REPLACEMENT OF PIPE IN MPPL

CLIENT: HINDUSTAN PETROLEUM CORPORATION LTD.

CONTRACTOR: NARMADA OFFSHORE CONSTRUCTIONS PVT. LTD.
WELDING PROCEDURE SPECIFICATION
Doc. No.: NOCPL/HPCL/RPM/RK/WPS/JP/02 Rev. 00

A. Process & Method Type : SMAW & MANUAL

B. Material : API 5L Gr. X46 to X65
C. Diameter & Wall Thickness: 14" & 6.4mm to 9.5mm
D. Range of Diameter Qualified: Above 12.7"
E. Range of Wall Thickness Qualified: 4.8mm to 19.1mm
F. Joint Design: Single Side Bevel Butt Joint (Ref Sketch)
1. E6010 AWS SFA5.1, 2.5mm Dia., For Root Pass
G. Filler Metal & No. of Passes:
2. E7018 AWS SFA5.1, 3.15mm Dia, For Other Passes
H. Electrical Characteristics: DCEP
I. Position: 5G, Horizontally Fixed
J. Direction of Welding: All passes Uphill.
K. No. of Welders: Two
Root Pass to Hot Pass: Max. 04 Minutes
L. Time Laps between Passes:
Hot Pass to Filler Pass: Max. 05 Minutes.
M. Type of Lineup Clamp: External
N. Removal of Clamp: After Completion of Root Pass
O. Min. no. of Passes before joint is allowed to cool: At least 3 Passes or 50% of pipe wall thickness.
P. Cleaning of weld: Power Brushing or grinding.
Q. Pre-heat Preheat 100°C by LPG Torch.
R. Inter-pass Temperature Max. 250°C
S. Shielding gas & flow rate NA
T. Shielding flux NA
U. Speed of weld travel Pls. refer table
V. Max. time between commencement and completion 24 Hours
SKETCH
37.5° Deg. ± 5°

1.6mm
1.4mm to
*T=Thickness of Pipe.
2.0mm

ELECTRICAL CHARATERISTICS
Electrode Dia in Speed in Max Heat Input
Passes Electrode Type Polarity Amps. Volts
Make MM mm/min. (in KJ/MM)
Root E6010 ADOR 2.5 DCEP 90-105 25-28 206-270
Hot E7018 ADOR 3.15 DCEP 139-165 31-35 270-302
Filler-1 E7018 ADOR 3.15 DCEP 127-140 27-30 142-233
Filler-2 E7018 ADOR 3.15 DCEP 119-136 27-33 150-233
Capping E7018 ADOR 3.15 DCEP 115-132 26-33 120-165

FOR NOCPL FOR TPIA FOR HPCL

SIGN SIGN SIGN

NAME NAME NAME

DATE DATE DATE

 PROCEDURE QUALIFICATION RECORD

Ref: API 1104 & HPCL Specification

Project: REPLACEMENT OF PIPE IN MPPL
Client: M/s. Hindustan Petroleum Corporation Ltd.
Contractor: M/s. Narmada Offshore Constructions Pvt. Ltd.
PQR No.: NOCPL/HPCL/RPM/RK/PQR/JP/02 Rev.00
Welding Process: SMAW
Joints (QW-402) 37½°±2½°
Joint Design: Single Butt Weld
Backing: No
Backing Material (Type): NA 2 mm
Base metal (QW-403)
Material Spec. : API 5L
Type or Grade : Gr. X-56 to X-65
P.No. : 1 to P.No. : 1
Thickness : 6.4mm
Diameter : 14" (INCH)
Other :
Filler Metals (QW-404) SMAW SMAW
Weld Metal Analysis A.No. 1 1
Size of Electrode 2.5mm 3.15mm
Filler Metal F.No. 4 4
SFA Specification 5.1 5.1
AWS Classification E6010 E7018
Other
Position (QW-405)
Position of Groove : 5G
Weld Progression : Uphill
Other :

Preheat (QW-406)
Preheat Temp. : Ambient
Interpass Temp. : 250°C
Other :
Postweld Heat Treatment (QW-407)
Temperature : NA
Time : NA
Other : NA

Gas (QW-408)
Type of Gas or Gas : : NA
Composition of Gas Mixture : NA
Other : NA

Electriacal Characteristics (QW-409)

Current : DC
Polarity : DCEP
Amps. : 80-130
Volts : 15-35

Technique (QW-410)
Travel Speed : 60-120mm/min.
String or Weave Bead : String for Root & Weave Bead for other Passes.
Oscillation : 2.5times of Electrode core dia.
Multipass or Single Pass : Multipass
Single or Multiple Electrodes : Multiple
Other :
Tensile Test (QW-150)
Specimen no. Width(mm) Thick.(mm) Area(mm²) U.T.S.(N/mm²) Character of Failure
T-1 19.00 14.33 272.27 600.00 Broken from outside the weld
T-2 19.06 14.40 274.46 596.00 joint
Specified UTS : 414.0 N/mm²

Guided Bend Tests (QW-160)

Specimen no. Thickness (in mm) Width (in mm) Diameter (in mm)
Side Bend 1 10.00 14.36 40.00
Side Bend 2 10.00 14.36 40.00
Side Bend 3 10.00 14.36 40.00
Side Bend 4 10.00 14.36 40.00

Impact Test (QW-170)

Specimen no. Notch Location Specimen Size Test Temperature Impact Value
1 150 J
2 Weld 150 J
3 156 J
1 140 J
2 HAZ 10 x 10 x 55 0°C 154 J
3 140 J
1 208 J
2 Parent Metal 192 J
3 186 J
Min. Req. Value : 27 J (Avg.)

Fillet Weld Test (QW-180) : NA

Macro Test : Satisfactory

Hardness Test (HV-10)

Location Vlaues of HV-10
PM 253, 251, 251, 249, 247, 249, 249, 247, 249, 247, 245, 247
HAZ 157, 156, 157, 158, 158, 157, 158, 157, 158, 157, 157, 156
WELD 173, 172, 172, 172, 172, 174

FOR NARMADA OFFSHORE CONSTRUCTIONS PVT. LTD. FOR HINDUSTAN PETROLEUM CORPORATI
SIGN: SIGN:

NAME: NAME:
NAME: NAME:

DATE: DATE:
Date: 07.12.2016
W.O. No. 16000173-OP-11577/AKK
Ref. WPS No. : NOCPL/HPCL/RPM/RK/W
PS/JP/02 Rev.00
Type: Manual

2.5 to 3.2mm
 Character of Failure Observation
oken from outside the weld Acc
joint Acc

Observation
Satisfactory
Satisfactory
Satisfactory
Satisfactory

Average Observation

152.00 J

Satisfactory
144.67 J

195.33 J

7, 249, 247, 245, 247

7, 158, 157, 157, 156
2, 174

AN PETROLEUM CORPORATION LIMITED