WELDING SPECIFICATION OF CARBON

STEEL & ALLOY STEEL PIPING

SCOPE
•This specification covers requirement for arc
welding of,
-carbon and low alloy steel pipes and fittings.
-For pipes to be used for steam services,
- the requirement of Indian boiler regulation
shall apply,
- in addition to all non-conflicting requirement of
this specification.
REFERENCE STANDARDS:

• ASME B 31.3 -Code for pressure piping.

• ASME PV Code Sec IX - Welding
• GRAI:PIP -Alignment of pipes & fittings for welding.
• GRAI:PIP -Inspection requirements of fusion welds of
pipes
WELDING QUALIFICATIONS:

• Welding procedure and welder shall be qualified as per

the requirement of ASME PV Code section IX.
• Weld as well as heat affected zone in pipe operating
below -100 °C shall meet the impact test requirement in
accordance with material specification.
• Impact values shall be recorded with welding procedure
and welders’ qualification test.
MATERIAL SPECIFICATION:

Materials have been grouped,

on the basis, of composition, mechanical properties and
weldability as given in Table-1 .

The typical, Material specification, have also been

indicated.
 TABLE -1
Material P- Material Typical Specifications
group number type
1 1 C S up to ASTM A105, A106 B, A234, API-5L
0.35 C BS:3602, DIN 17175 St 45.8
2 1 CS for low ASTM A233 GrI, A 420 Gr WPL 6,
temp service BS:3603 Gr 27, LT 50
below 33 °C

3 3 Carbon- Moly ASTM A335 Gr PI, A234 Gr WP 1,

Steel DIN 17175 Gr. 15 Mo 3
4 4 1Cr- 1/2 Moly, ASTM A335 Gr PI2/P11, A234 Gr
1 ¼ Cr- WP 12/WP11, A 182Gr.F11/12,BS3604
½ Mo steel Gr.620/621,DIN17175Gr.10,Cr-Mo 44
5 5 2 ¼ Cr-1 Moly ASTM A335 Gr P22, A234 Gr P22
Steel. A 182Gr.F22,BS3604 Gr.622,DIN 17175
Gr10, Cr-Mo 910
6 - 17 Cr-Mo-V10 ---

7 * 3 ½ Ni steels ASTM A333 Gr3, A420 Gr.WPL

 WELDING PROCESS

Welds shall be made by one of the process:

• Manual metal arc welding (MMA or SMAW).
• Inert gas shielded metal arc welding (MIG or GMAW).
• Inert gas shielded tungsten are welding (TIG or GTAW).

• Root run in case of pipes having pressure rating greater

than 64 KG/CM2 shall be made by MIG or TIG process.
• Inside of the pipe shall be purged with argon.
• However if chipping and back welding is possible the
shielded metal are welding may be used for root runs.
 FILLER METALS:
• Electrodes for manual metal are welding of different steels
shall be as per Table-2.
• Electrodes shall be dry prior to welding.
• Low hydrogen electrodes must be completely dry when used
and manufacturer's instruction for drying must be adhered to.
• It is good practice to dry electrodes in a suitable heater at
controlled temperature of 150-200°C for the whole night before
their use and in no case for less than four hours.
• For welding outside particularly in wet weathers, the
electrodes should be kept in portable heating containers until
their use.

• Electrodes, rods or filler wires used for inert gas shielded metal
are welding (MIG) and inert gas shielded tungsten are welding
(TIG) shall be of fabricator’s recommended type.
• Welds Produced shall have mechanical and metallurgical
properties equivalent to those of the base metal.
 TABLE-2

Material Base metal Specification Electrodes F-No.

Group type of steel class
1. Carbon steel AWS A 5.1 E 6010/13 for root run F-3
E 7015/16/18 for filling
1 a. CS for Low AWS A 5.1 E7015/16/18/24 F-4
Temp Service

(-11 to -33 °C )
2 Carbon steel for AWS A 5.5 E 7015-C1, E 7018-G F-4

low temp. services up to – 50 °C

below -33 °C

3 Carbon moly AWS A 5.5 E 8018-C1, E up to –70 °C F-4

(C-1/2 Mo)
4 1Cr-1/2Mo & AWS A 5.5 E 8015-B2 or E 8018-B2 F-4
1 1/4 Cr-1Mo
5 2 1/4Cr-1Mo AWS A 5.5 E 9015-B3 or E 9018-B3 F-4
6 17Cr-Mo-V10 BOILER FOX IN 9 kb
7. 3 1/2 Ni AWS A 5.5 E 8015-C2, E 8016-C2, F-4
E 8018-C2
NOTES ON TABLE 2:

• Equivalent material to other specification

may also be used.
• Electrodes corresponding to E XX 16 and E XX
18 low hydrogen types may also be used.
• Electrodes for welding of carbon and low
alloy steels to austenitic stainless steel shall
conform to class E309 Mo (25Cr-12 Ni with Mo).
• In weld joints between Cr-Mo steels of
different Cr-percent, the filler material shall have
an intermediate Cr percent, or if this is not
possible, the lower Cr percent of the two steel to
be welded.
 BASE METAL PREPARATION:

• The end shall be prepared by machining, grinding or flame

cutting.
• Edge preparation for U-grooves shall be prepared by machining
/ grinding only and shall not be flame cut.
• Flame cut surface shall be reasonably smooth and completely
free from all oxide prior to welding.
• Carbon molybdenum, 1 Cr -1/2 Mo and 11/4 Cr -1/2 Mo steel
pipes shall be preheated for thermal cutting to a minimum 100
°C when thickness of pipe is above 12 mm.
• 2 1/4Cr-lMo pipes shall be preheated for thermal cutting to 150
°C min, for all pipe thicknesses.
• Prior to welding, the groove and adjacent base metal, for a
distance of at least 2T or 50 mm, (where T is thickness at throat
of weld), shall be cleaned inside and outside of all scale, rust,
oxide, oil, dirt, or other foreign materials.
• The use of solvent for grease, oil, & paint removal is
recommended.
 ALIGNMENT

• The abutting edges of joints shall be aligned as

accurately possible and maintained in alignment during
welding by tack welding or otherwise,
• the alignment shall be within limits specified.
PREHEATING:

• Preheat requirement and preheat temperature shall be as

specified in Table -3.
• When welding dissimilar metals or materials with different
thickness, the material having the greater thickness or greater
carbon or alloy content shall govern. When slip- on flanges are
attached by fillet welds, the thickness of pipe shall govern.
• Preheat shall be applied to the area local to and including the
weld preparation and the temperature shall be maintained
during the entire welding operation.
• The preheat temperature shall be checked by the use of
temperature indicating crayons, thermo couples or other
suitable method.
• It shall be ensured that the required preheat is obtained at
position up to 100 mm from the outside edge of the joint
preparation.
PREHEATING:

• Preheating requirements shall also apply to tack welding

as well as welding of structural attachments to piping.
• The rate of preheating shall not exceed 100°C per hour
or 6°C /T/hour, where T is thickness in mm, whichever is
the smaller.
FIT –UP:
• In case of piping of nominal pressure more than
25 kg/cm2 with thickness 4 mm or larger, the pieces to
be butt welded shall be coupled by yokes or bridge C-
clamp.
• For alloy steel and low temperature service below-33°C,
electrodes conforming to E309 shall be used.
• Where Cr >2%, the pipe surface shall be preheated
locally to 150-200 °C before welding of the clamps.
• For welding of yokes or bridge C- clamps, 2.5 mm or
3.25 mm electrodes shall be used.
• Care shall be taken to avoid undercuts.
• During the root run, yokes or bridge C- clamps shall be
removed avoiding craters or damages on pipe.
• Any crater on pipe shall be repaired and surface
irregularities on the pipe after removal of yokes or
clamps shall be ground off.
FIT UP:

• For thickness 4 mm or less, tack weld in the groove in

place of clamps may be permitted provided they are
subsequently removed during the root run.
• Preheating is required as per Table-3.

• In case of piping of PN less than 16 kg/cm2, the tack-

welds may be left provided they are re-melted in the
weld and complete penetration is achieved.
• However, cracked tack weld shall be removed.

• In case of fillet welds, tack welds are permitted for fit-up

and they may become a part of the weld, provided they
are free from defects and re-melted in the subsequent
welding.
• Pre heating is required as per Table-3.
 TABLE -3 (PREHEATING REQUIREMENTS)

Material Thermal All other arc welding process except

cutting oxy- acetylene welding
==============================================================================
Material Type of Thickness for Min. Pre Thickness for which Min. Pre heating
group steel which Pre heating heating Pre heating is required Temp. °C
is Required, mm. Temp °C mm.
----------------------------------------------------------------------------------------------------------------------------------------
1 CS up - - > 18 100
to 0.35% C
2 CS for low temp. - - < 5 150
services below -33°C
3 Carbon- Moly 12 100 All 150

C- ½ Mo
4 1Cr- ½ Mo All 100 All 150
1 ¼ Cr– ½ Mo
5 2 ¼ Cr- 1 Mo All 150 All 200
6 17 Cr. Mo- V 10 All 150 All 250- 300
7 3 ½ Ni All 250 All 350
WELDING PROCEDURE:

• The electrode size for root pass shall not be greater

than 3.25mm.
• The filling shall be made by shielded metal are welding
(SMAW) with electrodes not larger then 4 mm.
• Direct current shall be used, with electrodes holder
connected to the position pole.
• For pipe in horizontal fixed position the upward
technique shall be used as a rule.
• Where root run is made by TIG or MIG, the inside of the
pipe shall be protected with the shielding gas.
• The root run of butt joints, regardless of the technique
used, shall be such to achieve full penetration.
• Fit-up tack welding shall be removed progressively
during the root run, except in cases mentioned in clause
10.3 and 10.4.
 Continuity of Welding and Preheat:

• Irrespective of the class of steel, root runs shall be made

without interruption other than for the changing of
electrodes or for allowing the welder to reposition himself.
• Root runs made in the workshop may afterwards be
allowed to cool provided that precautions are taken to
ensure a low cooling (e.g. wrapping in dry asbestos
blankets).
• Weld at site shall not be allowed to cool until the
thickness of weld metal deposited exceed one-third of the
final weld thickness or 10 mm whichever is greater.
• When welding 2 1/4 Cr-1Mo and 17 Cr-Mo-V10 steels it
is strongly recommended that arrangements be made to
avoid any interruption of welding.
Continuity of Welding and Preheat:

• Where such an interruption is necessary, either the

preheat temperature shall be maintained during
interruption or the joint shall be wrapped in dry asbestos
blankets to ensure slow cooling.
• Before recommencing welding, preheat shall again be
applied.
• On completion of welding, the joint shall be wrapped in
dry asbestos blankets to ensure slow cooling, unless
post-weld heat treatment is applied immediately.
Continuity of Welding and Preheat:

• On completion of root pass, regardless of

the technique used, any visible defects and all
irregularities of the weld which could be
detrimental to the next pass shall be ground off.
• At each interruption of welding, the slag shall
be removed from the restart zone and it is
recommended to grind off the end crater.
• On completion of each pass, slag shall be
carefully removed and any defect of weld which
could be detrimental to the next pass shall be
ground off.
Continuity of Welding and Preheat:

• The arc shall not be started by striking the

electrode on the pipe wall, off the joint area
• . At each interruption of welding, the arc shall be
blown out on the bevel instead of on the weld
metal and the argon flow shall be continued for
some seconds, so as to allow crater cooling
under its protection.
• It is recommended to remove the end crater
before the restart.
• This is particularly important in case of shielded
metal arc welding of alloy steels.
Continuity of Welding and Preheat:

• After the welding is started and until the joint has not
been completed, displacements, shocks, vibrations or
stresses shall be carefully avoided, in order to prevent
cracks or breaks in the weld.

• No welding should be done in heavy rain or high wind.

• After welding, welder's identifying sign assigned upon his

qualification, shall be clearly stamped at a distance of at
least 30 mm from the edge of the weld.
POST WELD HEAT TREATMENT
• Post weld heat treatment shall be required as specified
in Table-4.
• The heat treatment to be used in production welding
shall be stated in the welding procedure and used in the
qualification of the welding procedure.
• When welding dissimilar metals or materials with
different thickness, the material having the greater
thickness or greater carbon or alloy content shall
govern.
• Dissimilar joints including both ferritic and an austenitic
weld or component shall be heat treated according to
the requirement for the ferritic material.
• When slip-on flanges are attached by fillet welds, the
thickness of pipe shall govern.
• In the case of branch connections, metal (other than
weld metal) added reinforcement, whether integral or
attached, will not be considered in determining heat
treatment requirements.
POST WELD HEAT TREATMENT:

• Heat treatment procedure shall ensure uniform

temperature distribution around and through the
thickness of the joint.
• Effective local heating of the surface shall be
avoided. It is recommended to insert plugs in
piping or put blind flanges to prevent air
circulation through inside of the pipe.
 TABLE-4
Material Thickness for Soaking Time at Temp. Brinnel

Material Type of which post weld heat temp.°C per 25 mm of hardness,

steel treatment is required, mm thickness, hrs. max
=====================================================================
1 CS up to0.35% 18 mm. or more 600- 650 1 ( Min ) -
1.a CS. LT service All welds to be 600 -650 1 (Min ) -
- 11 to - 33 .°C stress relieved for
Temp. – 15 .°C &
thickness over 5 mm.
2 CS LT service As indicated in 600 – 650 1 ( Min ) -
( below -33 .°C ) Table-5
3 C- Mo steels All 630 – 670 1 ( Min ) 225
4 1 Cr – ½ Mo All 630 - 670 1 ( Min ) 225
1 ¼ Cr – ½ Mo
5 2 ¼ Cr – 1 Mo. All 680 - 720 1 ( Min ) 240
6 17 Cr – Mo- V 10 All 680 - 720 1 ( min ) 240
7 3 ½ Ni 12 mm. or more 580 – 620 1 ( Min ) -
POST WELD HEAT TREATMENT:

• The temperature shall be checked and recorded during

the period of heat treatment and it shall be ensured that
a required temperature is maintained.
• Post weld heat treatment shall be accomplished by one
of the following methods:
(a) Heating the complete structure as a unit.
(b) Heating the complete section containing the weld or
welds to be stress relieved before attachment to other
section of work.
(c) Local heat treatment.
POST WELD HEAT TREATMENT:

• The local heat treatment procedure shall meet the following minimum
requirements:
• The heating rate shall not exceed the following values:
• Carbon steel and 1/2 Mo steels

• 250°C /hr. for thickness up to 30 mm.

• 200°C /hr. for thickness over 30 mm.

• All other alloy steels and LT pipes

• 200°C /hr. for thickness below 15 mm.

• 150°C /hr. for thickness 15-30 mm.

• l00°C /hr. for thickness over 30 mm.

• The above values may be increased by 100°C when the treatment is made by
induction equipment.
POST WELD HEAT TREATMENT:

• The cooling rate for welds shall not exceed the following values
up to a temperature of 400°C.
• Carbon steels and 1/2 Mo. steel

• 200°C /hr. for thickness up to 30 mm.

• 150°C /hr. for thickness over 30 mm.

•
• All other alloy steels and LT pipes

• 150°C /hr. for thickness below 15 mm.

• 100°C /hr. for 15-30 mm.

• 70°C /hr. for thickness over 30 mm and all low temperature (LT
piping).
• The weld shall be covered till completion of cooling.
POST WELD HEAT TREATMENT:
• The disposition of heating elements shall be such as to
obtain a temperature profile which is approximately
symmetrical about the centre line of the weld and
circumferentially uniform .
• The minimum width of the circumferential band centered
on the welds, shall not be less than 6T where T is the
thickness of the pipe.

• The number of, thermocouples shall be proportional to

joint size and heating equipment type, They shall in any
way ensure a regular check of temperature over the
whole joint.
• In any case, there shall be one thermocouple for each
meter of circumference, or fraction there of and for each
panel of resistances.
• On horizontal pipe, thermocouple shall be place on the
lower side of the joint.
POST WELD HEAT TREATMENT:

• The longitudinal temperature gradient shall be

such that sufficient length of material on each
side of the weld remains at a temperature
exceeding half the stress relieving temperature.
• This length shall be greater than 2.5 Sq Root
(RT) where R is the radius of the bore at the joint
and T is the thickness of the material at the joint.
• A complete automatic temperature recording
shall be made of values taken by each
thermocouple as a function of the time by
suitable recorders, including cooling to 400°C.
POST WELD HEAT TREATMENT:

• Where hardness limit is given in table-4,

• a minimum of 10 percent of welds in each heat
treatment batch which are furnace heat-treated
• and 100 percent of those which are locally heat treated
shall be hardness tested.
• The hardness limit applies to weld and to heat affected
zone.
• Hardness test of the heat affected zone shall be made at
a point as near as practicable to the edge of the weld.
INSPECTION & TESTING

• ALL WELDS COVERED BY THE SPECIFICATION

SHALL BE SUBJECT TO INSPECTION BY
PURCHASER INSPECTOR AS PER SPECIFIED
INSPECTION REQUIREMENT.
 RECTIFICATION OF DEFECTS

• All defects in excess of those specified shall be

completely removed by chipping, grinding, machining or
thermal cutting to sound metal before re-welding.
• The ends and sides of the cut shall be gradually tapered
from the base of the cut to the surface of the weld metal.
• The size and profile of cut shall be such as to give
adequate access for welding.
• Where a faulty weld has been cut, re weld the entire girth
and there shall be no serious loss of pipe-length.
• The edges shall be prepared for re-welding as specified
for the original weld.
• In case of shortening of pipe length after cutting a faulty
weld, a length of pipe containing the faulty weld shall be
removed and a new length of pipe welded, with the edge
prepared as specified.
RECTIFICATION OF DEFECTS:

• Re welding of defective welds shall be done as

per the qualified procedure.
• Preheating and post weld treatment shall be as
required for original welds except for minor
repairs.
• All repairs to defective weld shall be reported to
the purchaser’s inspector.
• All repaired weld shall be subjected to the same
testing and inspection requirements as the
original welds.
 TABLE-5

POST WELD HEAT TREATMENT REQUIREMENT FOR

LOW TEMPERATURE PIPING:
Lowest service Thickness for which post
temperature, °C weld heat-treatment
required, mm-
- 34 to -40 13 and above
-41 to -50 9 and above
-51 to -604. 5 and above (thickness of the pipe
not to exceed 37 mm)-
61 to -70 All (thickness of the pipe not to
exceed 25 mm)
PRECAUTION AND SPECIAL REQUIREMENTS FOR LOW
TEMPERATURE SERVICE BELOW -33 °C.

• It must be remembered that care put into the design and

choice of material can be nullified by apparently minor
faults or carelessness in fabrication and welding.
• The quality of welding has a very important bearing on
the safety of the piping and this must be appreciated by
all concerned with the fabrication of low temperature
piping.
• Non-load bearing attachments and minor attachments
require the same standard of workmanship as the main
piping to which they are attached.

• Every precaution should be taken to avoid flaws &

notches from fabrication like under- cutting, excessive
reinforcement, slag inclusions, arc flashes etc.
 PRECAUTION AND SPECIAL REQUIREMENTS FOR LOW
TEMPERATURE SERVICE BELOW -33 °C.

• All cut edges (during edge preparation or otherwise) should be

machined or ground where necessary to remove the effect of
previous shearing, chipping, or flame cutting.
• Grinding to a depth of at least 1 mm is recommended.
• In addition, ends of branch pipe and other openings shall be
ground to a smooth radius after all welding is complete.
• It is preferable to use wrought tees and avoid welding at branch
connections.
• Care shall be taken when removing temporary erection cleats
etc. In order to prevent damage to the surface of pipe,
• after removal of such items, any remaining welding metal of
extensions shall be ground flush with the surface of the part.
• Uncontrolled tack welds or strikes and minor temporary
attachment should be avoided.
• Clamping should be preferred to welding for such attachments.
PRECAUTION AND SPECIAL REQUIREMENTS FOR LOW
TEMPERATURE SERVICE BELOW -33 °C.

• Every care shall be taken to ensure that all

electrodes used are those specified and
approved and they are stored and handled in
such a way as to ensure no deterioration.
• The electrodes must be dried prior to welding at
200- 250 °C for minimum one hour.
• They should be kept hot during welding by
keeping in a container.
• Preheating and post weld heat treatment shall be
carried on carefully at specified temperatures as
these treatment affect the notch toughness of the
weld and parent metal appreciably.
 PRECAUTION AND SPECIAL REQUIREMENTS FOR LOW
TEMPERATURE SERVICE BELOW -33 °C.

• Because the notch toughness of a weld deposit

depends critically upon the technique used, it is essential
that procedure employed in making welding procedure
tests is duplicated as far as possible during production
welding.
• Not only the current and voltage setting should be the
same, but also the manipulation technique, ie. bead
laying, weaving and speed of travel.
• Care shall be taken that electrodes are struck either in
weld groove or on dummy material outside the proper
material to be welded.
• If any arc strikes occur outside of the groove, the area
shall be ground and shall be inspected to ensure that no
cracks have resulted.
PRECAUTION AND SPECIAL REQUIREMENTS FOR LOW
TEMPERATURE SERVICE BELOW -33 °C.

• No welding shall be done after final heat treatment.

• Weld shall have full penetration. Under-cutting or bad

profile shall be avoided or corrected by careful grinding.

• Proper supervision of the welding work from the

beginning to the end of the job is imperative particularly
for pipe thicker than 6 mm.