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Research

Qualification of welding procedures

for 16” dia line 24 Kms from Mari Gas
Field to V/A QV-2 Transmission Line
and Health disorder related to
welding trade.
Chaudhry Muhammad Akram
Roll No. 2K17-MChe-16

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List of Contents
• Introduction
• Literature Review
• Problem Statement
• Objectives
• Proposed Methodology
• Conclusions
• Q&A

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 Introduction
What is Welding?
• Joining of metals by heating them to their welding temperature (melting
point),with or without the application of pressure and with or without the
use of filler metal.
• Welding is a common process for joining metals using a large variety of
applications.
• Welding is basic and fundamental key in pipeline manufacturing and
assembling.
• Even a minor defect in the manufacturing of pipes can lead to major
failures and other issues.
• The construction of the pipeline involves joining sections of spiral or line
welded pipes with circumferential welds with the help of SMAW, GMAW
and FCAW techniques.
• SAW is preferred technique during line pipe fabrication, whereas
SMAW,GMAW or FCAW techniques are usedin the field.
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• New welding techniques have been developed in the past decade to
address forlong pipeline construction projects.
• A weld is a homogeneous bond between two or more pieces of metal,
where the strength of the welded joint exceeds the strength of the base
pieces of metal.
• Welding involves the use of four components: the metals, a heat source,
filler metal, and some kind of shield from the air. The metals are heated
to their melting point while being shielded from the air, and then a filler
metal is added to the heated area to produce a single piece of metal. It
can be performed with or without filler metal and with or without
pressure.
• Welders are exposed to fumes containing different gases and or at risk
of various respiratory signs and symptoms , including metal fume fever,
bronchial asthma, chronic lungs disease, and other pulmonary fibrosis
(chronic beryllium disease, cobalt lung), and lung cancer.

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Project background

• Welding is performed with some international codes /

standard.
• AWS (American Welding Society) .
• API (American Petroleum Institute).
• ASME (American Society of Mechanical Engineering).
• JIS (Japanese Industrial standard).
• BS (British Standard).

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SNGPL follows the international code API 1104 for welding the pipe
line.Welding Procedure specification required for Construction of
pipeline 16” X 24 KM from Mari Gas Field to Valve
Assembly for Fatima Fertilizer. Different pipe grades and different wall
thickness were used for construction of gas pipeline.
• X-46 Wall Thickness 17.65 mm.
• X-46 Wall Thickness 12.95 mm.
• X-70 Wall Thickness 8.74 mm.
• X-70 Wall Thickness 7.92 mm.
• A 106 Grade B Wall Thickness 21 mm.
We have to establish welding procedures under listed.
• Procedure A for Mainline.
• Procedure B for Tiein / Crossings.
• Procedure C for Repairs.
• Procedure D for Fabrication.

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Problem Statement
• To check the weldability of different pipe grades.
• Construction of pipeline with different wall
thickness.
• Welding the pipes with dissimilar pipe grade.
• Fabrication of valve assembly with different pipe
grade.
• Overcome welding defects.
• Overcome heath disordeness of welding related
personals.

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Objectives
• Before production welding is started a detailed
procedure specification shall be established, to verify
compatibility of materials and techniques.
• To produce a sound weld with acceptable mechanical
properties.
• Quality of welds should be determined by destructive
testing. (Tensile Strength), ductility & hardness.
• To prepare WPS for different grade line pipes to
overcome.
• All joints are required to be uniform.
• To achieve high quality and defect free as possible.
• Welding defects
• Heath disorder related to shielded metal arc welding.
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Scope of Study
 Understanding the application for which the
WPS will be used.
 Develop welding procedure.
 Testing of weld coupon.
 Write the WPS.
 Flaws of welding in SMAW.

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Methodology
Things to know prior to qualifying a welding
procedure.
• What welding procedure are going to be used
during construction.
• What material are going to be used during.
construction.
• Types of Grades.
• Thickness of each material.
• Dissimilar metal.
Welding Variable:
• Essential Variable.
• Non Essential Variable.
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Essential Variable:
A change in welding condition, which will affect the
mechanical properties of the weldment e.g.
a. change in base material.
b. Welding process.
c. Filler metal.
d. Electrode, preheat & post heat treatment.
Non Essential Variable:
A change in a welding condition which will not affect the
mechanical Properties of a weld metal
a. Joint Design.
b. Cleaning Method.

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WPS
The purpose of WPS & PQR is to determine that the weldment
proposed for construction is capable of providing the required
properties for its application.
•Procedure qualification record:
PQR is a document in which the actual welding condition are used
to produce an acceptable test coupon joint.
•Diameter & Wall Thickness:
The ranges of out side climate and wall thickness shall be identified.
•Joint design:
The specification shall include a sketch of joint to show the bevel
angle, size of root face, root gap.

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•Filler metal and No. of Beads:
Size of filler metal its classification and sequence of beads shall be
designated.
•Electrical characteristic:
Range of current & voltage for each electrode shall be shown.
•Position:
Specification shall contains roll or position welding.
•Direction of welding:
The specification shall contain whether the welding is to be performed in
up hill or down hill direction.
•Time between passes:
The maximum time between the completion of the root beads & start up
of 2nd beads.

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•Change in Process:
a) pipe Grade
b) <42000 PSI SNYS.
c) > 42000 PSI but < 65000 PSI.
d) > 65000 PSI separate test for each Grade.
• Traveling Speed
• Filler metal Grade.

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Reference: API Standard 1104, 5.2

PROCEDURE SPECIFICATION NO.

For Welding of Pipe and fitting

Process
Material
Diameter and wall thickness
Joint design
Filler metal and no. of beads
Electrical or flam characteristics
Position
Direction of welding
No. of welders
Time lapse between passes
Type and removal of lineup clamp
Cleaning and/or grinding
Preheat/stress relief
Shielding gas and flow rate
Shielding flux
Speed of travel
Plasma gas composition Plasma gas flow rate
Plasma gas orifice size
Sketches and
tabulations attached

Tested Welder
Approved Welding Supervisor
Adopted Chief engineer
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Note: Dimensions are for example only

ELECTRODE SIZE AND NUMBER OF BEADS

Bead Number Electrode Size Voltage Amperage Speed
and Type and Polarity
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Welding Machines / Plants

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Welding Structure
Groove Face

Root Face
Welding Structure

Groove Angle
60 – 70O

Bevel Angle Bevel Angle

30 – 35O 30 – 35O

Root Gap – Root Opening

Welding Structure

Root Penetration
Welding Structure
Site Beveling Machine – Gas Cutting Operation
Welding Consumables
Electrodes

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Testing of Welds

Destructive Testing
Non Destructive Testing

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Testing of Welds

Destructive Testing
Tensile Test
Nick Break Test
Root Bend Test
Face Bend Test
Side Bend Test

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Testing of Welds

Non–Destructive Testing
Visual Testing
Radiography / Fluoroscopy / X-Ray Testing
Ultrasonic Testing
Dye Penetrant Testing
Magnetic Particle Testing

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Testing of Welds

Non–Destructive Testing
Visual Testing

Direct Visual Testing / Inspection

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Testing of Welds

Non–Destructive Testing
Ultrasonic Testing

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Testing of Welds

Non–Destructive Testing
Dye Penetrant Testing – Liquid Penetrant Testing

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Welding Defects

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Welding Defects
Cracks

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Welding Defects
Porosity

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Welding Defects
Cluster Porosity

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Welding Defects
Surface Undercut

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Welding Defects
Internal / Root Undercut

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Welding Defects
Inadequate Reinforcement

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Welding Defects
Excess Reinforcement

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Welding Defects
Lack of Fusion

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Welding Defects
Offset / Mismatch / Lack of Penetration due to high
low

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Welding Defects
Inter pass Cold Lap

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Welding Defects
Slag Inclusion

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