INDCON PROJECTS & EQUIPMENT LTD.

WORK PROCEDURE
FOR
WELDING OF PROCESS PIPING
{PIPE TO FLANGE/WELDOLET/FITTINGS/IF/VALVES/HIGHER THICKNESS PIPE.}
(PARTIAL WALL REPAIRS.)

PROJECT

: Panipat-Jalandhar LP Gas Pipeline Project

PROCEDURE NO

: INDCON-PJPL-STN-MECH-WPS-11

OWNER

: Indian Oil Corporation Limited, NRPL- PANIPAT

CONTRACTOR

: Indcon Projects & Equipment Ltd.

Date: 12th Nov. 2007

00

12.11.07

Rev. No

Date

Submitted for
approval
description

Ajit

Amit

Prepared Checked
by
by

GSB
Approved
by

Approved by IOCL

Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12/11/07, Page 1 of 11

INDEX
Sl. No.

Description

Page No.

Purpose

03

Scope

03

References

03

List of Equipments

03

Preparation of Pipe and other Fittings

03 04

Methodology WPS/ PQR Qualification

04

Partial wall repair

05

Method for welding of Partial wall repair

05

Health, Safety & Environment

06

10

Quality Assurance & Quality Control

06

11

Documentation

06

12

Inspection test Plan

07

13

Welding Procedure Specification (WPS)

08 09

14

Procedure Qualification Record (PQR)

10 11

Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12/11/07, Page 2 of 11

INDCON PROJECTS & EQUIPMENT LTD.

Procedure for

WELDING OF PROCESS PIPING

{PIPE TO FLANGE/WELDOLET/FITTINGS/IF/VALVES/HIGHER THICKNESS PIPE}
(PARTIAL WALL REPAIRS.)
Project: Panipat-Jalandhar LP Gas Pipeline Project
1.0

2.0

3.0

PURPOSE
This procedure describes the steps to be followed for Qualification of WPS and PQR of
station piping.
SCOPE
This scope covers the work method for Qualification of WPS and PQR of station
piping to be used for Panipat Jalandhar LP Gas Pipeline Project.
REFERENCES
Following documents in totality or in part shall form the reference documents:

1. IOCL Specification
2. ASME Sec-IX - Qualification Standard for Welding Procedure (Latest edition)
4.0

LIST OF EQUIPMENTS
Following equipments/instruments are to be used during welder qualification:

a.
b.
c.
d.
e.

Welding Machine.

5.0

PREPRATION OF PIPE & OTHER FITTINGS-

A.

The beveled ends of each joints of the pipe shall be thoroughly cleaned of
paints, rust, mill scale, dirt or other foreign materials to avoid defects in the
completed / welds use by power driven wire brushing wheels or other methods
approved by the site engineer.

B.

Any foreign matter or obstruction remaining inside the pipe shall be removed by
appropriate means.

C.

Fabricated intersections shall be in accordance with applicable codes and shall be of

the set-on type with branched pipe prepared to suit a full penetration weld of quality
comparable to the girth welds.

D.

Weld-o-lets shall be fitted accurately to the contour of the run pipe. The connection of
weld-o-lets to the run pipe shall be as per exhibit drawing.

Grinding Machine.
Buffing Machine.
Tong tester.
Stop watch

Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12/11/07, Page 3 of 11

INDCON PROJECTS & EQUIPMENT LTD.

Procedure for

WELDING OF PROCESS PIPING

{PIPE TO FLANGE/WELDOLET/FITTINGS/IF/VALVES/HIGHER THICKNESS PIPE}
(PARTIAL WALL REPAIRS.)
Project: Panipat-Jalandhar LP Gas Pipeline Project
E.

Coupling and half coupling shall be accurately shaped and set-on to suit the
contour of the run pipe.

F.

Pipes shall be properly supported and aligned using jigs or clamps as required in order
to provide extraneous loads and minimize strains during taking.

H.

Small tack welds i.e. between (12.5 mm) and (18 mm) in length penetrating to
the bottom of the groove may be used in fittings up.
Tacks should be equally spaced as follows.
For 2 pipe and smaller
- 2 tacks
For 3 to 12 pipe
- 4 tacks
For 14 and larger pipes
- 6 tacks
Unless otherwise specified all pipe to pipe joints shall be butt welded.

I.

Pipes with a wall thickness of (6 mm) and greater shall not have internal
misalignment of pipe wall exceeding 1/16 (1.5 mm).

J.

Pipes with a wall thickness of (6 mm) and greater shall not have internal
misalignment of pipe wall exceeding 25% of pipe wall thickness.

K.

When the misalignment is greater than the above, component shall be aligned by
drifting, rolling or machining in accordance with the code, ensuring that the nominal
wall or minimum wall thickness is not upon after considering the manufacturing
tolerances defined in the appropriate material specification.

6.0

METHODOLOGY WPS/ PQR QUALIFICATION

A.

First the Welders will be short listed on the basis of previous welder qualification
certificate, experience and or conducting show test pieces at the site.
After short listing of welders, Owner will be informed to witness the WPS qualification
test at the site.
The welding is carried out on the sample test piece as per the proposed WPS.
After the Welding process is completed the welded piece is sent to the well established
testing agency for NDT and destructive testing (DT) in order to evaluate the weld metal
performance.
The testing shall be conducted as per ASME Sec-IX, latest edition.
Welding for Procedure Qualification shall be carried out only in 6G position.

B.
C.
D.
E.
F.

Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12/11/07, Page 4 of 11

INDCON PROJECTS & EQUIPMENT LTD.

Procedure for

WELDING OF PROCESS PIPING

{PIPE TO FLANGE/WELDOLET/FITTINGS/IF/VALVES/HIGHER THICKNESS PIPE}
(PARTIAL WALL REPAIRS.)
Project: Panipat-Jalandhar LP Gas Pipeline Project
7.0

Partial Wall Repair

Each layer will be thoroughly checked for this type of discontinuity shown in NDT
reports. Smooth grinding will be done to make V Groove and clean all surfaces. The
minimum length of a repaired area shall be 100mm as measured over. This is limited
to 30% of weld length only. Minimum 2 runs shall be made for partial repair.

8.0

METHOD FOR WELDING OF PARTIAL WALL REPAIR

(Pipe to flange/Weldolet/fittings/if/valves/higher thickness pipe)

A.

Weld-o-lets, flanges, fittings & valves shall be fitted accurately to the contour of the run
pipe. The connection of all pipe fittings to the run pipe shall be as per drawing.

E.

After alignment & fit up, pre heating shall be carried out (minimum 100 degree C)
and the same shall be checked with thermo chalks / temperature indicating pyrometer
before starting the root run.

F.

Earthing clamps used for welding return circuit shall only be placed on bevel area or
circumferential welds.

G.

After completing every pass, the same shall be cleaned / flattened by grinding and
power brushing.

H.

As per approved WPS and PQR, for repair of weld, after identifying the defects. Care
shall be taken to ensure that no grinding marks are made on pipe surface anywhere.
Repair weld deposition shall be smooth, free from burrs, cuts and other surface
irregularities. The root gap shall be made carefully and shall conform to the welding
procedure. The welded area shall be thoroughly cleaned. Any repaired area that is
irregular shall be rejected and a full cut out and rebevelled to make a joint. Repairs
opening the root shall be carried out in the presence of experienced Supervisor. All
repairs shall be carried out after initial radiography.

I.

Welders shall be qualified as per the approved WPS and all the welders should have
identity cards duly signed by Indcon & IOCL.

J.

After completion of welding visual inspection shall be done and all the surface defects
shall be removed as per the specification. Liquid dye Penetration test shall be carried
out as per the approved Liquid dye Penetration test procedures. Repairs shall be
done as per approved WPS.

Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12/11/07, Page 5 of 11

INDCON PROJECTS & EQUIPMENT LTD.

Procedure for

WELDING OF PROCESS PIPING

{PIPE TO FLANGE/WELDOLET/FITTINGS/IF/VALVES/HIGHER THICKNESS PIPE}
(PARTIAL WALL REPAIRS.)
Project: Panipat-Jalandhar LP Gas Pipeline Project
9.
A.
B.
C.

10.

HEALTH, SAFETY AND ENVIRONMENT

This is an environment friendly project. Following safety points shall be taken care off.
All utilities shall be identified and protected so that they do not foul with the
execution work.
All heavy equipment shall be maintained in good condition as per maintenance
schedule.
All workmen shall use proper personal protection wears.
All employees shall follow the employee occupational health & safety rules.

QUALITY ASSURANCE & QUALITY CONTROL:

Quality Assurance shall be maintained by ensuring the systematic implementation of
this Quality Plan and ensure that necessary quality records are generated as per
approved ITP.

11.

DOCUMENTATION
-

Inspection Test Plan

Welding Procedure Specification
Procedure Qualification Record

Note:
In case of conflict between the requirements of this procedure and that of the above
referred specifications the requirements of the latter shall govern, until and unless
specific intention is meant.

Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12/11/07, Page 6 of 11

INSPECTION TEST PLAN

WELDING OF PROCESS PIPING
{PIPE TO FLANGE/WELDOLET/FITTINGS/IF/VALVES/HIGHER THICKNESS PIPE}
(PARTIAL WALL REPAIRS.)
: Indian Oil Corporations ltd.
Format No: INDCON-PJPL-STN-MECH-WPS-11

Client

Contractor: Indcon
Project

Projects & Equipments Ltd.

Revision : 00
Date: 06 th Nov. 2007

: Panipat Jalandhar LP Gas Pipeline Projects

Sl. No

Activity Description

Frequency of Insp./Testing

Submission and obtaining approval of

Procedure

Inspection category
INDCON

IOCL

At the Beginning

AP

Pre heating, Filler & Final Welding

100% During Qualification

Process

Weld Visual of Completed weld

100% During Qualification

Process

Liquid Dye Penetration Test of Weld

100% During Qualification

Process

Approval of WPS

Once prior to start of welding

process

Safety

Throughout

Legend
P

: Perform ,

RM : Random,
W

: Review Documents ,

AP : Approval,

: Witness,

For Indcon Projects & Equipment Ltd.

For IOCL

Name:
Sign:

Name:
Sign:

Date:

Date:

Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12/11/07, Page 7 of 11

WELDING PROCEDURE SPECIFICATIONS (WPS)

(See QW-200.1, Section: IX, ASME Boiler & Pressure Vessel Code)

Company name
Welding Procedure
Welding PQR No.
Welding Process

Indcon Projects & Equipment Ltd.

WPS-11
Revision : 0
PQR-11
Revision : 0
GTAW + SMAW
Type : Manual

Format No.: INDCON-PJPL-STN-MECH-WPS-11

Dated : 12.11.2007
Dated - 12.11.2007

JOINT (QW-402)
Joint Design : As per fabrication drawing
Backing
: Without backing
Backing material : Weld metal
Retainers : Not required

BASE METALS (QW-403)

P. No. 1
Group No. :
Specification type and grade
Thickness range: -Base metal
Pipe Dia. Range
T/t Limits > 8
P No. 5/9/10

JOINT DETAIL
As Per Fabrication Drawing

Any

TO
SA 106 Gr. B

P No.: 1

Groove : 1.6 mm to 17.48mm

Groove All
Not applicable
Not applicable

Group No. : Any

Fillet : All

FILLER METALS (QW-404)

GTAW

SMAW
5.1
E7018
6&4
1
2.5, 3.15 mm

Spec. No. (SFA)

AWS No. (Class)
F - No.
A No.
Size of Filler Metals (Dia)
WELD METAL:
Thickness range:
Groove
Fillet
Consumable insert

All sizes
None

POSITIONS (QW 405)

Position (s) of Groove
Welding progression
Position of Fillet

All
Up hill
All

PREHEAT (QW 406)

Preheat temp. Min.
Interpass temp. Max.
Preheat maintenance

16 C min
250 C
Not Required

POST WELD HEAT TREATMENT (WQ-407)

Temperature range
N/A
Time range
N/A

GAS (QW 408)

Shielding
Trailing
Backing

Percent Composition
Gas
Mixture
Argon
99.95 % purity
None
-None
--

Flow rate
10-20 LPM
---

Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12/11/07, Page 8 of 11

ELECTRICAL CHARACTERISTICS (QW 409)

Current
Amps range
Tungsten electrode size & type
Mode of metal transfer for GMAW
Electrode wire feed speed range
Pulsing

DC
See table

Polarity
Volts
3 mm, EWTH-2
Not applicable
Not applicable
None

WPS - 11
Dated : 12.11.2007
EN for GTAW, EP for SMAW
See table

TECHNIQUE (QW 410)

String OR weave bead
Orifice or gas cup size
Initial & interpass cleaning
Method of back gouging
Oscillation

String & weave ( 3 x Core Dia. Max)

5-8 mm
Brushing & grinding
Grinding
None

Electrode spacing
Multiple or single pass (per side)
Multiple or single electrodes
Travel speed (range)
Weld- Layers
Process
FILLER METAL

1st run
2nd run &
Subsequent runs

SMAW
SMAW

Performed by

Class

Dia.

ER-7018
ER-7018

2.5 mm
2.5 mm

Not applicable
Multiple. (No singe pass is greater than 13 mm)
Not applicable (Manual)
Refer table
CURRENT
Volt
Travel
Heat input
range speed
KJ/mm
range
( Max )
(mm /Min)
Type
Amp.
polarity
Range
DCEP
DCEP

Checked by

Approved by

Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12/11/07, Page 9 of 11

PROCEDURE QUALIFICATION RECORD (PQR)

(See QW 200.2, Section IX, ASME Boiler and Pressure Vessel Code)

Company Name: Indcon Projects & Equipment Limited

Procedure Qualification Record No.
PQR /11
WPS No.
WPS /11
Welding Process
GTAW + SMAW
Type Of Welding Process
Manual

Format No.: INDCON-PJPL-STN-MECH-PQR-11

Dated
12.11.2007
Dated
12.11.2007

JOINTS ( QW 402 )

JOINT DETAIL
As Per Fabrication Drawing

BASE METALS (QW-403)

Material Specs.
SA 106
Type or grade
Gr. B
P No.
1
To
Thickness of Test Coupon
Diameter of Test Coupon
FILLER METALS (QW 404)

P No.

POST WELD HEAT TREATMENT (QW-407)

Temperature
Time
Other

----

GAS (QW 408 )

GTAW
SFA Specification
AWS Classification
Filler Metal F No.
Weld Metal Analysis A No.
Size Of Filler Metal
Other (Electrode trade name)
Weld Metal Thickness
POSITION (QW 405 )
Position of Groove
Weld Progression
Other

6G
Uphill
--

PREHEAT ( QW 406 )
Preheat Temperature (Min.)

16 C

Inter pass Temperature

Other

250 C
-

SMAW
5.1
E-7018
4
1
2.5 MM

Shielding
Trailing
Backing

FOR GTAW ONLY

Percent Composition
Gas
Mixture

Flow rate

ARGON
---

10-20 LPM
---

99.95%
---

ELECTRICAL CHARACTERISTICS (QW 409)

Current
DC
Polarity
EN for GTAW, EP-SMAW
Amps
80 160
Volt
10-24
Tungsten Electrode Size 3.00 mm EW TH-2
Other
-TECHNIQUE ( QW 410 )
Travel Speed
String or Weave Bead
Oscillation
Multi pass or Single
pass (per side)
Single or Multiple
Electrodes
Other

60 90 mm / Min.
Root string, balance weave
Not applicable.
Multiple. No single pass is
greater than 13 mm
N/A (Manual)
-

Procedure No: INDCON-PJPL-STN-MECH-WPS-10 Rev No: 0, Dt. 12/11/07, Page 11 of 11

TENSILE TEST (QW 150 )

Specimen No.

Width
( mm )

Thickness
( mm )

Area
( mm )

Ultimate
Total Load
(Newton)

Ultimate
Tensile
Strength
(MPa)

PQR NO. 11
Date :12.11.2007
Type of Failure &
Location

T1
T2

GUIDED BEND TESTS (QW 160 )

Type and Figure No.
Root Bend RB 1, QW 462.3a
Root Bend RB 2, QW 462.3a
Face Bend FB 1, QW 462.3a
Face Bend FB 2, QW 462.3a
(Bend dia 4 t x 180 C)

Result

TOUGHNESS TESTS ( QW 170 )

Specimen No.

Notch
Location

Specimen
Size

Test
Temp.

Impact Values
Joules

1
2
Comments :

Yes

N/A
No

Macro Results
OTHER TESTS
Type of Test

Mils

N/A

FILLET WELD TESTS ( QW 180 )

Result Satisfactory

Shear

Type of Failure &

Location

Penetration into
Parent Metal

Yes

No

N/A

Radiography
Visual inspection -

Welders Name
Test Conducted By

Clock No.

Stamp No.
Laboratory Test Report No.:

We certify that the statement in this record are correct and that the test welds were prepared, welded, and tested in
accordance with the requirements of Section IX of the ASME Boiler & Pressure Vessel Code.

Manufacturer: INDCON PROJECTS & EQUIPMENT LTD.

HEAD QC /HEAD WELDING

INSPECTION AGENCY

Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12/11/07, Page 11 of 11

WELDING PROCEDURE SPECIFICATION - 11

PARTIAL WALL REPAIR
Client

: Indian Oil Corporations ltd.

Procedure No: INDCON-PJPL-STN-MECH-WPS-11

Contractor: Indcon Projects & Equipments Ltd.

Project : Panipat Jalandhar LP Gas Pipeline Projects

Revision : 00
Date: 12th Nov. 2007

For field welding of Pipes

Process
Type
Material
Outer Diameter
Pipe Wall Thickness
Applicable Specification

Joint design:

:
:
:
:
:
:

SMAW
Manual.
A 106 Gr. B
08 Dia
8.17 mm
Latest revision

As Shown in the Sketch

SKETCH SHOWING JOINT DESIGN
FOR 08 DIA PIPE A-106 Gr.B
Welding procedure specification (INDCON-PJPL-STN-MECH-WPS-10)
PARTIAL WALL REPAIR

T Wall Thick

08 DIA
Approx 2.5 - 3 mm

MAXIMUM EXTERNAL OPENING

1.60 to 2.00 mm
4

2
1

Approx 2.5 - 3 mm

SEQUENCE OF BEADS
T= Wall Thickness 8.17 mm

WELDING PROCEDURE SPECIFICATION - 11

PARTIAL WALL REPAIR
Client
: Indian Oil Corporations ltd.
Contractor: Indcon Projects & Equipments Ltd.
Project : Panipat Jalandhar LP Gas Pipeline Projects

Format No: INDCON-PJPL-STN-MECH-WPS-11

Revision : 00
Date: 12 th Nov. 2007

Filler Material:
Runs

Make & Type of Filler Metals

First Run
HONAVAR ER 7018-1(SPL)
Others Runs
HONAVAR ER 7018-1(SPL)
Other Electrical Characteristics : DC
Electrode
: EP
Shielding Gas : N.A
Direction Welding

Current
Type Polar Amp. Range
2.5 mm
EP
-3.15 mm
EP
-Type of Mixture : N.A
Position
:6G
Diameter

Voltage
---

Number of Welders
Root
: One
First Pass:
Up Hill
Second
: One
All others Passes
Up Hill
All other Runs : One
Time Lapse Between completion of root and commencement of second runs
:
4 Minutes (Maximum)
Time Lapse between completion of second run and commencement of subsequent runs: 5 Minutes (Maximum)
Minimum number of runs before joints is allowed to cool
Joint repair to be completed
Maximum arc Length that can be opened
For Root repair 20% of weld length
Maximum time between commencement & Completion of weld
Type of Line Up clamp : NA
Removal of clamp
: NA
Removal of Clamp
: NA
Lowering of on Skids
: NA
Cleaning: Craters, Welding, Irregularities Slag etc:
Pre Heating
: 1000 C Minimum
Type of Heater
: Propane Torch
Layer /
Pass

Filler Metal
Process

AWS
Class

Brand
Name

Dia
(MM)

Polarity
DC/AC

One Heat Cycle

By Grinding / Power Brushing

Post Weld heat treatment : N.A
Speed of Travel
: 60 90 mm / min
Current
Range
(Volts)

For INDCON
Name:
Sign:
Date:

Speed
MM/MM
(Minimum)

Direction
of
Welding

No of
Welders

For IOCL
Name:
Sign:
Date:

No of
Electrodes

Remarks