ML-04 Work Procedure For Mainline Welding

Tolani Projects Private Ltd.
WORK PROCEDURE No.:

BPCL-VCS-TPPL-PJPL-299-ML-04
MAINLINE WELDING
LAYING OF ATF PIPELINE FROM BPCL PIYALA TERMINAL TO JEWAR

PROJECT
INTERNATIONAL AIRPORT (14” x 32 Kms)
OWNER Bharat Petroleum Corporation Limited.
EPMC VCS QUALITY SERVICES PVT. LTD.
CONTRACTOR Tolani Projects Pvt Ltd.
Document Title PROCEDURE FOR MAINLINE WELDING
WORK PROCEDURE FOR

MAINLINE WELDING
PROCEDURE No.:
TPPL : Tolani Projects Pvt Ltd.

BPCL : Bharat Petroleum Corporation Limited
VCS : VCS QUALITY SERVICES PVT. LTD.
WP : WORK PROCEDURE
ML : MAINLINE
ISSUED FOR REVIEW
PURPOSE OF ISSUE PREPARED REVIEWED

REV DATE APPROVED BY
BY BY
DOCUMENT NO. REV. SHT.

MAINLINE WELDING
BPCL-VCS-TPPL-PJPL-299-ML-04 00 1 of 11
WORK PROCEDURE No.:
MAINLINE WELDING
PROJECT
INDEX
1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCE
4.0 EQUIPMENTS
5.0 RESPONSIBILITY
6.0 METHODOLOGY
7.0 QUALITY ASSURANCE & QUALITY CONTROL
8.0 HEALTH, SAFETY & ENVIRONMENT
9.0 DOCUMENTATION
1. PURPOSE
The purpose of this procedure is to lay guidelines and requirements and to

establish a method to control MAINLINE WELDING activity and inspection to be used in EPC
Tender for Pipeline and Associated Station Works for HRRL Connectivity (14” x 32 Km
approx.)
2. SCOPE

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MAINLINE WELDING
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The scope covers Mainline Welding of 14” (Pipe material: Spec: API 5L Gr. X 65
PSL-2)and the NDT for 14” PYALA – JEWAR - PIPELINE (PJPL),
PART C OF PJPL PROJECT.(SECTION I) BFOYC
3. REFERENCE
Following documents in totality or in part shall form the reference documents:
• Design and Construction Requirements For Cross Country

Hydrocarbon Pipelines OISDB141.
• Gas Transmission and Distribution Piping Systems ASME-B31.8.
• Specification for Welding of Onshore Gas Pipelines
• Standard for welding of pipelines and related Facilities-API 1104 latest
Edition.
• Specification for welding Electrodes and Filler Materials ASME Sec. IIC.
• Non Destructive Examination ASME Sec. V.
• American Society for Non-destructive Testing ASNT-SNT-TC-1A.
• OISD 226 for Gas Pipelines
• PNGRB T4S Guidelines - Petroleum & Natural Gas Regulatory Guidelines
• Project Specification For Welding and NDT of Pipelines IND-NCJ-00-PL-
SPC-00022
• Welding Specification Chart
• Boiler & pressure vessel code: Welding & Brazing Qualification ASME Sec.
IX. Approved WPS
4. EQUIPMENTS
• Side Boom /Crane

• D.G. Set with welding machine

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• Pneumatic / Manual Internal Clamp

• Digital Temperature indicator
• Grinding machine GQ4 with stringer brush.
• Measuring Tools & Tackles
• Induction Coil for preheating/Ring Burner
• Weld Gauge, Hi-Io gauge, Filler gauge, Measuring tape, dial gauge etc.
• Clamp meter, Stop Watch
• Pull through Tylon plate
• Fire Extinguisher
• Welding hood, wooden skid
• Welding electrode, Helmet, Safety shoes, Goggles, Hand gloves etc.
• Brass Hammer
• DPT kit
• Pay welder
• Compressor
• Tractor trolley
5. RESPONSIBILITY
Resident Construction Manager:

➢ Shall report to Project Director.
Shall provide all necessary resources to implement this procedure
➢ Shall report to the Resident Project Manager.
➢ Shall be responsible for overall implementation, monitoring and
control of construction and commissioning activities.

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QA/QC Engineer:
➢ Shall report to Resident Construction Manager.
➢ Shall ensure proper implementation of this procedure.
➢ Shall checks and verifies the activities.
➢ Ensures all Measuring Gauge & Temperature Element are available at site.
➢ Ensure that all welding parameters are followed as per approved WPS/PQR.
➢ Monitoring the welder performance and maintain the tool box
record for further improvement.
Welding Engineer:
➢ Shall report to the QA/QA Engineer.
➢ Shall be responsible for ensuring the implementation of all weld
joint numbering system on the pipe.
➢ Shall ensure welding activities are carried out as per Approved relevant WPS.
➢ Shall conduct a tool box meeting before start the activity in daily basis.
Safety Officer:
➢ Shall report to the Project Manager & Resident Construction Manager.
➢ Shall be responsible for ensuring the implementation of safe work
conditions and accident free job during all welding works.
Welding of various materials under this specification shall be carried out

using Shield Metal Arc Welding (SMAW) Process.
6.METHODOLOGY
A. PRIOR TO WELDING
The final WPS along with PQR shall be submitted for approval before the start of welding work.
Welders shall be qualified based on the approved WPS for this project.

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B. METHOD- HANDLING AND STORAGE OF WELDING CONSUMABLES

Welding consumables of approved manufacturer and approved classes which are qualified for the
project batch-wise, shall be used. TPPL shall maintain a system of traceability, whereby the batch no. of
welding consumables are related to weld no. on which they are used. At site of mainline welding a stock
of welding consumables shall be maintained by TPPL to ensure that progress may not be hampered due
to shortage of the same.
C. METHOD-BEVELING AND CLEANING

Correct wall thickness and proper placement with respect to alignment shall be checked. Pull through of
dia. 95% of I.D. of pass shall be passed through each pipe prior to start fitting.
If required each pipe shall be cleaned internally by using pull through wrapped with canvas or cotton
cloth.
Bevel shall be inspected; if found damaged / improper then with machining, it shall be rectified.
If bevel ends are beyond repair in the opinion of Client, the damaged ends shall be cut and re beveled
to the satisfaction of Client, with the automatic gas beveling machine to ensure flaw free base metal.
UT & DPT shall be carried out on new bevel ends.
Cleaning of bevels shall be done by power brush Minimum 25 mm length from the edge shall be
cleaned from inside and outside of pipe.
D. METHOD – ALIGNEMNT & FIT-UP

The first pipe shall be positioned on skids of height 500mm from the ground; supports shall have soft
pads placed on them to avoid damage to PE coating. Pipes shall be locked to prevent their rolling from
the skids with the help of side boom of required capacity.
Pneumatically operated Internal line up clamp shall be used for alignment purpose.
Root gap shall be maintained by taper wedge at two locations and the same shall be removed on aligning the pipes
with the clamps. The root gap shall be checked accurately and shall be as per qualified WPS/PQR.
The use of internal clamp is mandatory & shall be released after completion of 100% of root pass.
Long seams of pipes shall be in the upper quadrant of the pipe circumference with minimum
150 mm offset.
Pipe to Cold bend or Cold bend to Cold Bend (Horizontal/Vertical)- The position of seam shall be on
the Top half of the pipe with min. staggering distance of 150mm.
Pipe to Hot Bend or Hot Bend to Cold Bend (Horizontal/ Vertical) – the position of seam shall be on
the Top Half of the pipe with min. staggering distance of 250mm.

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For pipes of same nominal wall thickness the offset shall not exceed 1.6 mm.
When different thickness are involved transition pieces shall be used. The thickness of higher pipe
shall have a taper of minimum 1:4 from inside as per ASME 31.4. Alignment and fit-up shall be
checked before welding.
E. WELDING RETURN CIRCUIT:

An insulated, undamaged welding cable, electrode holder and special earthing clamp shall be used for
connecting pipe to welding machine to avoid arc burn & arc strike on pipe surface.
An earth clamp shall be placed on proceeding or succeeding weld joints to welding machine.
F. PRE-HEATING
As per approved WPS.
Pre-Heating shall be checked with Infrared Thermometer.
G. WELDERS:
Only qualified and approved welders shall be deployed for the welding of the joints. Minimum two
welders per joint are required for welding each run. The welder shall always have in possession the
identification card and produce it on demand by inspector. No welder shall be permitted to work
without the possession of the welder’s identity card. It shall be ensured by CIPL that welder shall
perform the type of welding for which he is qualified. If found otherwise, both welder and weld are
subject to rejection.
H. METHOD- WELDING
All welding shall be carried out as per qualified and Approved Welding Procedures
specification- WPS and are to be performed by qualified welders.
I. ROOT RUN
The root gap shall be accurately checked and shall be as per qualified WPS. The root pass of butt joint
shall be executed so as to achieve full penetration, with complete fusion of root edges. Welding shall
not be interrupted during a pass and shall be completed with a speed same as given in approved WPS.
Any kind of movement of components, shocks, vibration, bumping stresses & other stresses are
prohibited while welding is in progress.
TPPL shall inform client, if any section of pipeline containing incomplete weld falls from skid.

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WORK PROCEDURE No.:
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J. CLEANING
Removing the flux, craters, welding irregularities, slag etc. power brush/ grinding start from 12’O
clock and 6’O Clock proceeding clockwise.
K. LOWERING ON SKIDS
Lowering of pipe on pre-positioned skids will be done after completion of root & Hotpass.
L. REMOVAL OF CLAMP:
The internal clamp shall be removed/ released after completion of entire root pass. The skids used
during welding shall be removed only after completion of full welding. Minimum of one side boom shall
be deployed during line-up.
M. HOT PASS & FILLER -1

Same as root pass, the hot pass+first filler shall start within the time specified in the WPS.
N. FILLER AND CAPPING

Soon after cleaning the hot pass, filling and capping shall start within that time qualified during
procedure qualification. In case suspension of weld after third or following passes, essentially the
thickness of weld metal deposited shall be equal to at least 50% of pipe thickness upon restarting of
welding preheating for 100° C shall be carried out.
O. ARC STRIKE:
Arc Strike outside the bevel surface shall not be permitted. If any such arc strikes are caused
accidentally, such area shall be repaired as per the approved procedure. Stray arcs shall be completely
removed by grinding. Remaining wall thickness shall be checked by UT If the reading is below the
specific minimum wall thickness of the pipe, then the defective pipe shall be cut.
P. CLEANING AND RESTARTING:

Every pass shall be cleaned by power brush, grinding machine, starting and finishing shall be staggered
for every pass.
Q. CAPPING AND INSPECTION:

Capping shall be 0.8 to 1.6mm max. over the surface of pipe. Spatter band shall be removed and cleaning
shall be done by power brush and remedial grinding necessary, shall be performed limited to dressing;
after each day’s work or when work is interrupted, the open ends of the welded strings of pipes shall be

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capped with a securely closed metal cap.
R. SUBSEQUENT PIPE ALIGNMENT:

Subsequent joints shall be welded in the same manner as explained above.
S. WEATHER PROTECTION:
Wind Shield made of metallic frame covered by tarpaulin shall be provided to cover the welders and
joint during the welding, to protect against rain, drizzling / wind. Any such work shall be done to the
satisfaction of client.
T. VISUAL EXAMINATION:
All finished weld shall visually inspected of arc strikes, parallel and axial alignment of the work,
excessive reinforcement, concavity of welds, shrinkage, cracks, undercuts, dimensions of weld surface
porosity and other surface defects. The acceptance criteria shall be as per API 1104 and WSIPL
Specification. If any defects are noticed, they shall be rectified.
U. NON- DESTRUCTIVE TEST:

After 100% visual examination of each weld joint these shall be examined 100 % by using
Radiographic Examination after getting offer by QC Engineer. The NDT works shall be carried out in
accordance with API 1104 (Latest Edition), ASME Sec. V and approved procedure for NDT.
V. WELD JOINT NUMBERING:

As per approved procedure for Weld Joint Numbering. The weld numbers shall be legible and
identifiable up to post padding/ backfilling. Punch or steel stamping shall not be permitted.
W. WELDER’S PERFORMANCE
A separate log sheet for each welder’s performance will be maintained and submitted weekly to
BPCL/VCS. The welder found putting repair more than acceptable, will be trained and films will be
viewed to him explaining the location of defect and root cause for the same. After two warnings and if
no improvement is observed, the welder will be withdrawn from producing welding and will be
disqualified.
X. PRODUCTION TEST
0.1% of total number of welds completed shall be subjected to destructive testing. If one production

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weld fails to conform specified requirements, CIPL shall cut two additional weld joints from either side
of the failed one and shall carry destructive testing as per specification requirement. If one or both the
tested joints fail to conform to the specified requirements, the WIPL shall select joints randomly in
pipeline for production testing. If one or more out of ten joints fail, then welding work shall be
terminated and further investigation shall be carried out.
Y. DESTRUCTIVE TESTING
a) Tensile Test
b) Nick Break Test
c) Macroscopic Examination
d) Hardness Test
e) Charpy “V” Notch Impact Test
f) Bend Test
If a pup end cannot be avoided for tie-in, the minimum length that shall be added is 1.0 meters and two
or more such pups shall not be welded together. All cut-off lengths greater than 1.0 Meters shall be
moved ahead in order to be welded into the pipeline at a suitable location. Tie-in with two or more pups
may be used provided that they each have minimum length of 1.0 meter and are separated by an entire
length of pipe. In no case more than three (3) welds shall be permitted on a 10 meter length of pipeline.
NDT will be carried out as per approved NDT procedures. All mainline weld joints shall be examined by
100% RT. At the end of the days work or every time when joining / welding operations are interrupted,
the open ends are to be closed with nightcaps.
7. 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 as appended to this procedure.
8. HEALTH, SAFETY & ENVIRONMENT

• It is to be noted that the machine operators Involved shall be an experienced
/ Competent person.
• PPE shall be used in this activity.
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• Trained rigging personnel shall be deployed for this activity.

• During fit up operation special care to be taken to avoid personal injury.
• Personnel around the machine should be cautious about
frequent handling of pipes.
• During the movement of equipment the operator should blow
horn to caution the people around.
• All Measuring & Test Equipment used shall be well maintained.
• All lifting devices & Tolls used shall be well maintained.
• It is to be taken care that no spillage of fuel or lubricants is allowed at site.
9. DOCUMENTATION
Inspection Report : BPCL-VCS-TPPL-PJPL-299-ML-04/IR-01 Rev: 01

Inspection Test Plan : BPCL-VCS-TPPL-PJPL-299-ML-04/ITP-01 Rev: 01
Note: In case of any conflict between the above procedure and project
Specification the later shall govern without any prejudice to the term &
Condition of the contract

MAINLINE WELDING
INSPECTION REPORT: MAINLINE WELDING

Project INTERNATIONAL AIRPORT (14” x 32 Kms)
Client Bharat Petroleum Corporation Limited. Format No. BPCL-VCS-TPPL-PJPL-299-ML-04/IR-01
EPMC VCS QUALITY SERVICES PVT. LTD. Rev- 0
Contractor Tolani Projects Pvt Ltd. Report No. :
SPREAD Date :
WPS No: Pipe Size & Thickness :
Electrod Batch No :- Material :
KM FROM TO Weather
Page No.
ALIGNMENT SHEET NO. ______________________________________ REV. _01________
WELD WELDER DETAILS

Sl. COATING LENGTH Visual
PIPE NO. HEAT NO. JOINT Fit-Up REMARKS
No. NO. (In Mtrs.) ROOT HOT PAAS FIL-1 FIL-IICAPPING check
NO
T R T R T R T R T R
1
2
PROGRESS
TODAY'S PROGRESS
PREVIOUS PROGRESS
CUMMULATIVE PROGRESS
For TPPL
SIGNATURE SIGNATURE
NAME NAME
DATE DATE
INSPECTION TEST PLAN : MAINLINE WELDING
Project Format No: BPCL-VCS-TPPL-PJPL-299-ML-04/ITP-01
Client Bharat Petroleum Corporation Limited Rev : 0
EPMC : VCS QUALITY SERVICES PVT. LTD Date :
Contractor : Tolani Projects Pvt Ltd.
Inspection By Verification by
Sr. No. Activity Description Record to be submitted by TPPL
BPCL PMC/BPCL
01 Approval of Electrode/ Manufacturer batch certificate. P R
02 Approval of Welding Procedure Specification. P AP WPS Document.
03 Procedure Qualification Test. P W PQR Document.
04 Welder Qualification Test as per Spec. P W WQT Reports
05 Bevel Inspection. P W Mainline Welding Insp. Report.
Line- up (Fit- up), Pre- Heating & Root, Hot pass, 1st Filler & Welding
06 P RM Mainline Welding Insp. Report.
and Time lapse.
07 Visual inspection of completed weld. P W Mainline Welding Insp. Report.
08 Destructive Tests of production weld. P W Laboratory Test Reports.
09 All weld test for each batch of E6010 & 8010 P1 electrodes P W Laboratory Test Reports.
10 100% RT of completed weld. P R Relavant RT Reports.
11 Digitization of Pipeline Data P R As-Built Pipe book
Legend
P/W Perform/Witness
RM : Random.
R : Review Documents.
For Review & Approval
Rev Date Description Prepared and Checked By TPPL Reviewed&Approved by VCS / BPCL

ML-04 Work Procedure For Mainline Welding

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Tolani Projects Private Ltd.

WORK PROCEDURE No.:

LAYING OF ATF PIPELINE FROM BPCL PIYALA TERMINAL TO JEWAR

WORK PROCEDURE FOR

TPPL : Tolani Projects Pvt Ltd.

ISSUED FOR REVIEW

PURPOSE OF ISSUE PREPARED REVIEWED

DOCUMENT NO. REV. SHT.

7.0 QUALITY ASSURANCE & QUALITY CONTROL

8.0 HEALTH, SAFETY & ENVIRONMENT

The purpose of this procedure is to lay guidelines and requirements and to

DOCUMENT NO. REV. SHT.

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

• Design and Construction Requirements For Cross Country

• Side Boom /Crane

DOCUMENT NO. REV. SHT.

• Pneumatic / Manual Internal Clamp

Resident Construction Manager:

DOCUMENT NO. REV. SHT.

Welding of various materials under this specification shall be carried out

DOCUMENT NO. REV. SHT.

B. METHOD- HANDLING AND STORAGE OF WELDING CONSUMABLES

C. METHOD-BEVELING AND CLEANING

D. METHOD – ALIGNEMNT & FIT-UP

DOCUMENT NO. REV. SHT.

E. WELDING RETURN CIRCUIT:

DOCUMENT NO. REV. SHT.

M. HOT PASS & FILLER -1

N. FILLER AND CAPPING

P. CLEANING AND RESTARTING:

Q. CAPPING AND INSPECTION:

DOCUMENT NO. REV. SHT.

capped with a securely closed metal cap.

R. SUBSEQUENT PIPE ALIGNMENT:

U. NON- DESTRUCTIVE TEST:

V. WELD JOINT NUMBERING:

DOCUMENT NO. REV. SHT.

7. QUALITY ASSURANCE & QUALITY CONTROL

Quality Assurance shall be maintained by ensuring the systematic

8. HEALTH, SAFETY & ENVIRONMENT

• Trained rigging personnel shall be deployed for this activity.

Inspection Report : BPCL-VCS-TPPL-PJPL-299-ML-04/IR-01 Rev: 01

DOCUMENT NO. REV. SHT.

LAYING OF ATF PIPELINE FROM BPCL PIYALA TERMINAL TO JEWAR

WELD WELDER DETAILS

For Review & Approval

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