PIPELINES DIVISION

Title: LINING UP OF PIPE Work Procedure No.: M L- 07

& WELDING Revision No. :0
Effective from : 26.01.2004

1.0.0 SCOPE

1.1.0 The scope of this work procedure includes lining up, identification of pipe
defects and their repair, cleaning & re-bevelling of pipe ends, pipe placement &
skid spacing, alignment of pipes, welding process, welding procedure
qualification, welders qualification, welding, inspection & testing and fitting of
night caps.

2.0.0 WORK PROCEDURE

2.1.0 LINING UP

2.1.1 Each length of pipe shall be thoroughly examined internally & externally to
ensure that it shall be free from visual defects /damage, severe corrosion,
pitting, dirt or any other foreign matter.

2.1.2 Each pipe length shall be adequately swabbed using canvas belt disc of proper
diameter. Damaged/corroded pipes shall be segregated and kept separately.

2.1.3 Each pipe shall be pulled through by sizing plate with a diameter equal to 95%
of nominal internal diameter of pipe before being welded.

2.2.0 PIPE DEFECTS & REPAIRS

2.2.1 Acceptability of defects in the pipe detected during lining up shall be

determined in accordance with latest edition of code ASME B-31.4. A record of
all defects noticed and the repairs carried out along with the pipe identification
No., shall be maintained.

2.2.2 Dents containing stress concentration such as scratch, gauge, arc burn or
groove and dents located at longitudinal, spiral or circumferential weld shall be
removed by cutting the damaged portion of pipe.

2.2.3 Repair on line pipe shall be permitted as specified in code ASME B31.4.

2.2.4 No repair on pipe body by way of welding shall be permitted. If due to cutting or
repairs pipe identification number is removed, it shall be reprinted immediately.
No pipe shall be welded without pipe identification number.

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 PIPELINES DIVISION

Title: LINING UP OF PIPE Work Procedure No.: M L- 07

& WELDING Revision No. :0
Effective from : 26.01.2004

2.3.0 INSPECTION & CLEANING OF BEVEL ENDS

2.3.1 Prior to aligning of pipe for welding, the bevelled ends of each pipe and the
area immediately adjacent thereto (25mm from the edge on inside & outside of
the pipe) shall be thoroughly cleaned off paint, rust, mill scale, dirt, slag & any
other foreign matters by use of power-driven wire buffing wheels or by other
methods approved by IOCL.

2.3.2 All damaged (bent, cut or otherwise mutilated) ends of pipe shall be repaired or
cut-off, end re -bevelled to the correct angle with approved type of bevelling
machine.

2.3.3 Dents in bevels of depth less than one (1) mm shall be removed during the
cleaning & grinding ahead of the welding. Dented bevel ends with a depth
between 1 & 3 mm shall be re-bevelled.Dents over 3mm depth shall be
repaired by cutting and re -bevelling. Only approved methodology shall be
followed for pipe end repairs.

2.4.0 SPACING

2.4.1 Skids to be used shall be of at least 1.20 m long and contact length for pipes
(width of the skids) with OD of 12” or more, shall be minimum 200mm & for
pipes with OD less than 12”, shall be minimum 150mm. A strip of soft material
like sand bag etc. as approved by IOCL be placed in between skid and pipe.
2.4.2 The welded pipes shall be supported on skids at a minimum height of 500mm
above ground or as specified. Crotches shall be installed at frequent intervals
(at every 10 th support) with greater number required at bends & undulating
grounds. Pipe supports (skids or pack pads or any other approved suitable
means) shall be firm enough so that movement of pipes does not cause the
supports to move. Minimum two numbers of supports shall be provided for a
pipe being lined up for production weld.
2.5.0 PIPE ALIGNMENT

2.5.1 In case of external line-up clamp, root bead segments shall be uniformly
spaced around the circumference & the accumulated length of root bead shall
not be less than 50% of pipe circumference before the clamp is removed.

2.5.2 All pipe joints shall be aligned using internal line-up clamp. However, external
line-up clamp can be used in exceptional condition like Tie-up joints etc.

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CONSTRUCTION MANUAL-MAINLINE
 PIPELINES DIVISION

Title: LINING UP OF PIPE Work Procedure No.: M L- 07

& WELDING Revision No. :0
Effective from : 26.01.2004

2.5.3 The pipe-to-pipe fitting joints shall be aligned as accurately as practicable

giving consideration to existing commercial tolerances on pipe diameter, wall
thickness & out of roundness.

2.5.4 All joints shall be aligned & welded with a uniform gap all along the
circumference of pipe and no backing rings shall be permitted. The high-low
misfit shall be scattered around the periphery or swaged to fit with a set of
suitable flatter. Only brass coated Hammers, if required for cold dressing for
slight misalignment, shall be used. Hot dressing shall be not permitted.

2.5.5 If pipes contain longitudinal weld seams, alignment shall be such that the weld
seam should fall in the upper quadrant of the pipe circumference and shall be
offset by at least 20° from each other except in vertical bends. In no case the
longitudinal weld seam shall be permitted in the lower quadrant of the pipe
circumference.

2.5.6 Preparatory to aligning of pipe for welding, the inside of each joint of pipe shall
be thoroughly cleaned & swabbed with a leather or canvas belt disc of
diameter not less than the ID of the pipe minus 1.5cm and sufficient length to
remove all sand, dirt, loose mill scale or other debris that might clog the line.

2.5.7 The internal line-up clamp shall not be released until the entire (100%) root
pass is completed.

2.6.0 NIGHT/TEMPORARY CAPS

2.6.1 At the end of each days work or when the welding work is interrupted, the open
ends on the welded string of pipe shall be capped tight, as approved by IOCL,
so as to prevent the entry of dust, dirt, water or another foreign matter into the
pipeline. The cap/plug shall be of mechanical type.

2.6.2 The nightcaps shall not be removed until the work gets resumed.

2.7.0 WELDING

2.7.1 All welding for pipe sizes 4" OD and above shall be done in accordance with the
latest edition of API 1104, "Standard for welding of pipelines and related
facilities" and ASME B 31.4 "Liquid Petroleum Transportation Piping
System".

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 PIPELINES DIVISION

Title: LINING UP OF PIPE Work Procedure No.: M L- 07

& WELDING Revision No. :0
Effective from : 26.01.2004

2.8.0 WELDING PROCESS

2.8.1 Before starting production welding, welding procedure shall be qualified in

accordance with the API-1104 and a record shall be maintained for the same in
the prescribed format. All the production welds shall be in accordance with the
qualified procedure and any change in it would necessitate re-qualification.

2.8.2 Each welder to be deployed shall have to clear the Welders Qualification Test
(WQT) in accordance with API 1104. Duly signed, numbered and a photo
identity card shall be issued to him by IOCL, which is required to be in his
possession at job site.
2.8.3 ROOT PASS

a) The root pass is made with approved electrodes filler wire of size as per
qualified welding procedure. Welding shall be carried out continuously and
uninterrupted during the pass.

b) Upon completion of each run, craters, welding irregularities, slag etc, shall be
removed by grinding & chiselling. During the process of welding any movement
of components, shock, vibration & stresses should not take place to prevent
occurrence of cracks in weld.

c) The visual defects are repaired as per procedure approved for the same.

2.8.4 JOINT COMPLETION

a) First and second pass should be carried by a minimum of two welders working
continuously and so placed as to cause minimum distortion of the pipe. The
number of welders and allowable welding sequences should confirm to the
qualified Welding Procedure Specification (QWPS).

b) The internal clamp shall be removed before starting the second pass. The first
pass should be cleaned of slag/flux etc. & flattened with rotating grinders.

c) The interruption between completion of first pass & starting the second pass
shall not exceed 4 minutes. The welding speed shall be so selected as to
produce a bead, which is sufficiently thick & shows no under cutting.

d) The time lapse between second & third pass should normally not exceed 5
minutes for a wall thickness greater than 0.281", however, for pipes with wall

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 PIPELINES DIVISION

Title: LINING UP OF PIPE Work Procedure No.: M L- 07

& WELDING Revision No. :0
Effective from : 26.01.2004

thickness less than 0.281", the time lapse between second & third pass shall
be as per QWPS.

e) After completion of second/third or subsequent passes (as applicable), the

welding operation shall be suspended to allow the joints to cool down provided
the thickness of weld metal deposited is equal to at least 50% of pipe wall
thickness. Upon restarting, preheating as per QWPS shall be ensured.

f) Subsequent passes up to weld completion shall be protected to avoid rapid

cooling depending on weather conditions.

g) Cleaning between passes shall be carefully done so as to reduce the

possibility of inclusions. Electrode starting and finishing points shall be
staggered from pass to pass. Arc-strikes outside the bevel on the pipe surface
shall not be permitted. A separate striking plate shall be provided, if required.

h) Arc-strikes or arc-burn on the pipe surface outside the weld, whic h may be
caused by electrical arcs between the electrodes, electrode holder, welding
cable or welding ground and pipe should be removed by grinding in
accordance with a procedure approved by IOCL and the repair is checked by
ultrasonic/ radiographic / magnetic particle or dye-penetration tests. Repair of
arc -strikes by welding shall be prohibited.

i) The completed weld joint shall be properly brushed & cleaned to be free from
spatters and scales etc. and shall bear the joint number in accordance with
clause 2.8.11 of this chapter.

2.8.5 HEAT TREATMENT

a) The pre & post heating shall be in accordance with QWPS.

2.8.6 INSPECTION & TESTING OF PRODUCTION WELD

a) The joint welding shall be inspected for its acceptance is the

following manner:
i) Visual Inspection
ii) Non-destructive examination
iii) Destructive testing

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 PIPELINES DIVISION

Title: LINING UP OF PIPE Work Procedure No.: M L- 07

& WELDING Revision No. :0
Effective from : 26.01.2004

b) Visual Inspection
i) The standard of acceptability of welds shall be examined during the welding
and its finish as set forth in API 1104. The finished weld shall be visually
inspected for parallel and axial alignment of joint, excessive weld
reinforcement, connectivity of welds, shrinkage, crates, undercuts, surface
porosity, and other surface defects.
c) Non Destructive Testing
i) The non-destructive examination shall be carried out by means of X-ray
radiography of the weld in ac cordance with API 1104.

d) Destructive Testing
i) In addition to radiographic inspection of girth weld, designated weld joint as
fixed by IOCL shall be cut and tested for nick-break, U-bend and tensile
strength as described in API 1104.
2.8.7 FREQUENCY OF INSPECTION

a) As specified by IOCL.
2.8.8 ACCEPTANCE CRITERIA

a) The acceptance criteria for visual, radiography & destructive testing shall be in
accordance with API 1104 or as provided in the contract, whichever is
stringent.
2.8.9 REPAIR OF WELDS

a) Defects observed during visual & radiographic inspection of production welds

shall be repaired and inspection of the repaired weld shall be carried out in
accordance with the acceptance criteria indicated in visual & radiographic
inspection in line with API 1104/approved procedure.

b) Separate procedures and welders shall be qualified for the repair of welds.

2.8.10 WEATHER CONDITIONS

a) Welding shall not be carried out when weather condition is not conducive e.g.
high humidity, blowing sand and high winds, to obtain a sound production weld.
Windshields shall be deployed, wherever required.

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 PIPELINES DIVISION

Title: LINING UP OF PIPE Work Procedure No.: M L- 07

& WELDING Revision No. :0
Effective from : 26.01.2004

2.8.11 NUMBERING OF PRODUCTION WELDS

a) Each production weld shall be numbered as per below mentioned

nomenclature:

i) For mainline welding: K x M y.

ii) For tie -in joints: K x T y.
Where: K stands for Kilometre
M stands for Mainline.
T stands for Tie-in
The variables x & y are numerals. x denotes actual pipeline chainage in km & y
denotes successive joint serial number in a span between Km x and Km (x+1).
The weld number shall be written on the back pipe near adjacent to the joint.

For example a mainline production weld joint of 15 th & 16th pipes ex km

chainage 40 would be designated as K 40 M 15. If the joint between 25 th & 26 th
pipe is a tie-in joint, then it would be designated as K 40 T 25.

In case number of welding joints or tie-in joints increase, the same may be
denoted as Km 40M 15 A OR K 40 T 25A as the case may be.

b) In addition each welding joint shall identify the portion of weld performed by
specific welder by writing welders number, adjacent to the weld Number, on
the pipe as given hereunder:

Pass No. 1 2 3 4 5
Welders' ID a1 b1 C1 d1 e1
a2 b2 C2 d2 E2

Where 1, 2, 3, 4 & 5 stands for weld pass number and a1&a2, b1&b2, c1&c2,
d1&d2, e1&e2 stands for identification symbol of the qualified welders on both
side of the pipe joint who have made that particular pass.

2.8.12 WELDING PROCEDURE QUALIFICATION

a) Welding procedure qualification shall be carried out for under mentioned types
of production welding in accordance with API 1104.

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 PIPELINES DIVISION

Title: LINING UP OF PIPE Work Procedure No.: M L- 07

& WELDING Revision No. :0
Effective from : 26.01.2004

i) For mainline welding of pipes

ii) For tie -ins,
iii) For partial thickness repairs of welding
iv) For through thickness repairs of welding
v) For welding of pipe fittings

b) The following standards and codes shall be followed:

i) API 1104, for Welding Pipelines and Related facilities,

ii) ASME B31.4, Codes for Liquid Petroleum Transportation Piping system.
iii) ASTM E94, Recommended practice for Radiographic Testing.
iv) ASTME 142, Standard Method for Controlling Quality of Radiographic Testing.
v) The American Society for Non-Destructive Testing, Recommended prac tice
No. SNT -TC-1A, supplement-A.
vi) ASTME 1032, Radiographic examination of weldment

2.8.13 WELDER'S QUALIFICATION

a) The welder qualification test shall be conducted to determine the ability of

welder(s) to produce sound welds using approved welding procedure(s).

b) The welder qualification test shall be conducted as per guidelines contained is

API 1104 and witnessed by of the representative of IOCL and/or third party
inspector so appointed by IOCL for this purpose

3.0.0 REFERENCE DRAWINGS & DOCUMENTS

3.1.0 Manufactures batch test certificates in respect of welding electrodes.

3.2.0 Electrode qualification records (Refer Document No.: QAP/01,Exhibit-A to C at

Annexure “1” to this Procedure).

3.3.0 Welding Procedure(s) Qualification records and its approval.

3.4.0 Welders' Qualification records (Refer Document No.: QAP/01,Exhibit-D to E at

Annexure “1” to this Procedure) and their acceptance.

3.5.0 Contractual specification for welding.

3.6.0 API-1104, for welding pipelines and related facilities.

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 PIPELINES DIVISION

Title: LINING UP OF PIPE Work Procedure No.: M L- 07

& WELDING Revision No. :0
Effective from : 26.01.2004

3.7.0 ASME B31.4, Code for Liquid Petroleum Transportation Piping System.

3.8.0 The American society for non-destructive testing. Re-commanded practice No.
SNT-TC-IA Supplement-A.

4.0.0 REPORTING FORMATS

4.1.0 DR/03: Daily Report for production welding.

4.2.0 IR/07: Inspection Report for welding front end (Root & Hot Pass).

4.3.0 IR/08: Inspection Report for Welding back end (Filling, capping &
identification).

5.0.0 EQUIPMENTS
5.1.0 IOCL

5.1.1 As per site requirement

5.2.0 CONTRACTOR

5.2.1 As per contract and site requirement.

6.0.0 MANPOWER

6.1.0 IOCL

6.1.1 Engineer/supervisor.

6.2.0 CONTRACTOR

6.2.1 Engineer/supervisor/welders/fitter with adequate skilled/semiskilled labours.

7.0.0 CHECK POINTS

7.1.0 Pipe number, coating number & wall thickness is transferred on top of the pipe
coating for proper identification before lining up & alignment of pipes.

7.2.0 Visual inspection of pipes, both internally & externally, for maximum
permissible depth of dents 2% of pipe OD. If dented area is minor and at least

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 PIPELINES DIVISION

Title: LINING UP OF PIPE Work Procedure No.: M L- 07

& WELDING Revision No. :0
Effective from : 26.01.2004

200 mm away from the pipe end and steel is not stretched, severed or split, the
pipe may be straightened with a proper jack.
7.3.0 Pipe is properly swabbed to remove any dirt, grease for any other foreign
matters.

7.4.0 Pipes with damages beyond repair and corroded pipes are removed and
replaced by new pipes in the string.

7.5.0 Bevel ends from inside & outside for any defects and their proper repairs as
specified.

7.6.0 Proper slings with rubber padding only are used for lifting of pipe and the pipe
is not subjected to over stressing.

7.7.0 Strip of soft material is placed in between the wooden skid and the pipe bottom
to protect the pipe coating. Minimum two numbers of supports are provided
under a pipe during the progress of welding. The maximum distance between a
incomplete weld and support is 9% of normal support spacing. Supports under
a string are not removed prior to lowering in.

7.8.0 Only internal line-up clamp is used for mainlin e production welding. The
maximum offset allowed is 1.6 mm. No backing rings are used for alignment.

7.9.0 In case of pipes with longitudinal weld seam, alignment is done in such a way
that the seam falls in the upper quadrants of the pipe circumference with offset
of at least 20° or 150 mm from each other except for vertical bends.

7.10.0 Only specified electrodes as per QWPS are used for different runs in welding
operation.

7.11.0 Verification of batch certificates by the manufacturer for electrodes.

7.12.0 Electrodes are kept in a closed dust proof container at site.

7.13.0 The internal line-up clamp is removed only after completion of root pass. The
external line-up clamp is removed after completion of at least 50% of root pass.

7.14.0 In extreme weather condition of high humidity and low atmospheric

temperature for preheating and in case of high velocity winds, proper type of
windshields is provided. No welding is carried in dusty winds.

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 PIPELINES DIVISION

Title: LINING UP OF PIPE Work Procedure No.: M L- 07

& WELDING Revision No. :0
Effective from : 26.01.2004

7.15.0 No welder is allowed without possessing a valid identity card issue to him after
welder qualification test and carried only that portion of job for which he is
certified.

7.16.0 Marking of identification number of each weld & each welder performing
welding without fail. Permanent markers/paint are used for these markings
near the weld joints.

7.17.0 Partially used electrodes are discarded.

7.18.0 Visual inspections of all production weld & identify joints for radiographic
inspection based on visual inspection of joints, which are worst.

7.19.0 The defects observed during visual & radiographic inspections are rectified and
a proper record is maintained for the same.

7.20.0 Tight fit nightcaps are fixed at open ends of the string after completion of day’s
work.

8.0.0 RESPONSIBILITIES

8.1.0 Direct responsibility : Field Engineer/Supervisor.

8.2.0 General Responsibility :Spread In-Charge/Site -Engineer.

8.3.0 Overall Responsibility : Engineer-In-Charge.

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