SPC CR UR 510 3 (Important)
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GENERAL SPECIFICATION AUSTENITIC STAINLESS STEELS FOR UREA PLANT HIGH PRESSURE SECTION
SPC.CR.UR.510 Rev.03 September 2003
Form code : MDT.GG.QUA.0505 Sh. 01/Rev. 1.94
File code: spcgnrae.dot
Data file: spc_cr_ur_510_r03_e_f.doc
THE INFORMATION HEREIN AND IN THE FOLLOWING PAGES (N°35 , COVER INCLUDING) CONTAINED IS SECRET, CONFIDENTIAL AND BELONGS TO SNAMPROGETTI WHICH HAS PROVIDED IT SOLELY FOR AN EXPRESSLY RESTRICTED PRIVATE USE. ALL PERSONS, FIRMS OR CORPORATIONS WHO RECEIVE SUCH INFORMATION FROM SNAMPROGETTI SHALL BE DEEMED BY THEIR ACT OF RECEIVING THE SAME TO HAVE AGREED TO BE OBLIGED TO KEEP IT SECRET AND CONFIDENTIAL, TO MAKE NO DUPLICATION OR OTHER DISCLOSURE OR USE WHATSOEVER OF ANY OR ALL SUCH INFORMATION EXCEPT SUCH RESTRICTED USE AS IS EXPRESSLY AUTHORIZED IN WRITING BY SNAMPROGETTI AND SOLELY FOR THE SCOPE AGREED THEREIN. IN CASE OF UNDUE DISCLOSURE AND/ OR ANY FAILURE TO OBSERVE THE ABOVE PROVISIONS, THE DEFAULTING PARTY SHALL BE RESPONSIBLE FOR ANY AND ALL DAMAGES, WITHOUT LIMITATIONS.
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SPC.CR.UR.510 Rev. 03
Date
Sep. 2003 Sheet 2 (24)
CONTENTS 1
GENERAL
4
1.1
Scope and field of application
4
1.2
Definitions
4
1.3
Abbreviations
4
1.4
Referenced Codes (always latest revision)
5
2
MATERIALS
6
2.1
General
6
2.2
316L UG stainless steel (UNS S31603)
6
2.3
25Cr-22Ni-2Mo alloy (UNS S31050)
6
3
ADDITIONAL REQUIREMENTS
7
3.1
Chemical analysis
7
3.2
Mechanical properties
8
4
TESTING AND CERTIFICATION OF MATERIAL
9
4.1
General criteria for sampling
9
4.2
Test samples and specimens
9
4.3
Microstructure examination
11
4.4
Corrosion test procedure
12
4.5
Flaw assessment test
14
Note 1: It is the sum of all defects found on 7 tube welds at all levels
14
4.6
15
Certification
5
WELDING
16
6
ADDITIONAL TESTS ON MATERIALS
23
6.1
Workshop check of ferrite
23
6.2
Non Destructive Examinations
23
7
TESTS ON PRODUCTION WELDS AND CONSUMABLES
24
7.1
General
24
7.2
Tube to tubesheet weld production mock up
24
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
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SPC.CR.UR.510 Rev. 03
Date
Sep. 2003 Sheet 3 (24)
ATTACHMENT 1
1
ATTACHMENT 2
1
ATTACHMENT 3
1
ATTACHMENT 4
1
ATTACHMENT 5
1
ATTACHMENT 6
1
ATTACHMENT 7
1
ATTACHMENT 8
1
ATTACHMENT 9
1
ATTACHMENT 10
1
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
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SPC.CR.UR.510 Rev. 03
Date
Sep. 2003 Sheet 4 (24)
1
GENERAL
1.1
Scope and field of application
1.1.1
This specification covers the requirements for austenitic stainless steel materials and relevant welds in contact with the process fluid in the high pressure section of urea plants. These requirements shall be considered in addition to the ones of the codes and standards applicable to the product in question (equipment, piping components, plates, materials, testing, etc.). In case of conflict with any of the above standards, this document prevails.
1.1.2
This specification takes into consideration both the 316L UG stainless steel (UNS S31603) and the 25Cr-22Ni-2Mo type stainless alloy (UNS S31050).
1.2
Definitions
1.3
Owner:
The company that has placed the order to suppliers as permitted under the license granted by Snamprogetti.
Supplier:
Before placing the order it means each of the potential supplier(s) contacted; after placing the order, it means the selected supplier(s).
Snamprogetti:
Snamprogetti S.p.A., the licensor of the urea process.
316L UG:
“urea grade modified” 316L type austenitic stainless steel that shall meet all the requirements of the AISI 316L (UNS S31603) material specification and all the additional requirements mentioned in this specification.
“sample”
the piece of semifinished/ finished product (tube, plate, W.O., etc.) from which the specimens to be tested are taken out
“specimen”
a piece of material obtained from the sample and actually subjected to the destructive tests described below (corrosion test, metallography, etc.).
Abbreviations AISI ASME ASTM AWS DIN IIW UG UNS W.O.
American Iron and Steel Institute The American Society of Mechanical Engineers American Society for Testing and Material American Welding Society Deutsches Institut fur Nürmung International Institute of Welding Urea Grade alloy Unified Numbering System Weld Overlay Deposit
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
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SPC.CR.UR.510 Rev. 03
Date
Sep. 2003 Sheet 5 (24)
1.4
Referenced Codes (always latest revision) ASME Sect. VIII
Boiler and pressure vessel code - Pressure Vessel
ASME Sect. IX
Boiler and pressure vessel code qualifications
ASME Sect.V
Non Destructive Examination
ASME Sect. II Parts A & D
Materials
ASME Sect. II Part C
Specification for welding rods, electrodes and filler metals
EN 10204
Metallic materials – Types of inspection documents
ASTM A262
Standard Practices for Detecting Susceptibility to Intergranular Attack in Austenitic Stainless Steels
ASTM E562
Standard Test Method for Determining Volume Fraction by Systematic Manual Point Count
AD MERKBLATTER
Complete Technical Rules for Pressure Vessels (English Edition)
Welding and brazing
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
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SPC.CR.UR.510 Rev. 03
Date
Sep. 2003 Sheet 6 (24)
2
MATERIALS
2.1
General
2.1.1
The list of suppliers and subvendors of plates, forgings, bars, piping and tubes for High Pressure Urea equipment and piping to be operated in contact with the urea process fluid shall be submitted to Snamprogetti for acceptance. For filler materials the provisions of chapter 5 shall be applied.
2.1.2
All semifinished products shall be supplied in the solution annealed condition. No heating over 400 °C shall be allowed during machining or any other manufacturing activity, except welding. If heating above 400 °C cannot be avoided, a new solution annealing heat treatment shall then be performed and new samples shall be taken and tested as described in chapter 4.
2.1.3
If, after solution annealing heat treatment, forgings or bars are submitted to machining and more than 5 mm depth is removed from the side in contact with the process fluid, then a new solution annealing heat treatment is required except for the 25Cr-22Ni-2Mo alloy provided that the samples taken after machining satisfy the test requirements as per chapter 4.
2.1.4
All tubes and pipes shall be seamless type. Welded fittings are allowed provided that the requirements of chapter 5 are met.
2.1.5
Cast parts and rod bars are not permitted unless approved by Snamprogetti.
2.1.6
When 316L UG material is required, the use of 25Cr-22Ni-2Mo material is allowed as an alternative.
2.2
316L UG stainless steel (UNS S31603)
2.2.1
Stainless steel 316L UG type shall be in accordance with the ASME-(SA) specifications applicable to the relevant semifinished products; it shall also meet the additional requirements detailed in chapters 3 and 4.
2.3
25Cr-22Ni-2Mo alloy (UNS S31050)
2.3.1
Stainless steel 25Cr-22Ni-2Mo type shall be in accordance with the ASME-(SA) specifications applicable to the relevant semifinished products; it shall also meet the additional requirements detailed in chapters 3 and 4.
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
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SPC.CR.UR.510 Rev. 03
Date
Sep. 2003 Sheet 7 (24)
3
ADDITIONAL REQUIREMENTS
3.1
Chemical analysis In the following paragraphs the chemical or additional chemical requirements for 316 UG stainless steel and 25Cr-22Ni-2Mo alloy are reported. Any deviation from these requirements shall be subject to Snamprogetti’s acceptance.
3.1.1
316L UG stainless steel The 316L UG stainless steel base material shall have the following additional chemical requirements: C = 0.020 % max. P = 0.015 % max. S = 0.010 % max. Ni > 13 % N = 0.10 % max. The carbon content restriction above does not apply to forgings provided no welding is performed after the solution annealing heat treatment, not even for installation purposes.
3.1.2
25Cr-22Ni-2Mo stainless steel The 25Cr-22Ni-2Mo stainless steel base material shall have the following chemical composition: Cr = 24 ÷ 26 % Ni = 21 ÷ 23.5 % Mo = 2 ÷ 2.6 % Mn = 1.5 ÷ 2.0 % N = 0.10 ÷ 0.15 %
3.1.3
C = 0.020 % max. P = 0.020 % max. S = 0.010 % max. Si = 0.40 % max. B = 0.0015 % max.
W.O. deposit shall meet the following requirements for a depth of at least 3 mm (see Attachment 8) from the “as welded” or machined surface: Material type 316L UG: C = 0.030 % max. (SAW-ESW-GTAW) C = 0.040 % max. (SMAW) Cr = 16.5 % min. Ni = 15 % min. Mo = 2.2 % min.
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
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SPC.CR.UR.510 Rev. 03
Date
Sep. 2003 Sheet 8 (24)
Material type 25Cr-22Ni-2Mo: C = 0.030 % max. (SAW-ESW-GTAW) C = 0.040 % max. (SMAW) Cr = 24 % min. Ni = 21 % min. Mo = 1.9 % min. and
Creq Ni eq
=
%Cr + % Mo + 1,5% Si ≤ 1,20 % Ni + 30%C + 0,5% Mn
3.1.4
Chemical analysis at depth of 1 mm and 2 mm (see Attachment 8) shall also be performed and reported for information.
3.2
Mechanical properties The mechanical properties of 25Cr-22Ni-2Mo stainless steel, at room temperature, shall be as follows: Tensile strength
580 N/mm² min.
Yield strength (0,2% offset)
270 N/mm² min.
Elongation (l=5d)
30% min.
3.2.1
Short Time Tensile Test shall be performed/ certified at the design temperature (indicated on the Snamprogetti process data sheet) for each heat of Urea Stripper heat exchanger tubes.
3.2.2
If the design is carried out in accordance with ASME code BPVC section VIII, for forgings the code itself shall be applicable with reference to CODE CASE 2038.
3.2.3
For other requirements the relevant material/ product SA (ASME) specification shall be applied.
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
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SPC.CR.UR.510 Rev. 03
Date
Sep. 2003 Sheet 9 (24)
4
TESTING AND CERTIFICATION OF MATERIAL
4.1
General criteria for sampling
Product
Sampling for corrosion test
Sampling for metallographic examination
PLATES
One sample for each heat One sample from each lot of no more than 50 pieces of each heat and (1) same heat treatment
One sample for each plate One sample from each lot of no more than 50 pieces of each heat and (1) same heat treatment One sample from each lot even if of more than 50 pieces of each heat and (1) same heat treatment for bolts, nuts, and forgings of small size (Dia. ≤ 219,1 mm). One sample from each lot of 200 pieces (1) of each heat and same heat treatment
PIPING, FORGING
BOLTS, NUTS, One sample for each heat SMALL-SIZE FORGING EXCHANGER TUBES
One sample for each heat
NOTE (1): definition of same heat treatment: - If final heat treatment is in a batch-type furnace = in the same furnace charge - If final heat treatment is in a continuos furnace = in the same furnace at the same temperature, time at heat, and furnace speed.
4.2
Test samples and specimens
4.2.1
Samples for corrosion tests and microstructural examination shall be taken as per the above table (base material) and from each weld test during the welding procedure qualification. Overheating shall be avoided when cutting the specimens (thermal-cutting is not allowed). Each sample shall be marked, by stamping, with proper identification traceability number.
4.2.2
The area of each sample shall be of 180 cm as a minimum (if not otherwise specified in this document) and shall permit to take out with sufficient allowance the following specimens:
2
1 for check (chemical) analysis 1 for corrosion test (see para. 4.4) 1 for corrosion re-testing (if required) 3 for microstructure examination (see para. 4.3) 1 for metallography re-testing (if required) 4.2.3
Each specimen shall include the side that will be in contact with the process fluid if known (consequently liner plates shall then be installed by exposing to the process fluid the side that has been actually tested with positive results). Specimens for the corrosion test shall have an 2 area of approximately 30 – 32 cm , weight of 40 g minimum (100 g maximum) and, when feasible, an approximately rectangular shape with dimensions of about 50 x 25 x 5 mm.
4.2.4
In the case of plates with thickness over 7 mm, the specimen shall be reduced to 5 mm by machining material in excess on the opposite side from that (those) in contact with the process fluid (avoiding overheating).
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
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SPC.CR.UR.510 Rev. 03
Date
Sep. 2003
Sheet 10 (24)
4.2.5
In the case of tubes with outside diameter less than 30 mm, the sample shall have a cylindrical shape. In the case of tubes or pipes with outside diameter ≥ 30 mm, the sample shall be taken with length "a" approximately equal to arc "b" (see Attachment 5).
4.2.6
If the pipe or tube thickness is over 7 mm, the specimen thickness shall be reduced to 5 mm by machining material in excess on the opposite side from that (those) in contact with the process fluid (avoiding overheating).
4.2.7
In the case of forgings or bars, if it is not possible to take a sample with the surface to be in contact with the process fluid, the sample shall be taken from the core of the forging bar. Test specimens shall be taken from the forging extension or by a representative specimen with the same heat and heat treatment having maximum treated thickness size of those forgings.
4.2.8
In the case of special pieces (valves, thermocouples, fittings, instrument separators, etc.) the supplier shall submit to Snamprogetti for acceptance an overall drawing showing the location of the sample(s).
4.2.9
In the case of welding procedure qualification tests for SAW/ ESW/ SMAW weld overlay (see Attachment 1) three samples shall be taken: -
4.2.10
sample S1 (Attachment 2) which shall include at least 2 bead overlap of adjacent beads sample S2 (Attachment 3) which shall include stop and restart point of a bead sample S3 (Attachment 4) which shall include beads deposited by manual welding with SMAW and/ or GTAW on the automatic overlay, simulating repair if any.
The specimens obtained from each of the above samples shall be used as follows: -
specimen(s) labeled ‘A’ are to be used for metallographic analysis (one is for re-testing if required) specimen(s) labeled ‘B’ are to be used for corrosion test specimen labeled ‘B1’ is to be used for corrosion re-testing if required specimen labeled ‘C’ is to be used for macrographic examination specimen labeled ‘D’ is for chemical check analysis.
4.2.11
In the case of welding procedure qualification tests for additional automatic GTAW weld overlay on liner plates or SAW/ ESW/ SMAW weld overlay, a sample of S1 type including at least 2 bead overlap of adjacent beads (see Attachment 2) shall be taken out.
4.2.12
In the case of welding procedure qualification test for butt joints, the sample shall be as wide as the face of weld in contact with the process fluid plus 12 mm (6 mm each side) and 5 mm thick (see Attachment 6).
4.2.13
In the case of procedure qualification tests for welds between tube and tube-sheet, no. 2 mock-up shall be prepared. From the first one the specimens for corrosion test and metallographic examination shall be obtained and they shall include 3 tubes in central position. One central tube shall be used for the corrosion test, one shall be used for the metallographic examination, one is for re-testing, if required (see Attachment 7 for details). The second mock-
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003
Sheet 11 (24)
up shall be prepared following Attachment 9 and it will be subject only to the flaw assessment test as detailed in para 4.5. 4.2.14
The metallographic examination of the first mock-up shall be performed on the central tube assembly previously longitudinally sectioned following 4 perpendicular directions starting from the second weld pass stop as follows: a) on 4 of the 8 surfaces obtained from the sectioning a macrographic examination shall be performed in order to determine the extension of weld fusion (which shall not exceed at any point 75 % of wall tube thickness), weld throat thickness (minimum weld throats of all sections shall be not less than the specified tube wall thickness) and penetration. b) the 4 remaining surfaces shall be used for the microstructural examination (one surface for each of the 3 required etchings plus one for re-testing if required).
4.2.15
The surface to be in contact with the process fluid and the opposite one if not machined shall remain in the "as received" condition.
4.2.16
The specimens shall not be subjected to any heat treatment before the test.
4.2.17
The remaining part of each sample after taking out the specimens, with the identification number, shall be made available for five years (ex work delivery) at Supplier’s care for further Samprogetti investigation.
4.2.18
All tests described below (macrographic and micrographic examination, corrosion test, flaw assessment, etc.) shall be performed and certified by a laboratory approved by Snamprogetti. Laboratory shall officially inform Snamprogetti about any inconvenience (e.g. deviations from the material requirements etc.) encountered during the tests as well as in case of re-testing.
4.3
Microstructure examination
4.3.1
The material (base, welds and weld overlay) used in contact with the process fluid shall be subject to metallographic analysis following the methods detailed below. 3 (three) metallographic specimens, each for any required etching, shall be obtained from each of the sample(s) as detailed in para. 4.2.2 and 4.2.10. A fourth specimen shall be retained for retesting (if required). The re-use of the same metallographic specimen for two or more different etchings is not allowed.
4.3.2
The metallography shall be considered preliminary to the corrosion test.
4.3.3
Presence of ferrite shall be evaluated by means of a ferritometer on each of the 3 specimens before etching. Ferrite content shall not be greater than 0.6 % in all specimens except for SMAW welds for which 1% is allowed.
4.3.4
The material microstructure shall be determined following ASTM A262 Practice A. Only a fully austenitic step structure as defined in the above standard shall be considered acceptable. The presence of any structure other than the step structure (e.g. ditch structure, interdendritic ditches, end-grain pitting type I or II) is not allowed.
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003
Sheet 12 (24)
4.3.5
Presence of sigma phase shall be checked at 100x and 500x after electrolitic etching with 2 NaOH 10N at 3 V and 0.5 to 1 A/cm for 2 to 5 sec. Sigma phase shall be absent.
4.3.6
An etching with oxalic acid (10%, 6 V DC, 0.5 – 1 A/cm , 15 sec.) shall be performed and the specimen shall be examined at 100x and 500x. Presence of any intergranular or intragranular compounds or phases other than the austenitic phase is not allowed whatever their composition might be and irrespective of their quantity, with the exception of the ferrite phase within the limits stated in para. 4.3.3.
4.3.7
The material not in compliance with the above requirements shall be rejected.
4.4
Corrosion test procedure
4.4.1
The corrosion test, Huey type, shall be performed on the sample material that already resulted acceptable after the microstructure examination detailed in para 4.3.
4.4.2
AISI 316L UG specimens shall be subjected to 5 test periods and the acid shall be renewed each time. Each period shall last 48 hours actual boiling. 25Cr-22Ni-2Mo alloy shall be subjected to 10 test periods at the same conditions as above.
4.4.3
The corrosion test shall shall follow the ASTM A262 Practice C with the following additions:
4.4.4
Only one specimen shall be tested in each flask.
4.4.5
A finger type refrigerator shall be used and it is necessary to check, by litmus paper, that no acid vapours are released during testing.
4.4.6
The ratio of the solution volume to the sample area shall be 20 ml/cm² as a minimum.
4.4.7
The flasks for Huey test shall be used only for this purpose.
4.4.8
The flask, refrigerator and specimen shall be carefully rinsed after each test cycle to remove all the corrosion products (by means of a nonmetallic brush).
4.4.9
Before corrosion testing, the specimens shall be first degreased in acetone (chlorinated agents are not allowed), pickled in boiling nitric acid (65%) for thirty minutes, and then rinsed; the corrosion products shall be removed by nonmetallic brush.
4.4.10
After each test cycle and after rinsing, the specimens shall be dipped in acetone, dried by hot air, and weighed (when cold).
4.4.11
The time between two cycles shall be as short as possible.
4.4.12
Besides the determination of the corrosion rate (for each cycle and for the overall periods) obtained by weighting, it is also required to determine the maximum depth of attack by examining under a microscope the edges of a specimen section (for details see note 5 of table in para. 4.4.13)
2
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003
Sheet 13 (24)
4.4.13
The following table shows both the maximum corrosion rate and depht of attack allowed in each test cycle and for the average of the results of all cycles, calculated according to ASTM A262 Practice C:
Semifinished product
Type of material
Corrosion rate (mm/month)
Depth of attack (micron)
Plates, sheets, bars, tubes, pipes, forgings
316L UG
0.025 (1) (2)
90 (4) (5)
25Cr-22Ni-2Mo
0.015 (1) (2)
70 (4) (5)
316L UG
0.025 (1) (3) (4)
90 (3) (4) (5)
25Cr-22Ni-2Mo
0.015 (1) (3) (4)
70 (3) (4) (5)
Welds and W.O. surfacing
NOTES
General: the above limits are valid for each test cycle and for the average of the results of all cycles. (1) If the corrosion rate exceeds the rate specified in the table or if the corrosion rate in cycle 5 (cycle 10 for 25Cr-22Ni-2Mo alloy) exceeds the one in cycle 4 (cycle 9 for 25Cr-22Ni-2Mo alloy) by more than 50%, a second specimen taken from the same sample under examination shall be re-tested with the same procedure. Only the result of re-testing shall be taken into consideration. Further re-testings are not allowed. (2) No deviations allowed. (3) The heat affected zone and the bead overlap zone (for W.O.) shall also be examined. (4) Any deviation shall be subject to Snamprogetti’s acceptance. (5) Depht of attack shall be determined after completion of the corrosion test by taking a metallographic sample from the most corroded area, if visible. The value shall be reffered to the deepest attack observed on both the transverse and the longitudinal directions of the specimen.
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003
Sheet 14 (24)
4.5
Flaw assessment test
4.5.1
Samples to be tested shall be prepared in accordance with Attachment 9 (Procedure Qualification Record) and Attachment 10 (production mock-up).
4.5.2
The tube protusion shall be machined down until the contact between tube face and the upper weld toe. This surface shall be recorded as starting test level. The examination shall proceed on repeated plane at 1 mm distance from each other till the tube gets lose.
4.5.3
Each level shall be prepared for etching and examined under a binocular microscope with magnification from x15 to x25.
4.5.4
The following table gives the number and extension of the allowable defects:
Defect type Cracks (2) Pores Wormholes Slag inclusions Fusion defects Crater cracks Burn through
Max. allowed number of defects (1) 0 5 0 2 2 0 0
Max. dimensions allowed 0.6 0.6 2 -
Note 1: It is the sum of all defects found on 7 tube welds at all levels Note 2: Any deviation shall be subject to Snamprogetti’s acceptance 4.5.5
The weld fusion depht shall have a regular profile and its extension shall never exceed the 75 % of the wall tube thickness at any point
4.5.6
No more than 1 defect per tube and per level is allowed. Any deviation shall be subject to Snamprogetti’s acceptance.
4.5.7
Defects extended on different levels are not allowed.
4.5.8
A photograph shall be taken on each surface (scale 1:1) showing defects location, type and extension.
4.5.9
Certification of the flaw assessment test shall be in accordance with para. 4.6.
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003
Sheet 15 (24)
4.6
Certification
4.6.1
The laboratory shall certify that the test results are in compliance or not in compliance with the requirements of the present specification. The certification shall be made available to Snamprogetti as soon as the certificate is issued. Certification shall include the following:
4.6.2
A photograph(s) showing the samples as received; the identification stamping on the sample(s) shall be clearly visibile and readable.
4.6.3
The photomicrographs showing the material’s microstructure after each etching. The photos shall be of high quality and fully readable (e.g. laser prints on photographic quality paper, prints from photo negatives etc.). B/W or color photocopies are not acceptable.
4.6.4
The etching details, the magnifications employed and a short but comprehensive comment by a metallurgy specialist shall be reported in each caption. The result of the ferrite check on each specimen shall also be reported.
4.6.5
The corrosion rates after each testing cycle and the average corrosion rate values shall be reported.
4.6.6
As an option the testing certificate can be supplied in electronic (PDF) format provided the above requirements are fully met.
4.6.7
Snamprogetti reserves the right to require to the Supplier (or the Owner) further testing or investigation whenever Snamprogetti’s acceptance is required or the laboratory results are controversial.
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003
Sheet 16 (24)
5
WELDING
5.1
Weldings and weld overlays shall be performed with special filler materials, low ferrite type, approved by Snamprogetti. The approved filler materials for both 316L UG and 25Cr-22Ni-2Mo alloys are listed below. Different filler materials or wire/strip–flux combination shall not be used unless approved by Snamprogetti.
316L UG
CLASS 25Cr-22Ni-2Mo Electrodes
•(Avesta) P6 •(Thyssen) Thermanit 19/15 H •(Kobe Steel) NC 316 MF •(ESAB) 316 KCR •(Siderotermica) CITOXID B 316 LM
•(VEW) FOX EASN 25 M •(Thyssen) Thermanit 25 / 22 H •(Soudometal) Soudinox LF •(Kobe Steel) NC 310 MF •(Esab) FILARC BM 310 Mo L Wires
•(Thyssen) Thermanit 19/15 H •(Kobe Steel) no. 4051 •(Siderotermica) Siderfil 316 LM
•(Thyssen) Thermanit 25/22 H •(Kobe Steel) TGS 310 MF •(Sandvik) 25-22-2 L Mn •(VEW) FOX EASN 25 MIG Strips
•(Sandvik) 20-16-3 L Mn with (Soudometal) 12 b 316 LFT 2 flux •(Thyssen) 21.17.E with (Soudometal) Rekord 13 BLFT flux
•(Sandvik) 25-22-2 L Mn with (Soudometal) Rekord 13 BLFT flux or with (Sandvik) 31S flux •(Sandvik) 25-22-2 L Mn with (Sandvik) 37 S flux (electroslag) •(Thyssen) 25-22 H with (Soudometal) EST 122 flux (electroslag)
General note: the materials of class 25Cr-22Ni-2Mo can be used for welding of materials of class 316L UG.
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003
Sheet 17 (24)
5.2
WPS/PQR applicable codes and additional required tests are summarized in the following table: Weld Overlay Specimen
Applicable code (1)
-
Corrosion test Chemical analysis Microstructure examination
B D
Macroexamination
C
Flaw test
E
Sample S1
Sample S2
Sample S3
ASME IX YES (para. 4.4)
ASME IX
ASME VIII Div. 2 Art. F3
YES (para. 4.4)
YES (para. 4.4)
NO
NO
YES (para. 4.3)
YES (para. 4.3)
YES (para. 4.3)
YES (3)
YES (para. 4.2.13)
NO
YES (para. 4.5)
YES (2)
NO
NO
Tube to tubesheet joints
YES (para. 3.1.3 and 3.1.4)
A
NO
Butt joints
NO
NO
NOTES: (1) Unless otherwise specified in the design code indicated in the purchase order. (2)
For W.O. the macroexamination shall be performed only on sample S1. The purpose of macroetching is to identify the sequence of the weld beads overlay and the location of the heat affected region of each weld pass, due to the re-heating during the application of the subsequent pass. Specimen ‘B’ shall be taken out by the laboratory across the centerline of the above mentioned area (see Attachment 2).
(3) Macroexamination to be performed to check weld structure, presence of slag porosity and cracks in weld and heat affected zone.
5.3
PQR shall include the certification detailed in para. 4.6.
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003
Sheet 18 (24)
5.4
In addition to the provisions of the applicable codes the validity of the PQR is five years from issue date and the following essential variables, if modified from what qualified during the Procedure Qualification Record as indicated in the following tables, require the welding qualification tests to be repeated:
PRESSURE/ NOT PRESSURE RETAINING WELDS BUTT AND FILLET WELD ACCEPTED WELDING PROCESSES VARIABLES Shielded Metal Arc Welding
Gas Tungsten Arc Welding
Heat input
Heat input or volume of the weld metal increased more than 10%
Interpass
An increase of interpass temperature
Welding position
A change in the welding position (a PQR done in 3G-5G-6G-vertical-uphill progression qualify all other position except vertical-down progression)
Filler metal size
A change in filler metal size
Filler metals
A change in the type, manufacturer of filler metal and/or trade name
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003
Sheet 19 (24) CORROSION RESISTANT WELD OVERLAY ACCEPTED WELDING PROCESS VARIABLES
Submerged Arc Welding
Base Metal
Electroslag welding
Gas Tungsten Arc Welding
A change in the P or Gr number A change of ±30 % in the base metal thickness
Base Metal thickness current
A change of ±10%
A change of ±5%
A change of ±10%
Current density 2 (A/mm ) (strip welding)
A change of ±10%
A change of ±5%
Not required
Welding intensity
Shielded metal arc welding
Not required
Arc voltage
A change of ±10%
Not required
Welding speed
A change of ±5%
Not Required
An increase of heat input more than what qualified
Heat input or volume of the weld metal increase more than 5%
Heat input
Stick-out
Preheat and interpass
A change ±2.5% of the strip/wire stickout with respect to PQR
A change ±2.5% of the strip/wire stick-out with respect to PQR (for machine/ automatic process)
Not applicable
A change in the preheat±25°C (first layer) and/or an increase of interpass temperature (all layers)
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003
Sheet 20 (24)
CORROSION RESISTANT WELD OVERLAY ACCEPTED WELDING PROCESS VARIABLES
PWHT (on first layer)
Submerged Arc Welding
Electroslag welding
Gas Tungsten Arc Welding
Shielded metal arc welding
A change in the temperature (±15°C)
Bead overlap
A change +20%/ -0% of the overlap of adjacent beads with respect to that measured on PQR (applicable to first and last layers)
A change +20%/ 0% of the overlap of adjacent beads with respect to that measured on PQR (applicable to first and last layers (for machine/ automatic process)
N/A
Bead width
A change +20%/ -0% of the bead width with respect to that measured on PQR (applicable to first and last layers)
A change +20%/ 0% of the bead width with respect to that measured on PQR (applicable to first and last layers (for machine/ automatic process)
N/A
Welding position
A change in the welding position
Filler metal size and/ or thickness
A change in filler metal size and/or thickness
Layer thickness (to be specified in WPS/ PQR)
An increase in layer thickness (applicable to each layer)
Number of weld layers
A decrease in the number of weld layers with respect to PQR
Filler metals Flux
A change in the type, manufacturer and/or trade name A change in the type, manufacturer and/or trade name
Not applicable
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003
Sheet 21 (24)
TUBE TO TUBESHEET WELDING ACCEPTED WELDING PROCESS VARIABLES Orbital Gas Tungsten Arc Welding Manufacturer, type/ model of welding machine
A change of manufacturer, type/model of welding machine to another.
Welding program (supplementary document to be attached to the WPS)
A change in any data included in the supplementary document specifying all applicable equipment settings (pre-gas/post-gas/welding parameter for each sector/etc.) to assure a consistent performance.
Base Metal: Tubesheet (solid, W.O. or clad), Tube (internal or external)
A change in the base metal type, grade or product form
Tubesheet (solid pressure containment parts)
A change of ±30% in the tubesheet (solid pressure containment parts) metal thickness
Tubesheet (W.O., clad)
A decrease in the layer number and/or increase of layer thickness.
Shielding/Backing(inside tube gas)/Trailing gas
A change/deletion in the gas composition and flow rate used
Tubes Tube holes Clearance between tubes and tube holes Positioning system Non fusible electrodes
A change in the manufacturer, wall thickness or diameter A change in the pitch The clearance between the outside surface of the tubes and the inside surfaces of the tube holes shall not exceed clearance used in the welding qualification tests A change in the positioning/centering system of the weld head on the tube sheet A change in the type, size, tips shape/angle, protrusion from the torch
Welding position
A change in the welding position
Filler metal size
A change in filler metal size
Tubes protrusion
A change in the tube protrusion form tubesheet
Filler metals Interpass
A change in the type, manufacturer and/or trade name An increase of interpass temperature
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003
Sheet 22 (24)
5.5
The root pass on pipe butt joints shall be carried out by argon gas welding and with backing gas inside the pipe.
5.6
Weld overlays shall be performed with at least two layers in the case of automatic process, (except strip weld overlay on liner plates) and at least three layers in the case of manual welding: in any case, at least two layers shall be performed with low ferrite filler in compliance with para. 5.1.
5.7
Stress relieving heat treatment shall be carried out after first barrier layer before to start with the further corrosion resistant layer.
5.8
The weld face in contact with the process fluid shall be adequately smooth, free from undercuts or defects.
5.9
No grinding will be allowed, except on tube sheets or for removing local defects or discontinuities.
5.10
Care shall be taken during fabrication to avoid iron contamination of the austenitic surfaces by tools (grinding wheels, brushes, clamps, etc.).
5.11
The grinding wheels must not have been previously used on ferritic steels and the brushes must have austenitic stainless steel wires.
5.12
Weld overlay deposit on 25Cr-22Ni-2Mo liner plates shall be performed by providing a forced back water cooling circulation system during weld operations in order to keep interpass temperatures lower than 50°C. Automatic interpass temperature control shall be adopted.
5.13
Electrodes for manual welding or weld overlay shall have a diameter not greater than 4 mm (preferably 3.25 mm max.) and, where possible, shall be used with stringer bead technique.
5.14
All the welds of internal parts to the lining shall be performed by full-penetration welding procedure.
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003
Sheet 23 (24)
6
ADDITIONAL TESTS ON MATERIALS
6.1
Workshop check of ferrite In addition to the requirements of para 4.3.3 the ferrite content shall also be checked in the workshop by magnetic permeability measurement by means of appropriate portable equipment previously calibrated and certified per AWS A4.2. An annual calibration certification shall be available to the Snamprogetti inspector. Prior to use in production, instrument calibration shall be verified with IIW secondary weld metal standards (0 - 15 % ferrite range). This check shall be carried out on each plate or forging and on at least one every 50 pipes or tubes from the same heat and heat treatment and on one bolt and one nut for every lot and every size from the same heat and heat treatment (for definition of “same heat treatment see Note 1 in para. 4.1).
6.2
Non Destructive Examinations
6.2.1
The tubes for heat exchangers shall be 100% tested with ultrasonics and eddy currents in accordance with ASTM A 450.
6.2.2
For eddy current test the calibration tube shall contain all the following discontinuities to establish the minimum degree of sensitivity for rejection of tubes:
6.2.3
-
a longitudinal notch on a radial plane parallel to the tube axis on the outside surface, having a length of 6.35 mm, maximum width 0.8 mm, and depth 10% of the tube thickness but not less than 0.1 mm.
-
a circumferential notch on a transverse plane to the longitudinal axis of the tube, having a depth of 10% of the tube thickness but not less than 0.1 mm.
-
Three or more through holes, equally spaced circumferentially around the tube and longitudinally separated by a sufficient distance to allow distinct identification of the signal from each hole. The diameter of hole shall not be larger than 0.8 mm.
For ultrasonic examination, the calibration tube shall contain all the following discontinuities to establish the minimum degree of sensitivity for rejection of tubes: -
a longitudinal notch on a radial plane parallel to the tube centre line, having a depth 5% of the tube thickness but not less than 0.1 mm; on both the outside and inside surface
-
a transverse notch, tangent to the surface and perpendicular to the longitudinal centre line of the tube, having a depth 5% of the tube thickness but not less than 0.1 mm., on both the outside and inside surface
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003
Sheet 24 (24)
7
TESTS ON PRODUCTION WELDS AND CONSUMABLES
7.1
General
7.1.1
Welding consumables (electrodes, wires, rods, strips and fluxes) shall be certified for the different heats/lots according to EN 10204 type 3.1.B. Snamprogetti and the owner reserves the right to request a chemical check analysis on production welds.
7.1.2
Butt welds shall be fully radiographed (if physically feasible).
7.1.3
All welds and weld overlay deposit top layer shall be examined by dye penetrants, if possible on the side in contact with the process fluid or, if this is impracticable, on the outside.
7.1.4
After final machining (if any) the last tubesheet W.O. layer deposited shall have a minimum thickness of 3 mm. Along this thickness the chemical composition shall be in compliance with the requirements of para. 3.1.3. Supplier shall maintain full traceability of fulfiment of this requirement. Traceability data sheet shall be submitted to Snamprogetti inspector for review.
7.1.5
If the above requirement cannot be warranted by the supplier an additional weld overlay layer, other than that qualified on PQR, shall be deposited.
7.1.6
After machining of tubesheet weld overlay and before drilling operations a chemical sample shall be taken as per Attachment 8.
7.1.7
All the welds of internal parts to the lining shall be examined by dye penetrants after each welding pass.
7.2
Tube to tubesheet weld production mock up
7.2.1
Supplier shall provide no. 3 representatives production mock-up to verify the tube to tubesheet weld as per Attachment 9 and 10.
7.2.2
Mock-up shall be realised applying the same production tube sheet configuration, materials and welding parameters except for the carbon steel plate material on which the thickness should be reduced to a value equal at least the 30% of the original.
7.2.3
The frequency welding cycle verification shall be as follows: a) No. 1 mock-up before starting any production welds b) No. 1 mock-up around middle production c) No. 1 mock-up before completion of the last 100 welds
7.2.4
On the mock-up 7.2.3 (a) an additional impediment shall be located in order to simulate the peripheral tubesheet configuration (see Attachment 10).
7.2.5
Each tube samples shall have a minimum lenght of 100 mm.
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003
Sheet 25 (24)
7.2.6
Each tube weld sample shall be examined as per para 4.5.
Revision memorandum Novembre 1984 August 1993 September 1995
September 2003
Issue Rev. 01. Rev. 02. Modified para 2.3.2 specifying the yeld strenght at 0,2% offset. Updated the list of approved filler materials of table 3.5.1.a . Conversion in Word of the whole document. Rev. 03. General revision
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003 Sheet 1 (1)
ATTACHMENT 1
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003 Sheet 1 (1)
ATTACHMENT 2
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003 Sheet 1 (1)
ATTACHMENT 3
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003 Sheet 1 (1)
ATTACHMENT 4
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003 Sheet 1 (1)
ATTACHMENT 5
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003 Sheet 1 (1)
ATTACHMENT 6
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003 Sheet 1 (1)
ATTACHMENT 7
The arrows indicate the sectioning planes
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003 Sheet 1 (1)
ATTACHMENT 8
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003 Sheet 1 (1)
ATTACHMENT 9
Tubes To Tube Sheet Welds Qualification Procedure Test
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
$
SPC.CR.UR.510 Rev. 03
Date
Sep. 2003 Sheet 1 (1)
ATTACHMENT 10
Form code : MDT.GG.QUA.0515 Sh. 01/Rev. 1.94 File code: spcgnrae.dot Data file: spc_cr_ur_510_r03_e_f.doc This document is the property of Snamprogetti who will safeguard its rights according to the civil and penal provision of the law.
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