PARADIP - NUMALIGARH CRUDE OIL PIPELINE PROJECT
(PNCPL)
JOB PROCEDURE FOR MAINLINE WELDING
CIPL-PNCPL-EIL-PL-WP-09
Client Numaligarh Refinery Limited Date : 5-Feb-22
Consultant Engineers India Limited Revision : 01
Contractor Corrtech International Pvt. Ltd. Page No. : 1 of 7
JOB PROCEDURE FOR
MAINLINE WELDING
Document No.: CIPL-PNCPL-EIL-PL-WP-09
01 07.01.2022 Issued for Review VINAY SHARMA VINAY SHARMA
00 21.12.2021 Issued for Review VINAY SHARMA VINAY SHARMA
Rev. Date Purpose of Issue Prepared by CIPL Prepared by CIPL Approved by EIL/NRL
PARADIP - NUMALIGARH CRUDE OIL PIPELINE PROJECT
(PNCPL)
JOB PROCEDURE FOR MAINLINE WELDING
CIPL-PNCPL-EIL-PL-WP-09
Client Numaligarh Refinery Limited Date : 5-Feb-22
Consultant Engineers India Limited Revision : 01
Contractor Corrtech International Pvt. Ltd. Page No. : 2 of 7
Sr. No. Description Page No.
1 Purpose 3
2 Scope 3
3 References 3
4 Equipment 3
5 Method 3
6 Health , Safety & Environment 7
7 Appendix 7
1. PURPOSE:
The purpose of this work instruction is to lay guidelines and requirements to control the
Welding and inspection to be used in the 26’’ & 50” Dia, Paradip - Numaligarh Crude Oil
Pipeline Project(PNCPL).
2. SCOPE:
This Procedure covers the work instruction to lay guidelines and requirements and to establish
a method or a system to control the work method for mainline welding activity and inspection
to be used in Paradip - Numaligarh Crude Oil Pipeline Project (PNCPL).
3. REFERENCES:
1. EIL Specification for pipeline welding 6-71-0051
2. API 1104(Latest edition)
3. Specification for welding electrodes and filler materials ASME Sec II Part C (2020 Latest)
PARADIP - NUMALIGARH CRUDE OIL PIPELINE PROJECT
(PNCPL)
JOB PROCEDURE FOR MAINLINE WELDING
CIPL-PNCPL-EIL-PL-WP-09
Client Numaligarh Refinery Limited Date : 5-Feb-22
Consultant Engineers India Limited Revision : 01
Contractor Corrtech International Pvt. Ltd. Page No. : 3 of 7
4. ANSI B 31.4
5. Approved WPS.
6. B302-000-02-42-WSC-0001, Rev No-0, B302-000-02-42-WSP-0001, Rev No-0.
4. EQUIPMENTS:
Hydra, welding machine, Grinding machine, internal clamps, Gauge plate, Brass hammer,
External Clamp, Side Boom, Buffing M/c, Diesel generator welding sets etc.
5. METHOD:
All work will be carried out as per Welding Specification Charts.
Before fit-up pipe will be checked for correct thickness, specification, bevel ends visually
checked. If a dent found the same shall be repaired as follow.
a.) Dents less than or equal to 0.5 mm depth shall be re-beveled by grinding.
b.) Depth more than 0.5 mm shall be gas cut and re-beveled.
Before fit-up pipe ends inside & outside will be cleaned by power wire brush at least for 25mm
both sides of bevel end so that the welds are free from rust, paint, grease and other foreign
matters. Manual cutting and weld repairing of bevel ends is not allowed. On pipe have been cut
back, a zone 25mm back from the new bevel shall be ultrasonically tested to ensure freedom
from laminations. The new bevel shall be 100% Dye Penetrant / MPI tested.
If any laminations, split ends or any other manufacturing defects in the pipe be discovered, the
length pipe will be cut to the extent required with the knowledge of client / client’s
representative and a joint record will be generated. Pipes, which have been cut, will be checked
by UT to an extent of 50 mm at the new bevel to ensure it is free from laminations. The new
bevel will be 100 % visual and 100 % tested LPT or/& Manual UT tested. Reports will be prepared
for all the above tests. The bevel ends of pipe shall confirm to the joint design as per approved
WPS.
Before start the fit-up gauging should be completed. 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
pipe layer with internal fit-up Clamp loaded inside. After completion of root welding and
removal of internal 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 during welding on end of pipe shall be sealed off.
PARADIP - NUMALIGARH CRUDE OIL PIPELINE PROJECT
(PNCPL)
JOB PROCEDURE FOR MAINLINE WELDING
CIPL-PNCPL-EIL-PL-WP-09
Client Numaligarh Refinery Limited Date : 5-Feb-22
Consultant Engineers India Limited Revision : 01
Contractor Corrtech International Pvt. Ltd. Page No. : 4 of 7
Height of skidding arrangement from ground will be sufficient to easy position welding not less
than 40 cm &wooden block should be minimum of size of 150x150x1000mm
12 Mtr.
Skid skid
All Welding equipment’s, heating equipment’s, Other auxiliary functions shall meet as per job
specification no. B302-000-02-42-WSP-0001, Rev No-0, Rev-0. All electrodes shall be purchased
in sealed containers and stored properly to avoid any damages of flux coating and
deteriorations. Welding should be carried out as per the welding specification charts. When
welding pipes of different wall thickness, shall have minimum of 1:4 taper and the weld shall be
subject to both ultrasonic and radiographic inspection.
Maximum offset of the same nominal wall thickness pipe shall not be more than 1.6 mm.
Seam orientation of the two successive welded pipes shall be selected to ensure that the,
longitudinal welds will be staggered in top 90 degree of the pipeline or minimum distance 250
mm will be maintained between the two longitudinal seams whichever is lasser. In case of slight
misalignment, Hammering is permissible by Brass hammer only. Seam should be staggered
preferably at 10 ‘0’ clock & 2 ‘0’ clock position. Or 250mm distance. The longitudinal welds shall
be staggered in the top 90˚ of the pipe line except in case of sag and over bends and successive
horizontal bends. If a distance off 100mm cannot be maintained the weld of pipe shall be
examined by UT.
The joint can be allowed to cool after completion of 3 runs of welding or 50% of pipe thickness
of welding.
Joint groove preparation will be as per the approved WPS.
After alignment & fit-up, pre-heating shall be as per approved WPS/PQR. Earthing clamps used
for welding return circuit will only be placed on bevel area or circumferential seam weld. Pre
heating shall be performed using resistance on induction heating methods for Gr.x70 and Gr.
X65, at least 50mm both ends of weld.
Internal line up clamps shall be released after 100 % completion of the root run. In case of
External clamps at least 60 % of the root welds (between all spaces of the bars) shall be
PARADIP - NUMALIGARH CRUDE OIL PIPELINE PROJECT
(PNCPL)
JOB PROCEDURE FOR MAINLINE WELDING
CIPL-PNCPL-EIL-PL-WP-09
Client Numaligarh Refinery Limited Date : 5-Feb-22
Consultant Engineers India Limited Revision : 01
Contractor Corrtech International Pvt. Ltd. Page No. : 5 of 7
completed before releasing the clamps. Weld joint will be protected from rains / sand storms.
Wind shield will be used in the aforesaid conditions.
Weld projection inside the pipe shall not exceed 3mmwhichever not specified by applicable
code, while welding in progress, care shall be taken to avoid any kind of movement of the
component, shocks vibrations etc. Welding shall be continuous and uninterrupted during a
pass.
All the grith weld of mainline shall be subject to 100% Radiography or AUT Examination.one
check shot of full joint on main line weld shall be taken per 100 circumferential welds.
Pre heating welded joint made by automatic welding procedure shall be examined by AUT only
and inter-pass temperature shall be maintained as per the approved WPS / Procedure.
Before any pipe length is cut, the painted serial pipe number and the heat number will be
transferred to the either side of the joint, which is to be made by cutting. The length of single
welded string will not exceed 1000 Mtrs. The time lapse between 1 st & 2nd pass, 2nd & 3rd pass
will be as per PQR. According to ASME B 31.8 fig. I5, joint preparation for unequal thickness will
be as per 14˚ - 30˚ taper (1:4).0.1% of total production welds should be cut and seild for
destructive testing as per annexure- 1. B302-000-02-42-WSP-0001, Rev No-0
The length of the pipe to weld shall be at least a minimum of 1m. Where different 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/Electrode qualification for
pipe line procedure. All welding electrodes before use will be batch tested & meet the
requirements of WPS & EIL specification and shall be approved by EIL/NRL. All electrodes
intended for welding of pipeline will be stored & handled as per manufacturer recommendations
to avoid damage to them. Suitable container shall be used at site to avoid damages to flux
coating. A separate EQT is required for change of Batch No / Electrode dia.
Welding:
Welding shall be carried out as per the approved WPS with qualified welders. Minimum No. of
welders will be two for mainline and Tie- In welding for each pass. No welder will be permitted to
work, without the possession of welder ID Card. Respective WPS shall be displayed at site where
welding is to be carried out.
PARADIP - NUMALIGARH CRUDE OIL PIPELINE PROJECT
(PNCPL)
JOB PROCEDURE FOR MAINLINE WELDING
CIPL-PNCPL-EIL-PL-WP-09
Client Numaligarh Refinery Limited Date : 5-Feb-22
Consultant Engineers India Limited Revision : 01
Contractor Corrtech International Pvt. Ltd. Page No. : 6 of 7
Welding Sequence:
Welder No.1 will start from 12 ‘O’ Clock position and proceed towards 6 ‘O’ Clock,
Welder No.2 will start from 9 ’O’ Clock position and proceed towards 6 ‘O’ clock and then from 12
‘O’ clock to 9 ‘O” clock. Proper Overlap will be ensured.
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
provide the thickness of the weld metal, deposited will be 50 % of the pipe thickness or minimum
of 03 passes whichever is more.
Arc Strike outside the beveled area on the pipe surfaces is not permitted. Acceptance criteria for
arc strike / arc burn < 0.5 mm acceptable if ground out, > 0.5 mm un-acceptable and cut-out.
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 arc strikes same will be checked by DPT
method & thickness to be measured as instructed by EIL/NRL. Pipe should not be pumped or
shaken during welding.
Repair are limited to 30% of weld length. After the repair of weld re radiography of full joint shall
be carried out. A 100% ultrasonic test shall be carried out at the repaired area externally.
Welders shall be qualified as per the approved WPS and all the welders should have identity
cards duly signed by EIL / NRL.
After completing of welding, visual inspection shall be done and all the surface defects will be
removed as per specification. NDT will be carried out as per the approved NDT procedures. NDT
repairs will be done as per approved WPS. All mainline weld joint shall be examined by 100 % RT.
X-ray method
Repair procedure to be qualified separately for full through thickness and partial thickness
respectively. Only 02 attempt for through thickness repair is permitted. Repairs are restricted to
maximum 30% of the weld length.
Destructive testing of weld joints (Production joints) shall be one test per 1000 of joints
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. All weld must be completely filled at the end of
working day.
6. Health & Safety and Environment:
1. All PPE is a must in this activity.
2. Only trained personals to be deployed for this activity.
PARADIP - NUMALIGARH CRUDE OIL PIPELINE PROJECT
(PNCPL)
JOB PROCEDURE FOR MAINLINE WELDING
CIPL-PNCPL-EIL-PL-WP-09
Client Numaligarh Refinery Limited Date : 5-Feb-22
Consultant Engineers India Limited Revision : 01
Contractor Corrtech International Pvt. Ltd. Page No. : 7 of 7
3. All measuring & Test Equipment’s used must be well maintained.
4. All lifting devices & Tools used shall be well maintained.
5.During fit up operation, special care to be taken to avoid personal injury.
7. Appendix:
Inspection and Test Plan : CIPL-PNCPL-EIL-PL-WP-ITP-09, Rev No-00
Inspection Report: : CIPL-PNCPL-EIL-PL-WP-09/IR-09, Rev No-00
Note: In case of any conflict between this procedure and contracts specification, the later
supersedes this procedure.
