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Document typeNo.: STIM-03.009

Steam Turbine Information Manual Revision/Date: D 2005-09-29

Issued by: S32 / O 5413

Title

Welding of Turbine Piping ConnectionsProj Code UA Content Code

UNID-Nr

Document Status: Preliminary Final

Siemens Power Generation This document contains proprietary information. It is submitted inconfidence and is to be used solely for the purpose for which it is furnishedand returned upon request. This document and such information is not to bereproduced, transmitted, disclosed, or used otherwise in whole or in partwithout written authorization.

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Welding of Turbine Piping Connections Steam Turbine Information Manual Document No.: STIM-03.009Revision/Date: D 2005-02-02Page: 2 of14


Released by: H Luft Steam Turbine Eng S32 2001-07-31

Reviewed by: H Luft Steam Turbine Eng S32 2001-07-31

Reviewed by: P Pech Steam Turbine Materials S32 2001-07-31

Reviewed by G Rhrig Project Management S31 2001-07-31

Reviewed by K-H Bartsch Steam Turbine Manuf S33 2001-07-31

Reviewed by: G Czirnek Field Site Erection O 5413 2001-07-31

Prepared by H-J Jestrich Steam Turbine Materials S32 2001-11-08

Prepared by: EWE M. Kossmann Field Site Erection O 5413 2001-07-26

Prepared by: Dr F Hiss Steam Turbine Eng S32 2001-11-08

Name Org. Unit Signature Date

Also Reviewed By:

Revision History

REVISION REISSUEDATE

NAME SECTION DESCRIPTION OF CHANGE

A 2001-08-22 Hiss 3.5 Material Compatibility Table revised andaugmented

B 2001-11-06 Hiss section 3.5,section 4.1

Material Compatibility Table revised andaugmented modified.

C 2001-12-11 Hiss Initial section deleted in the front page

D 2005-09-29 Leu /Logar /

3.5

3.8

5

Material Compatibility Table revised forX6CrNiTi18-10 and GX12CrMoVNbN9-1Section 3.8 Requirements for post weld heattreatment addedNDT requirements added

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TABLE OF CONTENTS

REVISION HISTORY ......................................................................................................... 2

1 REFERENCE DOCUMENTS....................................................................................... 4

2 APPLICABILITY .......................................................................................................... 5

3 WELDS BETWEEN A COMPONENT SUPPLIED BY SIEMENS PG S AND ACOMPONENT SUPPLIED BY OTHERS............................................................................ 5

3.1 Welding Procedure Specification WPS 5

3.2 Welding Procedure Approval Records (WPAR) 5

3.3 Qualification of Companies 5

3.4 Qualification of Welder 6

3.5 Material Compatibi lity Table 6

3.6 Weld End Preparations of Turbine Connections and Valve Connections 7

3.7 Weld End Preparations of Adjoining Pipes 8

3.8 Requirements of Post Weld Heat Treatment for pipes smaller 4 in. 8

3.9 Selection of Heat Treatment Temperature 9

3.10 Selection of Heat Treatment Time 9

3.11 Quality Control 9

4 WELD BETWEEN TWO COMPONENTS SUPPLIED BY SIEMENS PG.................... 9

4.1 Welding Procedure Specification 10

4.2 Welding Coordination 10

4.3 Non-Destruct ive Testing for Welds between two Components supplied by Siemens PG 10

5 NON-DESTRUCTIVE TESTING FOR ALL WELDS WITHIN THE LUBRICATINGAND LIFTING OIL (MAV) AND CONTROL FLUID (MAX) SYSTEMS ............................ 11

5.1 Hardness Examination for welding joints 135.1.1 Scope .......................................................... ........................................................... .........................................135.1.2 Methods to be Used ........................................................ ........................................................... .....................135.1.3 Permissible Hardness Values..........................................................................................................................135.1.4 Personnel Qualification...................................................................................................................................135.1.5 Test method .......................................................... ........................................................... ...............................135.1.6 Preparing the Examination Surface .................................................... ........................................................... .145.1.7 Examination Report ........................................................ ........................................................... .....................14

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1 Reference Documents

The following drawings and standards are referenced in this STIM chapter. Note that xxxxxdenotes the actual order number of the turbine-generator set.

Drawing/Standard Titlexxxxx-980133 Turbine Piping Connection List

xxxxx-980135 Turbine Piping Connection Heat-Treatment

ISO 9692 Metal-Arc Welding with Covered Electrode, Gas-Shielded Metal-Arc Welding and Gas Welding; Joint Preparations for Steel

ASME B16.25-1997 Butt Welding Ends

ASME Code Section II A ASME Boiler and Pressure Vessel CodeMaterial Specification Ferrous Materials

ASME Code Section II C ASME Boiler and Pressure Vessel CodeWelding Rods, Electrodes and Filler Metals

ASME Code Section V ASME Boiler and Pressure Vessel CodeNon-Destructive Examination

ASME Code Section VII ASME Boiler and Pressure Vessel CodeRecommended Guidelines for the Care of Power Boilers

ASME Code Section IX ASME Boiler and Pressure Vessel CodeWelding and Brazing Qualifications

DIN EN 287-1 Approval Testing of Welders - Fusion Welding - Part 1: Steels(Includes Amendment A1:1997); German Version EN 287-1:1992 + A1:1997

ISO 9606-1 Approval Testing of Welders Fusion Welding - Part 1: Steels

DIN EN 288-3 Specification and Approval of Welding Procedures for MetallicMaterials - Part 3: Welding Procedure Tests for the Arc Weldingof Steel (includes Amendment A1:1997); German Version EN

288-3:1992 + A1:1997EN 719 Welding coordination Tasks and responsibilities

EN 729 Quality Requirements for Welding

PV 0026.0000 Siemens PG Test SpecificationNon-Destructive Examination of Welded Joints

Abbreviations

AWI American Welding InstituteDVS German Welding SocietyIIW International Institute of Welding

PQR Procedure Qualification RecordWPAR Welding Procedure Approval RecordsWPS Welding Procedure Specification

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2 Applicability

The manual covers the following welds:

Welds between a component supplied by Siemens PG and a component supplied by others, e.g.main-steam pipe and main-steam valve.

Welds between two components supplied by Siemens PG, e.g. main-steam valve and turbinecasing.

Non-Destructive Testing for lubricating (MAV) and control fluid (MAX) Systems

3 Welds between a component supplied by Siemens PG S and a componentsupplied by others

Welds connecting a component supplied by Siemens PG with a component supplier by others,

e.g. main-steam pipe and main-steam valve, are covered in this section. The welds belonging tothis category are marked accordingly in the turbine piping connection list xxxxx-980133.

3.1 Welding Procedure Specification WPS

Companies or contractors who perform welding tasks must prepare written Welding ProcedureSpecifications (WPS) which are defined as follows :

a) Welding Procedure Specification (WPS). A WPS is a written recognized welding procedureprepared to provide directions for making welds according to the requirements.

b) Contents of the WPS. The completed WPS must describe all of the essential, nonessential and

supplementary essential variables for every welding process used in the WPS.

c) During welding of oil pipes and pipes made of austenitic or 2 % CrMo materials or higheralloyed, the pipes must be flushed with inner purging gas.

d) A copy of the WPS must be available on the job site for reference by welders and inspectors.

The WPS has to make reference to the supporting Welding Procedure Approval Records (WPAR)or Procedure Qualification Record (PQR).

3.2 Welding Procedure Approval Records (WPAR)

Companies or contractors who perform welding tasks must possess their own Welding ProcedureApproval Records (WPAR) according to DIN EN 288-3 or Procedure Qualification Records (PQR)according to ASME Boiler and Pressure Vessel Code Section IX for the used welding processes,materials, material combinations and dimensions. These records are to prove that the company orcontractor is capable of carrying out the welding, including the pre- and post-weld heat treatmentsin a correct manner.

3.3 Qualification of Companies

Companies must fulfill the requirements of EN 719 and EN 729 or equivalent standards.

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3.4 Qualification of Welder

Welders must be qualified in accordance with the requirements of DIN EN 287-1, ISO 9606-1 orASME Boiler and Pressure Vessel Code Section IX.

3.5 Material Compatibi lity Table

The materials, that are typically used by SPG for seamless pipes, turbine casing connections andvalve body connections, and their comparable ASTM equivalents (regarding chemicalcomposition) are listed in the following table. Since the chemical compositions of the SPGmaterial and of the appropriate comparable ASTM material are very similar, for welding purposesthe SPG materials can be treated as they were the listed comparable ASTM materials.

Material Designation

of Siemens PGComponent

Material

No.

Chemical Composition (wt.%) of

Material of Siemens PG Component

Comparable

Equivalent

UNS No. Chemical Composition (wt.%) of

Comparable Equivalent

St35.8 / III(DIN 17175)

1.0305 C: max 0.17Si: 0.10 - 0.35Mn: 0.40 - 0.80P: max 0.040S: max 0.040

ASTMA 106Gr A

K02501 C: max 0.25Si: min 0.10Mn: 0.27 - 0.93P: max 0.035S: max 0.035

Cr: max 0.40Mo: max 0.15Ni: max 0.40V: max 0.08Cu: max 0.40

15 Mo 3 (16Mo3)(DIN 17175)

1.5415 C: 0.12 - 0.24Si: 0.10 - 0.35Mn: 0.40 - 0.80P: max 0.035S: max 0.035

Mo: 0.25 - 0.35 ASTMA 335Gr P1

K11522 C: 0.10 - 0.20Si: 0.10 - 0.50Mn: 0.30 - 0.80P: max 0.025S: max 0.025

Mo: 0.44 - 0.65

10325NH(SWPC Material)

Notavailable

C: 0.10 - 0.20Si: 0.50 - 1.00Mn: 0.30 - 0.80P: max 0.040S: max 0.040

Cr: 1.00 - 1.50Mo: 0.40 - 0.65

ASTMA 335Gr P11

K11597 C: 0.05 - 0.15Si: 0.50 - 1.00Mn: 0.30 - 0.60P: max 0.025S: max 0.025

Cr: 1.00 - 1.50Mo: 0.44 - 0.65

9SMnPb28k(11SMnPb30 +C)(EN 10277-3)

1.0718 C: max. 0.14Si: max 0.05Mn: 0.90 - 1.30P: max 0.11S: 0.27 - 0.33

Pb: 0.20 - 0.35 ASTMA 576Gr 12L14

G12144 C: max 0.15Mn: 0.85 - 1.15P: 0.04 - 0.09S: 0.26 - 0.35

Pb: 0.15 - 0.35

BS 3602 Pt 1 Gr 430(BS 3602)

Notavailable

C: max 0.21Si: 0.10 - 0.35Mn: 0.40 - 1.20P: max 0.035S: max 0.035

Al: max 0.06 ASTMA 106Gr B

K03006 C: max 0.30Si: min 0.10Mn: 0.29 - 1.06P: max 0.035S: max 0.035


En 3B(BS 970)

Notavailable

C: max 0.25Si: max 0.35Mn: max 1.00P: max 0.060S: max 0.060

ASTMA 105

K03504 C: max 0.35Si: 0.10 - 0.35Mn: 0.60 - 1.50P: max 0.035S: max 0.040


10 CrMo 9 10(DIN 17175)

1.7380 C: 0.08 - 0.15Si: max 0.50Mn: 0.40 - 0.70P: max 0.035S: max 0.035

Cr: 2.00 - 2.50Mo: 0.90 - 1.20

ASTMA 335Gr P22

K21590 C: 0.05 - 0.15Si: max 0.50Mn: 0.30 - 0.60P: max 0.025S: max 0.025

Cr: 1.90 - 2.60Mo: 0.87 - 1.13

13 CrMo 4 4(13CrMo4-5)(DIN 17175)

1.7335 C: 0.10 - 0.18Si: 0.10 - 0.35Mn: 0.40 - 0.70P: max 0.035S: max 0.035

Cr: 0.70 - 1.10Mo: 0.45 - 0.65

ASTMA 335Gr P12

K11562 C: 0.05 - 0.15Si: max 0.50Mn: 0.30 - 0.61P: max 0.025S: max 0.025

Cr: 0.80 - 1.25Mo: 0.44 - 0.65

X6CrNiTi18-10(DIN 17456)

1.4541 C: max 0.08Si: max 1.0Mn: max 2.0P: max 0.045S: max 0.015

Cr: 17.0 - 19.0Ni: 9.0 - 12.0Ti: 5 x C,

max 0.70

ASTMA 312Gr TP321

S32100 C: max 0.08Si: max 0.75Mn: max 2.0P: max 0.040S: max 0.030

Cr: 17.0 - 20.0Ni: 9.0 - 13.0Ti: 5 x (C+N),

max 0.70

X6CrNiMoTi17-12-2(EN 10222-5)


Cr: 16.5 - 18.5Mo: 2.00 - 2.50Ni: 10.5 - 13.5Ti: 5 x C,

max 0.70

ASTMA 182Gr F316L

S31603 C: max 0.035Si: max 1.0Mn: max 2.0P: max 0.045S: max 0.030

Cr: 16.0 - 18.0Mo: 2.00 - 3.00Ni: 10.0 - 15.0

C22.8(P250GH +N)

1.0460 C: 0.18 - 0.23Si: max 0.40

Cr: max 0.30Al: 0.015 - 0.050

ASTMA 105

K03504 C: max 0.35Si: 0.10 - 0.35

Cr: max 0.30Mo: max 0.12

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(DIN EN 10222-2) Mn: 0.40 - 0.90P: max 0.025S: max 0.015

Mn: 0.60 - 1.50P: max 0.035S: max 0.040

Ni: max 0.40V: max 0.05Cu: max 0.40

Material Designationof Siemens PG

Component

MaterialNo.

Chemical Composition (wt.%) ofMaterial of Siemens PG Component

ComparableEquivalent

UNS No. Chemical Composition (wt.%) ofComparable Equivalent

X10CrMoVNbN9-1(EN 10222-2)

1.4903 C: 0.08 - 0.12Si: max 0.50Mn: 0.30 - 0.60

P: max 0.025S: max 0.015

Cr: 8.00 - 9.50Mo: 0.85 - 1.05Ni: max 0.40

V: 0.18 - 0.25Nb: 0.06 - 0.10N: 0.030 - 0.070

Al: max 0.040

ASTMA 335Gr P91

K91560 C: 0.08 - 0.12Si: 0.20 - 0.50Mn: 0.30 - 0.60

P: max 0.020S: max 0.010

Cr: 8.00 - 9.50Mo: 0.85 - 1.05Ni: max 0.40

V: 0.18 - 1.05Cb: 0.06 - 0.10N: 0.030 - 0.070

Al: max 0.040

X22CrMoV12-1(EN 10269)


Cr: 11.00 - 12.50Mo: 0.80 - 1.20Ni: 0.30 - 0.80V: 0.25 - 0.35

ASTMA 565Gr 616

S42200 C: 0.20 - 0.25Si: max 0.50Mn: 0.50 - 1.00P: max 0.025S: max 0.025

Cr: 11.00 - 12.50Mo: 0.90 - 1.25Ni: 0.50 - 1.00V: 0.20 - 0.30W: 0.90 -1.25

G17CrMo5-5(EN 10213)


Cr: 1.00 - 1.50Mo: 0.45 - 0.65

ASTMA 217Gr WC11

J11872 C: 0.15 - 0.21Si: 0.30 - 0.60Mn: 0.50 - 0.80P: max 0.020S: max 0.015

Cr: 1.00 - 1.50Mo: 0.45 - 0.65Ni: max 0.50V: max 0.03Cu: max 0.35

Al: max 0.01

G17CrMo9-10

(EN 10213)

1.7379 C: 0.13 - 0.20

Si: max 0.60Mn: 0.50 - 0.90P: max 0.020S: max 0.020

Cr: 2.00 - 2.50

Mo: 0.90 - 1.20

ASTM

A 356Gr 10

J22090 C: max 0.20

Si: max 0.60Mn: 0.50 - 0.80P: max 0.035S: max 0.030

Cr: 2.00 - 2.75

Mo: 0.90 - 1.20

G17CrMoV5-10(EN 10213)


Cr: 1.20 - 1.50Mo: 0.90 - 1.10V: 0.20 - 0.30Sn: max 0.025

ASTMA 356Gr 9

J21610 C: max 0.20Si: 0.20 - 0.60Mn: 0.50 - 0.90P: max 0.035S: max 0.030

Cr: 1.00 - 1.50Mo: 0.90 - 1.20V: 0.20 - 0.35

GX12CrMoVNbN9-1(TLV 9263 01)

Notavailable

C: 0.11 - 0.14Si: 0.20 - 0.50Mn: 0.40 - 0.80P: max 0.020S: max 0.010

Cr: 8.00 - 9.50Mo: 0.90 - 1.05Ni: max 0.40V: 0.18 - 0.25Nb: 0.05 - 0.08N: 0.04 - 0.06

Al: max 0.020

ASTMA 217Gr C12A

J84090 C: 0.08 - 0.12Si: 0.20 - 0.50Mn: 0.30 - 0.60P: max 0.020S: max 0.010

Cr: 8.00 - 9.50Mo: 0.85 - 1.05Ni: max 0.40V: 0.18 0.25Cb: 0.06 - 0.10N: 0.030 - 0.070

Al: max 0.040

GS-C25(GP240GH)(EN 10213)


ASTMA 216Gr WCB

J03002 C: max 0.25Si: max 0.60Mn: max 1.20P: max 0.040S: max 0.045


GX5CrNiMo19-11(GX5CrNiMo19-11-2)(EN 10213)


Cr: 18.0 - 20.0Mo: 2.00 - 2.50Ni: 9.0 - 12.0

ASTMA 351Gr CF8M


Cr: 18.0 - 21.0Mo: 2.00 - 3.00Ni: 9.0 - 12.0

GX5CrNiNb19-10(GX5CrNiNb19-11)(EN 10213)


Cr: 18.0 - 20.0Ni: 9.0 - 12.0Nb: 8 x C,

max 1.00

ASTMA 351Gr CF8C


Cr: 18.0 - 21.0Ni: 9.0 - 12.0Cb: 8 x C,

max 1.00

3.6 Weld End Preparations of Turbine Connections and Valve Connections

For butt-welds the weld ends of the turbine connections and valve connections are machinedaccording to either ISO 9692, DIN EN 12627-1 or ASME B16.25 depending on what the contractdefines. However Siemens PG prefers weld end preparations according to ISO 9692 for wallthicknesses above 50 mm (1,968 inch).

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3.7 Weld End Preparations of Adjo ining Pipes

It is the responsibility of the welding company that the weld end of the adjoining pipe matches theweld end of the Siemens PG component in terms of the weld end preparation according to Section3.5, the inner diameter and the wall thickness of the connection.

3.8 Requirements of Post Weld Heat Treatment for pipes smaller 4 in.

In addition to the requirements in the ASME B31.1 Siemens Power Generation requires a postweld heat treatment for pipe connections at steam turbine components with NPS < 4 in. and a wallthickness < 12 mm (0.47 in.).

Siemens PGPower

Generation

Post weld heat t reatment of p ipes < NPS 4 in. and a wallthickness t < 12 mm (0.47 in.)

Post weld heat treatment

Base material 1 Weldingconsumable

Base material2

Wall thickness t

Preheat temperatureTV

Temperature

C (F)

Holding time

Minutes

15 Mo 3,1.5415

A335 P1P 1

BhlerDMO-IG

15 Mo 3,1.5415

A335 P1P 1

> 5 C (41 F)

15 Mo 3,

1.5415A335 P1P 1

Bhler

DMO-IG

13 CrMo 4-4,

1.7335A335 P11,P12P5

t< 8 mm (0.31 in.):

TV > 20 C (68 F)t >= 8 mm (0.31 in.):TV > 150 C (302 F)

580 - 620 C

(1076 1148 F)

30 Minutes

15 Mo 3,1.5415

A335 P1P 1

BhlerDMO-IG

10 CrMo 9-101.7380

A335 P22;P5

t< 8 mm (0.31 in.):TV > 20 C (68 F)

t >= 8 mm (0.31 in.): TV > 200 C (392 F)

620 - 660 C(1148 1220 F)

30 Minutes

13 CrMo 4-4,1.7335

A335 P11, P12;P5

BhlerDCMS-IG

13 CrMo 4-4,1.7335

A335 P 11,P12;P5

t< 8 mm (0.31 in.):TV > 20 C (68 F)

t >= 8 mm (0.31 in.):TV > 150 C (302 F)

600 - 700 C(1112 1292 F)

30 Minutes

13 CrMo 4-4,1.7335

A335 P11, P12;P5

BhlerCM2-IG

10 CrMo 9-101.7380

A335 P22;P5

t< 8 mm (0.31 in.):TV > 20 C (68 F)

t >= 8 mm (0.31 in.):TV > 200 C (392 F)

660 - 700 C(1220 1292 F)

30 Minutes

10 CrMo 9-101.7380

A335 P22P5

BhlerCM2-IG

10 CrMo 9-101.7380

A335 P22P5

t< 8 mm (0.31 in.):TV > 20 C (68 F)

t >= 8 mm (0.31 in.):TV > 200 C (392 F)

680 - 720 C(1256 1328 F)

t< 8 mm (0.31 in.):30 Minutes

t >= 8 mm (0.31 in.):60 Minutes

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3.9 Selection of Heat Treatment Temperature

The selection of the heat-treat temperature falls within the responsibility of the company or thecontractor who is doing the welding. However the limitations given in this section must be compliedwith.

For welds that require heat treatment, the heat-treatment-temperature range must be between5C and 25 C (9 F and 45 F) below the last tempering temperature last of the Siemens PGcomponent. Note that temperature differences in C are converted to temperature differences in F

according to the formula F = 9/5.C whereas temperatures in C are converted to F according to

F=9/5. C+32.

Example:

Last tempering temperature: last= 720C; (1328F)

Heat-treatment-temperature range: = 720C - 25C to 720C - 5C = 695C to 715C

Same computation in F: = 1328 F 45 F to 1328 F 9 F = 1283 F to 1319 F

In order to guarantee that for local heat-treatments of the components a sufficient annealingtemperature range will be achieved at the outer and inner surface, the higher temperature of the

heat-treatment-temperature range must be reached at the outer surface.

The last tempering temperature lastof each Siemens PG component with its respective welds isorder-specific and is given in transmittal xxxxx-980135 for each Siemens PG component.

3.10 Selection of Heat Treatment Time

The selection of the proper heat-treatment time falls within the responsibility of the weldingcompany. However the limitations given in this section must be complied with.

The tempering time correlates with the pipe wall thickness and the materials (base material andwelding consumables). The tempering time of the weld must be chosen such that under nocircumstances the mechanical properties of the Siemens PG component are affected.

The welding company must include all details of the heat treatment in the Welding ProcedureApproval Records (WPAR) or in the Procedure Qualification Records (PQR), see Section 3.2, forfuture reference.

3.11 Quality Control

It is the responsibility of the welding company to apply ISO 9001 or an equivalent standard forquality assurance.

4 Weld between two components supplied by Siemens PG

Welds between two components supplied by Siemens PG, e.g. main-steam valve and turbinecasing, are covered in this section. The welds belonging to this category are marked accordingly inthe turbine piping connection list xxxxx-980133.

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4.1 Welding Procedure Specification

A welding procedure specification is issued by the welding company for each weld of a SiemensPG components for which welding is carried out on site. The welding company must strictly followthese welding procedure specifications. The selection of the heat treatment temperature and theheat treatment time must be performed according to Section 3.8 and 3.9.

Welding procedure specifications are required to be submitted to Siemens PG for technical reviewa minimum of one month prior to starting any welds covered by this section. The specificationsmust be provided in German and English languages or in a national language and English.Siemens PG reserves the right to check the welding procedure specifications for correctness andcompleteness and, if need arises, make alterations. Where technical concerns exist with thesubmitted procedure, Siemens reserves the right to request welding procedure changes to ensurelong-term reliable operation of Siemens supplied equipment.

4.2 Welding Coordination

Companies must fulfill the requirements of EN 719 and EN 729 or equivalent standards. All

welding carried out on site must be supervised by a welding specialist who has passed weldingexaminations according to DVS regulations or according to similar standards such as ASME, AWSor IIW. The welding specialist is responsible for all welding to be carried out according to thewelding procedure specifications and pertinent specifications. His responsibilities include but arenot limited to:

to supervise and review skill tests,

to check all welds,

to assign welders to their particular work according to their qualifications,

to look after proper application of filler metals and to make sure that they have been dried

according to standard regulations, to check preparatory work for all kinds of welding seams,

to supervise heat treatment,

to keep a list of all welders,

to make sure that all weld are tested by a non-destructive method after completion.

4.3 Non-Destruct ive Testing for Welds between two Components supplied bySiemens PG

The Non-destructive testing of the welds must be performed according to Siemens PG drawingsand Test Specification PV 0026.0-00000 entitled Non-Destructive Examination of Welded Joints.

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5 Non-Destruct ive Testing for all Welds within the Lubricating and Lifting Oil(MAV) and Control Fluid (MAX) Systems

Siemens PG S requires a NDT for all welds within the Lubricating and Lifting Oil (MAV) andControl Fluid (MAX) Systems. The NDT must be performed according to following table.

The tables based on the Siemens Test Specification PV 0026.0-00000-11 and the VGB Guideline

VGB-R503M.

In table 1a the serial number must be chosen according to the operating pressure and nominaldiameter. In table 1b the required extend and type of testing for the serial number is given.

Table 1a: Selection of serial number:

Serialno.

Exam.grade 1)

Type of weldor part

Operating pressure(gauge)

Loadtransmission

Nominaldiameter

Serialno.

1 St.p 2.5 bar

p (36 PSI)- 1

2 3

DN 20

(NPS 0.75) 2

3 4

2.5 bar p 16 bar

(36 PSI < p 232 PSI) DN > 20

(NPS > 0.75)3

4 1DN 20

(NPS 0.75)4

5 1

Circ. Weldand long

welds

p > 16 bar

(p > 232 PSI) DN 20

(NPS 0.75)5

6 STp 2.5 bar

p (36 PSI)- 6

7 42.5 bar p 16 bar

(36 PSI < p 232 PSI)- 7

8 1

Nipples andnozzles

p > 16 bar

(p > 232 PSI)- 8

9 St. without - 9

10 4

p 2.5 bar

p (36 PSI) with - 10

11 St. without - 11

12 2

2.5 bar < p 16 bar

(36 PSI < p 232 PSI) with - 12

13 4 without - 13

14 1

Weld-on-parts

(fillet anddouble-bevel

groovewelds) p > 16 bar

(p > 232 PSI) with - 14

1)1 = 100%; 2 = 50%; 3 = 25%; 4 = 10%; 5 = 5%; St. = random test < 5%

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Table 1b: Required minimum extent of welding inspection

Serialno.

Quality level acc. toDIN EN 25817

Minimum extent of inspectionSerial

no.

RT in % 2) UT in % 2) SCE in % 2) HT 2)

1 B St. 6) - St. 6) - 1

2 B - - 25 3) 2

3 B 10 - 10 3) 3

4 B - - 100 4) 4

5 B 100 - 100 4) 5

6 B - 5) St. - 6

7 B - 5) 10 3) 7

8 B - 5) 100 4) 8

9 B - 5) St. - 9

10 B - 5) 10 - 10

11 B - 5) St. 3) 11

12 B - 5) 50 3) 12

13 B - 5) 10 4) 13

14 B - 5) 100 4) 142)

SCE = Surface crack examination

RT = Radiographic test

UT = Ultrasonic test

HT = Hardness test

3)10% hardness testing for 13CrMo4-5 and 10CrMo9-10 (ASTM A335 P11, P12 and P22)

4)25% hardness testing for 13CrMo4-5 (ASTM A335 P11, P12)

50% hardness testing for 10CrMo9-10 (ASTM A335 P22)

5)For nipples, nozzles and weld-on-parts with wall thickness < 15 mm, I addition to the surface crack examination an

ultrasonic examination must be performed with the same extent of examination.

6)Either RT/ UT or SCE

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5.1 Hardness Examination for welding joints

5.1.1 Scope

5.1.2

5.1.3

This test specification governs the procedure for performing mobile hardness tests and applies to metalssubjected to tempering after welding. The materials to be tested are listed in Table 1. Hardness testing isperformed on the base metal (BM) in the heat affected zone (HAZ) and in the weld metal (WM). Where

induction or resistance annealing has been performed on pipe circumferential welds DN 500 mm (NPS 20in.) hardness must be measured at two locations spaced 180 apart. No hardness tests are performed on

pipes and nozzles with outside diameters 76.1 mm and wall thicknesses t 5 mm or on fillet welds andseal welds.

Representative welds are to be tested in each annealing lot. At least one weld is to be tested. An annealinglot is understood to be individual welds or several welds subjected to common post-weld heat treatment in asingle batch and under the same conditions.

Methods to be Used

Portable hardness testing equipment is used which provides reproducible results. (e.g. Equotip, Microdur,Computest). The permissible wall thicknesses and the test method are in to be line with the instructions of

the equipment manufacturer.For hardness tests on dissimilar metal welds with austenitic weld metal, hardness is to be tested on theferritic heat-affected zone and the ferritic base metal. This can also be tested using Equotip.

Permiss ible Hardness Values

The hardness limits for similar-metal, heat-treated welds are given in the following table.

Table 1 Vickers Hardness Values

Mat. No EN-Material ASTM Material HV 10Max.

HAZ, WM

HV 10Min.BM

1.7335 13CrMo4-4 ASTM A335 P11, P12 320 110

1.7380 10CrMo9-10 ASTM A335 P22 320 120

5.1.4

5.1.5

Personnel Qualification

Employees may only perform hardness tests with portable testing equipment if they have been trained in itsuse. Quality assurance personnel are responsible for manual hardness testing performed in line with thistest specification to provide verification of weld quality.

Test method

The following methods may be used:

- Rebound hardness test using the Equo Hardness Testing System (Equotip)

- Hardness test using ultrasonic contact impedance (e.g. Microdur 2, Microdur 10)

- Rockwell hardness test (Computest)

The stipulations in the operating instructions must be observed when selecting the method for andperforming hardness tests. The equipment must be checked in line with the manufacturer's checkinginstructions.

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5.1.6

5.1.7

Preparing the Examination Surface

Testing is performed on a smooth, plane surface which must be free of scale and foreign particles and, mostimportantly, free of lubricants. The surface quality of the area for testing must be such as to allow accuratetesting.

As the diagonal of indentation (with HV 1 for standard metallic material around 0.05 to 0.12 mm) can be atthe micro/macro transition range depending on material structure and the hardness of the test specimen, a

very fine-ground surface (Rz 1 maximum) is absolutely essential for precise results. However considerationmust be given to the fact that measured values may be adulterated by any decarburization of the surfacefollowing heat treatment in an oxidizing atmosphere or increased hardness of abrasively-cleaned surfaces. Itis therefore recommended that the area for testing is roughly pre-ground to remove the affected surfacelayer.

Examination Report

The hardness value to be recorded must represent a mean value from at least three individual tests. Theresults obtained are to be entered in a test record .