PROCEDURE FOR

MAINLINE WELDING
Docs No: TGSPL/IGL/TEPL/ML/JP/04

REV-00

PROJECT : LAYING OF STEEL PIPELINE IN MEERUT, MUZAFFARNAGAR &

SHAMLI GA FOR SEGMENT- 2 & SEGMENT-5

CLIENT : M/s INDRAPRASTHA GAS LTD (IGL)

CONSULTANT : M/s TRACTEBEL ENGINEERING PVT LTD

CONTRACTOR : M/s TECHNO GLOBAL SERVICES PVT LTD

PROCEDURE FOR
MAINLINE WELDING
Docs No: TGSPL/IGL/TEPL/ML/JP/04

Prepared by Checked by Reviewed & Approved

Rev. Date Description
TGSPL TGSPL by TEPL/IGL

For Review &

00 02.09.2019
Approval

DOCUMENT NO. REV

MAINLINE WELDING Page 1 of 8
TGSPL/IGL/TEPL/ML/JP/04 00
 PROCEDURE FOR
MAINLINE WELDING
Docs No: TGSPL/IGL/TEPL/ML/JP/04

REV-00

INDEX

Sr. No. Description Page No.

1 Scope 3

2 Reference 3

3 Equipment 3

4 Method 4-8

5 Health, Safety & Environment 8

6 Documentation 8

DOCUMENT NO. REV

MAINLINE WELDING Page 2 of 8
TGSPL/IGL/TEPL/ML/JP/04 00
 PROCEDURE FOR
MAINLINE WELDING
Docs No: TGSPL/IGL/TEPL/ML/JP/04

REV-00

1. Scope:

This Procedure covers the work method for mainline welding of “ LAYING OF STEEL PIPELINE
IN MEERUT, MUZAFFARNAGAR & SHAMLI GA FOR SEGMENT- 2 & SEGMENT-5 ” constructed by
TGSPL.

2. Reference:

 Tender Document No: VCS/NOIDA/C&P/CP14588/WC/07-R0

 API 1104 (Latest edition)

 ANSI B 31.8
 API 5L
 ASME Sec II C.
 Approved Welding Procedure Specifications for Mainline.

3. Equipment:

a. Hydra
b. Welding machine
c. Grinding machine
d. External clamp
e. LPG Cylinder & Heating Torch
f. Filler Gauge
g. Demeter
h. Weld Gauge
i. Thermo Pan
j. Relative Tools & Trackers

DOCUMENT NO. REV

MAINLINE WELDING Page 3 of 8
TGSPL/IGL/TEPL/ML/JP/04 00
 PROCEDURE FOR
MAINLINE WELDING
Docs No: TGSPL/IGL/TEPL/ML/JP/04

REV-00

4. Method:

All work will be carried out as per specification.

Before the fit up pipe will be checked for correct thickness for proper placement, as per
alignment sheet, specification etc. Bevel ends will be visually checked, if any damages are
found the same shall be repaired as mentioned below:

a) Dents less than 1 mm depth will be removed by grinding.

b) Dents 1 mm to 3 mm depth will be re- beveled by grinding.
c) Depth more than 3 mm will be gas cut and re- beveled.
d) Negative Tolerance not allowed dent due to grinding and other Activities.

Before fit- up Pull through (95% of Pipe ID) should be passed to each pipe before welding.
Pipe ends inside & outside will be cleaned by power wire brush at least for 1" so that the
welds are free from rust, paint and other foreign matters.
If any laminations, split ends or any other manufacturing defects in the pipe be discovered,
the length of the pipe will be cut to the extent required with the knowledge of TEPL/IGL and
a joint record will be generated. The bevel ends of pipe shall confirm to the joint design as
per approved WPS.
During alignment and fit- up first pipe will be rested and locked on the pre- positioned
Weld Joint skids and the second pipe will be held by Hydra with External fit- up clamp
(Mechanical). After completion of 60% root welding and removal of External clamp, the
second pipe will be carefully lowered on pre-positioned skids. Skidding arrangement will be
shown below and skids may be removed only after completion of the entire welding and the
pipe will be rested on the sand bags. When the pipe is welded above ground the working
clearance around the pipe at the weld should not be less than 400 mm. During welding one
end of pipe will be sealed off.

DOCUMENT NO. REV

MAINLINE WELDING Page 4 of 8
TGSPL/IGL/TEPL/ML/JP/04 00
 PROCEDURE FOR
MAINLINE WELDING
Docs No: TGSPL/IGL/TEPL/ML/JP/04

REV-00

6000mm

Sand Bags Filled With Soft Soil

Maximum offset of the same nominal wall thickness pipe will not be more than 3 mm.

Seam orientation of the two successive welded pipes Will be selected to ensure that the,
the longitudinal welds will be staggered in top 45° of the pipeline & minimum distance 100
mm will be maintained between the two longitudinal seams. In case of slight misalignment,
cold hammering is permissible only by bronze hammer. Hot dressing is not permitted.
Seam should be staggered preferably at 10 ‘o’clock & 2 ‘o’clock position. The longitudinal
welds shall be staggered in the top 45° of the pipe line except in case of sag and over
bends and successive horizontal bends. Joint grove preparation will be as per the approved
WPS.

After alignment & fit- up pre-heating will be carried out by LPG heating torch and the same
will be checked with thermo Pen/ temperature indicating pyrometer before starting the root
run(If Needed/According to WPS).
Earthing clamps used for welding return circuit will only be placed on bevel area or
circumferential seam weld.

After completion of 60% of the root welds external clamp shall be removed. Weld joints will
be protected from rains/ sand storms, Wind shield will be used in the aforesaid conditions.

Pre- heating and interpass temperature shall be maintained as per the approved WPS/
Procedure. No welding should be preformed if the minimum preheating temperature is not
reached or exceeded by 100°C.

DOCUMENT NO. REV

MAINLINE WELDING Page 5 of 8
TGSPL/IGL/TEPL/ML/JP/04 00
 PROCEDURE FOR
MAINLINE WELDING
Docs No: TGSPL/IGL/TEPL/ML/JP/04

REV-00
Before any pipe length is cut, the painted serial number and the heat number will be
transferred to the either side of the joint, which is to be made by cutting. The time lapse
between 1st & 2nd pass, 2nd & 3rd pass will be as per WPS/PQR.

The length of the pipe to be welded shall be at least twice the pipe dia., with a minimum of 1
m. Where different wall thickness pipes are to be welded and the difference in wall
thickness is more than 1.6 mm then 1:4 taper internal grinding on the higher thickness will
be done.

Filler Metals/Electrode:

Selection of filler metals or electrodes will be as per approved WPS. All welding electrodes
before use will be batch tested & meet the requirements of WPS & TEPL specification and
shall be approved by TEPL/IGL. All electrodes intended for welding of pipeline will be
stored & handled as per manufacturer recommendations to avoid damage to them.
Suitable container will be used at site to avoid damages to flux coating.

Welding:

Welding shall be carried out as per the approved WPS with qualified welders. Minimum No.
of welders will be One for mainline and Tie- In welding for each Weld Joint. No welder will
be permitted to work, with out the possession of welder ID Card. Respective WPS shall be
displayed at site where welding is to be carried out.

DOCUMENT NO. REV

MAINLINE WELDING Page 6 of 8
TGSPL/IGL/TEPL/ML/JP/04 00
 PROCEDURE FOR
MAINLINE WELDING
Docs No: TGSPL/IGL/TEPL/ML/JP/04

REV-00
Weld Sequence:

After completing every pass, the same will be cleaned/ flattened by grinding and power
brushing. Electrode starting & finishing points will be staggered from pass to pass.
Interruption between first pass to second pass and to third pass will be as per the approved
WPS. After completion of the third pass welding may be suspended if required, so as to
allow the weld joint to cool down provided the thickness of the weld metal deposited will be
40% of the pipe thickness or minimum of 03 passes whichever is more. Upon restarting the
welding pre-heating will be carried out.

Arc Strike outside the beveled area on the pipe surfaces is not permitted. Accidental arc
strikes/ arc burns if any shall be repaired only by an approved procedure. Repair of arc
strike by welding is not allowed. After removal of arc strikes, same will be checked by
suitable NDT method as instructed by TEPL/IGL. Pipe should not be pumped or shaken
during welding.
Welders shall be qualified as per the approved WPS and all the welders should have
identity cards duly signed by TEPL/IGL.

After completion of welding, visual inspection shall be done and all the surface defects will
be removed as per the specification. NDT will be carried out as per the approved NDT
procedures. NDT repairs will be done as per approved WPS.

All Manual welded joints will be 100% tested by X-RAY OR Gamma ray (if X-Ray not
Possible) .

Repair procedure to be qualified separately for full through thickness and partial thickness
respectively. Only 01 attempt for through thickness repair is permitted. Repairs are
restricted to maximum 30% of the weld length for partial thickness repair and 20% of weld
length for root

DOCUMENT NO. REV

MAINLINE WELDING Page 7 of 8
TGSPL/IGL/TEPL/ML/JP/04 00
 PROCEDURE FOR
MAINLINE WELDING
Docs No: TGSPL/IGL/TEPL/ML/JP/04

REV-00
At the end of the day’s work or every time when joining and welding operations are
interrupted, the open ends are to be closed with nightcaps. Mention Numbering Method of
Joints.

5.0 HEALTH, SAFETY AND ENVIRONMENT

1. All PPE is a must in this activity.

2. Only trained personals to be deployed for this activity.
3. All measuring & Test Equipments used must be well maintained.
4. All lifting devices & Tools used shall be well maintained.

6.0 DOCUMENTATION:

Inspection Test Plan Appendix 1 TGSPL/IGL/TEPL/ML/ITP/04

Inspection Report ISO Format … F07 (PNG - P - 03)

DOCUMENT NO. REV

MAINLINE WELDING Page 8 of 8
TGSPL/IGL/TEPL/ML/JP/04 00