Approved: WPS No.

: GEN
Revision Date: August 1, 2000 Revision No.: 11

1.0 SCOPE

1.1 This General Welding Specification (GEN) addresses certain essential and
nonessential welding variables and supplemental information common to the
specific Welding Procedure Specifications (WPSs).

1.2 This specification shall be used in conjunction with all WPSs of The Shaw
Group, Inc.

1.3 WPSs are qualified per the requirements of ASME Section IX. However, WPSs
and their supporting Procedure Qualification Records (PQRs) will be enhanced,
where required, to comply with the added qualification and fabrication
requirements of the various construction codes (e.g. ASME Section III, B31.1,
B31.3, etc.).

1.4 Previously qualified WPS and PQRs of all companies acquired by The Shaw
Group, Inc., shall become the property of The Shaw Group, Inc. These WPS and
PQRs may be used by all companies owned by The Shaw Group, Inc., providing
the following requirements are met:

1.4.1 WPS/PQR are reviewed in accordance with ASME Section IX.

1.4.2 All information is transferred to The Shaw Group format.
1.4.3 The revised WPS reflects the name of The Shaw Group, Inc.
1.4.4 The PQR reflects both The Shaw Group, Inc. and the manufacturer or
contractor acquired by The Shaw Group, Inc.
1.4.5 The revised procedure is certified by The Shaw Group, Inc.

1.5 Companies of The Shaw Group, Inc., shall forward all new WPS and PQRs to
The Shaw Group Quality Assurance Manager. The Quality Assurance Manager
will make controlled distribution to companies within The Shaw Group as
appropriate.

2.0 WELDING PROCESSES

2.1 Welding Procedure Specifications shall list the welding process(es) to be used.

2.2 Generally, the Shaw Group WPSs are single process procedures that can be
combined for multi-process applications.

3.0 JOINTS (QW-402)

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 3.1 The various groove designs permitted for WPSs shall be as shown in Appendix
A. The special joint preparation for production welds shall be as specified in Job
Instructions and/or drawings.

3.2 Clamps, welded clips, lugs, tack welds, or other appropriate means shall be used
to properly align joints for welding.

3.2.1 Welded attachments used for fit-up shall be compatible with the base
materials, except that low alloy steels may have carbon steel attachments
welded with electrodes compatible with the base material. Austentitic
stainless steels may have carbon steel attachments provided the welding is
performed with austenitic filler material.

3.2.2 The attachments may be removed by any suitable method that does not
cause gouges in the base metal, followed by grinding flush with the
contour of the part. When thermal cutting is used to remove attachments,
at least 1/8 inch shall be left for finish removal by grinding and the ground
area shall be visually examined for defects. Any defects found shall be
removed by grinding and rewelded by an approved WPS.

3.2.3 Preheat for tack welding shall be performed in accordance with Section
7.0.

3.3 The use of non-metallic retainers and non-fusing metal retainers is not allowed,
unless otherwise specified in the WPS.

3.4 Backing rings shall not be used, unless otherwise specified in the WPS. When
specified backing rings shall be compatible with the base material. The sulphur
content of backing rings for ferrous materials shall not exceed 0.05%.

3.5 Root gaps for fitup shall be as shown in Appendix B.

4.0 BASE METALS (QW-403)

4.1 Only base metals referenced in the WPS may be welded with that WPS.

4.2 Consult Quality Control Manager and/or Welding Engineer for base metals and
combinations of base metals not found in published WPSs.

4.3 Each WPS specifies the allowable base metal thickness range applicable for that
WPS.

5.0 FILLER METALS (QW-404)

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 5.1 The filler metals specified in the WPSs have been chosen so as to provide
deposited weld metal which is compatible with the base metal(s) from the
standpoint of metallurgical properties, postweld heat treatment, design and service
requirements, and mechanical properties.

5.2 Filler metal shall be added during each weld pass for all processes, unless
otherwise specified in the WPS.

5.3 No supplementary filler metals shall be used.

5.4 No supplementary powdered filler metals shall be used.

5.5 Submerged arc welding fluxes shall be essentially neutral. That is, the allowable
content of the weld metal shall not be largely dependent upon the composition of
the flux used.

5.6 The brand name of submerged arc welding fluxes shall be shown in the WPS.

5.7 Maximum electrode diameters for filler metal shall be as specified in the WPS.

6.0 POSITIONS (QW-405)

6.1 Each WPS shall specify the allowable welding positions.

6.2 The special position commonly called Top Quarter (TQ) may be used when that
position or all positions is specified in the WPS. The top quarter position is
defined as follows:

6.2.1 The joint to be welded is oriented such that the pipe joint axis is in the
stationary, horizontal position. Welding is performed on each of the two
top quadrants of the weld joint. Then the pipe joint is rotated 180 degrees
and welding once again is performed in the two top quadrants. The
welding progression (uphill or downhill) shall be as specified in the WPS.
All tie-ins shall be feathered and staggered. The welding shall be balanced
throughout the joint rather than completing individual joint segments.

7.0 PREHEAT (QW-406)

7.1 Definitions:

7.1.1 Preheat Temperature the minimum temperature in the weld joint

preparation immediately prior to deposition of weld metal, or in the case
of multiple pass welds, the minimum temperature of the previously
deposited weld metal immediately before the next pass is deposited.

7.1.2 Preheating the application of heat to the base metal immediately before a
welding or cutting operation.

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 7.1.3 Interpass Temperature the highest allowable temperature of the
previously deposited weld metal immediately before the next pass is
deposited, as measured within a distance of 1 to 2 from the original
beveled joint.

7.2 The minimum required preheat temperature for all materials shall be 50F unless
a higher preheat temperature is stated below, in the applicable Job Instructions, or
in the applicable Welding Procedure Specification.

7.3 ASME Section I & VIII, & B31.1:

7.3.1 P-No. 1, Group No. 1, 2, 3:

175F for material which has both a specified maximum carbon content in
excess of 0.30% and a thickness at the joint in excess of 1.

7.3.2 P-No. 3, Group No. 1, 2, 3:

175F for material which has either a specified minimum tensile strength
in excess of 70,000* psi or a thickness at the joint in excess of 5/8*.
*60,000 psi and thickness for B31.1.

200F when the nominal thickness is or less and the nominal thickness
of either of the base metals exceeds 1 and the weld is not Post Weld Heat
Treated.

7.3.3 P-No. 4, Group No. 1, 2:

250F for all materials.

7.3.4 P-No. 5A, B, C:

400F for material which as either a specified minimum tensile strength in

excess of 60,000 psi or has both a specified minimum chromium content
above 6.0% and a thickness at the joint in excess of .

300F for all other materials in the grouping.

7.3.5 The base metal temperature prior to welding shall be at or above the
specified minimum temperature in all directions from the point of welding
for a distance of 3 or 1.5 times the base metal thickness, whichever is
greatest.

7.4 ASME B31.3

7.4.1 P-No. 1, Group No. 1, 2, 3:

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 175F for material which has a thickness at the joint equal to or in excess
of 1 and all thicknesses of material with a specified tensile strength
greater than 71,000 psi.

7.4.2 P-No. 3, Group No. 1, 2, 3:

175F for material which has a thickness at the joint equal to or in excess
of and all thicknesses of material with a specified tensile strength
greater than 71,000 psi.

7.4.3 P-No. 4, Group No. 1, 2:

300F

7.4.4 P-No. 5A, B, C:

350F

7.4.5 The weld joint shall be preheated for a distance of 2 or a distance equal to
the thickness of the thicker base metal being joined (whichever is greater).
This preheating shall apply to all directions from the weld area or the area
to be cut.

7.5 Preheating may be accomplished by electric resistance heaters, oxy-fuel torches,

natural gas/air torches or other methods that will provide uniform heating.

7.6 Preheat and interpass temperature shall be checked by suitable methods, such as
temperature indicating crayons or contact pyrometers.

7.7 When materials having different preheat requirements are welded together, the
higher required preheat temperature shall be used (e.g. P-No. 4 welded to P-No.
5).

7.8 Welds in P-No. 1 materials may be interrupted provided the welds are cooled
slowly to room temperature. Additionally, these welds need not have preheat
temperature maintained until postweld heat treatment (PWHT) is performed.

7.9 Welds in P-Nos. 3, 4, and 5 materials with a Chromium Content of 3% maximum

may be interrupted provided all of the following conditions are satisfied.

7.9.1 A minimum of at least 3/8 thickness of weld is deposited or 25% of the

welding groove is filled, whichever is less (the weldment shall be
sufficiently supported to prevent overstressing the weld if the weldment is
to be moved or otherwise loaded).

7.9.2 The weld is cooled slowly to room temperature.

7.9.3 Proper preheat is applied prior to the resumption of welding.

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 7.10 Welds in P-No. 5 with a Chromium Content greater than 3% (e.g. SA-335-P5, P9,
& P91) and P-No. 6 materials may be interrupted provided all of the following
conditions are satisfied:

7.10.1 A minimum of at least 3/8 thickness of weld is deposited or 25% of the

welding groove is filled, whichever is less (the weldment shall be
sufficiently supported to prevent overstressing the weld if the weldment is
to be moved or otherwise loaded).

7.10.2 The welds are postheated to a minimum of 100oF above the specified
minimum preheat temperature for at least 15 minutes, wrapped in thermal
insulating material and cooled in still air.

7.10.3 Proper preheat is applied prior to the resumption of welding.

7.11 All interrupted welds and any defects shall be visually inspected and removed
prior to the resumption of welding.

8.0 POSTWELD HEAT TREATMENT (QW-407)

8.1 WPSs requiring PWHT are qualified as per the various PWHT conditions
specified in ASME Section IX. As a minimum, WPSs shall describe the
qualified PWHT condition(s). For ASME Section III and for impact tested
fabrication, the WPS shall also show the maximum qualified time-at-temperature.

8.2 The PWHT condition may be given on the WPS by reference to the list of
conditions below, by actually stating the temperature range or by describing the
PWHT condition in the WPS.

8.3 PWHT CONDITIONS:

8.3.1 Condition (1) As-Welded (No PWHT)

8.3.2 Condition (2) Stress Relieved (PWHT below the lower transformation
temperature.)

8.3.3 Condition (3) Normalizing (PWHT above the upper transformation

temperature.)

8.3.4 Condition (4) Normalizing followed by tempering (PWHT above the

upper transformation followed by heat treatment below the lower
transformation temperature.)

8.3.5 Condition (5)-PWHT between the upper and lower transformation

temperatures.

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 8.4 PWHT is not controlled by the WPS, but it is required that the selected WPS fit
the intended PWHT. PWHT is controlled by Job Instructions, Shop Procedures
and Drawings. Job-special requirements for temperature range, time-at-
temperature, heating rates and cooling rates may be added to WPSs by
addendum.

9.0 GAS (QW-408)

9.1 The composition and flow rate of shielding and backing (purge) gas shall be as
specified in the WPS.

9.2 The purity level of gas(es) shall be welding grade or better.

9.3 Trailing shields shall not be used unless otherwise specified in the WPS.

9.4 Backing (purge) gas shall be used for open joint configurations when required in
the WPS.

9.4.1 When purge is required by the WPS, it shall be maintained for the
deposition of a minimum of two layers of weld metal.

9.4.2 The method for back-shielding (purge) shall be adequate to prevent visible
oxidation of the base metal or weld metal.

9.4.3 Each welder/welding operator shall monitor their welds throughout the
entire welding operation to assure that an adequate purge is maintained.

9.4.4 If detrimental oxidation does occur, the affected area shall be removed and
rewelded, as required.

9.4.5 Purge is not required for socket or fillet welds.

9.4.6 Purge is not required for the repair of groove welds provided the repair
cavity does not extend within 3/16 of the backside (ID) of the joint.

9.4.7 Purging is neither required nor prohibited when bridge tacks are used for
the alignment of groove welds, provided no detrimental oxidation occurs
in the base metal and the tacks are removed prior to the root pass.

9.4.8 Argon is an acceptable substitute where Nitrogen is specified as the purge

gas for P-Nos. 1. 3, 4, 5 and 8 materials, only.

9.5 The adequacy of purge prior to the commencement of welding shall be

determined by one of the following techniques:

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 9.5.1 Preweld purge shall be timed such that inert gas equal to at least six (6)
times the volume of the piping segment to be purges is allowed to flow.

9.5.2 An instrument calibrated to NIST standards is used to determine the

oxygen level of the purge gas (oxygen analyzer) and the oxygen level is
within that range permitted by the WPS.

10.0 ELECTRICAL CHARACTERISTICS (QW-409)

10.1 Refer to the specific WPS.

11.0 TECHNIQUE (QW-410)

11.1 When the width of weaving must be controlled, the control will be as shown in
the WPS.

11.2 Maximum weave width shall be determined at that point where the molten puddle
is at its maximum width (as measured in the direction transverse to the length of
the weld joint).

11.3 Prior to welding, the weld joint and the adjacent base metal on each side of the
weld joint (ID & OD) shall be free of slag, scale, oxide, oil, grease, paint, dirt,
moisture or other contaminates detrimental to the weld.

11.4 The joint preparation for carbon and low alloy steel base material (including any
required back-gouging for double welding) shall be by machining, grinding,
filing, flame cutting, air/carbon arc and/or plasma arc cutting. If thermal cutting
is used, the cut surface shall be smooth and true and all slag shall be cleaned from
the cut surfaces. The preheat requirements of Section 7.0 apply when thermal
cuttings is used.

11.5 The joint preparation for stainless steels, nickel-based alloys and nonferrous
materials shall be by machining, grinding, filing, air/carbon arc and/or plasma arc
cutting. If air/carbon arc or plasma arc cutting are used, the as-cut surface shall
be ground or buffed to bright steel.

11.6 When brushes are required, only austenitic stainless steel brushes shall be used on
stainless steels, nickel-based alloys and nonferrous materials. These brushes shall
not have been used previously on carbon or low alloy steels.

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11.7 When grinding wheels are required, wheels previously used on carbon and low
alloys steels shall not be used on stainless steels, nickel-based alloys and
nonferrous materials.

11.8 Nickel-based alloys and nonferrous materials shall be cleaned by vapor

degreasing or by swabbing with appropriate solvents just prior to welding.

11.9 All tack welds which are to be incorporated into the final weld shall be made by a
qualified welder and shall be free of defects. The ends of these tack welds shall
have a gradual taper at the ends. This tapering (feathering) may be performed by
grinding and/or filing. Tack welds which have cracked shall be completely
removed.

11.10 All pressure retaining welds shall have a minimum of two (2) passes. After each
weld pass, all slag, heavy oxide, glassy silicate deposits or other foreign materials
shall be removed from the weld surface. The welder/welding operator shall
visually examine each pass with special attention to the start and stop of the weld
pass. Detrimental indications shall be removed by chipping, gouging, grinding,
filing and/or wire brushing.

11.11 Arc strike pitting adjacent to the weld joint shall be removed by grinding and/or
filing. The dressed area shall be inspected and repaired as required by applicable
Codes and/or specifications.

11.12 The welding arc shall be protected by curtains or other suitable means in areas
where excessive drafts or winds may cause loss of shielding of the weld.

11.13 Peening is not permitted. The use of manual or pneumatic chipping hammers to
remove slag is not considered peening.

11.14 When components of different outside diameters or wall thickness are welded
together, the weld shall form a gradual transition (not to exceed 30) form the
smaller to larger diameter component. This condition may be met by adding
welding filler material, if necessary, beyond what would otherwise be the edge of
the weld.

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12.0 FINISHED WELDS

12.1 The maximum external weld reinforcement for girth welds shall be in accordance
with the following:

Base Material Maximum Weld Reinforcement Thickness, Inches

Thickness (t) B31.1
Inches Section I Section VIII >750F 250F-750F <350F B31.3 (1)
<3/32 3/32 3/32 1/16 3/32 3/16 1/16
>3/32 to <1/8 3/32 1/8 1/16 3/32 3/16 1/16
>1/8 to <3/16 1/8 1/8 1/16 1/8 3/16 1/16
>3/16 to <1/4 5/32 5/32 1/16 5/32 3/16 1/16
>1/4 to <1/2 5/32 5/32 1/16 5/32 3/16 1/8
>1/2 to < 3/16 3/16 3/32 3/16 3/16 5/32
>3/4 to < 1 3/16 3/16 3/32 3/16 3/16 5/32
>1 to <1 1/8 3/16
>1 to <2 1/8 3/16
>2 to <3 (2) 5/32 (2) (2) 3/16
>3 to <4 (2) 5/32 (2) (2) 3/16

(1) The limits listed are for Normal Fluid Service and Severe Cyclic Conditions. The limits for
Category D Fluid Service are twice the values listed.
(2) The greater of or 1/8 times the width of the weld in inches.

12.2 The maximum internal weld reinforcement for girth welds shall be the same as
the limits for external reinforcement. The internal reinforcement limits are not
defined in B31.1 however, the external limits shall be used for uniformity.

12.3 The thickness of weld reinforcement shall be based on the thickness of the thinner
of the materials being joined.

12.4 The weld reinforcement thickness shall be determined from the higher of the
abutting surfaces involved.

12.5 The weld reinforcement need not be removed except to the extent necessary to
meet the thickness requirements stated in paragraph 12.1 above.

12.6 As welded surfaces are permitted however, the surface of the welds shall be
sufficiently free from coarse ripples, grooves, overlaps, abrupt ridges, and valleys
to avoid stress risers. The surface of the finished weld shall be suitable to permit
proper interpretation of radiographs and other required non-destructive
examinations.

12.7 The maximum undercut for welds shall be in accordance with the following:

Section I & VIII 1/32 or 10% of the wall thickness, whichever is less.

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 B31.1 1/32 or any depth that encroaches on the minimum
required section thickness.

B31.3 1/32 or the nominal wall thickness of the thinner of the

two components being joined, whichever is less.

13.0 WPS MODIFICATIONS

13.1 Shaw Group WPSs may be modified for the inclusion of Job-Special
requirements by the generation of Contract Addenda.

13.2 Job-Special Addenda may be prepared by the QA/QC Manager, Welding

Engineer, or their designee.

13.3 Job-Special Addenda may be part of the Welding Procedure Applications Lists
(WPALs) and/or written as separate documents. These documents are made a
part of all Job Instructions.

14.0 ALIGNMENT

14.1 Internal misalignment shall be in accordance with Appendix C.

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SHAW GROUP
GENERAL WELDING SPECIFICATION
GEN, REV. 11
APPENDIX A

Grooves

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 SHAW GROUP
GENERAL WELDING SPECIFICATION
GEN, REV. 11
APPENDIX B

PROCESS & ROOT TYPE ROOT GAP

GTAW-MA:
Manual Tig w/Open Joint 1/16 5/32 (Target 1/8)

GTAW-ME:
Machine Tig W/Open Joint 0 1/32 (Target 0)

GMAW-S-SA:
Short Arc
SemiAuto Mig W/Open Joint 1/8 3/16 (Target 5/32)

GMAW-S-ME:
Short Arc
Machine Mig W/Open Joint 1/8 3/16 (Target 5/32)

All Processes:
Over Backing Ring/Bar 1/8 5/16 (Target 3/16)

LEGEND:
MA = Manual
ME = Machine
SA = Semi-Automatic

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 SHAW GROUP
GENERAL WELDING SPECIFICATION
GEN, REV. 11
APPENDIX C

The maximum misalignment at the joint shall be in accordance with the following:

B31.1: The inside diameters of piping components to be butt welded shall be aligned as
accurately as is possible within existing commercial tolerances on diameter, wall
thickness, and out-of-roundness. Alignment shall be preserved during welding. The
internal misalignment of the ends to be joined shall not exceed 1/16 unless the Job
Instructions and/or Drawings specifically states a different allowable misalignment.

When the internal misalignment exceeds the allowable, it is preferred that the component
with the wall extending internally be internally trimmed per Figure 1. However,
trimming shall result in a piping component thickness not less than the minimum design
thickness and the change in contour shall not exceed 30.

Figure 1

B31.3: The allowable misalignment shall be the same as for B31.1 except that the internal
misalignment of the ends to be joined shall not exceed the width of the root opening or
1/16, whichever is greater.

Section 1 &
Section VIII: The alignment of sections at edges to be butt welded shall be such that the maximum
offset is not greater than the applicable amount as listed in Table 1, where t is the nominal
thickness of the thinner section at the joint.

Any offset within the allowable tolerance provided above shall be faired at a 3 to 1 taper
over the width of the finished weld, or if necessary, by adding additional weld metal
beyond what would otherwise be the edge of the weld.

TABLE 1
ALIGNMENT TOLERANCE OF SECTIONS TO BE BUTT WELDED

Section Thickness, Inches Circumferential Weld Longitudinal Welds Misalignment

Misalignment
<1/2 1/4t 1/4t
>1/2 to <3/4 1/4t 1/8
>3/4 to < 1 3/16 1/8
>1 to <2 1/8t 1/8
>2 Lesser of: 1/8t or 3/4 Lesser of 1/16t or 3/8

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