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Welding Grooving Procedure
Welding Grooving Procedure
Welding/Grooving Procedure
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WELDING/GROOVING
PROCEDURES
Designation
Name
Prepared by
Reviewed by
Approved by
QA/QC Manager
QA/QC Manager
Signature
Date
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Table of Contents
1.0
Objective 03
2.0
Scope .. 03
3.0
References/ Abbreviations 03
4.0
Responsibilities 03
5.0
6.0
PPE Materials 06
7.0
Quality Requirements . 07
8.0
Manpower ...07
9.0
10.0
Welding ........................................................................................................... 08
11.0
12.0
13.0
14.0
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OBJECTIVE
The objective of this procedure is to ensure that production welding and/or groove
joining shall be done in accordance with the contract specifications, related codes &
standards and required quality standards shall be met.
2.0
SCOPE
This welding procedure covers all aspects of field and fabrication (production)
welding for the General Authority of Civil Aviation (Client) i.e. environmental
conditions, pipe laying and welding, inspections & testing and weld traceability.
In this procedure, qualification of welding procedures and welders, including NDT
and destructive testing, the instruction of welders, including the selection of welding
procedure based on the primary base material (pipes, fittings, flanges, spools)
characteristics, i.e. steel grade, wall thickness, diameter, and the specific Welding
Procedure Specification are not included. These are to be submitted separately.
This also includes procedure for grooving piping system as per project specification.
3.0
REFERENCES
API 5L
ASME B31.3
Process Piping
ASME IX
ASME V
ANSI/AWWA C-606
ABBREVIATIONS
4.0
NDT
SMAW
GTAW
WPS
RESPONSIBILITIES
4.1
all works
Project Manager
The Project Manager will be in charge of the full implementation of
related to the construction as required by the Employer.
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Construction Manager
QA/QC Engineer
All welds and weld repair will only be allowed as per approved procedure.
provided
of the
300mm
and the
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Ensure the traceability of materials. For pipe to be cut, make sure that
traceability (heat number) of both have. Copy/write the heat
number to the other cut length.
4.4
Site Engineer
Site Foremen
Safety Engineer
Conduct the safety induction course to all personnel involved in the work.
Ensure that the projects method statement and risk assessment are
understood, complied and applied in the worksite.
Ensure that all workers are provided with sufficient information regarding
workplace hazards and planned control measures.
4.7
Safety Officer
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The welder is responsible for starting his welding activities at the correct
temperature as specified in WPS, and performing the welds according to
approved WPSs. The welder should also visually inspect his own work, and
clean the area surrounding the weld from any contaminants.
4.9
Storekeeper
He is responsible for receiving, proper storing and distribution of welding
consumables and other materials to site and keeping all records.
4.10
Machine Operator/Installer
5.0
Cutting and cleaning tools (power brush, gas cutter and its accessories etc.)
Chipping hammer
GROOVE JOINT
6.0
Ratchet /Spanner
Level bar
Measuring tape
Jigs
Steel square
PPE MATERIALS
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WELDING
Face shield
Face mask/respirator
Welding Apron
Welding gloves
Welding glass/shield
Welding boots
Hardhat
GROOVING
7.0
Safety glasses
Hardhat
Foot protection,
Hearing protection
Reflectorized vest
QUALITY REQUIREMENTS
Quality Plan will be applied to the project in line with the project quality
requirements. Inspection Test Plan & Specifications to be verified by the QC
Engineer to confirm inspection stage, acceptance & method of verification. All
checklist & test reports to be maintained. All attachments to the report shall be
clearly mentioned for traceability. All equipment & instruments to be verified for
validity. All sequence to be Inspected & cleared by QC Engineer for further
clearance.
8.0
MANPOWER
Qualified welders as per applicable codes/standards will be deployed. A unique
identification number shall be assigned to each welder and a welder identification
card with the welder's name, photograph, identification number, and WPS's for which
the qualification is valid shall be issued for each qualified welder.
Each welder shall have the card or a copy available at work location and shall
produce the card to the QA/QC Engineer if asked for. Welders performing work
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without identification card shall be suspended from production welding until the card
can be produced and shown. In case a welder terminates his work, the identification
number shall not be reassigned to another welder.
Trained machine operator and installer are to be deployed to site.
9.0
10.0
General Conditions
Approved WPS shall be available on site with the welder and the QA/QC
Engineer. The QA/QC Engineer will be present at each welding location
during welding and he has to stamp and sign 100% visual inspection of
the welds on daily basis.
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Welding will be carried out with approved welding filler material as stated
in the approved WPSs
Vertical Down-Hill or Up-Hill positions will be carried out for welding all
pipe diameter, thicknesses and grades, in accordance with the approved
WPSs.
Welding Sequence
Welding operation will be performed as follows:
10.2.1 Before starting welding activities a protection mat will placed over the
PE coating adjacent to the weld, in order to protect it against damages
resulting from welding activities, i.e. welding sparks.
10.2.2 Grinding or cleaning with power brush for removal of flux/slag will be
done after every welding pass. After grinding or power brush cleaning
the weld pass will be inspected randomly by our QA/QC Engineer.
10.2.3 Hot-pass will be commenced immediately after root pass welding.
The interval of time will be as specified in the WPS. No weld joint will
be left without applying Hot Pass.
10.2.4 Any weld joint started will be completed on the same day for root &
hot passes.
10.2.5 External clamps will not be removed until completion of 75% of root
pass.
10.2.6 After complete welding of a joint, the joint will be cleaned with power
brush for removal of flux, weld spatter, arc burn etc. The joint will then
be ready for visual Inspection and NDT examination.
10.2.7 After each weld is finished, the QA/QC Engineer will perform a visual
inspection of the weld.
10.3
Protecting Welds
10.3.1 During welding activities, a tent should be over the weld at all times, to
protect the weld against weather conditions. At surrounding
temperatures of below 20 C or during rainy condition, all welds will be
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Weld Traceability
Weld traceability will proceed in the following way:
10.4.1 Pipe Welding Logbook
Every pipe delivered at site will be recorded in a "PIPEWELDING LOG BOOK" containing pipe number, heat number, wall
thickness, diameter, length and delivery date. Pipe number and
length, will be marked outside of the pipe with non-removable
ink/paint. Each pipe will also be given a unique sequence number,
which will determine its position in the pipeline and in the pipewelding log book. Any additional information such as non-conformities
to the pipe surface and mitre bend information, will also be recorded.
Directly after welding has finished, each weld will be given a unique
weld number. This weld number will be marked on the pipe, directly
adjacent to the weld. Together with the weld number, the welders
identification numbers will be marked. All information on the pipe will
be written at the service road side of the pipeline, to keep it readable
at all times.
10.4.2 Welder Identification Number and Record
Each welder will be given an identification number by which he will be
recognized, for welding his joint. This identification number will be
issued on a prescribed card.
11.0
Visual Check
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12.0
Profile of the finished weld, including but not limited to arc strikes outside
the groove area of the weld, spatter, oxides and residual slag.
WELDING CONSUMABLES
Welding electrodes shall be used in accordance with the approved WPS.
12.1
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All electrodes that are in good condition shall be returned to the Site
Foreman or QA/QC Engineer and stored in the holding ovens.
Damaged electrodes shall be scrapped. All scrapped electrodes shall
be segregated, removed and disposedoff.
Any questionable electrodes shall be brought to the attention of the
QA/QC Engineer for determination of final disposition.
Low hydrogen electrodes held in quivers shall be stored in the holding
ovens, as per manufacturers specification.
All low hydrogen electrodes returned that have been outstanding
a period shall be redried in accordance with the electrodes
manufacturer's recommendations. Basic or low hydrogen
electrodes
exposed to open air for a period longer than two
hours shall be re
dried in accordance with the
electrodes manufacturer's
recommendation.
for
12.3
12.0
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Pipe Preparation
The grooved piping method is based upon the proper preparation of grooves
to receive the housings keys. The groove serves as a recess in the pipe,
which allows ample depth for secure engagement of the housings, yet ample
wall thickness for full pressure rating.
Ductile iron pipe must be prepared to Victaulic specifications outlined for each
product style. Preparation may vary according to pipe wall thickness, outside
dimensions, and other factors. Victaulic recommends square-cut pipe for use
with grooved-end AWWA products.
The outside surface of the pipe, between the groove and the pipe end, must
be smooth and free from deep pits and swells to provide a leak-tight seal for
the gasket. All rust, loose scale, oil, grease, dirt, and cutting particles must be
removed. Peened surfaces may require rework to provide a leak-tight seal for
the gasket (refer to ANSI/AWWA C-606 or CSA B242).
13.1.1 Grooving
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13.2
Gaskets
Consider many factors like temperature, type of service etc. for optimum
gasket performance.
Selection of proper gasket will be conducive for gasket life and performance.
This can also avoid joint failure.
13.3
Lubrication
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Lubricants is required for coupling assembly. This not only help gasket
pinching prevention but also assist for easy installation. Compatible material,
such as silicone or a soap-based lubricant or manufacturer recommended
lubricant can be used.
13.4
Installation Steps
13.4.1 Before starting any activities, ensure that the working drawings are
controlled approved/IFC and in their latest revision.
13.4.2 Observe dimensions, cut pipes according to plans to avoid wasting of
materials and time
13.4.3 In the installation process, observe the following:
13.4.3.1 Check pipe ends:
The outside surface of the pipe, between the groove and the
pipe end, must be smooth and free from deep pits and
swells to provide a leak-tight seal for the gasket. All rust,
loose scale, oil, grease, dirt, and cutting particles must be
removed. Peened surfaces may require rework to provide a
leak-tight seal for the gasket
13.4.3.2 Check gasket and lubricate:
Check the gasket to make sure it is suitable for the intended
service. Apply a thin coat of Victaulic Lubricant or silicone
lubricant to the gasket lips and exterior.
Always use a compatible lubricant to prevent the gasket from
pinching/tearing during installation.
13.4.3.3 Install gasket:
Install the gasket over the pipe end. Make sure the gasket
does not overhang the pipe end.
13.4.3.4 Join pipe ends:
Align and bring the two pipe ends together. Slide the gasket
into position, and make sure it is centered between the
grooves. Make sure no portion of the gasket extends into the
groove on either pipe.
13.4.3.5 Install housings:
Install the housings over the gasket. Make sure the
housings keys engage the grooves properly on both pipes.
13.4.3.6 Install bolts and nuts:
Insert the bolts, and thread the nuts finger-tight onto the
bolts. Make sure the oval neck of the bolts seat properly in
the bolt holes.
13.4.3.7 Tighten nuts:
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Tighten all nuts evenly by alternating sides until metal-tometal contact occurs at the flat bolt pads.
NOTE: It is important to tighten all nuts evenly to prevent
gasket pinching.
For every style of coupling follow manufacturer installation
instruction.
13.5
13.6
The housings keys must not rest on or grip the bottom of the groove (with
the exception of Victaulic rigid couplings).
The housings keys must be fully engaged against the face of the groove.
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Keep work area clean and free of hazards. Make sure that no flammable, volatile
or explosive materials are in or near the work area.
Do not weld on sealed containers that have held combustibles, without taking
extra special precautions.
When it is necessary to weld in a damp or wet area, wear rubber boots and stand
on a dry insulated platform.
If it is necessary to slice length of welding cable together, make sure all electrical
connections are tight and insulated. Do not use with frayed, cracked or bare
spots in the insulation.
Dispose the electrode stubs in proper container since stubs on the floor are a
safety hazard.
Shield other from the light rays produced by the welding arc.
When workings at height make sure that scaffold, ladder or work surface is solid.
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GROOVE JOINT