IN-SERVICE
WELDING
In-service welding is the process of performing welding operations on pipelines or equipment while they remain in operation, typically under pressure or containing fluids. This method is often used in the oil and gas industry to repair, modify, or add connections without shutting down the system, minimizing downtime and production loss. Due to the inherent risks of welding on live systems, careful planning, specialized techniques, and strict safety protocols are essential to prevent accidents, such as explosions or leaks, ensuring a safe and successful operation.
KEY OF SUCCESS
01.
Engineering Deisgn
02.
Pre-Weld
Execution
03.
Welding Execution
04.
Post-Weld Inpsection
05.
Documentation &
Reporting
01
Engineering Deisgn
Feasibility Study: Determine if in-service welding is feasible, considering factors like pipe material, fluid type, pressure, and temperature.
Risk Assessment: Conduct a thorough risk assessment to identify potential hazards, such as the possibility of leaks, explosions, or fires.
Procedure Development: Develop a detailed welding procedure specification (WPS) that outlines the welding techniques, materials, and safety measures to be used.
Support Calculation: Calculate the required document such as Maximum Allowable Pressure (MAOP) during welding, PRCI calculation
02
Pre-Welding Execution
Inspect the Area: Examine the pipeline or equipment for the actual thickness, any defects, corrosion, or damage that could impact welding.
Verify Conditions: Ensure that conditions such as flow rates, pressure, and temperature are within safe limits for welding.
Procedure/Welder Qualification: Qualify provided welding procedure(WPS) make sure the procedure / welder is suaitable and ready for the job site.
Fire Protection: Install fire-resistant barriers and have firefighting equipment on standby
03
Welding Execution
Preheat (if required): Preheat the weld area to reduce the risk of cracking, especially in thick or high-carbon steel pipes.
Welding: Perform the welding according to the WPS/PQR/WQT, using techniques that minimize heat input and reduce the risk of burn-through or hot cracking.
Continuous Monitoring: Monitor the weld area and surrounding environment for any signs of leaks, pressure changes, or other hazards during welding. Perform NDT methods, such as Magnetic particle Test (MT) to confirm welding soundness every layer.
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04
Post-Welding Inspection
Visual Inspection: Inspect the weld visually for defects, such as cracks, porosity, or incomplete fusion.
Nondestructive Testing (NDT): Perform NDT methods, such as
phase array ultrasonic testing and/or Magnetic particle Test (MT), to ensure the weld's integrity and detect any internal flaws.
05
Documentation & Reporting
Record Keeping: Document all procedures, inspections, and tests performed during the in-service welding process.
Final Report: Prepare a final report summarizing the work done, including any issues encountered and corrective actions taken.
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CODE & STANDARD
API
(American Petroleum Institute)
API 1104 : Welding of pipeline & relate facilities
API RP 2201: Procedure for welding or hot tapping on equipment in service
ASME
(American Society of Mechanical Engineers)
ASME B31.1: Power Piping
ASME B31.3: Process Piping
ASME B31.4: Liquid Transmission
ASME B31.8: Gas Transmission
ASME Section IX: Qualification Standard for Welding, Brazing, and Fusing Procedures; Welders; Brazers;
and Welding, Brazing, and Fusing Operators
OTHERS
Shell DEP 30.10.60.30: Welding on pressurize pipe
​Shell DEP 31.38.60.10: Hot tapping on pipeline piping & Equipment
ANSI/NACE MR0175/ISO15156-1:
Petroleum, petrochemical, and natural
gas industries — Materials for use in H2S-containing environments in oil and gas production
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Expertise You Can Rely On
Our team of certified welders and engineers is equipped with the skills and knowledge to handle the most complex welding tasks on live systems. We have successfully completed projects on pipelines, pressure vessels, and other critical infrastructure for clients across various industries.
Customized Solutions
Every project is unique, and we tailor our in-service welding services to meet your specific requirements. Whether you need emergency repairs, pipeline modifications, or routine maintenance, we develop customized welding solutions that fit your operational needs and budget.
Safety is Our Top Priority
We understand the risks associated with in-service welding, which is why we adhere to the strictest safety protocols. Our welding procedures are developed with safety in mind, minimizing the risk of accidents while ensuring the integrity of your systems. We conduct thorough risk assessments and use advanced monitoring techniques to ensure every weld is executed flawlessly.
Proven Track Record
Our portfolio speaks for itself. We have a long list of satisfied clients who have benefitted from our in-service welding services. Browse our Case Studies to see how we’ve helped businesses like yours maintain their systems and avoid costly downtime.