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INDCON PROJECTS & EQUIPMENT LTD.

Project

: Panipat-Jalandhar LP Gas Pipeline Project

Owner

: Indian Oil Corporation Limited, NRPL- PANIPAT

Contractor

: Indcon Projects & Equipment Ltd.

WORK PROCEDURE
FOR
ELECTRODE QUALIFICATION
INDCON-PJPL-STN-MECH-WPS-16

Date: 27th OCT. 2007

00
Rev. No

27.10.07
Date

Submitted
for approval
description

Ajit
Prepared
by

Amit
Checked
by

GSB
Approved
by

Approved by
IOCL

Procedure No: INDCON-PJPL-STN-MECH-WPS-16 Rev No: 0, Dt. 27/10/07, Page 1 of 11

INDEX
Sr.No.

Description

Page No.

Purpose

References

Scope

Equipment

Methodology

35

Sketches

57

Health, Safety and Environment

Documentation

Inspection Test Plan for Electrode Qualification

10

Inspection Report for Electrode Qualification

11

Welding Qualification Specification

10-11

Procedure No: INDCON-PJPL-STN-MECH-WPS-16 Rev No: 0, Dt. 27/10/07, Page 2 of 11

INDCON PROJECTS & EQUIPMENT LTD.


Procedure for

ELECTRODE QUALIFICATION
Project: Panipat-Jalandhar LP Gas Pipeline Project
1.

PURPOSE
The procedure covers the requirement to carry out the necessary tests for
qualification of electrodes.

2.

REFERENCE
1)
2)
3)
4)

3.

IOCL Specification
ASTM A 106 Gr. B
ASME Sec-II Part C
Attached inspection and test plan

SCOPE
This scope covers the qualification test requirements for the electrodes to be
used for Panipat Jalandhar LP Gas Pipeline Project.

4.

EQUIPMENT
Welding Machine, Consumables, Tongue Tester, Stop watch etc.

5.

METHODOLOGY

1. a

DETAIL OF PROCESS AND REQUIREMENTS FOR ELECTRODE ER 70S2

Base Material Can be used

: A 285 Grade A or A 285 Grade B

For testing

: ASTM A 106 Gr. B

Process

: GTAW

Electrode Diameter

: 2.0 mm

Electrical Characteristics

: DCEN (DC, Straight Polarity)

Tungsten type

: EWTh02

Shielding Gas

: Argon

Joint Design

: As per Sketch No : 1

Procedure No: INDCON-PJPL-STN-MECH-WPS-16 Rev No: 0, Dt. 27/10/07, Page 3 of 11

INDCON PROJECTS & EQUIPMENT LTD.


Procedure for

ELECTRODE QUALIFICATION
Project: Panipat-Jalandhar LP Gas Pipeline Project
DETAIL OF CONSUMABLES

1. c

a.

Manufactures Name

b.

Batch No.

c.
d.
e.

Welding Position
Pre-Heat Temperature
Inter pass Temperature

REQUIRED TEST
a. Chemical Analysis
b. All-Weld Metal
Tension Test
c.

: Only of Bare Wire As per ASME Sec II Part C


SFA 5.18
: As per ASME Sec II Part C SFA 5.18

All Weld Impact : As Per ASME Sec II Part C SFA 5.18


Test

d. Radiographic Test

2. a

: As Per ASME Sec II Part C SFA 5.18

DETAIL OF PROCESS AND REQUIREMENTS FOR ELECTRODE E7018-1


Base Material used
For testing
Process
Electrode Diameter
Electrical Characteristics
Joint Design

2. b

: Will be written in the qualification test


record format
: Will be written in the qualification test
record format
: All Position
: Min 100 C.
: 105 C to 175 C

:
:
:
:
:
:

A 285 Grade A or A 285 Grade B


ASTM A 106 G
SMAW.
2.50 mm, 3.15 mm and 4.0 mm
DCEP (DC, Reverse Polarity)
As per Sketch No : 2, 3 & 4

DETAIL OF CONSUMABLES
a.

Manufactures Name

b.

Batch No.

c. Welding Position
d. Pre-Heat Temperature
e. Inter pass Temperature

: Will be written in the qualification test


record format
: Will be written in the qualification test
record format
: All Position
: Min 100 C.
: 105 C to 175 C

Procedure No: INDCON-PJPL-STN-MECH-WPS-16 Rev No: 0, Dt. 27/10/07, Page 4 of 11

INDCON PROJECTS & EQUIPMENT LTD.

Procedure for

ELECTRODE QUALIFICATION
Project: Panipat-Jalandhar LP Gas Pipeline Project
2. c

REQUIRED TEST

a.

Chemical Analysis

: Preparation of test pad, as per As per ASME Sec II

b.

All-Weld Metal Tension Test

Part C
: As Per ASME Sec II Part C, SFA 5.1

c.

All Weld Impact Test

: As Per ASME Sec II Part C, SFA 5.1

d.

Radiographic Test

: As Per ASME Sec II Part C, SFA 5.1

e.

Moisture Test

: As Per ASME Sec II Part C, SFA 5.1

1.

SKETCHES

45 0
.

16 mm
6.35mm Min.

150 mm

7.0 mm

SKETCH 1 for ER 70S2, 1.6 & 2.0 mm

Procedure No: INDCON-PJPL-STN-MECH-WPS-16 Rev No: 0, Dt. 27/10/07, Page 5 of 11

INDCON PROJECTS & EQUIPMENT LTD.

Procedure for

ELECTRODE QUALIFICATION
Project: Panipat-Jalandhar LP Gas Pipeline Project

60 0
.

16 mm
6.35mm Min.

150 mm

13mm

SKETCH 2 for E7018-1, 2.50 mm

45 0
.

16 mm
6.35mm Min.

150 mm

13mm

SKETCH 3 for E7018-1, 3.15 mm

Procedure No: INDCON-PJPL-STN-MECH-WPS-16 Rev No: 0, Dt. 27/10/07, Page 6 of 11

INDCON PROJECTS & EQUIPMENT LTD.


Procedure for

ELECTRODE QUALIFICATION
Project: Panipat-Jalandhar LP Gas Pipeline Project

45 0
.

20 mm
6.35mm Min.

150 mm

16mm

SKETCH 4 for E7018-1, 4.0 mm


7.

HEALTH, SAFETY AND ENVIRONMENT


Hazard identification and risk assessment will be carried out and operational
control measures shall be adopted during preparing the test pieces for electrode
qualification tests.
1.

PPE is a must in this activity.

2.

Fire protections system shall be handled carefully.

8.

DOCUMENTATION
Welding Procedure Specification : INDCON-PJPL-STN-MECH-WPS-16
Inspection Test Plan

: INDCON-PJPL-STN-MECH-ITP-16

Inspection Report

: INDCON-PJPL-STN-MECH-FM-16

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-16 Rev No: 0, Dt. 27/10/07, Page 7 of 11

INSPECTION TEST PLAN


FOR
ELECTRODE QUALIFICATION OF STATION PIPING
Client

: Indian Oil Corporations ltd.

Contractor: Indcon

Projects & Equipments Ltd.

Procedure No: INDCON-PJPL-STN-MECH-ITP-16


Revision : 00

Project

: 27 th Oct. 2007

: Panipat Jalandhar LP Gas Pipeline Projects Date

Sr.
No

Activity Description

Frequency of Insp./
Testing

Approval of procedure for electrode


qualification

Check base metal grade, dimension, thk

Check detail of welding consumables

Inspection of welding process

Perform required tests on test piece as


mentioned in approved procedure

Safety

App Proc
Once for each
classification, thk. Of
electrode
Once for each
classification, thk. Of
electrode
Once for each
classification, thk. Of
electrode
Once for each
classification, thk. Of
electrode
Throughout

Inspection Category
INDCON

IOCL

AP

Remarks

Legend
P

: Person

AP : Approval
R

: Review Documents

For INDCON PROJECTS & EQUIPMENTS LTD.

For INDIAN OIL CORPORATIONS LTD.

Name:

Name:

Sign:

Sign:

Date:

Date:

Procedure No: INDCON-PJPL-STN-MECH-WPS-16 Rev No: 0, Dt. 27/10/07, Page 8 of 11

INSPECTION REPORT
FOR
ELECTRODE QUALIFICATION FOR STATION PIPING

Client

Format No: INDCON-PJPL-STN-MECH-FM-16

: Indian Oil Corporations Ltd.

Contractor: Indcon Projects & Equipments Ltd.


Project : Panipat Jalandhar LP Gas Pipeline Projects

Revision : 00
Date:

ELECTRODE DETAILS
AWS Classification

Batch No.

Current Conditions

Brand Name

MTC No.

Welding Currents

Size of Electrodes
MANUFACTRURE DETAILS
Name:
TEST SPECIMEN DETAILS
Material Specification:
Thickness:

Joint Type:

WELDING DETAILS:
Layers

Process

Filler Metal
Class

Dia

Current Type

Ampere
Range

Volt
Range

Travel
Speed
Range

Welder Name:
Welder No:
Test Results
Visual Inspection

Report No

Radiography Test

Report No

Bend Test

Report No

All Weld Tensile Test

Report No

All Weld Impact Test

Report No

Moisture Test

Report No

For INDCON PROJECTS & EQUIPMENTS LTD.

Name:
Sign:
Date:

For INDIAN OIL CORPORATIONS LTD.

Name:
Sign:
Date:

Procedure No.: INDCON-PJPL-STN-MECH-WPS - 17 Rev No: 0, Dt. 27/10/07, Page 9 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-16
Revision : 0
PQR-16
Revision : 0
GTAW + SMAW
Type : Manual

JOINT (QW-402)
Joint Design : As per fabrication drawing
Backing
: Without backing
Backing material : Weld metal

Format No.: INDCON-PJPL-STN-MECH-WPS-16


Dated : 27.10.2007
Dated - 27.10.2007

30 deg + 2 deg

Retainers : Not required


5.54 mm
1.
150 mm
1.5mm + 0.8mm
Approx 2-3mm

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-16 Rev No: 0, Dt. 27/10/07, Page 10 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

D.C.
See table

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

WPS - 16
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-16 Rev No: 0, Dt. 27/10/07, Page 11 of 11