TECHNICAL STANDARD

GENERAL WELDING REQUIREMENTS

4-7TS

DATE: 01 MAY 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 1 OF 17

TABLE OF CONTENTS

Section Title Page No.

1. GENERAL ......................................................................................................................................1
1.1 Scope..............................................................................................................................................1
1.2 Codes and Industry Standards .......................................................................................................1
1.3 Conflicts, Omissions, and Alternatives ...........................................................................................2
2. REQUIREMENTS APPLICABLE TO ALL WELDING PROCESSES ...........................................2
2.1 General ...........................................................................................................................................2
2.2 WPS and PQR Requirements ........................................................................................................3
2.3 Documentation................................................................................................................................3
2.4 Filler Metals.....................................................................................................................................3
2.5 Joint Design ....................................................................................................................................4
2.6 Preheat ...........................................................................................................................................4
2.7 Heat Treatment ...............................................................................................................................5
2.8 Cleaning..........................................................................................................................................5
3. REQUIREMENTS FOR SPECIFIC WELDING PROCESSES.......................................................5
3.1 Submerged Arc Welding (SAW) .....................................................................................................5
3.2 Gas-Tungsten Arc (GTAW) and Plasma Arc (PAW) Welding ........................................................5
3.3 Shielded Metal Arc Welding (SMAW).............................................................................................6
3.4 Gas Metal Arc Welding (GMAW) ....................................................................................................6
3.5 Flux Cored Arc Welding (FCAW)....................................................................................................6
3.6 Electroslag (ESW) and Electrogas (EGW) Welding .......................................................................7
3.7 Stud Welding...................................................................................................................................7
3.8 Special Welding Processes ............................................................................................................7
4. REQUIREMENTS FOR SPECIFIC MATERIALS ..........................................................................7
4.1 Stainless Steels ..............................................................................................................................7
4.2 Cr-Mo Alloy Steels ..........................................................................................................................8
4.3 Titanium and Other Reactive Materials ..........................................................................................8
4.4 5%, 8% and 9% Nickel Steels ........................................................................................................8
4.5 Nickel Alloys....................................................................................................................................9
5. ADDITIONAL REQUIREMENTS FOR LOW TEMPERATURE SERVICES..................................9
5.1 General ...........................................................................................................................................9
6. ADDITIONAL REQUIREMENTS FOR OVERLAYS, AND CLAD MATERIALS...........................9
6.1 General ...........................................................................................................................................9
Appendix A - Weld Map..............................................................................................................17

1. GENERAL

1.1 Scope

1.1.1 This standard covers the general requirements for welding procedures, specifications, and qualifications.
Structural welding is not within the scope of this standard.

1.1.2 Requirements for welding, Welding Procedure Specifications (WPS), Procedure Qualification Records
(PQR) and requalification of procedures and operators shall be in accordance with this standard, the applicable
code of construction, and all additional applicable specifications.

1.2 Codes and Industry Standards

The following documents are referenced herein and form part of the Order. Current editions of the industry
standards including all mandatory addenda in effect at the time of the order shall apply unless otherwise
indicated.
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AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME Boiler and Pressure Vessel Code, Latest Edition, including all mandatory addenda in effect on the date of
the Order

Section II, "Materials"

Part C "Welding Rods, Electrodes and Filler Metals"
Section VIII, "Pressure Vessels" Division 1
Division 2" Alternative Rules"
Section IX, "Welding and Brazing Qualifications"

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM A488/A488M, "Standard Practice for Steel Castings, Welding, Qualifications of Procedures and
Personnel"

AMERICAN WELDING SOCIETY (AWS)

AWS A4.2/A4.2M, "Calibrating Magnetic Instruments to Measure the Delta Ferrite Content of Austenitic
and Duplex Austenitic-Ferritic Stainless Steel Weld Metal"

1.3 Conflicts, Omissions, and Alternatives

1.3.1 Any conflict between the requirements of this standard and the provisions of any applicable industry
standards, codes, or regulations or any specifications, standards, or purchasing documents contractually
required for a given application shall be referred to the Purchaser for resolution prior to start of welding.

1.3.2 All deviations from or alternatives to the requirements contained in this Standard shall be submitted to the
Purchaser for review and resolution prior to the start of welding or fabrication. Such submittal shall include the
following:

a. citation of provisions of this standard.

b. proposed deviation and rationale for the deviation.

c. WPS with PQR as applicable to the deviation.

d. all other technical data available supporting the proposal.

e. historical experience in support of the proposed deviation.

f. results of all applicable tests required by the applicable industry standard or code and this standard.

2. REQUIREMENTS APPLICABLE TO ALL WELDING PROCESSES

2.1 General

Fabrication involving welding shall not be sublet to others without prior approval of the Purchaser. When the
Purchaser approves subletting of welding, the sub-supplier must submit their WPS, PQR, and weld map to the
prime Supplier for forwarding to the Purchaser for review and comment prior to the start of welding.
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2.2 WPS and PQR Requirements

2.2.1 WPSs and PQRs shall conform to the requirements of the applicable code. WPSs shall comply with the
edition/addenda of ASME Section IX in effect on the date of the Order. WPSs qualified to the requirements of
earlier edition/addenda are not acceptable. Where base materials do not have the ductility to meet the bend
test requirements of ASME Section IX, the requirements of the applicable code or ASTM A488 shall apply. In
addition, all Purchaser's requirements shall be included. When WPSs are submitted for review, the weld map
form illustrated in Appendix A shall be completed and submitted with the applicable PQR's unless otherwise
directed by the Order.

2.2.2 WPSs shall list the electrical parameters and travel speed within reasonable ranges for each electrode
size to be used.

2.2.3 PQRs shall show actual joint details and list actual amperage, voltage, travel speed, contact tube to work
distance, pulsing, type of current, polarity, progression, AWS classifications or manufacturer and trade
designations used in qualifying the procedure.

2.2.4 Procedures and qualifications acceptable for low alloy steels of a given alloy content shall not be
accepted for welding materials of lower alloy content without advance written approval from the Purchaser.

2.2.5 When run-off plates are used, they shall be of the same nominal alloy composition as the base metal.

2.3 Documentation

2.3.1 All welding, including repair welding, shall comply with the appropriate WPS and PQR required by the
applicable codes, regulations, standards and specifications.

2.3.2 The welding procedure specification shall be available for ready review by the welder/welding supervisor.

2.4 Filler Metals

2.4.1 The selection of filler metals for joining similar materials shall be in accordance with:

a. Table I for steels and non-ferrous materials except aluminum and aluminum alloys; or

b. ASME SFA 5.10 for aluminum and aluminum alloys.

2.4.2 The selection of filler metals for welding dissimilar materials shall be in accordance with:

a. Table II for steels and for non-ferrous alloys except aluminum and aluminum alloys; or

b. ASME SFA 5.10 for aluminum and aluminum alloys.

2.4.3 Filler metals and fluxes shall be completely specified in the WPS and PQR by the use of applicable
ASME/AWS classification.

2.4.4 Prior to using non AWS filler metals and fluxes (filler metal and fluxes without an ASME/AWS
classification) the product's relevant physical and mechanical properties and chemical analysis shall be
submitted to the Purchaser with the request for using non AWS materials. Advance written approval is required
from the Purchaser prior to using non AWS materials.

2.4.5 PQR documents for procedures specifying "G" classification electrodes for which chemical composition is
not completely controlled by ASME Section II, Part C shall be separately qualified for each manufacturer, grade,
and heat of the electrode so classified.
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2.4.6 When welding materials are used outside the limits specified by the welding material manufacturer,
procedure qualification tests (for electrodes, fluxes, wires) are required for each lot, batch, or heat of material
used in production welding. Advance written approval is required from the Purchaser prior to use.

2.4.7 Storage of welding materials (covered electrodes, fluxes, bare wires, consumable inserts, and other
similar materials) in designated areas or in designated holding ovens shall be in accordance with the welding
material manufacturer's recommendations and ASME Section II Part C. Control and handling of welding
materials in fabrication shall be an integral part of the Supplier's quality assurance plan.

2.4.8 Welding process using coatings or fluxes shall not be used for austenitic stainless steel, nickel, or
aluminum alloy root passes unless the slag can be removed from the underside of the root passes and the area
inspected.

2.4.9 All socket welds shall be made using GTAW and/or SMAW processes only and shall consist of at least
two (2) passes.

2.5 Joint Design

2.5.1 The joint design, including root opening, shall be clearly shown in the WPS and PQR. Tolerances for all
dimensions shall be included. A dimensional sketch of the production weld preparation profile shall be attached
to the WPS when the production profile differs from the WPS profile.

2.5.2 Temporary backing material, such as non-metallic retainers and non-fusing metal retainers, paste, or
coatings, may be used provided:

a. No fusion of metallic backing to the underside of the weldment occurs.

b. All welding slag, remaining flux, paste, and foreign material are removed from the underside of the weld.

c. the specified backing material is used in the PQR.

2.5.3 The use of fusing backing strips is subject to advance written approval from the Purchaser. Permanent
backing rings, when used, shall be seal welded on the upstream side.

2.6 Preheat

2.6.1 The preheat recommendations of Appendix R of ASME Section VIII, Division 1 shall be mandatory for all
carbon and alloy steels. In addition, a minimum preheat of 200oF (93oC) shall be applied for carbon steel with a
thickness greater than 1 1/4 inches (32 mm). When preheat is a requirement for welding, it is also a
requirement for electric arc cutting, flame cutting, tack welding, back gouging, etc.

2.6.2 If a conflict arises between Paragraph 2.6.1 and the code or applicable specification governing the weld,
the higher preheat temperature shall be used.

2.6.3 Care shall be taken to ensure through-thickness preheating of thick sections to prevent an excessive weld
cooling rate. Surface temperature shall be measured in the weld joint and 1 inch (25 mm) on each side of the
joint immediately before initiation of weld arc.
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2.7 Heat Treatment

2.7.1 Postweld heat treatment shall be in accordance with the applicable code of construction or specification.

2.7.2 Postweld heat treatment cycles shall be clearly specified in the WPS and PQR. PQR test coupons shall
be subjected to the maximum anticipated heat treatment to be used in production.

2.7.3 Full details of all intermediate heat treatment, including number of cycles, time, temperature, heating
method, and heating and cooling rates, shall be specified in the WPS and PQR. PQR tests shall be made on
samples subjected to the maximum anticipated intermediate heat treatment. In the event that a component is
intended to receive multiple intermediate heat treatments, the details shall be provided as part of the WPS and
should be referenced in the weld map (see Paragraph 2.2.1).

2.8 Cleaning

2.8.1 Welding slag shall be removed from all welds.

2.8.2 For cleaning stainless steel or nickel alloys, use aluminum oxide or silicon carbide grinding wheels and/or
stainless steel brushes not previously used on carbon or low alloy steels.

2.8.3 Weld joint surfaces and a minimum of 1 inch (25 mm) of the internal and external surfaces of the adjacent
base metal shall be clean and free from paint, oil, dirt, scale, oxides, and other foreign material detrimental to
the integrity of the weld.

2.8.4 Peening is not permitted. The use of a pneumatic air tool for scale removal is not considered peening.

3. REQUIREMENTS FOR SPECIFIC WELDING PROCESSES

3.1 Submerged Arc Welding (SAW)

3.1.1 Welding procedures for submerged arc welding shall be requalified whenever the welding flux or wire is
changed from one manufacturer to another, or from one grade to another grade from the same manufacturer.
Equivalence under ASME Section II, Part C shall not be considered adequate for substitution without
requalification.

3.1.2 Alloy, semiactive, or active flux shall not be used. Fluxes that compensate for losses of alloying elements
are permitted.

3.1.3 Manual submerged arc welding is not permitted on pressure containing parts.

3.1.4 Reground fused flux or slag shall not be used.

3.1.5 Lincoln 860 flux shall not be used for impact tested weldments with design temperatures below -20oF
(-29oC).

3.1.6 EL8, EL8K, EL12, EM12, or EM12K filler metals shall not be used when welding 70 ksi (485 MPa) tensile
base materials which receive a postweld heat treatment and/or a postweld normalizing heat treatment.

3.2 Gas-Tungsten Arc (GTAW) and Plasma Arc (PAW) Welding

3.2.1 Inert backing gas is required for Base Material Numbers 4, 5, 6, 10 and greater in Table I and similar
materials not listed unless the joint is ground or back gouged to sound metal and back welded. Gas backing
shall be maintained for a minimum of two weld layers.
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3.2.2 When consumable inserts are permitted, the WPS shall specify:

a. type, style, dimensions, and material of the insert; and

b. detailed joint geometry of the weld joint and insert placement, including tolerances.

3.2.3 The GTAW process shall be used to deposit the root pass in buttwelds of NPS 2 and smaller.

3.3 Shielded Metal Arc Welding (SMAW)

3.3.1 Electrodes used for the SMAW process shall be of the low hydrogen type, except as specifically permitted
in Paragraph 3.3.2.

3.3.2 E6010 or E6011 electrodes may be used for: (1) welding galvanized structural attachments to carbon
steel pressure containing components, and (2) welding the root pass and the subsequent pass in all carbon
steel buttwelds and in pipe greater than NPS 2. Other uses of E6010 and E6011 electrodes require advance
written approval from the Purchaser.

3.3.3 Except for the electrodes permitted in Paragraph 3.3.2, the SMAW process shall not be used for root
passes unless the backside of the root is ground or back gouged to sound metal and back welded.

3.3.4 The SMAW process shall not be used for root pass applications in single welded joints of low alloy steel,
stainless steel or nickel alloys.

3.3.5 When impact tests are required for carbon and low alloy steel and when AWS/ASME filler metal
specification does not require impact tests for the classification at or below the MDMT, procedure qualification
impact tests are required for each manufacturer and brand to be used.

3.4 Gas Metal Arc Welding (GMAW)

3.4.1 Inert backing gas is required for Base Material Numbers 4, 5, 6, 10 and greater in Table 1 and similar
materials not listed unless the joint is ground or back gouged to sound metal and back welded. Gas backing
shall be maintained for a minimum of two weld layers.

3.4.2 GMAW procedures utilizing the "short circuiting" metal transfer mode shall be limited to groove, fillet, and
structural welds in materials 3/8 inch (10 mm) maximum thickness and to root passes in welds of greater
thickness. Downhill weld progression shall be permitted only on root passes. The "short circuiting" metal
transfer mode shall not be used for pressure containing parts in furnaces.

3.4.3 GMAW in the short circuiting transfer mode may be used for tackwelds, temporary attachments or other
applications where the weld metal shall be completely removed.

3.4.4 The GMAW process shall not be used for socket welds.

3.5 Flux Cored Arc Welding (FCAW)

3.5.1 The use and application of FCAW shall be subject to the Purchaser's approval.

3.5.2 Flux cored arc welding without external shielding gas may only be used for welding non-pressure
containing parts and non-pressure containing attachments to pressure containing parts.

3.5.3 When impact tests are required, the procedure qualification impact tests shall be performed for each
manufacturer and brand designation to be used for production welding.
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3.5.4 The FCAW process shall not be used for root passes unless the backside of the root is ground or back
gouged to sound metal and back welded.

3.6 Electroslag (ESW) and Electrogas Welding (EGW)

3.6.1 Welding procedures for electroslag welding shall be requalified whenever the welding flux or wire is
changed from one manufacturer to another, or from one manufacturer's grade to another grade from the same
manufacturer. Equivalence under ASME Section II, Part C shall not be considered adequate for substitution
without requalification.

3.6.2 All welds made by the ESW or EGW processes shall be given a grain refining heat treatment in
accordance with the applicable code or specifications. The procedure for this heat treatment shall be submitted
for review with the WPS.

3.6.3 All welds made by the ESW or EGW processes shall be subject to examination by an ultrasonic
procedure acceptable to the Purchaser. This procedure shall be submitted for review with the WPS.

3.6.4 Procedure qualification test coupons shall include all critical and subcritical heat treatment cycles. If
critical temperature heat treatment must be repeated to achieve required properties, test coupons shall receive
the required heat treatment.

3.6.5 Welding procedure qualification tests for the ESW and single pass EGW processes shall include side
bend tests.

3.7 Stud Welding

Welding procedures for automatic or semiautomatic stud welding shall be written and qualified in accordance
with ASME Section IX, and the applicable code of construction.

3.8 Special Welding Processes

Welding by other than those processes covered in this Standard shall be subject to review and acceptance by
the Purchaser.

4. REQUIREMENTS FOR SPECIFIC MATERIALS

4.1 Stainless Steels

4.1.1 When using 300 series stainless steel filler metals for design temperature applications above 1000oF
(538oC), or when "H Grade" materials are specified by the Purchaser, high carbon electrodes/wires, with
0.040 - 0.080% carbon shall be used.

4.1.2 The interpass temperature for austenitic stainless steels shall not be greater than 350oF (177oC).

4.1.3 Ferrite Control of Weld Metal

With the exception of Type 310 SS and austenitic stainless steels used in the radiant sections of furnaces,
ferrite control is required for austenitic stainless steel deposited weld metal when either or both of the following
conditions apply:

• the design temperature is > 700oF (371oC).

• the weld will be post weld heat treated.

a. Limits and Sequence - All readings shall be taken prior to any post weld heat treatment. The acceptable
ferrite number range shall be 3.0 to 10.0 for Types 321 and 347 and 3.0 to 12.0 for all others.
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b. Methods of Determination - Ferrite numbers may be determined by:

1. A calibrated Ferritscope (Fischer)

2. Magnetic instruments calibrated in accordance with AWS A4.2/A4.2M.

3. Use of the WRC Delta Ferrite Diagram and quantitative chemical analysis for Cr, Ni, C, Mn, Si, N, Mo,
and Cb of production deposited weld metal. This may not be used for weld overlays. When
determined using the diagram, the limit is FN 5.0 to FN 10.0.

c. Required Determinations - Locations for ferrite determinations shall be selected with approval of the
Purchaser. The number of determinations required is as follows:

1. Equipment -

i. Longitudinal and circumferential pressure containing welds, four (4) determinations per weld seam.

ii. Internal non-pressure parts and structural attachments, one (1) determination per weld.

2. Piping - Two (2) determinations on 5% of each welder's weld for each AWS filler metal classification
used.

4.2 Cr-Mo Alloy Steels

4.2.1 When step cooling embrittlement tests are required during weld procedure qualification, the Purchaser will
specify the step cooling cycle (time and temperature) and impact energy requirements for prequalifying
electrodes/wires/flux.

4.2.2 For 9Cr-1Mo-V (P/T/F91) materials, the minimum preheat temperature shall be 400oF (204oC), and the
maximum interpass temperature shall be 600oF (316oC). After completion of welding, allow weld to slow cool to
175oF (80oC) and maintain until post weld heat treatment (PWHT). Post weld heat treat at 1375-1425oF (746-
774oC), hold for 1 hr/inch (1 h/25 mm) with a 3 hour minimum hold time.

References:

Guideline for Welding P(T) 91, William F. Newell, Jr., PE

Welding Chromium Molybdenum Steel Pipe for Power Plants, Mike Roth

4.3 Titanium and Other Reactive Materials

Welding procedures for titanium and other reactive materials shall include provision for internal and external
continuous inert gas shielding until the metal temperature is less than the reactive temperature.

4.4 5%, 8% and 9% Nickel Steels

The GMAW "short circuiting" mode of metal transfer shall not be used.
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4.5 Nickel Alloys

4.5.1 Nickel alloys shall be solvent cleaned or vapor degreased prior to welding.

4.5.2 The interpass temperature for nickel alloys shall not be greater than 350oF (177oC).

5. ADDITIONAL REQUIREMENTS FOR LOW TEMPERATURE SERVICES

5.1 General

5.1.1 To ensure impact properties of austenitic steel welds with a design temperature colder than -155oF
(-104oC), each heat, lot or batch of filler metal and filler metal/flux combination shall be "pre-use” tested as
required by Paragraph 5.1.2. The following filler metals may be used without "pre-use" testing provided that the
procedure qualification impact testing in accordance with UG-84(h) at the MDMT or colder is performed using
the same manufacturer brand and type filler metal and the MDMT is not colder than -320oF (-196oC) when
permitted by the code of construction:

a. ENiCrFe-2, ENiCrFe-3, ENiCrMo-3, ENiCrMo-4, ENiCrMo-6 or E310-15 or 16 for SMAW

b. ERNiCr-3, ERNiCrMo-3, ERNiCrMo-4, ER308L, ER316L or ER310 for GTAW, GMAW or PAW

5.1.2 One set of Type 304 stainless steel plates, 1/2 inch (13 mm) thick, shall be buttwelded in each weld
position to be used or in the 3G position following the production WPS and using the maximum heat input to be
used in production. Impact testing shall be conducted on each weld (at the MDMT or lower) in accordance with
the requirements for welding procedure qualification using full size Charpy V-notch specimens. Only one heat,
lot or batch of filler metal is to be used in accordance with the test coupon. Test results shall include absorbed
energy and lateral expansion. Testing may be conducted by the welding consumable manufacturer provided
certified mill test reports are furnished with the consumables.

5.1.3 A filler metal qualification report listing the Charpy impact test results and all documentation required for
adequate traceability must be prepared and attached to the applicable PQR.

5.1.4 Filler metals used in production must be from the same heat, lot, and batch that were prequalified by the
steps listed above.

5.1.5 Documentation is required such that the heat, lot, and batch numbers of the production filler metal can be
traced back to the actual tested materials.

6. ADDITIONAL REQUIREMENTS FOR OVERLAYS AND CLAD MATERIALS

6.1 General

6.1.1 The PQR quantitative chemical analysis shall report all elements for which specific values are given in
ASME Section II Part C.

6.1.2 Weld overlay shall have the required chemistry to a depth of the lesser of 1/8 inch (3 mm) or 1/2 the
specified overlay thickness.

6.1.3 Ferrite determinations of austenitic stainless steel weld overlay are required and shall meet the
requirements of Paragraph 4.1.3 a. The methods of determination shall be in accordance with
Paragraph 4.1.3b. The required determinations are as follows:

a. Nozzles - two (2) readings each.

b. Shell and head - the greater of four (4) readings per shell ring or head or one (1) reading per
10 ft2 (0.929 m2).
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6.1.4 The specific method of overlay, bead overlap, and weld bead sequence shall be clearly shown on the
WPS and shall be duplicated during procedure qualification and production welding.

6.1.5 For clad materials, the alloy cladding shall be stripped back 1/4 inch (6.4 mm) at all seams prior to
welding the base metal.

6.1.6 Procedure qualification test coupons shall be subjected to the maximum anticipated heat treatment to be
used in production.

6.1.7 Filler metal for weld overlay, clad restoration (at seams of clad equipment), shall be selected from
Table III.
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TABLE I
SELECTION OF WELDING ELECTRODES AND RODS FOR JOINING SIMILAR
MATERIALS OF STEEL AND NON-FERROUS MATERIALS EXCEPT ALUMINUM
COATED ELECTRODES WELDING RODS
BASE
MAT'L BASE MATERIAL ASME PREFERRED ALTERNATIVE ASME
NO. CLASSIFICATION
SPEC ELECTRODE ELECTRODE SPEC

1 (1) SFA5.1 E70XX (3,19) E60XX (3) (4,5,6,7) -

Carbon Steel
2 (2) SFA5.1 E70XX (3,19) - (4,5,6,7) -
3a Carbon-molybdenum SFA5.5 E70XX-A1 - (4,8,14,17) -
E8018-D3 E8016-D3
3b Manganese molybdenum SFA5.5 (4,8,14,17) -
(0.40 Mo min) (0.40 Mo min)
4 2 1/4 nickel SFA5.5 E8018-C1 E8016-C1 (4,8,14,17) -
5 3 1/2 nickel SFA5.5 E8018-C2 E8016-C2 (4,8,14,17) -
6 5 or 9 nickel - (12) - (12) -
7 1/2Cr-1/2Mo SFA5.5 E8018-B2 E8016-B2 (20) (4,8,14,17) -
8 1Cr-1/2Mo SFA5.5 E8018-B2 E8016-B2 (20) (4,8,14,17) -
9 1 1/4Cr-1/2Mo SFA5.5 E8018-B2 E8016-B2 (20) (4,8,14,17) -
Low Chromium
10 2 1/4Cr-1Mo SFA5.5 E8018-B3L E8015-B3L (4,8,14,17) -
Ferritic Steels
11 5Cr-1/2Mo SFA5.5 E8018-B6 E8015-B6 SFA5.28 ER80S-B6

12 9Cr-1Mo SFA5.5 E8018-B8 E8015-B8 SFA5.28 ER80S-B8

13 9Cr-1Mo-V (P/T/F91) SFA5.5 E9018-B9 (21) E9015-B9 (21) SFA5.28 ER905-B9 (21)
14 Type 405 SFA5.4 E309-15/16 (18) SFA5.9 ER309 (18)
15 Ferritic or Type 410S SFA5.4 E309-15/16 (18) SFA5.9 ER309 (18)
Martensitic
16 Stainless Steels Type 410 SFA5.4 E309-15/16 (18) SFA5.9 ER309 (18)
17 Type 430 SFA5.4 E309-15/16 (18) SFA5.9 ER309 (18)
18 T Types 304 and 304H SFA5.4 E308-16 (9,13) E308-15 (9,13) SFA5.9 ER308 (9,13)
19 Type 304L SFA5.4 E308L-16 (13) E308L-15 (13) SFA5.9 ER308L (13)
Types 321, 321H, 347,
20 SFA5.4 E347-16 (9,10) E347-15 (9,10) SFA5.9 ER347 (9,10)
347H
E317 and E317 and ER317 and ER317L
21 Types 317 and 317L SFA5.4 SFA5.9
E 317L-16 (9,13) 317L-15 (9,13) (9,13)
22 Types 316 and 316H SFA5.4 E316-16 (9,13) E316-15 (13) SFA5.9 ER316 (9,13)
Austenitic
23 Stainless Steels Type 316L SFA5.4 E316L-16 (13) E316L-15 (13) SFA5.9 ER316L (13)
24 Type 309 SFA5.4 E309-16 (13) E309-15 (13) SFA5.9 ER309 (13)
25a Type 310 SFA5.4 E310-16 (13) E310-15 (13) SFA5.9 ER310 (13)
25b ASTM A351 Gr. HK40 - (11 and 12) (11 and 12) - (11 and 12)
25c HP MOD/HP MOD LC - (11 and 12) (11 and 12) - (11 and 12)
25d HK4M, HPM - (15) (15) - (15)

25e 45Ni-35Cr - (11 and 12) (11 and 12) - (11 and 12)
26a Alloy 800, 800H, 800HT SFA5.11 (15) - SFA5.14 (15)
26b Inco 803 (15) - - (15)
29 Copper SFA5.6 ECu - SFA5.7 ERCu
30 67Ni-30Cu SFA5.11 ENiCu-7 - SFA5.14 ERNiCu-7
Non-Ferrous
31 Metal and Hastelloy # - (16) - - (16)
32 Alloys Alloy 600, 625, 601 - (15) - - (15)
33 70Cu-30Ni SFA5.6 ECuNi - SFA5.7 ERCuNi
34 Nickel SFA5.11 ENi-1 - SFA5.14 ERNi-1
35 20Cr-29Ni-2 1/2Mo-3Cu SFA5.4 E320LR 15/16 - SFA5.9 ER320LR
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# : (Trademark of the Cabot Corporation)

NOTES TO TABLE I: (Numbers in parentheses in Table I refer to the following notes:)

1. Minimum ultimate tensile strength less than 65 000 psi (448 MPa).

2. Minimum ultimate tensile strength 65 000 psi (448 MPa) and greater.

3. The following classifications are not acceptable for use in pressure containing welds: E6012, E6013,
E6022, EXX14 and EXX24. However, these classifications may be used for tank fillet welds. See
Paragraph 3.3.2 for welding permitted with E6010 and E6011 electrodes.

4. Where no ASME material specification exists for wire or rods, wire or rods of the same nominal chemical
composition as the base material with substantially neutral flux or inert gas may be used if they have been
qualified in accordance with the applicable code and specification requirements.

5. Gas metal arc (GMAW) and flux cored arc (FCAW) wire shall conform to ASME SFA-5.18 and SFA-5.20.

6. Submerged arc (SAW) wire and flux shall conform to ASME SFA-5.17 or SFA-5.23; however, equivalence
under these standards shall not be considered adequate for substitution between different manufacturers or
between a single manufacturer's grades without requalification.

7. For gas tungsten arc (GTAW), ASME SFA-5.18 ER70S-2 is the preferred welding wire.

8. Flux cored arc (FCAW) wire shall conform to ASME SFA-5.29.

9. For design temperatures above 1000oF (538oC), 0.040 - 0.080% carbon is required.

10. For welding Types 321 and 347 material when the design temperature is greater than 750oF (400oC), and
the thickness is over 3/4 inch (19 mm), the procedure shall be as follows:

a. A 1/8 inch (3.2 mm) to 3/16 inch (4.8 mm) thick layer of E347-15, E347-16, or ER347 weld metal shall
be deposited for that portion of the weld exposed to the product.

b. The remaining portion of the weld shall be completed with E16-8-2-15, E16-8-2-16, or ER16-8-2.

11. Centrifugal casting alloys shall be welded with welding rods or electrodes depositing weld metal of
equivalent chemical composition, including carbon content.

12. Welding rods or electrodes shall be used, subject to the Purchaser's approval, which deposit weld metal of
equivalent mechanical properties as the base material.

13. For design temperatures colder than -155oF (-104oC), see Section 5 of this Standard.

14. Submerged arc (SAW) wire and flux shall conform to ASME SFA-5.23. Wire and flux combinations shall
deposit welds with the same nominal chemical composition and equivalent mechanical properties as the
base material. Limitations on substitution shall be as specified in Note 6 above.

15. For design temperatures thru 1500oF (816oC), ENiCrFe-2 or ERNiCr-3 shall be used. For design
temperatures greater than 1500o F (816oC), ERNiCrCoMo-1 filler metal or ENiCrCoMo-1 electrodes shall be
used.

16. Welding rods or electrodes used shall require the Purchaser's advance approval, and shall deposit weld
material of equivalent mechanical and corrosion resistant properties as the base material.
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17. For gas tungsten arc (GTAW) and gas metal arc (GMAW), rods and wire shall conform to ASME SFA-5.28
and shall deposit welds with the same nominal chemical composition and equivalent mechanical properties
as the base material.

18. ASME SFA-5.4 E309 electrode or SFA-5.9 ER309 wire when design temperature is less than
700o F (371oC) and post weld heat treatment will not be done. ASME SFA-5.11 ENiCrFe-2
electrode or SFA-5.14 ERNiCr-3 for other conditions except in sulphur service. For sulfur service,
specific requirements shall be requested from the Purchaser.

19. For impact tested carbon steel with an MDMT colder than -20oF (-6.7oC) use E7018-1.

20. For minimum ultimate tensile strengths less than 80 000 psi (552 MPa), E7015-B2L, E7016-B2L or E7018-
B2L can be used.

21. Filler material chemistry shall meet ASME Section IIC SFA 5.5, 5.23 or 5.28 requirements for B9 material
with Ni+Mn limited to 1.5% maximum. Certified material tests reports (CMTR's) are required for each heat,
lot and batch of welding consumables to be used.
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DATE: 01 MAY 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 14 OF 17

TABLE II
SELECTION OF WELDING ELECTRODES AND RODS FOR WELDING DISSIMILAR
MATERIALS OF STEEL AND NON-FERROUS MATERIALS EXCEPT ALUMINUM
Lower HIGHER BASE MATERIAL NUMBER (SEE TABLE I)
Base
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25a 25b 25c 26 35
Mat’l No.
1 A A A A A A B B B B B B C C C C C C C C C C D G G G G C
2 - A A A A B B B B B B B C C C C C C C C C C D G G G G C
3 - - * * * B B B B B B B C C C C C C C C C C D G G G G C
4 - - - A A * * * * * * * * * * * C C C C C C D G G G G *
5 - - - - A * * * * * * * * * * * C C C C C C D * G G G *
6 - - - - - * * * * * * * * * * * E E E E E E E * G G G *
7 - - - - - - A A A A A A C C C C C C C C C C D E G G G *
8 - - - - - - - A A A A A C C C C C C C C C C D E G G G *
9 - - - - - - - - A A A A C C C C C C C C C C D E G G G *
10 - - - - - - - - - A A A C C C C C C C C C C D E G G G *
11 - - - - - - - - - - A A C C C C C C C C C C D E G G G *
12 - - - - - - - - - - - A C C C C C C C C C C D E G G * *
13 - - - - - - - - - - - - C C C C C C C C C C D E G G * *
14 - - - - - - - - - - - - - C C C C C C C C C D E G G * *
15 - - - - - - - - - - - - - - C C C C C C C C D E G G * *
16 - - - - - - - - - - - - - - - C C C C C C C D E G G * *
17 - - - - - - - - - - - - - - - - C C C C C C D E G G * *
18 - - - - - - - - - - - - - - - - - A A A A A A A G G G C
19 - - - - - - - - - - - - - - - - - - F F F A F F G G G C
20 - - - - - - - - - - - - - - - - - - - A A A A A G G G C
21 - - - - - - - - - - - - - - - - - - - - A A A A G G G C
22 - - - - - - - - - - - - - - - - - - - - - A A A G G G C
23 - - - - - - - - - - - - - - - - - - - - - - A A G G G C
24 - - - - - - - - - - - - - - - - - - - - - - - C G G G C
25 a, d, e - - - - - - - - - - - - - - - - - - - - - - - - H H H C
25 b, d, e - - - - - - - - - - - - - - - - - - - - - - - - - H H C
25 c, d, e - - - - - - - - - - - - - - - - - - - - - - - - - - H C
26 a, b - - - - - - - - - - - - - - - - - - - - - - - - - - - G
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DATE: 01 MAY 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 15 OF 17

DESCRIPTION OF CODE LETTERS IN TABLE II:

A. As specified in Table I for material corresponding to either the higher or lower Base Material Number.

B. As specified in Table I for base material No. 9.

C. ASME SFA-5.4 E309 electrode or SFA-5.9 ER309 wire when design temperature is less than
700oF (371oC) and post weld heat treatment will not be done. ASME SFA-5.11 ENiCrFe-2 electrode
or SFA-5.14 ERNiCr-3 for other conditions except in sulphur service. For sulfur service, specific
requirements shall be requested from the Purchaser.

D. As specified in Table I for the material with the higher Base Material Number.

E. ASME SFA-5.11, ENiCrFe-2 electrodes and ASME SFA-5.14, ERNiCr-3 rods shall be used where design
temperature exceeds 1000oF (538oC). ASME SFA-5.4, E310 electrodes may be used where design
temperatures are below 1000oF (538oC) and expected to be relatively constant after startup. All rods,
including alternates, require written approval by the Purchaser.

F. ASME SFA-A5.4, E308 electrodes or as specified in Table I for the material having the higher Base Material
Number.

G. ASME SFA-5.11, ENiCrFe-2 electrodes and SFA-5.14 ERNiCr-3 rods shall be used.

H. For design temperatures of thru 1500oF (816oC), ENiCrFe-2 or ERNiCr-3 shall be used. For design
temperatures greater than 1500oF (816oC), ERNiCrCoMo-1 filler metal or ENiCrCoMo-1 electrodes shall be
used.

* Welding of these material combinations not permitted without permission from the Purchaser.

TABLE III
FILLER METAL SELECTION
WELD OVERLAY AND CLAD RESTORATION
WELD OVERLAY MATERIALS (Note 1)
CLADDING MATERIAL
FIRST LAYER TOP LAYER(S)
405 / 410S ENiCrFe-2 or ERNiCr-3 (Notes 2 & 3)

304 SS E/ER309 E/ER308

304L SS E/ER309L E/ER308L
316 SS E/ER309Mo E/ER316
316L SS E/ER309MoL E/ER316L
317L SS E/ER309MoL E/ER317L (Note 4)
321 / 347 SS E/ER309Cb E/ER347
MONEL ENiCu-7* E/ERNiCu-7
ALLOY 600, 800,
ENiCrFe-2 or ERNiCr-3 **
800H, 800HT (Note 5)
ALLOY 600, 800, Filler Metal ERNiCrCoMo-1 or
800H, 800HT (Note 6) Electrodes ENiCrCoMo-1

* For GMAW overlays, the first layer shall be deposited by ENiCu-7 or ERNi-1
** All Layers
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DATE: 01 MAY 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 16 OF 17

NOTES TO TABLE III:

1. Paragraphs NF7 and NF14 of Appendix NF in Part UNF of ASME Section VIII, Division 1 are mandatory for
nonferrous cladding.

2. For design temperature above 1000oF (538oC), specific requirements shall be requested from the
Purchaser.

3. E/ER309 may be used for all layers when design temperature is less than 700oF (371oC) and thermal
cycling conditions are not anticipated.

4. A minimum of two layers shall be deposited with E/ER317L.

5. Design temperature applications thru 1500oF (816oC).

6. Design temperature applications over 1500oF (816oC).

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DATE: 01 MAY 2003 ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC. PAGE 17 OF 17

APPENDIX A

WELD MAP

Type of Equipment:

Pressure Vessel Seller

Heat Exchanger Purchaser Order

Storage Tank Seller Order Number

Other Item Number

PWHT IMPACT
YES NO TESTING YES NO

Applicable Code Rev. Year

Draw a single-line sketch of equipment. Locate all welds. Identify each welding procedure by separate letter
or number.

Form Completed
Revision Number
Date
Review Comments:

Signed
Date