Handbook of Weld Inspection

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION
GUIDE BOOK FOR

PIPING/PIPE LINE
WELDING
INSPECTION
This note is prepared to give some idea about the
requirements of pipe line welding in accordance with the
code ASME sect. IX, API 1104, ASME B31.3/31.4/31.8 &
additional requirements by SAUDI ARAMCO. Use this note
for engineering education purposes only.
TEJAS V. ROOWALA
Project Inspector
Welding
AWS-CWI Certificate No.
08111791
[email protected]
TEJAS
ROOWALA
Digitally signed by TEJAS

ROOWALA
DN: cn=TEJAS ROOWALA, o=OM,
ou=INSPECTION,
[email protected],
c=IN
Date: 2010.01.04 11:17:13 +03'00'

WELDING REQUIREMENTS
Procedure Qualification
Either as per ASME sect. IX (or API 1104 for pipeline welding) with additional limitations as
per governing code B31.3, 31.4 or 31.8 and requirements of SAES-W-011/012/016.

Hardness testing of WPQ is required for hydrogen services, sour service applications and all services
requiring PWHT.
Only Vicker test method (in accordance with ASTM E92) is acceptable, with max. load of 10 Kg.
The location of the HAZ indents nearest the fusion line can be demonstrated to be within 0.2 mm of
the fusion line.
The max. allowable hardness is VHN 250. (for pipeline 250 VHN for sour services & 300 VHN for
offshore non sour services).
For procedure qualified to API 1104, the tensile test results shall be considered acceptable if the
specimen breaks in the base metal outside of the weld/fusion line, provided the strength is not more
than 5% below the specified min. tensile strength of the base metal.
Following are the max. tolerance limit for procedure qualified in accordance with sect. 9 (automatic
welding) of API 1104;
Travel speed:
20% of the actual PQR value
Voltage:
Current:
TEJAS ROOWALA
Performance Qualification
Either as per ASME sect. IX (or API 1104 for pipeline welding) with additional limitations as
per governing code B31.3, 31.4 or 31.8 and requirements of SAEP-321.

The test coupon shall be secured in the test position at a height of 18 above the floor of the test
booth.
Grinding, filing or mechanical dressing of the cap pass is not permitted.
Weld reinforcement and root penetration shall not exceed the given values in table-1.
Table-1
Test coupon wall thickness (mm)
t6.4
6.4<t12.5
12.5<t25.4
25.4<t
Maximum weld reinforcement/root penetration

1.6
3.2
4
5
Undercut up to the depth of 0.8 mm shall be permitted for a total length of 2 max. Undercut
exceeding 0.8 mm in depth is not permitted.
Under fill up to 1.6 mm in depth shall be permitted for a total length of 2 max. Under fill exceeding
1.6 mm in depth is not permitted.
Lack of penetration is not permitted.

Lack of fusion is not permitted.
Unremoved arc strikes on the base metal are not acceptable.
Guided bend testing;
Table-2
Test coupon thickness (mm)
t9.5
9.5<t19.05
t>19.05
No. & Type

2F & 2R
2F & 2R or 4S
4S
Test piece Shall be taken from the location shown in QW-463 of ASME IX.
Testing shall be done in accordance with ASME IX.
The repair rates shall be calculated on a lineal basis. The max. weekly repair rate for each welder
should not exceed 2%.
%RR = (Lr/Lw) X 100
Lr = welders total length of repair in one week, mm
Lw = welders total length of weld radiographed in one week, mm
Processes
TEJAS ROOWALA
Except for ASME P-No. 1 through P-No.5A/5B/5C base material, all manual GTAW shall use a high
frequency start and post purge gas flow for the torch.
Filler metal must always be added (i.e. autogeneous process is not permitted) unless specified.
The GTAW process shall be used for the root pass of butt welds without backing in piping and set in
fittings of 50.8 mm nominal pipe size or less, except for vent and drain piping open to the
atmosphere.
The GTAW process shall be used for the root pass of single sided groove welds without backing made
with SS or Ni based consumables.
GMAW/FCAW shall not be used for single sided tee or corner joints (i.e. branch/nozzle welds)
The GMAW dip mode (STT mode) shall not be used except for,
Structural attachments to the outside surface of the pipe, including seal welds.
Tacking that will be completely removed by back gouging and back welding.
The root pass and hot pass only for butt welds in P-No.1 CS.
FCAW Gas shielded process shall not be used for root pass on full penetration groove joints that are
welded from one side only without backing.
FCAW Self shielded process shall not be used unless specified.

Consumables
Low hydrogen consumables may be used. The root pass of single sided groove welds without backing
in P-No.1 CS may be made with an EXX10 electrode.
For welding P-No.1 CS, the weld deposit shall meet the A-No.1 analysis classification for normal
applications or A-No.10 for low temp. applications unless specified.
Filler metal or deposit chemistries conforming to A-No.2,i.e. C-0.5% Mo (E7010-A1 or E7018-A1) shall
not be used for sour services applications without PWHT unless specified.
SAW Fluxes:
Active flux shall not be used unless specified.
Flux that uses recrushed slag is not acceptable.
SAW Flux that the manufacturer recommended for single pass shall not be used for multi pass
welding.
SMAW Elect.:
F-No.1 & 2 elect. shall not be used on material requiring impact tests and pressure retaining welds.
Shielding Gases:
Shall confirm to the AWS A5.32 specifications for welding shielding gas.
TEJAS ROOWALA
Joint Details
All pressure containing welds shall be made with multiple pass.

All nozzles, branch and T-connections shall be made with full penetration groove welds only.
Internal misalignment of butt joints shall not exceed 1.5 mm.
Permanent backing strips or rings shall not be used. Temporary back up strips in weld joints may be
used if the backing m/t is of a composition similar to the base/weld metal. Under no circumstances
shall rebar or galvanized steel be used. Temporary back up shoes made of non-metallic, non-fusing
m/t may be used.
Consumable inserts may be used for all applications providing the composition matches the weld
metal composition.
Full penetration groove joint included angles less than 30 shall not be used unless specified.
All holes cut for set-on nozzles, bosses or branch connections shall be ground smooth and the dia. of
the hole shall be 1.6 mm of the inside dia. of the set-on member.
A min. of 1.5 mm depth shall be removed by grinding or machining from thermally cut or gouged
surface.
Fittings that are re-cut or re-beveled shall have the cut surface examined for laminations before
welding.
SS and non ferrous m/t shall be cleaned with grinding wheels or SS brushes not previously used on
other metals.

Buttering/weld build up on the prepared surfaces shall not exceed the lesser of 1/3 of the base metal
thk. or 10 mm unless specified. If it exceeds it shall be inspected by RT, PT/MT after completion of
the buildup but before final welding of the joint.
Tack Welds
Tack welds shall be of sufficient size to maintain joint alignment. The recommended tack thk. is 3.24.8 mm and length is 12.5-25.4 mm.
The min. no. of tack welds are,
pipe dia D4 3 equally spaced
D>4 min. 4 equally spaced
Tack welds that are to be incorporated into the final weld shall be thoroughly cleaned, prepared at
each end and inspected for cracks. Any cracked tacks shall be removed before welding the joint.
If the tack welds are to be incorporated into the final root pass weld and are made with different
process or elect. than the root pass, then the tack weld process and elect. shall have been used as the
root pass for an appropriate procedure qualification.
Bridge tacks (located above the root area) are acceptable but such tacks must be made completely
within weld groove and shall be completely removed prior to completion of weld.
Back Purging
An inert backing gas shall be used for GTAW/GMAW root passes on a single sided groove welds for
m/t of ASME P-No.5 and higher.
For P-No.5 and higher m/t, any back purging shall be maintained until at least 10 mm of the weld
deposit thk. has been completed.
The use of Nitrogen as a backing gas for austenitic SS is prohibited.
The back purge for low alloy steel shall reduce the oxygen level below 1%. The back purge for SS & Ni
alloys shall reduce the oxygen level below 0.05%. An oxygen analyzer should be used to determine
the oxygen content inside the pipe during purging. The below formula is used to achieve the required
purging time:
TEJAS ROOWALA
PT
(V/PGFR) x 4
V = vol. of pipe sect. to be purged, ft3

PGFR = purging gas flow rate, ft3/hr
Pre heating
The min. preheat shall not be less than the greater of 10C or recommended in ASME B31.3.
Whenever ambient temp. is below 0C then the recommendations given in particular code become
requirements.
CS having a carbon content in excess of 0.32% or a CE>0.65% shall be preheated to the temp.
indicated by the procedure.

If a weld joint is wet or has surface moisture or condensation, it shall be dried by heating for a dist. of
100 mm from the weld joint and shall be warm to the hand before welding unless a greater preheat
is required.
Pipe that has been used in sour gas services shall be heated for at least 20 min at 400F or higher to
drive off any hydrogen in the metal. Heating shall be done just prior to welding. This heating should
be in addition to and immediately preceding any pre heating specified in the welding procedure.
Temp. indicating crayons, thermocouples or calibrated contact pyrometers shall be used to measure
pre heat and interpass temp. Temp. indicating crayons shall not be used on any weld joint that is to
be coated or that will have a heat shrink sleeve installed on it.
The preheat temp. shall be established over a min. distance of 75 mm on each side of weld.
If wall thk. exceeds 25 mm then preheating shall be done from the same side as the welding, and the
heat source shall be removed for 1 min. to allow for temp. equalization prior to measuring the temp.
Welding
Dissimilar metal welds (DMW) are defined as any weld joint (excluding weld overlays/strip lining)
between ferritic steel and either austenitic SS, duplex SS or Ni based alloys.
They shall be restricted as follows,
Are not permitted for pressure containing welds in sour services.
TEJAS ROOWALA
Are permitted for non-sour hydrogen services if made with Ni based consumables.
Austenitic SS may be used only for following applications and if max. temp. is below 300C,
External structural attachments
Non-sour, non-hydrocarbon (e.g. water) services
Ni based consumables may not be suitable for direct exposure to sulfur or hydrogen-sulfur reducing
environment at temp. exceeding 400C due to possible sulfidation attack.
Any GMAW elect. to be used for procedures with impact toughness requirements and any SAW flux
or FCAW elect. shall be restricted to the specific brand, type and max. size as used for PQR.
A change in filler metal or deposit chemistry from A-No.1 to A-No.2 and vice-versa is not permitted
without approval. A change from A-No.1 to A-No.2 is not permitted for sour services applications
without requalification.
The direction of welding for the vertical position shall be an essential variable. If the procedure is not
qualified in the vertical position, then the direction of the welding shall be vertical up.
Procedure using any consumable with a G designation shall be restricted to the brand and type of
elect. used for the PQR.
Deletion of backing in a single sided groove weld shall be considered an essential variable.

Deletion of a backing gas purge or a change in the backing gas composition for a joint welded from a
one side without backing m/t shall require requalification.
Special requirements for procedures requiring impact testing,
The min. charpy impact value of P-No.1 Gr.1 m/t (including API 5L Gr B through X52) shall be 34/27 J
and for Gr.2 shall be 40/32 J.
If the PQR thk. exceeds 12 mm and multiple processes or consumables are used, separate impact test
specimens shall be conducted for each process or consumable.
The Heat input of each production weld must be calculated, if notch toughness tests are specified;
HI (J/cm)
(V*I*60)/travel speed (cm/min)
The max. allowable SMAW elect. size that can be used are,
Low hydrogen elect.
5 mm for 1G/1F position & 4 mm for all other position
Non low hydrogen elect.
5 mm for all position
The socket weld shall be at least two pass weld and with SMAW the max. permissible size of elect. is
3.2 mm.
Peening is not allowed unless specified. When peening is specified, the WPS shall include details of
how it will be performed. Peening is prohibited on root and final (cap) pass.
Adjacent beads of a weld shall be staggered and not started in the same location.
GTAW, GMAW and Gas shielded FCAW shall not be used for field or yard fabrication unless adequate
windshields are used. The wind velocity in the weld area for such applications shall not exceed 8 kph.
The min. distance between parallel butt welds and pressure containing welds (e.g. nozzles and other
attachments) from other pr. containing welds by no less than 20 mm or three times the WT of the
joint, whichever is greater. Radiography of butt welds is required for situations in which the min.
separation is not achieved. These restrictions do not apply if one of the welds has been PWHTed prior
to making the second weld or both welds have been PWHTed and inspected.
API Gr. X70 and higher require special stress corrosion cracking tests for sour services applications.
The min. distance (circumferential offset) between longitudinal welds (including spiral weld seams) of
adjacent pipe joints shall be 100 mm.
For pipelines the working clearance shall not be less than 900 mm all around the pipe.
An internal line-up clamp shall be used if the pipe dia. is 16 or larger, except for tie-in welds or
cements lined pipe. Special shoes must be used for internally coated pipe to ensure the coating is not
damaged. For pipelines less than 16 dia., either internal or external clamps may be used.
External line-up clamps may be used for pipe dia 16 or larger if approved by welding engr. with a
condition that 100% radiography is performed to the production welds.
The internal clamps shall not be removed before completion of root bead. For external clamps, the
root bead must be at least 50% complete prior to removal.
For pipelines greater than 16 dia. at least 2 welders shall be used, operating simultaneously and in
opposite quadrants.
TEJAS ROOWALA

For pipeline welding the second/hot pass shall be added as soon as possible after the completion of
the root pass, but shall not exceed 5 min. for vertical down welding with cellulosic elect. or 15 min.
for vertical up welding. If a production joint exceeds the specified time lapse, then MPI of the root
pass shall be conducted and the joint preheated to 60C min or the preheat specified in the
procedure, whichever is greater, prior to making the hot pass. If the joint has been completed
without MT of the root pass, then supplemental NDT of the joint, as specified by inspection, shall be
conducted.
The hot pass shall be made while the pipe is still fully supported by the side boom tractor or
supports.
The pipe shall not be lifted or moved or lowered into the ditch during partially welded joints .
The weld joint shall be completed within 24 hrs of starting. (for pipeline welding)
If welding is interrupted, the rate of cooling shall be controlled or other means shall be used to
prevent detrimental effects in piping. The preheating specified in WPS shall be applied before
welding is resumed.
Unless specified otherwise, the max. interpass temp. shall be 177C for P-No.8, 315C for P-No.1,3,4
& 5, 149C for P-No. 6 and 177-232C for P-No. 10I (27 Cr steel).
When backing rings are used, they shall conform to the following;
Ferrous metal backing rings shall be of weldable quality. Sulfur content shall not exceed 0.05%.
If there is a m/t difference between backing m/t and metal to be welded i.e. one of them is ferritic
and another is austenitic then the satisfactory use of such m/t shall be demonstrated by PQR.
Non ferrous and non metallic backing rings may be used provided the welding procedure using them
is qualified.
The welding machine should be calibrated every 6 months.
TEJAS ROOWALA
PWHT
The PWHT heating and cooling rates above 316C shall not exceed 222C/hr divided by weld thk. in
inches, but in no case shall it be more than 222C/hr.
The specified PWHT shall be applied over an area extending at least 3 times the thk. of m/t being
welded from each edge of the weld but not less than 25 mm from each edge of weld whichever is
greater.
For PWHT that are not permitted in a furnace, insulation shall be applied a min. of 300 mm on either
side of the weld that is to be PWHTed. The insulation shall not be removed before the temp. has
cooled to below 150C. The ends of open lines shall be closed off in order to eliminate drafts or air
circulation that could lowered the temp. on the inside surface of the joint unless the internal surface
is also insulated.
Code exemptions for PWHT of ferritic m/t based on the use of austenitic or Ni-based elect. are not
permitted.
Code exemptions for PWHT of P.No-4 & 5 m/t are not permitted for applications involving either sour
service or m/t exceeding 1.5% nominal Cr content.
Any reduction in the PWHT below the normal holding temp. listed in B31.3 are not permitted.

The min. PWHT soak time shall be 1 hr. If hardness limits are specified, the soak time for production
welds shall not be less than 80% of the PQR soak time unless specified.
All temp. within the heated zone for furnace or localized PWHT shall exceed the specified min. holing
temp.
The actual temp. range for the soak period, as recorded by thermocouples shall not have a spread of
more than 40C.
The thk. for PWHT temp. is the thk. of the thicker component at the joint, except as follows;
The thk. of reinforcement in the case of branch connection shall not be taken into account. Heat
treatment is required however, when the thk. through the weld in any plane through the branch is
greater than twice the min m/t thk. requiring heat treatment, even though the thk. of the
components at the joint is less than the min. thk.
In the case of fillet welds at slip-on and socket welding flanges and piping connections DN50 and
smaller, for seal welding of threaded joints in piping DN50 and smaller, and for attachment of
external non pr. parts in all pipe sizes heat treatment is required when thk. through the weld in any
plane through the branch is greater than twice the min m/t thk. requiring heat treatment, even
though the thk. of the components at the joint is less than the min. thk. But heat treatment is not
required for P-No.1 m/t when weld throat thk. is 16 mm or less, regardless of base metal thk. and not
required for P-No. 3, 4, 5 & 10A m/t when weld throat thk. is 13 mm or less, regardless of base metal
thk., provided that not less than the recommended pre heat is applied, and the base m/t is of min
tensile strength less than 71 ksi.
Welding or heating after the final PWHT is not permitted.
Welding or heating to joints that have been PWHTed requires re-PWHT prior to any hydro test.
For P-No. 10 (Cr-Cu Steel) cool as rapidly as possible after the hold period. For P-No. 10I cooling rate
to 649C shall be less then 56C/hr, thereafter the cooling rate shall be fast enough to prevent
embrittlement.
For P-No. 62 PWHT shall be applied within 14 days after welding.
PWHT shall be carried out using one or more of the following types of heat sources:
Permanent or semi permanent furnaces using gas or oil or electric heaters.
Electrical resistance heaters.
Induction heaters.
If localized PWHT is used, the following min. no. of equally spaced recording T/C shall be used;
D12
1
12<D24
2
D>24
4
Temp. recorders shall be calibrated every 3 months.
Only type K (Chromel Alumel) or type J (Iron Constantan) T/C are permitted.
CS having a carbon content in excess of 0.32% or a CE>0.65% or welds in all CS shall be stress relieved
when the nominal WT>31.75 mm.
Stress relieving shall be performed at a temp. of 1100F or greater for CS and 1200F or greater for
ferritic alloy steels.
Temp. recorders shall be calibrated every 3 months.
TEJAS ROOWALA

Inspection
The hardness indentation shall be made at or near the middle of the deposited weld bead by the
Brinel Hardness test method.
10% of the welds shall be sampled.
The max. allowed hardness is 200 BHN. For pipeline welding the max. hardness for P-No.1 material is
225 BHN for non sour services and 200 BHN for sour services.
If any reading exceeds the specified limit by no more than 10 BHN, then a min. of 3 additional
indentations shall be made near the original high reading. If all 3 retests are below the specified
limits, then the joint is acceptable. If any of the retest readings are found to exceed the specified
limits, then the weld shall be considered unacceptable. If any welds are found unacceptable, then
two additional welds from the same lot shall be tested. If more than one weld in a lot is found to be
unacceptable, then all welds in that lot shall be tested.
Inspection of all welds shall include a bend of base metal at least 25 mm wide on each side of weld.
For P-No. 3, 4 & 5 m/t, examination shall be performed after completion of any heat treatment.
For a welded branch connection the examination of and any necessary repairs to the pr. containing
weld shall be completed before any reinforcing pad or saddle is added.
For RT, fluorescent intensifying screens shall not be used. Only fluorescent metallic screens are
permitted.
If the joint is required to be radiographed and radiography is not feasible, then UT & MT may be used
in lieu of RT after getting approval. This does not apply if radiography is required by B31.3 or 31.8.
In MPT, permanent magnet yokes are not permitted. Prods are not permitted for use on air
hardenable m/t or on m/t with impact testing requirements or on the fluid side surface of
components in sour services.
All pr. containing welds, other than butt welds (including branch connections such as weldolets,
sockolets and welding boses) shall be 100% examined.
All attachment welds on pressurized components that are not hydrotested after making the
attachment weld shall be 100% examined.
Wire penetrameter in accordance with ASTM E747 may be used.
For B 31.8, the acceptance criteria is as per API 1104 for onshore, and API 1104 or ASME sect. VIII Div.
1 for sour services and offshore pipeline facilities.
For B 31.3, the acceptance criteria is as per given in table 341.3.2 in B 31.3. Any type of crack, LF, LOP
& surface porosity or exposed slag is not allowed.
The max. height of reinforcement or internal protrusion for piping welding shall be;
Wall thk. (mm)
Max. reinforcement (mm)
6
1.5
>6 , 13
3
>13, 25
4
>25
5
TEJAS ROOWALA
10

The max. root reinforcement acceptance criteria for pipeline welding shall be;
Max. reinforcement
Acceptable length
General
Internally coated
3mm or less
any
3 to 6 mm
25 mm max
Over 6 mm
none
2.5 mm or less
any
Over 2.5 mm
none
Onshore
A min of 10% of the weld joints made each day shall be radiographed.
If any joint found unacceptable then additional 10% is performed. If again any joint is found
unacceptable then 100% radiography shall be done.
TEJAS ROOWALA
An increase percentage of radiography is required if a higher percentage of radiographic coverage is

established by either of the following methods:
a) Lineal basis
%RAD =
(318 x L)/(N x D)
L = total length of repairs, mm
N= total no. of weld joints radiographed in one day
D = pipe dia, mm
The amount of RAD shall be rounded to the nearest amount divisible by 10. Any value
ending in 5 shall be rounded up.
b) Joint basis
The following repair rates are calculated on a joint basis, i.e., the no. of joints requiring repairs
divided by the total no. of joints radiographed that day.
(i)
An increase to 50% RAD is required when the repair rate exceeds 30%. This
increase shall be required for both the same days and the next days
production.
(ii)
An increase to 100% RAD is required when the repair rate exceeds 50%. This
increase shall be required for both the same days and the next days
production.
11

Offshore
All welds on submarine and offshore pipelines, risers and associated spool pieces require 100%
radiographed, except for open-non pr. vents and drains which shall be radiographed 10%.
Branch connections
Welds shall be inspected by MPT. The min inspection rate shall be 10%, except for the clauses a to j (as
per given for additional radiography) which shall be inspected 100%.
Additional radiography
If additional radiography is required by these provisions, these radiographs shall not count towards
the required radiographic coverage for the remaining joints of that days production. However, all of
the joints radiographed that day shall be used in calculating the repair rate and the required
radiographic coverage for the following day.
a) All welds of the first days production for a particular job or a min of the first 40 production
joints, whichever is greater.
b) The joint preceding and the joint succeeding a repaired weld, if previously not radiographed.
c) The ten preceding and ten succeeding welds of a cracked weld, if previously not
radiographed.
d) All welds within 60 m of paved road, rail road and airport crossing.
e) All welds over water, over tidal flats or within 30m of the shoreline.
f) All welds that cant be hydrostatically tested.
g) All hook-up or tie-in welds.
h) All expansion loop fitting welds.
i) All repair welds
j) All welds in class 3 or 4 locations.
TEJAS ROOWALA
PMI (Positive Material Identification):

o For welding consumables, one consumable from each lot shall be PMI tested.
o PMI testing of weld is an acceptable alternative to PMI testing of consumable provided it is
conducted immediately prior to or during welding.
o X-Ray Fluorescence Spectrometer is quite often used for PMI. But because of inherent
limitations of XRF, it is not possible to detect all elements. Elements lighter than sulfur can not
be detected using portable XRF spectrometers. Therefore this technique cant be used to
detect carbon.
o Optical Emission Spectrograph may be used to check for all the required elements, including
carbon. A hot work permit may be required before using this equipment. Any burn damage
resulting from the usage of the emission spectrograph shall be removed by grinding.
o Acceptance criteria: alloys shall be acceptable if the alloying elements are each within 10%
of specified range of values. Welds with consumables that match, or nearly match, the base
metal composition shall be within 12.5% of the ranges allowed in ASME sect. II part C.
Repair
Welds may be repaired twice at any defect location.
12

Repair of cracks that are fabricated related or welding consumables or base metal and are of less
than 8% of total weld length shall require the approval. Crater cracks do not require special repair
and shall be ground out only.
In process repairs (i.e. repairs performed prior to completion of the joint using the same welding
procedure as for the original fabrication) during production do not require a separate repair
procedure except for cracks.
For offshore pipeline girth welding the repair criteria is limited as,
full thk. repair openings shall be limited in length to 25% of the pipe dia.
Partial thk. repair excavations less than 50% of the WT shall be limited in length to 30% of the pipe
dia.
Welding of Special Corrosion Resistance Materials

This is defined as SS and Ni based alloys for piping in severe corrosion and high temp. service (above
427C).
The WPQ and production welds for austenitic SS, except type 310, shall include a determination of
the Fettire No. in the as-welded condition. The Ferrite no. shall be between 3 to 10.
The GTAW process shall be used for the following applications;
The root pass of single sided groove welds without backing.
For all passes for piping, tubes and nozzles of 1 nominal dia or less.
For all passes for wall thk. less than 9.5 mm for duplex SS or for WT less than 6.5 mm for other
corrosion rest. alloys.
All manual GTAW shall use a high frequency start and post-purge gas flow for the torch.
For all GTAW welding, filler metal shall be used.
The max. interpass temp shall not exceed 100C.
The purge time for the backing gas shall be calculated to give a theoretical volume charge of 6 times
the enclosed pipe vol. The purge shall achieve actual oxygen levels inside or existing the joint (via the
vent) no greater than 0.05% prior to and during welding.
A min of 4 equi-spaced tacks around a pipe circumference shall be used. Either root tacks or bridge
tacks are permitted. Root tacks must be either feathered or ground out prior to making the root pass.
The continuous feed technique shall be used for the root pass.
Stringer beads shall be used. Minor arc oscillations to ensure sidewall fusion is permitted.
Whenever the welder stops welding, the welding current shall be gradually decreased by use of the
remote current control. The torch shall be held in position close to the weld pool until the gas
shielding post purged flow is completed.
Grinding of all starts/stops is required.
TEJAS ROOWALA
13

Ferrite content of the weld metal shall be measured, unless the weld metal is Ni based. The ferrite
range must be within 35 to 60% as measured by metallographic methods. Min ferrite content should
be 50% for service that have potential for chloride stress cracking. The fabricator shall establish a
correlation between the % ferrite and FN (as measured using AWS 4.2). Ferrite measurements using
both methods shall be recorded on the PQR.
Corrosion testing to ASTM G48, using method A (pitting test) at 35C for 72 hrs shall be performed.
No pitting or crevice corrosion in either the weld metal or HAZ is permitted.
Charpy impact testing shall be conducted on the weld metal and HAZ at a test temp of -20C. The min
charpy impact value shall be 34/27 J for full size (10mm x 10mm) specimen.
The heat i/p shall be restricted to a min and max. value. If a single PQR is used the WPS heat i/p shall
be limited to 10% of actual PQR value.
STORAGE, CONDITIONING AND EXPOSURE OF CONSUMABLES
DRYING
STORAGE
EXPOSURE
RE DRYING
LOW HYDROGEN
ELCT. (A 5.1)
260-430C for 2
hrs. min
120C min
May
not
be
exposed
to
atmosphere more
than 4 hrs. The
exposure may be
extended to 8 hrs.
if the elect. are
continuously
stored
in
a
portable oven at
65C min
LOW HYDROGEN
ELCT. (A 5.5)
370-430C for 2
hrs. min
120C min
May
not
be
exposed
to
atmosphere more
than 2 hrs for
E70XX & E80XX
and 30 min for any
higher
strength
elect.
The
exposure may be
doubled (to 4 hrs
and
1
hr
respectively) if the
elect.
are
continuously
stored
in
a
portable oven at
65C min
Elect. exposed in
excess of the
permitted
time
period must be re
dried.
Higher
strength
elect.
SS
&
NON
FERROUS ELECT.
120-250C for 2
hrs. min
120-200C
May
not
be
exposed
to
atmosphere more
than 4 hrs. The
exposure may be
extended to 8 hrs.
if the elect. are
continuously
stored
in
a
portable oven at
65C min
NON
LOW
HYDROGEN ELECT.
The elect. shall be
stored
in
dry
environment.
TEJAS ROOWALA
Elect. exposed in
excess of the
permitted
time
period must be re
dried. Elect. may
be re dried only
14
Elect. exposed in
excess of the
permitted
time
period must be re
dried. Elect. may
be re dried only

once.
must be re dried once.

after
any
atmospheric
exposure.
Elect.
may be re dried
only once.
RE CONDITIONING Elect. exposed to Elect. exposed to Elect. exposed to
atms. for less than atms. for less than atms. for less than
permitted
time permitted
time permitted
time
may be returned may be returned may be returned
to
a
oven to
a
oven to
a
oven
maintained
at maintained
at maintained
at
120C min. After a 120C min. After a 120C min. After a
min.
holding min.
holding min.
holding
period of 4 hrs. at period of 4 hrs. at period of 4 hrs. at
120C the elect. 120C the elect. 120C the elect.
may be re used.
may be re used.
may be re used.
The drying steps for E70XX and E80XX may be deleted if the elect. are supplied in the dried condition in
hermetically sealed metal can/vacuum sealed package.
Electrode that have become wet or moist shall not be used and shall be discarded.
The consumables for SAW, GTAW, GMAW/FCAW shall be stored in a dry place.
TEJAS ROOWALA
15
Welding Inspection Check list Points

Pre welding inspection
a)
b)
c)
d)
Review of drawings & specifications.

Check qualification of procedures and personnel to be used.
Review of material test certificates.
Check for base metal discontinuity.
TEJAS ROOWALA
e) Weld no. is marked adjacent to the weld joint and verified to confirm with the weld map.
f) An approved WPS to be used is available at the weld site.
g) Weld joint confirms with the weld joint details of the approved WPS. (Base m/t, thk., bevel type,
root gap)
h) Internal misalignment of butt welds shall not exceed 1.5 mm.
i) Oil, moisture, scale, rust, paint or other foreign matter has been removed from the weld surface
and at least 25 mm of the adjacent base metal surface prior to welding.
j) Irregular edges/thermal cut surfaces are ground or machined to bright metal prior to welding.
k) Thermally cut or gouged surfaces for all m/t have been power brushed or ground prior to
welding.
l) A min of 1.5 mm depth has been removed by grinding/machining from thermally cut or gouged
surface for air hardenable m/t (Cr Mo steels).
m) SS and non ferrous m/t have been cleaned with grinding wheels or SS brush not previously used
on other m/t.
n) Re-cut or re-beveled fittings, have surfaces examined for laminations before welding.
o) Temporary attachments or back-up strips have been made from compatible m/t. No rebar or
galvanized steel is used.
p) Tack welds are made by qualified welder.
16

q) All tacks or temporary welds shall be performed with the same care, m/t, elect, min preheat and
procedures that are used for permanent weld.
r) Tack welds shall be of sufficient size to maintain joint alignment;
3.2-4.8 mm thk. and 12.5-25.4 mm long
s) Min no. of tack welds are,
D4 3 equally spaced
D>4
min four equally spaced
t)
Tack welds that are to be incorporated into the final weld shall be thoroughly cleaned, prepared
at each end and inspected for cracks. Any cracked tack shall be removed before welding the
joint.
u) Bridging tacks (located above the root area) are made completely within the weld groove and
shall be completely removed prior to completion of the weld.
v) As the thumb rule the min dist. between adjacent butt welds is 1D or 1 whichever is greater
to prevent the overlapping of HAZ. And min dist. between circumferential welds between
centerlines shall not be less than 4 times the WT or 25 mm whichever is greater.
w) Calibration of equipments;
General purpose equipments: all parameters should be 10%
For automatic or automated equipment parameters should be 2.5% for current and wire feed
speed, 5% for voltage and temp. reading equipments i.e. thermocouples, 20% for gas flow
rate.
TEJAS ROOWALA
In process welding inspection
1. Joint Preparation & Cleanliness

The same points a, b, e, & i that of pre weld inspection. Furthermore coated and clad or overlaid
surfaces are protected from the welding arc, associated weld spatter and damaged from ground
clamps or other associated equipments.
2. General
a) Wind velocity in weld area for GTAW, GMAW or Gas shielded FCAW shall not exceed 8 kph.
b) For field welding remote current control shall be used if the welding is more than 30 m from the
welding power source or when the welders are working in remote locations (e.g. on an elevated
pipe rack).
c) Filler metal size, type and classification confirms with the approved WPS.
d) Storage, handling of consumables are done as per recommendation.
3. Pre heat
a) Wet or damp weld joints are dried by heating to a dist. of 100 mm from the toe, and are hand
warm before welding.
b) The pre heat temp. shall be established over a min dist of 75 mm on each side of weld.
c) Min pre heat temp. is 10C or specified by code.
17

d) On WT exceeding 25 mm, preheat is done from the same side as the welding and heat source
removed for 1 min prior to measuring the temp.
4. Back Purging & Shielding Gas
a) Inert gas is used for GTAW or GMAW root pass on single sided groove welds, on ASME P-No.5 and
higher.
b) For P-No.5 and higher m/t back purging is maintained until at least 10 mm of the weld deposit thk.
is completed.
c) Nitrogen as a backing gas for austenitic SS is prohibited.
d) Back purge for carbon and low alloy steel has reduced the oxygen level to below 1% and for SS &
Ni based alloys below 0.05%.
5. Root pass
a) The direction of welding conforms with WPS.
b) The GTAW process shall be used for the root pass of butt welds without backing in piping and
nozzles of 50.8 mm nominal dia. and less. GTAW shall also be used for root pass when the
consumables are SS or Ni based alloys.
6. Hot pass & Weld out
a) The direction of welding conforms with the WPS.
b) Each weld, weld pass is thoroughly cleaned and all slag or other foreign matter removed before
the next pass is deposited.
c) SAW flux fused during welding shall not be reused.
d) The max allowable SMAW elect. size that can be used are;
Low hydrogen elect.
5 mm for 1G/1F position, 4 mm for all other positions
Non low hyd. elect.
5 mm for all positions
e) The heat i/p of each production weld is calculated.
f) Adjacent weld beads shall be staggered and not started from the same location.
g) Unless specified otherwise the max interpass temp.;
177C for P-No.8
315C for P-No.1 to 5
TEJAS ROOWALA
7. During the entire welding process the checking of variables i.e. current, voltage & welding speed.
Post welding inspection

1. General
a) All slag, flux and spatter is removed from the completed weld and surrounding weld.
b) All arc strikes, gouges and other surface imperfections are removed by grinding.
c) Temporary attachments have been cut off no closer than 3 mm to the base metal, then ground
flush.
d) Grinding does not reduce the base metal thk. than the design thk.
18

e) Where temporary welds were removed, base metal repairs made, or arc strikes repaired by
grinding, examined by MT or PT has been carried out.
f) All weld joints are marked for identification by a weld no. and a welder symbol.
g) Surface irregularities, including weld reinforcement, which inhibit accurate interpretation of the
specified method of NDT (including VT) are ground out.
h) Inspection of all welds include a band of base metal at least 25 mm wide on each side of the weld.
i) Visually inspection finished weld for weld appearance and to confirm that ht. and width of
reinforcement and technique of cap (multi pass or weave) comply with WPS.
2. PWHT
a) Post Weld Heat Prior to the start of work the contractor or fabricator has prepared a table listing
each joint or component requiring heat treatment.
b) The table includes the following information for each joint or component: location, drawing
number, diameter, wall thickness, material, heating rate, cooling rate, soak temperature, and soak
time.
c) PWHT heating and cooling rates > 316 degrees C shall not exceed 222 degrees C/hr. divided by the
weld thickness in inches, but in no case is it > 222 degrees C/hr.
d) The specified PWHT is applied over an area extending at least three times the thickness of the
material being welded from the weld toe, but not < 25mm from the weld toe, which ever is
greater.
e) If localized PWHT is used, the following minimum numbers of equally spaced thermocouples (T/C)
are used:
Pipe diameter of 305mm or less: 1(T/C).
Pipe diameter > 305mm and up to and including 610 mm: 2 (T/C).
Pipe diameter > 610mm: 4(T/C).
f) Temperature recorders are calibrated every three months. Current calibration sticker details are
maintained.
g) Only Type K (Chromel - Alumel) or Type J (Iron-Constantan) thermocouples are used.
h) Prior to the start of PWHT, components are checked to ensure all restraints are removed, and that
the component is free to expand and contract and that suitable and sufficient supports are used.
i) Machined surfaces such as flange faces, threaded bolt holes, threads, etc., are protected from
oxidation during the heat treatment process by coating with deoxaluminite, or other approved
suitable material.
j) When PWHT is not performed in a furnace, a minimum of 300 mm insulation is applied on either
side of the weld. The insulation is not removed before the temperature has cooled below 150
degrees C. The ends of open lines are closed off to eliminate drafts.
k) The min soak time for PWHT is 1 hr/inch. Hold time shall be increased by each hr for each 25
mm increase after 25 mm WT.
l) After PWHT all thermocouples are removed, the attachment is ground smooth to clean sound
metal.
m) The PWHT shall be applied within 14 days after welding.
TEJAS ROOWALA
19
ACCEPTANCE CRITERIA FOR INSPECTION OF BARE LINE PIPES AS PER API 5L

Brief description of this specification is explained here;
Scope:
Applicable to Petroleum & Natural gas systems, sour & offshore services
TEJAS ROOWALA
Two basic levels of standard technical requirements for line pipes:

PSL (Product Specification Level) 1: provides a standard quality levels for line pipe
PSL 2: has additional mandatory requirements for chemical composition, notch toughness and
strength properties and additional NDE.
Inspection
Pipe length
Cold expansion
Skelp width for helical
seam pipe
Undercuts
11.7-12.7 mtr
0.5-3.0% X OD
0.3-1.5 X OD
Laminations in bevel
face
Straightness
Weld reinforcement
Exceeding 6.4 mm is defect
Misaligned welds
Not cause for rejection provided within:

t20 mm: 3 mm
a) depth0.4 mm acceptable any length

b) 0.8>d>0.4 mm acceptable with indiv. length 0.5t & max 2 in 300 mm
removed by grinding
Not to exceed 0.2% length & 4 mm within 1m from pipe end

t13 mm: 0-3.5 mm
t>13 mm: 0-3.5 mm ID & 0-4.5 mm OD
20

t>20mm : 4 mm
& provided NDT confirms complete penetration and fusion
Radial offset of
strip/plate edges
t15 mm: 1.5 mm

25t>15: 0.1 t
t>25
: 2.5 mm
Burn through
RT density
Not allowed
Density of radiograph shall not be less than 2.0 and the density through
the thickest portion of the weld shall not be less than 1.5
Destructive testing
TS min TS for grade
The test piece shall not,
a) Fracture completely
b) Weld crack/rupture>3.2 mm long & any depth
c) Parent metal/HAZ/fusion line crack/rupture>3.2 mm long & >12.5%t
deep though edge cracks>6.4 mm long
Tensile test
Bend test
CVN test
DWTT
27 J at temp. 0C or lower & average shear area85% for each test

Average shear area85%/test unit at temp. 0C or lower
Manufacturing process qualification
Test per Table-18 of API 5L as applicable at start of production
TEJAS ROOWALA
Essential Variables
Welding process
Pipe material
process
method
grade category
a) X42
b) X65Gr>X42
c) <X65
CE>0.03% of material qualified
Welding materials:
filler metal classification
consumable brand name (if CVN required)
electrode dia.
composition of shielding gas
shielding gas flow rate
SAW flux designation
Welding parameters:
current type (AC to DC)
polarity
I>10%, V>7%, Speed>10%
weld bead width>50%
Pre/post-weld heat treatment
Welder qualification
Qualification by API 5L or ASME IX

Operator qualified on one grade is qualified on any lower grade provided
same weld process
21

Tests
Repair weld procedure
qualification
all tests as per given in inspection with same acceptance criteria

Repair of weld
per API 5L or ASME IX
Repair length<5% of total weld length
Weld defects separated by less than 100 mm shall be repaired as a
continuous single weld repair
Each single repair shall be carried out with a min of two layers/passes over
a min length of 50 mm.
BRIEF DISCRIPTION ABOUT CODES: ASME IX, VIII & API 1104
ASME SECT. IX
Welding qualifications to ASME 9 are for use with the ASME boiler and pressure vessel code or the
ASME pipe work codes.
Advantages of ASME welding procedures are:
1) All joint types approved each other, i.e., a double sided weld approves a single sided weld and
vice versa.
2) No limits on dia. approval for pipe. A plate procedure can be used to weld any dia. of pipe.
3) Any butt weld will qualify all fillet weld sizes on any parent metal thk.
4) A welding procedure qualified in one position approves all positions unless impact tests are
required then only a vertical up approves all positions.
TEJAS ROOWALA
Advantages of ASME welder approval tests are:

1) There is no min parent metal thk., only max., and they are applied to the deposited thk. of the
weld not the parent metal thk.
2) There is no upper limit on dia. approval for pipe, only a lower limit.
3) Any butt weld approval will qualify all fillet weld sizes on any parent metal thk.
o P - NUMBER GROUPING:
P1 TO P11 STEEL & STEEL ALLOYS
P21 TO P25 AL & AL BASE ALLOYS
P31 TO P35 CU & CU BASE ALLOYS
P41 TO P47 NI & NI BASE ALLOYS
P51 TO P53 TI & TI BASE ALLOYS
P61 TO P62 ZI & ZI BASE ALLOYS
22

P No.
Base Metal
Carbon Manganese Steels, 4 Sub Groups
Group 1 up to approx 65 ksi

Group 2 Approx 70ksi
Group 3 Approx 80ksi
Group 4 ?
Not Used
2 Sub Groups:- Typically 1/2Mo and 1/2Cr-1/2Mo
2 Sub Groups:- Typically 1Cr-1/2Mo and 1 1/4Cr-1/2Mo
5A
Typically 2 1/4Cr-1Mo
5B
3 Sub Groups:- Typically 5Cr-1/2Mo, 7Cr-1/2Mo & 9Cr-1Mo
5C
5 Sub Groups:- Chrome moly vanadium
6 Sub Groups:- Martensitic Stainless Steels Typically Grade 410
Ferritic Stainless Steels Typically Grade 409

Austenitic Stainless Steels, 4 Sub groups
9A, B, C
TEJAS ROOWALA
Group1 Typically Grades 304, 316, 347
Group 2 Typically Grades 309, 310
Group 3 High manganese grades
Group 4 Typically 254 SMO type steels
Typically two to four percent Nickel Steels
10A,B,C,F,G Mixed bag of low alloy steels, 10G 36 Nickel Steel

10 H
Duplex and Super Duplex Grades 31803, 32750
10J
Typically 26 Chrome one moly
11A Group 1 9 Nickel Steels

11 A Groups
Mixed bag of high strength low alloy steels.
2 to 5
11B
12 to 20
10 Sub Groups:- Mixed bag of high strength low alloy steels.

Not Used
21
Pure Aluminium
22
Aluminium Magnesium Grade 5000
23
Aluminium Magnesium Silicone Grade 6000
24
Not Used
25
Aluminium Magnesium Manganese Typically 5083, 5086
26 to 30
Not used
23

31
Pure Copper
32
Brass
33
Copper Silicone
34
Copper Nickel
35
Copper Aluminium
36 to 40
Not Used
41
Pure Nickel
42
Nickel Copper:- Monel 500
43
Nickel Chrome Ferrite:- Inconel
44
Nickel Moly:- Hastelloy C22, C276
45
Nickel Chrome :- Incoloy 800, 825
46
Nickel Chrome Silicone
47
Nickel Chrome Tungstone
47 to 50
Not Used
51, 52, 53
Titanium Alloys
61, 62
Zirconium Alloys
TEJAS ROOWALA
o F NUMBER GROUPING:
F
General Description
Number
1
Heavy rutile coated iron powder electrodes :- A5.1 : E7024
Most Rutile consumables such as :- A5.1 : E6013
Cellulosic electrodes such as :- A5.1 : E6011
Basic coated electrodes such as : A5.1 : E7016 and E7018
High alloy austenitic stainless steel and duplex :- A5.4 : E316L-16
Any steel solid or cored wire (with flux or metal)
2X
Aluminium and its alloys
3X
Copper and its alloys
4X
Nickel alloys
5X
Titanium
6X
Zirconium
7X
Hard Facing Overlay
o A NUMBER GROUPING:
24
A1
Plain unalloyed carbon manganese steels.
A2 to A5 Low alloy steels containing Moly and Chrome Moly

A6
Chrome- Martensitic
A7
Chrome- Ferritic
A8 to A9 Chrome Ni (Austenitic stainless steels such as type 316)

A10
Ni upto 4%
A11
Mn Mo
A12
Ni Cr - Mo
o PROCEDURE QUALIFICATION FOR GROOVE WELDS PLATE

THE TEST PLATE WELDING IS USUALLY CARRIED OUT IN THE FLAT POSITION ONLY.
A BUTT OR GROOVE WELD APPROVES BRANCH AND FILLET WELDS BUT NOT THE VICE VERSA .
PRESSURE RETAINING BRANCH WELDS MUST BE QUALIFIED BY GROOVE WELDS .
A TEST IN ONE P -NO . APPROVES ALL M / T LISTED UNDER THAT P-NO., EXCEPT WHERE IMPACT TESTS ARE REQUIRED
THEN APPROVAL IS RESTRICTED TO M /T LISTED IN THE GROUP NO . WITHIN P -NO .
NOTE P 5,
9 & 10 ARE DIVIDED INTO SUB GROUPS I.E. 5A, 5B, ETC. TREAT EACH SUB GROUP LIKE A SEPARATE P -
NO.
TEJAS ROOWALA
NOTE S -NO. ARE FOR PIPE WORK TO B -31. A P-NO . COVERS AN S -NO. BUT NOT VICE VERSA .
WHEN IMPACT TESTS ARE REQUIRED THE MIN THK. APPROVED IS RESTRICTED.
THE THK .t OF DEPOSITED WELD METAL FOR EACH PROCESS INVOLVED IS APPROVED FROM 0 TO 2t EXCEPT ;
MIG /MAG (GMAW/FCAW) DIP TRANSFER WELD OF DEPOSITED THK. LESS THAN
APPROVES MAX . THK. OF
1.1t ONLY.
IF ANY PASS IN A SINGLE OR MULTI PASS WELD>1/2 THAN THE THK . APPROVED EQUALS TO 1.1t.
FOR DISSIMILAR THICKNESS THE THICKER AND THINNER PART MUST BE QUALIFIED , EXCEPT P 8 AND P4X THE
THINNER PART CAN BE QUALIFIED IF NO IMPACTS AND TEST COUPONS >6 MM.
WHEN MORE THAN ONE WELDING PROCESS OR FILLER METAL IS USED TO WELD A TEST COUPON , THE DEPOSIT
WELD METAL THICKNESS OF EACH PROCESS AND FILLER METAL WOULD BE RECORDED .
PREPARATION OF TEST JOINT:
METHOD OF TAKING TEST SPECIMENS FROM PLATE & PIPE:
25
TEJAS ROOWALA
26
THE RECOMMENDED PIPE SIZE IS 5 IN DIAMETER AND 9.57 MM IN WT, ALTHOUGH LARGER PIPE SIZE MAY
BE USED . SMALLER PIPE SIZE MAY BE USED , BUT IN SUCH CASES THE PROCEDURE MUST BE QUALIFIED FOR
THICKNESS BET AND TWO TIMES THE WT OF TEST PIPE , BUT NOT OVER 19.05 MM.
THE TYPE AND NUMBER OF TEST SPECIMENS , RANGE OF THICKNESS QUALIFIED FOR PROCEDURE
QUALIFICATION ARE SHOWN IN FOLLOWING TABLES;
TEJAS ROOWALA
THICKNESS (T) OF TEST

COUPON
(MM)
LESS THAN 1.58

1.58 TO 9.57 INCLUSIVE
OVER 9.57 & LESS THAN
19.05
19.05 TO LESS THAN 38.01
38.01 & OVER

COUPON
(MM)
LESS THAN 1.58

OVER 38.01
RANGE OF THICKNESS
QUALIFIED (MM)
MAX.
MIN. (6)
(1,3,6)
T
2T
1.58
2T (2)
TYPE AND NUMBER OF TESTS REQUIRED
TENSION
2
2
TRANSVERSE BEND TESTS (4)

SB
FB
RB
2
2
2
2
4.76
2T
4.76
4.76
2T
8
2
2
4 (4)
4
RANGE OF THICKNESS
QUALIFIED (MM)
MAX.
MIN. (6)
(1,3,6)
T
2T
1.58
2T
4.76
2T

TENSION
2
2
2
LONGITUDINAL BEND TESTS (5)

FB
RB
2
2
2
2
2
2
THE NOTES TO TABLES ARE ESSENTIAL TO THE USE OF THE TABLES . THE APPLICABLE NOTES ARE:
1) THE MAXIMUM THICKNESS QUALIFIED IN GAS WELDING IS THE THICKNESS OF THE TEST PLATE OR PIPE.
27

2) THE MAX. THICKNESS QUALIFIED FOR PIPE SMALLER THAN 5 IS TWO TIMES THE THICKNESS OF THE PIPE WALL
BUT NOT MORE THAN 19.05 MM.
3) FOR SAW AND GMAW, THE THICKNESS LIMITATION FOR PRODUCTION WELDING, BASED ON PLATE
THICKNESS T , SHALL BE AS FOLLOWS ;
(a)
FOR SINGLE PASS WELDING WITH NO BACKING STRIP OR AGAINST A METAL OR CERAMIC (FLUX)
BACKING , THE MAXIMUM THICKNESS WELDED IN PRODUCTION SHALL NOT EXCEED THE THICKNESS OF
THE TEST PLATE OR PIPE WALL .
(b)
IF THE TEST PLATE IS WELDED BY A PROCEDURE INVOLVING ONE PASS FROM EACH SIDE , THE
MAXIMUM THICKNESS THAT MAY BE WELDED IN PRODUCTION SHALL BE 2T, WHERE 2 T SHALL NOT
EXCEED 2. IF SECTION HEAVIER THAN 2 ARE TO BE WELDED IN PRODUCTION , A SEPARATE TEST
PLATE SHALL BE PREPARED WITH THE THICKNESS NOT LESS THAN THE THICKNESS TO BE USED IN
PRODUCTION .
(c)
FOR MULTIPLE PASS WELDING, THE THICKNESS LIMITATIONS IN TABLES ARE APPLY.
4) EITHER FACE AND ROOT BENDS OR SIDE BENDS MAY BE USED FOR THICKNESSES FROM 9.57 MM TO 19.05
MM.
5) LONGITUDINAL BEND TESTS MAY BE USED IN LIEU OF TRANSVERSE BEND TESTS ONLY FOR TESTING MATERIAL
COMBINATIONS DIFFERING MARKEDLY IN MECHANICAL BENDING PROPERTIES BETWEEN (A) THE TWO BASE
MATERIALS OR (B) THE WELD METAL AND BASE MATERIALS .
6) FOR QUENCHED AND TEMPERED STEELS (TENSILE STRENGTH 95,000 PSI OR HIGHER ) OF THICKNESSES LESS
THAN 15.87 MM, THE THICKNESS OF TEST PLATE OR PIPE IS THE MINIMUM THICKNESS QUALIFIED . F OR TEST
PLATES OR PIPE RECEIVING A PWHT IN WHICH THE LOWER CRITICAL TEMP . IS EXCEEDED , THE MAXIMUM
THICKNESS QUALIFIED IS THE THICKNESS OF THE TEST PLATE OR PIPE .
TEJAS ROOWALA
Tensile test:
28
TENSION REDUCED SECTION FOR PLATE/PIPE
TEJAS ROOWALA
The tensile strength must not be less than,

1) THE MINIMUM STRENGTH SPECIFIED FOR THE BASE MATERIAL .
2) THE MINIMUM SPECIFIED FOR THE WEAKER OF THE TWO, IF MATERIAL OF DIFFERENT SPECIFIED MIN . TENSILE
STRENGTHS ARE USED .
3) THE MIN. SPECIFIED FOR THE WELD METAL WHERE THE WELD METAL HAS LOWER ROOM TEMP. STRENGTH
THAN THE BASE METAL .
29

IF THE SPECIMEN BREAKS IN THE BASE METAL , THE TEST SHALL BE ACCEPTABLE IF THE TENSILE STRENGTH IS NOT
MORE THAN 5% BELOW THE MIN . SPECIFIED FOR THE BASE METAL .
BEND TEST :
TEJAS ROOWALA
30
TEJAS ROOWALA
BEND SPECIMEN PASSES IF ANY CRACK OR OTHER OPEN DISCONTINUITY DOES NOT EXCEED 3.17 MM AFTER
BENDING THROUGH AN ANGLE OF 180. CRACKS AT CORNERS ARE NOT CONSIDERED unless there is evidence
of slag inclusions or other internal discontinuities.
THE TESTING REQUIREMENTS FOR FILLET WELDS ON PLATE IS
5 MACRO SECT. ONLY. FOR PIPE FILLET WELDS 4
MACRO SECT . NO FRACTURE TEST REQUIRED .
Brief summary of variables:

Legends:
Change
> Increase
<Decrease
+ Addition
- Deletion
Uphill
Downhill
1) QW-402 (JOINT DESIGN )
GROOVE DESIGN
BACKING
(+ BACKING ONLY FOR GTAW)
ROOT SPACING
+
RETAINERS
ALL ARE NON ESSENTIAL VARIABLES
31

2) QW-403 (BASE METAL)
NON ESSENTIAL VARIABLES:
DIAMETER IN THE CASE OF PIPE

ESSENTIAL VARIABLES :
T QUALIFIED (REFERENCE : TABLE 451.1 & 451.2)
P NO.
>1/2 T (INCREASE IN WELD DEPOSITION THICKNESS BEYOND 13MM)
SUPPLEMENTARY ESSENTIAL VARIABLES :
GROUP NO.
3) QW-404 (FILLER METAL )
+
CONSUMABLES /INSERT (ONLY FOR GTAW)
F NO.
A NO.
T ( REFERENCE : TABLE 451.1 & 451.2)

+
FILLER (ONLY FOR GTAW)
>10% MORE THAN 10% CHANGE IN VOLUME OF FILLER METAL
RECRUSHED SLAG
AWS CLASSIFICATION
>6 MM DIAMETER (CHANGE IN DIA . MORE THAN 6MM ONLY FOR SMAW)
TEJAS ROOWALA
4) QW-405 (POSITION)
+
POSITION
VERTICAL WELDING
POSITION (A CHANGE FROM ANY POSITION TO THE VERTICAL POSITION

PROGRESSION E .G. 3G, 5G OR 6G)
5) QW-406 (PREHEAT )
32
UPHILL

TEMP. FOR PREHEAT MAINTENANCE
<100F DECREASE IN PRE HEAT TEMP. GREATER THAN 100F
>100F INCREASE IN PRE HEAT TEMP . GREATER THAN 100F
6) QW-407 (PWHT)
TEMP. OF PWHT
7) QW-408 (GAS)
FLOW RATE
TEJAS ROOWALA
+/
BACKING FLOW
SINGLEMIXTURE
8) QW-409 (ELECTRICAL CHARACTERISTIC )

CURRENT & POLARITY (ACDC, DC+VEDC-VE)
I & E RANGE (CHANGE WITHIN RANGE I .E. + 15%)
TRANSFER MODE (SPRAY/GLOBULAR/PULSE ARC SHORT CIRCUIT )

>10% HEAT INPUT (INCREASE IN MORE THAN 10%)
9) QW-410 (TECHNIQUE )
33
STRING WEAVE
METHOD OF CLEANING
METHOD OF BACK GOUGE
MANUAL AUTOMATIC
PEENING
TUBE-WORK DISTANCE
ELECTRODE SPACING
CLOSED TO OUT OF CHAMBER (ONLY FOR GTAW)
SINGLEMULTIPLE ELECT .
SINGLEMULTI PASS
TEJAS ROOWALA
(BOTH ARE NOT APPLICABLE IN CASE OF PWHT WHERE LOWER CRITICAL TEMP. EXCEEDED )
o PERFORMANCE QUALIFICATION TEST FOR GROOVE WELDS

NOTE A SINGLE SIDED WELD IS CLASSED AS A WELD WITHOUT BACKING AND A DOUBLE SIDED
WELD OR WELD WITH SEALING RUN IS CLASSED AS A WELD WITH BACKING.
THE F-NO. CANT BE CHANGED WITHOUT REQUALIFICATION EXCEPT THAT FOR PERFORMANCE
QUALIFICATION ONLY USING SMAW F-NO. UP TO AND INCLUDING 4 APPROVES ALL LESSER FNO FOR DOUBLE SIDED OR WELDS WITH BACKING ONLY.
NOTE A NO. DO NOT APPLY TO WELDER APPROVAL TESTS.
THE THK. LIMIT ONLY APPLIES TO THE DEPOSITED WELD METAL THK. NOT THE PLATE THK. AND
ANY GROOVE WELD APPROVES ALL FILLET WELD SIZES. FOR T>13 MM THERE IS NO
RESTRICTION ON THE SIZE THAT CAN BE WELDED. (PROVIDING THE TEST WELD DEPOSIT
CONTAINS AT LEAST 3 LAYERS OF WELD)
JOINT GEOMETRY, A DOUBLE V (OR U) IS CONSIDERED THE SAME AS A JOINT WITH BACKING
AND DOES NOT QUALIFY A SINGLE V (OR U) WITHOUT BACKING, BUT A SINGLE FULL
PENETRATION JOINT WITHOUT BACKING QUALIFIES ALL JOINT CONFIGURATION.
THE
CODE PROVIDES THAT THE WELDER WHO PREPARES THE WELDING PROCEDURE QUALIFICATION TEST
SPECIMENS MEETING THE REQUIREMENTS OF THE CODE IS THEREBY QUALIFIED WITHOUT FURTHER TESTING .
WELDERS QUALIFIED ON GROOVE WELDS ARE AUTOMATICALLY QUALIFIED FOR FILLET WELDS IN
THICKNESS . W ELDERS QUALIFIED ON FILLET WELDS ONLY ARE QUALIFIED TO MAKE FILLET WELDS ONLY .
34
ALL

THE BASE MATERIAL FOR THE TEST SPECIMENS MAY BE EITHER PLATE OR PIPE. THE MINIMUM NOMINAL
DIA . OF 5 IS RECOMMENDED FOR PIPE USED AS BASE MATERIAL .
THE DIMENSIONS OF THE WELDING GROOVE FOR THE TEST JOINT USED IN MAKING WELDER
QUALIFICATION TESTS , ON DOUBLE WELDED BUTT JOINTS AND SINGLE WELDED BUTT JOINTS WITH BACKING
STRIP , SHALL BE SAME AS THOSE FOR PROCEDURE QUALIFICATION .
TEJAS ROOWALA
35
QUALIFICATION ON A SINGLE WELDED PLATE WITH A BACKING STRIP SHALL ALSO QUALIFY FOR PIPE WITH A
BACKING STRIP AND VICE VERSA IN POSITION 1G AND 2G ONLY .
QUALIFICATION ON A SINGLE WELDED PLATE WITHOUT A BACKING STRIP SHALL ALSO QUALIFY FOR SINGLE
WELDED PIPE WITHOUT A BACKING STRIP AND VICE VERSA IN POSITIONS 1G AND 2G ONLY.
FOR ALL OTHER POSITIONS QUALIFICATION ON PIPE SHALL QUALIFY FOR PLATE BUT NOT VICE VERSA .
THE METHOD FOR REMOVING TEST SPECIMENS AND ACCEPTANCE CRITERIA ARE THE SAME AS FOR
PROCEDURE QUALIFICATION TEST . T HE TYPE , NUMBER OF TEST SPECIMENS ARE GIVEN IN FOLLOWING TABLE ;
TEJAS ROOWALA
COUPON (3)
(MM)
19.05 (4)
19.05 (4)
19.05 & OVER

(1)
TRANSVERSE BEND TESTS (4)
SB
FB
RB
1
1
-
2(4)

LONGITUDINAL BEND TESTS (5)
FB
RB
1
1
1
1
THE NOTES TO TABLES ARE ESSENTIAL TO THE USE OF THE TABLES . THE APPLICABLE NOTES ARE:
COUPON (3)
(MM)
OVER 9.57
1) A TOTAL OF FOUR SPECIMENS ARE REQUIRED TO QUALIFY FOR POSITION 5G.
36

2) THE MAXIMUM THICKNESS QUALIFIED IN GAS WELDING IS THE THICKNESS OF TEST PLATE OR PIPE.
3) THE BASE MATERIAL MAY CONSIST OF EITHER PLATE OR PIPE . THE MINIMUM NOMINAL DIA. OF 5 IS
RECOMMENDED FOR PIPE USED AS BASE MATERIAL .
4) EITHER FACE AND ROOT BENDS OR SIDE BENDS MAY BE USED FOR THICKNESSES FROM 9.57 TO 19.05 MM.
5) LONGITUDINAL BEND TESTS MAY BE USED IN LIEU OF THE TRANSVERSE BEND TESTS ONLY FOR TESTING
MATERIALS COMBINATIONS DIFFERING MARKEDLY IN MECHANICAL BENDING PROPERTIES BETWEEN (A ) THE
TWO BASE MATERIALS OR (B ) THE WELD METAL AND BASE MATERIALS .
OD LIMITS FOR WPQ
TEJAS ROOWALA
POSITION & OD LIMITATIONS FOR WPQ
37

RADIOGRAPHIC ACCEPTANCE CRITERIA FOR QUALIFYING WELDERS/WELDING OPERATORS:
RADIOGRAPHY IS OPTIONAL AND MUST BE SUPPLEMENTED BY BEND TESTS WHEN USING GMAW WITH DIP TRANSFER
OR WHEN WELDING SOME SPECIAL M /T .
UT IN LIEU OF RT IS NOT PERMITTED .
A LENGTH OF AT LEAST
6 MUST BE EXAMINED FOR PLATE OR THE ENTIRE CIRCUMFERENCE FOR PIPE.
ANY IMPERFECTION IN EXCESS OF SPECIFIED BELOW SHALL BE JUDGED UNACCEPTABLE:

a) LINEAR INDICATIONS :
ANY TYPE OF CRACK /LF/LOP IS NOT PERMITTED .
ANY ELONGATED SLAG INCLUSION WHICH HAS A LENGTH GREATER THAN ;
T10 MM
3 MM
T>10 MM & T 57 MM
T/3 MM
T>57 MM
19 MM
ANY GROUP OF SLAG INCLUSIONS IN LINE THAT HAVE AN AGGREGATE LENGTH GREATER THAN T IN A LENGTH
OF 12T, EXCEPT WHEN THE DIST . BETWEEN SUCCESSIVE IMPERFECTIONS EXCEEDS 6L WHERE L IS THE
LENGTH OF THE LONGEST IMPERFECTION IN THE GROUP .
TEJAS ROOWALA
b) ROUNDED INDICATIONS:
THE MAX. PERMISSIBLE DIMENSION FOR ROUNDED INDICATION SHALL BE 20% OF T OR 3 MM, WHICHEVER IS
SMALLER .
FOR WELDS IN M /T LESS THAN 3 MM IN THK., THE MAX . NO. OF ACCEPTABLE ROUNDED INDICATIONS SHALL
NOT EXCEED 12 IN A 6 LENGTH.
FOR WELDS IN M/T 3 MM OR GREATER THK ., THE CHARTS IN APP.I REPRESENTS THE MAX . ACCEPTABLE
CRITERIA . R OUNDED INDICATIONS LESS THAN 0.8 MM IN MAX . DIA SHALL NOT BE CONSIDERED IN
RADIOGRAPHIC ACCEPTANCE TESTS OF WELDERS /OPERATORS IN THESE RANGE OF M / T THK .
Brief summary of essential variables:

1) QW-402
-
Backing
2) QW-403
Pipe dia. (reference: table 452)
P no.
3) QW-404
F no.
t
Inserts
Solid/Metal cored Flux cored
38

4) QW-405
+ Position (The addition of other welding position than qualified)
Vertical welding
5) QW-408
-
Deletion of Inert gas backing
Metal transfer mode

Current/Polarity
6) QW-409
o Following tables should be need to remembered for sect. IX;

QW-416 :
WELDING VARIABLES FOR WPQ
QW-422 :
BASE M/T P-NO. GROUPING
QW-432 :
F-NO. GROUPING FOR FILLER M/T
QW-433 :
F-NO. RANGE QUALIFIED FOR WPQ
QW-442 :
A-NO. GROUPING FOR DEPOSITED WELD METAL
QW-451 :
QUALIFIED THK. LIMITS & REQUIRED NO. OF TEST SPECIMENS FOR PQR
QW-452.1(A):
NO. OF TEST SPECIMENS REQUIRED FOR WPQ
QW-452.1(B):
RANGE OF THK. QUALIFIED FOR WPQ
QW-461.9 :
RANGE OF QUALIFIED DIA & POSITIONS FOR WPQ
QW-462 :
GRAPHICAL REPRESENTATION FOR TEST SPECIMENS
TEJAS ROOWALA
39

API 1104
o PROCEDURE QUALIFICATION TEST
Table shows the type and number of butt weld test specimens required for procedure qualification;
Pipe Size, Outside

Dia. (mm)
Tensile
Under 60.3
60.3 to 114.3
inclusive
Over 114.3 to
323.9 inclusive
Over 323.9
0
0
114.3 and smaller

Over 114.3 to
323.9 inclusive
Over 323.9
Number of Specimens
NB
RB
FB
Wall Thickness 12.7 mm
2
2
0
2
2
0
2
SB
Total
0
0
4
4
16
0
2
4
4
4
Wall Thickness >12.7 mm
2
0
0
2
0
0
2
4
4
8
16
TEJAS ROOWALA
BELOW IS SHOWN THE ORDER OF REMOVAL FOR TEST SPECIMENS ;
40
TENSILE TEST :
TEJAS ROOWALA
THE TENSILE STRENGTH OF THE WELD, INCLUDING THE FUSION ZONE, SHALL BE EQUAL TO OR GREATER THAN
THE MINIMUM SPECIFIED TENSILE STRENGTH OF THE PIPE MATERIAL .
41

NICK BREAK TEST :
TEJAS ROOWALA
IN THE NICK BREAK TEST, THE EXPOSED SURFACES OF EACH SPECIMEN SHALL SHOW COMPLETE PENETRATION
AND FUSION , WITH THE GREATEST DIMENSION OF ANY GAS POCKET NOT TO EXCEED 1.6 MM AND THE COMBINED
AREA OF ALL GAS POCKETS SHALL NOT EXCEED 2% OF THE EXPOSED AREA . SLAG INCLUSIONS SHALL NOT BE MORE
THAN 0.8 MM IN DEPTH NOR 3 MM OR THE NOMINAL WT IN LENGTH , WHICHEVER IS SHORTER , AND THERE
SHALL BE AT LEAST OF SOUND WELD BETWEEN ADJACENT INCLUSIONS .
BEND TEST :
42
THE BEND TESTS SHALL BE CONSIDERED ACCEPTABLE IF NO CRACK OR OTHER DISCONTINUITY EXCEEDING 3.2
MM OR THE NOMINAL WT, WHICHEVER IS SMALLER , IN ANY DIRECTION IS PRESENT IN THE WELD OR BETWEEN
THE WELD AND THE FUSION ZONE AFTER BENDING. C RACKS WHICH ORIGINATE ALONG THE EDGES OF THE
SPECIMEN DURING TESTING, AND WHICH ARE LESS THAN 6.35 MM MEASURED IN ANY DIRECTION , SHALL NOT BE
CONSIDERED UNLESS DISCONTINUITIES ARE OBSERVED .
BRIEF SUMMARY OF ESSENTIAL VARIABLES :
CHANGE IN WELDING PROCESS
CHANGE IN BASE MATERIAL GROUP, I.E., A)
MIN. YS42,000 PSI
B)
42,000<YS<65,000
C)
YS65,000
MAJOR CHANGE IN JOINT DESIGN, I.E., FROM V TO U GROOVE
A CHANGE IN POSITION FROM ROLLFIX
A CHANGE IN WT GROUP, I.E.,
A) WT<4.8 MM
B) 4.8WT19.1
C) WT>19.1
A CHANGE IN DIA. GROUP, I.E.,
A)OD<60.3 MM
B)60.3OD323.9 MM
C)OD>323.9 MM
TEJAS ROOWALA
CHANGE IN FILLER METAL GROUP, I.E., A) GROUP 1: A 5.1 (E6010, E6011) & A 5.5 (E7010, E7011)
(ONLY FOR SMAW IS GIVEN HERE ) B) GROUP 2: A 5.5 (E8010, E8011, E9010)
C) GROUP 3: A 5.1/A 5.5 (E 7015/16/18, E 8015/16/18, E 9018)
43

CHANGE IN ELECTRICAL CHARACTERISTICS , I.E., CHANGE MORE THAN 10% IN AMPERAGE & SPEED, MORE THAN
7% IN VOLTAGE
TIME BETWEEN PASSES
CHANGE IN DIRECTION OF WELDING
CHANGE IN SHIELDING GAS & FLOW RATE
CHANGE IN SPEED OF TRAVEL
DECREASE IN SPECIFIED MIN. PREHEAT TEMP .
ADDITION OF PWHT OR A CHANGE FROM THE RANGES
o PERFORMANCE QUALIFICATION TEST

THERE ARE TWO TYPES OF WELDER QUALIFICATION IN API 1104: SINGLE QUALIFICATION & MULTIPLE
QUALIFICATION .
1) SINGLE QUALIFICATION :
WHEN THE WELDER IS QUALIFYING IN THE FIXED POSITION , THE AXIS OF THE PIPE
SHALL BE IN HP, IN VP OR INCLINED FROM HP AT AN ANGLE OF NOT MORE THAN 45.
2) MULTIPLE QUALIFICATION: FOR MULTIPLE QUALIFICATION, WELDER SHALL SUCCESSFULLY COMPLETED THE
TWO TESTS , USING QUALIFIED PROCEDURES . FOR FIRST TEST , THE WELDER SHALL MAKE A BUTT WELD IN THE
FIXED POSITION WITH THE AXIS OF THE PIPE EITHER IN THE H.P. OR INCLINED FROM H.P. AT AN ANGLE NOT
MORE THAN 45. THIS BUTT WELD SHALL BE MADE ON PIPE WITH AN OD OF AT LEAST 6 AND WITH A WT AT
LEAST 6.4 MM WITHOUT BACKING STRIP .
FOR THE SECOND TEST , THE WELDER SHALL WELD A FULL SIZE BRANCH ON PIPE CONNECTION . THIS
TEST SHALL BE PERFORMED WITH A PIPE DIA . OF AT LEAST 6 AND WT 6.4 MM . THE WELD SHALL BE MADE
WITH THE RUN PIPE AXIS IN THE H.P. & THE BRANCH PIPE AXIS EXTENDING VERTICALLY DOWNWARD FROM
THE RUN .
THE WELD SHALL EXHIBIT COMPLETE PENETRATION AROUND THE ENTIRE CIRCUMFERENCE,
COMPLETED ROOT BEADS SHALL NOT CONTAIN ANY BURN THROUGH OF MORE THAN 6 MM. T HE SUM OF MAX
DIMENSION OF SEPARATE UNREPAIRED BURN THROUGH IN ANY 12 LENGTH WELD SHALL NOT EXCEED 13
MM.
TEJAS ROOWALA
SCOPE: A WELDER WHO QUALIFIED FOR MULTIPLE QUALIFICATION ON PIPE DIA. GREATER THAN 323.9
(12) MM SHALL BE QUALIFIED TO WELD IN ALL POSITIONS, ALL WT, JOINT DESIGNS & FITTING AND ALL PIPE
DIA . A WELDER QUALIFIED ON DIA. LESS THAN 323.9 SHALL BE QUALIFIED TO WELD IN ALL POSITIONS , ALL
WT, JOINT DESIGNS & FITTING AND ALL PIPE DIA. LESS THAN OR EQUAL TO OD USED IN THE QUALIFICATION
TEST .
44

LOCATION OF TEST SPECIMENS:
TEJAS ROOWALA
45
TEJAS ROOWALA
46

IN PRODUCTION WELDS ;
o The pipe must be aligned carefully using internal pneumatically or hydraulically operated clamps. The
alignment must not be altered during the welding or the root pass and the internal clamps shall not
be removed until the root welding is finished and for external clamps weld shall be completed more
than 50%.
o Any misalignment of abutting ends of pipe of the same nominal thickness should not exceed 1.6 mm.
o It is convenient practice to preheat joints to approximately 100C particularly when ambient temp. is
below 5C or if the WT of the pipe exceeds 12.5 mm. This reduces the risk of martensite formation in
the HAZ, which is the main cause for hydrogen induced cracking.
o The second or hot weld pass is deposited immediately after the root pass has been completed,
before the temp. of the pipe in the weld zone drops to less than 100C.
o The weld bead height at no point shall neither fall below the outside surface of pipe nor shall be
raised above the parent metal by more than 1.6 mm.
o Two beads shall not be started at same location. The face of the completed weld shall be
approximately 3 mm wider than the width of original groove.
o In order to evaluate the weldability of these line pipe steels, sometimes slot weldability test is
conducted to as a field test. This test is done when welding problems are encountered especially
during site welding.
The test involves creating a through thickness slot of 90 mm length on a sample test piece of
250 mm length. Welding is carried out to fill up the groove with a pre qualified welding procedure.
After aging for 24 hrs the sample is reheated to 500C to arrest further cracking. The sample is heat
treated at 300C for 10 min and the sample is broken up by hammering from the other side. The c/s is
examined for the development of hydrogen induced cracks. In case of doubt, welding procedures are
suitable modified and adopted for the site welding.
TEJAS ROOWALA
o Acceptance criteria in production welds:
WITH MPT
WITH LPT
ANY INDICATION GREATER THAN 1.6 MM IN ANY

DIRECTION SHALL BE TREATED AS RELEVENT AND SHALL BE
CONFIRMED BY LPT OR ONETHER NDE TESTING.
ANY LINEAR INDICATION EVALUTED AS CRATER CRACK
EXCEED IN DIMENSION GREATER THAN 4 MM SHALL BE
CONSIDERED DEFECT.
LINEAR INDICATION OTHER THAN CRACK SHALL BE
CONSIDERED DEFECT.
LINEAR INDICATION EVALUTED AS LF AND EXCEED 1 IN
CONTINUOUS 12 WELD LENGTH OR 8% OF TOTAL WELD
LENGTH IN THE CASE OF WELD LENGTH LESS THAN 12
SHALL BE CONSIDERED AS DEFECT.
THE ACCEPTANCE CRITERIA FOR ROUNDED INDICATIONS IS
SAME AS PER GIVEN FOR RT.
ANY INDICATION GREATER THAN 2 MM IN ANY DIRECTION
SHALL BE TREATED AS RELEVENT AND SHALL BE
47
WITH UT
WITH RT/VISUAL INSPECTION

DEFECT TYPE
REINFORCEMENT (HEIGHT)
REINFORCEMENT (APPEARANCE)
INCOMPLETE FILLING
SLAG INCLUSIONS
CONFIRMED BY LPT OR ONETHER NDE TESTING.

ACCEPTANCE
STANDARD
FOR
LINEAR/ROUNDED
INDICATIONS IS SAME AS PER MPT.
ANY DEFECT INTERPRETETED AS CRACK IS CONSIDERED AS
DEFECT.
LINEAR BURIED INDICATIONS (OTHER THAN CRACK) NOT
OPEN TO THE ID/OD AND EXCEED 2 IN CONTINUOUS
WELD LENGTH OF 12 OR 8% OF TOTAL WELD LENGTH.
LINEAR SURFACE INDICATIONS (OTHER THAN CRACK) OPEN
TO THE ID/OD AND EXCEED 1 IN CONTINUOUS WELD
LENGTH OF 12 OR 8% OF TOTAL WELD LENGTH.
TRANSEVERSE INDICATIONS HAVE SAME ACCEPTANCE
CRITERIA AS PER GIVEN FOR VOLUMETRIC INDICATIONS.
VOLUMETRIC CLUSTER INDICATIONS ARE CONSIDERED TO
BE DEFECT WHEN DIMENSION EXCEED 13 MM.
VOLUMETRIC INDIVIDUAL INDICATIONS ARE CONSIDERED
TO BE DEFECT WHEN DIMENSION EXCEED 3 MM.
ACCEPTANCE CRITERIA IS AS PER GIVEN BELOW;
MAX ALLOWANCE
WELD FACE
3 MM
SMOOTH
NOT ALLOWED
ESI : 1.6 MM WIDTH & 50 MM LENGTH IN ANY 12 WELD LENGTH
ISI: 3 MM WIDTH & 13 MM LENGTH IN ANY 12 WELD
LENGTH
MAX 4 ISI IN ANY 12 WELD LENGTH
THE AGGREGATE LENGTH OF ESI & ISI 8% OF WELD LENGTH
IN THE CASE OF WHEN WELD LENGTH IS LESS THAN 12
TEJAS ROOWALA
UNDERCUT
POROSITY
CRACKS
LACK OF FUSION
0.4 MM OF ANY LENGTH

>0.4<0.8 MM OF 50 MM LENGTH
>0.8 MM NOT ACCEPTABLE OF ANY LENGTH
FOR SCATTERED PORO. DIA. OF INDIVIDUAL PORO . UP TO 25%
OF WT OR 3 MM WHICHEVER IS SMALLER
FOR CLUSTER PORO. MAX. DIA OF CLUSTER 13 MM AND
AGGREGATE LENGTH IS 13 MM IN ANY CONTINUOUS 12
WELD LENGTH
NOT ALLOWED ACCEPTING CRATER CRACK UP TO 4 MM
INDIVIDUAL & AGGREGATE LENGTH 25 MM (OR 8% IN THE CASE OF
WELD LENGTH LESS THAN 12) IN ANY CONTINUOUS 12 WELD
LENGTH
LF DUE TO COLD LAP

ARC STRIKE
MECHANICAL DAMAGE
MISALIGNMENT
INDIVIDUAL AND AGGREGATE LENGTH UP TO 50 MM

NA
NA
3 MM
48

WELD ROOT
MISALIGNMENT
REINFORCEMENT (HEIGHT)
LACK OF ROOT PENETRATION WITHOUT
HIGH- LOW
LACK OF ROOT PENETRATION DUE TO
HIGH- LOW
LACK OF ROOT FUSION
ROOT CONCAVITY
3 MM
1.6 MM
INDIVIDUAL & AGGREGATE LENGTH UP TO 25 MM IN ANY
CONTINUOUS 12 WELD LENGTH .
INDIVIDUAL LENGTH UP TO 50 MM & AGGREGATE LENGTH UP TO 75
MM IN ANY CONTINUOUS 12 WELD LENGTH .
SAME AS FOR WELD FACE
ANY LENGTH IS ACCEPTABLE BUT THE DENSITY OF THE RADIOGRAPH
IMAGE OF INTERNAL CONCAVITY SHALL NOT EXCEED THAT OF THE
THINNEST ADJACENT PARENT MATERIAL . IN SUCH CASES CRITERIA FOR
BT IS APPLICABLE.
ROOT UNDERCUT
MECHANICAL DAMAGE
POROSITY
BURN THROUGH

NA
INDIVIDUAL LENGTH UP TO 6 MM OR THINNER OF THE NOMINAL WT
WHICHEVER IS SMALLER
AGGREGATE LENGTH UP TO
LENGTH .
13 MM IN ANY CONTINUOUS 12 WELD
TEJAS ROOWALA
49

ACCEPTANCE CRITERIA AS PER ASME SECT. VIII DIV. I
1. LPT (Appendix 8)
Reference given in sect. V, article 6.
Relevant indications: only indications with major dimensions greater than 1.5 mm shall
be considered as relevant.
A linear indication is one having a length greater than 3 times the width.
A rounded indication is one of circular or elliptical shape with the length equal or less than
3 times the width.
Acceptance criteria:
All surfaces to be examined shall be free of;
a) Relevant linear indications
b) Relevant rounded indications greater than 5 mm.
c) Four or more rounded indications in a line separated by 1.5 mm or less (edge to edge).
2. MPT (Appendix 6)
All evaluations of indications and acceptance criteria are same as for LPT.
TEJAS ROOWALA
3. UT (Appendix 12)
Indications which produce a response greater than 20% of the reference level shall be
investigated to the extent that the operator can determine the shape, identity and
location of all such imperfections and evaluate them in terms of the acceptance standard
given below;
a) Indications characterized as cracks, LF or LOP are unacceptable regardless of length.
b) Other imperfections are unacceptable if the indication exceeds the reference level
amplitude and have lengths which exceeds:
6 mm for t up to 19 mm.
1/3t for t from 19 mm to 57 mm.
19.05 mm for t over 57 mm.
Where t is the thickness of the thinnest member excluding any allowable reinforcement.
50

4.
o
o
RT
Acceptance criteria for linear indications:
Cracks, LF & LOP are not acceptable.
Other imperfections are unacceptable if length exceed;
6 mm for t up to 19 mm.
1/3t for t from 19 mm to 57 mm.
19.05 mm for t over 57 mm.
o Where t is the thickness of the thinnest member excluding any allowable reinforcement.
For fillet welds with full penetration throat thk. (th) is included in t.
o Any group of aligned indications in which aggregate length exceeds t in a weld length of
12 t, except when the distance between two edges of adjacent indication exceeds 6L,
where L is the dimension of the longest indication.
Acceptance criteria for rounded indications:
o Appendix 4
o Rounded indications which exceed the following dimension shall be considered relevant;
1/10t for t less than 3 mm
0.4 mm for t 3 to 6 mm.
0.8 mm for t 6 to 50 mm.
1.6 mm for t>50 mm.
TEJAS ROOWALA
o Max. size of rounded indications;

The max permissible size of any indication shall be 1/4t or 4 mm, whichever is smaller,
except that an isolated indication separated from an adjacent indication by 1 or more
may be 1/3t or 6 mm whichever is less. For t greater than 2 the max permissible size of
isolated indication shall be 10 mm.
Aligned rounded indications are acceptable when the summation of the dia. of the
indications is less than (t) in a length of 12t. (fig 4-1 to 4-2 in App. 4)
For t less than 3 mm, the max no. of rounded indications shall not exceed 12 in a 6 weld
length.
For t greater than 3 mm, follow chart 4-3 through 4-8 of App. 4.
The length of acceptable cluster rounded indications shall not exceed the lesser of 1 or
2t. Where more than one cluster is present, the sum of the lengths of the clusters shall
not exceed 1 in a 6 weld length.
51

WELD JOINT DETAILS (Ref: ASME B 31.3, 31.4/31.8)
Joint preparation for un equal wall thickness
TEJAS ROOWALA
52

Branch connections
Branch connections which abut the outside surface of the run pipe shall be contoured for groove
welds which meet the WPS requirements (fig-a & b).
Branch connections which are inserted through a run opening shall be inserted at least as far as the
inside surface of the run pipe at all points (fig-c).
Lateral transition of branches and connections from the centerline of the run shall not exceed 1.5
mm.
Branch connections, including branch connection fittings, which abut the outside of the run or which
are inserted in an opening in the run shall be attached by fully penetrated groove welds. The welds
shall be finished with cover fillet welds having a throat dimension not less than tc. (fig-1&2)
TEJAS ROOWALA
The nomenclature used here are;

Tb = nominal thickness of branch
53

Th = nominal thickness of header
Tr = nominal thickness of reinforcing pad or saddle
tc = lesser of 0.7Tb or 6 mm (14 in.)
tmin = lesser of Tb or Tr
A reinforcing pad or saddle shall be attached to the branch pipe by either;
a) A fully penetrated groove weld finished with a cover fillet weld having a throat dimension
not less than tc
b) A fillet weld having a throat dimension not less than 0.7tmin.
The outer edge of a reinforcing pad or saddle shall be attached to the run pipe by a fillet weld having
a throat dim not less than 0.5Tr.
The corners of the pad shall be rounded corners.
For Fillet & Socket welds

The max size of socket welded joints in hazardous services shall be 1.5 for new construction. Max 2
may be used in hazardous service for maintenance, minor field modifications of existing piping
systems, and when necessary to match existing equipment connections.
For sour services socket welded joints should be avoided. In case they could not be avoided the max.
size of socket welded joints shall be 1.
Generally, socket welded joints should be avoided in any services where crevice corrosion, severe
erosion, or cyclic loading may occur.
The axial gap between male and female component shall be max of 3 mm and min of 1.5 mm. This
gap is required prior to welding.
TEJAS ROOWALA
DETAILS FOR DOUBLE WELDED SLIP-ON & SOCKET WELDING FLANGE
54
MIN WELDING DIMENSIONS FOR SOCKET WELDING OF COMPONENTS OTHER THAN FLANGE
TEJAS ROOWALA
55

SERVICE CODES
Line material:
CA Impact tested carbon steel
CB Killed CS
CC Low carbon CS
CS Carbon steel
CG Galvanized CS
CJ
1-1/4 Cr Mo alloy steel
CK 2-1/4 Cr 1 Mo alloy steel
CL
5 Cr Mo alloy steel
CM 9 Cr 1 Mo alloy steel
BC Copper tubing
BD 90-10 Cu-Ni
DC Cast Iron Grey
SC 304H SS
SD 316/316L SS
SJ
321 SS
SX Duplex SS
NM Monel 400
PV PVC
TEJAS ROOWALA
Corrosion allowance:
0
Zero corrosion allowance
1
1.6 mm
2
3.2 mm
3
4.8 mm
4
6.4 mm
9
Corrosion allowance as noted
Pressure rating:
1
150
3
300
4
400
6
600
9
900
15 1500
25 2500
Services:
A
Acid
C
Caustic
56

D
H
P
Q
T
U
W
Y
Drain, sewer
Hydrogen
Process (General hydrocarbon)
Chlorination gas
Well head piping
Utility
Water
Chlorine gas
Ex.
6-FG-123-1CS9P
6 fuel gas line no. 123 and m/t specification;
1
Pressure rating (150#)
CS
Carbon steel
Corrosion allowance (corrosion allowance as noted)
Process (General hydrocarbon) services
TEJAS ROOWALA
57

PIPE LINE WELDING PRACTICES
DOWNHILL WELDING VS UPHILL WELDING
3.17 TO 9.5 MM. THE
RELATIVELY THIN WALL OF THE PIPE RETAINS THE HEAT LONGER THAN THICK METAL WOULD . WHEN WELDING MS PIPE ,
DOWNHILL WELDING IS USED PRIMARILY TO WELD THIN WALL MS PIPE HAVING A WT OF
THE SLOWER COOLING RATE OF THE THIN WALLED PIPE DOES MAKE IT POSSIBLE TO DEPOSIT THE WELD AT A FASTER
RATE WITHOUT HARMFUL EFFECTS TO THE WELDED JOINT . ALSO DOWNHILL WELDING TECHNIQUE ALLOWS FASTER
WELDING SPEEDS WITH LESS TENDENCY TO BURN THROUGH THE ROOT OF THE JOINT .
DOWNHILL WELDING REQUIRES THE USE OF FAST-FREEZING , LIGHTLY COATED ELECTRODES (F3 GROUP ) SUCH
6010, 6011 THAT PRODUCE MINIMUM SLAG . THE USE OF THE HEAVIER ELECT. SUCH AS 7024 AND THE IRON
POWDER LOW HYDROGEN TYPES ARE NOT SUITABLE IN DOWNHILL WELDING AS THE PROBLEMS OF SLAG ENTRAPMENT ,
POROSITY AND COLD LAPPING BECOME INSURMOUNTABLE . SUCH ELECT . WILL ALSO REQUIRE HIGHER OPERATING
CURRENTS THUS INCREASING THE CHANCE OF BURN THROUGH .
AS
UPHILL WELDING IS PREFERRED FOR WELDING HEAVY WALL PIPE AND PIPE MADE OF ALLOY STEEL. THE
THICKER PIPE WALL ACTS AS A HEAT SINK BY WITHDRAWING THE HEAT MORE RAPIDLY FROM THE WELD AREA THAN
DOES A THIN WALL PIPE. THE FASTER COOLING RATE CAUSES THE METAL IN THE WELD AREA TO BECOME MORE
BRITTLE IN MS PIPE . IN ALLOY STEEL PIPE THE TENDENCY TOWARD BRITTLENESS IS GREATLY INCREASED . TO OVERCOME
THIS TENDENCY THE COOLING RATE IN THE WELD AREA MUST BE REDUCED . THIS CAN BE ACCOMPLISHED BY
TEJAS ROOWALA
DECREASING THE WELDING SPEED AND BY DEPOSITING A HEAVIER BEAD. BOTH OF THESE OBJECTIVES ARE ACHIEVED BY
UPHILL WELDING .
VERTICAL DOWN WELDING WITH CELLULOSIC ELECT . IS NORMALLY DONE WITH HIGH CURRENTS AND HIGH TRAVEL
SPEED. CELLULOSIC ELECT . HAVE A THIN COATING CONTAINING A LARGE AMOUNT OF ORGANIC CELLULOSE . WHEN THE
ELECT . IS BURNED , THE COATING FORMS A PROTECTIVE GAS COATING FOR THE MOLTEN METAL . BECAUSE OF THE
ORGANIC M /T AND MOISTURE CONTENT OF THESE ELECT . THEY HAVE A VERY STRONG ARC FORCE BUT AT THE SAME
TIME THE WELD METAL FREEZES VERY QUICKLY . THIS METHOD OF WELDING IS FAST AND ECONOMICAL ,
CONSEQUENTLY MOST CROSS COUNTRY PIPELINES ARE WELDED WITH THE PROGRESSION VERTICALLY DOWNWARD .
HOWEVER IT IS RECOMMENDED PRACTICE TO USE UPHILL TECHNIQUE WITH LOW HYDROGEN ELECT . (F4 GROUP ) FOR
WELDING THE ROOT BEAD AND THE SUCCESSIVE BEAD WELDING SHOULD BE CARRIED OUT WITH DOWNHILL
TECHNIQUE FOR WELDING OF HIGH PR ., HIGH TEMP ., LOW TEMP . PIPELINES WHICH DEMANDS FOR MORE STRICT
RADIOGRAPHY REQUIREMENTS . THE REASON IS THAT WITH UPHILL TECHNIQUE WITH RELATIVELY LOW CURRENT AND
LOW TRAVEL SPEED PRODUCES JOINTS RELATIVELY FEW, BUT LARGE BEADS WHICH GIVES GREATER HEAT INPUT SO
LESS CHANCE OF LF OR LOP IN THE ROOT BEAD . ALSO WITH LOW HYDROGEN ELECT . WITH VERTICAL UPHILL WELDING
WELDS MAY BE MADE VIRTUALLY FREE OF ANY SLAG ENTRAPMENT AND POROSITY . ALSO WITH UPHILL WELDING THE
DEPOSITED BEAD IS SOMEWHAT OF CONVEX PROFILE WHICH PUTS THE DEPOSITED BEAD IN CONTRACTION STRESSES SO
LESS SUSCEPTIBLE TO STRESS INDUCED CRACKING .
IT IS DESIRABLE NOT TO FINISH A WELD IN EXACTLY THE BOTTOM OF THE PIPE BECAUSE THE TIE -IN CAN BE MORE
DIFFICULT . SIMILARLY IT IS BEST TO AVOID STARTING AT EXACTLY THE TOP OF PIPE .
58

WHEN THE ARC IS STRUCK, IT SHOULD NOT BE SHORTENED IMMEDIATELY . TIME SHOULD BE ALLOWED TO STABILIZE
THE ARC AND TO ALLOW THE GASEOUS SHIELD TO FORM .
WELDING OF ROOT BEAD:

KEYHOLE IS AN ESSENTIAL PART IN WELDING THE ROOT BEAD. IT IS A TEARDROP SHAPED ENLARGEMENT OF THE ROOT
OPENING AHEAD OF THE BEAD AND IT SHOULD BE ABOUT 1 1/3 TIMES THE DIA . ACROSS THE ELECT . COATING IN SIZE .
THE KEYHOLE HELPS TO INSURE THAT THE DEPOSITED BEAD WILL PENETRATE TO THE ROOT AS EVIDENCED BY THE
SMALL CROWN AT THE BACK OF THE BEAD . THIS CROWN SHOULD RISE ABOUT
1.6 MM ABOVE THE INSIDE SURFACE OF

THE PIPE . WHILE WELDING , THE WELDER SHOULD WATCH THE KEYHOLE CONSTANTLY . IF IT BECOMES ENLARGED, OVER
PENETRATION WILL RESULT. THIS CAN BE CORRECTED BY REDUCING THE WELDING CURRENT OR , IN SOME CASES , BY
INCREASING THE WELDING SPEED . IF THE KEYHOLE IS TOO SMALL , THE PENETRATION OF THE ROOT BEAD WILL BE
INSUFFICIENT . WHILE SLOWING THE SPEED OF WELDING OR THE ELECT . ANGLE SHOULD BE DECREASED SLIGHTLY BY
POINTING THE ELECT . MORE DIRECTLY TOWARD THE KEYHOLE WILL HELP IN SOME CASES, USUALLY IT IS NECESSARY TO
INCREASE THE WELDING CURRENT TO CORRECT THIS CONDITION .
THE ARC SHOULD BE STRUCK IN THE JOINT AND NEVER ON A TACK WELD . A LONG ARC LENGTH SHOULD BE
MAINTAINED FOR A SHORT PERIOD AFTER THE ARC HAS BEEN STRUCK . DURING THIS TIME WEAVE THE ELECT .
BACKWARD AND FORWARD TO PREHEAT THE BEVEL OF THE WELD . IN ADDITION TO PREHEATING THE BEVEL
MAINTAINING THE LONG ARC LENGTH STABILIZES THE ARC AND ALLOWS THE GASEOUS SHIELD TO FORM. NO FILLER
METAL IS TRANSFORMED FROM THE ELECT . TO THE WORK PIECE WHEN THE LONG ARC IS MAINTAINED IN THE
TEJAS ROOWALA
OVERHEAD POSITION . AFTER THE ARC HAS BEEN STABILIZED AND THE GASEOUS SHIELD HAS FORMED, THE ELECT . IS
BROUGHT BACK TO THE ACTUAL START POSITION FOR THE ROOT BEAD . WITH THE ELECT . HELD AT THE CORRECT
ANGLE, IT IS CAREFULLY MOVED TOWARD THE ROOT BEAD UNTIL THE CORRECT ARC LENGTH IS ESTABLISHED.
THE WHIPPING PROCEDURE MUST ALWAYS BE USED WHEN WELDING IN THE VERTICAL UPHILL PORTION OF THE PIPE . IT
12 OCLOCK POSITION . THE OBJECTIVE OF WHIPPING IS TO ALLOW

THE MOLTEN POOL OF METAL TO COOL SUFFICIENTLY TO LOSE OF ITS FLUIDITY . WHEN THE MOLTEN METAL IN THE
PUDDLE IS SOMEWHAT MUSHY, A FURTHER DEPOSIT OF FILLER METAL FROM THE ELECT . WILL NOT CAUSE IT TO
OVERFLOW . THE LENGTH OF THE STROKE WHEN WHIPPING SHOULD NOT BE EXCESSIVE . IF IT IS EXCESSIVE , THE HOT
IS CONTINUED UNTIL THE WELD IS STOPPED AT THE
LIQUID METAL IN THE PUDDLE WILL BE EXPOSED TO THE ATMOSPHERE AS A RESULT OF THE REMOVAL OF THE GASEOUS
SHIELD . RAPID OXIDATION WILL RESULT , WHICH LEADS TO POROSITY IN THE WELD . EXCESSIVE WHIPPING CAN ALSO
CAUSE SLAG ENTRAPMENT.
TO STOP THE WELD , THE ARC IS BROKEN BY MAKING A QUICK STAB THROUGH THE KEYHOLE WITH ELECT AND THEN BY
WITHDRAWING IT QUICKLY TO CLEAR THE WORK . BY THIS PROCEDURE A FULL SIZE KEYHOLE IS LEFT SO THAT COMPLETE
PENETRATION CAN BE OBTAINED WHEN RESTARTING THE WELD OR WHEN MAKING A TIE-IN AT THIS POINT . FOR RE
STARTING THE WELD STRIKE THE ARC SOMEWHAT AHEAD OF THE KEYHOLE AND MAINTAIN LONG ARC TO STABILIZE IT
AND TO FORM GASEOUS SHIELD . AFTER STABILIZATION CAREFULLY DECREASE THE ARC LENGTH WITH MOVEMENT
UPTO THE KEYHOLE AND GRADUALLY CLOSE THE KEYHOLE AND START WELD FROM HERE .
WELDING THE ROOT BEAD WITH LOW HYDROGEN ELECT.:

ROOT BEADS ARE SELDOM WELDED WITH LOW HYDROGEN ELECT . BECAUSE THE DIA . ACROSS THE COATING FOR THE LOW HYDROGEN ELECT . IS SOMEWHAT MORE
THAN FOR SAME SIZE CELLULOSIC ELECT . THE HEAVIER COATING OF THE LH ELECT . DOES NOT ALLOW THE ARC TO BE
59

TAKEN CLOSE ENOUGH TO THE ROOT FACE , THEREBY MAKING IT DIFFICULT TO ESTABLISH THE CORRECT ARC LENGTH.
WELDING WITH AN ARC THAT IS TOO LONG CAN CAUSE SUCK -IN. FURTHERMORE , THE HEAVIER COATING INTERFERES
WITH THE MANIPULATION OF THE ELECT WHEN MAKING A WEAVE .
A HIGHER CURRENT SETTING IS ALWAYS USED FOR WELDING WITH LOW -HYDROGEN ELECT . AND
THEREFORE MORE HEAT IS LIBERATED . THE ARC CHARACTERISTIC IS ALSO DIFFERENT. THE LH ELECT . PRODUCES AN
ARC THAT IS RELATIVELY SMOOTH BUT LACKS THE PENETRATING POWER OF THE MORE LIGHTLY COATED ELECT .
A HEAVY COATING WILL FORM A HEAVY BLANKET OF SLAG OVER THE LIQUID PUDDLE OF MOLTEN
METAL , WHICH CAUSES THE COOLING RATE TO BE SLOWER AND THE METAL TO REMAIN LIQUID FOR A LONGER PERIOD .
THE VISCOSITY OF THE MOLTEN SLAG AND WELD METAL IS LOWER; I. E., IT WILL FLOW MORE READILY THAN A LIQUID
HAVING A HIGHER VISCOSITY . THE COMBINED EFFECT OF THE SLOWER COOLING RATE AND THE LOWER VISCOSITY OF
THE LIQUID WILL CAUSE THE MOLTEN PUDDLE TO DRIP READILY . FOR THIS REASON , DIFFICULTY IS EXPERIENCED WHEN
WELDING IN THE OVERHEAD AND VERTICAL POSITIONS WITH LH ELECT .
A VERY SHORT ARC SHOULD BE USED AT ALL TIMES WHEN WELDING WITH LH ELECT . TO OBTAIN
ADEQUATE PENETRATION . ALSO WHEN WELDING WITH LH ELECT ., PINHOLES CAN BE CAUSED BY INCORRECT ARC
STRIKING , CHIPPED FLUX COATING , MOISTURE IN THE WELD JOINTS , OR WET ELECT . TO AVOID PINHOLES WHILE
STRIKING THE ARC , STRIKE JUST AHEAD OF THE STARTING POINT AND SHORTEN THE ARC AS QUICKLY AS POSSIBLE TO
THE PROPER LENGTH . THEN BACK -UP THE ARC TO THE STARTING POINT AND PROCEED TO WELD AS SOON AS THE
MOLTEN POOL OF METAL HAS FORMED . THE WHIPPING PROCEDURE SHOULD NEVER BE USED WHEN WELDING WITH LH
ELECT .
TEJAS ROOWALA
A V-SHAPED WEAVE, MUST BE USED FOR WELDING THE ROOT BEAD ENTIRELY , AROUND THE PIPE
WHEN USING THE LH ELECT. THE OBJECTIVE OF THIS WEAVE IS TO ALLOW THE MOLTEN SLAG AND METAL IN THE
PUDDLE TO COOL AND TO LOSE SOME OF ITS FLUIDITY IN ORDER TO PREVENT DRIPPING . USING THIS WEAVE ALSO
PREHEATS THE METAL AHEAD OF THE WELD .
WELDING THE ROOT BEAD WITH GTAW: USUALLY, ONLY THE ROOT BEAD IS WELDED BY THE GTAW PROCESS.
HOWEVER , SOMETIMES THE SECOND PASS IS ALSO MADE BY THIS PROCESS BECAUSE GTAW WELDED ROOT BEADS TEND
TO SOMEWHAT THIN . SS AND HIGH ALLOY STEEL PIPES , AS WELL AS MS PIPES , ARE WELDED BY THE GTAW PROCESS ,
ESPECIALLY FOR HIGH PR. PIPE JOINT THAT REQUIRES HIGH QUALITY WELDS .
THE OUTSTANDING FEATURES OF THE GTAW PROCESS ARE :
1)
2)
3)
4)
5)
6)
WELDS OF EXCEPTIONAL QUALITY CAN BE MADE IN ALMOST ALL METALS

PRACTICALLY NO PWHT IS REQUIRED .
THE ARC AND THE POOL OF MOLTEN METAL ARE READILY VISIBLE BY THE WELDER .
NO FILLER METAL IS TRANSPORTED ACROSS THE ARC STREAM ; THUS THERE IS NOT SPATTER.
WELDING IS POSSIBLE IN ALL POSITIONS .
THERE IS NO SLAG WITH MIGHT BE TRAPPED IN THE WELD .
60

THE PROCEDURE FOR PREPARING THE WELD JOINT IS THE SAME AS FOR PREPARING THE JOINT WHEN WELDING BY
SMAW . THE PRINCIPAL DIFFERENCE IS IN THE DIMENSIONS OF THE JOINT . THE WIDTH OF THE ROOT FACE IS REDUCED
TO 1.6 MM AND THE ROOT OPENING IS NARROWED TO 1.6 TO 2.4 MM .
FOR THE ELECT . TIP, THE INCLUDED ANGLE OF THE POINT SHOULD BE ABOUT
GROUND BACK TO A DIST. EQUAL TO ABOUT
22 TO 23, OR THE LENGTH SHOULD BE
2-1/2 ELECT. DIA. IT IS IMPORTANT TO BLUNT THE TIP SLIGHTLY BY
GRINDING IT FLAT AT THE END FOR A DIST . SLIGHTLY LESS THAN 0.4 MM FROM THE POINT .
5G POSITION, THE TACK WELDS SHOULD BE MADE IN THE 8:30, 4:30, 1:30 AND 11:30
POSITIONS . THE REGULAR ROOT BEAD IS STARTED IN THE 6 OCLOCK POSITION .
WHEN THE PIPE IS IN THE
THE ARC SHOULD NOT BE STRUCK IN A MANNER SIMILAR TO THE PROCEDURE USED FOR SMAW WITH CONSUMABLE
ELECT . AS THIS PROCEDURE WOULD SERIOUSLY DAMAGE THE TUNGSTEN ELECT . TO START THE WELD , THE CURRENT
AND THE INERT GAS SUPPLY TO THE WELDING TORCH MUST BE SHUT OFF. AFTER POSITIONING THE TORCH AND FILLER
METAL , THE WELDER SWITCH ON THE WELDING CURRENT USING THE FOOT SWITCH OR THE SWITCH ON THE WELDING
TORCH . SLOWLY AND CAREFULLY HE WILL STRAIGHTEN THE WELDING TORCH THEREBY REDUCING THE ELECT . ANGLE
AND BRINGING THE TIP OF THE ELECT . INTO THE GROOVE . AFTER THE ARC HAS BEEN ESTABLISHED , THE WELDING
TORCH IS HELD IN PLACE UNTIL A PUDDLE OF MOLTEN METAL HAS APPEARED. AFTER THE PUDDLE IS ESTABLISHED , THE
FILLER ROD IS DIPPED INTO THE MOLTEN METAL. THE WELDER THEN BEGINS TO OSCILLATE THE WELDING TORCH FROM
SIDE TO SIDE , ALLOWING THE ARC TO TRAVEL SLIGHTLY BEYOND THE EDGES OF THE PIPE. WHEN THE PUDDLE HAS BEEN
BUILT UP TO THE REQUIRED SIZE BY THE ADDITION OF FILLER METAL, THE WELDING TORCH IS THEN MOVED ON BY
SLOWLY AND STEADILY GLIDING IT OVER THE BEVEL WHILE AT THE SAME TIME THE TORCH IS OSCILLATED FROM SIDE
TO SIDE . FILLER IS ADDED CONTINUOUSLY TO THE MOLTEN PUDDLE FROM THE END OF THE ROD WHICH IS HELD IN THE
PUDDLE .
TEJAS ROOWALA
TO STOP THE WELD , THE WELDING CURRENT IS SIMPLY SWITCHED OFF . IF THE FILLER ROD IS TO BE REPLACED OR IF THE
WELD BEAD IS FINISHED, THE FILLER ROD SHOULD BE WITHDRAWN BEFOREHAND . HOWEVER , IF THE BEAD IS TO BE
CONTINUED , THE FILLER ROD IS LEFT IN THE PUDDLE TO SOLIDIFY AGAINST THE END OF THE BEAD .
THE PROCEDURE FOR RESTARTING THE WELD AGAINST A LAYER OF WELD METAL IS SIMILAR TO THE STARTING
PROCEDURE AS PREVIOUSLY DESCRIBED .
FOR MAKING A TIE -IN, WHEN THE WELD APPROACHES ANOTHER BEAD , THE NORMAL GTAW WELDING PROCEDURE IS
CONTINUED UNTIL THE WELD IS APP .
1.6 MM FROM THE BEAD. AT THIS POINT THE FILLER ROD IS WITHDRAWN, BUT
THE WELDING TORCH IS SLOWLY MOVED ON ; IT IS TILTED AS NECESSARY TO PREVENT THE ELECT . FROM COMING IN
CONTACT WITH THE WELD METAL . WHEN A SMOOTH BEAD BETWEEN THE BEADS HAS BEEN OBTAINED THE CURRENT IS
SWITCHED OFF .
WHEN A SECOND PASS WITH THE GTAW TORCH MUST BE MADE , THE PROCEDURE IS SAME AS THAT USED IN WELDING
THE ROOD BEAD . HOWEVER THE LENGTH THAT THE ELECT . PROTRUDES FROM THE END OF THE NOZZLE MUST BE
SHORTENED SO THAT IT WILL NOT COME IN CONTACT WITH THE ROOT BEAD OR THE MOLTEN POOL OF METAL .
WELDING OF INTERMEDIATE AND COVER PASSES

HOT PASS:
AFTER THE ROOD PASS IS WELDED , THE ROOT BEAD IS GENERALLY VERY CONVEX . THE NORMAL
PROCEDURE IS TO GRIND THE ROOT PASS TO ELIMINATE THE EXCESSIVE CONVEXITY . NORMALLY , THE ENTIRE WELD IS
NOT GROUND OUT RATHER ONLY ENOUGH TO EXPOSE WAGON TRACKS . THESE ARE LINES OF SLAG THAT ARE ON
EITHER SIDE OF THE BUILT UP CONVEX REGION.
61

THE PURPOSE OF THE HOT PASS IS PRIMARILY TO BURN OUT THE WAGON TRACKS . TO DO THIS , A HIGH CURRENT IS
NORMALLY USED .
FILL PASS :
FOR LIGHT COATED ELECT., THE ARC LENGTH SHOULD BE ABOUT
2.3 TO 3.2 MM. THIS WILL
PROVIDE ENOUGH HEAT SO THAT THE PUDDLE OF MOLTEN METAL WILL BE LARGE ENOUGH TO ACCEPT THE GLOBULES
OF FILLER METAL WITHOUT EXCESSIVE BUILD-UP. IF A SHORT ARC IS USED, THE SIZE OF THE PUDDLE OF MOLTEN
METAL IS DECREASED CONSIDERABLY . IN THIS CASE THE SIZE OF THE POOL OF MOLTEN METAL IN WHICH THE FILLER
METAL CAN BE DEPOSITED IS LIMITED . WHEN THE GLOBULE ENTERS THE SMALLER BODY OF LIQUID METAL , IT WILL RISE
AND, AT THE SAME TIME , COOL MORE RAPIDLY CAUSING THE BEAD TO HAVE A HIGH CROWN AND , PERHAPS , LACK OF
GOOD EDGE FUSION .
EACH LAYER SHOULD BE START IN A DIFFERENT POSITION ON THE JOINT. FOR EX ., THE ROOT BEAD WAS STARTED IN
6:30 POSITION; THUS THE SECOND LAYER SHOULD THEN NOT START IN THIS POSITION BUT IN THE 6 OCLOCK
POSITION .
THE
IN CRITICAL APPLICATIONS FOR LOW TEMP . SERVICES , IT MAY BE NECESSARY TO MAXIMIZE THE IMPACT TOUGHNESS
PROPERTIES OF A WELD . IN THIS CASE , ONE TECHNIQUE IS TO SPLIT THE LAYERS INTO TWO PASSES . THE OBJECTIVE IS
TO ALIGN FINE GRAINED REHEATED ZONES ALONG THE CENTERLINE OF THE WELD , FROM WHERE THE TEST SAMPLES
ARE TAKEN .
WHEN THE END OF A BEAD IS REACHED OR WHEN THE ELECT . IS CONSUMED , THE WELD MUST BE STOPPED. THIS IS
TEJAS ROOWALA
DONE BY SIMPLY REVERSING THE DIRECTION OF THE ELECT . TRAVEL FOR A SHORT DIST. AND THEN BREAKING THE ARC
WITH A QUICK MOVEMENT. THE PROCEDURE FOR RESUME OF WELDING IS SAME AS FOR ROOT BEAD .
CAP PASS :
NORMALLY THE COVER BEAD SHOULD OVERLAP THE EDGES OF THE BEVEL FOR APP . 1.6 MM .
IF THE PIPE IS TOO HOT THE MOLTEN METAL WILL SOLIDIFY MORE SLOWLY AND IT WILL BE VERY DIFFICULT TO
CONTROL THE PUDDLE . AS A RESULT THERE WILL BE A ROUGH -LOOKING WELD WHICH IS UNSATISFACTORY AS A COVER
PASS . THE REMEDY WOULD BE TO ALLOW THE PIPE TO COOL UNTIL IT IS WARM (ABOUT
200 TO 300 F) BEFORE
STARTING TO WELD .
THE CAP PASS SHOULD BE WELDED AT LOWER CURRENTS THAN THE FILL PASSES .
GENERALLY,
1)
THE CURRENT RANGE SHOULD BE ,
PASS
ROOT
HOT
FILL
STRIPPER
CAP
CURRENT RANGE
125-165
160-200
160-190
150-180
150-180
THE RANGE IS GIVEN IN THE REFERENCE TO THE 4 DIA. ELECT .
2) AS A RULE OF THUMB , FOR A 4 MM ELECT THE WELDING TIME FOR ONE ELECT SHOULD BE APPROXIMATELY 1
MIN AND THE LENGTH OF WELD SHOULD BE APPROXIMATELY SAME AS THE LENGTH OF THE ELECT
CONSUMED . THIS WOULD PRODUCE A TRAVEL SPEED OF APP .
TO JOINT PREPARATION AND EXACT WELDING CONDITIONS .
62
12/MIN, BUT THIS IS EXTREMELY SENSITIVE

3) NO. OF PASSES REQUIRED ,
PIPE WT ( MM )
NO. OF PASSES (WITH 4 MM DIA . OF ELECT .)
7.9
9.5
12.7
4
5
7
4) RECOMMENDED JOINT DESIGN AS PER API 1104,

DOWNHILL WELDING ,
UPHILL WELDING ,
TEJAS ROOWALA
63

LIST OF STANDARDS USED DURING WELDING INSPECTION
INTERNATION STANDARDS:
ASME SECT. IX
ASME SECT. II (PART C)
ASME SECT. V
API 5L
API 1104
ASME B 31.1
ASME B 31.2
ASME B 31.3
ASME B 31.4
ASME B 31.5
ASME B 31.8
ASME B 16.5
API 598
WELDING AND BRAZING QUALIFICATION

FILLER MATERIAL SPECIFICATION
NON DESTRUCTIVE EXAMINATION
SPECIFICATION FOR LINE PIPE
WELDING REQUIREMENTS FOR PIPE LINE AND RELATED FACILITIES
POWER PIPING
FUEL GAS PIPING
PROCESS PIPING
PIPELINE TRANSPORTATION SYSTEM FOR LIQUID HYDROCARBON & OTHER LIQUIDS
REFRIGERATION PIPING
GAS TRANSMISSION PIPING
PIPE FLANGES AND FLANGE FITTINGS
HYDROSTATIC TEST FOR VALVE
SAUDI ARAMCO STANDARDS:

SAES-W-011
SAES-W-012
SAES-W-016
SAEP 323
SAEP 352
SAES-L-350
SAES-L-450
SAES-L-150
SAES-A-004
SAES-A-007
SAES-L-125
SAES-A-206
WELDING REQUIREMENTS FOR ON PLOT PIPING

WELDING REQUIREMENTS FOR PIPE LINES
WELDING REQUIREMENTS FOR CORROSION RESISTANCE MATERIALS
PERFORMANCE QUALIFICATION TESTING OF CONTRACT WELDERS AND BRAZERS
WELDING PROCEDURE REVIEW AND APPROVAL
CONSTRUCTION OF ON PLOT PIPING
CONSTRUCTION OF PIPE LINE
PRESSURE TEST FOR PIPING AND PIPELINES
GENERAL REQUIREMENTS FOR PRESSURE TESTING
PRESSURE TEST FLUID REQUIREMENTS AND LAY UP PROCEDURES
SAFETY INSTRUCTION SHEET
PMI
TEJAS ROOWALA
64

Handbook of Weld Inspection

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GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

GUIDE BOOK FOR

Digitally signed by TEJAS

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

per governing code B31.3, 31.4 or 31.8 and requirements of SAES-W-011/012/016.

per governing code B31.3, 31.4 or 31.8 and requirements of SAEP-321.

Maximum weld reinforcement/root penetration

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

Lack of penetration is not permitted.

No. & Type

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

All pressure containing welds shall be made with multiple pass.

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

V = vol. of pipe sect. to be purged, ft3

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

(V*I*60)/travel speed (cm/min)

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

An increase percentage of radiography is required if a higher percentage of radiographic coverage is

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

PMI (Positive Material Identification):

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

Welding of Special Corrosion Resistance Materials

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

STORAGE, CONDITIONING AND EXPOSURE OF CONSUMABLES

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

must be re dried once.

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

Welding Inspection Check list Points

Review of drawings & specifications.

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

min four equally spaced

In process welding inspection

1. Joint Preparation & Cleanliness

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

Post welding inspection

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

ACCEPTANCE CRITERIA FOR INSPECTION OF BARE LINE PIPES AS PER API 5L

Two basic levels of standard technical requirements for line pipes:

Exceeding 6.4 mm is defect

Not cause for rejection provided within:

a) depth0.4 mm acceptable any length

Not to exceed 0.2% length & 4 mm within 1m from pipe end

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

t15 mm: 1.5 mm

27 J at temp. 0C or lower & average shear area85% for each test

Qualification by API 5L or ASME IX

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

all tests as per given in inspection with same acceptance criteria

Advantages of ASME welder approval tests are:

GUIDE BOOK FOR PIPING/PIPE LINE WELDING INSPECTION

Group 1 up to approx 65 ksi

2 Sub Groups:- Typically 1/2Mo and 1/2Cr-1/2Mo

2 Sub Groups:- Typically 1Cr-1/2Mo and 1 1/4Cr-1/2Mo

3 Sub Groups:- Typically 5Cr-1/2Mo, 7Cr-1/2Mo & 9Cr-1Mo

(VI60)/travel speed (cm/min)