PROPOSE WPS-01 FOR MAINLINE WELDING ( 16.
00" φ)
Project :- Laying & Construction of Steel Pipelines for Transportation of Oil Through Pipeline from Chattogram to Dhaka (CDPL), Bangladesh for
SECTION-VI
Client :- The 24 Engineer Construction Brigade (24 ECB) of Bangladesh Army
PMC :- M/s China Petroleum LONGWAY Engineering Project Management Co. Limited (LONGWAY)
Contractor:- M/s Steelmark Buildings Limited (SMBL)
WPS No. :- CDPL/SEC-VI-0001-PLL-DOC-0006 (WPS-01) REV-00 & Supporting PQR No. :- To be Established
APPLICABLE CODE:- API 1104 (Latest Edition ), ASME SEC. II PART-C, ASME B31.4 (Latest Edition) Mecon Spec. No. MEC/08PS/05/21/02 REV-00 and
MEC/WSC/01 REV-00
1 Process & Type SMAW (Manual) - MAINLINE
2 Base Material API 5L GR X-70 PSL 2
Material Range Qualified (API 5L GR X-70 PSL 2), SMYS 60,000 PSI
3
Diameter & Wall Thickness 16.00" dia & 11.1 mm Thk
Diameter Range > 12.750" to 30.000" (>323.9 to 762.0 mm)
4
Thickness Range 4.8 mm to 19.1 mm
5 Joint Design Single Bevel " V " Butt weld (refer Sketch)
ROOT Pass - SFA.5.1,E6010 (3.2MM)
6 Filler Metal& No. Of Beads HOT Pass - SFA.5.5,8010-P1 (4.0 MM)
Filler & Capping - SFA.5.5,E8010-P1 (4.0MM)
7 Electrical Characteristics All passes DC electrode Positive
8 Position 5G- Fixed horizontal
9 Direction of welding ALL PASSES - DOWN HILL
10 No. of Welder Two, (For each pass)
Max 4 min - Completion of Root pass and start of Hot pass
11 Time Lapse between Passes
max 5 min - Completion HOT pass and start of subsequent passes
d Type of Lineup Clamp Internal, Pneumatic & Manual
13 Removal of Lineup clamp 100 % Completion of Root & Hot Pass
14 Min No. of passes before the joint allow to cool 50% of wall thickness or Root +3 pass ( Whichever is more)
15 Cleaning and/ or Grinding Power Brushing ( Wire brush) , Grinding And Chipping
16 Completion of Joints Joint shall be completed with in 24 hours from start of weld
17 Method of Heating Rosebud Gas Burner
18 Pre-heat Temperature. 80⁰C Min
19 Inter Pass Temperature Maximum 250⁰ C
20 Temperature Checking Crayon / Pyrometer
21 Shielding Gas & Flow Rate N/A
22 Shielding Flux N/A
23 Speed of travel Refer Table
Max. time between commencement &
24 One heat cycle
completion of weld
25 Sketches and Tabulations Attached Yes
26 Lowering off (On skid) After completion of Root Run and Before removal of internal clamp
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PROPOSE WPS- 01 FOR MAINLINE WELDING ( 16.00" φ)
WPS No. :- CDPL/SEC-VI-0001-PLL-DOC-0006 (WPS-01) REV-00 & Supporting PQR No. :- To be Established
30⁰±2. 5
1.6±0.8mm 1.6 mm Max.
11.1 mm
1.6±0.8mm
1.6 mm Approx. 2mm Max 1.6±0.8mm
T= Thickness of Test Coupon RUN SEQUENCE SKETCH
STANDARD 'V' BEVEL BUTT JOINT
Travel Heat
DIRECTION OF Electrode Current
PASSES Manufacturer Dia In mm Polarity Volts Technique speed in Input Remarks
WELDING Type/Trade Name in Amps.
(mm/min) (kJ/mm)
ROOT
Downhill SFA 5.1 E 6010 BOHLER 3.2 mm DCEP 85-105 25-30 STRING 140-150 1061.38
PASS
HOT SFA 5.5 E 8010-
Downhill BOHLER 4.0 mm DCEP 125-145 28-35 WEAVE 230-250 1046.25
PASS P1
SFA 5.5 E 8010-
FILLER-1 Downhill BOHLER 4.0 mm DCEP 115-135 28-35 WEAVE 145-185 1409.09
P1
SFA 5.5 E 8010-
FILLER-2 Downhill BOHLER 4.0 mm DCEP 115-135 28-35 WEAVE 145-185 1409.09
P1
SFA 5.5 E 8010-
FILLER-3 Downhill BOHLER 4.0 mm DCEP 115-135 28-35 WEAVE 145-185 1409.09
P1
SFA 5.5 E 8010-
CAP Downhill BOHLER 4.0 mm DCEP 115-135 28-35 WEAVE 120-140 1788.46
P1
Proposed Parameter :- Actual Parameter to be recorded during PQR Qualification and same to be incorporate in WPS.
General Notes: (As per Applicable Specification.) Special Notes:
1. The surface to be welded shall be smooth, uniform and free of laminations
scale, slag, grease, paint and other foreign material that adversely effect 1. Manufacturer’s recommendations shall be followed for current & Voltage
welding.
2. Consumable batch test certificate shall be provided conforming to
2. The electrode starting and finishing point shall be staggered by 100 mm.
ASME SEC II C. SFA 5.1 & 5.5.
3. Consumable Batch Test Certificate (BTC) to be reviewed & EQT for Each
3. Two beads shall not be started from same location.
Batch has to be Performed.
4. Pipe end beveling shall be done by machine tool and grinding. 4. Welding Consumable Qualification test shall performed for all batches
5. Mismatch in Pipes of same nominal wall thickness shall not exceed 1.6 mm. including notch Toughness test as per ASME Sec.II,Part-C
5. Cleaning of Mile Scale/Grease/Dust etc. will be done on either side of the
6. Weaving shall be done upto maximum 2.5 times the dia of electrode.
bevel surface before start of welding.
6. One Pipes which have been cut back more than 25 mm.New Bevel Prepared
shall be 100% Visual, Dye Penetration Examination and UT Examination up to
a distance of minimum 25 mm shall be carried to ensure Lamination free
surface.
7. Only calibrated measuring and testing equipment shall be used
Prepared & Checked by: Reviewed & Approved By:
FOR SMBL FOR LONGWAY
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