11 Pipe to Flang Higher Thickness Pipe.partial Wall Repair

INDCON PROJECTS & EQUIPMENT LTD. WORK PROCEDURE FOR WELDING OF PROCESS PIPING {PIPE TO FLANGE/WELDOLET/FITTINGS/IF/VALVES/HIGHER THICKNESS PIPE.} (PARTIAL WALL REPAIRS.)

PROJECT

: Panipat-Jalandhar LP Gas Pipeline Project

PROCEDURE NO

: INDCON-PJPL-STN-EC!-"PS-##

O"NER

: Indian Oil Corporation Corpora tion Li$ited% NRPL- P&NIP& P&NIP&T T

CONTR&CTOR

: Indcon Projects ' E()ip$ent Ltd*

Date: 12th Nov. 2007

++

#,*##*+

Re0* No

Date

S).$itted /or appro0al description

&jit

&$it

Prepared Chec3ed  .2  .2

GS1 &ppro0ed  .2

&ppro0ed .2 IOCL

Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12110!, P"#e 1 o$ 11

INDEX Sl. No.

De!"#$t#o%

Pae No.

1

Pur%o&e

0'

2

Sco%e

0'

'

Re$ere(ce&

0'

)

L*&t o$ E+u*%e(t&

0'



Pre%"r"t*o( o$ P*%e "(d oter /*tt*(#&

0'  0)



Metodoo#3  WPS P4R 4u"*$*c"t*o(

0)

!

P"rt*" 5" re%"*r  

0

6

Metod $or 5ed*(# o$ P"rt*" 5" re%"*r

0

7

He"t, S"$et3 8 E(v*ro(e(t

0

10

4u"*t3 9&&ur"(ce 8 4u"*t3 Co(tro

0

11

Docue(t"t*o(

0

12

I(&%ect*o( te&t P"(

0!

1'

Wed*(# Procedure S%ec*$*c"t*o( WPS;

06  07

1)

Procedure 4u"*$*c"t*o( Record P4R;

10  11

Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12110!, P"#e 2 o$ 11

INDCON PROJECTS & EQUIPMENT LTD. P"o!e'("e )o" 

WELDING OF PROCESS PIPING *PIPE TO +L,N-E/ELDOLET+ITTIN-SI+,LESI-ER TICNESS PIPE3 4P,RTI,L /,LL REP,IRS.5 P"o6e!t: Pa%#$atJala%'ha" LP -a P#$el#%e P"o6e!t 1.0

2.0

8.0

PURPOSE T*& %rocedure de&cr*"& P*%e*(e Pro?ect. RE+ERENCES /oo5*(# docue(t& *( tot"*t3 or *( %"rt &" $or te re$ere(ce docue(t&:

#* IOCL S%ec*$*c"t*o( ,*  9SME Sec- I4 - 4u"*$*c"t*o( St"(d"rd $or Wed*(# Procedure L"te&t ed*t*o(; 9.0

LIST O+ EQUIPMENTS /oo5*(# e+u*%e(t&*(&true(t& "re to
a*

Wed*(# M"c*(e.

 .*

>r*(d*(# M"c*(e.

c*

@u$$*(# M"c*(e.

d*

To(# te&ter.

e*

Sto% 5"tc

.0

PREPR,TION O+ PIPE & OTER +ITTIN-S

 9.

Te
@.

9(3 $ore*#( "tter or o<&truct*o( re"*(*(# *(&*de te %*%e &"
C.

/"
D.

Wed-o-et& &"
Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12110!, P"#e ' o$ 11

INDCON PROJECTS & EQUIPMENT LTD. P"o!e'("e )o" 

WELDING OF PROCESS PIPING *PIPE TO +L,N-E/ELDOLET+ITTIN-SI+,LESI-ER TICNESS PIPE3 4P,RTI,L /,LL REP,IRS.5 P"o6e!t: Pa%#$atJala%'ha" LP -a P#$el#%e P"o6e!t E.

Cou%*(# "(d "$ cou%*(# &"
/.

P*%e& &"
H.

S" t"c= 5ed& *.e.
I.

P*%e& 5*t " 5" t*c=(e&& o$ B  ; "(d #re"ter &" (ot "ve *(ter(" *&"*#(e(t o$ %*%e 5" eceed*(# 11B 1. ;.

J.

P*%e& 5*t " 5" t*c=(e&& o$ B  ; "(d #re"ter &" (ot "ve *(ter(" *&"*#(e(t o$ %*%e 5" eceed*(# 2 o$ %*%e 5" t*c=(e&&.

.

We( te *&"*#(e(t *& #re"ter t"( te "
;.0

METODOLO-< = /PS PQR QU,LI+IC,TION

 9.

/*r&t te Weder& 5* %o&*t*o(.

@. C. D.

E. /.

Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12110!, P"#e ) o$ 11

INDCON PROJECTS & EQUIPMENT LTD. P"o!e'("e )o" 

WELDING OF PROCESS PIPING *PIPE TO +L,N-E/ELDOLET+ITTIN-SI+,LESI-ER TICNESS PIPE3 4P,RTI,L /,LL REP,IRS.5 P"o6e!t: Pa%#$atJala%'ha" LP -a P#$el#%e P"o6e!t 7.0

Pa"t#al /all Re$a#"  E"c "3er 5* roove "(d ce"( " &ur$"ce&. Te *(*u e(#t o$ " re%"*red "re" &"
>.0

METOD +OR /ELDIN- O+ P,RTI,L /,LL REP,IR 4P#$e to )la%e/el'olet)#tt#%#)valveh#he" th#!?%e $#$e5

 9.

Wed-o-et&, $"(#e&, $*tt*(#& 8 v"ve& &"
E.

9$ter "*#(e(t 8 $*t  u%, %re  e"t*(# &"
/.

E"rt*(# c"%& u&ed $or 5ed*(# retur( c*rcu*t &" o(3
>.

9$ter co%et*(# ever3 %"&&, te &"e &"
H.

9& %er "%%roved WPS "(d P4R, $or re%"*r o$ 5ed, "$ter *de(t*$3*(# te de$ect&. C"re &"
I.

Weder& &"
J.

9$ter co%et*o( o$ 5ed*(# v*&u" *(&%ect*o( &"
Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12110!, P"#e  o$ 11

INDCON PROJECTS & EQUIPMENT LTD. P"o!e'("e )o" 

WELDING OF PROCESS PIPING *PIPE TO +L,N-E/ELDOLET+ITTIN-SI+,LESI-ER TICNESS PIPE3 4P,RTI,L /,LL REP,IRS.5 P"o6e!t: Pa%#$atJala%'ha" LP -a P#$el#%e P"o6e!t @.  9. @. C.

10.

E,LTA S,+ET< ,ND ENIRONMENT T*& *& "( e(v*ro(e(t $r*e(d3 %ro?ect. /oo5*(# &"$et3 %o*(t& &"
QU,LIT< ,SSUR,NCE & QU,LIT< CONTROL: 4u"*t3 9&&ur"(ce &"
11.

DOCUMENT,TION

-

I(&%ect*o( Te&t P"( "eldin5 Proced)re Speci/ication Proced)re 6)ali/ication Record

Note: I( c"&e o$ co($*ct
Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12110!, P"#e  o$ 11

INSPECTION TEST PL,N WELDING OF PROCESS PIPING

*PIPE TO +L,N-E/ELDOLET+ITTIN-SI+,LESI-ER TICNESS PIPE3 4P,RTI,L /,LL REP,IRS.5 : I(d*"( O* Cor%or"t*o(& td. /or"t No: INDCON-PJPL-STN-EC!-"PS-##

C*e(t

Co(tr"ctor: Indcon Projects ' E()ip$ents Ltd*

Rev*&*o( : 00

Pro?ect

D"te: 0t Nov. 200!

: P"(*%"t J""(d"r LP >"& P*%e*(e Pro?ect&

S. No

9ct*v*t3 De&cr*%t*o(

/re+ue(c3 o$ I(&%.Te&t*(#

1

Su<*&&*o( "(d o
I(&%ect*o( c"te#or3 INDCON

IOCL

 9t te @e#*((*(#

P

9P

2

Pre e"t*(#, /*er 8 /*(" Wed*(#

100 Dur*(# 4u"*$*c"t*o( Proce&&

P

R

'

Wed *&u" o$ Co%eted 5ed

100 Dur*(# 4u"*$*c"t*o( Proce&&

P

R

)

L*+u*d D3e Pe(etr"t*o( Te&t o$ Wed

100 Dur*(# 4u"*$*c"t*o( Proce&&

P

R



9%%rov" o$ WPS

O(ce %r*or to &t"rt o$ 5ed*(# %roce&&

P

R



S"$et3

Trou#out

P

P

Lee%' P

: Per$or ,

RM : R"(do, W

R

: Rev*e5 Docue(t& ,

9P : 9%%rov",

: W*t(e&&,

+o" I%'!o% P"o6e!t & EB(#$e%t Lt'.

+o" IOCL

N"e: S*#(:

N"e:

D"te:

D"te:

S*#(:

Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12110!, P"#e ! o$ 11

/ELDIN- PROCEDURE SPECI+IC,TIONS 4/PS5 4See Q/200.1A Se!t#o%: IXA ,SME o#le" & P"e("e eel Co'e5

Co%"(3 ("e Wed*(# Procedure Wed*(# P4R No. Wed*(# Proce&&

I(dco( Pro?ect& 8 E+u*%e(t Ltd. WPS-11 Rev*&*o( : 0 P4R-11 Rev*&*o( : 0 >T9W  SM9W T3%e : M"(u"

/or"t No.: INDCON-PJPL-STN-MECH-W PS-11 D"ted : 12.11.200! D"ted - 12.11.200!

JOINT 4Q/9025 Jo*(t De&*#( : 9& %er $"
,SE MET,LS 4Q/9085 P. No. 1 >rou% No. : S%ec*$*c"t*o( t3%e "(d #r"de T*c=(e&& r"(#e: -@"&e et" P*%e D*". R"(#e Tt L**t&  6B P No. 710

JOINT DET9IL  9& Per /"
9(3

TO S9 10 >r. @

P No.: 1

>roove : 1.  to 1!.)6 >roove 9 Not "%%*c"<e Not "%%*c"<e

+ILLER MET,LS 4Q/9095   S%ec. No. S/9;  9WS No. C"&&; / - No.  9  No. S*e o$ /*er Met"& D*"; WELD MET9L: T*c=(e&& r"(#e: >roove /*et Co(&u"<e *(&ert

>T9W

>rou% No. : 9(3

/*et : 9

SM9W .1 E!016 8) 1 2., '.1 

9 &*e& No(e

POSITIONS 4Q/ = 905 Po&*t*o( &; o$ >roove Wed*(# %ro#re&&*o( Po&*t*o( o$ /*et

9 G% * 9

PREE,T 4Q/ = 90;5 Pree"t te%. M*(. I(ter%"&& te%. M". Pree"t "*(te("(ce

1 C *( 20 C Not Re+u*red

POST /ELD E,T TRE,TMENT 4/Q9075 Te%er"ture r"(#e N9 T*e r"(#e N9

-,S 4Q/ = 90>5

S*ed*(# Tr"**(# @"c=*(#

Perce(t Co%o&*t*o( >"& M*ture 9r#o( 77.7  %ur*t3 No(e -No(e --

/o5 r"te 10-20 LPM ---

Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12110!, P"#e 6 o$ 11

ELECTRIC9L CH9R9CTERISTICS 4W  )07; Curre(t  9%& r"(#e Tu(#&te( eectrode &*e 8 t3%e Mode o$ et" tr"(&$er $or >M9W Eectrode 5*re $eed &%eed r"(#e Pu&*(#

DC See t"<e

Po"r*t3 ot& ' , EWTH-2 Not "%%*c"<e Not "%%*c"<e No(e

WPS - 11 D"ted : 12.11.200! EN $or >T9W, EP $or SM9W See t"<e

TECHNI4GE 4W  )10; Str*(# OR 5e"ve
Str*(# 8 5e"ve  '  Core D*". M"; -6  @ru&*(# 8 #r*(d*(# >r*(d*(# No(e

Eectrode &%"c*(# Mut*%e or &*(#e %"&& %er &*de; Mut*%e or &*(#e eectrode& Tr"ve &%eed r"(#e; Wed- L"3er& Proce&& /ILLER MET9L

1&t ru( 2(d ru( 8 Su<&e+ue(t ru(&

SM9W SM9W

Pe")o"e' F

C"&&

D*".

ER-!016 ER-!016

2.  2. 

Not "%%*c"<e Mut*%e. No &*(#e %"&& *& #re"ter t"( 1' ; Not "%%*c"<e M"(u"; Re$er t"<e CGRRENT ot Tr"ve He"t *(%ut r"(#e &%eed J r"(#e  M" ;  M*(; T3%e  9%. %o"r*t3 R"(#e DCEP DCEP

Che!?e' F

,$$"ove' F

Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12110!, P"#e 7 o$ 11

PROCEDGRE 4G9LI/IC9TION RECORD P4R; See 4W 200.2, Sect*o( IQ, 9SME @o*er "(d Pre&&ure e&&e Code;

Co$a%F Nae: I(dco( Pro?ect& 8 E+u*%e(t L**ted P"o!e'("e Q(al#)#!at#o% Re!o"' No. P4R 11 /PS No. WPS 11 /el'#% P"o!e >T9W  SM9W TF$e O) /el'#% P"o!e M"(u"

+o"at No.: INDCON-PJPL-STN-MECH-P4R-11 Date' 12.11.200! Date' 12.11.200!

JOINTS 4 Q/ = 902 5

JOINT DET9IL  9& Per /"
,SE MET,LS 4Q/9085 Mate"#al S$e!. S9 10 TF$e o" "a'e >r. @ P No. 1 To Th#!?%e o) Tet Co($o% D#aete" o) Tet Co($o% +ILLER MET,LS 4Q/ =9095

P No.

POST /ELD E,T TRE,TMENT 4Q/9075 Te$e"at("e T#e Othe"

1

  

-,S 4Q/ = 90> 5 -T,/

S+, S$e!#)#!at#o% ,/S Cla#)#!at#o% +#lle" Metal + No. /el' Metal ,%alF# , No. S#e O) +#lle" Metal Othe" 4Ele!t"o'e t"a'e %ae5 /el' Metal Th#!?%e POSITION 4Q/ = 90 5 Po#t#o% o) -"oove /el' P"o"e#o% Othe"

SM,/ .1 E-!016 ) 1 2. MM

Sh#el'#% T"a#l#% a!?#%

+OR -T,/ ONL<

Pe"!e%t Co$o#t#o% -a M#Gt("e

+loH "ate

,R-ON  

10-20 LPM  

77.7  

ELECTRIC,L C,R,CTERISTICS 4Q/ = 90@5 > G%* 

PREE,T 4 Q/ = 90; 5 Pree"t Te%er"ture M*(.;

1  C

I(ter %"&& Te%er"ture Oter

20 C -

C(""e%t DC Pola"#tF EN $or >T9W, EP-SM9W 60  10 ,$ olt 10-2) T(%te% Ele!t"o'e S#e '.00  EW TH-2 Othe"  TECNIQUE 4 Q/ = 910 5 Tr"ve S%eed Str*(# or We"ve @e"d O&c*"t*o( Mut* %"&& or S*(#e %"&& %er &*de; S*(#e or Mut*%e Eectrode& Oter

0  70   M*(. Root &tr*(#, <""(ce 5e"ve Not "%%*c"<e. Mut*%e. No &*(#e %"&& *& #re"ter t"( 1'  N9 M"(u"; -

Procedure No: INDCON-PJPL-STN-MECH-WPS-10 Rev No: 0, Dt. 12110!, P"#e 11 o$ 11

TENSILE TEST 4Q/ = 10 5 S$e!#e% No.

/#'th 4  5

Th#!?%e 4  5

,"ea 4   5

Ult#ate Total Loa' 4NeHto%5

Ult#ate Te%#le St"e%th 4MPa5

PQR NO. 11 Date :12.11.2007 TF$e o) +a#l("e & Lo!at#o%

T1 T2

-UIDED = END TESTS 4Q/ = 1;0 5 TF$e a%' +#("e No. Root e%' R 1A Q/ =9;2.8a Root e%' R 2A Q/ =9;2.8a +a!e e%' + 1A Q/ =9;2.8a +a!e e%' + 2A Q/ =9;2.8a 4e%' '#a 9 t G 1>0 K C5

Re(lt

TOU-NESS TESTS 4 Q/ = 170 5 S$e!#e% No.

Not!h Lo!at#o%

S$e!#e% S#e

Tet Te$.

I$a!t al(e Jo(le

1 2 Coe(t& :

e&

-

N, No

Ma!"o Re(lt OTER TESTS TF$e o) Tet

M#l

N9

+ILLET = /ELD TESTS 4 Q/ = 1>0 5 Re(lt Sat#)a!to"F

Shea"

TF$e o) +a#l("e & Lo!at#o%

-

Pe%et"at#o% #%to Pa"e%t Metal

e&

-

No

-

N9

Ra'#o"a$hF = #(al #%$e!t#o% 

/el'e" Nae Tet Co%'(!te' F

Clo!? No.

 Sta$ No. Lao"ato"F Tet Re$o"t No.:

We cert*$3 t"t te &t"tee(t *( t*& record "re correct "(d t"t te te&t 5ed& 5ere %re%"red, 5eded, "(d te&ted *( "ccord"(ce 5*t te re+u*ree(t& o$ Sect*o( IQ o$ te 9SME @o*er 8 Pre&&ure e&&e Code.

Ma%()a!t("e": INDCON PROJECTS & EQUIPMENT LTD.

E,D QC E,D /ELDIN-

INSPECTION ,-ENC<

Procedure No: INDCON-PJPL-STN-MECH-WPS-11 Rev No: 0, Dt. 12110!, P"#e 11 o$ 11

/ELDIN- PROCEDURE SPECI+IC,TION  11 P,RTI,L /,LL REP,IR C*e(t

: I(d*"( O* Cor%or"t*o(& td.

Procedure No: INDCON-PJPL-STN-EC!-"PS-##

Co(tr"ctor: Indcon Projects ' E()ip$ents Ltd*

Rev*&*o( : 00

Pro?ect

D"te: 12 t Nov. 200!

: P"(*%"t J""(d"r LP >"& P*%e*(e Pro?ect&

+o" )#el' Hel'#% o) P#$e Proce&& T3%e M"ter*" Outer D*"eter P*%e W" T*c=(e&&  9%%*c"<e S%ec*$*c"t*o(

Jo#%t 'e#%:

: : : : : :

SM9W M"(u". 9 10 >r. @ 06B D*" 6.1!  L"te&t rev*&*o(

, ShoH% #% the S?et!h SETC SO/IN- JOINT DESI-N +OR 0> DI, PIPE = ,10; -". Wed*(# %rocedure &%ec*$*c"t*o( INDCON-PJPL-STN-MECH-WPS-10; P9RTI9L W9LL REP9IR

T  W" T*c=

06B DI9 &ppro8 ,*9 -  $$

M,XIMUM EXTERN,L OPENIN#*7+ to ,*++ $$ 9 ; 

T

, #

&ppro8 ,*9 -  $$

SEQUENCE O+ E,DS T /all Th#!?%e >.17 

/ELDIN- PROCEDURE SPECI+IC,TION  11 P,RTI,L /,LL REP,IR C*e(t : I(d*"( O* Cor%or"t*o(& td. Co(tr"ctor: Indcon Projects ' E()ip$ents Ltd* Pro?ect : P"(*%"t J""(d"r LP >"& P*%e*(e Pro?ect&

/or"t No: INDCON-PJPL-STN-EC!-"PS-## Rev*&*o( : 00 D"te: 12t Nov. 200!

+#lle" Mate"#al: R(%

Ma?e & TF$e o) +#lle" Metal

/*r&t Ru( HON99R ER !016-1SPL; Oter& Ru(& HON99R ER !016-1SPL; Oter Eectr*c" C"r"cter*&t*c& : DC Eectrode : EP S*ed*(# >"& : N.9 D*rect*o( Wed*(#

C(""e%t TF$e Pola" ,$. Ra%e 2.  EP -'.1  EP -T3%e o$ M*ture : N.9 Po&*t*o( :> D#aete"  

oltae ---

N(e" o) /el'e" Root : O(e /*r&t P"&&: G% H* Seco(d : O(e  9 oter& P"&&e& G% H*  9 oter Ru(& : O(e T*e L"%&e @et5ee( co%et*o( o$ root "(d coe(cee(t o$ &eco(d ru(& : ) M*(ute& M"*u; T*e L"%&e
L"3er  P"&&

/*er Met" Proce&&

 9WS C"&&

@r"(d N"e

D*" MM;

Po"r*t3 DC9C

O(e He"t C3ce

@3 >r*(d*(#  Po5er @ru&*(# Po&t Wed e"t tre"te(t : N.9 S%eed o$ Tr"ve : 0  70   *( Curre(t R"(#e ot&;

+o" INDCON

N"e: S*#(: D"te:

S%eed MMMM M*(*u;

D*rect*o( o$  Wed*(#

No o$  Weder&

+o" IOCL

N"e: S*#(: D"te:

No o$  Eectrode&

Re"r=&