PIPE WELDING PROCEDURE FOR ERW, BLACK STEEL, SCHEDULE 40, GRADE ‘B’, AND FITTINGS-WELDING NDT

OUTLINE

Outline for the method statement/pipe welding procedure 

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Pipe welding procedures for ERW (Electric Resistance Welded) black steel pipes, Schedule 40, Grade 'B', and fittings typically involve the following steps. It's important to note that specific welding procedures can vary based on the project requirements, applicable codes, and regulations. Always consult the project specifications and welding codes before proceeding. Below is a general guideline:

1. Preparation:

• Inspect the pipes and fittings to ensure they are clean, free from contaminants, and have no visible defects or damage.
• Verify that the materials comply with the required standards and specifications.

2. Joint Preparation:

• Bevel the pipe ends for butt-welding if required. The degree of bevel will depend on the pipe size and welding process.
• Ensure proper alignment and fit-up of the pipes and fittings to achieve a suitable joint configuration.

3. Welding Process:

• Common welding processes used for ERW black steel pipes are Shielded Metal Arc Welding (SMAW) or Gas Metal Arc Welding (GMAW).
• For SMAW, use appropriate electrodes, such as E6010 or E6011, for root passes, and E7018 for fill and cap passes.
• For GMAW, use a compatible filler wire for the base metal, often matching the specifications of the pipe material.

4. Welding Technique:

• Employ the proper welding technique to ensure consistent and sound welds.
• Control the travel speed, heat input, and electrode/filler wire angles for optimum results.

5. Welding Parameters:

• If required, · Follow the welding procedure specification (WPS) and welder qualifications.
• Set the welding parameters (current, voltage, wire feed speed, etc.) per the WPS or welding code.

6. Post-welding Inspection:

• Inspect the completed welds visually to ensure they are free from cracks, undercut, porosity, and other defects.
• Conduct non-destructive testing (NDT) if required, such as radiographic testing or ultrasonic testing, to assess the weld quality.

7. Post-weld Treatment:

Depending on the project specifications, post-weld treatments like stress relieving or heat treatment may be necessary.

8. Documentation:

Record all relevant welding parameters, inspection results, and any necessary reports as per project and regulatory requirements.

9. Quality Control and Assurance:

Adhere to the project's quality control and assurance protocols to maintain the required standards.
It's crucial to have the procedure carried out by qualified and certified welders who have experience with black steel pipes and fittings. Additionally, consult the specific standards and codes applicable to your project to ensure compliance with all safety and quality requirements.

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