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1、MANUAL WELDING OF METALS DEP 30.10.60.18-Gen. October 1995 DESIGN AND ENGINEERING PRACTICE This document is confidential. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of Shell International Oil Products B.V. and Shell Internati
2、onal Exploration and Production B.V., The Hague, The Netherlands. The copyright of this document is vested in these companies. All rights reserved. Neither the whole nor any part of this document may be reproduced, stored in any retrieval system or transmitted in any form or by any means (electronic
3、, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owners. PREFACE DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of: Shell International Oil Products B.V. (SIOP) and Shell International Exploratio
4、n and Production B.V. (SIEP) and Shell International Chemicals B.V. (SIC) The Hague, The Netherlands, and other Service Companies. They are based on the experience acquired during their involvement with the design, construction, operation and maintenance of processing units and facilities, and they
5、are supplemented with the experience of Group Operating companies. Where appropriate they are based on, or reference is made to, national and international standards and codes of practice. The objective is to set the recommended standard for good design and engineering practice applied by Group comp
6、anies operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such facility, and thereby to achieve maximum technical and economic benefit from standardization. The information set forth in these publications is provided to users for their
7、consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual operating companies to adapt the information set forth in DE
8、Ps to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Princip
9、al will expect them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal or its technical advisor. Th
10、e right to use DEPs is granted by SIOP, SIEP or SIC, in most cases under Service Agreements primarily with companies of the Royal Dutch/Shell Group and other companies receiving technical advice and services from SIOP, SIEP or SIC. Consequently, three categories of users of DEPs can be distinguished
11、: 1)Operating companies having a Service Agreement with SIOP, SIEP, SIC or other Service Company. The use of DEPs by these Operating companies is subject in all respects to the terms and conditions of the relevant Service Agreement. 2)Other parties who are authorized to use DEPs subject to appropria
12、te contractual arrangements. 3)Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards. Su
13、bject to any particular terms and conditions as may be set forth in specific agreements with users, SIOP, SIEP and SIC disclaim any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, app
14、lication or implementation of any DEP, combination of DEPs or any part thereof. The benefit of this disclaimer shall inure in all respects to SIOP, SIEP, SIC and/or any company affiliated to these companies that may issue DEPs or require the use of DEPs. Without prejudice to any specific terms in re
15、spect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of SIOP and SIEP, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose for which they have been provided to the user. They s
16、hall be returned after use, including any copies which shall only be made by users with the express prior written consent of SIOP and SIEP. The copyright of DEPs vests in SIOP and SIEP. Users shall arrange for DEPs to be held in safe custody and SIOP or SIEP may at any time require information satis
17、factory to them in order to ascertain how users implement this requirement. All administrative queries should be directed to the DEP Administrator in SIOP. NOTE: In addition to DEP publications there are Standard Specifications and Draft DEPs for Development (DDDs). DDDs generally introduce new proc
18、edures or techniques that will probably need updating as further experience develops during their use. The above requirements for distribution and use of DEPs are also applicable to Standard Specifications and DDDs. Standard Specifications and DDDs will gradually be replaced by DEPs. DEP 30.10.60.18
19、-Gen. October 1995 Page 2 TABLE OF CONTENTS 1.INTRODUCTION.4 1.1SCOPE 4 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS4 1.3DEFINITIONS AND ABBREVIATIONS.4 1.4CROSS-REFERENCES5 2.GENERAL WELDING GUIDELINES6 2.1INTRODUCTION.6 2.2WELDING QUALIFICATIONS.7 2.3SHIELDING GASES FOR WELDING AND
20、CUTTING .9 2.4WELDING CONSUMABLES.12 2.5WELDING 13 3.HARDNESS REQUIREMENTS15 4.PREHEAT AND POST-WELD HEAT TREATMENT16 4.1GENERAL REQUIREMENTS.16 4.2PREHEAT REQUIREMENTS16 4.3POST-WELD HEAT TREATMENT (PWHT).17 4.4THERMOCOUPLES18 4.5REPAIR/MODIFICATIONS19 5.GUIDELINES FOR THE WELDING OF SPECIFIC MATER
21、IALS20 5.1CARBON AND CARBON-MANGANESE STEELS.20 5.25% AND 9% NICKEL STEELS22 5.30.3% AND 0.5% MOLYBDENUM STEELS.23 5.4LOW-ALLOY CHROMIUM-MOLYBDENUM STEELS24 5.5STAINLESS STEELS26 5.6NICKEL AND NICKEL ALLOYS30 5.7ALUMINIUM AND ALUMINIUM ALLOYS33 5.8COPPER AND COPPER ALLOYS35 5.9TITANIUM, ZIRCONIUM AN
22、D TANTALUM36 5.10CAST IRON. 38 6.GUIDELINES FOR THE WELDING OF SPECIAL COMBINATIONS40 6.1STRIP LINING AND CLAD STEELS.40 6.2DISSIMILAR METALS.45 6.3WELDING OF TUBES TO TUBE SHEETS48 7.REFERENCES51 APPENDICES APPENDIX 1STANDARD AND SPECIAL QUALITY TUBE TO TUBE SHEET JOINTS 53 APPENDIX 2EXAMINATION OF
23、 WELDING QUALIFICATION TEST PIECES FOR TUBE TO TUBE SHEET JOINTS57 APPENDIX 3ALTERNATIVE WELD STRENGTH TEST RIGS58 DEP 30.10.60.18-Gen. October 1995 Page 3 1.INTRODUCTION 1.1SCOPE This DEP specifies requirements and gives recommendations for welding of steels and non- ferrous metals. It is a revisio
24、n of an earlier publication with the same number, dated August 1986. This DEP does not give detailed technical specifications for weld preparations, welding procedures, etc. For such information use can be made of commercially available systems, such as the software application “WPSelect“ published
25、by the Netherlands Welding Institute (see Section 7). 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorised by SIOP and SIEP, the distribution of this DEP is confined to companies forming part of or managed by the Royal Dutch/Shell Group. It may be distributed to Ma
26、nufacturers/Suppliers nominated by them (i.e. the distribution code is “F“, as defined in DEP 00.00.05.05-Gen.). This DEP is intended for use in oil refineries, chemical plants, gas plants, exploration and production facilities and supply and marketing installations. If national and/or local regulat
27、ions exist in which some of the requirements may be more stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable as regards safety, economic and legal aspects. In all case
28、s the Contractor shall inform the Principal of any deviation from the requirements of this document which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned with the object of obtaining agreement to
29、 follow this document as closely as possible. 1.3DEFINITIONS AND ABBREVIATIONS 1.3.1General definitions The Contractor is the party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility. The Principal
30、may undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party which manufactures or supplies equipment and services to perform the duties specified by the Contractor. The Principal is the party which initiates the project and ultimately pays for its design and con
31、struction. The Principal will generally specify the technical requirements. The Principal may also include an agent or consultant authorised to act for, and on behalf of, the Principal. The word shall indicates a requirement. The word should indicates a recommendation. DEP 30.10.60.18-Gen. October 1
32、995 Page 4 1.3.2Specific definitions and abbreviations Design code:The code or standard specified by the Principal to which the equipment or piping shall conform. High-alloy steel:Stainless steels, 12 Cr and higher Low-alloy steel:Steels from 0.5 Mo up to 9Cr-1Mo Steels from 0.5 up to 9% Ni Unalloye
33、d steel:Carbon manganese steels, including 0.3 and 0.5 Mo steels AWSAmerican Welding Society BSBritish Standard CeqCarbon equivalent DSSDuplex Stainless Steel EBWElectron Beam Welding ERWElectric Resistance Welding ESWElectro Slag Welding FCAWFlux cored Arc Welding FWFriction Welding GMAWGas Metal A
34、rc Welding GMAW PPulsed Arc Welding GMAW SShort-Circuit Arc Welding GMAW STSpray Transfer GTAWGas Tungsten Arc Welding GTAW-PPulsed Arc Welding GTAW-HWHot Wire Welding GWGravity Welding HAZHeat Affected Zone LBMLaser Beam Welding MTMagnetic Particle Inspection NDENon Destructive Examination OFWOxy F
35、uel Gas Welding PAWPlasma Arc Welding PQRProcedure qualification Record PTLiquid Penetrant Inspection PWHTPost Weld Heat Treatment SAWSub-merged Arc Welding SMAWShielded Metal Arc Welding SSStainless Steel UTSUltimate Tensile Strength WPSWelding Procedure Specification 1.4CROSS-REFERENCES Where cros
36、s-references to other parts of this DEP are made, the referenced section number is shown in brackets. Other documents referenced in this DEP are listed in (7). DEP 30.10.60.18-Gen. October 1995 Page 5 2.GENERAL WELDING GUIDELINES 2.1INTRODUCTION In this section general information is given on qualif
37、ications, welding processes and welding methods. DEP 30.10.60.18-Gen. October 1995 Page 6 2.2WELDING QUALIFICATIONS 2.2.1General All welding consumables shall have specified or actual mechanical properties equal to or greater than the material being welded, unless otherwise specified. No production
38、welding shall be carried out until welding procedures and welders are qualified according to the design code and this DEP and approved by the Principal. 2.2.2Welding procedure qualification Welding procedures shall be qualified before performance qualification of welders. Welding procedure specifica
39、tions together with their qualifications shall be subject to review by the Principal. It is the Manufacturers responsibility to ensure that welding operations are carried out in accordance with the parameters as specified on the qualified WPS. Irrespective of the design code, under the following con
40、ditions the welding procedure qualification shall be requalified: Joints -A change from double sided to single sided welding, but not the converse; -a decrease in welding groove angle of more than 10 degrees. Consumables -Any change of consumable classification; -any change in consumable brand name
41、when corrosion testing or impact testing is required; -any change in size of consumable in the root run of single sided welds. Welding position -Change in welding direction (vertical up to vertical down welding or vice versa). 2.2.3Welder performance qualifications Welder performance qualification t
42、esting shall be carried out in accordance with the design code and/or as specified by the Principal. 2.2.4Welding documentation Welding Procedure Specification Qualified procedures in the Manufacturers own format are acceptable provided the information presented contains all the essential and supple
43、mentary essential variables listed in the design code and this DEP. Welder Qualifications In order to maintain the validation of approval qualification, a welder performance register should be kept up-to-date by the Manufacturer. This register should at least contain the following data: -Welders nam
44、e and stamp; -Weld position and X-ray number; -Data of weld inspection and weld result; -Materials (base and consumable); -Configuration data (diameter, wall thickness etc.); -Reference to welding procedure specification used; -All other essential variables. 2.2.5Welding process restrictions For som
45、e welding processes restrictions exist. DEP 30.10.60.18-Gen. October 1995 Page 7 2.2.5.1OFW OFW may be used only if all of the following are satisfied: -base material is carbon or carbon-manganese steel; -UTS 250 mm, electrical heating or heating by means of infra-red or ringburners (sulphur-free fu
46、el) is required. Specifically designed heating nozzles and torches shall be used; cutting torches shall not be used. Oxy-acetylene preheating shall not be applied. An even temperature distribution shall be achieved. Temperature control can be carried out with temperature sensitive crayons, digital p
47、yrometers, contact thermometers or calibrated thermocouples. DEP 30.10.60.18-Gen. October 1995 Page 16 The width of the heated zone shall be as shown below. If electric resistance elements are used, insulation shall be applied with a width as shown below. t = nominal wall thickness of the pipe. The
48、weld shall be completed before the preheat temperature is lowered, except that intermediate lowering of preheat temperature is permitted for unalloyed steels if at least 50% of the weld has been completed. The joint shall be cooled under insulation. Preheating shall be restored to the specified temp
49、erature and maintained for 30 minutes before welding is recommenced. 4.3POST-WELD HEAT TREATMENT (PWHT) PWHT temperature ranges and holding times for various materials shall be in accordance with the design code. The following rules also apply: 1.PWHT may be required for Ceq 0.45 or C 0.23 depending on the application and the hardness requirements. 2.For optimum high temperature creep properties, the lower side of the temperature range is normally used. 3.For 0.3-0.5% Mo steels in hydrogen service, PWHT is required irrespective of the wall thickness. 4.For maximum softening the higher s