Which types of materials does SAES-W-016 cover?

SAES-W-016 specifically addresses the welding and testing requirements for special corrosion-resistant piping materials, including stainless steel (excluding types 304/304L/316/316L), nickel-based alloys, and duplex stainless steels. These materials are used in severe corrosion service and high-temperature service applications.

What is considered severe corrosion service?

Severe corrosion service, as defined in SAES-L-032, includes any service where austenitic stainless steel (excluding types 304/304L/316/316L), nickel-based alloys, or duplex stainless steels are specified. This covers applications where the materials are exposed to highly corrosive environments.

How does the standard define high-temperature service?

High-temperature service refers to any application with a design temperature above 427°C. The standard provides specific requirements for welding and testing materials in these high-temperature environments.

Does SAES-W-016 cover strip lining and weld overlay applications?

No, SAES-W-016 does not cover strip lining and weld overlay applications. For such requirements, separate standards should be referenced. SAES-W-014 addresses overlays, while SAES-W-015 covers strip lining.

Are there any additional considerations when using this standard?

When referring to SAES-W-016, it is important to note that it serves as a supplement to SAES-W-011. If other applications, such as vessels, heat exchangers, valves, or pumps, refer to this standard, they may also need to adhere to its requirements. The requirements of ASME SEC IX for welding and brazing qualifications are in addition to the requirements of SAES-W-016.

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SAES-W-016 PDF Download

SAES-W-016

Welding of Special Corrosion-Resistant Materials [SAES-W-016]

The SAES-W-016 standard provides specific requirements for welding and testing special corrosion-resistant piping materials, including stainless steel and nickel-based alloys, in severe corrosion service and high-temperature service. Here are some key points from the standard:

Severe corrosion service includes any service listed in SAES-L-032 that specifies the use of austenitic stainless steel (excluding types 304/304L/316/316L) or nickel-based alloys. It also includes any service that uses duplex stainless steels.
High-temperature service is defined as any application with a design temperature above 427°C.
The standard does not cover strip lining and weld overlay applications. For such requirements, refer to SAES-W-014 for overlays and SAES-W-015 for strip lining.
The standard serves as a supplement to SAES-W-011. If other applications such as vessels, heat exchangers, valves, or pumps refer to this standard, they may also be subject to its requirements.
The requirements of ASME SEC IX (Welding and Brazing Qualifications) are in addition to the requirements of this standard.
The entire standard can be attached to and made a part of purchase orders. Additional requirements may be specified in Scopes of Work, Drawings, or other Instructions or Specifications related to the specific work items.
When the standard mentions Consulting Services Department (CSD), it refers to the CSD Welding Specialist or a representative designated by CSD who can provide further guidance and interpretation.

This standard aims to ensure the appropriate welding and testing of special corrosion-resistant piping materials in severe corrosion service and high-temperature service, providing guidelines for maintaining the integrity and performance of the piping systems.

General Points About Welding of Special Corrosion-Resistant Materials

Here are some additional general points from the SAES-W-016 standard:

4.1 Welding procedures used must be qualified in accordance with ASME SEC IX, and they must also meet the additional requirements specified in SAES-W-011 and SAES-W-016.

4.2 Ferrite measurements, which are used to determine the ferrite content in stainless steel welds, should be performed following the guidelines of AWS A4.2.

4.3 When working with carbon steel or stainless steel materials, abrasive tooling and grinding disks should not have been used. The selection of grinding and cleaning tools should be appropriate for the base material being worked on. For example, carbon steel brushes should not be used on stainless steel materials to prevent contamination or damage.

4.4 All filler materials used in the welding process should be clearly marked or labeled for traceability and correct usage on the site. This ensures that the correct filler materials are used and that their origin can be identified if needed.

These requirements contribute to the quality, integrity, and proper handling of welding procedures, as well as ensuring compatibility between materials and preventing contamination or damage during the welding process.

High Temperature Applications

In high-temperature applications, the SAES-W-016 standard specifies the following requirements:

5.1 The welding procedure qualification for austenitic stainless steels (excluding type 310) must include a determination of the Ferrite Number (FN) in the as-welded condition. The Ferrite Number should be between 3 and 10 FN. This test helps ensure the appropriate ferrite content in the weld, which affects the mechanical and corrosion properties of the stainless steel.

5.2 For production welds in high-temperature applications, the ferrite content must be checked in the as-welded condition. The Ferrite Number should be between 3 and 10 FN. This check ensures that the ferrite content remains within the specified range and maintains the desired properties of the stainless steel welds.

5.3 If welding is required on high carbon grades of austenitic stainless steel material (such as 304H or HK40) after the equipment has been in service for more than 1 year, a re-solution heat treatment is necessary prior to welding. This heat treatment helps restore the material’s microstructure and mechanical properties, ensuring the integrity of the weld joint.

These requirements are important for maintaining the structural integrity and corrosion resistance of austenitic stainless steels in high-temperature service conditions. Proper ferrite content and pre-weld heat treatments are essential to ensure the desired performance of the welded components.

Corrosive Services

In corrosive services, the SAES-W-016 standard specifies the following requirements:

6.1 The Gas Tungsten Arc Welding (GTAW) process shall be used in the following applications:
1) The root pass of single-sided groove welds without backing.
2) All passes for piping, tubes, and nozzles with a nominal diameter of 2 inches or less.
3) All passes for wall thickness less than 9.5 mm for duplex stainless steel or less than 6.5 mm for other Corrosion Resistant Alloys (CRA).

6.2 All manual GTAW welding shall utilize a high frequency start and post-purge gas flow for the torch. A remote contractor and current control (pedal or torch mounted) is required. Alternatively, pre-set power source current start/rise and decay/stop controls triggered by a foot switch or torch mounted control can be used as an acceptable alternative for remote control.

6.3 For all GTAW welding, filler metal must be added. Autogenous welding (welding without filler metal) of any pass is not permitted. The filler metal selection should follow the guidelines provided in Table 1.

6.4 The maximum interpass temperature, which is the temperature between subsequent welding passes, shall not exceed 100°C to prevent excessive heat-related issues.

6.5 Backing gas and purging play a crucial role in maintaining the integrity of the weld joint in corrosive services. The purge times for the backing gas shall be calculated to achieve a theoretical volume change of 6 times the enclosed pipe volume. Table 2 provides information and standard conditions for purge times. Additional purging time may be necessary if the purge gas inlet and outlet cannot be placed at opposite ends of the enclosed volume, ensuring complete displacement of original air.

The purge shall achieve actual oxygen levels inside or exiting the joint, via the vent, not exceeding 1% prior to and during welding. Oxygen levels shall be measured using an oxygen analyzer. Periodic measurements should be conducted during production to ensure the desired oxygen levels are maintained. If excessive internal oxidation is observed based on the visual appearance of the oxide tint, analyzers shall be used for all joints. During pre-weld purging, the joint area must be adequately sealed at all openings to maintain the purge and prevent air ingress.

If purge dams are used but cannot be retrieved after welding, proprietary dissolvable (water-soluble) dams should be employed to ensure their easy removal.

These requirements are crucial for maintaining the corrosion resistance and integrity of welds in corrosive service conditions. Proper welding procedures, filler material selection, purging techniques, and interpass temperature control help ensure the desired performance and longevity of the weld joints.

FAQs about SAES-W-016 PDF Download

Which types of materials does SAES-W-016 cover?

SAES-W-016 specifically addresses the welding and testing requirements for special corrosion-resistant piping materials, including stainless steel (excluding types 304/304L/316/316L), nickel-based alloys, and duplex stainless steels. These materials are used in severe corrosion service and high-temperature service applications.
What is considered severe corrosion service?

Severe corrosion service, as defined in SAES-L-032, includes any service where austenitic stainless steel (excluding types 304/304L/316/316L), nickel-based alloys, or duplex stainless steels are specified. This covers applications where the materials are exposed to highly corrosive environments.
How does the standard define high-temperature service?

High-temperature service refers to any application with a design temperature above 427°C. The standard provides specific requirements for welding and testing materials in these high-temperature environments.
Does SAES-W-016 cover strip lining and weld overlay applications?

No, SAES-W-016 does not cover strip lining and weld overlay applications. For such requirements, separate standards should be referenced. SAES-W-014 addresses overlays, while SAES-W-015 covers strip lining.
Are there any additional considerations when using this standard?

When referring to SAES-W-016, it is important to note that it serves as a supplement to SAES-W-011. If other applications, such as vessels, heat exchangers, valves, or pumps, refer to this standard, they may also need to adhere to its requirements. The requirements of ASME SEC IX for welding and brazing qualifications are in addition to the requirements of SAES-W-016.

SAES-W-016 PDF – Welding of Special Corrosion-Resistant Materials