PTS – PIPELINE MaGL-PTS-HDD-

WELDING PIPELINE
WELDING-0??

Mahesh Gas Limited

CITY GAS DISTRIBUTION PROJECT

PTS – PIPELINE WELDING

Rev. Date Description Prepared Checked by Approved

by by

Page 1 of 38
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TABLE OF CONTENT
1. SCOPE……………………………………………………………………………………………………….3
2. REFERENCE CODE AND STANDARD………………………………………………………………….3
3. SUBMITTALS BY CONTRACTOR………………………………………………………………………3
4. BASE MATERIAL………………………………………………………………………………………….3
5. WELDING CONSUMABLES……………………………………………………………………………...3
6. EQUIPMENT AND ACESSORIES REQUIRMENT…………………………………………………….4
7. WELDING PROCESSES…………………………………………………………………………………..4
8. BEVEL CLEANING / BEVEL INSPECTION……………………………………………………………5
9. ALIGNMENT AND SPACING…………………………………………………………………………….5
10. WEATHER CONDITIONS………………………………………………………………………………...6
11. WELDING…………………………………………………………………………………………………..6
12. HEAT TREATMENT……………………………………………………………………………………….7
13. INSPECTION AND TESTING…………………………………………………………………………….7
14. REPAIRS OF WELDS……………………………………………………………………………………...9
15. DOCUMENTATION……………………………………………………………………………………......9
16. ENCLOSURE……………………………………………………………………………………………….10
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1. SCOPE
This specification shall be followed for the fabrication of all types of welded joints of mild steel pipe line
& piping systems connected with the pipeline and related facilities.The welded pipe joints shall include
the following.

a) All line pipe joints of the longitudinal and circumferential butt-welded and socket weldedtypes.
b) Attachments of flanges and other supports topipes.
c) Welded manifold headers and othersub-assemblies.
d) Welded branchconnections.
e) Joints in welded / fabricated pipingcomponents.
f) The attachments of smaller connections for vents drain drips and other instrumenttapping.
Any approval granted by the Engineer-in-charge/TPIA shall not relieve theCONTRACTOR of his
responsibilities and guarantees.

2. REFERENCE CODE AND STANDARD

Following Standards and codes of latest edition have been used in this specification.
Governing Standard

ASME B 31.8-Code for Gas Transmission and Distribution Piping Systems API1104-
Standard for welding of Pipelines and Related Facilities -
ReferenceStandard

ASME Sec. II, Part - C - Specification for welding Electrodes and Filler Materials ASME Sec. V. -
Non-Destructive examination
ASME Section IX - Qualification for welding and brazing

3. SUBMITTALS BY CONTRACTOR
3.1 The CONTRACTOR shall submit the Welding Procedure Specification, Procedure Qualification
Record, Welder Qualification Test, Ultrasonic Testing Procedure, Magnetic Particle Testing Procedure,
Dye-Penetrant Testing Procedure and
RadiographyProcedurealongwithqualityrecordsandInspectionTestPlanfor welding and NDT compatible
to this specification at least two weeks prior to commencement of the work for the approval of
MAHESH GAS/TPIA.
3.2 The CONTRACTOR shall submit Electrode and Welding Consumable Qualification Records in respect
of the electrodes tested by the CONTRACTOR, for obtaining approval of the Engineer-in-
charge/TPIA

4. BASE MATERIAL
4.1 In general, use of MS Pipe & Fittings is envisaged. The details of material specifications are given in
the welding specification chart.
4.2 The CONTRACTOR shall provide the manufacture’s test certificates for every heat of material, if any,
supplied by the CONTRACTOR, also maintain the record of test certificates of all the materials for the
reference of the Engineer-in-charge/TPIA

5. WELDING CONSUMABLES
5.1 The CONTRACTOR shall provide at his own expense all the welding consumable necessary for the
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execution of the job such as electrodes, oxygen, acetylene etc., and these shall bear the approval of the
Engineer-in-charge/TPIA.
5.2 The SMYS of electrodes / filler wires shall be equal to or more than the parent material to be welded.
5.3 Physical properties of the welds produced by electrodes recommended for the welding of a particular
base metal shall not be lower than the minimum values specified for the base metal. The choice of
electrode shall be the sole prerogative of the Owner/Owner’s Representative.
5.4 The Contractor shall submit batch test certificates from the electrode manufacturer giving details of
physical and chemical tests carried out for each batch of electrodes to be used.
5.5 For each batch, electrode qualification test report shall be submitted as per Annexure to the Owner/
Owner’s Representative for approval.
5.6 The welding electrodes / filler wires supplied by the CONTRACTOR shall conform to the class
specified in the welding specifications chart. The materials shall be of the make approved by the
Engineer-in-charge/TPIA.
5.7 All electrodes shall be purchased in sealed containers and stored properly to prevent deterioration. The
electrodes removed from the containers (except cellulose coated electrodes) shall be kept in holding
ovens, at the temperature recommended by the electrode manufacturer. Ovens shall be used for low
hydrogen electrodes only. Out-of-the oven time of electrodes before they are consumed shall not
exceed the limits recommended by the electrode manufacturer. The electrodes shall be handled with
care to avoid the any damage to the flux covering. Different grades of electrodes shall be
storedseparately. Cellulose electrodes used shall however be used as per specific recommendations of
manufacturer.
5.8 The electrodes used shall be free from rust, oil, grease, earth and other foreign matter, which affect the
quality of welding.

6. EQUIPMENT AND ACCESSORIES REQUIREMENT

6.1 The CONTRACTOR shall have sufficient number of welding and cutting equipment, welding clamp,
auxiliaries and accessories of sufficient capacities to meet the target schedules.
6.2 CONTRACTOR shall make necessary arrangements at his own expenses, for providing the
radiographic equipment, radiographic films, all the equipment/material required for carrying out for
satisfactory and timely completion of the job. The CONTRACTOR has to carry out 100% X-ray testing
for all joints. Where ever radiography is not feasible due to weld / site condition, same joints shall be
examined through Ultrasonic examination.
6.3 All the equipment for performing the heat treatment, including transformers, thermocouples,
pyrometers, automatic temperature recorders with suitable calibration arrangements, etc., shall be
provided by the CONTRACTOR, at his own expense and these shall bear the approval of the Engineer-
In-charge/TPIA.
6.4 Redoing of any work necessitated by faulty equipment or operation used by theCONTRACTOR shall
be done at his own expense.
6.5 CONTRACTOR shall take prior approval before involving any SUB-CONTRACTOR (including NDT
agency) in the work.

7. WELDING PROCESSES
7.1 Welding of various materials under this specification shall be carried out using Shielded Metal Arc
Welding Process (SMAW) with the approval of the Engineer – in – charge/TPIA.
7.2 The welding processes to be employed are given in the welding specification chart. Any deviation
desired by the CONTRACTOR shall be obtained through the express consent of the Engineer – In –
charge/TPIA and shall be documented in Deviation Requests.
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7.3 Welding technique shall be adopted as per the procedure qualified for welding of pipe having diameter
4” and above which shall be held fixed with its axis horizontal.
7.4 Upward technique shall be adopted for welding of fittings & pipe having diameter less than 2”, as well
as were ever is required as guided by Engineer–In– Charge/TPIA.

8. BEVEL CLEANING / BEVEL INSPECTION

8.1 Line pipe supplied by MAHESH GAS shall have bevel ends as specified in the applicable specification
for line pipe. Any modification thereto, if required by CONTRACTOR due to his special welding
technique shall be carried out by the CONTRACTOR at his own cost.
8.2 Before welding, all rust and foreign matter shall be removed from the bevelled ends by power operated
tools. This shall be effected inside and outside and for a minimum distance of 25 mm from the edge of
the weld bevel. The bevels shall be thoroughly inspected at this stage.
8.3 If any of the ends of the pipe joints are damaged to the extent that, in the opinion of Engineer – in –
charge/TPIA, the damaged ends shall be cut and bevelled to the satisfaction of the Engineer – in –
charge/TPIA with an approved bevelling machine. A manual cutting and weld repair of bevels shall not
be allowed. If laminations, split ends or inherent manufacturing defects in the pipe shall be discovered,
the lengths of pipe containing such defects shall be removed from the line to the satisfaction of
Engineer-in-charge/TPIA. On pipes which have been cut back, a zone extending 25 mm back from the
new field bevel, shall be ultrasonically tested to the requirement of the line pipe specification to ensure
freedom from laminations. The new bevel shall be 100% visual and 100% dye penetrate / MPI tested.
A report shall be written for all testing and records shall be kept.

9. ALIGNMENT AND SPACING

9.1 Immediately prior to line up, CONTRACTOR shall inspect the pipe ends inside and outside for
damage, dents, laminations etc. Pipe for welding shall be set up, correctly spaced; allowing for
temperature changes during welding, in correct alignment and shall in no circumstances be sprung into
position.
9.2 Temporary attachments of any kind shall not be welded to the pipe. Welds are joining the sections of
the pipeline, Valve installation or similar welds classified, as tie in welds shall be made in the trench.
Otherwise the alignment and welding shall be made alongside the ditch with the pipe supported on
skids and back pads or other suitable means approved by Engineer–in- charge/TPIA, at least 500 mm
above the ground unless approved by the Engineer-in-charge in specific cases.
9.3 Seam orientation of welded pipe shall be selected to ensure that at the circumferential welds, the
longitudinal welds shall be staggered in the top 90° ofthe pipeline, or 250 mm whichever is the lesser.
A longitudinal joint shall pass an appurtenance of a structural element at a minimum distance of 50
mm. Should a section of the line containing uncompleted welds fall from the skids, the
CONTRACTOR shall immediately inform Engineer-in-charge/TPIA.
9.4 Every effort shall be made to reduce misalignment by the use of the clamp and rotation of the pipes to
the best fit. For pipe of same nominal wall thickness, the offset/Hi-Low shall not exceed 1.6 mm. The
offset/Hi-Low may be checked from outside using Hi-Low Gauges. Any branch connection sleeve,
etc., shall be at least 150 mm from any other weld (Underground pipeline). The welds for fittings shall
be so located that the toe of the weld shall not come within 50 mm of any other weld. Cold dressing is
permissible only in cases of slight misalignment and may only be carried out with a bronze-headed
hammer. Hot dressing shall not be permitted. When welding pipes of different wall thickness (as
directed by Engineer-in-charge/TPIA.) A special transition piece shall be used. This shall have a
minimum of 1:4 taper. The welds shall be subject to both ultrasonic and radiographic inspection.
9.5 The root gap shall be accurately checked and shall conform to the qualified welding procedure. The use
of pipe clamp either internal or external is selected considering requirements of pigging of pipeline in
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future. However, in some case (tie in welds, flanges, fittings, diameter of pipe 10” etc.) where it is
impossible to use internal clamps, an external line up clamp may be used.
9.6 The internal line up clamp shall not be released before the entire first pass has been completed.
9.7 When an external line up clamp is used, all spaces between bars or at least 60% of the first pass shall be
welded before the clamp is released and the pipe remaining adequately supported on each side of the
joint.
9.8 Segments thus welded shall be equally spaced around the circumference of the pipe. slog., etc. shall be
cleaned off and the ends of the segments shall be prepared by grindings as to ensure continuity of the
weld bead.

10. WEATHER CONDITIONS

10.1 The parts being welded and the welding personnel shall be adequately protected from rain and strong
winds. In this absence of such a protection no welding shall be carried out. The completed welds shall
be suitably protected in case of bad weather condition

11. WELDING
11.1 Root Pass
11.1.1 Root pass shall be made with electrodes / filler wires recommended in the welding specification
chart.
11.2.1 The size of the electrodes used shall be as per the approved welding procedure.
11.3.1 The vertical down method of welding shall be adopted for welding pipe held fixed with its axis
horizontal.
11.4.1 The vertical up method of welding shall be used for the root pass of the tie ins, special crossing,
fittings and special parts, fillet welds, repairs and when an external line clamp is used.
11.5.1 The root pass of butt joints shall be executed properly so as to achieve full penetration with
complete fusion of the root edges. Weld projection inside the pipe shall not exceed 3 mm
wherever not specified by the applicable code.
11.6.1 Any deviations desired from the recommended welding technique and electrodes indicated in
the welding specification chart shall be adopted only after obtaining express approval of the
Engineer-in-charge/TPIA by Deviation Requests.
11.7.1 Welding shall be continuous and uninterrupted during a pass.
11.8.1 On completion of each run, craters, welding irregularities, slag etc., shall be removed by
grinding.
11.9.1 While the welding is in progress care shall be taken to avoid any kind of movement of the
components, shocks, vibration and stresses to prevent occurrence of weld cracks.
11.10.1 Fillet welds shall be made by shielded metal arc welding process irrespective of the thickness
and class of piping. Electrode size shall not exceed 3.15-mm diameter for socket joints. At least
two passes shall be made on socket weld joints.
11.2 Joint Completion
11.2.1 The number of welders and the allowable welding sequences shall be as per laid down in the
qualified welding procedure specifications. Once the deposit of the first pass has been started, it
must be completed as rapidly as possible, reducing interruptions to the minimum. The welding
and wire speed shall be approximately same as that established in the qualified welding
procedure specification.
11.2.2 The pipe shall always be adequately supported and must not be pumped or shaken during
welding. The clamp shall be removed, as indicated in clause 9.0 above. Before starting the
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second pass, the first pass shall be cleaned and flattened with rotating grinders.
11.2.3 The interruption between completion of the first pass and starting the second pass shall be as
stated in the procedure specification, normally not exceeding four minutes.
11.2.4 The Welding/Travel Speed selected shall enable production of a bead which is sufficiently
thick and which shows no undercutting.
11.2.5 The time lapse between second and third pass shall be as stated in the procedure specification,
normally not exceeding five minutes. After completion of the third or following passes,
welding operations may be suspended, so allowing the joint to cool down, provided that the
thickness of the weld metal deposited is equal to at least 50% of the pipe thickness. In any case,
the welds shall be completed within 24 Hrs, otherwise it shall be cut-out as per EIC/TPIA
instruction. Upon restarting, depending on the materials, wall thickness and welding process, a
preheating to at least 100oC shall be carried out. Subsequent passes up to weld completion shall
be protected to avoid rapid cooling, if meteorological conditions so dictate. Cleaning between
passes shall be done carefully so as to reduce the possibility of inclusions.
11.2.6 Electrode starting and finishing points shall be staggered from pass to pass. Arc strikes outside
the bevel on the pipe surface are not permitted. Arc strike or arc burn on the pipe surface
outside the weld, which are caused accidentally by electrical welding cable or welding cable
round and the pipe shall be removed by grinding in accordance with a procedure approved by
Engineer-in-charge/TPIA and the repair checked by ultrasonic, radiographic, magnetic particle
or dye penetrant tests which the Engineer-In-charge/TPIA feels necessary. The pipe wall
thickness after grinding shall not be less than the minimum thickness limit permitted for the
pipe. Repair of arc strikes by welding is prohibited.
11.2.7 The completed weld shall be carefully brushed and cleaned and shall appear free from spatters
scales, etc.
11.2.8 These requirements apply not only to completed welds but also to the bare strip at least so wide
as to allow full skid examination at both ends of the pipe to allow a good ultrasonic inspection
when it is required.

12. HEAT TREATMENT

12.1 Preheating: [Where ever applicable]
12.1.1 Preheating shall be performed using resistance or induction / heating methods. Preheating by
gas burners, utilizing acetylene or propane gas may also be carried out. Oxy-propane gas may
be used with the permission of the Engineer-In- charge/TPIA under careful supervision.
12.1.2 Preheating shall extend uniformly to at least three times the thickness of the joint, but not less
than 50 mm, on both sides of the weld.
12.1.3 Preheating temperature shall be maintained over the whole length of the joint during welding.
The CONTRACTOR to check the temperature shall provide temperature indicating crayons or
other temperature indicating devices.

13. INSPECTION AND TESTING

13.1.1 General
13.1.1 The CONTRACTOR shall also afford the MAHESH GAS/TPIA inspector all means and
facilities necessary to carry out inspection. The MAHESH GAS/TPIA Inspector shall have
free access to all concerned areas, where the actual work is being performed.
13.1.2 The MAHESH GAS is entitled to depute his own inspector to the shop or field where pre
fabrication and erection of pipelines are being done, with (but not limited to) the following
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objectives:

a) To check the conformance to relevant standards and suitability of various welding

equipment and the welding performance.
b) To witnessed the welding procedure qualification.
c) To witnessed the welders’ performance qualification.
d) To check whether shop / field welding being executed is in conformity with the relevant
specifications and codes of practice followed in pipe construction.
13.1.3 As far as possible, all welder qualification and procedure qualification test shall be conducted
on the site. CONTRACTOR shall intimate sufficiently in advance the commencement of
qualification tests, welding works and acceptance tests, to enable the Engineer-in-charge/TPIA
to be present to supervise them.
13.2.1 Welding Procedure Qualification
13.2.2 The CONTRACTOR, at his expense shall carry out welding procedure qualification in
accordance with the relevant requirements of API 1104 latest edition or other applicable codes
and other job requirements. Qualification shall include Toughness testing requirements as
applicable.
13.2.3 Standard tests as specified in the code shall be carried out in all cases. In addition to these
tests, other tests like radiography, macro / micro examination, hardness tests, dye penetrate
examination, Charpy-V-notch etc. shall be carried out on specimens (Refer Table 1). It shall
be the responsibility of the CONTRACTOR to carry out all the tests required to the
satisfaction of the MAHESH GAS’s/TPIA Inspector. The destructive testing of welded joints
shall be as per Annexure - I.
13.1.2 Welders’ Qualification
13.3.1 Welders shall be qualified in accordance with the API 1104 and other applicable specifications
by the CONTRACTOR at his expense. The butt weld test pieces of the qualification test shall
meet the radiographic test requirements specified in Clause 13.5 and Annexure - 3 of this
specification. The MAHESH GAS’s or TPIA inspector shall witness the test and certify the
qualification of each welder separately. Only those welders who have been approved by the
MAHESH GAS’s or TPIA inspector shall be employed for welding.
13.3.2 The welders shall always have in their possession the identification card as shown in Exhibit –
D and shall produce it on demand by the MAHESH GAS’s/TPIA Inspector. It shall be the
responsibility of the CONTRACTOR to issue the identity cards after it has been duly certified
by the MAHESH GAS’s/TPIA Inspector.
13.3.3 No welder shall be permitted to work without the possession of identity card.
13.3.4 If a welder is found to perform a type of welding or in a position for which he is not qualified,
he shall be debarred from doing any further work. All welds performed by an unqualified
welder shall be cut and redone by a qualified welder at the expense of the CONTRACTOR.
13.1.3 Visual Inspection
13.4.1 Inspection of all welds shall be carried out as per the latest editions of API – 1104 and other
the applicable codes and specifications by the CONTRACTOR at his expense. In addition to
the requirements of API 1104, no root crack shall be permitted. All finished welds shall be
visually inspected for parallel and axial alignment of the work, excessive reinforcement, and
concavity of welds, shrinkage, cracks, under cuts, dimensions of the weld, surface porosity
and other surface defects. Undercutting adjacent to the completed weld shall not exceed the
limits specified in the applicable standard / code.
13.1.4 Non-destructive Examination
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13.5.1 The non-destructive examination shall mainly consist of examination using X-ray radiography
as detailed in Annexure - III.
13.5.2 Radiographic examination of one hundred percent (100%) butt welds will be required by the
MAHESH GAS’s/TPIA. Where ever radiography is not feasible due to weld / site condition,
same joints shall be examined through Ultrasonic examination. Welds shall meet the standards
of acceptability as set forth in API 1104 as well as the requirements laid in subsequent
paragraphs. In addition, no root crack shall be permitted, The CONTRACTOR shall make all
the arrangements for the radiographic examination of work covered by the specification at his
expense.
13.5.3 The MAHESH GAS’s/TPIA will review all the radiographs of welds and inform the
CONTRACTOR regarding unacceptable welds. The decision of the MAHESH GAS’s/TPIA
shall be final and binding in this regard. All requirements mentioned in the specification shall
be arranged and executed by the CONTRACTOR through his own resources. In addition,
ultrasonic inspection is required in the following cases as per Annexure II of this
Specification.
a) When 20 mm or more are cut from the pipe end as supplied, the ends shall be DPT,
ultrasonically and Magnate particle test (MPT) inspected for an additional length of 20
mm to assure no lamination exist.
b) When welds are repaired.
c) When in the opinion of Engineer-in-charge/TPIA, ultrasonic inspection is required to
confirm or clarify defects indicated by radiography.
d) Pipe cutting by means of Grinding is Strictly prohibited.
13.5.4 In addition, ultrasonic inspection may be required for certain critical welding of the pipeline
(i.e., tie ins, welding of valves, flanges) randomly selected at Engineer-in-charge/TPIA
discretion. All fillet and groove welds other than those radiographs shall be subjected to dye
penetrate / MP inspection. The non- destructive test system used for inspecting welds must be
approved by the Engineer-in-charge/TPIA.
13.5.5 Weld quality is judged on the basis of the acceptability criteria mentioned below:
13.5.6 Any weld which as a result of radiographic and /or ultrasonic examination in the opinion of
Engineer-in-charge/TPIA exhibits imperfections greater than the limits stated in API 1104
latest edition shall be considered as defect and shall be marked with an identification paint
marker.
a) Any length of inadequate penetration of the root bead as defined by API 1104 is not
acceptable except that root concavity is allowed as per API - 1104.
b) Any amount of incomplete fusion at the root of the joint as per referred standards,
considered unacceptable.
c) All burn through areas is to be repaired.
d) In addition to the API 1104 requirements, the welds containing cracks including crater
cracks regardless of size or location are unacceptable.
13.5.7 Suitable records shall be maintained by the CONTRACTOR as desired by the Engineer-in-
charge/TPIA on the day to day work done on welding radiography, ultrasonic testing. The
CONTRACTOR shall present the records to the Engineer- in-charge/TPIA on day to day basis
and whenever demanded, for approval.
13.1.5 Destructive Testing
13.6.1 The Engineer-in-charge/TPIA has the authority to order the cutting of up to 0.1% of the total
number of welds completed for subjecting to destructive tests at no extra cost to MAHESH
GAS’s/TPIA. The destructive testing of weld joints shall be made as per Annexure - I.
13.6.2 Destructive Testing of Welding Specimen during construction shall be as follows:
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a) 1 No after first 100 Production Joints
b) 1 No after next 500 Production Joints
c) 1 No for after 1000 Production Joint onwards till project completion
d) Quantity may vary depending upon results
13.6.3 The CONTRACTOR at his own expense shall carry out the sampling and the re- execution of
welds. If the results are unsatisfactory, welding operations shall be suspended and may not be
restarted until the causes have been identified and the CONTRACTOR has adopted measures,
which guarantee acceptable results. If it is necessary in the Engineer-in-charge/TPIA opinion
the procedure shall be re qualified. The weld joint represented by unsatisfactory weld shall
stand rejected unless investigation proves otherwise.

14. REPAIRS OF WELDS

14.1 With the prior permission of Engineer-in-charge/TPIA welds which do not comply with the standards
of acceptability shall be repaired or the joint cut out and re-welded.
14.2 A separate welding procedure specification sheet shall be formulated and qualified by CONTRACTOR
for repair welds simulating the proposed repair to be carried out. Separate procedures are required to be
qualified for
a) through thickness repair
b) partial thickness repair.
c) capping repair
14.3 Welders shall be qualified in advance for repairs. The root pass, for repairs opening the root, shall be
replaced by the vertical uphill technique. The procedure shall be proven by satisfactory procedure tests
to API 1104 including the special requirements of the specification, and shall also be subjected to
metallographic examination, hardness surveys and Charpy tests to determine the effects of repair
welding on the associated structure.
14.4 Root sealing or single pass repair deposit shall not be allowed. Internal root defects shall be ground
thoroughly and welded with a minimum of two passes. However, while grinding for repairs, care shall
be taken to ensure that no grinding marks are made on the pipe surface anywhere.
14.5 The repair shall be subjected, as a minimum requirement to the same testing and inspection
requirements as the original weld. The entire joint shall be re- radiographed. A 100% ultrasonic test
shall be done at the repaired area externally. Any repaired area that is wide, irregular or rough shall be
rejected and a full cut out shall be done.
14.6 Re-repair of welded joints is not allowed. CONTRACTOR shall maintain a report of all repairs. All
repairs shall be carried out the day after initial radiography or earlier. A full report of all repairs made
shall be submitted every day to the Engineer-in-charge/TPIA.
13.1.6 Limitations on Repairs
14.7.1 Only one attempt at repair of any region is permitted. Repairs are limited to a maximum 30%
of the weld length. For internal repairs or external repairs, which open the weld root, only 20%
of the weld length may be repaired. Repairs opening the root must only be carried out in the
presence of Engineer-in- charge/TPIA. The minimum length of a repaired area shall be 100
mm as measured over the recapped length. Welds Containing cracks shall be cut out and re-
bevelled to make a joint. Engineer-in-charge/TPIA shall authorize all repairs.
13.1.7 Weld rejected by accumulation of Defects
14.8.1 Where a weld is rejected by the accumulation of defect clause, as defined by API 1104 (Latest
Edition) and this specification, repairs within these limitations are permitted. Defects in the
filling and capping passes shall be repaired preferentially.
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15. DOCUMENTATION

15.1 CONTRACTOR shall submit the following as minimum:

15.2 Batch Test Certificates, for the Electrodes used, obtained from the electrode manufacturers.
15.3 Quality records of each process
15.4 Calibration certificate of measuring instruments and testing equipment.

16. ENCLOSURE
a) ANNEXURE – I- Guideline Destructive testing of welded joint
b) ANNEXURE – II Guideline for Ultra Sonic inspection
c) ANNEXURE – III Radiography
i. EXHIBIT A - Electrode qualification test record
ii. EXHIBIT B - Record form for welding procedure approved test
iii. EXHIBIT C - Record form for welder approved test
iv. EXHIBIT D - Welder’s identification card
v. EXHIBIT E - Format for radiography procedure
vi. TABLE 1 - Number of specimens for destructive test
vii. Welding Specification Chart.
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ANNEXURE - I

1. DESTRUCTIVE TESTING OF WELDED JOINT - BUTT WELDS

Preparation

 Having passed the visual and non-destructive inspection, the test weld shall be subjected to
mechanical test.
 After satisfactory completion of all visual and non-destructive testing, the procedure test weld
shall be set aside for a period not less than 24 hours. No further work on the test weld and no
cutting of test specimens from the weld shall be performed until a period of at least 24 hours has
expired.
 Weld specimens shall be taken from the positions indicated in Fig. 1 and Fig. 1A of this
specification from areas as free from defects as possible; for this reason, it is necessary to take
the previous non-destructive tests into account. The minimum number of tests to be carried out is
given in Table 1 of this specification.
 The test shall be carried out at laboratories approved by MAHESH GAS/TPIA. The specimens
shall be prepared in accordance with the figures given in the paragraphs, which refer to the
individual test.
1.1. Tensile Strength

 Specimens shall be taken from the position indicated in Fig. 1 and Fig. 1A. Two ISO type
specimens and two API type specimens shall be taken.

 The ISO test specimens are shown in figure 2 of this specification.

Method

 The test shall be carried out in accordance with ISO 375.

1.2. Nick Break Test

Preparation

 Specimens for nick break test with notches thus worked can break in to base metal, instead of in
the fusion zone; therefore, an alternative test piece may be used after authorization by the
MAHESH GAS/TPIA with a notch cut in the reinforcement of outside weld bead to a maximum
depth of 1.5 mm, measured from the surface of the weld bead.
1.3. Macroscopic Inspection
Preparation

 Specimens shall be taken from the positions indicated in Fig. 1 of this specification and shall be
prepared in accordance with ASTM E2 and E3.

 The width of the macro section has to be at least three times the width of the weld. The section is
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to be prepared by grinding and polishing and etched to clearly reveal the weld metal and heat
affected zone.
Method

 Specimens shall be carefully examined under the microscope, with a magnification of at least 25
times (25:1). MAHESH GAS/TPIA may ask for a macrograph with 5 times (5:1) magnification,
for documentation purposes.
Requirements

 Under macroscopic examination, the welded joints shall show good penetration and fusion,
without any defect exceeding the limits stated in the evaluation criteria of the nick break test.
1.4. Hardness Test
Preparation

 The prepared macro section is to be used for hardness testing using the Vickers method with 10
Kg. loads. Indentations are to be made along traverses each approximately 1 mm below the
surface at both side of the weld.

 In the weld metal a, minimum of 6 indentations equally spaced along the traverses are to be
made. The HAZ indentations are to be made along the traverses for approximately 0.5 mm each
into unaffected material, and starting as close to the fusion line as possible.

 One indentation at each side of the weld along each traverse has to be made on parent metal.
Reference is made in this specification. The indentations are to be made in the adjacent region as
well as on the opposite side of the macro section along the specified traverses.
Method

 The test shall be carried out in accordance with Recommendation ISO R81, Vickers hardness,
using a laboratory type machine, controlled as pre recommendation of ISO R 146 and using a
diamond pyramid penetrator set at 2.37-rad (1360C) with a load of 10 Kg.
Requirements

 Hardness value shall not exceed the maximum limit. In case of a single reading, slightly (+ 10
HV) higher than the specified limit, further indentations shall be made to check if the high value
was an isolated case.

 All the hardness values contained from the heat-effected zone shall not exceed 100 HV with
respect to the average hardness of the values obtained for the base metal.
1.5. Charpy-V-Notch Impact Test

 Specimens shall be taken from the position indicated in this specification. The test specimens will
be prepared in accordance with ISO R 148. Charpy V notch specimens shall have dimensions as
given in Fig. 4 of the specification.

 Three test specimens shall be taken from each sample and they shall be cut and worked so that
their length is transversal and perpendicular to the weld bead with the notch position as per the
specification. The notch shall be perpendicular to the roller surface. The test specimen width
shall depend upon the pipe wall nominal thickness as following:
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Nominal wall thickness in Test specimen width in mm mm
Over 12 10.0
Over 9.5 and up to 12 7.5
From 7 up to 9.5 5.0

Less than 7 2.5

Test Method

 The test shall be carried out as indicated in ISO R 148 Beam impact test V notch. Test pieces
shall be immersed in a thermostatic bath and maintained at the test temperature for at least 15
minutes. They shall then be placed in the testing machine and broken within 5 seconds of their
removal from the batch.

 The test temperature shall be -100 C.

Requirements (Note 1)

 The impact energy shall be

Test Average of Three Minimum Single

Specimen Specimen Value
(in mm) Joules (min) (joules)

10.0 27.0 22.0

7.5 21.5 17.5

5.0 18.5 15.0

2.5 10.0 8.0

Note 1: Only one value is permitted to be lower than average value up to the value specified.
Bend test requirements

 The Bend Test Specimens shall be made and tested as per the requirements of API- 1104
Nineteenth edition, May 1999 except that the dimensions of the Jig for guided bend test Fig. 9,
API 1104 shall be modified as follows:
Radius of the Plunger-A =2t
Radius of the die-B = 3t + 1.6mm
Radius of the die-C = 50.8mm

 The acceptance criterion shall however be as per para 5.643 and 5.653 of API 1104 Sixteenth
edition May 1999.

Note: t = thickness of specimen.

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ANNEXURE – II

1. ULTRASONIC INSPECTION
1.1. Ultrasonic Inspection
 In addition to the radiographic inspection, ultrasonic inspection is required as per conditions
listed in paragraph 13.5 of this specification. This section covers manual ultrasonic inspection.
However ultrasonic inspection by automatic equipment may be used if approved by the
MAHESH GAS/TPIA.
 Equipment and Operators
 The Contractor who carries out the ultrasonic inspections shall have sufficient qualified
personnel, equipment and instruments at his disposal to be able to effect the tests without
hindering or delaying the pipeline assembly operations.
 The operators shall be fully qualified as per a recognized standard (ASME Sec. V or equivalent)
and they shall have qualified as a minimum level II. The operators shall be able to:
o Calibrate the equipment; Perform an operational test under production conditions;

o Interpret the screen picture;

o Evaluate the size and location of reflectors/discontinuity.

o Interpret the type of defects detected.

 MAHESH GAS/TPIA has the option of checking the ability of personnel employed for ultrasonic
testing by means of qualification tests.
 The Contractor appointed to carry out ultrasonic inspections shall supply all the instruments
necessary for their execution on site.
 Specification for Ultrasonic Testing Procedure Qualification
 Before work begins, the Contractor shall present a specification describing the proposed U.T.
procedure qualification.
 This specification shall state, as an indication only but not limited to the following information:
o Type of U.T. equipment used

o Type and dimensions of Transducers

o Frequency range

o Details for calibration

o Coupling Medium

o Inspection Technique

o Record details

o Reference to the welding procedure where it is intended to adopt the specification.

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o Temperature range of the joints to be inspected.
Qualification of Ultrasonic Inspection Procedure

 The ultrasonic inspection procedure shall be approved by MAHESH GAS/TPIA. Before

inspection begins, MAHESH GAS/TPIA may require the qualification test of the ultrasonic
inspection procedure. This test consists in testing (under normal operating conditions) some
welds made according to the same production procedure, where there are typical defects the test
intends to detect. This test shall be conducted in the presence of MAHESH GAS/TPIA.

Test Procedure

 Circumferential welds shall be inspected from both sides using angled probes. The surface with
which the probe comes into contact shall be free of metal spatter, dirt, iron oxide, and scales of
any type. Therefore, it shall be necessary to clean a strip at least 150 mm wide on both sides of
the weld with steel wire brushes and strip must be wide enough to allow full scale examination.
The weld shall be tested from both sides and testing shall include the adjacent area of weld for
laminations, scanning for transverse indication in weld and base material. The probe movement
shall not exceed 100mm/sec.
 Manual ultrasonic testing equipment is applicable for pulse echo technique and for double probe
technique and shall cover as a minimum frequency range from 2 to 6 MHz, have a calibrated gain
regulator with maximum 2dB per step over a range of at least 60 dB, allow echoes with
amplitudes of 5% of full screen height to be clearly detectable under test conditions. For flaw
detection the corrected primary gain may be increased by maximum 6 db. Defect size evaluation
is not being performed at this increased gain level. The indications are to be investigated by
maximizing the echoes with different angle probes and by rotating the probes. All indications
exceeding 20 % of the reference curve are to be investigated and all indications exceeding 50 %
are to be reported. Investigation is to be performed to the extent that the operator can determine
the shape and location of the indication. For dimensional evaluation either the “20 dB -drop
“method, time of flight or maximum amplitude method is to be used. The half value drop method
is to be used for length determination only. Acceptance criteria for visual examination and
surface method testing shall be as per API 1104 Section 6 and Clause 13.5.
 If, during the test, echoes of doubtful origin appear, it shall be necessary to inspect a convenient
area on the pipe surface, close to the weld, with a straight beam transducer in order to check
whether any manufacturing defects are present which could have interfered with the ultrasonic
beam. By way of an example, the equipment shall include but not be limited to the following:

o Ultrasonic equipment and coupling medium.

o Sample sections for calibration of instruments.

o Equipment for cleaning of surface to be examined.

o Rules calibrated in centimeters for exact location of the position of defects.

 The characteristics of the above listed instruments and equipment shall guarantee:

a) That the required standards of the inspection procedure, as previously established and
approved by MAHESH GAS/TPIA, are satisfied.
b) Continuous operation:
o All the instruments and equipment shall be approved by the MAHESH GAS/TPIA before
being used. MAHESH GAS/TPIA has the authority to reject any item, which is
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considered unsuitable. The decision of MAHESH GAS/TPIA is final. The Contractor

appointed to carry out ultrasonic inspections shall also ensure the operational efficiency
and maintenance of the instruments and equipment, and shall immediately substitute any
item rejected by MAHESH GAS/TPIA.
o All the instruments and equipment necessary for carrying out ultrasonic inspection on site shall
satisfy the requirements laid down by the public boards of institutions which regulate safety at work.
Ultrasonic Instruments
 The ultrasonic instrument shall be each pulse type, able to generate, receive and display, on the
screen a cathode ray tube (CRT), pulse at frequencies between 2 and 6 MHz. The useful part of
the CRT screen shall be at least 70 mm wide and at least 50 mm high.

o Shall have variable amplification, with steps of 1 or 2 dB over a range of at-least 60 dB.

o The regulation control shall be accurate to within +1 dB and the Instrument may be
powered by a battery or an electric generator. Manufacturer shall certify this accuracy. In
the first case, the autonomy of operation (endurance) of the instrument shall be sufficient
to carry on working without frequent interruptions, and the instrument shall be equipped
with an automatic switch which switches it off when the battery runs down; in the second
case, there must be a voltage stabilizing device with a tolerance of +2 Volts.
Probes
 The probes used shall have dimensions, frequencies, and a refraction angle suited to the type of
steel, the diameter the thickness of the pipeline and to the joint design.
Reference Sample Pieces
 The efficiency of the equipment used, the effective refraction angle of the probe, and the beam
output point, shall be checked using a V1 and V2 sample block, IIW type or the calibration block
ASTM E- 428.
 For the calibration of runs and the regulation of detection sensitivity during the test, a calibration
piece shall be used. This piece shall be taken from the production material and will be at least
150 mm long (measured in the direction of the axis), and at least 50 mm wide (measured in the
direction of the circumference) See Fig. 6 of this specification. In the middle of the inside and the
outside surface of the calibration piece a groove shall be made. The groove will have a
rectangular cross section, a flat bottom and the following dimensions:

o Depth: 1 + 0.1 mm

o Breadth (measured parallel to the 150 mm side): 1+01 mm.

o Length (measured parallel to the 50 mm side): not less than 30 mm.

 In addition, the calibration piece shall have a hole, 2 mm in diameter, passing through its
thickness, and positioned so that during calibration the echoesreturning from the two grooves do
not interfere with those returning from the hole.
Calibration
 For a precise check of the sound paths necessary for a full inspection of the weld joint, the probe
shall be moved (half skip and full skip distance). The relevant defect limits the path lengths on
the time base scale distance) until internal and external notches on the test piece are detected (See
Fig. The calibration of reference sensitivity is obtained by utilizing the through drilled test hole in
the thickness of the reference block to draw the distance - amplitude correction curve relevant to
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the test probe. Calibration shall be carried out according to the following procedure: place its
internal vertex until the maximum height of echo is displayed on the screen; this echo is adjusted
to 80% of full screen height by means of the sensitivity adjuster set in dB. Without varying the
amplification, the probe placed at full skip distance from the hole is moved to detect the external
vertex of the hole until the maximum height of echo is obtained. The straight line connecting the
peaks of the two echoes obtained by the above procedure represents the 100% reference level,
while the one connecting the two points at half height of the same echoes represents 50%
reference level. The two straight lines shall be marked on the screen with a pen. Calibration shall
be repeated each time tests are re-started; at intervals not longer than 30 minutes during normal
operations; each time the conditions fixed in advance are altered. This calibration is applicable
provided that the crystal of the probe is 8 x 9 mm size. Should this size of the crystal be different,
the value of the sensitivity obtained from the calibration by a crystal of a different size shall be
brought to the value of sensitivity obtained from the calibration by a 8 x 9 mm crystal. The
sensitivities of the two different size probes shall be compared through the echoes obtained on
the notch of the test piece with the probe position at half skip of the distance.
Regulation of Amplification during Production Testing
 The amplification during production testing shall be obtained by adding 2 - 6 dB (according to
the surface condition of the pipe and its cleanness) to the reference amplification.
Qualification of Ultrasonic Testing Operators
 Before the inspection begins or during the same inspection, MAHESH GAS/TPIAmay require a
qualification test for the ultrasonic equipment operators
Evaluation of Indications Given by Ultrasonic Tests
 Each time the echoes from the weld bead appear during production testing, the instrument
amplification shall be altered to coincide with the referenceamplifications and the probe shall be
moved until maximum response is obtained, paying attention all the time to the probe tube
coupling.
 If, under these conditions, the height of the defect echo is equal to or greater than that of the
reference echo, the defect shall be evaluated according to clause
 1.12.5 of this Specification. If the defect has also been detected by the radiographic and/or visual
examination, the dimensions shall be judged according to the type of examination, which detects
the greater defect. Returns, which are less than 50% of the reference echo, will not be considered.
If returns are above 50% but lower than 100% of the reference echo, and if the operator has good
reasons to suspect that the returns are caused by unfavorably oriented cracks, he shall inform the
MAHESH GAS/TPIA.
 Moreover, when there is a defect to be repaired, such defect shall be removed for a length
corresponding to the one where no more return echo is given.
Other Equipment
 The use of rules calibrated in centimeters, attached if possible, to the probe, for the precise
location of the position of welding defects, is recommended. Defect location is effected by
measuring the projection distance between the probe output and the reflecting surface. The
operators carrying out the tests shall have, besides the probing instrument, tools for cleaning the
pipe surface (Files, Brushes, etc.) as well as the coupling liquid or pastes appropriate for the
temperature of the section to be examined.
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ANNEXURE - III

1. RADIOGRAPHY
1.1. SCOPE
 This Annexure covers the radiographic inspection of all types of welded joints of the pipeline.
 The welded joints shall include the following:

i. 100% of all Butt Weld Joints.

ii. Full girth welds on the mainline construction including double jointing of pipe, if
adopted.
iii. Welds for installation of block valves, insulating joints and other appurtenances and tie-
ins.
iv. Welds at scraper launching and receiving barrels.
v. Terminal Piping.
1.2. APPLICABLE STANDARDS
 This specification shall apply in conjunction with the following (all latest edition):

i. API 1104, Standard for welding Pipelines and related facilities.

ii. ASME B 31.8, Code for Gas Transmission and Distribution Piping Systems.
iii. ASTM E 94, recommended practice for Radiographic Testing.
iv. ASTM E 142, Standard Method for Controlling Quality of Radiographic Testing.
v. The American Society for Non-destructive Testing. Recommended Practice No. SNT-
TC-1A supplement A.
vi. ASME BPV – Boiler and Pressure Vessel Code – Section IX
vii. BARC rules for radioactive isotopes handling.
viii. ASME Section V non-destructive examination.
1.3. PROCEDURE
 The radiographic examination procedure to be adopted shall be submitted by theContractor as per
Exhibit - E.
 The procedure of radiographic examination shall be qualified to the entire satisfaction of
MAHESH GAS/TPIA prior to use. It shall include but not be limited to the following
requirements:
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i. Lead foil intensifying screens, at the rear of the film shall be used for all exposures.
ii. Type 2 and 3 films as per ASTM E - 94 shall be used.
 A densitometer shall be used to determine film density. The transmitted film density shall be 2.0
to 3.5 throughout the weld. The unexposed base density of the film shall not exceed 0.30.

i. Radiographic identification system and documentation for radiographic interpretation

reports and their recording system.
 The Contractor shall qualify each procedure in the presence of the MAHESH GAS/TPIA prior to
use the procedure of radiographic examination shall produce radiographs of sufficient density,
clarity and contrast so that defects in the weld or in the pipe adjacent to the weld, and the outline
and holes of the penetrometer are clearly discernible.
 All butt welds in the Pipeline and all the girth welds of mainline shall be subjected to 100%
radiographic examination. The Contractor shall furnish all the radiographs to MAHESH
GAS/TPIA, immediately after processing them, together with the corresponding interpretation
reports on approved format. The details of the radiographs along with the joint identification
number shall be duly entered in a register and signed by the Contractor and submitted to
MAHESH GAS/TPIA for approval.
 When the radiation source and the film are both on the outside of the weld and located
diametrically opposite each other, the maximum acceptable length of film for each exposure shall
not exceed the values given in API 1104. The minimum film overlap, in such cases, shall be 40
mm. The ellipse exposure technique may be used on nominal pipe sizes of 2 inch and smaller
provided that the source of film distance used is a minimum of 12 inch.
 Three copies of each acceptable radiographic procedure (as per Exhibit - E) and three copies of
radiographic qualification records shall be supplied to MAHESH GAS. One set of the qualifying
radiographs on the job shall be kept by the Contractor’s authorized representative to be used as a
standard for the quality of production radiographs during the job. The other two sets shall be
retained by MAHESH GAS/TPIA for its permanent record.
 Three copies of the exposure charts relating to material thickness, kilo voltage, source of film
distance and exposure time shall also be made available to MAHESH GAS/TPIA by the
Contractor.
 The Contractor shall, on a daily basis, record for each radiograph

1) radiograph’s number,
2) approximate chainage of weld location,
3) whether or not the welds meet the specified acceptance standards and
4) the nature and approximate location of unacceptable defects observed.
 It must be possible to relate back to a particular butt weld and welder on piping drawing and pipe
line alignment drawing.
 Each day’s production of processed radiographs shall be properly packaged separately, identified
by at least the

1) date,
2) radiographic unit,
3) job locations,
4) starting and ending progress survey stations and
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5) shall include original and three copies of the daily radiographic record.
 The package shall be submitted to the MAHESH GAS/TPIA daily when possible, but in no event
later than noon of the following day.
 The Contractor shall provide all the necessary facilities at site, such as a dark room with
controlled temperature, film viewer etc. to enable the MAHESH GAS/TPIA to examine the
radiographs.
 The Contractor, if found necessary, may modify the procedure of radiographic examination
suiting to the local conditions prevailing. This shall, however, be subject to the approval of the
MAHESH GAS/TPIA.
 MAHESH GAS/TPIA shall have free access to all the Contractor’s work facilities in the field.
 Any approval granted by MAHESH GAS/TPIA shall not relieve the Contractor of his
responsibilities and guarantees.

1.4. RADIATION SOURCE

 Radiographic examination shall be carried out using X-Rays only. Radiographic examination by
Gamma Rays can be done prior approval of MAHESH GAS/TPIA.
 Whenever possible, pipeline welds will be inspected by placing the radiation source inside the
pipe, on the pipeline axis, with a radiation of 6.28 rad. (360oC) crawler type of x-ray machine
shall be used for all main line joints.
 If it is impossible to place the radiation source inside the pipe, the weld will be inspected with the
source on the outside. An overlap of at least 40 mm at the ends of each film shall be required to
ensure that the first and last location increment numbers are common to successive films and to
establish that no part of a weld has been omitted.
1.5. LEVEL OF QUALITY
 The quality level of radiographic sensitivity required for radiographic inspection shall be at least
equivalent to the values specified in ISO standards (IQI Sensitivity curve).
1.6. PENETRAMETERS
 The image quality indicator (abbreviation: IQI) shall be used for the qualification of the welding
procedure and during normal line production.
 Radiographic sensitivity shall be measured with the wire image quality indicator (penetrometer).
The Penetrometer shall be selected according to DIN 54109 or ISO 1027. For radiographs made
with the source on the outside, a penetrometer shall be placed on each side of the film with the
smaller wire of the penetrometer turned towards the end of the film itself. When a complete weld
is radiographed in a single exposure using a source inside the piping, 4 penetrometers
approximately equally spaced around the circumference shall be used. During the procedure
qualification, IQI shall be placed both on the source side and on the film side. The sensitivity
obtained with IQI on the source side shall not be less than the values shown in the specification.
 The sensitivity limit may be considered to have been reached when the outline of the IQI, its
identification number and the wire of the required diameter show up clearly on the radiograph.
 MAHESH GAS/TPIA may authorize use of types of IQI other than those planned, provided that
they conform to recognized standards and only if the Contractor is able to demonstrate that the
minimum sensitivity level required is obtained. For this demonstration, a test shall be carried out
comparing the IQI specified and the Contractor’s. To show up the identification number and
other details of the proposed IQI, this must be visible in the test radiograph.
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1.7. FILM IDENTIFICATION MARKERS
 All films shall be clearly identified by lead numbers, letters, and/or markers. The image of the
markers shall appear on the films, without interfering with the weld interpretation. These marker
positions shall also be marked on the part to be radiographed and shall be maintained during
radiography.
1.8. PROTECTION AND CARE OF FILM
 All unexposed films shall be protected and stored properly as per the requirements of API 1104
standard and ASTM E-94.
 The exposed and unexposed film shall be protected from heat, light, dust and moisture. Sufficient
shielding shall be supplied to prevent exposure of film to damaging radiation prior to and
following the use of the film for radiographic exposure.
1.9. RE-RADIOGRAPHY
 The weld joints shall be re-radiographed in case of unsatisfactory quality of the radiographs, at
the expense of the Contractor.
 All the repaired weld joints shall be re-radiographed at no extra cost to the MAHESH GAS in the
same manner as that followed for the original welds. In addition, the repaired weld areas shall be
identified with the original identification number plus the letter R to indicate the repair.
 When evaluating repair film, radiographers shall compare each section (exposure) of the weld
with the original film to assure repair was correctly marked and original defect removed.
 MAHESH GAS/TPIA will review prior to any repair of welds, all the radiographs of welds,
which contain, according to the Contractor’s interpretation, unacceptable defects. The final
disposition of all unacceptable welds shall be decided by MAHESH GAS/TPIA.
1.10. QUALIFICATION OF RADIOGRAPHERS
 Pipeline radiographers shall be qualified in accordance with the requirement of API 1104 and to
the full satisfaction of MAHESH GAS/TPIA.
 Certification of all the radiographers, qualified as per clause 10.1 above, shall be furnished by the
Contractor to MAHESH GAS/TPIA before a radiographer will be permitted to perform
production radiography. The certificate record shall include

i. Background and Experience Record

ii. Training Course Record.
iii. Doctor’s report on radiographer’s Oaecuer 0-1 acquity eye test.
iv. Date of qualification.
 The radiographers shall be required to qualify with each radiographic procedure they use, prior to
performing the work assigned to him in accordance with the specification.
1.11. PRESERVATION OF RADIOGRAPHS
 The radiographs shall be processed to allow storage of films without any discoloration for at least
Five years. All the radiographs shall be presented in suitable folders for preservation along with
necessary documentation.
 All radiographs shall become property of MAHESH GAS at the end of project.

1.12. EQUIPMENT AND ACCESSORIES

 Contractor shall make necessary arrangements at his own expense, for providing the radiographic
equipment, radiographic films and all the accessories for carrying out the radiographic
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examination for satisfactory and timely completion of the job.

 For carrying out the mainline radiographic examination, Contractor shall be equipped with
suitable mobile / stationary type dark rooms. These shall have all the required facilities for film
processing. Film viewer used shall be equipped with the film illuminator that has a light source of
sufficient intensity and suitably controlled to allow viewing film densities up to 4.0 without
damaging the film.
1.13. RADIATION PROTECTION
 Contractor shall be responsible for the protection and personal monitoring of every man with or
near radiation sources.
 The protection and monitoring shall comply with local regulations.
 In view of visual hazards in the handling of Radioactive source of material, Contractor shall be
solely responsible for complying with all rules and regulations set forth by Atomic Energy
Commission or any other Government agencies of India in this regard and MAHESH GAS/TPIA
shall not be responsible and shall be kept indemnified by the Contractor for default (s) of
whatever nature by the Contractor. Safety equipment as considered adequate by MAHESH
GAS/TPIA for all necessary personnel shall be made available for use and maintained for
immediate and proper use by the Contractor. Storage of radioactive isotopes andrelated items
shall be followed by Contractor as per atomic energy commission rules.
1.14. DISPLAY OF SAFETY INSTRUCTIONS:
 The safety provisions shall be brought to the notice of all concerned by display on a notice board
at prominent place at the work spot. The Contractor shall name the person responsible for the
Safety.
1.15. ENFORCEMENT OF SAFETY REGULATIONS
 To ensure effective enforcement of the rules and regulations relating to safety precautions, the
arrangement made by the Contractor shall be open to inspection by MAHESH GAS/TPIA or its
representative.
1.16. FIRST AID AND INDUSTRIAL INJURIES
 Contractor shall maintain first aid facilities for its employees and those of sub-Contractors.
 Contractor shall make outside arrangements for ambulance service and for treatment of industrial
injuries. Names of those providing these services shall be furnished to MAHESH GAS/TPIA
prior to start of work and their telephone No. shall be posted prominently in Contractor’s field
office
 All critical industrial injuries shall be reported promptly to MAHESH GAS/TPIA and a copy of
Contractor’s report covering each personal injury requiring the attention of physician shall be
furnished to MAHESH GAS/TPIA.
1.17. NO EXEMPTION
 Notwithstanding the above there is nothing in these to exempt the Contractorfrom the operation
of any other act or rules in force.
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EXHIBIT - A
ELECTRODE QUALIFICATION TEST RECORD

A: Tested at
Date :
(SiteName) :
Manufacturer’sName :
Brand Name :
BatchNumber :
Size tested Classification&Code :
Intended for weldinginpositions :
In Combination with(Ifany) :
Code of Reference (Used for testing) : Special
requirements(Ifany) :
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B: All-Weld Tensile Test

BaseMaterialUsed :
Pre-HeatTemp. :
Post-weld Heat Treatment Details :
Visual Examination :
Radiographic Examination Results :
Tensile test Results :

Identification No. U.T.S Yield Point Elongation Remark

C: Impact Test Results

Test Temperature : Notch in :
Type of Specimens (Charpy) : Size of Specimens :
————————————————————————————————————
Specimen No. Impact Value Average
————————————————————————————————————
1.
2.
3.
4.
5.
-——————————————————————-—————————————
D: Chemical Analysis Results:
Electrode Size Used :
BatchNo. :
—————————————————————————
%C %S %P %Si %Mn %Cr %Ni %Mo Other

—————————————————————————
E: Fillet Weld Test Results:
Welding Positions :
BaseMaterials :
Size ofElectrodeUsed :

Visual Inspection Results :

 PTS – PIPELINE WELDING MaGL-PTS-
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1) :

2) :

3) :

Macro Test Results :

Fracture Test Results :

Remarks :

F: Other Test Results:

Transverse Tensile Test :

In combination with :
Base Material Used :
Position of welding :
Preheat Temperature :
Post weld heat treatment :
Radiography :
Identification No. :
U.T.S. Fracture in Remarks :

2. Guided Bend Test:

—————————————————————————————————————————
Position ID No. Root, Face or Side Bend Remarks
—————————————————————————————————————————
1)

2)

3)

4)

5)
—————————————————————————————————————————
Any other tests :
Conclusions :
 PTS – PIPELINE WELDING MaGL-PTS-HDD-
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---------------------- ---------------------- ----------------------

PREPARED BY REVIEWED BY APPROVED BY
(CONTRACTOR) (CONTRACTOR) (OWNER/TPIA)

EXHIBIT - B
Example of Record form for Welding Procedure Approval Test:

Project/Contract :
Contractor :
Pipe and Fitting Material :
Process :
Outside Diameter :
Pipe Thickness :
Joint design (Sketch Attached) :
Make and Type of filler metal :
Diameter :
 PTS – PIPELINE WELDING MaGL-PTS-
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Current :
Voltage :
Root :
SecondRun :
OtherRuns :
Other electrical characteristics:
A.C./D.C :
Electrode Negative / Positive :
Shielding Gas :
Type of Mixture :
Flow :
Shielding Flux :
Position :

Direction of Welding :
Root : Vertical up* / Vertical Down
Second Run : Vertical up* / Vertical Down
Other Runs : Vertical up* / Vertical
Down Number of Welders :
Root :
Second Run :
Other Runs :
Time Lapse between Commencements of Root and Commencement of Second Run:

Time lapse between commencement of second run and commencement of other runs:

Minimum number of runs before point allowed to cool:

Maximum time between commencements and completion or weld:

Type of line-up clamp :

Removal of clamp after : Run

Lowering off after : Run

Cleaning
Preheating

Minimum temperature0C : Ambient Temperature 0C :

Type of heater to be used
Inter pass temperature0C

Minimum0C : Maximum 0C :

Post weld heat treatment

 PTS – PIPELINE WELDING MaGL-PTS-HDD-
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Speed of travel : Test Results :

[State acceptable non-acceptable (with reasons) or give numerical results]:
Non-destructive tests:
Visual :

Destructive Test 1 2 3 4
Transverse tensile
Tensile strength (with units)
Fracture location
Test temperature
Macro examination
Fillet weld fracture
Hardness survey
Hardness range
Parent Metal
Heat affected zone
Weld
Chary V-notch impact tests
Specimen location and size
Notch location
Test temperature
Results (With units)
Type Load Location of hardness measurements (Sketch)

Additional test(s) and results, e.g., chemical analysis, micro-examination, CTOD tests, Bend tests, Nick-Break
Tests.
The test joints were prepared, welded and tested in accordance with the requirements of specification.

The statements in this record are correct.

Contractor Inspector

Designation Witnessed by

Date Date

EXHIBIT - C
Example of record form for welder approval test

Welder test certificate : Test No. :

Project/Contract : Date :

Contractor : Inspector :
Welder’s Name :
Address :
Pipe material :
Pipe thickness :
Pipe outside diameter :
Welding Process For Root: For Filler and Cap:

 Root Current : Voltage :

 Second run Current : Voltage :

 Current : Voltage :
Filler&Cap
Direction of travel
Root :
Filler and cap :
Reason for failure :
Visual :
Non-destructive testing :
Butt joint :
Fillet Weld :

Number of attempts :
Comments :
Accepted Date&Time :
Contractor’sSign :

Inspector’sSign :
* Delete as necessary.
 EXHIBIT - D
WELDER’S IDENTIFICATIONCARD
MAHESH GAS LTD.
WELDER’S IDENTITY CARD

Name Welding Position

WelderNo. Material

Date of Testing Valid Diameter

upto Wallthickness

Approval of Welding Type of welding Consumables Thickness

Range Qualified Diameter Range

W.P.S. Nos.
Qualified

APPROVEDBY MAHESH GAS/TPIA

VALID FROM: VALID TILL:

MAHESH GAS SITE ENGINEER THIRD PARTY AGENCY
SIGN SIGN
DATE DATE

NOTE:
1) Validity Period of Welder shall be up to the satisfactory performance / 1 year whichever is lesser.
2) Repair percentage for any welder should be 5% max., minimum of 25 joints shall be welded by any welder
for calculating repair percentage calculation.
3) Contractor shall track the repair percentage of welders and report shall be made available to MAHESH
GAS/TPIA on monthly basis. In case, the repair percentage for any welder is more than the specified limit as
mentioned above, at any point of time, contractor shall terminate the welderimmediately.
4) Welder after qualification, if is not performing any welding work due to any reasons for more than 90 days,
welder requalification shall be done.

EXHIBIT - E

RADIOGRAPHIC PROCEDURE FOR PIPE WELDING

1. Location
2. Date of Testing
3. Name of Supervised Contractor
4. Material
5. Dia. and Thickness
6. Type of Weld Joint
7. Radiation Source (X-ray,iridium)
8. Type of equipment (External /Internal)
9. Intensifying screens andmaterial
10. Filter type and placement mask, Diaphragm Lead screen etc. adjacent to radiation source orspecimen.
11. Geometric relationship (Source local spot size, max and min source strength, object to film distance,
radiation angle with respect to weld andfilm).
12. Limit of film coverage
13. Film type and make
14. Exposure time
15. Processing (time temperature for development, stop bath or rinse, fixation, washing, dryingetc.)
16. Density
17. Sensitivity
18. Type ofPenetrameter
19. Essential wire to be seen on sourceside.
20. Essential wire accepted for filmviewing

Approval of the MAHESHGAS/TPIA Signature of Contractor with seal

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TABLE 1

NUMBER OF SPECIMENS
PIPE SIZE, OUTSIDE DIAMETER
INCHES TENSILE TENSILE NICK ROOT FACE SIDE MACRO HARD IMPACT TOTAL
API ISO BREAK BEND BEND BEND NESS

WALL THICKNESS – ½” INCH UNDER (12.7 mm)

UNDER 2 3/8 0 0 2 2 0 0 0 0 0 4

2 3/8 – 4 ½ 0 0 2 2 0 0 0 0 0 4

OVER 4 ½ - 12 ¾ 2 0 2 2 2 0 2 2 12 24

12 ¾ AND OVER 2 2 4 4 4 0 2 2 24 44

WALL THICKNESS – ½” INCH OVER (12.7 mm)

4 ½ AND SMALLER 0 0 2 0 0 2 0 0 0 4

OVER 4 ½ LESS THAN 12 ¾ 2 0 2 2 0 2 2 2 12 24

12 ¾ AND OVER 2 2 4 0 0 8 2 2 24 44
 WELDING SPECIFICATION CHART

PIPE WELDING PROCESS FILLER

SR.NO. ITEM MATERIAL NDT
DIA./THK METAL
. ROOT FILLER ROOT FILLER

1 Pipe to Pipe SMAW SMAW

1.1 Pipe API 5L Gr. X52 ALL SIZE 100 %

UP Hill/ Down UP Hill/ Down
Hill Hill As per approved Radiography
WPS
1.2 Pipe API 5L Gr. X52 ALL SIZE

2 Pipe to Fitting SMAW SMAW

2.1 Pipe API 5L Gr. X52 ALL SIZE 100 %

Uphill Downhill As per approved Radiography

2.2 Fitting MSS SP WPHY 52 ALL SIZE WPS
OR ASTM A 694 F 52

3 Pipe to Flange 100 %

Radiography
3.1 Pipe API 5L Gr. X 52 ALL SIZE
UP Hill UP Hill
3.2 Flange MSS SP F 52 OR ALL SIZE As per approved
WPS
ASTM A694 F 52