INDCON PROJECTS & EQUIPMENT LTD.

WORK PROCEDURE
FOR
WELDING OF FIRE WATER PIPELINE
PROJECT

: Panipat-Jalandhar LP Gas Pipeline Project

PROCEDURE NO

: INDCON-PJPL-STN-MECH-WPS-06

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-06 Rev No: 0, Dt. 12/11/07, Page 1 of 10

INDEX
Sl. No.

Description

Page No.

Purpose

03

Scope

03

References

03

List of Equipments

03

5
6

Methodology WPS/ PQR Qualification

Method for welding of process piping

03
04 - 05

Health, Safety & Environment

05

Quality Assurance & Quality Control

05

Documentation

05

10

Inspection test Plan for Welding of Process

Piping

06

11

Welding Procedure Specification (WPS)

07 08

12

Procedure Qualification Record (PQR)

09 10

Procedure No: INDCON-PJPL-STN-MECH-WPS-06 Rev No: 0, Dt. 12/11/07, Page 2 of 10

INDCON PROJECTS & EQUIPMENT LTD.

Procedure for

WELDING OF FIRE WATER PIPELINE

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 fire water
pipeline 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. Welding Machine.
b. Grinding Machine.
c. Buffing Machine.
d. Tong tester.
e. Stop watch

5.0

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.
B.
The welding is carried out on the sample test piece as per the proposed WPS.
C.
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.
D.
The testing shall be conducted as per ASME Sec-IX, latest edition.
Welding for Procedure Qualification shall be carried out only in 6G position.

Procedure No: INDCON-PJPL-STN-MECH-WPS-06 Rev No: 0, Dt. 12/11/07, Page 3 of 10

INDCON PROJECTS & EQUIPMENT LTD.

Procedure for

WELDING OF FIRE WATER PIPELINE

Project: Panipat-Jalandhar LP Gas Pipeline Project
6.0

METHOD FOR WELDING OF FIRE WATER PIPELINE

a.

Before the fit up, pipe shall be checked for correct thickness, free from pitting
and dent, etc. Bevel ends shall be visually checked and repairing is carried out
as mentioned below.
a.
b.
c.

Dents less than 1 mm depth shall be removed by grinding.

Dents 1 mm to 3 mm depth shall be rebeveled by grinding.
Surface check for 100mm and if required LPT to be conducted as
per site inspectors instructions.

b.

Before fit-up, pipe ends inside / outside shall be cleaned by power wire brush
at least for one inch so that the welds are free from rust, paint and other foreign
matters.

c.

If any laminations, split ends or any other manufacturing defects in the pipe be
discovered, the length of the pipe shall be cut to the extent required with the
knowledge of IOCL site engineer & fresh bevel is to be prepared subjected to
100% LPT and visual inspection of a joint record shall be generated.

d.

Root gap shall be as per the approved WPS.

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.

Electrode starting & finishing points shall be staggered from pass to pass.
Interruption between first pass to second pass and to third pass shall be as per
the approved WPS. After completion of the third pass welding may be
suspended if required, so as to allow the weld joint to cool down provided the
thickness of the weld metal deposited shall be 50% of the pipe thickness or
minimum of 03 passes whichever is more. Upon restarting the welding preheating shall be carried out.

Procedure No: INDCON-PJPL-STN-MECH-WPS-06 Rev No: 0, Dt. 12/11/07, Page 4 of 10

INDCON PROJECTS & EQUIPMENT LTD.

Procedure for

WELDING OF FIRE WATER PIPELINE

Project: Panipat-Jalandhar LP Gas Pipeline Project
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. NDT shall be
carried out as per the approved NDT procedures. Repairs shall be done as per
approved WPS and if required it shall be tested for NDT.

7.

HEALTH, SAFETY AND ENVIRONMENT

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

8.

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.

9.

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-06 Rev No: 0, Dt. 12/11/07, Page 5 of 10

INSPECTION TEST PLAN

WELDING OF PROCESS PIPING
: Indian Oil Corporations ltd.
Procedure No: INDCON-PJPL-STN-MECH-WPS-06

Client

Contractor: Indcon Projects & Equipments Ltd.

Project : Panipat Jalandhar LP Gas Pipeline Projects

Revision : 00
Date: 12 th Nov. 2007

Sl. No

Activity Description

Frequency of Inspt/Testing

Submission and obtaining approval of

Procedure

Inspection category
INDCON

IOCL

At the Beginning

AP

Fit up, pre heating and root, Hot pass,

Filler & Final Welding

100% During Qualification

Process

Weld Visual of Completed weld

100% During Qualification

Process

Non Destructive 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-06 Rev No: 0, Dt. 12/11/07, Page 6 of 10

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-06
Revision : 0
PQR-06
Revision : 0
SMAW
Type : Manual

Format No.: INDCON-PJPL-STN-MECH-WPS-06

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

64 deg + 2 deg

6.01 mm
1.
150 mm
1.5mm + 0.8mm
Approx 3-4mm

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

Any

TO
SA 106 Gr. B

P No.: 1

Groove : 1.6 mm to 17.48mm

Groove All
Not applicable
Not applicable

FILLER METALS (QW 404)

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

Group No. : Any

Fillet : All

5.1
E 6010 & E 7018
4
1
2.5mm / 3.15mm
Maximum 32 mm
All
None

POSITIONS ( QW 405)
Position(s) of Groove
Welding Progression
Position of Fillet

All
Uphill (Vertical)
All

PREHEAT ( QW 406 )
Preheat Temp. Min.
Interpass Temp. Max.
Preheat Maintenance

50 C
250 C
Not Required

POST WELD HEAT TREATMENT (WQ-407)

Temperature Range
Not Applicable
Time Range
Not Applicable

GAS ( QW 408 )
Percent Composition
Gas(es)
Mixture
Flowrate
Shielding N/A
N/A
N/A
Trailing
N/A
N/A
N/A
Backing
N/A
N/A
N/A

ELECTRICAL CHARACTERSTICS ( QW 409 )

Current
DC
Polarity
Amps
See Table
Volts
Tungsten Electrode Size & Type
Mode of Metal Transfer for GMAW
Electrode Wire Feed Speed Range

EP
See table
Not Applicable
Not Applicable
Not Applicable

TECHNIQUE ( QW 410 )
String OR Weave Bead
Orifice or Gas Cup Size
Initial & Interpass Cleaning
Method of Back Gouging
Oscillation
Electrode Spacing
Multiple or Single Pass ( Per Side )
Multiple or Single Electrodes
Travel Speed
Peening

String & Weave (3 x Core Dia. Max)

N/A
Chipping/Brushing / Grinding
Grinding
None
N/A.
Multiple
Single
See Table
Not Applicable

Table :
Weld Layers
Root Run
1st Run
2nd Run
3rd Run

Process FILLER METAL

SMAW
SMAW
SMAW
SMAW

Class

Dia.

E 6010
E 7018
E 7018
E 7018

2.5 mm
3.15mm
3.15mm
3.15mm

CURRENT
Type
Amp.
Polar Range
EP
70-95
EP
100-120
EP
100-120
EP
100-120

Volt
Range
20-24
22-24
22-25
22-25

Travel
Speed
Range
-----

Back gouged to defect free sound metal ensured by DP Testing.

1st Run

SMAW

E 7018

3.15 mm

EP

100-120

22-25

--

2nd Run

SMAW

E 7018

3.15 mm

EP

100-120

22-25

--

NOTE:
This welding procedure can be used where impact tests are not required.
APPROVED BY

HEAD QC/ HEAD WELDING

Procedure No: INDCON-PJPL-STN-MECH-WPS-06 Rev No: 0, Dt. 12/11/07, Page 8 of 10

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 /06
WPS No.
WPS /06
Welding Process
SMAW
Type Of Welding Process
Manual

Format No.: INDCON-PJPL-STN-MECH-PQR-06

Dated
12.11.2007
Dated
12.11.2007
64 deg + 2 deg

JOINTS ( QW 402 )
6.01 mm
150 mm

1.5mm + 0.8mm

Approx 3-4mm

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.
6.01 mm
DN 100

POST WELD HEAT TREATMENT (QW-407)

Temperature
Time
Other

----

GAS (QW 408 )

SMAW
SFA Specification
5.1
AWS Classification
E 6010 & E-7018
Filler Metal F No.
4
Weld Metal Analysis A No.
1
Size Of Filler Metal
2.5, 3.15 mm
Other (Electrode trade name)
Weld Metal Thickness
6.02 mm
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
-

Shielding
Trailing
Backing

FOR GTAW ONLY

Percent Composition
Gas
Mixture

Flow rate

NA
NA
NA

NA
NA
NA

NA
NA
NA

ELECTRICAL CHARACTERISTICS (QW 409)

Current
DC
Polarity
EP-SMAW
Amps
80 160
Volt
10-24
Tungsten Electrode Size -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
Single
-

Procedure No: INDCON-PJPL-STN-MECH-WPS-06 Rev No: 0, Dt. 12/11/07, Page 9 of 10

TENSILE TEST (QW 150 )

Specimen No.

Width
( mm )

Thickness
( mm )

Area
( mm )

Ultimate
Total Load
(Newton)

Ultimate
Tensile
Strength
(MPa)

PQR NO. 06
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-06 Rev No: 0, Dt. 12/11/07, Page 10 of 10