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PROCEDURE FOR MAINLINE

WELDING

PROJECT NO.

IOAGPL/WO-STLYG-PANIPAT-UDN/016

PROJECT NAME

LAYING & CONSTRUCTION OF 8 NB & 4 NB U/G STEELP/L


NETWORK & ASSOCIATED WORKS FOR INDIAL OIL-ADANI GAS
PVT.LTD AT PANIPAT GA

CLIENT

IOAGPL

CONTRACTOR

AMP INFRA PVT LTD

Rev.

00

Procedure
For
Mainline Welding
PROCEDURE NO: AMP/IOAGPL/STEEL/JP-03

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Procedure for Mainline Welding

PROCEDURE FOR MAINLINE


WELDING

00

09-12-2015

For Review &


Approval

Rev.

Date

Description

Prepared By
AMP

Checked By
AMP

TABLE OF CONTENTS

1.

PURPOSE..3

2.

SCOPE.3

3.

REFERENCES..3

4.

TERMS AND DEFINITIONS3

5.

EQUIPMENT LIST..3

6.

METHODOLOGY...3-6

7.

HEALTH, SAFETY & ENVIRONMENT6

8.

QUALITY ASSURANCE & QUALITY CONTROL..7

9.

APPENDICES / FORMATS.7

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Procedure for Mainline Welding

Approved By
TPIA/IOAGPL

PROCEDURE FOR MAINLINE


WELDING

1.0

PURPOSE
The purpose of this work instruction is to lay guidelines and requirements and to
establish a method or a system to control the MAIN LINE activity and inspection to
be used in the IOAGPL Project Work at Panipat by AMP INFRA PVT LTD for executing
the Project.

2.0

SCOPE
This scope covers the MAIN LINE joints for IOAGPL Project Work.

3.0

REFERENCES
Following documents in totality or in part shall form the reference documents:
a) Standard IOAG Specification.
b) Standard for welding of pipelines & related facilities- API 1104(LATEST).
c) Specification for welding Electrodes Materials ASME Sec. II, part-C

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d) Standard for Design and Construction Requirements for Cross country Hydrocarbon
Pipeline, OISD 226
e) Standard For Non Destructive examination, ASME Sec-V
f) Specification For Destructive Testing for Metallic Material, ASTM E23 & ASTM E92
4.0

TERMS & DEFINITIONS


For the Purpose of this document, the term shall indicates a mandatory requirement
and should indicates a recommended practice.

5.0

EQUIPMENT LIST:
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6.0

Welding Machines
DG sets
Prime Movers/Hydra
Measuring Tools / Tackles

#
#
#
#

Grinding Machines
Buffing Machine
Pick-up Vehicles
External Clamps

METHODOLOGY
Each length of pipe shall be thoroughly examined internally and externally. To make
sure it is free from visual defects, corrosion, dirt or foreign matter. Each pipe length
shall be adequately swabbed to remove foreign matter and pulled through proper to
ensure it is free from dirt before lineup. While using pull through proper care should be
taken to avoid damage of coating before welding, all rust and foreign matter shall be
removed from the beveled ends by power-operated tools. This shall be affected inside
and outside and for a minimum distance of 25mm from the edge of the weld bevel. On
pipes, which have been cut back, a zone extending 25mm back from the new bevel,
shall be ultrasonically tested to the requirement of the line pipe specifications to
ensure freedom from laminations. The new bevel shall be subjected 100% visual &
100% DPT tested. A report shall be written for all testing and records.
ALIGNMENT, FIT UP
Pipes shall be checked for correct thickness, dia. and spec. with respect to the
approved alignment sheets. The first pipe shall be positioned on skids of height 500
mm from the ground, skid shall be prepared by cross stacking wooden logs of 6 X 6
X 4ft long or some other suitable size up to a height of 500 mm (min.) and such
supports shall be minimum two per pipe and skid shall have soft pads placed over
them to avoid damage to the FBE coating, Pipes shall be
locked to prevent their
rolling from the skids.. The second pipe shall be held by Hydra and shall be aligned
with the first pipe and the external clamp shall be actuated. The root gap& ROOT FACE

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Procedure for Mainline Welding

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shall be checked accurately and shall be as per qualified WPS. Long seams of the pipes
shall be staggered in the top 2 & 10 O Clock of the pipe or 250 mm whichever is less.
For pipe of same nominal wall thickness the off set shall not exceed 1.6 mm. Before
starting of welding works AMP INFRA PVT LTD shall submit batch Certificates of the
electrodes for review by IOAG. Only approved batch of electrodes / filler wires shall be
used at site.
WELDING RETURN CIRCUIT:
Earthing clamp shall be used for connecting pipe to welding machine terminal.
WELDING
Welding shall be done as per the approved welding procedure specifications (WPS).
Only qualified welders shall be engaged and each welder shall bear an identity card
during welding operation. For diameter less than 12 the number of welders shall be
decided based on PQR / WPQ.
PREHEATING
Pipe shall be heated using LPG Split ring burner wherever specified in the WPS.
Preheat temperature of at least 100.C (winter or monsoon period) shall be maintained
prior to commencement of root run and subsequent runs. The burners shall be equally
spaced, so as to ensure uniform heating all around the joint. The temperature shall be
checked by calibrated temperature crayons and digital pyrometers.
ROOT RUN PROCESS
The root gap shall be accurately checked and shall be as per qualified WPS. The use of
External clamp shall not be released before 60% completion of the root pass. AMP
INFRA PVT LTD shall inform IOAG, if any section of pipeline containing incomplete
welds falls from the skids.
The root pass of butt joints shall be executed properly so as to achieve full penetration
with complete fusion of the root edges. Welding shall not be interrupted during a pass
and shall be completed as early as possible.
Any kind of movement of components, shocks, vibrations, bumping and stresses are
prohibited while welding is in progress. Peening shall not be permitted. Once the
deposit of first pass has been started, it must be completed as rapidly as possible
to reduce interruption to the minimum. The welding speed shall be approximately
same as that established in the qualified welding procedure.
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Procedure for Mainline Welding

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STARTING
Welder shall start from 12'O' clock position and proceed towards 6'O' clock position
then start from 9`O`clock position and proceed towards 6`O`clock position then from
12OClock to 9 Oclock. Welder shall be overlapping the weld at 12 O clock position.
CLOSING
Welder shall close by over-lap 6 O' clock position then close overlap 9 'O clock
position.
CLEANING
Removing the flux craters, welding irregularities slag etc. by Grinding & Buffing wheel.
REMOVAL OF CLAMP
External line up clamp shall be released only after 60 of root welding is completed.
HOT PASS
Welding progression shall be same as root pass; second pass shall start within the time
qualified during procedure qualification.
FILL AND CAP
Soon after cleaning the hot pass, filling and capping starts within the time qualified
during procedure qualification. Two weld beads shall not be started from the same
location, if required; welding may be suspended after the completion of the third pass
or 50% of pipe wall thickness, whichever is greater so as to allow the joint to cool
down.
The skids used in during welding shall be removed only, after completion of full
welding.
CLEANING AND RESTARTING
Every pass shall be cleaned by power-brush, grinding
machine
starting and finishing points shall be
staggered for every pass.
CAPPING AND INSPECTION

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Procedure for Mainline Welding

and

chisel,

PROCEDURE FOR MAINLINE


WELDING

Capping shall be max 1.6 mm over the surface of the pipe. Spatters shall be removed
and cleaning shall be done by
power
brush
and
any
remedial grinding
necessary, shall be performed limited to dressing.
SUBSEQUENT PIPE ALIGNMENT
Further, joints shall be welded

in

the same manner as explained above.

WEATHER PROTECTION
Wind-shield made of metallic frame covered by. G.I sheets/ canvas/ HDPE sheet shall
be provided
to
cover
the
welders and joint during welding, if necessary
to
protect against rain/ drizzling/ wind.
VISUAL EXAMINATION
All finished welds shall be visually inspected for excessive reinforcement,
concavity of welds, shrinkage, cracks, undercuts, dimensions of weld surface.
Porosity and other surface defects. If any such defects are noticed they shall be
rectified. Night Caps to be welded after completion of main line section as per IOAG
specification.
7.0

HEALTH, SAFETY & ENVIRONMENT


Note: The approved procedure for health, safety and environment shall be followed
during execution.
1.
2.
3.
4.
5.
6.

The machine operators Involved must be an experienced / competent Person.


PPE shall be used by all crew.
Only trained rigging personnel to be deployed for this activity.
During fit up operation special care to be taken to avoid personal injury.
Personnel around the machine must be cautious about frequent handling of pipes.
During the movement of equipment the operator must blow horn to caution the
people around.
7. All Measuring & Test Equipment used must be well maintained.
8. All lifting devices & Tools used shall be well maintained and approved by a
competent authority.
9. It is to be taken care that no spillage of fuel or lubricants is allowed at site.

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QUALITY ASSURANCE & QUALITY CONTROL


Quality Assurance shall be maintained by ensuring the systematic implementation of
this procedure and ensure that necessary quality records are generated.

9.0

FORMATS
Appendix-I
Appendix-II

: Inspection & Test plan


: Inspection Report

AMP/ IOAGPL/STEEL/ITP/05
AMP/ IOAGPL/STEEL/IR/05

Note: In case of any conflict between the requirements of this procedure IOAGPL Specification
the later shall govern.

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Procedure for Mainline Welding