Procedure For

Main Line Welding

PROJECT NO.
LAYING & CONSTRUCTION OF 12”, 6” & 4” NB U/G STEEL
PROJECT NAME P/L NETWORK & ASSOCIATED WORKS AT
HYDERABAD.
OWNER BHAGYANAGAR GAS LIMITED (BGL)
CLIENT MECON LIMITED
CONTRACTOR MPEC
JOB PROCEDURE MPEC/BGL/MEC/BF/01
Rev. 0

Procedure
For
Main Line Welding

For Review &

0 30.09.2016
Approval

Checked &
Prepared By Approved By
Rev. Date Description
MPEC
Reviewed By
MECON
MPEC

1 OF7 Procedure for Main Line Welding

 Procedure For
Main Line Welding

TABLE OF CONTENTS

1. PURPOSE
2. SCOPE
3. REFERENCES
4. TERMS AND DEFINITIONS
5. EQUIPMENT LIST
6. METHODOLOGY
7. HEALTH, SAFETY & ENVIRONMENT
8. QUALITY ASSURANCE & QUALITY CONTROL

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 Procedure For
Main Line 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 BGL-CNG & CGD Project Work at Hyderabad by MPEC for executing
the Project.

2.0 SCOPE

This scope covers the MAIN LINE joints for BGL-CNG & CGD Project Work.

3.0 REFERENCES

Following documents in totality or in part shall form the reference documents:

a) Standard MEC Specification: MEC/S/05/21/02

b) Standard for welding of pipelines & related facilities- API 1104(Latest Edition).
c) Specification for welding rods, Electrodes and filler Materials ASME Sec. II, part-C
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:

# Welding Machines # Grinding Machines

# DG sets # Buffing Machine
# Prime Movers # Pick-up Vehicles
# Measuring Tools / Tackles # External Clamps

CONSUMABLE LIST:

ELECTRODE, GAS ….. ETC : TC shall be maintained for all the

consumables…

6.0 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
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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 100% visual 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 8” X 8”
X 4”ft 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 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 offset shall not exceed 3.0 mm.

Before starting of welding works MPEC shall submit batch Certificates of the electrodes
for review by MEC / BGL. 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.

Welding shall be continuous and uninterrupted during the pass

PREHEATING

Pipe shall be heated using LPG Split ring burner wherever specified in the WPS.
Preheat temperature of at least 100º.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. MPEC

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shall inform MEC / BGL, 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
(projection inside the pipe shall not exceed 1.6mm) 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. Peeling 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.

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
12’O’Clock to 9 O’clock. 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

Clamp to be removed after completion of Root Pass. The pipe shall be lowered on pre-
positioned skids after completion of Hot Pass.

HOT PASS
Welding progression shall be same as root pass; second pass shall start within the
time qualified during procedure qualification.

FILLER AND CAPPING

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

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Every pass shall be cleaned by power-brush, grinding machine and chisel,

starting and finishing points shall be staggered for every pass.

CAPPING AND INSPECTION

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 tender
technical specification.

7.0 HEALTH, SAFETY & ENVIRONMENT

Note: The approved procedure for health, safety and environment shall be followed
during execution.

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

2. PPE shall be used by all crew.
3. Only trained rigging personnel to be deployed for this activity.
4. During fit up operation special care to be taken to avoid personal injury.
5. Personnel around the machine must be cautious about frequent handling of pipes.
6. 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 & Tolls 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.

8.0 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.

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Note: In case of any conflict between the requirements of this procedure and MEC tender
technical Specification the later shall govern.

7 OF7 Procedure for Main Line Welding