
GWS-2 General Welding Standard VT-AWS Nondestructive Examination, Visual Examination
GWS-Ductwork General Welding Standard WD-2 ASME Weld Documentation
GWS-P91 General Welding Standard WFMC-2 Weld Filler Metal Control
GWS-SW General Welding Standard – Stud Welding WQ-1 Welder Performance Qualification
MT-ASME Magnetic Particle Examination WQ-2 Welder Performance Qualification (Structural)`
PHT-2 Post Weld Heat Treatment

b. Fillet welds for pipe attachments of like materials – Shall be made with WPS’s as identified on the applicable pipe class sheet.
c. PWHT of P5B(P91) Field Welds that are within heating-proximity of Shop made welds – Contact CE&T and the FWE BEFORE heat
treatment is commenced.
* Standard Piping Class Sheets No. 0-3DS-P72G-00001, Rev. 005 & TEAMWorks Line List as of 3 January, 02 are included in this issuance.
PREPARE CHECK REVIEW APPROVE
Rev.No REVISION DATE DATE DATE
(CE&T) (CE&T) (MET) (CE&T)

2* LAO General Update to Incorporate Line List Revision

Remove UT from NDE (%) Blocks and remove specific note to
UT in lieu of RT where referenced on this 167. Add Note (J).
2 July, 3 July, 3 July,
1 LAO Changed Revision signoff block. Changed the joint type to BR PAL HK JDD
2001 2001 2001
for Branch connections. Updated pre & post heat
requirements.
24
24 May, 25 May,
0 LAO ISSUED FOR CONSTRUCTION LAO HK LAO May,
2001 2001
2001

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 Field Welding Engineer’s Manual Revision 1

Piping Classes
Design Code: ASME B31.1 Category: Non Boiler External
Pipe Design Pressure
Line Services: Design Temperature (°F)
Class(es): (psig)
**43D SL 0 to 232 > 750
*43D SL 0 to 2 0 to 731
46D AB 0 to 610 0 to 715
Hardness
Piping Material Type: 1-1/4 Cr P Number: 4 NA
Requirements:
Ferrite
CVN Requirements: NA PMI Requirements: NA NA
Requirements:

Heat Treatment
Pipe Max NDE (%)
Pipe Class or Weld Joint POST
Size W.T. PRE Welding Procedure Specification(s) Notes
Description Type (ºF)
(nps) (Inch) (ºF)
(Note 2) RT MT PT VT

≤2 NA SW 250 (Note 2) P4-T, P4-A --- 100 or 100

**43D 100
>2 All BW 250 1300- P4-T, P4-AT 100 --- -- 100
1375 -
≤4 ALL BR 250 1300- P4-T, P4-AT --- 100 or 100
Branch Welds 1375 100
>4 ALL BR 250 1300- P4-T, P4-AT 100 --- -- 100
1375 -
≤2 NA SW 250 (Note 2) P4-T, P4-A --- --- -- 100
*43D, 46D -
2½-24 1.125 BW 250 1300- P4-T, P4-AT --- --- -- 100 1
1375 -
Branch Welds ALL ALL BR 250 1300- P4-T, P4-AT --- --- -- 100
1375 -
Notes:
1. The thickness of butt welds is defined as the thicker of the two abutting ends after end preparation.
2. PWHT is not mandatory for P-No. 4 material under the following conditions:
a. Welds in pipe or attachment welds to pipe complying with all of the following conditions:
1. A nominal material thickness of ½ in. or less;
2. A specified carbon content of the material to be welded of 0.15 percent or less;
3. A minimum preheat of 250°F is maintained during welding.

Ch. 2 – Welding Control Manual & From 167 Page 2-7

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 Revision 1 Field Welding Engineer’s Manual

Piping Classes
Design Code: ASME B31.1 Category: Non Boiler External Piping
Pipe Design Pressure
Line Services: Design Temperature (°F)
Class(es): (psig)
96D AB 530 1060 to 1065
9LD AB 2060 1065
Piping Material Type: P91(9Cr – 1Mo‐V) P Number: 5B Hardness Requirements: NA
Ferrite
CVN Requirements: NA PMI Requirements: NA NA
Requirements:
Heat Treatment
Pipe Class or Weld Pipe Max Joint NDE (%)
Size W.T. PRE POST Welding Procedure Specification(s) Notes
Description Type (ºF) (ºF)
(nps) (Inch)
RT MT PT VT
1380- --
96D 8-24 0.875 BW 400 P5B-T-Ng[P91], P5B-AT-Ng[P91] 100 --- 100 1
1420 -
1380- --
9LD 8-24 0.875 BW 400 P5B-T-Ng[P91], P5B-AT-Ng[P91] 100 --- 100 1
1420 -
1380- 100 or
≤4 ALL BR 400 P5B-T-Ng[P91], P5B-AT-Ng[P91] --- 100 1
1420 100
Branch Welds
1380- --
>4 ALL BR 400 P5B-T-Ng[P91], P5B-AT-Ng[P91] 100 --- 100 1
1420 -
Dissimilar Welds To the Above Pipe Classes
5B
Hardness
Piping Material Type: Gr. P91(9 Cr-1 Mo-V) to (2¼ Cr) P Number: to NA
Requirements:
5A
CVN Requirements: NA PMI Requirements: NA Ferrite Requirements: NA
Heat Treatment
Pipe Class or Weld Pipe Max Joint NDE (%)
W.T. PRE POST Welding Procedure Specification(s) Notes
Description Size (nps) Type (ºF) (ºF)
(Inch)
RT MT PT VT
≤2 to 1380- P5B,P5A-T-Ng(A4)[P91], P5B,P5A-AT-Ng(A4) 100 or
96D to KJD ALL Olets 400 --- 100 1
Run 1420 [P91] 100
&
1380- P5B,P5A-T-Ng(A4)[P91], P5B,P5A-AT-Ng(A4) --
9LD to KSD 2½ ≤6 ALL BW 400 100 --- 100 1
1420 [P91] -
Notes:

CAUTION: If field PWHT will be in heating-proximity of Shop made welds, contact CE&T and the FWE BEFORE the heat treatment is commenced.

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Field Welding Engineer’s Manual Revision 1

Piping Classes

Design Code: ASME B31.1 Category: Non Boiler External

Pipe Class(es): Line Services: Design Pressure (psig) Design Temperature (°F)
BED PA 150 0 to 130
ASTM B88 Copper: Hardness Requirements:
Tubing Material Type: TYPE L – ABOVEGROUND ONLY S Number 107 Temper H58
TYPE K – ABOVEGROUND OR UNDERGROUND S Number 107 Temper H58
ASTM B75, Wrought Copper, Above or Underground P Number 107 Hardness Requirements: ASTM B88, Temper H58
Fitting Material Type:
ASTM B584, Cast Bronze, Underground Service Only S Number 107

CVN Requirements: NA PMI Requirements: NA Ferrite Requirements: NA

Heat Treatment
Pipe Class or Weld Pipe Max Joint NDE (%)
Size W.T. PRE POST Joining Procedure Specification(s) Notes
Description Type (ºF) (ºF)
(nps) (Inch)
RT MT PT VT
BED ≤4 NA B NA NA P107,H101-2 --- --- --- 100 1
Notes:
1. Aboveground: Brazed
Underground and Embedded: Brazed

Ch. 2 – Welding Control Manual & From 167 Page 2-9

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Revision 1 Field Welding Engineer’s Manual

Piping Classes

Design Code: APPLICABLE PLUMBING CODE(BEQ) & NFPA(BFF) Category: Water Services
Pipe Class(es): Line Services: Design Pressure (psig) Design Temperature (°F)

BEQ PW 100 100

BFF PF 100 to 150 90 to 150

ASTM B88 Copper: Hardness Requirements:

TYPE L – ABOVE GROUND S Number 107 Hard Drawn, Hard Temper

Tubing Material Type:
TYPE K – UNDERGROUND & EMBEDDED IN S Number 107 Temper 060 OR 050, Annealed
CONCRETE

ASTM B75, Wrought Copper P Number 107 Hardness Requirements: ASTM B75, Temper H55
Fitting Material Type:
ASTM B584, Cast Bronze S Number 107

CVN Requirements: NA PMI Requirements: NA Ferrite Requirements: NA

Join Heat Treatment

Pipe Class or Weld Pipe Max t NDE (%)
Size W.T. PRE POST Joining Procedure Specification(s) Notes
Description Typ
(nps) (Inch) (ºF) (ºF)
e RT MT PT VT
ANSI
BEQ, BFF 3/8≤4 B NA NA P107,H101-2 --- --- --- 100 1
H23.1
Notes:
1. Aboveground: Brazed
Underground and Embedded: Brazed

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Field Welding Engineer’s Manual Revision 1

FORM 84Q

WELDING PROCEDURE SELECTION CHECKLIST

Project: Log No:

Comp. / Equip. Description:

Drawing Number:

Work Package Number:

Installation / Design Code:

Material Type(s) & P‐No(s):

Size(s):
Type of Weld:

Pre / PWHT Requirement:

Assigned WPS:

NDE Req’t / Procedure Number:

Documentation:

Special Comments:

Current Revision of Form 167:

Prepared By:
LEAD FIELD WELDING ENGINEER / Supervisor DATE

EGS / PE:
DATE

The following signatures confirm that the above interim change is acceptable and that the change will be
incorporated into the next revision of the WCM / SPM. When required, It is the projects responsibility to obtain
customer approval of these documents, prior to their use.

Concurrence By:
WELDING & NDE SERVICES DATE
(BY TELECON or e‐mail)

If by Telecon, signature of person obtaining approval:

EGS / PE:
DATE

Customer
Approval: DATE

Ch. 2 – Welding Control Manual & From 167 Page 2-11

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3.0 CHAPTER 3 – WELDER AND BRAZER QUALIFICATION TESTS

3.1 SCOPE

This chapter explains requirements for welder, welding operator, and brazer performance qualification
tests. The FWE’s primary sources of information for performing qualifications are included in, but not
limited to, the performance specifications listed below.

• WQ-l ASME Section IX

• WQ-2 AWS D1.1
• WQ-3 Sheet Metal AWS D9.1
• BQ-1 Brazing Qualification ASME Section IX
It is a mandatory ASME Section IX requirement that a company conduct its own welder qualification tests.
Some national societies and unions have established qualification programs that may or may not meet
the requirements of Section IX. Welding & NDE Services should be notified prior to any participation in
such programs to assure that Code requirements and corporate concerns are met. Acceptance of
welders qualified, under such programs, is not permitted unless Welding & NDE Services is informed and
concurs in such acceptance. (Example: “Common Arc” is the Boilermakers program that Bechtel is
signatory to).

3.2 GENERAL INFORMATION

All welder performance qualifications for all projects are to be conducted by Bechtel FWEs, and the
results recorded on the "Performance Qualification Test Record" contained in the relevant WQ-X or BQ-X
Specification (see Standard Work Process Procedure 4MP-T81-03705, Welding & NDE Documentation
and Records Management). Contracts that permit or mandate tests be performed by others do not
constitute Corporate agreement to depart from the requirements contained in the WQ or BQ Qualification
Specifications.

The Request for Welding Test Form provides a systematic method for craft supervision to request new or
updated qualification tests for welders and brazers already assigned to the job site.

If the project is large enough to have a full-time welder testing/upgrading facility on-site, a roster showing
the day-by-day activities of the facility should be maintained. The Welder's Test Roster provides spaces
for information on the number of tests performed, the procedures used for testing, and the number of
rejected tests. The FWE directs all on-site upgrading training and qualification testing. Performance
qualification records from another Bechtel project may be accepted, provided:
a. The qualification record is current as described in the applicable Qualification Specification.
b. An FWE is available at the job site to evaluate the need to give a visual test of the welder or
brazer claiming prior qualification, and to provide a competent evaluation of any such test
coupons.
c. The FWE calls the previous job site or CE&T Welding & NDE Services to confirm the welder's
qualifications
The FWE shall review Bechtel welding requirements with new welders before they perform production
work at the site. The form Welder Requirements shown in Fig. 3-1 may be used for this purpose.
Information may be added or deleted on the form, as appropriate, for the particular project. The purpose

Ch. 3 – Welder and Brazer Qualification Tests Page 3–1

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Revision 1 Field Welding Engineer’s Manual

of the form is to acquaint welders with Bechtel and project-specific welding requirements. Welders are
responsible for each weld they make; the form makes them aware of management quality expectations.

For some projects it may be necessary to recruit and test welders offsite. In this situation, the offsite
testing is conducted by CE&T Welding & NDE Services or by an FWE designated by CE&T Welding &
NDE Services.

3.3 CODES AND STANDARDS

Performance qualification requirements for work to be performed under the various Codes are specified
in but not limited to the following Standards:

• WQ-1 ASME Section IX qualifications for welders

• WQ-2 AWS D1.1 qualifications for structural welding
• WQ-3 AWS D1.3 or AWS D9.1 for sheet metal qualifications
• BQ-1 ASME Section IX qualifications for Brazing
3.4 QUESTIONS AND ANSWERS ON PERFORMANCE QUALIFICATION

Numerous calls are received from the field for assistance with interpretations for specific welding
qualification applications. The following is intended to clarify the most frequently asked questions.

Can customer or independent laboratories perform Bechtel welder qualification activities provided that
they follow an American Welding Society qualification program accepted at the job site for use on work
performed by Bechtel?

Bechtel welder or brazer performance qualification tests must be conducted under the direct supervision
of a Bechtel FWE. Failure to follow these requirements constitutes violation of the Code and might be
cause for withdrawal of the Code Symbol Stamps and Certificates of Authorization to perform work under
the ASME Boiler and Pressure Vessel Code.

• Preparation of test material and mechanical testing of weldments may be performed by others.
Bechtel cannot permit evaluation of bend specimens by others.
• The customer or an independent NDE contractor may perform project required radiography; however,
the radiographs must be evaluated by Bechtel personnel qualified to SNT-TC-1A Level II
requirements.
• The FWE supervising the qualification testing shall sign qualification forms.
What documents govern the administration of welder qualification tests?

Welder performance qualification tests must meet the applicable Code under which the welder will be
performing production work, and must be welded in accordance with a welding procedure approved by
the job Form 167). In Canada, the authorized provincial authority (Boiler Branch=AIA) should also
approve the welding procedure, for the province where the work is to be performed. The specific details
of testing, such as the type of test given shall conform to the requirements contained in the appropriate
WQ (or BQ for brazers) document. No departure is permitted from the WQ requirements, regardless of
customer or AIA preference without specific approval from Welding & NDE Services.

What tests apply to the craft that perform work where no Code is specified, or where the welds to be
performed are not considered critical?

Page 3–2 Ch. 3 – Welder and Brazer Qualification Tests

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Field Welding Engineer’s Manual Revision 1

All welders on a job site shall be tested. This includes electricians, ironworkers, millwrights, sheet metal
workers and carpenters. Where no Code is specified, and a question exists as to the proper test, CE&T
Welding & NDE Services should be contacted for advice. It must be remembered that the rules and
philosophy-governing welder testing are constantly undergoing revision due to Code or liability
considerations, and concepts acceptable for a job this year may not be acceptable next year. It should
also be noted that testing all welders to meet Section IX or D1.1 requirements when the work they shall
be doing is not covered by those documents, might not be cost-effective or appropriate.

Can a welder weld with an electrode size (diameter), which is not shown on the welding procedure (WPS)
applicable to the work he is performing?

While the welder might be legally qualified to use other electrode diameters, they are permitted to use
only the electrode diameters shown in the welding procedure specification. If there is a specific reason to
use an electrode diameter not permitted by the applicable WPS, then CE&T Welding & NDE Services
should be contacted to determine if the diameter range could be expanded to cover the specific
application.

For Stud Welding, is a performance qualification test required in all situations?

Yes, but the test may be somewhat less formal than detailed in WQ -1 or WQ - 2 for qualification. The
ASME code does not require qualification of stud welders for the attachment of non-pressure parts, which
have essentially no load carrying function (such as insulation attachment pins). For all applications, a job
site test of the stud weld joint (such as the hammer test) must be carried out at the start of each shift.

What is the preferred initial test for a pipe welder when he first arrives at the job site?

Initial welder qualification tests are made in accordance with the job site needs. Initial pipe tests should
be on 8” NPS Sch-80 (.500”) in the 6G position. If the need is for small bore piping, use 2” NPS Sch-80
(.218). All coupons should be carbon steel. Other pipe diameters and thickness and positions may be
used at the option of the FWE; however all the requirements of WQ-1 must be complied with, without
exceptions.

Is it permissible to give copies of the Performance Qualification document (WR-1) to the welders or to the
local Union hall if they request it?

Under No circumstances is it permissible to provide copies of the qualification papers to either the welder
or the Local Union Hall. There are overriding commercial and legal reasons for this rule. If agreements
have been made by labor relations with the Local Union to provide such documents, the FWE shall
contact CE&T Welding & NDE Services for resolution. It is permissible and beneficial to provide a listing
of welders and their job site qualifications to the Local Union in a tabular or other format. The use of the
qualification documents themselves, even if they are stamped "For Information Only" is not permissible.

3.5 WELDER QUALIFICATION LOG

A Welder Qualification and Maintenance Record Log (see Standard Work Process Procedure 4MP-T81-
03705, Welding & NDE Documentation and Records Management) shall be maintained by the project
FWE, and it shall include an entry for each person qualified to weld (or braze) on the job site. The log
must be kept current on at least a weekly basis with any performance qualification changes or
termination. The Log provides the FWE and supervision with:
a. Quick reference to welders' qualifications.
b. Assistance to supervision in assigning welders according to their qualifications.

Ch. 3 – Welder and Brazer Qualification Tests Page 3–3

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Revision 1 Field Welding Engineer’s Manual

A Master Welder Performance Qualification Log should contain all of the welding procedures specified for
use in the Form 167. The log may then be entered into the job site computer or recorded in a PC weld
tracking system (Max Trax or TEAMWorks). All entries, changes etc., may then be performed using the
computer to aid in keeping track of the constant revisions resulting from new qualifications, expired or
canceled qualifications and termination. As welders are qualified, their names, symbol numbers, and the
procedures they are qualified to use are entered into the computer. The log should be updated weekly
(or as required) and distributed as shown:
a. SM
b. Field Piping Superintendent(s)
c. FWE(s)
3.6 BRAZER QUALIFICATIONS

Performance Specification BQ-l covers requirements qualifying crafts to perform brazing using the
manual torch process. Performance qualifications for brazing are conducted by the FWE and the results
recorded on the Brazer Performance Qualification Record. All brazers shall be qualified.

The Request for Welding Test and the Welder Performance Qualification Log are used for brazer
qualifications in the same manner as described previously for welder qualification.

3.7 SOLDERING QUALIFICATIONS

Personnel who will be performing soldering operations are not required by Code to receive a qualification
test. However, soldering by a craftsman must be performed in accordance with a soldering procedure to
assure that legal and environmental concerns are met when the filler metal is selected. The craftsman
performing the soldering does not need to pass a qualification test, unless there is some specific reason
that this might be desirable. In most cases, since soldering is not used for high pressure or high
temperature systems, it is not necessary. Subcontractors who perform soldering operations are not
required to have a procedure or a certified solderer, unless the contract under which they are working
specifically states otherwise. They must however, adhere to any local ordinances, which may limit the
type of solder to be used due to environmental concerns.

3.8 WELDER SYMBOLS & STAMPING

All welding or brazing within the scope of ASME I, III, VIII, ASME B31.1, B31.3 or AWS Standards require
that the work of each person qualified be identified. It is necessary to set up a system, which identifies
welds as having been made by a certain welder(s) or brazer(s). The following details the program for
meeting these Code requirements.

3.8.1 Numbering

A unique identification symbol (number etc.) shall be assigned to each individual after qualification.
Each symbol shall identify the craft (P = pipe-fitters, B = boilermakers, I - ironworkers, E =
electricians, and M - millwrights) and number within the craft (P-1, P-11, etc.). Once a symbol has
been assigned it shall not be reassigned to another individual for the job duration. The assigned
unique I.D. Symbol shall be entered into the welder’s log as well as on each welder performance
qualification record. The welders log, or a separate log, must be maintained to assure that no
duplications occur in assigning symbols.

Page 3–4 Ch. 3 – Welder and Brazer Qualification Tests

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Field Welding Engineer’s Manual Revision 1

3.8.2 Application

Three methods of meeting the requirement to identify each welder's joints are permitted. The
selection of the method used is a project prerogative to the extent permitted by the guidelines
contained in this chapter. Regardless of the method used, the requirement that each welder be
assigned a unique identification is mandatory. The methods used to identify a welder's work when
governed by the ASME Quality Control Manual shall be communicated to the AI earlyin the project so
that they are familiar with the method Bechtel elects to use. The three methods are:

TABLE 3-1 – WELDER IDENTIFICATION METHODS

This method is acceptable for all applications covered
by ASME I or B31.1. While it is acceptable for AWS
METHOD 1
D1.1 work, it is not cost-effective for structural work or
Hard Stamping by the welder
for applications involving electrician, sheet metal,
millwright and/or carpenter welders.
This method is preferred for D1.1 structural welds,
METHOD 2 and for miscellaneous welds performed by electrician,
Marking the I.D. on the joint by the welder sheet metal, millwright and/or carpenter welders.
using paint sticks etc* It may be used for pressure welds only with the
specific agreement of the FWE.
This method is recommended for all applications
which involve ASME I and B31.1 components. It
can be accomplished either through the use of WR-4
METHOD 3 forms (for boiler and boiler external piping) or by a
Documentation of the welders I.D. computerized tracking system such as "MaxTrax" or
(by the FWE or designee) “TEAMWorks” system. A method by which the
individual who made the joint places some mark
(which can be temporary) on the joint must be
established.

* This marking should be performed using a paint stick, marking crayon or other device
made for this purpose, which leaves a readily visible mark, which is permanent enough to
last until construction is complete. For stainless steel joints, the marking material must
be suitable for use on stainless. The FWE shall approve any marking material intended
for use on stainless prior to purchase.

If hard stamps are used for the ID symbol, both letters and numbers shall be 1/4-inch size. Stamps may
be purchased from the following suppliers or from hardware stores. Many specifications call for the use
of low stress stamps. Such stamps have rounded (or dotted) symbol surfaces that do not leave a sharp
notch in the surface of the material being stamped. To avoid problems it is recommended that low stress
stamps be purchased through:

Ch. 3 – Welder and Brazer Qualification Tests Page 3–5

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Revision 1 Field Welding Engineer’s Manual

TABLE 3-2 – WELDER STAMP SUPPLIERS

McMaster-Carr Supply Co McMaster-Carr Supply Co
P.O. Box 54960 P.O. Box 440
Los Angeles, CA 90054-0960 New Brunswick, NJ 08903-0440
Phone: (562) 692-5911 Phone: (908) 329-3200
Fax: (562) 695-2323 Fax: (908) 329-3772

3.8.3 Code Requirements

If the job site elects to "hard stamp" or otherwise mark the completed joints, the specific Code
requirements are provided below. Each welder is responsible for stamping or otherwise identifying
each weld or partial weld he performs. The Welder Requirements (Fig. 3-1) should state the FWE's
preference. The welder’s identification shall be accomplished upon completion of the work.

Apply the stamp on or adjacent to all welds or on continuous welds at intervals not
ASME Section I exceeding 3 feet. In lieu of stamping, a record shall be kept of welders and/or
operators employed on each joint and shall be available for the AI.
Welders' stamps shall be applied to all work performed by a welder in a manner
specified by employer. If stamping or marking on the pipe is instituted, we recommend
ANSI B31.1 that for horizontal pipe runs, the symbol be placed on or adjacent to the weld at top
dead center. If placed on the weld, the cap should be filled smooth enough so that the
stamp can be easily identified at a later date.
Each pressure containing weld or adjacent area shall be marked with the welder
identification. In lieu of marking the weld, appropriate records shall be filed. If
ANSI B31.3 stamping or marking on the pipe is instituted, we recommend that for horizontal pipe
runs, the symbol be placed on or adjacent to the weld at top dead center. If placed on
the weld, the cap should be filled smooth enough so that the stamp can be easily
identified at a later date.
WQ-2 contains a requirement for issuing a unique identification to welders who will be
performing structural work. How this identification is applied, or if it is applied is at the
option of the FWE on the site. For structural work to be examined by any NDE
AWS D1.1 method, it is prudent to require marking of the joint by the welder with their unique
identification. Subcontractors working on structural components at the site shall follow
their own quality program insofar as how or if a welder identifies the work he has
performed.
Lap welded roof seams and flange-to-neck joints require no stamping. Other welds
API 650 shall be stamped or may be tracked using a record established for that purpose such
as is provided in Method 2 and 3 of paragraph 3.2 above.

3.8.4 Hard Stamping Limitations

Hard stamping should not be permitted on materials or welds less than 3/16 inch thick. Vibra pencils
have been used on many job sites to satisfy Nuclear Code or customer requirements. This is not
considered a cost-effective method of identifying welds, and should not be instituted unless
permanent identification of the welder, on the joint, is a specified requirement of the job specification.

Page 3–6 Ch. 3 – Welder and Brazer Qualification Tests

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Field Welding Engineer’s Manual Revision 1

For austenitic stainless steels or high nickel alloys, a cost-effective alternative to hard stamping or
vibra etching is an appropriate approved paint stick.

3.9 SAMPLE DOCUMENTS

The complete Welding and NDE Forms Index can be located in Attachment A of Standard Work Process
Procedure 4MP-T81-03705, Welding & NDE Documentation and Records Management.

Ch. 3 – Welder and Brazer Qualification Tests Page 3–7

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Revision 1 Field Welding Engineer’s Manual

WELDER REQUIREMENTS (Fig.3-1)

WELDER REQUIREMENTS – CONSTRUCTION JOBSITES

PROJECT NUMBER: PROJECT NAME: DATE:

WELDER NAME: BADGE NUMBER:

SYMBOL: CRAFT:

The following requirements have been prepared to acquaint you with the jobsite policies regarding welders.

Welder Qualification - All welding and brazing on this project shall be performed by personnel qualified by in strict
accordance with the applicable codes, job specifications, and company procedures.

Welding Procedure - It is the welder’s responsibility to know the procedure to be used on the weld(s) he is assigned to
make. No welder is permitted to weld with a procedure he is not fully qualified to use.

Joint Fit-Up - Be sure that the joint to be welded is properly cleaned and correctly aligned. If for any reason the joint is not
properly fit-up, do not attempt to weld it without prior approval from the welding engineer.

Filler Metal Control - Disbursal of welding filler metal has been controlled to assure that the correct filler metal will be used to
weld any given joint. Damaged, wet, or unidentified filler metal shall be immediately returned to the welding engineer or
foreman.

Preheat and Interpass Temperature - Welding procedures specify preheat minimums and interpass temperature
maximums. It is the welder’s responsibility to know these temperature requirements and assure that they are being followed.

Tack Welding - All tack welding shall be done in a neat and effective manner. Tack welds shall be of sufficient length to
prevent closing of the weld spacing. Faulty tack welds shall be removed and replaced with acceptable tack welds. Only
qualified welders are allowed to perform tack welds.

Weld Out (Completion) - Each successive weld pass shall be checked for visible defects. Any defects noted shall be
removed before continuing the weld. Defects appearing in the base material, i.e. cracks, laminations and holes, etc. shall be
brought to the attention of the welding engineer.

Arc Strikes - Arc strikes on the base metal outside the weld zone may cause stress concentrations that could result in
material failure, therefore, arc strikes outside of the weld groove are not permitted. The arc must be struck within the weld
groove.

Socket Welds - Assure that the correct space is used between the pipe end and socket base (1/16 in. - 1/8 inch gap). As a
minimum two passes are required on socket joints. The starting point for the second pass shall be staggered from the
starting or ending point of the first pass.

Final Cleaning - All welds including pipe, supports, hangers, structural members, etc. shall be thoroughly cleaned of slag and
visually checked for defects, such as: pin holes, undercut, insufficient or excessive reinforcement, etc. before a welder leaves
the joint.

Welder Identification - Each welder is responsible for marking their work whether it be a partial weld or a complete weld.
Marking shall be done immediately upon completion of the work with the welder’s assigned symbol. The FWE will direct
where and how the welds are marked. Failure to comply with these requirements will result in termination of welder’s
qualifications.
The above requirements are intended to alert welders and brazers of requirements, which this project considers necessary to
produce a quality product.

Page 3–8 Ch. 3 – Welder and Brazer Qualification Tests

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4.0 CHAPTER 4 – WELDING FILLER MATERIAL CONTROL

4.1 SCOPE

This chapter addresses the mandatory requirements for filler metal control in accordance with the
Welding Filler Material Control Standard (WFMC-2).

4.2 FILLER METAL SUPPLIERS

The FWE is responsible for selecting the correct type of filler materials (manufacturer and type) for the
assigned project, unless the welding procedure specification or CE&T Welding and NDE Services
references a specific manufacture and type.

The FWE choice of filler material should be based upon an evaluation of the "user friendliness" of the
filler material. Price is not a consideration except when two or more equally acceptable brands are being
evaluated. Filler materials should not be purchased based on the lowest cost available. Some sole
sourcing for certain electrodes may be necessary (Example: Filler materials for P91).

A specific reference to a manufacture, or brand name electrode, is not typically found on procedures for
non-nuclear plants except in the case of Flux Cored Arc Welding or Submerged Arc Welding electrodes.
If tanks are being erected by Bechtel, a specific manufacturer and brand may be specified for semi-
automatic and automatic welding processes. If a specific brand name is referenced on a Bechtel WPS,
its use is mandatory, unless otherwise approved by CE&T Welding and NDE Services.

CE&T Welding & NDE Services shall be contacted in cases where a nominated brand specified on a
WPS is not available.

As a minimum, any of the following problems with a particular brand should be noted in the project
welding historical and lessons learned reports:

• Receipt of high percentages of defective material or bad packing.

• Electrodes which have poor operator appeal.
4.3 FILLER MATERIALS REQUISITIONS

Orders for welding filler materials are originated by the FWE. All required data is input on a Field
Material Requisition (FMR) Sheet, or Bechtel’s procurement tracking system (PTS) or (BPS). Sufficient
lead times must be allowed to assure timely delivery. Normal supply documentation to the manufacturers
standard testing level AWS Part IIC SFA-5.01 Schedule ‘F’ or ‘G’ requirements shall be met. It is not
necessary to order filler materials with "actual" certified material test reports [CMTR] (i.e., SFA-5.01
Schedule H or I) for each heat/batch/lot unless specifically required on the Form 167 or project
specifications.

The FMR form should include the following information:

a. ASME/AWS Specification. For example, SFA /A5.1, E7018 or E6010. (This information can be
obtained from the applicable Bechtel welding procedure specification).
b. Filler Material Diameter(s) (1/8, 5/32, etc.)
c. Filler Material Quantities (in pounds)
d. Manufacturer documentation requirements (i.e. AWS SFA-5.01)

Ch. 4 – Welding Filler Material Control Page 4–1

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Revision 1 Field Welding Engineer’s Manual

e. Packaging requirements (for example, 10 lb.or 50 lb. hermetically sealed containers).

f. Special marking or identification requirements (Example: filler rod shall be stamped, etched or flag
tagged on both ends).
g. Any customer or special requirements, such as ferrite requirements, actual chemical analysis, or
special ordering information which may be required or referenced by applicable project standards,
such as the Form 167 or welding procedures.

* A "Certificate of Conformance" or "Typical" certification papers, as a minimum, shall be

supplied by the vendor for all electrode orders.

4.4 FILLER MATERIAL COLOR CODE

Bare welding filler material shall be identified with the type or classification in the form of stamping,
etching or flag tags. For bare alloy filler material, the identification shall be at both ends. If any suppliers
of electrodes can not meet this requirement, find a new supplier and notify CE&T Welding & NDE
Services. Contact CE&T Welding & NDE Services for a interim color code system if stamping or flagging
is not done.

4.5 ELECTRODE CLASSIFICATION SYSTEM

Filler material specifications for ASME (Section II, Part C) use the same numbering system as AWS, but
the specification prefix is “SFA” instead of “A”. The letter "S" designates that the material is ASME
approved and the letter "F" represents filler metal. From a practical standpoint, filler metals with either
designation are the same, and the filler metal suppliers will mark their cans to indicate that the contents
meet both AWS and ASME requirements.

Tables 4-1 through 4-3 illustrate typical AWS and Canadian Electrode Classification Systems, and
numeric and chemical designations for electrodes generally used in field work. AWS suffixes that have
been added for low hydrogen type coatings indicate that the electrodes have been tested for moisture
content and for diffusible hydrogen content in the weld metal.

TABLE 4-1 – AWS ELECTRODE CLASSIFICATION SYSTEM

1st two (or 3)
Min. tensile strength E60xx 60,000 Minimum tensile strength
digits
Exx1x Suitable for all position welding
Next to last digit Welding position,
Exx2x Suitable for flat and horizontal positions

Exxx0 Cellulose coating, for DC current

Cellulose potassium coating suitable for either AC

Exxx1
Coating type and type of or DC electrode positive (DCRP)
Last digit current for which it is
designed Titanium Potassium coating, for AC or DC either
Exxx3 electrode positive (DCRP) or electrode negative
(DCSP)

LH potassium, iron powder coating for AC or DC

Exxx8
electrode positive (DCRP) operation

Page 4–2 Ch. 4 – Welding Filler Material Control

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Field Welding Engineer’s Manual Revision 1

TABLE 4-2 – AWS Suffix Sample Designations

Suffix Molybdenum Chromium Nickel Manganese Vanadium Silicon

E7018 - A1 0.40 to 0.65 --- --- 0.90 --- 0.80

E8018 - B1 0.40 to 0.65 0.40 to 0.65 --- 0.90 --- 0.80

E8018 - B2* 0.40 to 0.65 1.00 to 1.50 --- 0.90 --- 0.80

E9018 - B3* 0.90 to 1.20 2.00 to 2.50 --- 0.90 --- 0.80

ER90S –B3* 0.40 to 0.70 2.30 TO 2.70 0.20 0.40 to 0.70 --- 0.40 to 0.70

ER90S - B9 0.80 to 1.10 8.00 to 9.50 1.0 1.25 0.15 to 0.25 0.15 to 0.30

V / 0.10 min.
7018 - G** 0.20 min. 0.30 min. 0.50 min. 1.00 min. 0.80 min.
Cu / 0.20 min.

* An "L" after any of these suffixes indicates a low carbon grade (0.05 percent maximum).
Low carbon grades will generally have a lower strength except in the case of austenitic
stainless steels. L grades are typically used in refinery applications rather than power
plant applications. In accordance with ASME B3.1, filler metals with less than 0.5
percent carbon content (L grades) shall not be used for high temperature applications
(over 850oF) in low alloy steels due to reduced creep rupture properties. The use of L
grades is prohibited unless specified on the Form 167.

** To meet requirements for chemistry, a "G" suffix electrode must meet at least one of
the minimum alloy contents shown in the table. Other alloys may be added as agreed
between suppliers and buyers.

TABLE 4-3 – Breakdown of the AWS Classification for E9018-B3

90 1 8 - B3
AC or DCRP Current. Moderate
90,000 psi minimum to heavy slag. Moderate
All position 2-1/4 Chrome - 1 Moly
tensile strength penetration. Low hydrogen iron
powder coating.

For work in Canada, most electrode manufacturers will list both the AWS and the equivalent Canadian
Standards Association (CSA W48. M1980). The Canadian system is based upon the metric system.
The Canadian electrode designations listed below are essentially the same as AWS designations except
that strength is expressed in metric terms. Thus a 60 ksi tensile strength (60,000 lbs. per inch force)
becomes 410 MPa ( 410 mega pascals stress of force) and 70 ksi becomes 480 MPa.

Ch. 4 – Welding Filler Material Control Page 4–3

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TABLE 4-4 – Canadian Electrode Equivalents

AWS Electrode Classification Canadian Standard Classification
E6010 E41010
E6011 E41011
E6013 E41013
E7016 E48016
E7018 E48018

Some E7018 electrodes are manufactured to inhibit moisture pick up from the atmosphere. Through
testing and consultation with manufacturers, Bechtel has found that many electrodes can be left out of
warmers or ovens for a full shift and not pick up a sufficient amount of moisture to create a problem. This
is true even in areas of high humidity. Due to the type and thickness of steels welded in the field, and
standard practice of issuing these electrodes in a container, CE&T Welding & NDE Services has not
mandated putting E7018 electrodes in portable ovens or warmers.
If the WFMC-2 does not require the use of portable ovens or warmers for E7018, don’t use them. If
portable ovens or warmers are used, all technical requirements in WFMC-2 shall be used.
The moisture content of low hydrogen electrodes delivered from the manufacturer can be measured at
the factory if requested by the purchaser. If electrodes are measured they must not exceed the following
limits on moisture content (percentage by weight). Electrodes which meet the requirements for moisture
content as received and after exposure to moisture have the following designations applied to them.

Electrode As received As-exposed

Designation Moisture (%) Moisture (%)

E7018 0.6 not specified

E7018R 0.3 0.4

E7018M 0.1 0.4

In addition E7018 (and other) electrodes may be tested, by the manufacturer, for the diffusible hydrogen
contained in the deposited weld metal. E7018M has no designator (it is automatically tested and must
have no more than 4.0 mL(H2/100g diffusible hydrogen content.). If testing is specified in a purchase
order (PO) for E7018, other than E7018M, the diffusible hydrogen designators shown on the
documentation accompanying the electrodes will be:

Designator Maximum Diffusible Hydrogen(H2)

(ml/100g of weld metal)

H16 16.0

H8 8.0

H4 4.0

A number of manufactures now supply low hydrogen and low alloy electrodes in small quantity vacuum
packed envelopes, that can be used straight from the packet without baking. These electrodes have a

Page 4–4 Ch. 4 – Welding Filler Material Control

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Field Welding Engineer’s Manual Revision 1

specific maximum exposure time after the packet seal has been opened to atmosphere, therefore, when
using vacuum packed electrodes the manufacturers stated exposure time shall not be exceeded.
On international projects where different country filler metal classification may be used (i.e. Europe)
contact CE&T Welding and NDE Services for assistance.

4.6 STORAGE AND ISSUE

The filler metal control system is detailed in WFMC-2, which can be found in the site welding control
manual or will be issued in conjunction with the Form 167 on jobs which have not been issued a WCM.
WFMC-2 contains specific requirements for the procurement, receipt, control, issuance and return of
welding filler materials.

It is particularly important that the requirements of WFMC-2 be followed. For instance, WFMC-2 states
that E6010 electrodes are not to be stored or issued in any type of heated oven or warmer. These
electrodes need the controlled amount of moisture in their coatings to operate effectively. Drying them
out would adversely affect their operation. E7018 on the other hand, needs to be kept dry, but WFMC-2
will normally permit them to be out of ovens or heaters for a full work shift. On the other hand, WFMC-2
requires that electrodes for low alloys (chrome moly) be issued in portable ovens or warmers.

It is the responsibility of the FWE to monitor baking or holding rod ovens, portable rod ovens, and/or
heated quivers when used.

4.7 FILLER METAL INVENTORY

The FWE shall monitor quantities of welding consumables on-site. This may be accomplished by
regularly inventorying storage and warehouse disbursal areas or by maintaining a running inventory on a
"Filler Metal Inventory Form". The FWE is responsible for ordering and maintaining proper quantities of
filler material on the site (Min / Max). If questions arise on how to estimate the quantities required for the
project, contact CE&T Welding & NDE Services for assistance.

When a rod room attendant has been assigned, or for those filler metals maintained and distributed from
a procurement controlled storage area, the responsibility for keeping track of the inventory should be
carried out by the person doing the distribution. In turn they should alert the FWE when additional
purchase of filler metals is required.

If you are working on an international project make sure what weight you are ordering quantities in,
kilograms or pounds, and coordinate this with the site procurement manager. Some buyers have changed
the weight from pounds to kilograms and we finished the job with excessive amounts of electrodes.

4.8 DELTA FERRITE

Job specifications may require that delta ferrite for austenitic stainless steel filler metals be determined.
If such requirements exist, they will be specified on the Form 167, which will also state the permitted
range of ferrite. If ferrite is not a criteria, then purchase of any stainless steel filler material made in the
US will generally provide sufficient ferrite to assure freedom from weld cracking.

One way to assure that the electrodes purchased have adequate ferrite is to check the cans for a MIL
standard number. If electrodes are made to meet a MIL standard (and most US filler metals are), they
have been manufactured to contain sufficient ferrite, and there is no practical concern related to having
sufficient minimum ferrite. There is generally no limit placed on the ferrite maximum for fossil plant work.

Ch. 4 – Welding Filler Material Control Page 4–5

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If the service conditions (exposure to high temperatures) should be such that this needs to be considered,
the Form 167 shall state a maximum ferrite number which would need to be addressed when ordering
filler material.

The ferrite determination of covered electrodes is made from a chemical analysis of an undiluted weld
metal deposit. The ferrite determination for bare wire is made from either the analysis of an undiluted
weld metal deposit or from an analysis of the filler metal itself.

A copy of the Schaeffler Diagram can be found in Bechtel Standard GWS.

4.9 IMPACT TESTED CONSUMABLES FOR LOW TEMPERATURE SERVICE

4.9.1 Carbon Steel

For ASME B31.3 design applications below minus 29°F the Code requires impact tested welding
procedures. For design temperatures at or below minus 50°F the welding consumables shall also be
impact tested in accordance with the applicable AWS specification.

4.9.2 Stainless Steel

For cryogenic service design applications below minus 150°F the welding consumables shall be
impact tested in accordance with the applicable AWS specification. (Note: Impact values at this
temperature are recorded as Lateral Expansion)

For further information on this subject refer to the Project 167, and/or contact Welding & NDE
Services.

4.10 FORMS

Filler Metal Withdrawal Form (WR-22), Alloy Filler Metal Withdrawal Form (WR-21), and Filler Metal
Inventory Form (WR-52) can be referenced in Standard Work Process Procedure 4MP-T81-03705,
Welding & NDE Documentation and Records Management.

Page 4–6 Ch. 4 – Welding Filler Material Control

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5.0 CHAPTER 5 – NDE & WELD REPAIRS

5.1 SCOPE

This chapter details the duties of the FWE related to non-destructive examination (NDE). Bechtel FWEs
are responsible for directing, scheduling, monitoring, and accepting/rejecting all work performed by the
subcontractor.

Forms to assure proper control and documentation of NDE activities are included in Standard Work
Process Procedure; 4MP-T81-03705 Welding & Documentation and Records Management and in the
NDE procedures contained in the job Welding Control Manual or sent to the jobsite with the Form 167.

The PFE and the FWE(s) reporting to the customer are responsible for the welding QC functions at the
site regardless of inspection coverage by a customer.

5.2 NDE CONTRACTS

In most cases the FWE will be asked to evaluate and review NDE contractors abilities, procedures, and
personnel qualification records. The FWE may also be asked to provide quantity information and
technical requirements for bid packages prior to selection of NDE contractors.

In some cases, depending on local areas, Bechtel NDE procedures must be used by the contractor when
contractor selection and skill are insufficient.

5.3 NDE REQUIREMENTS

The extent and method(s) of NDE are stipulated on the project Form 167.

In preparing a bid package for an NDE subcontract, the technical requirements for that package shall be
in accordance with the Bechtel NDE procedures assigned to the jobsite. These shall be attached to bid
documents sent to the subcontractors. Typical S/C attachment detailing methods of measuring or pricing
NDE bids can be obtained from CE&T Welding and NDE Services.

5.4 EXAMINATION RESULTS

The results of examinations performed by the NDE subcontractor shall be given to the Bechtel FWE only.
Acceptance or rejection is the sole responsibility of the Bechtel FWE. When conflict arises between
Bechtel and a customer inspector or AI on NDE results, contact CE&T Welding & NDE Services for a
resolution.

Bechtel's obligation to the customer involves meeting Code and contractual requirements. Where
Bechtel is asked to exceed Code or contractual requirements (example: performing additional unspecified
NDE), unwarranted costs to Bechtel or the customer may develop, and should be brought to the attention
of the PFE. Bechtel's FWEs are responsible for alerting the PFE of any significant items affecting quality
or cost.

Ch. 5 – NDE & Weld Repairs Rev. 5–1

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5.5 RADIOGRAPHY (RT) GENERAL REQUIREMENTS

The FWE is responsible for reviewing the applicable Bechtel RT procedures and Form 167 for
radiography requirements.

Radiographs of Bechtel work will be filed and maintained by Bechtel. Radiographs performed by
contractors shall be maintained by them until radiograph work is complete. Upon completion, they shall
arrange storage, disposal, or turn over to Bechtel, depending upon the job and Code requirements.
Radiographs are not normally released to others for review. Such reviews by others should be performed
in the facilities of Bechtel or the responsible contractor. Radiographs must also be available to the
customer for review. Reviews will also be available to Bechtel, when radiographs are done by others
under contract or management of Bechtel. Since Bechtel accepts ultimate responsibility for the job,
Bechtel interpretations of radiographs and Code acceptance standards are final.

AIs for ASME Code work must indicate acceptance of Code items. After the Bechtel FWE reviews and
accepts radiographs on Code items, the AI may review the radiographs. If a review occurs, the AI should
show concurrence by countersigning the RT interpretation report and the WR-4 Field Welding Checklist
(see Standard Work Process Procedure 4MP-T81-03705, Welding & NDE Documentation and Records
Management).

ASME Section I has retention requirements for film after completion of the work. The PFE will give
instructions as to disposition of the applicable film upon completion of the project. It is Bechtel's
responsibility to assure the film is retained for the Code required time and stored in a secure place. The
Owner (of the plant) may be permitted by Bechtel to retain Film for the required period. Any such
arrangement should be undertaken by the PFE. If Bechtel is to maintain the film, BCOI QC CE&T needs
to be notified.

An NDE Request/Record (see Standard Work Process Procedure 4MP-T81-03705, Welding & NDE
Documentation and Records Management) (optional for small jobs) is the first step in initiating the
"shooting" of a field weld. The Request/Record form is used to schedule examination of welds, and
enables an FWE to:

• Signify welds requiring NDE

• Receive "feedback" on completed NDE
• Receive "feedback" on NDE not completed (re-scheduled by the subcontractor)
A "flagging" system may be used to aid in identifying the NDE status of welds in the field. Tape,
surveyor's ribbon, paint markers, or crayons can be used for flagging. Paint markers or crayon should
not be used on stainless steel or high nickel alloys. Refer to Appendix A for requirements for marking
materials used on austenitic stainless and high nickel alloys. The following illustrates the use of colors to
designate field weld status:

5.5.1 White

A white flag or marking is applied when a weld is ready for NDE. It should be attached or marked by
the FWE or designee.

5.5.2 Red

A red flag or marking is applied when the weld is rejectable. It should be attached or marked by the
FWE or NDE technician. When flagging welds for repair (red), the NDE technician or FWE removes
the old flag marking.
Rev. 5–2 Ch. 5 – NDE & Weld Repairs
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5.5.3 Orange

An orange flag or marking is applied upon completion of repairs and signifies the joint is ready for
reexamination. It should be attached or marked by the FWE or the NDE technician.

5.5.4 Blue

A blue flag or marking is applied by the NDE technician or FWE after the repaired weld is
reexamined. If the weld is acceptable the blue flag remains on the weld.

Identification of welds for documenting NDE shall be as outlined in Chapter 7. All films
and film reports shall reference individual weld numbers according to the identification
system contained in Chapter 7.

After the film is interpreted, the film and report will be filed numerically by weld number or date. On
large jobs, the files will be divided by unit and system.

In some cases, the FWE may find it prudent to perform "Information Radiography". "Information
Radiography" is in addition to that required by Code. It provides the FWE with means of checking
root quality on heavy wall welds (typically joints over 1 inch thick), where early identification of
problems could save time and effort for the project. "Information Radiography" is the option of the
FWE and recommended for situations where the cost of extra radiography could be offset by the
savings realized if repairs through heavy wall thicknesses could be avoided. This extra radiography
should not continue once it has been established that the welders involved are not going to have
problems, nor shall it be used to raise the level of inspection specified in the Form 167.

Information radiographs and reports are filed separately from Code required radiographs. No
mandatory Code requirements exist for retention of these records. Any repairs resulting from this
additional radiography are not counted in the overall reject rate for the job and are tracked informally
by the FWE (excessive repairs might indicate a need to replace welders).

Weld surface preparation is one of the most controversial subjects discussed on all jobsites where
radiography is being performed. The basic reason for this controversy stems from the fact that the
interpretation of the Code rests with the individual reviewing radiographs. When individual judgment
is required as to the extent of weld surface preparation required, numerous and varied opinions
result. A very important aspect of the controversy is the time and expense involved in preparing
welds in the field. The information below attempts to establish a reasonable approach to interpreting
the applicable Code and provide common sense guidelines.

A comparison of weld surface preparation from one jobsite to another across the country revealed a
range of no weld surface preparation to extensive weld surface preparation. Several jobsites were
preparing the surfaces of all welds to be radiographed; others, only those weld surfaces which were
objectionable to radiographic interpreters.

There is no hard and fast rule that dictates the type of weld surface which might require preparation
by grinding prior to examination. This judgment is usually, and should be, rendered by a FWE
experienced in both welding and radiographic interpretation.

When the decision has been made to prepare a weld surface for radiography, there are three points
to be considered: (1) the craftsman assigned to the work, (2) the required appearance of the
prepared surface, and (3) the equipment to be used to perform the task.

Ch. 5 – NDE & Weld Repairs Rev. 5–3

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Revision 1 Field Welding Engineer’s Manual

1. A certain amount of weld surface preparation is required on every job and the people performing
this work should be selected on their ability to produce acceptable, economical weld surfaces or
be trained in the proper technique(s) required to meet requirements.
2. The following points must be considered when making a judgment regarding weld surface
preparation.
a. What is required by Code or specification?
b. Does the weld meet the requirements in the as-welded condition?
c. Is the weld reinforcement within Code limitations?
d. Are the weld ripples severe enough to affect radiographic contrast?
e. Is the weld reinforcement variation critical enough to exceed the -15 percent to 30 percent
density requirements?
f. Does the weld merge smoothly into the parent metal?
3. The selection of a grinder and grinding disks is important to accomplish economical and
acceptable weld surface preparation. The selection of grinding equipment is a judgment factor,
and the ultimate goal is to provide equipment that will meet the requirements of the job in the
most economical and expeditious manner.
There are many references made to "blending" when weld surface preparation is discussed. This
practice is objectionable for several reasons. The primary reason is the removal of parent metal that
occurs when attempting to blend the weld reinforcement into the parent metal. Secondly, this type of
weld surface preparation is not required by Code(s). Further, this blending operation is extremely
expensive, unwarranted and provides no significant advantage.

5.6 MAGNETIC PARTICLE (MT) / LIQUID PENETRANT (PT)

The applicable Bechtel standards for examination will be listed on the Form 167.

MT and PT examinations are performed by both Bechtel and subcontractors. Whoever is performing the
examination normally does the interpretation. If subcontractors are performing the examination, the
Bechtel FWE will monitor the use of procedures and perform surveillance to assure required
examinations and proper interpretations are being performed. The FWE shall assure that subcontractor
technicians are qualified to perform the work.

5.7 NDE PERSONNEL QUALIFICATION

Bechtel and subcontractor NDE personnel shall be qualified as specified in the applicable NDE
procedures.

Bechtel personnel are qualified by CE&T Welding & NDE Services. Copies of the NDE certification
records are kept in the project files. The full records, including the certifications of the person who
administered the test, are maintained by CE&T Welding & NDE Services. Projects are not encouraged to
request these due to the cost involved. In any event, Bechtel's quality program does not permit the
portions of the records, related to the test, to be distributed.

Subcontractors qualify their personnel in accordance with the appropriate supplement of The American
Society for Nondestructive Testing (ASNT) Recommended Practice No. SNT-TC-lA. Subcontractor
personnel qualification records shall be submitted to Bechtel prior to any NDE work being performed by
that subcontractor. The subcontractor’s NDE procedures must also be submitted to and approved by
Bechtel. Assistance may be requested from CE&T Welding & NDE Services in reviewing these
procedures and/or personnel qualification records.
Rev. 5–4 Ch. 5 – NDE & Weld Repairs
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Field Welding Engineer’s Manual Revision 1

Interpretation of NDE results require an individual to be qualified as a Level II in accordance with SNT-
TC-lA. CE&T Welding & NDE Services personnel can give training classes at a jobsite when requested.
Literature for study prior to upgrading to Level II in accordance with SNT-TC-lA is listed below:
1. Bechtel NDE Guidelines
2. Classroom Training Handbooks (General Dynamics - Convair Division, Published by The
American Society for Nondestructive Testing)
a. Nondestructive Testing, Radiography, Welders CT-6-6
b. Nondestructive Testing, Liquid Penetrant, Welders CT-6-2
c. Nondestructive Testing, Magnetic Particle, Welders CT-6-3
3. ASME Section V
a. SE 94 Recommended Practice for Radiographic Testing
b. SE 142 Standard Method for Controlling Quality of Radiographic Testing
c. SE 165 Standard Method for Liquid Penetrant Inspection
d. SE 109 Standard Method for Dry Magnetic Particle Inspection
e. SE 138 Standard Method for Wet Magnetic Particle Inspection
4. Bechtel Procedure Specifications (NDE)
a. RT-ASME / ANSI
b. PT(SR) ASME / ANSI
c. MT ASME / ANSI
d. VACCUM BOX LT-VB
5.8 REPAIRS TO WELDS

5.8.1 Repairs to Boiler Code Welds

The Bechtel ASME Quality Control Manual (BQCM) references Bechtel procedure WD-2 for weld
repair requirements and documentation for ASME Section I boiler proper and B31.1 boiler external
piping. An outline of the basic requirements is provided below:
a. Form WR-4, "Field Welding Checklist" (see Standard Work Process Procedure 4MP-T81-03705,
Welding & NDE Documentation and Records Management) is used to document weld history.
b. Weld joints requiring rework or repair based on visual examination prior to completion of the weld
may be reworked or repaired as necessary. Documentation of the rework or repair is not
necessary.
c. Welds which fail to pass NDE (PT, MT or RT) but can be corrected by mechanical means such
as grinding are not indicated as rejected on the WR-4 and may be reworked as necessary. If
after rework the weld passes NDE, the weld is indicated as acceptable on the WR-4.
d. Welds which fail to pass NDE (PT, MT, or RT) and require repair by welding are listed as rejected
under the remarks column of the WR-4. A new entry is made on the WR-4 below the rejected
weld entry. The new entry duplicates the rejected weld identity followed by the repair cycle
number (R1, R2, etc.). The new entry is used for checking off progressive inspections as the
repair is made.

Ch. 5 – NDE & Weld Repairs Rev. 5–5

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5.8.2 Repairs to Other Welds

Weld repairs shall be made under the direct control of the FWE. It is also necessary that the FWE be
able to demonstrate that all required repairs have been made and reexamined. The FWE, or a
welding foreman designated by the FWE, personally controls all weld repair activities. These include:
a. lay out of area to be repaired
b. selection of welder(s) who will perform the repair (for repairs grinding is considered to be an
activity that should be performed by a welder)
c. provide direction to the repair personnel
d. inspect the repair cavity prior to any required rewelding
e. give permission to proceed with repair welding
f. visually inspect the completed weld
g. perform or arrange any required NDE of the joint after the repair has been completed
5.8.3 Welder Performance

Excessive repairs attributed to an individual welder indicates a need for action by the FWE. This
could include removal of the welder’s qualification or recommending the craft supervisor to upgrade
or assign work requiring a lower skill level to the welder. Before questioning a welder's ability to
produce sound welds the FWE should:
a. Be certain of who produced the weld(s) under question.
b. Determine if any extenuating circumstances exist, such as, machine failure, joint design,
defective material, or accessibility.
c. Consider the degree of unacceptability of weld(s) under question.
d. Review the welder's previous history.
5.8.4 Reject Rates

Reject rates are the total welds rejected expressed as a percentage of the total welds examined by
NDE, not the "amount" of rejected weld. For example, consider two cases where large diameter pipe
is being welded:

Case 1 Case 2
100 Total Joints 100 Total Joints

10 Rejected Joints 2 Rejected Joints

Each requiring 1 inch of repair Each requiring 15 inches of repair

Reject Rate = 10 Percent Reject Rate = 2 Percent

Total length of weld repair is 10 inches Total length of weld repair is 30 inches

In Case 1 the reject rate is 10 percent and the total length of repair is 10 inches, while in
Case 2 the reject rate is only 2 percent but the total length of repair is 30 inches.

Rev. 5–6 Ch. 5 – NDE & Weld Repairs

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Field Welding Engineer’s Manual Revision 1

When reject rates exceed 10 percent, the FWE is expected to determine the causes, and recommend
solutions to bring the reject rate percentages back to an acceptable level. The FWE may need to
recommend a change in welders or re-qualify/upgrade current welders. Procedure and/or technique
changes may also be involved. The FWE may contact the CE&T Welding and NDE Services
Section for assistance or recommendations on how to reduce reject rates.

5.9 WEEKLY OR MONTHLY REPORT ON WELDING, NDE AND DOCUMENTATION

This report provides a quick summary or status of the welding and NDE activities on the jobsite. Any
deficiencies or problems requiring resolutions must be flagged, receive immediate attention, and be
corrected. The FWE submits the Weekly or Monthly Reports and issues a copy to the Manager of
Welding and NDE Services as required in Standard Work Process Procedure; 4MP-T81-03705 Welding
and NDE Documentation and Records Management. The Weekly or Monthly Welding Report (WR-9)
and NDE Weld Reject Report (WR-27) shall include welding and HDPE production rates, reject rates,
and manpower concerns as applicable.

Ch. 5 – NDE & Weld Repairs Rev. 5–7

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Field Welding Engineer’s Manual Revision 1

6.0 CHAPTER 6 – POSTWELD HEAT TREATMENT (PWHT)

6.1 SCOPE

This chapter outlines the duties of the FWE relative to the proper control and documentation of PWHT
operations on site. Bechtel Welding Standard PHT-2 is the procedure for performing PWHT in the field
for non-nuclear projects. It is also used as a technical attachment to bid documents where PWHT work is
contracted out to others. PWHT requirements for specific pipe classes are specified on the Form 167.

The FWE is responsible for assuring that all site PWHT operations are properly conducted and
documented. These responsibilities apply to both Bechtel PWHT operations and work by subcontractors.

The FWE shall have copies of the following, prior to the start of any PWHT:
a. Instrument Calibration Record (Recorder)
b. Certification that PWHT thermalcouples and thermalcouple wires meet the PHT-2 requirements.
6.2 DOCUMENTATION

PHT-2 requires PWHT temperatures to be checked by use of chromel-alumel thermocouples and

thermalcoulple wire with calibrated multiple point temperature indicating recorders. The resulting stress
relief chart provides a record of the PWHT.

A rubber stamp is used to identify and record information of a PWHT, from the temperature recorder
chart. The FWE, or the responsible subcontractor's supervisor, fills in the required information. In all
cases, the signature on the chart is that of the Bechtel FWE. If the chart represents one weld, then the
portion of the stamp "Thermocouple Number and Location" need not be filled out. If multiple welds are
represented, then each T/C number (or color) shall be linked with the weld number it represents.
Typical PWHT Chart Stamp
(Fig.6—1)

Job # DATE

ISO No. Weld No.

Material/Thickness /

Chart Speed Diameter

Holding Time Holding Temperature

THERMOCOUPLE NUMBER AND LOCATION

T/C #1 T/C #4

T/C #2 T/C #5

T/C #3 T/C #6

Verified by
Bechtel Welding Engineer

Ch.6 – Postweld Heat Treatment (PWHT) Page 6–1

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Revision 1 Field Welding Engineer’s Manual

One or more joints may be PWHT'd at one time and recorded on the same strip chart with a multiple point
recorder. In such cases, there are two ways to complete the documentation:
a. If the documentation system requires that individual packages be maintained for each weld, then
the original chart should be filed with one of the weld packages, and copies of the original chart
filed with the packages for the other welds recorded on that chart. The Stamp (Fig. 6-1) will
identify which thermocouple(s) relate to individual welds.
b. Then Place the PWHT chart in a file set up. The PWHT Log (WR-23) and applicable PWHT
chart shall be set up and enable one to trace the documentation from the actual weld to the
PWHT chart, or to trace from the PWHT chart to the actual weld. A drawings file set up to track
PWHT is crucial to assure that all required joints have been heat treated, especially on jobs with
significant number of welds to be heat treated. For smaller jobs, the system should provide
complete traceability that demonstrates all PWHT has been performed, in a manner that does not
require an extensive paper work system.
c. Track the progress and trace the required documentation using Bechtel's “TEAMWorks” or "Max
Trax" computer programs.
For work covered by the Bechtel BQCM, the appropriate columns on the Form WR-4 are filled in. Form
WR-4 is intended for Boiler Proper and Boiler External Piping.

6.3 BECHTEL-PERFORMED PWHT

Experience has shown that unless the FWE assigned to the jobsite has had hands-on experience with
local PWHT, it is more cost-effective to subcontract the work to a specialized company. The cost and
schedule implications resulting from having someone who is inexperienced, responsible for the required
planning, equipment purchase or lease, and training of craft personnel, can quickly create a serious
situation. PWHT should be performed prior to the hydrotest. Discuss with PFE to assure this
understanding.

The specific procedure for Bechtel performed PWHT on all non-nuclear jobs is PHT-2, which contains the
rate of heating, cooling, and requirements for thermocouple placement. The soak temperature and the
required time at that temperature are specified on the Form 167.

6.4 WHEN PWHT IS SUBCONTRACTED

The Bechtel FWE’s responsibilities are:

a. Coordinate and schedule subcontractor efforts.
b. Monitor subcontractor operations to assure conformance to Codes and standards.
c. Assure that the subcontractor documents operate in accordance with Bechtel requirements.
d. File and maintain all documentation, including completion of the appropriate sections of
e. WR-4 Form (see (see Standard Work Process Procedure 4MP-T81-03705, Welding & NDE
Documentation and Records Management), if applicable.
f. Review subcontractor invoices for correctness.
6.5 ADDITIONAL REQUIREMENTS

The PWHT temperature ranges shown on Bechtel Welding Procedures indicate the Code-allowable
temperature range. Because Bechtel WPSs are used for work governed by a number of different Codes,
all of which have different PWHT requirements, the Project Form 167 is used to specify the requirements
applicable to each project (i.e., the specific requirements for PWHT are not to be taken from a WPS).

Page 6–2 Ch.6 – Postweld Heat Treatment (PWHT)

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Field Welding Engineer’s Manual Revision 1

Similarly, the qualified PWHT temperature range for dissimilar metal joints are shown on the WPS. The
Form 167 may provide a tighter range than that shown on the WPS, and in all cases, requirements
stated in the Form 167 shall govern.

Bechtel does not permit the use of exothermic, torch or other flame type equipment to accomplish local
Code required PWHT on piping. If specific situations occur where there is no other practical way to
perform the work, CE&T Welding & NDE Services group should be consulted. CE&T Welding and NDE
Services may be able to secure a job only waiver or suggest some practical alternative. POTENTIAL
PROBLEMS AND CORRECTIVE ACTION FOR PWHT

Numerous problems can occur during PWHT. Problems that have happened in the past include power
failure, heaters burning out, recorder malfunction, thermocouples burning out, thermocouples breaking
loose, heat input unstable, and holding temperature never reached. Any type of failure effecting the
PWHT must be corrected.
a. If the PWHT is briefly interrupted, the PWHT may be continued (not repeated) after the problem
is corrected, provided:
• The soak period shall be the time at the PWHT temperature before the problem plus the
time at the PWHT after the problem is corrected.
• The temperature recorder chart is acceptable and the delay is noted on the chart and
initialed by the FWE.

If any of the above conditions are not met, the PWHT shall be repeated. Be aware of the
time-at-temperature maximums stated on the WPS.

b. If the PWHT temperature cannot be reached, the PWHT operation should be stopped and the
power source checked to assure it is receiving the required current to operate at full capacity.
Inadequate or erratic power supply may cause a power source to operate below its rated
capacity. When the problem is resolved, the PWHT operation shall be repeated.
c. If the holding temperature is not reached and it is impossible to increase the temperature, ASME
Sections I and ANSI B31.1 allow longer holding times at reduced temperature for the materials
shown below:

Carbon Steel Pl
Carbon 1/2 Moly P3
Low Nickel alloys P9 and P9B
Manganese-Vanadium alloys Pl0A materials

d. If the conditions of Table PHT-2 (Fig.2) cannot be met, the PWHT shall be stopped, the problem
identified (inadequate power supply, inadequate insulation, excessive air movement on inside of
joint, water in the line etc.), and corrected. After problem correction, PWHT may be restarted to
complete the time at temperature stated in Table PHT-2, or alternatively the PWHT shall be
restarted at the originally specified temperature and held there until the total time at that
temperature (time at temperature before the interruption plus after the PWHT was restarted) is
accomplished.

Ch.6 – Postweld Heat Treatment (PWHT) Page 6–3

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Revision 1 Field Welding Engineer’s Manual

ALTERNATE POSTWELD HEAT TREATMENT REQUIREMENTS

FOR CARBON AND LOW-ALLOY STEELS
(Fig. 6—2)

Decreased Temperature, Minimum Holding Time at Below

hr/in. of Thickness Minimum Specified Temperature (Hours)
50 2
100 3
150 5
200 10

e. If the controller malfunctions and the heat input is erratic, the PWHT should be continued by
manual control. If manual control is not possible, the PWHT should be stopped and the controller
replaced or repaired before repeating the PWHT.
f. If a heater pad *shorts out and arcs the pipe, the PWHT shall be stopped and heating elements
removed when the temperature reaches 600 °F. The FWE shall make a preliminary inspection of
any damage caused to the pipe, and shall inform the CE&T Welding and NDE Services contact
of the occurrence. Depending upon the type of material and the results of the site FWE’s
preliminary inspection, a damage report may have to be prepared and dispositioned prior to any
further work being performed on that joint. The need for a damage report shall be discussed with
CE&T Welding and NDE Services prior to any report being initiated.
If a damage report must be prepared for project engineering, it shall state the material specification and
the length, width and depth of damaged area(s). If a special repair procedure is required, it shall be
provided by CE&T Welding and NDE Services.

* This situation can be avoided by not allowing the pipe or building structure to be used
for grounding. Run two leads from the power supply – an independent circuit cannot arc
to the joint being PWHT’d.

Page 6–4 Ch.6 – Postweld Heat Treatment (PWHT)

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Field Welding Engineer’s Manual Revision 1

7.0 CHAPTER 7 – PIPING

7.1 SCOPE

This chapter describes the use of piping drawings and isometrics to specify, control, and document
welding, NDE, and PWHT activities. Every job will need a weld identification system to track and identify
field welds, that require NDE and PWHT, and control the important information of these field welds until
the completion of construction. In addition, a good weld identification system will aid in the transfer of
welding requirements, from project specifications (Form 167), to the craft performing the work.

Two methods that are used by Bechtel to track and identify welds, and aid in the transfer of technical
requirements to the craft, are:
a. Information stamps applied on piping drawings to specify welding, NDE, and PWHT requirements
for construction.
b. Bechtel's "TEAMWorks" or “Max Trax” computerized tracking systems.

***Note: For Boiler Proper and Boiler External Piping, use of the WR-4 Form is mandatory.
The WR-4 form will be attached in the WCM for that particular job. This form is not a stand
alone method of fulfilling welding control requirements. It does constitute the basis for final
AI sign off. It is not intended for use on work ungoverned by the BQCM.

7.2 INFORMATION STAMP SYSTEM

7.2.1 Drawings

Drawings are normally available for each piping system. If suitable drawings for the FWE do not
exist, then field sketches should be made to assure technical requirements from the job Form167 are
properly transferred to the craft. It is also important that PWHT and NDE are accurately documented
to the extent necessary to permit traceability. Each jobsite will have identification problems unique to
the site. The FWE is expected to solve these problems in a logical way by having positive
identification of welds requiring NDE or PWHT, and easily identifying documentation and locating
welds.

7.2.2 Weld Numbers

As a minimum, the FWE and Piping Engineer will mark weld numbers on the drawings for those
welds which are subject to NDE or PWHT. Drawings marked with weld numbers are essentially
intended to assist the FWE in the control of NDE and PWHT. The drawings for systems that call for
PWHT or 100 percent radiography will (by weld number) identify the "as built" condition. In other
words, any new joints added due to field changes, must be shown on these drawings to assure that
they are covered during the required NDE and PWHT activities.

7.2.3 Drawing Control (Welding)

The FWE may receive controlled piping drawings (including field sketches) from the PFE. These
drawings are routed to the FWE to assure that material changes (thickness, ASME P-number), Code
boundary changes, or line class specification changes are identified so that proper instruction (via the
information stamp) can be provided to the welder. Drawings are returned to the PFE for copying and

Ch. 7 – Piping Page 7–1

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Revision 1 Field Welding Engineer’s Manual

distribution after the information stamp has been applied. Revised isometrics are similarly marked
prior to distribution.

7.3 INFORMATION STAMP

The informational stamp is used to mark all applicable drawings and subsequent revisions with the
information required by supervision and crafts to perform welding. In normal situations, structural
drawings need not be stamped, as Bechtel welding procedures and other requirements are essentially
the same for all site-welded structural steel. The information stamp system is not very effective unless
the Master drawings are stamped, and that is not always possible. Electronic production weld numbers
may have to be assigned by Engineering.

*** For Boiler proper and Boiler External Piping, weld numbers must be assigned, but the
"information stamp" step may not be necessary or cost-effective. All such welds are
required to have WR-4 Forms traceable to each weld. These forms adequately
communicate requirements to the welders and constitute documentation which is adequate
for the AI.

The FWE should request the information stamps early in the project. Individual stamps may be
purchased for each basic welding procedure listed on the Form 167 plus one blank stamp for any
additional procedures not shown on the Form 167. The Figure below shows a typical information stamp.
Typical Information Stamp

Applicable Code

Weld Procedure

Filler Material Root Fill

Preheat Temperature

PWHT

NDE

Non-Pressure Attachment WPS

Welding Engineer:

Page 7–2 Ch. 7 – Piping

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Field Welding Engineer’s Manual Revision 1

It is important that information contained on a marked-up isometric is correct, since field supervisors
obtain the requirements for welding from this information. Piping isometrics are used by field supervisors
to erect and/or fabricate piping systems. Field supervisors use the specified information on the
information stamp to:

• Assign qualified welders based upon the specified procedure.

• Select filler metal(s) based upon the specified base metals.
• Obtain requirements for preheat and postweld heat treatment (PWHT).
• Obtain requirements for NDE.
Any additional notes, such as special technical requirements, or the application of ASME Section I or VIII
Bechtel ASME Manual (BQCM) requirements will be "flagged" on the isometric information stamp.

7.4 CONTROL USING “TEAMWORKS” OR “MAX TRAX”

Bechtel's computer software programs “TEAMWorks” or "MaxTrax” may be used to perform the same
functions as hard stamping of drawings.

7.5 FIELD WELDING CHECKLIST ASME, FORM WR-4

Bechtel's ASME Quality Control Manual for Section I and Section VIII (Division 1), makes reference to the
WR-4 form. Instructions for use are contained in the documentation requirements of Standard WD-2
which will be found in the WCM issued to the jobsite.

Prior to the start of welding, the FWE pre-enters from the From WR-4. Technical requirements are
obtained from Form 167. Weld numbers will be taken from other job documents as available (boiler
manufacture weld maps etc.), or will be assigned by the Boiler Engineer or FWE.

The FWE retains the WR-4 forms in an orderly manner in a controlled file. Each WR-4 Form is retained
in the FWE's file until all the welds identified on that WR-4 are completed and accepted. See WD-2 and
the BQCM for record retention requirements.

Ch. 7 – Piping Page 7–3

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Field Welding Engineer’s Manual Revision 1

8.0 CHAPTER 8 – FIELD ERECTED STORAGE TANKS

8.1 SCOPE

This chapter details the duties of a FWE for tank erection. Tank erection will normally be subcontracted.
Whether subcontracted or erected by Bechtel, tank documentation should be basically the same. If tank
erection is subcontracted, documentation will be the responsibility of the subcontractor. The FWE is
responsible for monitoring the subcontractor’s documentation and tank work until tank completion.

8.2 BASIC REQUIREMENTS

All pertinent information such as contract requirements, drawings, specifications, and erection procedures
must be reviewed prior to the start of erection. If deficiencies are detected early enough, they may be
corrected without delaying the erection schedule. The PFE may expand the FWE’s duties into non-weld
related areas. Therefore the FWE must be aware of all factors related to the tank erection. The specific
responsibilities of the FWE are outlined below.

• Welding Qualifications
− Assure that all welders are qualified and that qualified welding procedures are available, for
tank work to be performed. If required by customer or project documents, a subcontractor's
welding procedures must be approved by CE&T Welding and NDE Services prior to use.
• Radiographs
− All radiographs are checked by the FWE prior to signing of Bechtel or subcontractor test
reports. For Bechtel-performed work, copies of a subcontractor's NDE or test reports are
verified and signed by the FWE. Copies of these reports are kept in the FWE's file.
Radiographs are normally retained by the erection contractor. If Bechtel is the erector, then
Bechtel shall turn NDE and test reports over to the customer or discard them, unless there is
a mandatory retention clause in the technical requirements.
• Progress Report
− A monthly tank report (see 8.3.3 / 8.3.4) is included in the regular welding report. The report
reflects progress of testing, examinations, and if the FWE has been made responsible for
reporting general progress. It shall include an update of how much work has been
accomplished to date. Additional information such as high weld reject rates should be noted
in the remarks section to alert the PFE of any problems that will require resolution.
One method of keeping track of work in progress and the status of testing for storage tanks is to maintain
a "stretch-out", which is updated as progress is made. For jobs where Bechtel performs the tank
erection, it is recommended that a "stretch-out" or equivalent record be maintained for tracking all
activities related to testing. When subcontractors are erecting the tank they are responsible for
maintaining records. The FWE should use these records to the fullest extent possible. The FWE is also
responsible to perform sufficient surveillance of the progress and activities of work, to assure that the
"story" being shown on their records is an accurate reflection of what has really occurred. (There is no
corporate computer program at this time to track these welds. If the site is familiar with excel, a spread
sheet with the pertinent information would be acceptable.)

• Test Verification Reports

− A "Test Verification Report" (8.3.1) is required to ensure a consistent record of NDE and final
acceptance of tanks. The FWE will fill out Test Verification Reports for tanks erected by
Bechtel as well as tanks erected by others. These reports will be filled out as each type of

Ch. 8 – Field Erected Storage Tanks Page 8–1

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Revision 1 Field Welding Engineer’s Manual

NDE is completed, verified, and accepted on each tank. These reports will be kept and filed
by the Field.
• Final Conformance Form
− When all operations are completed, for tanks erected by Bechtel or by others, a Final
Conformance Form (8.3.6) is initiated by the erector. In the case of Bechtel-erected tanks,
the Final Conformance Form will be signed by the FWE. The Final Conformance Form is
filled out by the FWE using copies of the NDE test reports. The completed form is distributed
to the PFE for the job file. A copy is placed in the FWE's file.
8.3 FINAL DOCUMENTATION

Upon completion of the tank erected by Bechtel, the FWE shall provide the PFE with a complete package
for each tank. This package shall include stretch outs (showing the location of radiography or other
NDE), all inspection reports and radiographs, an etching of the tank nameplate, a listing of the welders
who were assigned to weld on the tank, and one copy of the Final Tank Conformance Report for each
tank. The disposition of these records is a matter of agreement between the Owner and Bechtel.

For subcontracted tanks, the erection contractor will provide the following data to Bechtel for turnover to
the owner (when required):

• Welder Performance Qualification Records

• Welding Procedure Specifications
• Copies of all test and examination records.
• Radiographs
If the erection was performed by Bechtel, the FWE's files should contain radiographs, radiographic
procedures and personnel qualification records for the person(s) who performed Code examinations.
These are included with the Job records which are turned over to the PFE at the end of the job.

Page 8–2 Ch. 8 – Field Erected Storage Tanks

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Field Welding Engineer’s Manual Revision 1

8.3.1 TANK TEST VERIFICATION

Date Job Number

Equipment No.

Component Description

Complete N/A

NDE: Penetrant

Magnetic Particle

Radiography

Vacuum Box

Oil Penetrant Test

Remarks:

Signed Date
Bechtel FWE

Ch. 8 – Field Erected Storage Tanks Page 8–3

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Revision 1 Field Welding Engineer’s Manual

8.3.2 TANK TEST VERIFICATION

Date DECEMBER 30, 1996 Job Number 12345

Equipment No.
T-1

Component Description
DIESEL OIL STORAGE TANK

Complete N/A

NDE: Penetrant

Magnetic Particle

Radiography

Vacuum Box

Oil Penetrant Test

Remarks:
ALL TEST AND INSPECTION ITEMS MARKED AS HAVING BEEN COMPLETE HAVE DOCUMENTED
INSPECTION RECORDS SHOWING ACCEPTABLE RESULTS ON FILE.

Signed Date
Bechtel FWE

Page 8–4 Ch. 8 – Field Erected Storage Tanks

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Field Welding Engineer’s Manual Revision 1

8.3.3 TANK MONTHLY WELDING REPORT

FOR MONTH
ENDING

TANK SUBCONTRACTOR CONTRACT NO.

REMARKS:

Signed Date
Bechtel FWE

Ch. 8 – Field Erected Storage Tanks Page 8–5

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Revision 1 Field Welding Engineer’s Manual

8.3.4 SAMPLE TANK MONTHLY WELDING REPORT

FOR MONTH 1/18/91
ENDING

TANK SUBCONTRACTOR ADM CONTRACT NO. 22222

REMARKS:
D101 vertical seams on 1st shell course rejected for failure to meet hardness
requirements per project
specifications. Contractor, customer, and Bechtel to meet next week, January 24, to
review subcontractor's proposal to correct situation. Work has been stopped until
agreement is reached.
Work on other tanks continuing (note that hardness requirements do not apply to other
tanks).

Turn over of subcontractor’s welding personnel continues to be a problem. Tank

contractor could use twenty more welders. Contractor has five new welders coming in
on January 2, 1998.

Notified Welding & NDE Services Representative in Houston.

Signed Date
Bechtel FWE

Page 8–6 Ch. 8 – Field Erected Storage Tanks

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Field Welding Engineer’s Manual Revision 1

8.3.5 FINAL TANK CONFORMANCE

JOB NO. DATE

Equipment No. Applicable Code

Component Description

Subcontractor

X-RAY Disposition of Film

Disposition of Reports

LIQUID PENETRANT Disposition of Reports

MAG PARTICLE Disposition of Reports

VACUUM BOX (TANKS) Disposition of Reports

OIL PENETRANT (TANKS) Disposition of Reports

OTHER:

PRESSURE TEST COMPLETE Date Accepted

CLEAN UP COMPLETE Date Checked & Accepted

DOCUMENTATION PACKAGE COMPLETE Turned over to:

Signed Date
Bechtel FWE

Ch. 8 – Field Erected Storage Tanks Page 8–7

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Revision 1 Field Welding Engineer’s Manual

8.3.6 FINAL TANK CONFORMANCE

JOB NO. XXXXX DATE 12/12/01

Equipment No. D-20 Applicable Code API 650

Component Description Storage Tank - Fuel Oil 2000 Gal.

Subcontractor Chicago Bechtel & Iron

RADIOGRAPHY X Disposition of Film CB&I Retain

CB&I Retain
LIQUID PENETRANT N/A Disposition of Reports
CB&I Retain
MAG PARTICLE N/A Disposition of Reports
VACUUM BOX OR OIL
CB&I Retain
PENETRANT (BOTTOM) X Disposition of Reports

CB&I Retain
Disposition of Reports

OTHER:

STATIC TEST COMPLETE X Date Accepted 12-10-01

CLEAN UP COMPLETE X Date Checked & Accepted

DOCUMENTATION PACKAGE COMPLETE Turned over to: Retained by CB&I

Signed Date
Bechtel FWE

Page 8–8 Ch. 8 – Field Erected Storage Tanks

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9.0 CHAPTER 9 – INSPECTION, CODE STAMPS, NAMEPLATES AND CODE DATA REPORTS
9.1 SCOPE

This chapter details the requirements for Authorized Inspection, Code symbol stamping, nameplates, and
Code Data Reports.

This chapter also gives a general description of the applicability of the various codes and how code
effective dates are established.

9.2 ORDERING REQUIRED CODE BOOKS

Where ASME boiler Code work is to be performed, ASME Section I must be available at the jobsite.
ASME Section IX is not normally required as the Bechtel WQ-1 document addresses details of all Code
criteria that the jobsite will be involved in. Cost-effectiveness dictates that only those Codes which are
needed will be ordered. In any event, by the time the project is completed, any Codes ordered may not
be valid for the next job. Other codes applicable to a fossil plant are noted below. Copies of these are
not normally needed, as the requirements they address are covered by the Form167 along with Bechtel's
welding procedures and specifications.

9.3 APPLICABLE CODES AND STANDARDS

9.3.1 ASME Section I – Power Boilers

Covers rules for construction of power boilers, electric boilers, miniature boilers and high temperature
water boilers, and boiler proper. It also covers certification and stamping of boiler external piping
constructed under the rules of ANSI B31.1.

9.3.2 ASME Section IX – Welding and Brazing Qualifications

Covers the rules for qualification of welding and brazing procedures, and personnel who will perform
welding or brazing for work governed by an ASME or ANSI (piping) Code.

9.3.3 ASME B31.1 – Power Piping

Covers rules for construction of power pressure piping systems. For Boiler External Piping (BEP)
only, design, examinations and testing is in accordance with the requirements of B31.1.
Administrative control comes under ASME I, which means that Bechtel's ASME Quality Control
Manual, applicable data reports, use of an AI, and application of a PP stamp apply.

9.3.4 ASME B31.3 – Chemical Plant and Petroleum Refinery Piping

Covers rules for engineering and construction requirements for pressure piping systems in chemical
plant and petroleum refinery piping applications.

9.3.5 AWS D1.1 – Structural Welding Code

Covers welding requirements for welded steel structures. The minimum recommended thickness
covered by D1.1 is 1/8 inch(see D1.3 and D9.1 below).

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9.3.6 AWS D1.3 – Structural Welding Code for Sheet Steel

Covers welding performed on sheet steel thickness, and is referenced by D1.1 for structural
applications for thicknesses less than 1/8 inch.

9.3.7 AWS D1.4 – Structural Code - Reinforcing Steel

Covers reinforcing bar and steel, including requirements for welding qualification.

9.3.8 AWS D9.1 – Sheet Metal Welding Code

Covers welding of heating, ventilating and air conditioning duct work, and other sheet metal
applications which do not have a structural function.

9.3.9 API Standard 650 – Welded Steel Tanks for Oil Storage

Covers rules for construction of storage tanks operating at approximately atmospheric pressures.

9.3.10 AWWA Standard C-206 – Field Welding of Steel Water Pipe

Covers field welding of steel water pipe and appurtenances under 1-1/4 inches thick (It should be
noted that welder qualification should be to ASME Section IX rather than the AWS "Standard
Qualification Procedure" noted in the 1962 edition of this Standard).

9.4 CODE-EFFECTIVE DATES

The applicable Codes governing construction are established from job specifications and supplementary
requirements. The PFE or project engineer can provide the Code-effective dates to the FWE when
needed. Contracts are negotiated on the basis of the Codes and Standards in effect at that time,
including mandatory addenda or supplements. Codes are not retroactive. The effective contract date for
the Code item is the governing factor in establishing the Codes to be implemented on a given project.

NDE or PWHT subcontractors for Bechtel construction work shall specify the use of the same Code and
addenda used in the construction. Bechtel subcontracts for fabrication or installation of a Code item shall
be governed by the Code edition and addenda in effect on the subcontract PO date. Materials, PWHT,
and NDE subcontracts for the same Code item shall be governed by the same Code and addenda as for
the fabrication or installation.

ASME Codes editions are issued every three years. Addenda (revisions) are issued on July 1st.

Code editions and addendas earlier than the mandatory dates cannot be used. Later Code editions and
addendas may be used on mutual consent of the parties involved. Before using later Code editions,
addendas, or Code cases less restrictive than former requirements, acceptance is needed by the
customer and the jurisdiction (authorized inspection agency or state) at the location where the component
is to be installed. Rules on specific effective date for the various Codes is provided below:

9.4.1 ASME Section IX

The current Code edition in effect on the date the welding (or brazing) performance qualification test
is performed, determines the mandatory rules for qualification testing. Addendas become mandatory
six months after date of issue.

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Field Welding Engineer’s Manual Revision 1

9.4.2 ASME B31.1

New editions are published at irregular intervals of three to four years. Amendments and revisions
are issued periodically. The latest Code edition in effect on the contract date for fabrication and/or
installation of the piping system or portions of the piping system determines the mandatory rules for
fabrication and installation. Later Code editions and addendas that are not mandatory may be used
upon mutual consent of the user of the piping system and the fabricator or installer. AWS, API AND
AWWA CODES

These Standards are issued periodically. Where a Standard issued by AWS is also an ANSI
standard it must be reissued every three years. Generally, the latest editions and revisions on the
date of the contract will apply.

9.5 AUTHORIZED INSPECTOR (AI)

Fabrication, installation, modification, and/or repair of items within the jurisdiction of ASME Section I are
subject to monitoring, verification, and inspection by a representative of an agency, authorized by the
jurisdiction (State, Province, or Municipality) to perform ASME required inspections at each jobsite. The
use of an ASME authorized inspection agency is optional for work performed by Bechtel outside North
America.

In North America, Bechtel is required to possess a valid agreement with an Authorized Inspection Agency
prior to the performance of ASME-related work. For Canadian provinces, the Authorized Inspection
Agency is the provincial authority, not an insurance agency. The agreement with the Authorized
Inspection Agency shall be in force during the entire course of ASME work.

Prior to performing any ASME work, the PFE and FWE shall ensure a copy of the appropriate Certificates
of Authorization, and a controlled copy of the Corporate ASME Quality Control Manual (BQCM) is on-site.
The PFE and FWE will assure this is done. The applicable Code symbol stamp(s) are requested from
BCOI CE&T separately prior to the application of the stamp to the Name plates.

Prior to performance of any ASME Section I work, a meeting with the AI representing the state/province
and/or Authorized Inspection Agency will take place. Discussions should cover the scope of Code work
to be performed, implementation of the quality control system outlined in the BQCM, and identification of
"hold points" which will require the AI's presence. Copies of the applicable Bechtel Certificate(s) of
Authorization and the BQCM should also be available at this meeting for review.

The AI shall have free access to areas of the jobsite where work is being done on ASME Code items. All
applicable records and documentation for Code work shall also be available to the AI. The duties and
prerogatives of the AI for ASME I work are detailed below:
a. Verify that the manufacturer, assembler, and installer has a valid Certificate of Authorization.
b. Verify that the applicable design calculations are available.
c. Review material certification as applicable.
d. Review any mill test reports or material certifications for material used. Review evidence that all
examinations of materials required prior to fabrication have been performed.
e. Review evidence that material identification has been maintained on all material.
f. Verify that the welding procedures used for construction have been properly qualified to Section
IX of the ASME Code.

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g. Verify that welders and welding operators performing Code welding have been properly qualified
to ASME Section IX.
h. Review records of all heat treatments performed on the boiler and boiler parts.
i. Review selected NDE operations and records for compliance with ASME.
j. Witness pressure tests required by ASME.
k. Certify Manufacturers' Data Reports.
l. Verify that the Code nameplate stamping is proper.
m. Verify the application and location of the Code name plate.
Fabrication, installation, modification, and/or repair of items fabricated or erected to ASME B31.1 Code
are not within the scope of an Authorized Inspection Agency except as follows:

• Each province in Canada provides AIs whose scope includes all welding on pressure components
encountered in Fossil plants.
• B31.1 Boiler External Piping is inspected (by an AI), fabricated and erected under the rules of the
BQCM and stamped with the appropriate Code Symbol stamp. All examinations and tests are in
accordance with B31.1
9.6 CODE SYMBOL STAMPS

Requirements for ASME Section I certification and stamping are specified in Bechtel's ASME Quality
Control Manual which covers both ASME Sections I and VIII. Code stamping must be done in strict
accordance with the applicable Code. It shall be authorized, and if desired, witnessed by the AI. The
Code symbol stamp(s) must be placed in the custody of a Bechtel Supervisor at the jobsite, and
maintained in a locked desk or area when not being used. When all Code stamping is completed, the
Code symbol stamp(s) shall be returned to BCOI CE&T by registered mail.

Bechtel applies the A symbol stamp to Bechtel field-assembled ASME Section I boilers supplied by
others. Parts of that boiler or Boiler External Piping may be supplied by an S or PP Symbol stamp holder.
Supplied parts will be stamped with the S or PP symbol stamp upon acceptance by their AI by those
suppliers. Bechtel's A stamp is applied at completion of field assembly and acceptance by Bechtel's AI.
This is addition to the S or PP stamps already applied by others.

9.6.1 “A” Stamp – Boiler assembly

An A symbol stamp is applied to ASME Section I boilers, completely shop or field assembled by a
boiler manufacturer. If he fabricates or erects boiler external welded piping and does not possess a
PP stamp, that piping may be stamped with the A symbol stamp. The A stamp is applied at
completion of field assembly, test, and acceptance by the AI. Depending on how the PO for a Boiler
is written, there may be instances where Bechtel is the manufacturer of the Boiler, and applies the A
symbol stamp after acceptance by Bechtel's AI.

9.6.2 “S” Stamp – Power Boilers (Manufacturer of boiler)

Boiler External Piping is under the administrative jurisdiction of ASME Section I, but is designed,
fabricated, examined, and tested in accordance with ASME B31.1. Because it is under the
administrative jurisdiction of Section I, Boiler External Piping is inspected by an AI, has data report
requirements, and is stamped with an A, S or PP symbol stamp after completion of shop or field
assembly, test, and acceptance by the AI. The PP symbol stamp is valid only for Boiler External
Piping.

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9.6.3 “PP” Stamp – Pressure Piping

ASME Alteration or Repair - Modification, alteration or repair of ASME items in operating plants shall
be performed under the rules of the National Board Inspection Code by a holder of an A ,S, or R
stamp. The AI has the same responsibilities for monitoring and verifying repairs or alterations as for
new work. After the work has been completed and at the option of the AI, verified, an R-1 form is
completed as documentation, and is filed as required by the jurisdictional authority (State or
Province). Prior to performing any work, the steps outlined below should be taken as applicable.

9.6.4 “R” -Stamp – Repairs

a. For components which have not been turned over to a customer, the manufacturer of the item
should be consulted to make sure Bechtel modification or repair will not void the warranty or
Code Stamp, and the AI should be advised of the work being planned.
b. The jurisdictional authority should be consulted for their requirements regarding calculations,
design, fabrication, testing, inspection, and documentation. A key economic factor in work
governed by National Board rules is whether the work is designated as a repair or an alteration.
Because of the economic impact of correctly designating the nature of the work, CE&T Welding
& NDE Services should be consulted if there is any question.
9.7 LOCATION OF STAMPS, NAMEPLATES AND ATTACHMENTS

The following paragraphs give requirements for locating the stamping , data on required nameplates, and
attachments. In addition to these requirements, the AI should be consulted to determine if additional
requirements apply in the jurisdiction as some states or provinces have special requirements.

9.7.1 Boilers

In addition to the Code symbol (S or A), the following items shall also be stamped on boilers with
letters and figures at least 5/16 inch high after hydrostatic testing and acceptance by the AI:
a. Name of manufacturer
b. Rated steaming capacity (required only for waste heat boilers not equipped for direct firing).
c. Maximum allowable working pressure when built
d. Heating Surface (or Kilowatt power input for electric boilers)
e. Manufacturer's serial number.
f. Year built
BBBB Engineering Incorporated
Rated Capacity 150,000 lbs/hr MAWP 275 psi
Mfr's Serial No. 973011
Water Wall Heating Surface 947 sq. ft.
Contract Job Number 67285
Year Built 1972

9.7.2 Sample Nameplate (ASME Section I)

When the boiler manufacturer completes and tests a boiler in the shop or field, it is stamped with an S
symbol stamp, plus either stamps or nameplates the boiler directly needs, with the information

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Revision 1 Field Welding Engineer’s Manual

required as illustrated above. If a nameplate is used it shall be attached to the boiler at the same
location as the S symbol stamp is applied.

When a manufacturer supplies a boiler, and Bechtel performs the field assembly of that unit,
responsibility for the completed boiler unit is assumed jointly by the manufacturer and Bechtel. The
boiler manufacturer applies the S stamp and nameplate, which is supplemented by Bechtel's A stamp
and nameplate. Bechtel's A stamp and nameplate are applied on the boiler under the manufacturer's
S stamp.

For equipment operating at temperatures above 800oF, the stamping may be applied to
a nameplate which is securely attached by suitable means. If attachment is by welding,
all Code requirements for welding shall be met.

Bechtel qualifies as the boiler manufacturer when Bechtel, as engineer and erector, provides design
specifications that establish the pressure and temperature conditions for each component of a
complete boiler unit and assembles the fabricated parts in the field. Bechtel will also performs the
master stamping (Bechtel’s S symbol stamp and the information required in 9.7.1) of the boiler.

All data except the S stamp symbol shall be cast, etched, or stamped on the plate. The S symbol
shall be stamped and stamping shall be witnessed by the AI. The letters and figures on these name
plates shall not be less than 5/32 inch high.

BECHTEL CONSTRUCTION .
CO
A AUTHORIZATION NO.
20,512
YEAR BUILT
1991

Code Data Plate

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In addition to the primary stamping and nameplates described above, the manufacturer and
assembler shall furnish a metallic plate (or plates) that contains the same data shown on the primary
Code name plate(s), for all items manufactured or assembled by that manufacturer. The letters and
figures on these nameplates shall be not less than 5/32 inch high.

When the original stampings of a completed boiler are readily visible from one place of
the operating floor or platform, the requirement for an additional plate(s) does not apply.

9.8 BOILER EXTERNAL PIPING

When Boiler External Piping is only being fabricated, a PP stamp shall be applied by the fabricator.
Alternatively, if the fabricator has an S or A stamp, either of those stamps may be applied to the piping.
In addition to the PP stamp, the fabricators name and ASME serial number shall be stamped onto welded
piping over 2 inches (nominal diameter). Stamping shall be on the pipe, valve, or fitting adjacent to the
welded code joint farthest from the boiler. Stamping shall be with letters and figures at least 5/16 inch
high, and shall be performed after hydrostatic test and AI acceptance.

When Bechtel erects and welds Boiler External Piping supplied by a shop fabricator who has applied their
code stamp to the piping, Bechtel will, after completion of testing and acceptance by Bechtel’s AI, apply a
Bechtel stamp and nameplate to cover the work performed by Bechtel. This stamp may be either a PP or
A stamp.

For piping operating at temperatures above 800oF, the symbol may be stamped on a
nameplate permanently attached by welding (provided such welding is postweld heat
treated), or on a circular metal band at least 1/4 inch thick. This band around the pipe
shall be secured in such a manner as to prevent it from slipping off during handling and
installation.

Welded piping 2 inches (nominal pipe size) or less within the scope of ASME Section I, shall be
marked with an identification acceptable to the AI and traceable to the required data report. Such
marking shall be of a type that will remain visible until the piping has been installed.

9.8.1 API 650 Tanks

API 650 tanks shall have a nameplate with the information as shown below. It is to be attached to an
auxiliary plate which shall be attached to the tank shell adjacent to a manhole or a manhole
reinforcing plate, immediately above the manhole. Nameplates placed directly on the tank shell or
reinforcing plate shall be attached by continuous welding or brazing. The nameplate itself shall be
made of a rolled or cast corrosion-resistant metal and the letters and numbers shall be roughened or
black-etched.

API STD 650

YEAR 1976
Nominal Diameter: 70 ft Nominal Height: 49 ft.
Barrels: 42 Gal. Nominal Capacity: 32,900
Fabricated By: ABC Co. Erected By: ABC Co.
API 650 Nameplate

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9.9 CODE DATA REPORTS -- ASME SECTION I FORMS

The Appendix of ASME Section I provides guides to aid in completion of the Manufacturer's Data Report
Forms. Examples showing combinations of required Data Report Forms are included. Manufacturer's
Data Reports are signed by the organization that performed the work, certifying Code compliance. These
are countersigned by the AI confirming that the witnessed work complies with the Code rules.
Manufacturer's Data Reports shall be furnished to the purchaser, the inspection agency, and the state or
provincial authority having jurisdiction at the place of installation. The Forms may be obtained from the
ASME order dept., 22 Law Drive, Box 2300, Fairfield, NJ 07007-2300

Seven types of Manufacturer's Data Report Forms are used in the design, manufacturer, or assembly of
a boiler unit, including the boiler external piping. They are:

9.9.1 Form P-2 – Manufacturer’s Data Report

Used for all types of boilers except water tube boilers and electric.

9.9.2 Form P-3 – Manufacturer’s Data Report for Watertube Boilers, Superheaters, Waterwalls, and
Economizers

Used to record all required items in a complete water tube boiler unit.

9.9.3 Form P-3A – Engineering / Contractor Date Report for a Compete Boiler

Used when an organization assumes the Manufacturer's Code responsibility and to certify Code
responsibility for the design specification of the complete boiler unit (Manufacturers individually certify
Components).

9.9.4 Form P-4 – Manufacturer’s Partial Date Report

Used to record individual component parts and as supporting data for information given in Data
Forms P-2, P-3, or P-5, except for replacement of, or additions to, an existing installation.

9.9.5 Form P-4A – Manufacturer’s Data Report for Fabricated Piping

Used to record all shop or field welded piping which falls within the administrative scope of ASME
Section I, including Boiler External Piping, but which is not furnished by the Boiler Manufacturer.

9.9.6 Form P-5 – Summary Data Report for Process Steam Generators

This is the Master Data Report for complete Boiler units. Used by the manufacturer to record all
items comprising a field assembled boiler unit and when any part of the Code responsibility, is
performed by someone other than the manufacturer.

9.9.7 Form P-6 – Manufacturer’s Data Report Supplementary Sheet

Used to record additional data where space was insufficient on a Data Report Form.

9.9.8 Form A-357 – Guide to Data Report Forms Distribution

Guide To Section I Data Report Forms Distribution

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9.9.9 Form R-1 – Report of Welded Repair

National Board Inspection Code - Used for repairs, modifications or alterations performed on
operating plants.

9.9.10 Form R-2 – Report of Alteration

National Board Inspection Code – Used for alterations performed on operating plants.

9.9.11 Form R-3 – Report of Parts Fabricated by Welding

National Board Inspection Code

9.9.12 Form R-4 – Report Supplementary Sheet

National Board Inspection Code

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Page 9–2 Ch. 9 – Inspection, Code Stamps, Nameplates and Code Data Reports
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Field Welding Engineer’s Manual Revision 1

10.0 CHAPTER 10 – JOB RECORDS & HISTORY

10.1 SCOPE

This chapter outlines the requirements for project welding and inspection records, maintained by the
Bechtel FWE, throughout the construction phase of the project. The PFE sets up the record keeping
system for the site and the FWE’s records shall conform as a component of the system.

This chapter also outlines the information which should be compiled and transmitted to the CE&T
Welding & NDE Services group after job completion.

10.2 MAINTENANCE OF RECORDS DURING CONSTRUCTION

Binders or files containing welding documentation and records are maintained by the FWE during the
construction phase of the project. The records shall allow easy retrieval of specific document(s). The job
records include, but are not limited to the following:
a. Index to the files
b. Welding Control Manual
• Form 167
• Bechtel Welding Standards
• Bechtel Welding Procedures
c. Field Welding Checklists - WR-4's
d. Stamped Isometric Drawings
e. Erection Subcontractor Welding Procedures
f. Erection Subcontractor Welder Qualifications
g. Erection Subcontractor NDE Reports
h. Erection Subcontractor Test Reports
i. Test Verification Reports
j. Subcontractor Tank Stretch-Outs, if used
k. Filler Metal C of C’s or CMTR’s as applicable
l. Bechtel Welder Qualification Records
m. Welder Qualification Logs
n. Bechtel NDE Reports
o. Bechtel NDE Personnel Qualification Records
p. Bechtel RT Film, Interpretations and Logs
q. Bechtel PWHT Charts
r. Bechtel PWHT Logs
s. Instrument Calibration Records and Certificates where applicable
t. Code Data Reports

Ch. 10 – Job Records & History Page 10–1

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Revision 1 Field Welding Engineer’s Manual

10.3 RETENTION OF RECORDS AT COMPLETION OF CONSTRUCTION

NDE records (including radiographs) for welds performed by Bechtel, and governed by the requirements
of the BQCM for ASME Section I, must be retained for five years to satisfy Code requirements. When
permitted by the Quality Control Manual, these records may be turned over to the owner for retention.
Originals of all Bechtel executed Code Data Reports shall be maintained unless the Data Reports are
filed with the National Board of Boiler and Pressure Vessel Inspectors.

10.4 WELDING HISTORICAL REPORT (CE&T WELDING & NDE SERVICES USE)

The Welding Historical report is a summary of the job’s welding program performance. It includes
successes and failures, and areas that could have been improved throughout the duration of the job. The
report shall contain cost, technical data, and all pertinent information that can be used by Bechtel and
CE&T Welding and NDE Services to improve the performance of the welding program for future jobs.
This report is not intended for the customer or upper management, it is an “in-house” report, and shall be
transmitted to CE&T Welding and NDE Services for review.

Page 10–2 Ch. 10 – Job Records & History

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Field Welding Engineer’s Manual Revision 1

11.0 CHAPTER 11 – USEFUL INFORMATION

11.1 SCOPE

This Chapter contains common charts, tables, and data that is useful to the FWE’s daily work.

• Inch-millimeter conversion
• Pressure and stress equivalents
• Metric Unit SI prefixes
• Electrode and fillet Weld Conversions
• Metric Units of Measurement Related to Welding
• Gage Numbers and Equivalent Thickness in Inches and Millimeters

Ch. 11 – Useful Information Page 11–1

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Inch-millimeter conversion
1 in. = 25.4 mm exactly

To convert inches to millimeters, To convert millimeters to inches, divide the

multiply the inch value by 25.4. millimeter value by 25.4.

Inch Inch
Fraction Decimal Millimeter Fraction Decimal Millimeter
1/64 0.015 0.396 33/64 0.515 13.096
1/32 0.031 0.793 17/32 0.531 13.493
3/64 0.046 1.190 35/64 0.546 13.890
1/16 0.062 1.587 9/16 0.562 14.287
5/64 0.078 1.984 37/64 0.578 14.684
3/32 0.093 2.381 19/32 0.593 15.081
7/64 0.109 2.778 39/64 0.609 15.478
1/8 0.125 3.175 5/8 0.625 15.875
9/64 0.140 3.571 41/64 0.640 16.271
5/32 0.156 3.968 21/32 0.656 16.668
11/64 0.171 4.365 43/64 0.671 17.065
3/16 0.187 4.762 11/16 0.687 17.462
13/64 0.203 5.159 45/64 0.703 17.859
7/32 0.218 5.556 23/32 0.718 18.256
15/64 0.234 5.953 47/64 0.734 18.653
1/4 0.250 6.350 3/4 0.750 19.050
17/64 0.265 6.746 49/64 0.765 19.446
9/32 0.281 7.143 25/32 0.781 19.843
19/64 0.296 7.540 51/64 0.796 20.240
5/16 0.312 7.937 13/16 0.812 20.637
21/64 0.328 8.334 53/64 0.828 21.034
11/32 0.343 8.731 27/32 0.843 21.431
23/64 0.359 9.128 55/64 0.859 21.828
3/8 0.375 9.525 7/8 0.875 22.225
25/64 0.390 9.921 57/64 0.890 22.621
13/32 0.406 10.318 29/32 0.906 23.018
27/64 0.421 10.715 59/64 0.921 23.415
7/16 0.437 11.112 15/16 0.937 23.812
29/64 0.453 11.509 61/64 0.953 24.209
15/32 0.468 11.906 31/32 0.968 24.606
31/64 0.484 12.303 63/64 0.984 25.003
1/2 0.500 12.700 1 25.400

Page 11–2 Ch. 11 – Useful Information

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PRESSURE AND STRESS EQUIVALENTS

Pounds-force per square inch to kilopascal
Thousand pounds-force per square inch to mega pascals.

1 psi = 6894.8 Pa 6894.8 Pa = 6.8948 kPa

To convert psi to pascals, multiply the psi value by 6.894 x I03
To convert pascals to psi, divide the pascal value by 6.894 757 x 103

psi 0 1 2 3 4 5 6 7 8 9
ksi

0 0.0000 6.8948 13.7895 20.6843 27.5790 34.4738 41.3685 48.2633 55.1581 62.0528
10 68.9476 75.8423 82.7371 89.6318 96.5266 103.4214 110.3161 117.2109 124.1056 131.0004
20 137.8951 144.7899 151.6847 158.5794 165.4742 172.3689 179.2637 186.1584 193.0532 199.9480

30 206.8427 213.7375 220.6322 227.5270 234.4217 241.3165 248.2113 255.1060 262.0008 268.8955
40 275.7903 282.6850 289.5798 296.4746 303.3693 310.2641 317.1588 324.0536 330.9483 337.8431
50 344.7379 351.6326 358.5274 365.4221 372.3169 379.2116 386.1064 393.0012 399.8959 406.7907

60 413.6854 420.5802 427.4749 434.3697 441.2645 448.1592 455.0540 461.9487 468.8435 475.7382
70 482.6330 489.5278 496.4225 503.3173 510.2120 517.1068 524.0015 530.8963 537.7911 544.6858
80 551.5806 558.4753 565.3701 572.2648 579.1596 586.0544 592.9491 599.8439 606.7386 613.6334

90 620.5281 627.4229 634.3177 641.2124 648.1072 655.0019 661.8967 668.7914 675.6862 682.5810
100 689.4757

ksi values are in the first column. Equivalent values, normally expressed in MPa (megapascals) when
converting from original values that were in ksi, are given in the second column. For example 10 ksi is
equal to 10,000 psi x 6.894.8 = 68,940.8 kpa.

Ch. 11 – Useful Information Page 11–3

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Electrode Diameters (inches / millimeters)

Electrode Sizes Fillet Weld Sizes

Inch mm Inch mm
0.030 0.76 1/8 3
0.035 0.86 5/32 4
0.040 1.02 3/16 5
0.045 1.14 1/4 6
1/16 1.59 5/16 9
5/64 1.98 3/8 10
3/32 2.38 7/16 11
1/8 3.18 1/2 13
5/32 3.97 5/8 16
3/16 4.76 3/4 19
7/8 22.2

Metric Unit SI Prefixes

Exponential Multiplication Assigned Metric (SI)

Expression Factor Symbol Prefix Letter Symbol

1012 1 000 000 000 000 Tera T
109 1 000 000 000 Giga G
106 1 000 000 Mega M
103 1 000 Kilo k
102 100 Hecto h h
10 10 Deka da
10-1 0.1 Deci d
10-2 0.01 Centi c
10-3 0.001 Milli m

Metric Units Related to Welding

Property Unit Symbol
Area Dimensions Millimeter squared mm2
Current Density Ampere per millimeter squared A/mm2
Deposition Rate Kilogram per hour kg/h
Ω
Electrical resistance Ohm
Flow Rate (gas or liquid) Liter per minute L/min
Fracture Toughness Mega newton meter -3/2 MN•m-3/2
Impact Strength Joule N•m
Pressure (gas or liquid) Pascal Pa = N/m2
Tensile strength Pascal Pa = N/m2
Travel speed Millimeter per second mm/s
Wire Feed Speed Millimeter per second mm/s

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Gage Numbers and Equivalent Thickness in Inches and Millimeters

TABLE 1 TABLE 2 TABLE 3

Hot-Rolled and Cold-Rolled Gage Thickness Gage Thickness
Steel Sheet Galvanized Steel Sheet Stainless Steel Sheet
Manufacturers’ Galvanized Manufacturers
Standard Thickness Equivalent Sheet Thickness Equivalent ’ Thickness Equivalent
Standard
Gage No. inch mm Gage No. inch mm Gage No. inch mm

3 0.2391 6.07 8 0.1681 4.27 8 0.1719 4.37

4 0.2242 5.70 9 0.1532 3.89 9 0.1573 3.97

5 0.2092 5.31 10 0.1382 3.51 10 0.1406 3.57

6 0.1943 4.94 11 0.1233 3.13 11 0.1250 3.18

7 0.1793 4.55 12 0.1084 2.75 12 0.1094 2.78

8 0.1644 4.18 13 0.0934 2.37 13 0.0938 2.39

9 0.1495 3.80 14 0.0785 1.99 14 0.0781 1.98

10 0.134 3.42 15 0.0710 1.80 15 0.0703 1.79

11 0.1196 3.04 16 0.0635 1.61 16 0.0625 1.59

12 0.1046 2.28 17 0.0575 1.46 17 0.0563 1.43

13 0.0897 2.78 18 0.0516 1.31 18 0.0500 1.27

14 0.0747 1.90 19 0.0456 1.16 19 0.0438 1.11

15 0.0673 1.71 20 0.0396 1.01 20 0.0375 1.95

16 0.0598 1.52 21 0.0366 0.93 21 0.0344 0.87

17 0.0538 1.37 22 0.0336 0.83 22 0.0313 0.79

18 0.0478 1.21 23 0.0306 0.78 23 0.0281 0.71

19 0.0418 1.06 24 0.0276 0.70 24 0.0250 0.64

20 0.0359 0.91 25 0.0247 0.63 25 0.0219 0.56

21 0.0329 0.84 26 0.0217 0.55 26 0.0188 0.48

22 0.0299 0.76 27 0.0202 0.51 27 0.0172 0.44

23 0.0269 0.66 28 0.0187 0.48 28 0.0156 0.40

24 0.0239 0.63 29 0.0172 0.44 29 0.0141 0.36

25 0.0209 0.53 30 0.0157 0.40 30 0.0125 0.32

26 0.0179 0.46 31 0.0142 0.36 31 0.0109 0.28

27 0.164 0.42 32 0.0134 0.34

28 0.0149 0.38

Ch. 11 – Useful Information Page 11–5

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Field Welding Engineer’s Manual Revision 1

A. APPENDIX A
Definitions
The following definitions and abbreviations have been compiled to acquaint the Field Welding Engineer
(FWE) with commonly used project terminology. These definitions and abbreviations will benefit a FWE
who is new and not familiar with some of the terminology frequently encountered. These definitions are
not limited to welding oriented definitions. It is important that a FWE have general knowledge of
construction trade jargon and commonly used expressions.

Authorized Inspector (AI)

Inspector performing the inspections required by the ASME Code who has been qualified by written
examination under the rules of any state or municipality of the United States or province of Canada that
has adopted the ASME Code. The inspector shall not be an employee of Bechtel, the manufacturer, or
the owner.

Authorized Inspection Agency (AIA)

An authorized inspection agency is one designated as such by the appropriate legal authority of a state or
municipality of the United States or a province of Canada. The agency employs the Authorized
Inspectors who perform inspections required by ASME Sections I and VIII. The agency may be a state of
the United States or a province of Canada or an insurance company authorized to write boiler and
pressure vessel insurance (Examples: Hartford Steam Boiler, Kemper etc.).

Components
Items such as vessels, piping systems, pumps, valves, and storage tanks.

Component Supports
Metal supports that are designed to transmit loads from the pressure retaining barrier of the component to
the load carrying structure.

Constructor
Organization responsible for the construction of the component, installation and placement of parts,
materials and appurtenances.

Designer
Organization responsible for the preparation and completion of the design documents for the component,
parts, and appurtenances.

Fabricator
Organization that builds one or more parts of a component.

Hold Point
A pre-selected activity/ task on the Inspection Plan that is performed/ witnessed by the Field Welding
Engineer and/or Authorized Inspector. Work shall not proceed forward without this activity/task being
performed and accepted.

Appendix A – Definitions Page A–1

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Inspection
Close visual examination or measurement to determine the conformance of an item, activity, task, or
system, to predetermined quality requirements.

Installation
Those actions required to place and attach components to their support structures and join items of a
power system in the field by welding or mechanical means.

Monitor
To watch over, observe, or examine a work operation. Results of the operation may or may not be
recorded.

Part
A constituent that is fabricated, inspected, and stamped independently of the component into which it will
subsequently be incorporated.

Piping Subassemblies
Items defined as sections of a piping system, consisting of fittings, pipes, or tubes that are fabricated as
subassemblies in a shop or in the field before they are installed in a power system.

Quality Control
Comprises the examinations of the physical characteristics of a material, component, part or
appurtenance and the acceptance standards associated with those examinations.

Review
To examine documentation to determine acceptability to requirements.

Surveillance
Monitor by observation designated activities/tasks to assure that they are performed in the specified
manner.

Technical Direction
Instructions and procedures relating to technical requirements for an activity. This may include furnishing
prescribed procedures, technical requirements, design approaches, specifications, and design details.

Technical Guidance
Providing advice representing a preferred method or approach to a function or activity. This may include
establishing general requirements or policy, but not specific procedures or instructions.

Verification
An act of confirming, substantiating and assuring that an activity or condition has been implemented in
conformance with the specified requirements.

Witness Point
A pre-selected activity/task to be witnessed by the AI.

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Acronyms and Abbreviations

Common Bechtel Abbreviations
AI Authorized Inspector
BQCM Bechtel Quality Control Manual
CE&T Construction Engineering and Technologies
DCN Drawing Change Notice
FCR Field Change Request
FWE Field Welding Engineer
FREU Frederick Execution Unit
FMR Field Material Requisition
HOEU Houston Execution Unit
LOEU London Execution Unit
NCR Nonconformance Report
NDE Nondestructive Examination
PFE Project Field Engineer
PO Purchase Order
PQR Procedure Qualification Record
SFEU San Francisco Execution Unit
WPS Welding Procedure Specification

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Miscellaneous Bechtel Welding Standards and Specifications

BQ-l Brazer Qualification Performance Specification

Form 84/167 Welding and NDE Requirements for Field Welding

GBS/GSS General Brazing and Soldering Specification

GIS-BA General Installation Specification Anchor Bolt Adjustments

GIS-DH General Installation Specification Thermal Pipe Alignment Diamond Heat

GIS-PA-2 General Installation Specification Pipe Adjustment at PWHT Temperature

GIS-RHW General Installation Specification Restoration of Holes by Welding

GPS-1 General Purging Standard Internal Gas Purging

GWS- 1 General Welding Standard (Nuclear ASME IX)

GWS-2 General Welding Standard (Non-nuclear ASME IX)

GWS - Sheet General Welding Standard - Sheet (For D1.3, D9.1 & general sheet metal).

GWS-Structural General Welding Standard - Structural (AWS D1.1)

PHT-1 Specification for Postweld Heat Treatment of Field Welds (Nuclear)

PHT-2 Specification for Postweld Heat Treatment of Field Welds (Conventional)

WD-1 Welding Fabrication and Quality Control Documentation (Nuclear)

WD-2 Welding Fabrication and Quality Control Documentation (ASME I and VIII)

WFMC-1 Welding Filler Material Control Procedure Specification (Nuclear)

WFMC-2 Welding Filler Material Control Procedure Specification (Conventional)

WQ- l Welder Performance Qualification - (ASME IX)

WQ-2 Welder Performance Qualification - (AWS D1.1)

WQ-3 Welder Performance Qualification - (AWS D1.3)

WQ-4 Welder Performance Qualification - (AWS D9.1)

WQ-5 Welder Performance Qualification - (AWS B2.1)

WQ-6 Welder Performance Qualification - (Aluminum Bus Bar)

WQ-7 Welder Performance Qualification - (AWS D1.4 Rebar)

Page A–4 Appendix A – Definitions

Welding & NDE Services
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© Bechtel Corporation 2008, 2004, 2001, 2000. Contains confidential and/or proprietary information to Bechtel and its affiliated companies
which shall not be used, disclosed or reproduced in any format by any non-Bechtel party without Bechtel’s prior written permission.
All rights reserved.
Field Welding Engineer’s Manual Revision 1

Code and Standards

AAR Association of American Railroads

AFNOR Association Francise de Normalisation (French)

AGA American Gas Association

AISC American Institute of Steel Construction

AISI American Iron and Steel Institute

ANS American Nuclear Society

ANSI American National Standards Institute

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASTM American Society of Testing Materials

ASNT American Society of Nondestructive Testing

AWS American Welding Society

AWWA American Water Works Association

BSI British Standards Institute (British)

CGA Compressed Gas Association

DIN Deutscher Normenausschuss (German)

GOST Russia

HEI Heat Exchanger Institute

JIS Japanese Standard Association (Japanese)

MIL Military Specifications

MSS Mfg. Standardization Society of Valve and Fitting Ind. INC.

NBN Institute Belge de Normalization (Belgium)

NFPA National Fire Protection Association

NEMA National Electrical Manufactures Association

PFI Pipe Fabrication Institute

UNI Entre Italiano di Unificazione (Italian)

UNS Unified Numbering System

SAE Society of Automotive Engineers

SS Sweden

TEMA Tubular Exchangers Manufacturing Association

Appendix A – Definitions Page A–5

Welding & NDE Services
Electronic documents, once printed, are uncontrolled and may become outdated.
© Bechtel Corporation 2008, 2004, 2001, 2000. Contains confidential and/or proprietary information to Bechtel and its affiliated companies
which shall not be used, disclosed or reproduced in any format by any non-Bechtel party without Bechtel’s prior written permission.
All rights reserved.
Revision 1 Field Welding Engineer’s Manual

Welding & Cutting Processes

AAC Air Carbon Arc Cutting
CAW Carbon Arc Welding
EGW Electrogas Welding
FCAW Flux Cored Arc Welding
GMAW Gas Metal Arc Welding
GMAW-S Gas Metal Arc Welding - Short Circuit
GMAW-P Gas Metal Arc Welding - Pulse
GMAW-STT Gas Metal Arc Welding – Modified Pulse
GTAW Gas Tungsten-Arc Welding (Tig welding)
OFW Oxy-Fuel Welding (Gas welding)
PAW Plasma Arc Welding
SAW Submerged Arc Welding
SMAW Shielded Metal-Arc Welding (stick welding)

Page A–6 Appendix A – Definitions

Welding & NDE Services
Electronic documents, once printed, are uncontrolled and may become outdated.
© Bechtel Corporation 2008, 2004, 2001, 2000. Contains confidential and/or proprietary information to Bechtel and its affiliated companies
which shall not be used, disclosed or reproduced in any format by any non-Bechtel party without Bechtel’s prior written permission.
All rights reserved.
Field Welding Engineer’s Manual Revision 1

Code Books for a Typical Non-Nuclear Project

Normally a non-nuclear project will not require a large number of Code books. Those shown below will generally
cover all of the work to be performed.

ASME Section I Power Boilers

ASME B31.1 Power Piping
ASME B31.3 Chemical Plant and Petroleum Refinery Piping
AWS D1.1 Structural Welding Code
AWWA C-206 Field Welding of Steel Water Pipe
API 650 Welded Steel Tanks for Oil Storage

If Boiler Code work is involved, the jobsite shall have ASME Section I on the jobsite.
Some AIs take a dim view of having photocopies of ASME Code books instead of an
original. For short duration jobs, contact CE&T Welding and NDE Services.

Ordering Addresses

ASME and ANSI Standards AWS Standards

ASME Order Department American Welding Society, Inc.
345 East 47th Street 2501 N.W. Seventh Street
New York, NY 10017 Miami, FL 33125

API Standards AWWA Standards

American Petroleum Institute American Water Works Association
1801 K Street N.W. 6666 West Quincy Avenue
Washington, D.C. 20006 Denver, CO 80235

Appendix A – Definitions Page A–7

Welding & NDE Services
Electronic documents, once printed, are uncontrolled and may become outdated.
© Bechtel Corporation 2008, 2004, 2001, 2000. Contains confidential and/or proprietary information to Bechtel and its affiliated companies
which shall not be used, disclosed or reproduced in any format by any non-Bechtel party without Bechtel’s prior written permission.
All rights reserved.
Revision 1 Field Welding Engineer’s Manual

Marking Materials for Austenitic Stainless Steel

The use of marking materials on austenitic stainless steels and high nickel alloys must be done with care.
Contaminants found in some marking materials can lead to stress-corrosion cracking, pitting, and
sensitization-intergranular corrosion in austenitic stainless steel. Sulfur can lead to embrittlement of
nickel base alloys. Low melting point metals can result in liquid metal grain boundary attack if the
stainless steel is heated to the melting point of the metal contaminant. If marking materials are to be
used on austenitic stainless steels and nickel base alloys, the following maximum level of contaminants
should be used:

Table A1 – Contaminants

Inorganic Halogens 200 ppm by weight

Total Halogens (Inorganic and organic) 1 percent by weight.

Sulfur 1 percent by weight.

Low melting point metals* 200 ppm by weight total, 50 ppm by weight for any one individual metal.
* lead, bismuth, zinc, mercury, antimony and tin

Table A2 – Pen Inks (Felt or Ball Point)

Following is a potential list of suitable marking materials and possible suppliers for felt or ball point pen
Inks.
John P. Nissen Co.
“No Chloride” Ink (White) Glenside, Pennsylvania, 19038
(215) 886-2025
Dykem Company
8501 Delport Drive
DX-100 (Blue)
St. Louis, Missouri 63114
(314) 423-0100
Mark-Tex Corporation
163 Collidge Avenue
Texpen XF (Black)
Englewood, New Jersey 07631
(201) 567-4111
Eberhard Faber
Markett 680/690 (Black) Wilkes-Bane, Pennsylvania 18703
(717) 474-6711
Carters Ink Company
239 First
Marks-A-Lot (Black)
Cambridge, Massachusetts 02141
(617) 547-2950

Page A–8 Appendix A – Definitions

Welding & NDE Services
Electronic documents, once printed, are uncontrolled and may become outdated.
© Bechtel Corporation 2008, 2004, 2001, 2000. Contains confidential and/or proprietary information to Bechtel and its affiliated companies
which shall not be used, disclosed or reproduced in any format by any non-Bechtel party without Bechtel’s prior written permission.
All rights reserved.
Field Welding Engineer’s Manual Revision 1

Table A3 – Crayons
The following is a potential list of suitable marking materials and possible suppliers for industrial crayons.
Binney & Smith, Inc
Industrial Crayons 2035 Edgewood Avenue
(Selected Colors) Easton, Pennsylvania 18042
(215) 253-6271
Adhesive Back Tape 3M Company
Industrial Tape Division
Scotch 481-Black St. Paul, Minnesota 55101
Scotch 850 - Various Colors (612) 733-1110
Technical Tape Company
90T-Various Colors 1 Lefevre Inc.
92T-Yellow New Rochelle, N Y 10801
(914) 235-1000

Ventilation for Welding, Cutting and Brazing

There are certain metals which, when heated to high temperatures, generate toxic fumes. These toxic
fumes will cause illness and, in extreme cases, death if proper precautions involving ventilation are not
taken. The temperatures reached in welding, cutting, and brazing operations are high enough to
generation of these fumes.
When welding, cutting or brazing on or with any of the following in an enclosed space, general
mechanical or local ventilation must be employed:
1. Zinc-bearing base or filler metals, or metals coated with zinc-bearing materials (e.g. galvanized).
2. Lead base metals.
3. Chromium-bearing metals (e.g. stainless steel) metals coated with chromium-bearing materials.
Local exhaust ventilation or airline respirators must be employed when welding, cutting, or brazing on or
with any of the following:
1. Metals containing lead as an alloy, or materials coated with lead bearing materials.
2. Cadmium-bearing metals or cadmium-coated base metals or cadmium containing filler metals.
3. Metals coated with mercury-bearing materials.
Any high temperature work involving beryllium shall require both local exhaust ventilation and airline
respirator, regardless of location of the work.
Judgment must be used when determining if a work area should be considered as an enclosed space.
However the following guidelines, from ANSI Z49.1, should be followed as a minimum:

• Any confined space with less than 10,000 cubic feet of free space per welder
• Any work area with a ceiling height less than sixteen feet.

Any obstructions or partitions in the work area should be considered as further limitations
on the enclosed space.

Of the materials discussed, only zinc coated base metals, chromium containing metals (stainless steels),
and cadmium containing brazing filler metals are commonly encountered in Bechtel construction. The
cadmium containing braze materials are commonly called "silver braze" and designated as follows:

Appendix A – Definitions Page A–9

Welding & NDE Services
Electronic documents, once printed, are uncontrolled and may become outdated.
© Bechtel Corporation 2008, 2004, 2001, 2000. Contains confidential and/or proprietary information to Bechtel and its affiliated companies
which shall not be used, disclosed or reproduced in any format by any non-Bechtel party without Bechtel’s prior written permission.
All rights reserved.
Revision 1 Field Welding Engineer’s Manual

B Ag-l
B Ag-2
B Ag-3
B Ag-la
B Ag-2a

The current Bechtel Brazing Procedures employing the cadmium-bearing brazing filler materials are:

P101, H-101-4 using B Ag-la

P102, H-101-1 using B Ag-l
P107, H-101-4 using B Ag-l

Other Bechtel Brazing Procedures have been qualified and are available that do not use cadmium-
bearing filler materials. These procedures are:

P101, H-101-2 using B CuP-5

P107, H-101-1 using B CuP-3
P107, H-101-2 using B CuP-5
P107, H-101-3 using 6 percent Ag, 6 percent P, balance Cu

In addition to the welder, brazer, or cutter, any other personnel exposed to the same atmosphere as the
welder, brazer, or cutter shall be similarly protected. In addition to these requirements, any state or local
requirements shall also apply.

Page A–10 Appendix A – Definitions

Welding & NDE Services
Electronic documents, once printed, are uncontrolled and may become outdated.
© Bechtel Corporation 2008, 2004, 2001, 2000. Contains confidential and/or proprietary information to Bechtel and its affiliated companies
which shall not be used, disclosed or reproduced in any format by any non-Bechtel party without Bechtel’s prior written permission.
All rights reserved.