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Mechanical Test 1

This document outlines 3 welding procedure specifications (WPS) for Jimit & Co. for the Ahmedabad City Gas Distribution Project for Adani Gas Limited. The WPS describe the SMAW welding process for API 5L Grade X42 steel pipe with diameters from 2.375" to 12.750" and wall thicknesses from 0.188" to 0.750". The WPS cover new construction welds, full through repair welds, and partial repair welds. Key parameters specified include preheat temperature, filler metals, electrode sizes, voltages, currents, travel speeds, and positions.

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Manoranjan sharma
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307 views21 pages

Mechanical Test 1

This document outlines 3 welding procedure specifications (WPS) for Jimit & Co. for the Ahmedabad City Gas Distribution Project for Adani Gas Limited. The WPS describe the SMAW welding process for API 5L Grade X42 steel pipe with diameters from 2.375" to 12.750" and wall thicknesses from 0.188" to 0.750". The WPS cover new construction welds, full through repair welds, and partial repair welds. Key parameters specified include preheat temperature, filler metals, electrode sizes, voltages, currents, travel speeds, and positions.

Uploaded by

Manoranjan sharma
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLS, PDF, TXT or read online on Scribd
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Welding Procedure Specification

(AS PER API 1104:2016 & client spec.)


Welding Procedure for: Mainline & Tie-In Welding
JIMIT & CO.

Preliminary WPS No: JIMIT & CO./AGL/ACGD/WPS-01


Name of the Project Ahmedabad City Gas Distribution Project.
Client Adani Gas Limited
Welding Process SMAW
Pipe Material with Grade API 5L Gr. X 42
Pipe Group (a) in 5.4.2.2 of API 1104 , Less than or equal to 42,000 psi (290 MPa)
Pipe Outside Diameter 219.1mm
Diameter Range From 2.375" (60.3 mm) through 12.750" (323.9 mm)
Wall Thickness of Pipe 6.4 mm
Wall Thickness Range From 0.188" (4.8 mm) through 0.750" (19.1 mm)
Joint Design Sketch Refer drawing enclosed
Weld Technique Stringer / Weave
Pre Heat Temperature NA
Post weld Heat Treatment NA
Filler Metal
a) Root E 6010, 2.5 mm
b) Hot, Filler I, Filler II & Capping E 7010-P1, 3.2 mm
Electrical Characteristic DCEP
Position 5G
Direction of Welding
a) Root Up Hill
b) Hot, Filler & Capping Down Hill
No. of Welders One
Time lapse between Pass Maximum 5 minutes
Type of Line up Clamp External
Removal of Clamp After 60% of root run
Cleaning of All Passes Grinding / Power brushig

Other Electrical Characteristics


Current Travel Speed
Bead Electrode Make Dia (mm) Voltage (Amps) (mm per Minute)
Root Pass E 6010 Lincoln 2.5 26 - 36 55 - 90 52 - 80
Hot Pass E 7010-P1 Lincoln 3.2 27 - 34 75 - 115 210 - 260
Filler I E 7010-P1 Lincoln 3.2 26 - 34 85 - 115 180 - 250
Filler II E 7010-P1 Lincoln 3.2 26 - 34 85 - 115 190 - 240
Capping E 7010-P1 Lincoln 3.2 25 - 34 90 - 115 160 - 200

FOR JIMIT & CO. FOR ICS FOR AGL

Name:
Signature:
Date:
Welding Procedure Specification
(AS PER API 1104:2016 & client spec.)
Welding Procedure for: Mainline & Tie-In Repair Welding
(FULL THROUGH REPAIR)
JIMIT & CO.

Preliminary WPS No: JIMIT & CO./AGL/ACGD/WPS-02


Name of the Project Ahmedabad City Gas Distribution Project.
Client Adani Gas Limited
Welding Process SMAW
Pipe Material with Grade API 5L Gr. X 42
Pipe Group (a) in 5.4.2.2 of API 1104 , Less than or equal to 42,000 psi (290 MPa)
Pipe Outside Diameter 219.1mm
Diameter Range From 2.375" (60.3 mm) through 12.750" (323.9 mm)
Wall Thickness of Pipe 6.4 mm
Wall Thickness Range From 0.188" (4.8 mm) through 0.750" (19.1 mm)
Joint Design Sketch Refer drawing enclosed
Weld Technique Stringer / Weave
Pre Heat Temperature 100° C minimum at repair area before welding start.
Post weld Heat Treatment NA
Filler Metal
a) Root E 6010, 2.5 mm
b) Hot, Filler I, Filler II & Capping E 7010-P1, 3.2 mm
Electrical Characteristic DCEP
Position 5G
Direction of Welding
a) Root Up Hill
b) Hot, Filler & Capping Down Hill
No. of Welders One
Time lapse between Pass Maximum 5 minutes
Type of Line up Clamp NA
Removal of Clamp NA
Cleaning of All Passes Grinding / Power brushing
Note : After repair cutting DPT shall be carried out of repair area.

Other Electrical Characteristics

Bead Electrode Make Dia (mm) Voltage Current Travel Speed


(Amps) (mm per Minute)
Root Pass E 6010 Lincoln 2.5 26 - 36 55 - 90 52 - 80
Hot Pass E 7010-P1 Lincoln 3.2 27 - 34 75 - 115 210 - 260
Filler I E 7010-P1 Lincoln 3.2 26 - 34 85 - 115 180 - 250
Filler II E 7010-P1 Lincoln 3.2 26 - 34 85 - 115 190 - 240
Capping E 7010-P1 Lincoln 3.2 25 - 34 90 - 115 160 - 200

FOR JIMIT & CO. FOR ICS FOR AGL

Name:
Signature:
Date:
Welding Procedure Specification
(AS PER API 1104:2016 & client spec.)
Welding Procedure for: Mainline & Tie-In Repair Welding
(Partial repair)
JIMIT & CO.

Preliminary WPS No: JIMIT & CO./AGL/ACGD/WPS-03


Name of the Project Ahmedabad City Gas Distribution Project.
Client Adani Gas Limited
Welding Process SMAW
Pipe Material with Grade API 5L Gr. X 42
Pipe Group (a) in 5.4.2.2 of API 1104 , Less than or equal to 42,000 psi (290 MPa)
Pipe Outside Diameter 219.1mm
Diameter Range From 2.375" (60.3 mm) through 12.750" (323.9 mm)
Wall Thickness of Pipe 6.4 mm
Wall Thickness Range From 0.188" (4.8 mm) through 0.750" (19.1 mm)
Joint Design Sketch Refer drawing enclosed
Weld Technique Stringer / Weave
Pre Heat Temperature 100° C minimum at repair area before welding start.
Post weld Heat Treatment NA
Filler Metal
a) Root NA
b) Hot, Filler I, Filler II & Capping E 7010-P1, 3.2 mm
Electrical Characteristic DCEP
Position 5G
Direction of Welding
a) Root NA
b) Hot, Filler & Capping Down Hill
No. of Welders One
Time lapse between Pass Maximum 5 minutes
Type of Line up Clamp NA
Removal of Clamp NA
Cleaning of All Passes Grinding / Power brushig
Note : After repair cutting DPT shall be carried out of repair area.

Other Electrical Characteristics

Bead Electrode Make Dia (mm) Voltage Current Travel Speed


(Amps) (mm per Minute)
Hot Pass E 7010-P1 Lincoln 3.2 26-32 80 - 110 200 - 260

Filler I E 7010-P1 Lincoln 3.2 27-30 85 - 110 190 - 240

Filler II E 7010-P1 Lincoln 3.2 26-32 85 - 115 190 - 240

Capping E 7010-P1 Lincoln 3.2 28-34 90 - 115 150 - 200

FOR JIMIT & CO. FOR ICS FOR AGL

Name:
Signature:
Date:
Welding Procedure Specificatoion
(As Per API 1104:2016 & client spec.)
Welding Procedure For Mainline & Tie-In Repair Welding
( Partial Repair)
JIMIT & CO.

Sketch:

1= Hot Pass
2= Filler I
3=Filler II
N= Capping

FOR JIMIT & CO. FOR ICS FOR AGL

NAME:
SIGN:

DATE:
Procedure Qualification Record
(API 1104- Edition 2016 & client spec.)
JIMIT & CO.

Date of Welding of Test Coupen 17.01.2019


PQR No.: JIMIT & CO./AGL/AGCGD/PQR/01
Supporting WPS No. JIMIT & CO./AGL/ACGD/WPS-01
Name of the Project Ahmedabad City Gas Distribution Project.
Client Adani Gas Limited
Welding Process SMAW
Pipe Material with Grade API 5L GR X 42
Pipe Outside Diameter 219.1 mm
Base Material SMYS Group (a) in 5.4.2.2 of API 1104
Wall Thickness of Pipe 6.4 mm
Weld Technique Stringer / Weave
Pre Heat Temperature NA
Post weld Heat Treatment NA
Filler Metal
a) Root E 6010, 2.5 mm
b) Filler I, Filler II & Capping E 7010-P1, 3.2 mm
Electrical Characteristic DCEP
Position 5G
Direction of Welding
a) Root Up Hill
b) Hot pass, Filler & Capping Down Hill
Name of Welder Niyaz Aahmad- Welder No-01
Time lapse between Root & Filler Pass 4 Minutes
Time lapse between Filler & Capping
Passes 5 minutes

Type of Line up Clamp NA


Removal of Clamp NA
Cleaning of All Passes Grinding / Power brushig

Other Electrical Characteristics


Current Travel Speed
Bead Electrode Make Dia (mm) Voltage (Amps) (mm per Minute)
Root Pass E 6010 Lincoln 2.5 29-32 60-68 230
HOT PASS E 7010-P1 Lincoln 3.2 27-30 85-92 132
Filler I E 7010-P1 Lincoln 3.2 28-32 75-80 128
Filler II E 7010-P1 Lincoln 3.2 30-32 78-82 128
Capping E 7010-P1 Lincoln 3.2 31-33 78-85 145

FOR JIMIT & CO. FOR ICS FOR AGL

Name:
Signature:
Date:
Procedure Qualification Record For Full thickness Repair
(API 1104- Edition 2016 & client spec.)
JIMIT & CO.

Date of Welding of Test Coupen 17.01.2019


PQR No.: JIMIT & CO./AGL/ACGD/PQR/02
Supporting WPS No. JIMIT & CO./AGL/ACGD/WPS-02
Name of the Project Ahmedabad City Gas Distribution Project.
Client Adani Gas Limited
Welding Process SMAW
Pipe Material with Grade API 5L GR X 42
Pipe Outside Diameter 219.1 mm
Base Material SMYS Group (a) in 5.4.2.2 of API 1104
Wall Thickness of Pipe 6.4 mm
Weld Technique Stringer / Weave
Pre Heat Temperature NA
Post weld Heat Treatment NA
Filler Metal
a) Root E 6010, 2.5 mm
b) Filler I, Filler II & Capping E 7010-P1, 3.2 mm
Electrical Characteristic DCEP
Position 5G
Direction of Welding
a) Root Up Hill
b) Hot pass, Filler & Capping Down Hill
Name of Welder Niyaz Aahmad- Welder No-01
Time lapse between Root & Filler Pass 4 Minutes
Time lapse between Filler & Capping
Passes 5 minutes

Type of Line up Clamp NA


Removal of Clamp NA
Cleaning of All Passes Grinding / Power brushig

Other Electrical Characteristics


Current Travel Speed
Bead Electrode Make Dia (mm) Voltage (Amps) (mm per Minute)
Root Pass E 6010 Lincoln 2.5 29-31 62-65 232
HOT PASS E 7010-P1 Lincoln 3.2 28-30 80-92 132
Filler I E 7010-P1 Lincoln 3.2 30-32 75-80 129
Filler II E 7010-P1 Lincoln 3.2 30-32 78-82 130
Capping E 7010-P1 Lincoln 3.2 31-33 78-85 145

FOR JIMIT & CO. FOR ICS FOR AGL

Name:
Signature:
Date:
Procedure Qualification Record for Partial thickness Repair
(API 1104- Edition 2016 & client spec.)
JIMIT & CO.

Date of Welding of Test Coupen 17.01.2019


PQR No.: JIMIT & CO./AGL/ACGD/PQR/03
Supporting WPS No. JIMIT & CO./AGL/ACGD/WPS-03
Name of the Project Ahmedabad City Gas Distribution Project.
Client Adani Gas Limited
Welding Process SMAW
Pipe Material with Grade API 5L GR X 42
Pipe Outside Diameter 219.1 mm
Base Material SMYS Group (a) in 5.4.2.2 of API 1104
Wall Thickness of Pipe 6.4 mm
Weld Technique Stringer / Weave
Pre Heat Temperature NA
Post weld Heat Treatment NA
Filler Metal
a) Root E 6010, 2.5 mm
b) Filler I, Filler II & Capping E 7010-P1, 3.2 mm
Electrical Characteristic DCEP
Position 5G
Direction of Welding
a) Root NA
b) Hot pass, Filler & Capping Down Hill
Name of Welder Niyaz Aahmad- Welder No-01
Time lapse between Root & Filler Pass 4 Minutes
Time lapse between Filler & Capping
Passes 5 minutes

Type of Line up Clamp NA


Removal of Clamp NA
Cleaning of All Passes Grinding / Power brushig

Other Electrical Characteristics


Current Travel Speed
Bead Electrode Make Dia (mm) Voltage
(Amps) (mm per Minute)
HOT PASS E 7010-P1 Lincoln 3.2 28-30 82-92 132
Filler I E 7010-P1 Lincoln 3.2 30-32 75-80 130
Filler II E 7010-P1 Lincoln 3.2 30-32 75-82 132
Capping E 7010-P1 Lincoln 3.2 31-33 78-85 145

FOR JIMIT & CO. FOR ICS FOR AGL


Name:
Signature:
Date:
01.2019
IT & CO./AGL/ACGD/PQR/03
IT & CO./AGL/ACGD/WPS-03
medabad City Gas Distribution Project.
ani Gas Limited
AW
5L GR X 42
9.1 mm
in 5.4.2.2 of API 1104
mm
nger / Weave

010, 2.5 mm
010-P1, 3.2 mm
EP

wn Hill
az Aahmad- Welder No-01
Minutes

minutes

nding / Power brushig

Other Electrical Characteristics


Travel Speed
(mm per Minute)
132
130
132
145

FOR AGL
Procedure Qalification Recod For Partial Thickness Repair
(As Per API 1104:2016 & client spec.)

JIMIT & CO.

Sketch:

1= Hot Pass
2= Filler I
3=Filler II

FOR JIMIT & CO. FOR ICS FOR AGL

NAME:
SIGN:

DATE:
Procedure Qualification Record
(API 1104- Edition 2016 & client spec.)

Mechanical Testing Result


Welder Name: Niyaz Aahmad Welder No.: W-01

Tensile Testing Results: Accepted Report No.: ME/TA19/5


Specimen No. 1: 477.59 N/mm² Specimen No. 2 : 478.58 N/mm²

Nick break Test Results: Accepted Report No.: ME/TA19/5


Specimen No. 1: Satisfactory Specimen No. 2: Satisfactory

Root bend Test Results: Accepted Report No.: ME/TA19/5


Specimen No. 1: Satisfactory Specimen No. 2: Satisfactory

Face bend Test Results: Accepted Report No.: ME/TA19/5


Specimen No. 1: Satisfactory Specimen No. 2: Satisfactory

Impact Test(Charpy V notch Test at -10°) Results: Accepted


Report No.: ME/TA19/5
Size Weld Fusion Line 2mm fromFL 5mm from FL
Energy Observed in
10 x5mm 54-68-66 92-88-78 108-82-114 122-118-124
J Min 8 J
Average Value J Min
10 x5mm 62.66 86 101.33 121.33
10J

Impact Test(Charpy V notch Test at 0°) Results: Accepted


Report No.: ME/TA19/5
Size Weld Fusion Line 2mm fromFL 5mm from FL
Energy Observed in
10 x5mm 78-86-66 102-108-108 124-122-132 132-128-138
J Min 8 J
Average Value J Min
10 x5mm 76.66 106 126 132.66
10J

Hardness Test Results: Accepted Report No.: ME/TA19/5

Sample 1 Sample 2 Sample 1 Sample 2 Sample 1 Sample 2


Location
Reading 1 Reading 2 Reading 3
1mm below(Top) Parent 175 174 171 176 178 172
1mm below(Top) HAZ 166 161 160 163 166 164
1mm below(Top) Weld 174 173 182 178 185 180
centre Parent 169 168 168 172 171 175
centre HAZ 162 161 166 164 160 166
centre Weld 192 189 188 190 190 186
1mm below(Bottom) Parent 174 170 178 173 169 176
1mm below(Bottom) HAZ 164 160 166 162 164 166
1mm below(Bottom) Weld 182 182 185 186 188 188

Macro Test Results: Accepted Report No.: ME/TA19/5


Specimen No. 1: Satisfactory Specimen No. 2: Satisfactory

Micro Structure Test Results: Accepted Report No.: ME/TA19/5


Specimen No. 1: Satisfactory Specimen No. 2: Satisfactory

Tested at: Meta Lab Enterprise(Ahmedabad)


Report No.: ME/TA19/5
Date: 22.01.2019

FOR JIMIT & CO. FOR ICS FOR AGL

SIGN:

NAME:

DATE:
Procedure Qualification Record for Full thickness
Repair
(API 1104- Edition 2013 & client spec.)

Mechanical Testing Result


Welder Name: Niyaz Aahmad Welder No.: W-01

Tensile Testing Results: Accepted Report No.: ME/TA19/6


Specimen No. 1: 468.96 N/mm² Specimen No. 2 : 465.76 N/mm²

Nick break Test Results: Accepted Report No.: ME/TA19/6


Specimen No. 1: Satisfactory Specimen No. 2: Satisfactory

Root bend Test Results: Accepted Report No.: ME/TA19/6


Specimen No. 1: Satisfactory Specimen No. 2: Satisfactory

Face bend Test Results: Accepted Report No.: ME/TA19/6


Specimen No. 1: Satisfactory Specimen No. 2: Satisfactory

Impact Test(Charpy V notch Test at -10°) Results: Accepted


Report No.: ME/TA19/6
Size Weld Fusion Line 2mm fromFL 5mm from FL
Energy Observed in J
10 x 5mm 50-48-50 70-56-54 80-76-78 98-98-90
Min 8 J
Average Value J Min
10 x 5mm 49.33 60 78 95.33
10J

Impact Test(Charpy V notch Test at 0°) Results: Accepted


Report No.: ME/TA19/6
Size Weld Fusion Line 2mm fromFL 5mm from FL
Energy Observed in J
10 x 5mm 58-64-46 64-64-72 90-98-88 110-108-114
Min 8 J
Average Value J Min
10 x 5mm 56 66.66 92 110.66
10J

Hardness Test Results: Accepted Report No.: ME/TA19/6

Sample 1 Sample 2 Sample 1 Sample 2 Sample 1 Sample 2


Location
Reading 1 Reading 2 Reading 3
1mm below(Top) Parent 166 168 172 162 162 167
1mm below(Top) HAZ 162 158 161 168 165 163
1mm below(Top) Weld 186 194 190 188 186 189
centre Parent 167 170 165 169 164 162
centre HAZ 157 160 155 154 159 158
centre Weld 182 183 183 192 181 188
1mm below(Bottom) Parent 160 163 164 169 165 175
1mm below(Bottom) HAZ 153 159 154 168 157 163
1mm below(Bottom) Weld 185 190 182 194 188 186

Macro Test Results: Accepted Report No.: ME/TA19/6


Specimen No. 1: Satisfactory Specimen No. 2: Satisfactory

Micro Structure Test Results: Accepted Report No.: ME/TA19/6


Specimen No. 1: Satisfactory Specimen No. 2: Satisfactory

Tested at: Meta Lab Enterprise(Ahmedabad)


Report No.: ME/TA19/6
Date: 23.01.2019

FOR JIMIT & CO. FOR ICS FOR AGL

SIGN:

NAME:

DATE:
Procedure Qualification Record for Partial thickness
Repair
(API 1104- Edition 2013 & client spec.)

Mechanical Testing Result


Welder Name: Niyaz Aahmad Welder No.: W-01

Tensile Testing Results: Accepted Report No.: ME/TA19/7


Specimen No. 1: 467.29 N/mm² Specimen No. 2 : 467.61 N/mm²

Nick break Test Results: Accepted Report No.: ME/TA19/7


Specimen No. 1: Satisfactory Specimen No. 2: Satisfactory

Root bend Test Results: Accepted Report No.: ME/TA19/7


Specimen No. 1: Satisfactory Specimen No. 2: Satisfactory

Face bend Test Results: Accepted Report No.: ME/TA19/7


Specimen No. 1: Satisfactory Specimen No. 2: Satisfactory

Impact Test(Charpy V notch Test at -10°) Results: Accepted


Report No.: ME/TA19/7
Energy Observed in
10 x 5mm 48-50-54 76-76-70 88-90-86 108-104-98
J Min 8 J
Average Value J Min
10 x 5mm 50.66 74 88 z
10J

Impact Test(Charpy V notch Test at 0°) Results: Accepted


Report No.: ME/TA19/7
Size Weld Fusion Line 2mm fromFL 5mm from FL
Energy Observed in
10 x 5mm 52-50-62 72-78-68 98-82-86 110-108-106
J Min 8 J
Average Value J Min
10 x 5mm 54.66 72.66 88.66 108
10J

Hardness Test Results: Accepted Report No.: ME/TA19/7

Sample 1 Sample 2 Sample 1 Sample 2 Sample 1 Sample 2


Location
Reading 1 Reading 2 Reading 3
1mm below(Top) Parent 174 182 177 171 177 178
1mm below(Top) HAZ 153 153 159 156 154 150
1mm below(Top) Weld 190 198 186 193 189 194
centre Parent 163 169 162 164 161 160
centre HAZ 154 151 155 158 152 156
centre Weld 186 187 183 190 190 192
1mm below(Bottom) Parent 168 169 161 165 163 160
1mm below(Bottom) HAZ 155 158 156 153 153 154
1mm below(Bottom) Weld 190 195 192 190 188 197

Macro Test Results: Accepted Report No.: ME/TA19/7


Specimen No. 1: Satisfactory Specimen No. 2: Satisfactory

Micro Structure Test Results: Accepted Report No.: ME/TA19/7


Specimen No. 1: Satisfactory Specimen No. 2: Satisfactory

Tested at: Meta Lab Enterprise(Ahmedabad)


Report No.: ME/TA19/7
Date: 23.01.2019

FOR JIMIT & CO. FOR ICS FOR AGL

SIGN:
NAME:

DATE:

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