INDCON PROJECTS & EQUIPMENT LTD.

WORK PROCEDURE
FOR
WELDING PROCEDURE QUALIFICATION
IN
STATION PIPING
PROJECT

: Panipat-Jalandhar LP Gas Pipeline Project

PROCEDURE NO

: INDCON-PJPL-STN-MECH-WPS-17

OWNER

: Indian Oil Corporation Limited, NRPL- PANIPAT

CONTRACTOR

: Indcon Projects & Equipment Ltd.

Date: 27th OCT. 2007

00

27.10.07

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-17 Rev No: 0, Dt. 27/10/07, Page 1 of 11

INDEX
Sr.No.

Description

Page No.

Purpose

03

Scope

03

References

03

List of Equipments

03

5
6

Methodology WPS/ PQR Qualification

Proposed WPS and Application

03 04
04

Health, Safety & Environment

05

Quality Assurance & Quality Control

05

Documentation

05

10

Inspection test Plan for Welding Procedure Qualification

07

11

Welding Procedure Specification (WPS)

08 09

12

Procedure Qualification Record (PQR)

10 11

Procedure No: INDCON-PJPL-STN-MECH-WPS-17 Rev No: 0, Dt. 27/10/07, Page 2 of 11

INDCON PROJECTS & EQUIPMENT LTD.

Procedure for

WELDING PROCEDURE QUALIFICATION

Project: Panipat-Jalandhar LP Gas Pipeline Project
1.0

PURPOSE
This procedure describes the steps to be followed for Qualification of WPS and
of station piping.
2.0

3.0

PQR

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. Welding Machine.
b. Grinding Machine.
c. Buffing Machine.
d. Weld Gauge.
e. Tong tester. (Calibrated and with certificate of calibration)
f. 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 following test shall be conducted as per ASME Sec-IX, latest edition.
Welding for Procedure Qualification shall be carried out only in 6G position.
E
Mention the no. of welders regarding for a single joint.

Procedure No: INDCON-PJPL-STN-MECH-WPS-17 Rev No: 0, Dt. 27/10/07, Page 3 of 11

INDCON PROJECTS & EQUIPMENT LTD.

Procedure for

WELDING PROCEDURE QUALIFICATION

Project: Panipat-Jalandhar LP Gas Pipeline Project
DESTRUCTIVE TESTING

Having passed the visual testing, the test weld shall be subjected to mechanical test.
Test specimen for Tensile, Root Bend & Face Bend shall be taken from the test piece
as position indicated in fig.1.
Test specimen for Impact test shall be taken from test piece as the position indicated
fig.2.
Test specimen for Hardness test taken from test piece from any position.

Type, No: & size of. Test Specimens for Procedure Qualification test is as per table below.
S. No.

Type Of Test

1
2
3
4
5

Tensile
Root Bend
Face Bend
Hardness
Charpy V-Notch

6.0
Sr.

No. Of
Specimens
2
2
2
3
5

Size of Specimens As
per
Spec & ASME Sec-IX
Spec & ASME Sec-IX
Spec & ASME Sec-IX
Spec & ASME Sec-IX
Spec & ASME Sec-IX

Acceptance
Criteria
ASME Sec-IX
ASME Sec-IX
ASME Sec-IX
ASME Sec-IX
IOCL Specification

PROPOSED WPS AND APPLICATION

WPS
No

Test
Coupon
Size

Process

Min. Thk.
Qualified

Max.
Thk.
Qualified

Stress
Relieving

GTAW+SMAW

4.54 MM

28.6MM

NO

Application
Original +
additional

NOTE
If range of thickness is not covered in proposed WPS then required WPS shall be
qualified later as per this procedure.
PROPOSED MATERIAL FOR WPS
The procedure shall be qualified ASTM A 106 Gr. B.

Procedure No: INDCON-PJPL-STN-MECH-WPS-17 Rev No: 0, Dt. 27/10/07, Page 4 of 11

INDCON PROJECTS & EQUIPMENT LTD.

Procedure for

WELDING PROCEDURE QUALIFICATION

Project: Panipat-Jalandhar LP Gas Pipeline Project
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 ITP.

9.

DOCUMENTATION
Inspection Test Plan

INDCON-PJPL-STN-MECH-ITP-17

Welding Procedure Specification

INDCON-PJPL-STN-MECH-WPS-17

Procedure Qualification Record

INDCON-PJPL-STN-MECH-PQR-17

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-17 Rev No: 0, Dt. 27/10/07, Page 5 of 11

INDCON PROJECTS & EQUIPMENT LTD.

Procedure for

WELDING PROCEDURE QUALIFICATION

Project: Panipat-Jalandhar LP Gas Pipeline Project
LOCATION OF TEST BUTT WELDS SPECIMENS FOR WELDING PROCEDURE QUALIFICATION

Figure -1

Figure 2
Procedure No: INDCON-PJPL-STN-MECH-WPS-17 Rev No: 0, Dt. 27/10/07, Page 6 of 11

INSPECTION TEST PLAN

WELDING PROCEDURE SPECIFICATION

Client

: Indian Oil Corporations ltd.

Format No: INDCON-PJPL-STN-MECH-ITP-17

Contractor: Indcon Projects & Equipments Ltd.

Revision : 00
Project : Panipat Jalandhar LP Gas Pipeline Projects Date: 27 th Oct. 2007
Sr. 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

R/W

Weld Visual of Completed weld

100% During Qualification

Process

R/W

Destructive Test of Weld

Once for Each PQR

R/W

Procedure Qualification Test

Once prior to start of

welding process

R/W

Approval of WPS

Once prior to start of

welding process

Safety

Throughout

Legend
P : Perform , R : Review Documents , RM : Random, AP : Approval, W

For Indcon Projects & Equipment Ltd.

: Witness

For IOCL

Name:
Sign:

Name:
Sign:

Date:

Date:

Procedure No: INDCON-PJPL-STN-MECH-WPS-17 Rev No: 0, Dt. 27/10/07, 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-17
Revision : 0
PQR-17
Revision : 0
GTAW + SMAW
Type : Manual

Format No.: INDCON-PJPL-STN-MECH-WPS-17

Dated : 27.10.2007
Dated - 27.10.2007

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

30 deg + 2 deg

5.54 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

Group No. : Any

Fillet : All

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
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

GTAW
5.18
ER-70S-2
6
1
2.0 mm

SMAW
5.1
E7018
6&4
1
2.5 mm

1.6 mm to 17.48 mm
All sizes
None

All sizes
None

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-17 Rev No: 0, Dt. 27/10/07, 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 - 17
Dated : 27.10.2007
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

Root run
1st run
2nd run &
Subsequent runs

GTAW
SMAW
SMAW

Performed by

Class

Dia.

ER-70S2
ER-7018
ER-7018

2.0 mm
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
DCEN
DCEP
DCEP

Checked by

Approved by

Procedure No: INDCON-PJPL-STN-MECH-WPS-17 Rev No: 0, Dt. 27/10/07, 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

Format No.: INDCON-PJPL-STN-MECH-PQR-17
Procedure Qualification Record No.
PQR /17
Dated
26.09.2007
WPS No.
WPS /17
Dated
26.09.2007
Welding Process
GTAW + SMAW
Type Of Welding Process
Manual
30 deg + 2 deg
JOINTS ( QW 402 )
5.54 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.
5.54 mm
DN 50

POST WELD HEAT TREATMENT (QW-407)

Temperature
Time
Other

----

GAS (QW 408 )

GTAW
SFA Specification
5.18
AWS Classification
ER 70S2
Filler Metal F No.
6
Weld Metal Analysis A No.
1
Size Of Filler Metal
2.0 MM
Other (Electrode trade name)
Weld Metal Thickness
1.6 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
-

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%
---

3.94 mm
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-17 Rev No: 0, Dt. 27/10/07, Page 10 of 11

TENSILE TEST (QW 150 )

Specimen No.

Width
( mm )

Thickness
( mm )

Area
( mm )

Ultimate
Total Load
(Newton)

Ultimate
Tensile
Strength
(MPa)

PQR NO. 17
Date : 26.09.2007
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-17 Rev No: 0, Dt. 27/10/07, Page 11 of 11