HCC Management System

Procedure for
MAINLINE WELDING
Project: Kalol Mehsana Gas Pipeline Project
(Job No: GSPL/113)

PROCEDURE FOR MAINLINE WELDING

HCC-NOVA P 46 17 09
Date: 22nd Feb 2006
DOCUMENT RELEASE AUTHORIZATION

0
Rev.
No

22.02.06

Dt. of Rev

For Review &

Approval

Description

Docum
Contr
Prepared
By (HCCNOVA
-JV)

Checked By
(Manager QA
HCC-NOVA
JV)

Reviewed
by (ABS)

Approved By
(Dorsch Consult (I)
Pvt. Ltd / GSPL)

Project:

Kalol Mehsana Gas Pipeline Project (Job No: GSPL/113)

Owner:

Gujarat State Petronet Ltd.

Consultant:

Dorsch Consult (India) Pvt. Ltd.

TPIA:

ABS Industrial Verification Ltd

Contractor:

HCC-NOVA JV.

Approved and
Issued for
Construction
by
GSPL
(KMPL Project)

Issued as: CONTROLLED COPY

This document is the property of HCC and is copyright protected. Unauthorized
photocopy either partly or fully is prohibited. Authorized controlled copy of this
document can be had from Doc. Controller

Doc No: HCC NOVA 46 17 09 Rev 1 Dt. of Rev 22/02/06,

Page 1 of 9

Releas
Constru
(HCC-NO

HCC Management System

Procedure for
MAINLINE WELDING
Project: Kalol Mehsana Gas Pipeline Project
(Job No: GSPL/113)
CONTENTS

S.NO

DESCRIPTION

PAGE NO

Scope

Reference

Method

3, 4 & 5

4
5

Health, Safety and Environment

Documentation

Doc No: HCC NOVA 46 17 09 Rev 1 Dt. of Rev 22/02/06,

6
6

Page 2 of 9

HCC Management System

Procedure for
MAINLINE WELDING
Project: Kalol Mehsana Gas Pipeline Project
(Job No: GSPL/113)
1.

SCOPE
This Procedure covers the work method for Mainline Welding of
pipeline works.

2.

REFERENCE
1. GSPL Specification 1013 113 103
2. API 1104
3. ASME B 31.8
4. ASME Sec II C and
5. Approved WPS.

3.

METHOD

1.

Before the fit up, pipe shall be checked for correct thickness, free from
pitting and dent, etc. Bevel ends shall be visually checked and repairing
is as mentioned below.
a.
b.
c.

d.

Dents less than 1 mm depth shall be removed by grinding.

Dents 1 mm to 3 mm depth shall be re beveled by
grinding
Depth more than 3 mm shall be gas cut and re beveled.
UT shall be carried on pipes which have been cut to an
extent of 25mm at the new bevel to ensure, it is free from
lamination. The bevel shall be 100% visual, DP & UT
(Lamination) tested and report shall be prepared.
Surface check for 100mm and if required LPT to be
conducted as per site inspector requirements.

2.

Before fit-up pipe ends inside / outside shall be cleaned by power wire
brush at least for one inch so that the welds are free from rust, paint and
other foreign matters. Manual cutting and repairing of pipes and bevels
by welding is not allowed.

3.

If any laminations, split ends or any other manufacturing defects in the

pipe be discovered, the length of the pipe shall be cut to the extent
required with the knowledge of GSPL/TPIA site engineer & fresh bevel is
to be prepared subjected to 100% VI,LPT, & UT (lamination) and a joint
record shall be generated.

Doc No: HCC NOVA 46 17 09 Rev 1 Dt. of Rev 22/02/06,

Page 3 of 9

HCC Management System

Procedure for
MAINLINE WELDING
Project: Kalol Mehsana Gas Pipeline Project
(Job No: GSPL/113)
4.

During alignment and fit up, first pipe will be rested and locked on the
pre - positioned skids and the second pipe will be held by hydra crane
with internal fit-up clamp (Mechanical), the second
pipe will be
carefully lowered on pre positioned skids. Skidding arrangement shall
be as shown below and skids may be removed only after completion
of the entire welding and the pipe shall be rested on the sand bags. The
height of the Support must be such that each weld is at 50 cm above the
ground during welding and after weld, height of support shall be 30 cm.

4.

WELD JOINT
12000mm Typ
Skid

Skid

30 Cm
Ground

Skid Size 150 mm x 150 mm x 1000mm

Skip Size for equal to & more than 12.75 OD = 150 mm x 1000 mm

5.

Maximum offset of the same nominal wall thickness pipe shall not be
more than 1.6 mm.

6.

Longitudinal seam orientation to be checked for both end of pipes in

respect of top centre of pipe. Offset from each other long seam to be
maintained min.distance of 300mm and 140mm in case of staggered
bends on top of pipes.

7.

In case of slight misalignment, cold hammering is permissible only by

brass hammer. Hot dressing is not permitted.

8.

Root gap shall be as per the approved WPS.

9.

After alignment & fit up, pre heating shall be carried out(minimum
100 degree C) and the same shall be checked with thermo chalks /
temperature indicating pyrometer before starting the root run.

10.

Earthing clamps used for welding return circuit shall only be placed on
bevel area or circumferential welds.

11.

Internal line up clamps shall not be released before the root and hot
pass runs are completed. Weld joints shall be protected from rains /
sand storms. Wind shield shall be used in the aforesaid conditions.

Doc No: HCC NOVA 46 17 09 Rev 1 Dt. of Rev 22/02/06,

Page 4 of 9

HCC Management System

Procedure for
MAINLINE WELDING
Project: Kalol Mehsana Gas Pipeline Project
(Job No: GSPL/113)
12.

Pre-heating may be done by induction heating methods. Pre-heating by

gas burners, utilizing acetylene or propane gas (ensuring uniform
heating) may also be used. Preheating and inter-pass temperature shall
be maintained as per the approved WPS.Minimum pre-heating shall be
100 degree centigrade.

13.

Before any pipe length is cut the painted serial No. & Heat No shall be
transferred to the either side of the joint which is to be made by cutting &
record shall be prepared as per approved format. The length of the pup
to be welded shall be at least 1 m. On either side of each circular joint,
only one round joint shall be permitted within a distance of 8m. Where
different wall thickness pipes are to be welded and the difference in wall
thickness 1:4 taper internal grinding on the higher thickness shall be
done.

14.

Welding shall be carried out as per the approved WPS. Minimum

number of welders shall be two for mainline as well as Tie-In welding for
each pass.For different wall thickness, cut out joint shall be carried out
as per approved Tie-in welding procedure.

15.

Welder No. 1 shall start from 12 O Clock position and proceed towards
6 O Clock. Welder No.2 shall start from 9 O Clock position and
proceed towards 6 O clock and then from 12 O Clock to 9 O Clock.
Proper Overlap shall be ensured.

16.

After completing every pass, the same shall be cleaned / flattened by

grinding and power brushing.

17.

Electrode starting & finishing points shall be staggered from pass to

pass. Interruption between first pass to second pass and to third pass
shall 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 shall be
50% of the pipe thickness or minimum of 03 passes whichever is more.
Upon restarting the welding pre-heating shall be carried out.

18.

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,
>0.5mm un-acceptable and cut out.

19.

Repair of arc strike by welding is not allowed.

20.

Pipe should not be pumped or shaken during welding.

Doc No: HCC NOVA 46 17 09 Rev 1 Dt. of Rev 22/02/06,

Page 5 of 9

HCC Management System

Procedure for
MAINLINE WELDING
Project: Kalol Mehsana Gas Pipeline Project
(Job No: GSPL/113)
21.

Welders shall be qualified as per the approved WPS and all the welders
should have identity cards duly signed by GSPL/Dorsch and TPIA.

22.

After completion of welding visual inspection shall be done and all the
surface defects shall be removed as per the specification. NDT shall be
carried out as per the approved NDT procedures. Repairs shall be done
as per approved WPS and if required it shall be tested for NDT.

23.

Repair procedure to be qualified separately for full through thickness and

partial thickness respectively. Only ONE attempt for repair is permitted.
Repairs are restricted to maximum 30% of the weld length for partial
thickness repair and 20% for root repairs. Minimum length of root repair
shall be 100mm.

24.

At the end of the days work or every time when joining and welding
operations are interrupted, the open ends are to be closed with
nightcaps.

4.0

HEALTH, SAFETY AND ENVIRONMENT

1.
2.
3.
4.

5.0

All PPE is a must in this activity.

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

DOCUMENTATION
Inspection and Test Plan
Inspection Report

:
:

HCC NOVA T 46 17 09
HCC NOVA F 46 17 09 01

Note:
In case of any conflict between the requirements of this procedure of this
procedure and that of GSPL standard specification, then the requirement of
GSPL specification intention is meant.

Doc No: HCC NOVA 46 17 09 Rev 1 Dt. of Rev 22/02/06,

Page 6 of 9

INSPECTION TEST PLAN

MAINLINE WELDING
Owner

: Gujarat State Petronet ltd

Format No: HCC NOVA T 46 17 09

Consultant

: Dorsch Consult India Pvt.Ltd.

Revision : 0

TPIA

: ABS industrial Verification Ltd.,

Date :

Contractor

: HCC NOVA joint Venture

Format No:

Project

: Kalol Mehsana Gas Pipeline Project

Sr.
No

Activity Description

Controlling
Specification

Acceptance
Criteria

Verifying
Document

Frequency
of Insp./
Testing

Inspection Category

Remarks

HCC
NOVA
JV

TPIA

Dorsch/
GSPL

Line up (Fit - up), Pre

Heating & Root, Hot pass, 1st
Filler & Welding and Time lapse

Approved Procedure
HCC NOVA
P 46 17 09

Approved WPS P 46
17 21 and API 1104

HCC NOVA
P 46 17 09 01

Every Weld

W/R

RM

Visual inspection of completed

weld

Approved Procedure
HCC NOVA
P 46 17 09

Approved Procedure
HCC NOVA
P 46 17 09 and API
1104

HCC NOVA
P 46 17 09 01

Every Weld

RM

NDT of completed weld

Approved Procedure
HCC NOVA
P 46 17 38
P 46 17 43
P 46 17 29

Approved Procedure
HCC NOVA
P 46 17 38
P 46 17 43
P 46 17 29 and API
1104

Relevant NDT Report

Every Pipe
Weld

W/R

RM

Destructive Tests of Production

weld

Approved Procedure
HCC NOVA
P 46 17 09

Contract Specification
1013-113-103 and API
1104

Laboratory Test
Reports

1 in 1000
Weld

W/RM

Legend
W

: Witness

RM : Random Inspection
R

: Review Documents

For HCC NOVA JV

For ABS (TPIA)

For Dorsch / GSPL

Name:

Name:

Name:

Sign:

Sign:

Sign:

Date:

Date:

Date:

Page 7 of 9

INSPECTION REPORT
MAINLINE WELDING
Owner

: Gujarat State Petronet ltd

Format No: HCC NOVA F 46 17 09 01

Consultant : Dorsch Consult India Pvt.Ltd.

Revision

TPIA

Report No:

: ABS industrial Verification Ltd.,

:0

Contractor : HCC NOVA joint Venture

Date

Project

Pipe Size :

: Kalol Mehsana Gas Pipeline Project

Spread :

From CH:

To CH:

Electrode Batch No and size :

Thickness:

WPS No: 01

Weather :

Alignment Sheet No_____________________________ Rev_________________________________________

S no

Pipe No

Heat NO

Length(in
metres)

Coating No

Todays progress

Root/Hot

F&C

Joint number

Previous Progress

Visual
inspection

Remarks

Cumulative Progress

No. of Joints
Length in Mtr.

For HCC NOVA JV

For ABS (TPIA)

For Dorsch / GSPL

Name:

Name:

Name:

Sign:

Sign:

Sign:

Date:

Date:

Date:

Page 8 of 9

INSPECTION REPORT
MAINLINE / TIE-IN WELDING

Owner

: Gujarat State Petronet ltd

Format No: HCC NOVA F 46 17 09 02

Consultant : Dorsch Consult India Pvt.Ltd.

Revision

TPIA

Report No:

: ABS industrial Verification Ltd.,

:0

Contractor : HCC NOVA joint Venture

Date

Project

Pipe Size :

: Kalol Mehsana Gas Pipeline Project

Spur Line :

From CH:

To CH:

Electrode Batch No and size :

Pipe No

Heat NO

Thickness:

WPS No:

Alignment Sheet No____________________________

Sr.
No.

A.S.L. No

Todays progress

Length(in
metres)

Weather :
Rev_______________

Joint No

Welder No.

Previous Progress

Visual
inspection

Remarks

Cumulative Progress

No. of Joints
Length in Mtr.

For HCC NOVA JV

For ABS (TPIA)

For Dorsch / GSPL

Name:

Name:

Name:

Sign:

Sign:

Sign:

Date:

Date:

Date:

Page 9 of 9