Project-overview

IOCL VGM Spurline project , a venture in its pride to escalate

technology in the Oil business to the next shift making CAIRN
Energy India Ltd.
L&T`s construction contract for this project valued over Rs.10 Cr,
where, both Pipeline & Piping activities included, Launcher in VGM
Terminal and Receiver at IOCL Terminal.
Project Pipeline spans for over 2.5km, bridging Cairn and IOCL
terminal; Piping scopes over 2200inch-dia with 5 packages.
This Projects construction with elevated measures in Safety, Quality
& Stringent accomplishments with sophistication in each level of this
execution.
A Paramount in its possession, scope consists of Procurement,
Fabrication, Construction, Installation, Pre-commissioning, Testing,
Commissioning and Performance test run.
 ROLLER COASTER RIDE ACCIDENT
One of the theories was due to the failure of a weld (car onto rolling
member). This speeds up more than 80kmph. It is reported that an
average of 900 fatalities are reported each year in spite of constant
inspection and most of theories were fatigue weld failures.
 LEARNER INDUCTION PROGRAM
• Welders are to be taught about the WPS, explained to depths in the
manner he understands;
• To ensure that he practices surface preparation;
• Fit-up checks like high-low, vertical/horizontal alignment and to re-
ensure that he abides welding by the approved WPS;
• Qualified Filler wire/Electrode to be made to use and their storage
conditions to be checked;
• Use of Owen for Low Hydrogen Electrodes(E-7018) and their effect on
the weldments.
• Effect of Pre-heating & Stress Relieving on the weldments are to be
defined in detail.
• Forbid multiple Fit-ups;
• Restrict Support tack-welds (over parent material) to a minimum;
• All welders must bear their ID`s on site.
Welding Procedure Specification
This directs the welder/welding operator
to weld by the rules/parameters as per
the code requirements

ESSENTIAL VARIABLES
These variables are a must during
execution and subject to changes/re-
qualification of WPS/PQR, when these
variables are changed. All that derive
changes in the mechanical property are
essential variables listed in the PQR

SUPPLEMENTARY VARIABLES
These are variables that are termed with
specificity of their requirement, any
change in the variables will summon for
re-qualification/re-certification of the
WPS/PQR

NON-ESSENTIAL VARIABLES
Variables can be changed without re-
qualifying the WPS
 P number
Assigned based on the BASE metal
characteristics towards Weldability,
Composition & Mechanical properties;

G number
Applied for steel & steel alloys that
belong to a group of P-numbers for the
purpose of procedure qualification,
where, notch toughness requirements
are specified and metallurgical
compatibilities should be considered;

F number
Applied for grouping of electrodes
based on their usability characteristics;
Grouping done to reduce voluminous
WPS/PQR and metallurgical
compatibilities should be
considered;
WELDING POSITIONS
 ELECTRODE CLASSIFICATION
CLASSIFICATION CURRENT ARC/PENETRATION ELECTRODE COATING
E XXX0 DCEP DIGGING/DEEP CELLULOSE - Na

E XXX1 AC/DCEP DIGGING/DEEP CELLULOSE - K

E XXX2 AC/DCEN MEDIUM/SHALLOW RUTILE – Ti & Na

E XXX3 AC/DCEN/DCEP SOFT/SHALLOW RUTILE – Ti & K

E XXX4 AC/DCEN/DCEP SOFT/SHALLOW RUTILE – Ti & Fe powder

E XXX5 DCEP MEDIUM/SHALLOW BASIC – LOW H2 - Na

E XXX6 AC/DCEP MEDIUM/SHALLOW BASIC – LOW H2 - K

E XXX7 AC/DCEN/DCEP MEDIUM/SHALLOW IRON OXIDE - Fe powder

E XXX8 AC/DCEP MEDIUM/SHALLOW BASIC – LOW H2 - Fe powder

E XXX9 AC/DCEN/DCEP MEDIUM/SHALLOW RUTILE – IRON OXIDE- Fe powder

E (electrode) – 70 (x1000 psi Tensile Strength) 1 (Welding Position) 8 (Coating, Penetration & Current)
1 Flat, Horizontal, Vertical (up), Overhead
WELDING POSITION 2 Flat, Horizontal
4 Flat, Horizontal, Overhead, Vertical (down)
 WELDING ELECTRODES – A STUDY
۞ CELLULOSE RUTILE BASIC

MECHANICAL PROPERTY GOOD GOOD EXCELLENT

WELD-ABILITY &
EASY & DEEP MEDIUM & SHALLOW DIFFICULT & MODERATE
PENETRATION
LIGHTER & EASIER,
STRONGER & HARDER, MORE LIGHTER & EASIER, LESS
ARC-STABILITY REDUCED SPATTER, DROP-
SPATTERS, SPRAY-FORM SPATTER, SPRAY-FORM
FORM
THICK & HYGROSCOPIC
COATING THICKNESS THIN / MEDIUM MEDIUM
(BAKING NECESSARY)

MEDIUM DUE TO STRONGER

DE-SLAGGING EASY DIFFICULT-MORE VISCOUS
ARC INTENSITY

WELDING POSITION & DEEP-PENETRATION AT ALL VERY GOOD AT VERTICAL- FLAT, HORIZONTAL &
ANGLE POSITIONS & 45° to 60° DOWN & 45° to 60° VERTICAL-UP & 75° to 90°

WELD METAL DEPOSITION 85% 65% 115%

DC(-) & DC(+) for SHALLOW & DC preferred for continuous

PARAMETERS AC / DC
DEEP PENETRATION ARC-STABILITY
ARC WELDING - SAFETY CONCERNS
• Rays from Arc-Welding ranges from 2500°C to 6500°C, hence,
direct eye-view would cause corneal aberration, IR heating- causing
distortion of cartilaginous lens;
• Sparks and molten spatters impinge on the skin with high velocity-
causing burns & fire hazard;
Electrical Hazards In-sufficient safety-wears-gloves, goggles, shoes,
un-insulated / damaged holders, bare live cables and proper earthing
with soil conductivity is also a factor;
Fumes Confined areas, electrode certification through OSHAS/other
safety standards are a must, as toxicity is a major issue;
• Equipment operation familiarity is a concern & Safety is a priority
measure; Use of Flash-back arrestors & tarpaulin overs which are
not fire-proof;
• Site Management-evaluating working / conditions of clothing and
different areas of work-nature, Usage of safety-wears in the right
manner; committing to provide thoughts to the fellow workers.
1. Make sure machine is properly grounded (earth-ing);
2. Never permit “live electric parts” to touch bare skin;
3. Do not cool electrode holders by immersing in water;
4. Turn off power supply when welder is not in use;
5. Do not stand on wet areas while welding;
6. Wear leather gloves;
7. Make sure that cables are not open-striped off making the inner bare
wire naked;
8. Make certain that electrode holders are properly insulated;
1. Protect eyes and face from flying particles of slag by use of safety
glasses or face shield.
2. Wear adequate protective clothing.
3. Always wear leather gloves.
4. Wear high top shoes.
5. Keep collar, shirt pockets, etc buttoned.
6. Do not touch the electrode or metal where welding has taken place.
7. Handle hot metal with pliers or tongs.
8. Keep electrode stubs properly disposed of.
1. Use a welding helmet with the correct shade lens for each welding
process, in good condition.
2. Wear suitable clothing—do not leave bare skin exposed to the rays of
the arc.
3. Do not strike the arc without covering the face and eyes. Give
warning to others before striking the arc.
4. Avoid looking directly at the arc where others are welding without
proper eye protection.
5. If administered seeing the arc with the naked eyes, immediately wash
eyes with water.
1. Work only in well-ventilated, clean areas.
2. Use great care when working on metals covered with lead or zinc.
3. If working in a confined area use respirator or other approved
breathing devices.
4. In confined spaces, presence of toxic gases and ventilation for gases
during welding should be checked initially.
5. Necessary precautions to be taken when welding near combustible
materials of any kind.
6. Never weld on covered containers which may have held combustible
materials without first taking adequate safety precautions. For
example, fill them with water, steam clean or fill with an inert gas.
1. Be familiar with location and types of fire extinguishers.
2. Familiarity with the use of extinguishers;
3. Report any unsafe conditions that might start a fire.
4. Do not weld near inflammable materials.
5. Do not weld on containers that has/had inflammable materials.
6. Do not weld near electrical fittings or lines.
HEAT TREATMENT
 HEAT TREATMENT – an Introduction

• Pre-heating:
Localized heating of the parent
material on either sides of the joint above the
ambient temperature before welding.
• Post-heating:
Localized heating of the welded joint
and the HAZ.
 Pre-Heating
• Decreases rate of thermal conductivity;
• Decreases the cooling rate after welding,
thereby, susceptibility towards cracking &
martensitic transformation is meagre;
• Reduces stress across the weld-parent metal
interface, thus, reduces distortion;
• Reduces shrinkage and increases parent metal
surface wettability;
• Moisture evacuation;
• Usually, ranging between 10° C to 400° C.
 Pre-heat Temperature-Information
• Chiefly based on Carbon Equivalent values (Ceq) for carbon steels
dependent on the weight percentage of carbon presence.
Ceq = C + Mn /6 + (Cr + Mo + V) /5 + (Cu + Ni) /15
• Material thickness is a main factor to be considered in the evaluation
of heat-treatments. Material with Large thickness dissipates heat or
cools off sooner and Thinner materials tend to distort with large
linear/lateral variation and cools slowly as the volume for thermal
distribution is less.
• Upon pre-heating, hydrogen emissivity is increased, thereby,
reducing prone to Weld-metal, HAZ hydrogen cracking.
• A welded joint on a high thickness job cools off immediately, as the
volume more is large to conduct/dissipate heat through the material.
Therefore, pre-heating, will help the weld-puddle (molten weld
before solidification) to cool at a slower rate. Therefore, shrinkage is
minimized.
 MEDIUM CARBON & HIGH CARBON &
۞ MILD STEEL
ALLOYED STEEL ALLOYED STEEL

CARBON
EQUIVALENT Ceq < 0.4 0.4< Ceq <0.5 Ceq >0.5
Ceq
WELDABILITY EASY MEDIUM DIFFICULT

10°C for thickness <1in 150°C to 400°C as per

150°C to 180°C as per ASME B31.3 and
80°C for thickness >1in as
PRE-HEAT ASME B31.3 and 93°C
per ASME B31.3 and 204°C to 370°C
to 204°C by BS 5135
Optional by BS 5135 by BS 5135
USE OF LOW Optional for Thin
Conditional for all size-
HYDROGEN Optional for Thicker sections sections & Conditional
dimensions
ELECTRODES for thicker sections

POST-WELD Conditional for thicker Conditional for all size-

Optional for Thicker sections
HEATING sections at 1 hr/in dimensions at 2 hr/in

COOLING RATE AIR-COOLING SLOW VERY SLOW

HEAT
Not susceptible, if low Less susceptible, if Higher susceptibility.
AFFECTED
hydrogen electrodes are low hydrogen Mandatory use of Low
ZONE (HAZ)
used electrodes are used Hydrogen Electrodes
Cracking
 Post-weld Heat Treatment
• Post weld heat treatment (PWHT), defined as
any heat treatment after welding, is often used to
improve the properties of a weldment.
• This process is commonly referred to stress
relief, so called because it is carried out at
temperatures below the critical range of the
base metal, followed by uniform cooling.
• PWHT-Stress Relieving: decreases hardness,
increases ductility by decreasing yield strength
of the material.
 Post Weld Heat Treatment
• Relaxes residual stresses;
• Recovers cold work-deformations;
• Improves toughness;
• Tempering to the required levels (softening), as
in the case for Leaf springs used as suspensor
in heavy vehicles;
• Re-crystallization & Spherodization for special
purpose applications.
• PWHT to be done within 14 days from the day of
welding completion-as per ASME B31.3.
 HEAT COOLING MECHANICAL
PROCESS
TREATMENT RATE PROPERTIES

DUCTILITY ▲
Heated above UCT & soaked for
TOUGHNESS ▼
ANNEALING 1Hr for every 1in. SLOW STRENGTH ▼
Then, cooled in Furnace
COARSE GRAINED

SUB-CRITICAL or ONLY RESIDUAL STRESS

Heating around LCT (~635°C),
STRESS-RELIEF depending on the steel and locality SLOW RELIEVED; NO CHANGE IN
ANNEALING GRAIN STRUCTURE

DUCTILITY ▼
Heated above UCT & soaked for TOUGHNESS ▲
NORMALIZING 1Hr for every 1in. MEDIUM STRENGTH ▲
Then, cooled in Air FINE GRAINED

DUCTILITY ▲
Re-Heated(220°C to 723°C) to TOUGHNESS ▲
TEMPERING
(DRAWING)
convert the remaining Hardness into MEDIUM STRENGTH ▲
Toughness
FINE GRAINED

DUCTILITY ▼ HARDNESS ▲
Heated above UCT & soaked for TOUGHNESS ▼
HARDENING 1Hr for every 1in. RAPID STRENGTH ▲
Then, cooled in Quenching FINE GRAINED
 HEAT INPUT - INFORMATION
• Heat Input (H) is a relative measure of the amount of
Energy transferred during welding.
• Any change in values from the WPS will call for re-
qualification.
• Welding with High “Q” will weaken the HAZ due to its
high temperature & Slower cooling rate-coarser grain
structure.
• H = Power / Velocity of motion
during welding, Watt-sec/mm;
• One Joule = One Watt-sec;
• Cooling Rate is conversely
proportional to the Pre-heat
temperature and the Heat Input;
 If the HEAT-INPUT is large,
Reduced Tensile & Yield Strength
MECHANICAL Increased Ductility, Reduced Hardness
PROPERTIES Notch Toughness ↑ for 15<Heat Input>50 kJ/in for SMAW
Notch Toughness ↓ for 50<Heat Input>110 kJ/in for SMAW
Blow Hole, In-complete penetration, Porosity, Improper Bead
if S, ↑
size, Ir-regular weave profile
Complex & profuse melting of electrode, localized weld
if V A, ↑ lumps, reinforcement, under-cuts, pressurized-gouging arc,
weak HAZ, forced slag entrapment
Large & Weak-HAZ/oxidation of the parent material,
HAZ
precipitation in some steels
COOLING Lower cooling rate, Large metallurgical changes, Pre-heat
RATE required for some metals with low heat-input (faster cooling)
DISTORTION Depends on thickness & large variation-angular/linear
 Post Heating Method

• Flexible Ceramic Pads (FCP) heating

elements- desired temperature up to 1150ºC
• Burners
- Infrared gas burners - smaller
sized objects.
- Oil burners or High Velocity gas
burners- larger objects
 Heat Treatment Furnaces

• Temporary furnaces
• Permanent furnaces
• High temperature
furnaces
 BASIC FIT-UP REGULATIONS
• Inside cleaning, Surface Buff, Paint/stain & foreign material removal;
• Groove-design, Face-width, Bevel taper & Angle-made as per the
approved procedure;
• Check for the appropriate material & thickness in use;
• Material for tack-supports shall be the same as the parent material
made in use & be restricted to 4 at each 90° of 10mm max;
• Wedge/Bridge inserts tacked between the grooves are better
preferred & After welding, De-tacks shall not be hammered out;
• Suspended pipings/Sand-bag supports tend to deviate, hence, mitre
possibilities are to be checked & counter alignment has to be made;;
• RF pads shall be drilled for a hole before welding onto pipes;
• Use of machining wheels-GRINDING/CUTTING for appropriate
applications;
• Punching/Tracing shall be made out before welding;
 Improper BEVEL-ANGLE,
Insufficient GAP and
DIS-QUALIFIED Branch Fit-up
 UN-REGULATED GAP(7mm) /
MIS-MATCH FOUND, THIS
INVOLVES SUPPORT PIPE RE-
LENGTHING & WELDING
JOINT INVOLVING MORE THAN 4
FIT-UP SPOTS; PARENT METAL
ELECTRODE-STROKED; POOR
BEVEL & GROOVE DESIGN
 RESTRICT TACK WELDS TO A
MINIMUM & EACH SHOULD
CONTAIN STITCH WELDS/ DROPS
NOT TO EXCEED 10 mm
De-LINEAR ALIGNMENT
 IMPROPER BRANCH CUTS FOR
WELDING OF „OLETS – INNER
DIAMETER DOEST NOT MATCH THE
`OLET in FIG A; SQUARE CUTTING
BY GRINDING WHEEL
as in FIG B & C;
FLOW OBSTRUCTION & SHOCK
TURBULENCE MAY BE OBSERVED IN
DUE SERVICE
 `OLETS WELDED WITH
FLANGES BEFORE WELDING
ONTO PIPES; HIGH RATED
FLANGES ARE HEAVY, WOULD
POSE A MIS-FIT IN ALIGNMENT

SIMULTANEOUS FIT-UPS-NOT
ADVICED; CAUSES RESTRAINT
AMONG THE MEMBERS
FIG A & B : SUPPORT
CHANNELS DIRECTLY
WELDED TO THE PARENT
MATERIAL WITHOUT ANY
SANDWICH(SIMILAR TO
PARENT METAL);
FIG C : CS SUPPORTS ARE
GIVEN TO SS PIPINGS-
REGRETTED;
 PRE/POST WELD REGULATIONS
• Welder ID/Qualification to be checked;
• Electrode-baking, Amperage controls, Pre-heat are to be checked;
• Earthing to be tight, blunt, insulated & clamped and should not be placed
over the parent metal;
• Welding cleats for fit-ups to be made by approved welder for the right
material;
• Conductivity check of the electrode be made over a scrap piece;
• For Socket welds, minimum 2 runs required & the start point shall not
coincide with the end point;
• Post weld – De-slagging, Re-capping be made if convex peeks, Under-cuts
& removal of welded cleats are observed;
• Arc-strikes must be restricted and if made should be filed-off;
• Weaving width shall not exceed 2.5D;
OBSERVATION : RF PAD WELDED ONTO PIPE JOINT;
CONSEQUENCE : HAZ WEAKENING or PRECIPITATION
SEGREGATION, JOINT INSPECTION IN-ABILITY, SERVICE LOAD
IMBALANCE;
 CRATERS ASSISTED WITH ELECTRODE DRAG &
PENETRATED ARC-STRIKE

IN-COMPLETE
CAPPING,
UN-REGULATED
WEAVING
CLEAT
REMOVAL
UN-DONE
 DAMAGES MADE BY
FIT-UP TACKS &
GRINDING

DAMAGED-PIPE TACK WELD SPOTS

 POOR AMPERAGE CONTROLS & PARAMETERS

EXCESS
PENETRATION

IN-COMPLETE PENETRATION
ARC-STRIKES & INAPPROPRIATE EARTHING SPOTS
 NO SURFACE PREPARATION-WELDED OVER
COATING, RESULTING IN HEAVY OXIDATION DUE TO
HIGH HEAT INPUT & PIPE DAMAGE

SUPPORT
PENETRATING
THRO` THE PIPE
INSUFFICIENT OVERLAPPING OF BEADS
LEAKS OBSERVED DUE TO ELECTRODE
PENETRATION THROUGH THE THICKNESS OF
THE PIPE, INDISCIPLINED WELD LEAKS
WITNESSED
OBSERVATION: Leak during hydro-test, a 7 mm
protrusion (thro` thickness) found;
REASON: Pipe welded with R-pad support, but, was
poorly welded with the electrode penetrating thro` the
thickness;
 Stainless steel - AWARENESS
Awareness:
 Heat Input (H) parameters to be checked as per the approved WPS, as
they vary from CS to SS (“H”,usually lower than CS);
 Pipes/Tubes 2” & below are to be welded by GTAW for shallow
penetration;
 Inter-pass time delay for Distortion control in SS;
 Purging for SS avoids OXIDATION;
 Use of low/no chloride markers for markings on SS, as punching &
materials/tools used in CS are regretted for use in SS;
 Use of the appropriate electrodes for SS;
 Use of the appropriate SS materials for supports, fit-up cleats,
grinding/buffing tools;
THERMAL BEHAVIOUR CS SS
Thermal Conductivity ▲ ▼
Thermal Expansion & Distortion ▼ ▲
OXIDIZATION of impurities present in the
filler / foreign material interference

UNDERCUT

CRATER STROKES
THANK U