L&T POWER-TPPC BU, ITPCL POWER PROJECT CUDDALORE

Quality Month Celebrations Nov-13

L&T POWER-TPPC BU
2 x 600MW ITPCL THERMAL POWER PROJECT

EXCELLENCE IN
WELD QUALITY

Compiled by : QA/QC Team, ILFS Project, Cuddalore

Date of Issue : 30-11-2013 ,Quality Month Celebrations Nov-13

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PREFACE
Welding is key process in Mechanical engineering that too
in Power plants it is one of the Main Technology area. To
achieve proper welding quality, awareness on welding
parameters is necessary.

As a preliminary step towards awareness creation,

we would like to present this

“ Excellence in Weld quality ”

This guide will help in understanding welding terms ,
Resource requirements, Reference standars, HSE
requirements etc.

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Topic Page
1. Introduction to Quality & Welding 4
2. Welding Processes 8
3. Power sources 14
4. Types of weld Joints& Weld symbols 20
5. WPS/ PQR 26
6. Parent material 32
7. Filler material 37
8. Thickness and Diameter 44
9. Welder qualifications & Weld positions 48
10. Preheat, Post heat , SR 54
11. Shielding and Purging 58
12. Other welding parameters 62
13. NDT Methods 64
14. Welding defects and control 71
15. HSE Management 82
16. Important Calculations & Norms 84
17. Reference standards & codes 92
18. Special Welding & NDT Practices 98
19. Project specific Technical data 110
20. Project Quality Management system 117

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1. INTRODUCTION TO QUALITY&
Definitions
1.1) QUALITY MANAGEMT SYSTEM is a method for
ensuring that all the activities necessary to design, develop
and implement a product or service are effective and
efficient with respect to the system and its performance
1.2) QUALITY ASSURANCE refers to planned and systematic
production processes that provide confidence in a product's
suitability for its intended purpose. It is a set of activities
intended to ensure that products (goods and/or services)
satisfy customer requirements in a systematic, reliable
fashion
1.3) ISO 9000 Definition of QUALITY : "Degree to which a set
of inherent characteristic fulfills requirements." The standard
defines requirement as need or expectation

Mere compliance to Procedures , codes and Quality plans doesn’t meant

of achieving 100% quality. The real quality is to Meet or Exceed the
Customer Expectations
1.4) Steps towards Achieving Excellence in Welding quality
• Compliance to Drawings
• Compliance to Field Quality Plan
• Compliance to Procedures
• Compliance to Codes and Standards

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• Compliance to Weld Data Sheet

• Zero Rework
• Achieving or Betterment of Norms
• Continuous Improvement
• Customer Satisfaction

1.5) Code is a body of laws, as of a nation , city etc., arranged

systematically easy reference. Code is a legal binding.
e.g: IBR, ASME Codes

1.6) Standard is something established for use as a rule or basis

of measuring or judging capacity, quantity, content, extent,
value, quality ,etc. Standard is a voluntary model.
e.g: ASTM, ISO

1.7) WELDING INSPECTION operation

Welding inspection operations will, for the most part, follow the
general sequence of the fabrication process. The following outline is a list of
activities encountered in welding inspection:
(1) Review of drawings, specifications, and manufacturing instructions
(2) Review of the manufacturer’s approved quality assurance & quality control
program
(3) Verification of welding procedures and personnel qualifications
(4) Verification of approved procedure for qualifying welding and inspection
personnel
(5) Selection and examination of production test samples
(6) Evaluation of test results
(7) Preparation of test reports and maintaining
(8) Observance and monitoring of recommended safety guidelines.

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1.8 Welding Inspector Responsibilities

It is appropriate here to consider attributes desirable for an individual
employed as a welding inspector. The nature of the job emphasizes an
individual’s physical, technical, and ethical qualities. Any weaknesses in these
areas can reduce the effectiveness of the individual’s performance.

The job of welding inspector carries a tremendous amount of responsibility.

Selection of the right person for that position should be based on consideration
of the following four critical attributes:
(1) Physical
-good physical condition
-good vision, whether natural or corrected

(2) Technical
- Interpretation of Drawings and Specifications
-Inspection Experience.
-Knowledge of Welding.
-Knowledge of Examination Methods.

(3) Ethical
-Integrity
-Responsibility to the Public
-Public Statements
-Conflict of Interest

(4) Personal
-Solicitation of Employment
-Professional Attitude
-Learning Potential
-Completing and Maintaining Inspection Records

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2. WELDING PROCESSES
2.1 Classification of welding methods

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What is welding ? Welding is a process of a localized

coalescence of metals or non-metals produced either by heating the
materials to the welding temperature with or without the application of
pressure alone, and with or without the application of filler material.
There are various welding methods available which can be selected
according to the quality standards, Economical considerations, Resource
availability etc. Following paragraph will summarize some of the
processes.

2.1 SMAW (Shielded Metal Arc welding)

Arc melts parent plate and electrode to form a weld pool which is
protected by flux cover.
CONSUMABLES

Metal rods 1.5-8mm diameter with flux covering (1-5mm radial
thickness).

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The characteristics of manual metal arc electrodes, I.e. arc stability,

depth of penetration, rate of deposition,
osition, position of welding, depends
on the chemical composition of the electrode coating classified by
AWS specifications.
Types of Consumables used in SMAW
Rutile: Titanium Dioxide, Clay , Sodium silicate
ide, Sodium silicate
Cellulosic: Cellulose( wood pulp), Titanium Dioxide,
Basic: Lime stone ( Calcium carbonate ), Titanium Dioxide, Sodium silicate

SMAW - OPERATING PARAMETERS

Current range : 75-300 A,

Range of Thickness: 2mm upwards

Deposition rate : 2-11 lb/Hr

Types of joint : All

Welding position : all (depending on flux coating)

Access : Good

Portability : Good

2.2 GTAW (Gas Tungsten Arc Welding)

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The GTAW welding process uses a non-consumable tungsten

electrode to provide an arc.Filler metal, when required, is fed from a
separate filler rod.A shielding gas, e.g. argon, is fed through the welding
gun to the weld area and provides a gas shield to prevent contamination
by the atmospheric gases. No fluxes are used with the process.
A high o.c.v. of around 90 volts is required for GTAW welding to ensure
arc stability at all times.The power sources used for GTAW are generator,
transformer , transformer-rectifier.High frequency current is superimposed
at the start of all d.c.welding operations.

2.3 GMAW (Gas Metal Arc welding)

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TYPE OF OPERATION : Manual, mechanized or automatic.

EQUIPMENT : Power Source ,wire feed Unit Welding gun or
torch, Gas supply system traveling unit if mechanized.

GMAW - OPERATING PARAMETERS

Current range : 65-500 A

Range of Thickness: Dip transfer, pulsed arc –
Above 0.5mm Spray transfer
6mm upwards

Deposition rate :12-10 Kg/Hr (2-20 Lb/Hr)

Types of joint : All including spot welds

Welding position : Dip transfer, pulsed Arc- All Spray
transfer – Flat(TJoints only-H.v)(with aluminum, spraytransfer
can be used in all positions)

Access : Fair

Portability : Fair

2.4 FCAW (Flux Cored Arc welding)

An arc welding process that uses an arc between a continuous filler
metal electrode and the weld pool. The process is used with shielding gas from
a flux contained within the tubular electrode, with or without additional
shielding from an externally supplied gas,and without the application of
pressure.The benefits of FCAW are achieved by combining
(1) The productivity of continuous wire welding
(2) The metallurgical benefits that can be derived
(3)A slag that supports and shapes the weld bead
FCAW combines characteristics of shielded metalarc welding (SMAW), gas
metal arc welding (GMAW), and submerged arc welding (SAW).

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3. POWER SOURCES
Eventhough electric arc can be struck with higher voltages (100-
200V), it is not recommended to use directly an industrial power connection
(440V/230V) for welding, for the following reasons. The arc struck with a
higher voltage will be inconveniently large and long. Hence the manipulation
of the arc will be difficult to achieve welding. Moreover, the energy loss of
such an arc will be uneconomically high making the welding process inefficient
in power.
The most important reason is that historically the manual arc welding
was developed first, hence the safety of the welder for reducing the risk of
electric shock hazard, necessitated a separate welding source to give reduced
operating arc voltages. A welding power source converts the input voltage to a
conveniently reduced safe operating voltage. Arc struck with such a power
supply will be small, and can be easily guided and manipulated.

3.1 CLASSIFICATION OF ARC WELDING POWER

SOURCES:

As we have seen already different arc welding processes require

different operating conditions, the power sources are also necessarily different.
Therefore a simplest classification of power sources is according to the
processes. But there are also some common aspects to these power sources.
Based on these common aspects we can classify these arc welding power
sources according to
1. Output characteristics
2. Nature of current output
3. Construction.

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There is wide range of Welding equipments available such as Welding

generators, Rectifiers, Transformers etc which can be selected according to the
Process and suitability. Almost all GMAW power supplies are constant voltage
machines, while Stick Electrode (SMAW) and TIG (GTAW) machines are a
constant current design.
The cables used must be subjected to periodical inspection to detect any
injury or other defects damaging their insulation. The cables connections must
be insulated correctly and the earth connection fixed securely to prevent any
parasite ignition arcing on surrounding pipes and components. The electrode-
holders shall be kept in good condition.
Power source selection guide

Sl.No Type Process Eff Critical MTCE Remarks

Cont. Cont.
01. Generators MMAW 60 – Medium Height Stable &
TIG 65 Smooth noisy
02. Transformers MMAW 40 Low Low Poor Arc
TIG stability
noiseless
03. Rectifiers MIG / 80 – Medium Low Highly
(Critical & CO2 SAW 90 Efficient most
SCR ) preferred
04. Electricity, MIG 80 – High Medium Sophisticated
Inverters, pulsed 90 critical jobs
Choppers TIG

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3.2 Welding generators

Historically these type of power

sources were developed first for Arc
welding applications and even now
these types are popular. These rotary
converters are of two types namely
motor driven and engine driven. The
engine driven type also comes in two
models. Diesel engine driven
generators (with Auxiliary power
output for grinder etc) are very useful
in heavy duty structural applications and for pipeline work. Petrol Engine
driven generators which are light and portable are useful for light duty and
repair works at site. The efficiency of rotary converter is rather low (60%for
motor driven & Engine driven) and the maintenance is also costly due to wear
and tear of rotating machinery

3.3 Rectifiers

The next popular power

sources are of rectifier type.
Three phase transformer (step
down) connected to a rectifier
to give DC output is the
simplest form. These DC
output rectifiers are available
with flat and drooping

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characteristics. The flat characteristic DC output rectifiers are used for

MIG/CO2 welding and SA welding. The output voltage (Arc voltage)
selection is provided by a tap changing on the primary side of input
transformer. The power factor and efficiency of these flat DC output
rectifiers are very high.

Rectifiers with drooping characteristics dc output are used for

MMAW, TIG, plasma and sometimes SA welding. The current control is
done by magnetic amplifier connected between secondary and rectifier.
Compensation for line voltage fluctuations is also incorporated in some of
the latest rectifier type power sources.

3.4 Transformers

These are the

simplest and cheapest type
available for Arc welding.
These are the mainly used
for MMAW, AC SA
welding and gouging
applications. These are
mostly designed to give a
drooping characteristic
output. Some
manufacturers give OCV
selection for transformers
by providing tap changing
at the primary.

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The control of current for welding for these type of power sources is done
by any one of the following method.
i. Moving coil
ii. Moving core shunt
iii. Variable choke at the output.
vi. Saturable reactor control at the output.
Out of these the most commonly used type is the moving core shunt.
In all these types the power factor and hence the efficiency of power
source is not good. When there are many transformer type power sources
connected in a shop the load should be more or less balanced for providing
balanced loading. In some cases power factor correction capacitors are
integrated along with each transformer.

3.5 Other sources

Recent advances in the field of solid-state power electronics have

helped to improve the status of welding power sources. With the development
reliable high current thyristors (SCR's) and transistors many things are possible
in the field of Arc welding power sources. Universal power sources with
selectable output characteristics are now available.
With this type of equipment one can do MMAW, TIG & MIG welding
and gouging all with a single power sources . A switch on the front panel
selects the output characteristic required and the rectifier output is
controlled by electronic circuits to give the desired output.
Application of power transistors and thyristors in the field of welding
power sources has produced new welding-techniques like. Pulsed TIG,
pulsed spray MIG, and Synergic pulse MIG welding. These techniques
were not known previously and these were evolved as part of equipment

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development.

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4. TYPES OF JOINTS& Weld symbols

Basic weld joints :There are four basic joints used in arc welding:
•Butt joints •Tee joints •Lap joints •Corner joints
1: Butt joint: a joint between two members aligned approximately in the
same plane.

2: Corner joint: a joint between two members located approximately atright

angles to each other in the form of an L.

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3: T-joint: a joint between two members located approximately at right angles

to each other in the form of a T.

4: Lap joint: a joint between two overlapping members located in parallel.

5: Edge joint: a joint between the edges of two or more parallel or nearly
parallel members.
When more than two members are brought together, the joint is a combination
of one of the five basic joint.

Each welding joint has several variations to provide for different needs.
Two different types of welds are used when welding these joints. The
groove-type weld (butt weld) fills in grooves that are cut on the inside of
two pieces of metal that are positioned next to each other. The fillet-type
weld fills in space on the outside of pieces of metal that are positioned at an
angle to each other.

4.1 BASIC SYMBOLS:

Distinction Between Weld Symbol and Welding Symbol. This standard
makes a distinction between the terms weld symbol and welding symbol.
The weld symbol indicates the type of weld and, when used, is a part of the
welding symbol.

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Weld Symbols. Weld symbols shall be as shown in above Figure.

The symbols shall be drawn “on” the reference line (for illustrative
purposes shown dashed).

Welding Symbols. The welding symbol consists of several

elements. Only the reference line and arrow are required elements.
Additional elements may be included to convey specific welding
information. Alternatively, welding information may be conveyed by other
means such as by drawing notes or details, specifications, standards, codes,
or other drawings which eliminates the need to include the corresponding
elements in the welding symbol. All elements, when used, shall have
specific locations within the welding symbol .Mandatory requirements
regarding each element in a welding symbol refer to the location of the
element and should not be interpreted as a necessity to include the element
in every welding symbol. (See Para 4.2)

Supplementary Symbols. Supplementary symbols to be used in

connection with welding symbols. see below fig.

Placement of Welding Symbol.

The arrow of the welding symbol shall point to a line on the
drawing which conclusively identifies the proposed joint. It is
recommended that the arrow point to a solid line (object line, visible line);
however, the arrow may point to a dashed line (invisible, hidden line).

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4.2 STANDARD LOCATIONOF WELDING

SYMBOL:

4.3 BASIC Welding Symbols &Location significance:

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4.4 Some important Types of weld joint symbol interpretation

Complete Joint Penetration. Omitting the depth of bevel and
groove weld size dimensions from the welding symbol requires complete
joint penetration only for single-groove welds and double-groove welds
having symmetrical joint geometry

Partial Penetration Welds, Groove Weld size Specified, Depth of Bevel

Not Specified. The size of groove welds that extend only partly through the
joint shall be specified in parentheses on the welding symbol

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Chain Intermittent Fillet Welds. Dimensions of chain intermittent fillet

welds shall be specified on both sides of the reference line. The segments of
chain intermittent fillet welds shall be opposite one another across the joint

4.5 Weld Geometry/ Nomenclature

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5. WPS / PQR

5.1 Importance of WPS/ PQR

It establishes the basic criteria for welding which are observed in the
preparation of welding requirements that affect procedure and performance.It
determines that the weldment proposed for construction is capable of having
the required properties for its intended application. It is presupposed that the
welder or welding operator performing the welding procedure qualification test
is a skilled workman.
5.1.1Sample WPS
As per ASME SECTION-IX

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There are essential and non-essential variables to control welding

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5.1.2 Sample PQR

As per ASME SECTION-IX

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5.2 There are essential and non-essential variables to control

welding process as follows. Some variables may be essential in some processes
and non-essential in the other or vice versa. ASME Sex-IX describes these
variables in detail. when other Sections of the Code require notch toughness
qualification of the WPS, the applicable supplementary essential variables must
be addressed and this will become essential variable.
The following table is the example for SMAW Process.

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6. PARENT MATERIAL
Parent material should be selected according to the End use requirements like
i) Temperature range of intended use, Cyclic service, fatigue load,
external /internal pressure , corrosion/erosion environment etc
ii) Mechanical Properties like ultimate tensile strength, yield
strength, reduction of area, and elongation,Notch toughness
iii) Weldability, postweld heat treatment required, susceptibility to air
hardening, effect of welding and heat-affected zone
iv) coefficient of thermal expansion, thermalconductivity and
diffusivity, Young’s modulus, shear modulus, and Poisson’s ratio
v) The influence of fabrication practices, such as forming, welding,
and thermal treatment, on the mechanical properties, ductility, and
microstructure of the material are important, particularly where
degradation in properties may occur.
vi) Form of products such as Plate, Bar, Tube , Pipe etc
vii) Method of production Rolling, Casting, Forging etc
To match the above requirements, various material forms are available
with the various Chemical composition made of different manufacturing
processes. The above characteristics are clearly given on ASME Sec-II.
6.1 BASE METAL CLASSIFICATION
Base metal/ Parent metal is classified here are according to ASME-
SEC-IX. (Refer respective standards for equivalent classification). To reduce
the number of welding procedure qualifications required, P-Numbers are
assigned to base metals dependent on characteristics such as composition,
weldability, and mechanical properties, where this can logically be done.

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Following is the small introduction ferrous materials used for welding

The two general types of steel are plain carbon steels, and alloy steels.

Plain carbon steel contains iron with controlled amounts of

carbon.Among plain carbon steels are: low-carbon types which contain less
than 0.30% carbon (C); medium-carbon steels contain approximately
0.3&0.55% C; and high-carbon steels contain up to 1.7% C.

Alloy steel may be defined as a steel whose distinctive properties are

due to the presence of one or more elements other than carbon.The following
are some elements which are alloyed with carbon steels:

(1) Chromium. Increases resistance to corrosion; improves hardness and

toughness, improves the response to heat treatment.

(2) Manganese. Increases strength and responsiveness to heat treatment.

Manganese is added in small amounts as a deoxidizer, desulfurizer.

(3) Molybdenum. Increases toughness and improves strength at higher

temperatures.

(4) Nickel. increases strength, ductility and toughness.

(5)Vanadium. Retards grain growth and improves toughness.

The following is the comprehensive list of Parent metal groups (Steel) typically
used in power plants.
 P1 _Carbon Manganese Steels (four Group Numbers)
 P3 _1/2 Molybdenum or 1/2 Chromium, 1/2 Molybdenum (three
Group Numbers)
 P4 _1.25 Chromium, 1/2 Molybdenum (2 Groups)

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 P5A_2.25 Chromium, 1 Molybdenum

 P5B_(5 Cr, 1/2 Moly & 9Cr ,1 Mo )
 P5C_Cr, Moly, Vanadium (5 Groups)
 P.No.6_Martensitic Stainless Steels (410, 415, 429)
 P.No.7_Ferritic Stainless Steels (Grade 409, 430)
 P.No.8_Austenitic Stainless Steels
Group 1 - Grades 304, 316, 317, 347
Group 2 - Grades 309, 310
Group 3 - High Manganese Grades
Group 4 - High Molybdenum Grades
 P15E_(9 Cr, 1 Moly)
 Code case- T/P23, Super304H etc
6.2 Typical Manufacturing process of Materials used (ASME Sec-II & IX)

 SA36- CS Plates, Bars,

 SA53- Res.weld or Seamless Pipe
 SA105 –CS Forging,
 SA106 –CS Seamless pipe ,
 SA182 - Forging
 SA213 –Seamless Tube ,
 SA216,217-Castings
 SA234 –Fittings,
 SA240- SS Plates and Bars
 SA335- Seamless Pipe,
 SA336- Forgings
 SA387 –Alloy Plates,

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 SA516, 572- CS Plates

 SA671,672- CS Fusion welded Pipe
6.3 P.Nos of Typical Materials used
i) Gr.A, B,C – CS P.No 1
ii) WCB, WCC- P.No 1 Gr.B,C
iii) F11, F12 ,P11, P12, Gr.11, Gr.12,WC6 – P.No.4
iv) F22, P22, Gr.22, WC9 – P.No.5A
v) P91, C12A- P.No.15E)
vi) TP304,316,TP347 –P.No.8
6.4 CHEMICAL COMPOSITION & 6.5 MECHANICAL PROPERTIES of some
commonly used materials

Sl.NO Material Type or Chemical Composition Mechanical

Specification Grade Properties

A C - Si 48 ksi

1 SA 106 B C – Mn – Si 60 Ksi

C C – Mn – Si 70 Ksi

3 SA 213 T11 1.25Cr – 0.5 Mo - Si 60 Ksi

T12 1Cr – 0.5 Mo 60 Ksi

T22 2.25Cr – 1Mo 60 Ksi

T91 9Cr – 1Mo - V 85 Ksi

TP 304 18Cr – 8Ni 75 Ksi

TP 316 16Cr – 12Ni – 2Mo 75 Ksi

TP 347 18Cr – 10Ni - Cb 75 Ksi

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4 SA 216 WCB C - Si 70 Ksi

WCC C – Mn - Si 70 Ksi

5 SA 217 WC 6 1.25Cr – 0.5 Mo 70 Ksi

WC 9 2.25 Cr- 1Mo 70 Ksi

6 SA 335 P 11 1.25 Cr – 0.5 Mo 60 Ksi

P 12 1 Cr – 0.5 Mo 60 Ksi

P 22 2.25 Cr – 1 Mo 60 Ksi

P 91 9Cr – 1Mo - V 85 Ksi

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7. Filler Material
WELDING MATERIAL SPECIFICATION AND SELECTION
Welding Material/ Filler Metal (both Electrode and Filler wire) is
classified here are according to ASME-SEC-IX & ASME SEC-II Part-C. (Refer
respective standards for equivalent classification). Filler metals classification is
made According to the F-Number listed below (only for limited filler wires
used in site, for detailed list refer ASME & AWS)
F.No. AWS Classification No. ASME Specification No. *

1 Exx20 ,Exx27 etc SFA 5.1

Exxx(x)-26 SFA 5.4
Exx20-x ,Exx27-x etc SFA 5.5
2 Exx12, Exx13, Exx14, Exx19 SFA 5.1
E(x)xx13-x SFA 5.5
3 Exx10, Exx11Exx10-x, Exx11-x SFA 5.1
4 Exx15, Exx16, Exx18 etc SFA 5.1
Exxx(x)-15, Exxx(x)-16, Exxx(x)-17 SFA 5.4
etc SFA 5.5
E(x)xx15-x, E(x)xx16-x, E(x)xx18-x
etc
5 Exxx(x)-15, Exxx(x)-16, Exxx(x)-17 SFA 5.4
etc
6 Filler wires-All classifications SFA 5.18,5.28 etc
*Note : 5.1 =Carbon Steel Electrodes for Shielded Metal Arc Welding
5.4 =Stainless Steel Electrodes for Shielded Metal Arc Welding
5.5 =Low-Alloy Steel Electrodes for Shielded Metal Arc Welding
5.18=Carbon Steel electrodes and rods for Gas Shielded Arc Welding
5.20=Carbon Steel Electrodes for Flux Cored Arc Welding

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5.28=Low-Alloy Steel Electrodes and Rods for Gas Shielded Arc Welding
7.2 Filler Material Selection

Filler metal selection should be based Strictly upon Primary documents like
Drawing, WPS, Weld schedule, Contract document/Technical Specification etc.
Also all filler metals should be purchased from Client approved Manufacturer
only.

Generally filler metals are selected for the particular welding work is based
upon the different characteristics as mentioned below. The details mentioned
here are only for reference when there is no document available for selection.

 Welding Process conditions

- Filler wire (GTAW) , Electrode (SMAW) e.g, ER90S-B9 (GTAW) ,
E9018-B9(SMAW)
 Base Material - Homogeneous , Dissimiliar
e.g CS to CS – E7018 , CS to SS- E309, Alloy steel to SS – ENicr Fe-
3
 Service Conditions
e.g CS to CS in Piping & Pressure Parts– E7018,CS to CS in Ducting–
E6013, Tube Mtl and Attachment mtl – Electrode/Filler wire suited to
Tube material
Table for Filler Material Selection

Base Metal & Area of Usage Filler / Electrode

P.No 1_CS & Q235 Gr.B (Chinese standard)

E6013
(Ducting,ESPetc )

G.I (Handrail) E6013

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P.No 1 CS & Q235 Gr.B (Chinese standard)

E7018
(Structure etc)

ER70S-D2
P.No 1 CS (Piping , Pressure Parts-Tubes)
E7018

ER308, ER316, ER347 ,

P.No 8 Stainless Steel
E308, E316, E347

Filler- ER80S-B2
P.No 4_T12, P12
Electrode- E8018-B2,E8016-B2

Filler- ER 90S-B3
P.No 5_T22, P22
Electrode- E9018-B3,E9016-B3

Filler- ER 90S-B9, TG-S9C6

P.No 15E_T91, P91
Electrode- E9018-B9,E9015-B9

Stainless Steel to Carbon steel E309, ER309

inconel or Filler- ER309,ERNiCr3

Alloy Steel+Stainless Steel Electrode- E309,ENiCr Fe-3

7.3 Electrode designation

Figure lists the significance of the digits of the SMAW electrode

identification system

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- The identification consists of an “E)’ which stands for electrode,

followed by four or five digits.
- The first two, or three, numbers refer to the minimum tensile
strength of the deposited weld metal. These numbers state the minimum
tensile strength in thousands of pounds per square inch. For example,“70”
means that the tensile strength of the deposited weld metal is at least 70,000
psi.
- The next number refers to the positions in which the electrode
can be used. “1” indicates the electrode is suitable for use in any position.
“2” means that the molten metal is so fluid that the electrode can only be
used in the flat position for all welding types and in the horizontal position
for fillet welds only. A “4” means the electrode is suitable for welding in a
downhill progression. The number “3” is no longer used as a designation.
- The last number in the designation describes other characteristics
which are determined by the composition of the coating present on the
electrode.This coating will determine its operating characteristics and
recommended electrical current: AC (alternating current), DCEP (direct
current, electrode positive) or DCEN (direct current, electrode negative).

Refer the below table.

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It is important to note that those electrodes ending in “5,” “6,” or “8”

are classified as “low hydrogen” types. To maintain this low hydrogen
(moisture) content, they must be stored in their original factory-sealed metal
container or an acceptable storage oven.

Steel Alloy suffix for SMAW Electrode

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Designation of FCAW Electrode

7.4 Tungsten Electrode selection

 The electrode used in GTAW is made of tungsten or a tungsten
alloy, because tungsten has the highest melting temperature among
pure metals, at 3,422 °C.
 Diameter or rod is 0.5 to 6.4mm, length 75 to 610mm

 Pure tungsten electrodes.Poor heat resistance and electron emission .

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They find limited use in AC welding

 Cerium oxide (or ceria)) as an alloying element improves arc stability
and ease of starting while decreasing burn-off.
off. cerium is not
radioactive.
 Using an alloy of lanthanum oxide (or lanthana)) has a similar effect.
Addition of 1% has the same effect as 2% of cerium.
 Thorium oxide (or thoria)) alloy electrodes were designed for DC
applications and can withstand somewhat higher temperatures while
providing many of the benefits of other alloys more resistant to
contamination . However, it is somewhat radioactive
zirconium oxide (or zirconia)) increase the current capacity while
improving arc stability and starting and increasing electrode life .
Melts easier than tungsten

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8.Diameter & Thickness

8.1 Nominal Pipe Size (NPS) is a North American set of standard sizes for
pipes diameter based on inches, and a schedule (Sched. or Sch.) for wall
thickness. For NPS ⅛ to 12 inches, the NPS and OD values are different.
For NPS 14 inches and up, the NPS and OD values are equal
8.2 The European designation equivalent to NPS is DN (diamètre
nominal/nominal diameter), in which sizes are measured in millimetres
8.3 The term NB (nominal bore) is also frequently used interchangeably
with NPS
8.4 Tube vs Pipe : The terms like NPS, DN, NB are used only for Pipes.
There are other significant differences between tube and Pipe based on
the functional and Geometrical differences like
• Pipe and tube is ever so simple.Pipes are used for Mass transfer
only, the temperature at entry and exit point will be same. Tubes are
used for Heat and Mass transfer, the temperature at the entry and exit
point will be different. Pipes are used to transport something, and
Tubes are to construct something.
• Tubes are defined by the OD “Outside Diameter" and WT “Wall
Thickness" (for construction stability)
• Pipes are designated by a "Nominal Pipe Size“ (NB / DN) based
upon the ID (inside diameter) of the most common wall thickness to
allow a calculation for transportation viz., speed, volumes etc. (OD =
ID + 2 x WT). The following is the Terms used in Piping and
Sample Standard pipe schedule is given for reference.
AWT/MWT- Average/Mean Wall thickness ,SCH-Schedule thickness

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8.5 SAMPLE PIPE SCHEDULE

Wall Inside Weight

Pipe
Outside Outside Thickness Diameter
Steel (pounds
Pipe Size Diameter Diameter -t -d- per foot)
Pipe Schedule
Size No.
(inches) (inches) mm mm mm
. . 1.651 18.034 0.54
STD 40 2.7686 15.7988 0.85
XS 80 3.7338 13.8684 1.09
. 160 4.7498 11.8364 1.31
DN15 0.84 21.336 XXS . 7.4676 6.4008 1.71
. . 1.651 23.368 0.69
STD 40 2.8702 20.9296 1.13
XS 80 3.9116 18.8468 1.47
. 160 5.5626 15.5448 1.94
DN20 1.05 26.67 XXS . 7.8232 11.0236 2.44
. . 1.651 30.099 0.87
STD 40 3.3782 26.6446 1.68
XS 80 4.5466 24.3078 2.17
. 160 6.35 20.701 2.84
1(DN25) 1.315 33.401 XXS . 9.0932 15.2146 3.66
. . 1.651 57.023 1.61
STD 40 3.9116 52.5018 3.65
XS 80 5.5372 49.2506 5.02
2 . 160 8.7376 42.8498 7.46
(DN50) 2.375 60.325 XXS . 11.0744 38.1762 9.03
. . 2.1082 68.8086 2.48
STD 40 5.1562 62.7126 5.79
XS 80 7.0104 59.0042 7.66
2.5 . 160 9.525 53.975 10.01
(DN65) 2.875 73.025 XXS . 14.0208 44.9834 13.69
. . 2.1082 84.6836 3.03
. . 3.048 82.804 4.33
STD 40 5.4864 77.9272 7.58
XS 80 7.62 73.66 10.25
3 . 160 11.1252 66.6496 14.32
(DN80) 3.5 88.9 XXS . 15.24 58.42 18.58

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. . 2.1082 110.0836 3.92

STD 40 6.0198 102.2604 10.79
XS 80 8.5598 97.1804 14.98
. 120 11.1252 92.0496 19
4 . 160 13.4874 87.3252 22.51
(DN100) 4.5 114.3 XXS . 17.1196 80.0608 27.54
. . 2.7686 162.7378 7.6
STD 40 7.112 154.051 18.97
XS 80 10.9728 146.3294 28.57
. 120 14.2748 139.7254 36.39
6 . 160 18.2372 131.7498 45.35
(DN150) 6.625 168.275 XXS . 21.9456 124.3838 53.16
.
STD 40 8.1788 202.7174 28.55
. 60 10.3124 198.4502 35.64
XS 80 12.7 193.675 43.39
. 100 15.0876 188.8998 50.95
. 140 20.6248 177.8254 67.76
8 XXS . 22.225 174.625 72.42
(DN200) 8.625 219.075 . 160 23.0124 173.0502 74.69
. . 3.4036 266.2428 15.19
STD 40 9.271 254.508 40.48
XS 60 12.7 247.65 54.74
. 80 15.0876 242.8748 64.43
. 100 18.2626 236.5248 77.03
. 120 21.4376 230.1748 89.29
10 . 140 25.4 222.25 104.13
(DN250) 10.75 273.05 . 160 28.575 215.9 115.64
.
STD 30 9.525 336.55 54.57
. 40 11.1252 333.3496 63.44
XS . 12.7 330.2 72.09
. 60 15.0876 325.4248 85.05
. 80 19.05 317.5 106.13
. 120 27.7876 300.0248 150.79
. 140 31.75 292.1 170.28
14 14 355.6 .. 160 35.7124 284.1752 189.11
18 18 457.2

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STD . 9.525 438.15 70.59

. 30 11.1252 434.9496 82.15
XS . 12.7 431.8 93.45
. 40 14.2748 428.6504 104.67
. 60 19.05 419.1 138.17
. 100 29.3624 398.4752 207.96
. 140 39.6748 377.8504 274.22
. 160 45.2374 366.7252 308.5

STD 20 9.525 539.75 86.61

XS 30 12.7 533.4 114.81
. 60 22.225 514.35 197.41
. 80 28.575 501.65 250.81
. 120 41.275 476.25 353.61
. 140 47.625 463.55 403
22 22 558.8 . 160 53.975 450.85 451.06
. 10 7.9248 644.5504 85.6
STD . 9.525 641.35 102.63
26 26 660.4 XS 20 12.7 635 136.17
. 10 7.9248 695.3504 92.26
STD . 9.525 692.15 110.64
XS 20 12.7 685.8 146.85
28 28 711.2 . 30 15.875 679.45 182.73
. 10 7.9248 796.9504 105.59
STD . 9.525 793.75 126.66
XS 20 12.7 787.4 168.21
. 30 15.875 781.05 209.43
32 32 812.8 . 40 17.4752 777.8496 230.08
. 10 7.9248 898.5504 118.92
STD . 9.525 895.35 142.68
XS 20 12.7 889 189.57
. 30 15.875 882.65 236.13
36 36 914.4 . 40 19.05 876.3 282.35
STD . 9.525 1047.75 167
XS 20 12.7 1041.4 222
. 30 15.875 1034.288 276
42 42 1066.8 . 40 19.05 1028.7 330

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9. Welder qualification
The performance qualification tests are intended to determine the
ability of welders and welding operators to make sound welds. Each
welder or welding operator shall be qualified for each welding process to
be used in production welding.The performance qualification test shall be
welded in accordance with qualified Welding Procedure Specifications.
9.1.1 Parent metal qualification Limits
Tested Qualified
P No. Specification (for e.g) (as Per QW-423 of ASME
Sec-IX)
P No.1 Any metal SA36, SA53, SA106, etc
Q235 Gr.B, Q345 Gr.Betc
P No.3 Any metal SA209 T1, etc P No.1 through 15F_All
P No.4 Any metal SA335P11, 12, SA182 F11, 12. metals
SA387 Gr11, 12, etc Including unassigned metals
P No 5A Any metal SA335 P22, SA182 F22, etc of similar chemical
P No 8 Any metal SA213 composition to these
TP304,TP316,TP347etc
P No.15E/5BAny SA335 P91, etc
metal
Any metal within P No.1 through 15F

9.1.2 Thickness qualification Limits

Tested (mm) Qualified (mm)
Code GROOVE FILLET GROOVE FILLET

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ASME IX 13 below N.A Max. 2t All

(refer Notes 13 and over N.A All
1,2,3) Unlimited
N.A >5 No All
AWS D1.1 9.5 below N.A 19 below All
9.5~25.4 N.A Max. 2t All
25.4 and N.A All
over Unlimited
N.A 12.7 No All

Note 1 : When more than one welder and/or more than one process andmore
than one filler metal F-Number is used to deposit weld metalin a coupon, the thickness,
t, of the weld metal in the coupondeposited by each welder with each process and each
filler metalF-Number in accordance with the applicable variables underQW-404 of
ASME Sec-IX shall be determined and used individually in the“Thickness, t, of Weld
Metal in the Coupon” column to determinethe “Thickness of Weld Metal Qualified.
Note 2 :Two or more pipe test coupons with different weld metal
thicknessmay be used to determine the weld metal thickness qualified andthat thickness
may be applied to production welds to the smallestdiameter for which the welder is
qualified in accordance withQW-452.3.of ASME Sec-IX
Note 3 :Thickness of test coupon of 3⁄4 in. (19 mm) or over shall be usedfor
qualifying a combination of 3 or more welders each ofwhom may use the same or a
different welding process.

9.1.3 Diameter qualification Limits

Tested(inch) Qualified(inch)

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Code GROOVE (Outer Dia) FILLET GROOVE FILLET

ASME 1” below(25mm) TestDia.&Ab ALL
IX ove
N.A
(refer 1’’ (25mm) to 2 7/8” 1”and over ALL
Notes 2 7/8” (73mm)and over 2 7/8”& over ALL
1,2) 1” below No Tested
Dia&Above
N.A 1 to 2 7/8” No 1” and over
2 7/8” No 2 7/8” &over
&over

Note 1 :Type and number of tests required shall be in accordance with QW-452.1 of
ASME Sec-IX for Groove welds and QW-452.5 of ASME Sec-IX for Groove welds
Note 2 : 27⁄8 in. (73 mm) O.D. is the equivalent of NPS 21⁄2 (DN 65)

9.2 Welding Positions and qualification criteria

Welders and welding operators who pass the required tests for groove/Fillet
welds in the test positions of following table shall be qualified for the positions
shown in the same table.
Code Tested Qualified
Weld Position Plate and Pipe <24 in Fillet
Pipe > 24”( (610mm Plate& Pipe
610mm)O.D O.D)
ASME IX PIPE- 1G 1G 1G 1F
GROOVE 2G 1G,2G 1G,2G 1F,2F
5G 1G,5G 1G,5G ALL
6G ALL ALL ALL
2G&5G ALL ALL ALL

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SP-Special SP,1G SP,1G SP,1F

Position
PLATE- 1G (flat) 1G 1G 1F
GROOVE 2G (horiz.) 1G,2G 1G,2G 1F,2F
3G (vertical) 1G,3G 1G 1F,2F,3F
4G overhead 1G,4G 1G 1F,2F,4F
3G & 4G 1G,3G,4G 1G ALL
2G,3G,4G ALL ALL ALL
SP SP,1G SP,1G SP,1F
ASME IX PIPE- 1F -- -- 1F
FILLET 2F -- -- 1F,2F
2FR -- -- 1F,2F
4F -- -- 1F,2F,4F
5F -- -- ALL
SP -- -- SP,1F
ASME IX PLATE- 1F -- -- 1F
FILLET 2F -- -- 1F,2F
3F -- -- 1F,2F,3F
4F -- -- 1F,2F,4F
3F&4F -- -- ALL
SP -- -- SP,1F
AWS D1.1 PLATE- 1G 1G 1G 1F,2F
GROOVE 2G 1G,2G 1G,2G 1F,2F
3G 1G,2G,3G 1G,2G,3G 1F,2F,3F
4G 1G,4G 1G,4G 1F,2F,4F
3G + 4G ALL ALL ALL
AWS D1.1 PLATE- 1F -- -- 1F
FILLET 2F -- -- 1F,2F
3F -- -- 1F,2F,3F
4F -- -- 1F,2F,4F
3F + 4F -- -- ALL

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9.2.1 Welding Position

1G(FLAT) 2G(HORIZONTAL) 4G(OVERHEAD) 3G (VERTICAL) 3G (VERTICAL)

downhill Uphill

1F(FLAT) 2F(HORIZONTAL) 4F(OVERHEAD) 3F (VERTICAL) 3F (VERTICAL)

downhill Uphill

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1G(PIPE 5G (PIPE FIXED) 5G (PIPE FIXED) 2G (VERTICAL) 6G (45 Degree)

ROTATED) DOWNHILL UPHILL

2FR (PIPE 5F (PIPE FIXED) 5F (PIPE FIXED) 2F (PIPE FIXED) 4F (Overhead)

ROTATED) DOWNHILL UPHILL

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10. Preheat, Postheat& SR

The control of preheat and post heating shall be in accordance with
approved WPS & Approved PWHT procedures
Importance of Preheating
 Use of Preheat will tend to reduce the cooling rate in Weld and HAZ
,thus improves ductility.
 Higher the carbon equivalent, the hardenability is more. Hence more
preheating temperature is required
 If the thickness of the base metal is higher, cooling rate will be more
rapid. To decrease the cooling rate and to improve metallurgical
properties , Preheating is necessary
Methods of Preheating &Equipments used
The equipment used for preheating welded joints is of the following types.
• resistance heating
• heating by stationary burners or racks adapted to the pieces with neutral
flame (inner cone flame must not be in contact with the work piece)
For pipe of base metal P5B (P15E) and P5C with outside diameter greater
than 219mm and thickness greater than 20mm, it is required to perform
preheating by resistance or Induction Heating. For the others, stationary
burner may be used for preheat. The preheated zone on either side of the joint
shall be at least 5 times the wall thickness. Preheat and inter-pass temperature
shall be tested by thermocouple or thermal crayon regularly.
Importance of PWHT
 Stress Relief Anneal or Post Weld Heat Treatment is used to reduce
residual stresses in welded parts. Such parts tend to have stresses due

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to thermal cycling or work hardening.

 To relieve or reduce the above stresses, the welded material is heated
at a constant rate to the Temperature below the lower transformation
temperature and soaked at requisite time duration. Then it is cooled
in a controlled manner at constant rate.
Methods of PWHT &Equipments used
The machines used for stress relieving are Induction/resistance heating
type. The heating, holding and cooling time is to be measured and recorded
through thermocouples and calibrated recorder. The calibration certificates
shall be available for Client inspection.
10.1 Preheat, SR Temperature value Tables*
P No Steel Minimum Preheating PWHT Holding Temperature &
Grade Temperature & conditions
conditions
1 SA105, A106, 100℃
℃ when 600 to 640 ℃ or (600 -620) when T>19
SA210, SA234 T>19 mm mm ,(Or) preheat<95℃ for T>25 mm

4 SA213T12, 121℃
℃ for All thickness 650 to 670 ℃ when T>16 mm (or)
SA335P11,P12 C>0.15% (or) preheat<120℃
5A SA213T22, 150/200℃
℃ for T22 710 to 730 ℃ when T>13 mm (or)
SA335P22 200/250℃
℃ for P22 C>0.15% (or) preheat<200℃
15E SA213 T91, (205℃
℃) for T91 740 to 760 ℃ for All
SA335 P91 250℃
℃) for P91 thickness(According to the WPS firstly)
8 Stainless Steel None None

* The above table is only for guidance. Proper values and ranges will be
according to the approved WPS
10.2 Cares to be taken while performing heat treatment
 As heating and Electricity involved in PWHT, necessary safety
precautions to be taken

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 Backup power in the form of D.G is necessary in the case Induction

heating , where cycle interruption is not allowed
 During Preheat, PWHT protection from Moisture , Wind is necessary
for troublefree and Proper heating
 Recording equipments need to be calibrated at periodic intervals (6 or
12 months ) by external agency
 No.of.Thermocouples and Position of thermocouples to ensured for
Each size ,type and material
 Proper PWHT has to be ensured by Hardness measurement for
Critical mtls and High thickness materials
10.3 Hardness test after post weld heat treatment
After post weld heat treatment, random hardness test shall be
performed to check the mechanical characteristics as required by the code.
Quantum of Inspection shall follow concerned Weld data sheet/
Specifications/ Standards.
10.4 Hardness value Table

Sl.No Material Acceptance code Acceptance Max in HB for

Range in HB
& Limits in HB for Parent
welding area.
metal
1 210C ASTM A 210 ≤ 130 179 welding ≥base area
179
2 T1A,20MoG,STB ASTM A 209 ≤ 125 153 welding ≥base area
A12,15 Mo3 153
3 T2,T11,T12,T21,T ASTM A 213 ≤ 120 163 welding ≥base area
22,10crMo910 163 and welding shall be
4 P2,P11,P12\P21,P2 125 179 below 241
2, 10crMo910
5 T23 ASTM A213 ≤ 220 150 220 welding ≥base area
6 12CrMoWVTib 150 220 welding ≥base area

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(G102)
7 T24 ASTM A213 ≤ 250 180 250 welding ≥base area
8 T91,T92, ASTM A213 ≤ 250 180 250 welding ≥base area
T911,T122 and welding shall be
9 P91,P92, ASTM A335 ≤ 250 180 250 below 300
P911,P122
10 WB36 ASME Code case 150 252 welding ≥base area
2353
≤ 252
11 A515,A106B, 130 197 welding ≥base area
A106C,
A672B70
12 12CrMo GB 3077 ≤ 179 120 179 welding ≥base area
13 15CrMo JB 4726 118 118 180 welding ≥base area
180 (Rm:440 115 178
610) ,JB 4726_
115 178
(Rm:430 600)
14 12Cr 1 Mo V GB 3077 , S179 135 179 welding ≥base area
15 15Cr 1 Mo V 135 180 welding ≥base area
16 F2 ASTM A182, 143 182 welding ≥base area
143 182
17 F11,1 ASTM A182, 121 174 welding ≥base area
121 174
18 F11,2 ASTM A182, 143 207 welding ≥base area
143 207
19 F11,3 ASTM A182, 156 207 welding ≥base area
156 207
20 F12,1 ASTM A182, 121 174 welding ≥base area
121 174
21 F12,2 ASTM A182, 143 207 welding ≥base area
143 207
22 F22,1 ASTM A182, ≤ 130 170 welding ≥base area
170
23 F91 ASTM A182, ≤ 248 Max welding ≥base area
248
24 F92 ASTM A182, ≤ 269 Max welding ≥base area
269

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11. Shielding & Purging

Shielding Gas / Purging gas
 Shielding gases are necessary in GTAW to protect the welding area
from atmospheric gases which can cause fusion defects, porosity, and
weld metal embrittlement
 The gas also transfers heat from the tungsten electrode to the metal,
and it helps start and maintain a stable arc
Argon is the most commonly used shielding gas. Helium-argon mixtures
used for A/C welding. The purity of argon gas should be around 99.9%
and the flow rate will be around 8 to 12 Litre/Min (any how these
parameters has to follow approved WPS)
 The function of purging gas is to maintain inert atmosphere during
initial passes of the welding at root side. Purging is necessary for
high alloy steels like SS, T91 and P91.
 Test certificate will be produce for the purity records of consumable
from the approved manufacturer identified by TIEJUN.
 Arrangements like Water Soluble dam-paper can be done for
Effective purging. The purity of gas used for purging should be more
than shielding gas around 99.997% and the flow rate will be around 5
to 8 Litre/Min Min (any how these parameters has to follow WPS)

11.1 Argon gas parameters

General Characteristics : A colorless, nonflammable and odorless gas
Molecular Weight Specific Gravity Specific Volume

39.95 1.378 @ 70 F 9.68 cu.ft./lb @ 70 F

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Common cylinder Volume : 7 cu.metre (25cm dia & 1.5m Length), Cylinder
Pressure : Around 140 Kg / Cm2,Body colour-BLUE

11.2 Argon Purity Level

INDIAN STANDARD for ARGON, Compressed & Liquid Specification no.
IS 5760: 1998 shall be referred.
There are 3 grades of argon, namely:
• Grade 1 : Ultra high purity argon for use in electronics and allied industries
and indirect reading vacuum spectrograph,
• Grade 2 : High purity argon for use in lamp and allied industries and
• Grade 3 : Commercial grade argon for use in welding industry and for other
metallurgical operations.
Accordingly the argon shall comply with the requirements given below:

The Purchase & control of gas shall be in accordance with approved WPS &
Respective standards, Contractual Requirements

11.3 Selection of Shielding Gas

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11.4 Typical Gas cylinder Set-up

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12.Other Welding Parameters

12.1 A-Numbers used for weld metal analysis as follows

12.2 Type of Weld metal transfer :globular, spray or pulsedspray transfer

welding to short circuiting transfer weldingor vice versa.

12.3Polarity : AC to DC, or vice versa; andin DC welding, a change from

electrode negative (straightpolarity) to electrode positive (reverse polarity), or
viceversa.

12.4Technique : Manual or Semi-automatic or Automatic; Travel speed or

Deposition speed
12.5 Type of cleaning: grinding , back gouging, Chemical or Mechanical
12.6 Single pass welding or Multipass welding, single or multiple electrode
12.7 Heat input

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13 NDT &Destructive Methods

 WHAT IS NDT?
The use of noninvasive techniques to determine the integrity of a
material, component or structure or quantitatively measure some characteristic
of an object.
 WHY NDT ?
To ensure the soundness of weldment there should be a testing and it
should be without any damage to the Product. So as to analyse and find the
Discontinunities and to find whether the discontinuity is defect or not with
respect to the applicable standards, NDT is required.
NDT (i.e. PT, MT, and RT, UT) shall be done as per requirement of
drawing / codes. Quantum of Inspection shall follow concerned Weld data
sheet/ Specifications/ Standards.

13.1 Visual
In any effective welding quality control program, visual inspection
provides the basic element for evaluation of the structures or components being
fabricated. In order to gain some assurance as to the suitability of the welding
for its intended service, codes and standards will always stipulate the
performance of visual inspection as the minimum level of acceptance/rejection
evaluation. Even when other nondestructive or destructive methods are
specified, they are actually meant to supplement, or reinforce, the basic visual
inspection. When we consider the various other methods used to evaluate
welds, they can really be thought of as simply visual enhancement techniques,

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because the final evaluation of the test or test results will be accomplished
visually

13.1.1 Commonly used visual inspection tools

Tool Illustration Functions

Hi-Lo Check Root
gauge Misalignme
nt, Surface
Misalignme
nt, Root gap

Socket Throat
weld Dimensions
gauge , Checks All
Pipe
Schedule

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Bridge Angle of
cam Preparation,
Excess
Weld Metal,
Depth of
Undercut,
Depth of
Pitting,
Weld
Throat Size,
and more.

Magnifyi Aids all

ng glass visual
& Lens : inspection

Bore- Very useful

scope for
inspecting
inaccessible
areas

NDT Method comparison

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13.3 Destructive Testing

Mechanical Tests :
Various Mechanical tests are done to establish the soundness of weld
specimensused in procedure or performance qualification as follows :-

Tension Tests are used to determine the ultimate strength of groove-weld

joints. It also gives the properties like percentage increase in length and
percentage reduction in area. Geometry of failure also an indication to the
different mode of defect origin.(Ref : ASME SecIX _ QW-150) like
i) Reduced section Plate _QW 462.1 a
ii) Reduced section Pipe _QW 462.1 b,c
iii) Turned section _QW 462.1 d
iv) Full section _QW 462.1 e

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Guided-Bend Testsare used to determine the degree of soundness of weld

metal and Ductility of groove-weld joints.(Ref : ASME SecIX _ QW-160) like
i) Transverese side bend _QW 462.2
ii) Transverese Face & Root bend _QW 462.3 a
iii) Longitudional Face & Root bend _QW 462.3 b

Fillet-Weld Testsare used to determine the size, contour, and degreeof

soundness of fillet welds (root penetration and fusion) (Ref : ASME SecIX
_QW-180) like
i) Fracture Tests_QW 462.4 b,c
ii) Macro examination_QW 462.4, 470

Notch-Toughness Tests (charpy v-notch, Drop weight ) are used to

determine the notchtoughness of the weldment. i.e the amount of energy
absorbed in the fracturing specimen under standard testing conditions. (Ref :
ASME SecIX _QW-171,172)

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Stud-Weld Test_Deflection bend, hammering,torque, or tension tests(Ref :

ASME SecIX _QW-192,466)

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14 Weld defects and their control

A weld discontinuity is an interruption of the typical structure of a
weldment, such as an inhomogeneity in the mechanical, metallurgical, or
physical characteristics of the material or weldment. A discontinuity is, by
definition, not necessarily a defect.

A weld that does not meet any or all of the specific requirements of a
particular specification or code is considered a defective weld. A defective
weld is impossible to assess Without reference to some particular standard or
requirement related to the intended use of the weld.

There are three general classifications of discontinuities:

(1) ProcedureProcess
(2) Metallurgical
(3) Base Metal
These classes of discontinuities may be further subdivided many classes. The
purpose of this classification is to
• Understand the type of Discontinuties /defects
• The effects and possible causes
• The best methodology which can be followed to avoid or reduce
the same

14.1 Defect control for Procedure/Process discontinuties

Type of
Discontinuties Effects Causes Remedies
(a) Geometric
improper fit, fixturing,
Proper Fitup, Training to
Misalignment/ Stress risers at root tack welding, or a
Welder , Fitter,
Offset/ Mismatch and toe of weld combination of these
Supervisor
factors.
careful selection of
improper welding
Alignment , welding sequence,
sequence, No rigid
Distortion Performance based welding
supports or jigs/
concerns processes, and joint
fixtures used
design

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No proper review of Training to Welder ,

Final Dimension Reduces the intended tolerances, improper Fitter, Supervisor and
performance w.r.to fitup and alignment
Careful review of
design
Weld Size Lack of awareness drawing / Specifications
tends to produce incorrect welding
Proper Fitup, careful
notches can be technique or by
Overlap selection of welding
detrimental to improper welding
sequence and joint design
weldment parameter settings.
Convexity,
Concavity may affect the Lack of awareness, by Proper Fitup, Training to
service performance improper welding Welder , careful selection
Weld of the joint. parameter settings. of welding process
Reinforcement
(b) Weld / Structural
Incorrect welding
techniques,improper
-Incomplete preparation of the Proper cleaning, Proper
Fusion The unfused area materials for welding, edge preparation,
permits stress or incorrect Training to Welder and
concentrations jointdesigns Fitter , Proper welding
heat input
-Incomplete Joint Improper root face,
Penetration reduced heat transfer
Training to Welder ,
excessive arc length, or Proper welding heat
Detrimental effect
welding current, or input, Correct travel
- Undercut and reduction of
both, excess travel speed, Correct size of
service performance
speeds electrode, proper welding
process
Lack of awareness by
- Underfill
welder
Improper cleaning, Proper heat input,
-Inclusions : Improper heat input, Interbead cleaning,
Slag Reduction in Improper baking of Following of Baking
weldment service electrode process
-Inclusions :
High heat input Proper heat input
Tungsten

14.1c) Defect control for Crack type discontinuities

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Cracking of welded joints results from localized stresses that exceed the ultimate
strength of the material. When cracks occur during or as a result of welding, little
deformation is usually apparent.

Cracks which occur during solidification are sometimes called hot cracks. Cold
cracks are those that occur after the weld has cooled to ambient temperature, or
once the weldment has been placed in service. Hot cracks will propagate along
grain boundaries while cold cracks, sometimes associated with hydrogen
embrittlement, will propagate both along grain boundaries and through grains.

Type of crack Causes Remedies

Improper contour, Less weld metal Change of welding
On Weld Metal
to resist stress,Faster rate of cooling technique, correct travel
high degree of restraint in the weld speed, Preheating/ post-
i) Transverse
axis direction. heating, Low hydrogen
may occur as the extension of crater electrodes
ii) Longitudinal cracks formed at the end of the Change of welding
weld technique, correct travel
Improper startup and End of speed, Preheating/ post-
iii) crater welding heating, Low hydrogen
electrodes
High temperature, More heat input,
Thickness, Thermal conductivity,
On Parent Metal
Ambient temperature, Hardenable
material
i) Transverse Steels with high hardenability Use of preheat to
control cooling rate
ii) Longitudinal Extension of weld interface
Use of controlled heat input
High residual stress due to profile,
iii) Toe Use of the correct
shrinkage strain
filler metal
iv) Root High residual stress due to profile
Hydrogen in solid solution
v) Underbead
A crack susceptible microstructure,
(delayed)
High residual stress

14.1d) Defect control for Porosity type discontinuities

Porosity is the result of gas being entrapped in solidisling weld metal.
The discontinuity is generally spherical, but may be elongated.

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Porosity results when contaminants or moisture become included in the

weld puddle. Sources of these impurities include: the base metal
surface, the filler metal surface, welding fluxes, welding gases, and
welding equipment (cooling systems, drive roils, etc.)

Type of Pore Causes Remedies

Faulty welding technique,
Scattered contaminated materials or both
maintaining cleanliness
Improper initiation or
Cluster for welding, by
Termination of welding arc
providing protection
Often occurs along
barriers in preventing
the weld interface,weld root,
the loss of gas
the weld interbead develops
Aligned shielding, and by
by contamination that causes
keeping the equipment
gas to be liberated at these
maintained.
locations.
During welding,
Faulty welding technique,
Piping (isolated) contaminated materials or both excessive current and
Elongated welding of the root bead with excessive arc length
(Pockmarks, Worm cellulosic electrodes should be avoide
tracks,Hollowbead) and excessive travel speed

Porosity differs from inclusions in that porosity contains a gas rather

than a solid substance and generally are spherical in shape.
14.1e) Defect control for Other Welding related discontinuities
Perfectly acceptable welds will naturally exhibit some degree of
surface roughness, however, improper technique or equipment adjustment can
result in surface irregularities that exceed specification requirements.
Unsatisfactory workmanship indicates that proper are not being followed.
Surface irregularities are not limited to, but generally grouped as weld ripples,
spatter, and arc strikes.
Weld ripples may create high stress concentrations can be avoided by
proper welding technique and correct heat input
Spatters may be detrimental to the product and having potential to
inflict burns can be avoided less welding current, Proper travel speed

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Arc strikes result when the arc is initiated on the base metal surface
away from the weld joint, either intentionally or accidentally. Arc strikes are
not desirable and often are not acceptable,as they could lead to cracking and
should be removed by good workmanship and proper training.

14.2 Defect control for Metallurgical Type discontinuities

Metals not only offer many useful properties and characteristics in

their mechanical behavior, but they can also develop a large number of
combinations of those properties. The versatility of metals with respect to
mechanical properties has encouraged the selection of the best combination of
properties to facilitate fabrication and to ensure good service performance.

It should be pointed out that not all discontinuities are due to improper welding
conditions. Many such discontinuities may be attributed to the base metal. Base
metal requirements are defined by applicable specifications or codes. Departure
from these requirements should be considered cause for rejection.

Property in Precautions to be
consideration Effects adopted
Change in microstructure, grain
- Strength size and other factors
- Ductility Weldability
Proper Preheating & Heat
- Hardness Weldability, Prone to cracks treatment , Proper
selection of Filler metal,
Showing different properties Proper welding technique,
-Corrosion
between Parent metal , weld and controlled travel speed,
resistance HAZ Controlled cooling Rate
affect its hardness, ductility,
- Chemical tensile strength and corrosion
resistance

14.3 Defect control for Base metal Type discontinuities

It should be pointed out that not all discontinuities are due to improper
welding conditions.Many such discontinuities may be attributed to the base

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metal. Base metal requirements are defined by applicable specifications or

codes.Departure from these requirements should be considered cause for
rejection.
The inspector should keep factors such as these in mind when trying
to determine the reason for welding discontinuities that have no apparent cause

Type of
discontinuity Reason of discontinuity How to detect
They are usually caused by
inclusions or blow holes in the Both lamination or
originai ingot. During rolling, delamination, if
- Laminations these discontinuities become extended to the edges of
elongated and appear as flat the material, may be
longitudinal stringers of detected by visual,
nonmetaüics. MPT, DPT.
ultrasonic testing should
Delamination is the separation
be conducted utilizing
of lamination under stress. The
the straight beam
- Delaminations stresses may be generated by
method
welding or by externally applied
loads.
When restraint stresses and
thermal strains imposed by
Some rolled structural
welding exceed the strength of
materials are
- Lamellar Tears the material in the through-
susceptible to a
thickness direction, the stress
cracking having step like
concentration at nonmetallic nature.
inclusions initiates cracks
when seams and laps are
perpendicular to the applied or Welding over seams
residual stresses, they will often and laps of Forged/
- Seams and Laps propagate as cracks. Seams and Rolled can cause
laps are surface-connected cracking
discontinuities.

14.4 Illustration and Acceptance criteria of Discontinuties

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Discontinuity Figure (illustration) Acceptance

Criteria
a) Geometric
Mismatch Refer Table
14.6

Weld Re- Refer Table

inforcement 14.7

Distortion No specific

b) Weld / Structural
Lack of Not acceptable
Fusion (ASME Sec-I)

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Incomplete Not acceptable

Penetration (ASME Sec-I)

Undercut not exceed 0.8 mm

or 10% of thickness,
whichever is less,
and shall not
encroach the
minimum required
thickness

Slag indication that has a

length greater than
Inclusions a) 6 mm for t up to 19
mm
(b) 1/3t for t from 19
mm to 57 mm
(c) 19 mm for t over 57

Tungsten mm , Where t is the

thick of the weld
Inclusion

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Cracks (any Not acceptable

type) (ASME Sec-I)

Pores-Isolated Refer Below

Pores- Cluster table 14.5

14.5 Rounded indications acceptance criteria

Thickness t, Random, Isolated, Maximum Size of Non relevant
mm mm mm Indication ,mm
Less than 3 ¼t 1/3 t 1/10t
3 0.79 1.07 0.38

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5 1.19 1.60 0.38

6 1.60 2.11 0.38
8 1.98 2.64 0.79
10 2.31 3.18 0.79
13 3.18 4.27 0.79
16 3.96 5.33 0.79
19 to 50 incl. 3.96 6.35 0.79
Over 50 3.96 9.53 1.60
Cluster Pore : aggregate length greater than t in a length of 12t, except when the distance between the
successive imperfections exceeds 6L where L is the length of the longest imperfection in the group.

Table 14.6 Alignment / Mismatch Tolerance (ASME Sec-I)

Table 14.7 Maximum Reinforcement Allowed (ASME Sec-I)

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15.HSE MANAGEMENT
Safety is an important factor in all aspects of Welding & nondestructive
examination (NDE) methods. The inspector should read and understand the
manufacturers’ instructions and the material safety data sheets (MSDSs) on
safety and recommended practices for the inspection process, materials, and
equipment, to minimize personal injury and property damage, and assure
proper disposal of wastes.

The following are the general guidelines/ Precautions to be followed in

Welding and allied operations
1) Welding machines should be kept inside welding booth / rain
protection arrangements.
2) All welding machine to be routed through ELCBs.
3) Body earthing should be done by 8 gauge GI wire
4) Welders must be provided with PPEs (Leather hand gloves, safety
shoes. safety belt, face shield, hand sleeves, leg sleeves etc.).
5) No one shall sit or attend on haphazardly stacked materials or loose
stones / soils.
6) Overlapping of power and welding cable should be avoided.
7) Avoid welder standing on wet places or with wet shoes or gloves.
8) Proper access to approach the work place & working platform with
proper guard rail.
9) Fall protection arrangements should be ensured.
10) Provision of PPEs (Safety harness, life line & fall arresters).
11) All cable joints are to be done with proper lugs.
12) Fire extinguishers should be kept at the entry of the welding booth
and at the work place.
13) Combustible materials are to be removed from the area below
welding activity.
14) Spatters may be arrested by providing fire blankets or the area below
are to be barricaded.

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15) A helper will be present below the welding area.

16) Welders are to be provided with container to collect all the waste
electrode bits.
17) Proper ventilation arrangement to be done.
18) Flammability checks to be done before issuing permit to work.
19) Induction training to be given before deployment.
20) Proper supervision at all time during work is to be done.
21) All the machines, tools & tackles must be checked before starting the
job.
22) Entry register to be maintained while working inside the confined
space.
23) Awareness training program to be conducted periodically.
24) Safety induction training before deployment should be ensured.
25) Proper supervision at all time during work should be ensured.
26) Motivational programs (Rewards) & penalty systems should be
ensured.
27) Provision of drinking water should be ensured.
28) Provision of first aid kit should be ensured.

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16. Important calculations and Norms

16.1 Calculating Filler wire and Electrodes required for welding
The following table gives the general idea of filler wire and
Electrode consumption typically in Power plants. The values are practical,
hence the calculated values can be directly purchased from vendor.

Types of joints Process & Range Norms Remarks

Theoretical Volume(m3)*
General
GTAW, SMAW 7890 (Kg/m3)/ wastage see
formula for
all fillets & Butts factor/ deposition table-1
Steel welding
efficiency

Fillet & GTAW & SMAW

K X 4F^2 grams/wastage see
Attachment for all fillets (F=Leg
factor/deposition efficincy table-1
1 meter length size in MM

Only GTAW 160 grams per equivalent

Tubes butt upto 2 equivalent* joint
joints upto 3" GTAW: 50 grams per eqvt
and thickness GTAW & SMAW joints
upto 13MM above 2 to 5
SMAW : 190 grams per
equivalent*
Eqvt joints
* Equivalent Joint calculation
To simplify the calculation purpose and to avoid separate calculations for each sizes ,
equivalent joint concept is used.This is especially used for Tube joints , but widely
used in Pressure parts for both tubes and Pipes.The concept is useful for even
monitoring Welder productivity in Pressure parts
1 Equivalent = (Dia x thk of the Joint )/ (Standard dia x standard thk)
Here the standard dia and thick is 63.5mm x 6.3 mm = 400 = 1 Equivalent Jt
e.g To calculate eqvt for 51mm dia X 5.6mm thick joint

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= (51 x 5.6) / (63.5 x6.3) = 285.6 / 400

= 0.714 Equivalent

Table-1
Wastage factor Deposition efficiency
Process (16.1.1) (16.1.2) (16.1.3)
GTAW (2.5MM filler wire) 0.85 0.98
SMAW (2.5mm Electrode) 0.6
0.98 to 1.1 based on
SMAW (3.15mm Electrode) 0.55 manufacture
SMAW (4 MM Electrode) 0.5
K= Fillet type factor
single fillet , K=1 ; double fillet / single-V, K=2; double -V, K=4

16.1.1 Process combination

For all the joints , the combination of SMAW and GTAW or the combination of
Different sizes of electrodes will not be same. To get the process combination we have
refer the approved WPS and To get the rough idea for different size combination refer
the table 2.

Table-2 Electrode size wise, %consumption in total weight

Electrode size in MM
Thickness/Equivalent range
2.5 3.15 4
Tubes upto 7MM 100.00% Nil Nil
Tubes 7MM and above 65.00% 35% Nil
Pipes upto 5MM 100.00% Nil Nil
Pipes above 5MM to 13MM 50.00% 40% 10.00%
Pipes above 13MM to 19MM 25.00% 30% 45.00%
Pipes above 19MM to 40MM 10.00% 30% 60.00%
Pipes above 40Mm to 70MM 5.00% 15% 80.00%
Pipes above 70MM and above 2.00% 8% 90.00%

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For Fillet welding throat thickness need to taken for above thickness
range

16.1.2 Wastage factor : it includes 2 components; one is the unusable end or tip of
the filler metal which is applicable for both SMAW & GTAW, The other is the flux
content of the electrode which is not deposited in weld metal applicable for SMAW.
The values given above are general , it may vary depending upon the manufacturer and
type of coating to be selected wisely according to the case specific conditions. The
following table gives typical weights of D&H Secheron E7018 electrodes with and
without flux and Filler wire weight which can be assumed for any manufacturer/brand

Table-3, Electrode Weight

Length in
Dia in MM With flux in gram Without flux in gram
MM
2.4 350 24 13.5
3.2 350 36 23
4 350 54 34
3.2 450 46.3 29.6
4 450 69.4 43.7

Table-4 FILLER Weight

Dia Length without flux
2.4 1000 36

16.2 General norms for Welder Productivity

To complete the work within scheduled time , welders planning and
productivity compliance is the major factor. Otherwise misplanning may
bring a crisis management inadvertently brings quality lapses also. To
avoid this productivity of welders need to be taken care. The following

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table gives general idea of productivity norms

Welder Productivity Norms

Types of joints Joints can be welded per shift

Pressure Parts
Preasembly ,Tube -GTAW 12 Equivalent Joints
Preassembly, Tube -GTAW & SMAW 15 Equivalent Joints
Erection ,Tube -GTAW 10 Equivalent Joints
Preasembly, Tube -GTAW & SMAW 12 Equivalent Joints
Preassembly, Pipe -GTAW & SMAW 25 Equivalent Joints
Erection, Pipe -GTAW & SMAW 20 Equivalent Joints
Attachment welding -GTAW 4~6 Metre
Fin welding -SMAW 10~14 Metre
Other Areas
Ducting Fillet welding - 8mm by SMAW 8~12 Metre
Ducting Fillet welding - 5mm by SMAW 16~20 Metre
Condenser butt welding - 20mm 4 Metre
GENERAL
5KG / Welder/ shift by SMAW
1.5KG / Welder/ shift by GTAW

16.3 Shielding and Purging gas required for Pressure Parts

The following table gives the general idea of consumption of Argon used for
Shilding and Purging typically in Power plants. The values are practical.

ARGON Consumption BASIC NORMS

Type of joints Process of welding Norms Remarks
Tubes butt joints upto 3' -short panels only sheilding @26 jts/cylinder
Tubes butt joints upto 2.5' -short panels shielding & purging @13 jts/cylinder

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Tubes butt joints upto 2.5' -length panels only sheilding @22 jts/cylinder
Tubes butt joints upto 2.5' -length panels shielding & purging @11 jts/cylinder

Tubes butt joints upto 2.5' -in for special

shielding & purging @09 jts/cylinder note 2
alloy steel

Link & piping jionts 3' to 6' only sheilding @06 jts/cylinder
Link & piping jionts above 6' to 10' only sheilding @3.5 jts/cylinder
Link & piping jionts above 10' to 18' only sheilding @2.5 jts/cylinder
Link & piping jionts above 18' to 24' only sheilding @1.5 jts/cylinder
Link & piping jionts 3' to 6' shielding & purging @01 jts/cylinder note 2
Link & piping jionts above 6' to 10' shielding & purging @0.7 jts/cylinder note 2
Link & piping jionts above 10' to 24' shielding & purging @0.4 jts/cylinder note 2
General thumb rule for attachment for 700 grams of
only sheilding
welding ( 1 Cu.Metre= 1 Run.Metre) filler- 1 cylinder
Erosion shield &
Case specific: Economiser, LTRH coils @1.5 cylinder/ assy note 3
retainer
Erosion shield &
Case specific: SH, RH, Screen tubes coils @3 cylinder/ assy note 3
retainer

Considerations:
1. For piping joints, purging is to be extented upto hotpass
2. For joints, purging is to be extented upto hotpass for special material like T91, T23, T92, high
carbon stainless steel
3. Case specific means applicable to particular assembly of particular project only
4. One cylinder volume is 7 cubic meter
5. All norms are calculated including wastage

16.4 Radiography Exposure time

Exposure time :Time (min) = (Film factor x SFD2 x 2N x 60) /
(Rhm x 10000 x source strength in Ci)
 Film factor = 1.4 for Particular Film
 Source to Film Distance in cm
 N = Thick,mm / Half value Layer ,12.5mm for Ir-192

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 Rhm = 0.5 for Iridium-192

16.5 Radiography Safe distance
 Safe distance at Air in Metre
=SQ.RT (Ci x RHM X 1000X12) / safe dose
The safe distance will be reduced if we introduce the barrier like steel ,
concrete, lead etc. E.g suppose if put 12.5mm steel plate (equal to half value
layer of Ir-192 for steel) the safe distance will be half to the original
 Ci= source strength in curie
 RHM = Radioactivity constant , 0.5 for Iridium 192
 Safe dose = Generally taken as 0.2 mR/Hr
16.6 Ultrasonic test Important ratios and calculations

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Trignometric Values
Angle in
0 30 45 60 70 90
Degrees

Sin 0.000 0.500 0.707 0.866 0.939 1.000

Cos 1.000 0.866 0.707 0.500 0.343 0.000
Tan 0.000 0.577 0.999 1.730 2.742 ∞

16.7 DPT Usage norms

Ratio of Kits generally used: Penetrant : Developer : Cleaner = 1 : 5 : 7
Running meter can be achieved for one Penetrant (200ml bottle) : around
25 metre

16.8 Costs Involved in Welding &Allied Process

Cost Head Unit of Measurement
Labor cost Welding time (min/p'ce)

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Unit labor cost (Rs/hour)

Labor cost (Rs/p'ce)
Required quantity of deposit metal (g/m)
Deposition efficiency (%)
Consumable cost Consumption of consumable (Kg/m)
Unit price of consumable (Rs/kg)
Cost of consumable (Rs/m)
Gas shield in welding (liter/p'ce)
Gas cost Unit price of gas (Rs/liter)
Gas cost (Rs/p'ce)
Unit price of electricity (Rs/KVA.hour)
Electricity cost Consumed electricity (AxVxwelding time/60)
Electricity cost (Rs/m)
Ginding wheel cost (Rs/nos)
Ginding wheel cost (Rs/m)
Unit labor (Ginder) cost (Rs/day)
Back chipping & DPT Labor cost (Rs/m)
cost
DP kit cost (Rs/can)
DP kit cost (Rs/m)
Unit labor (DP Workman) cost (Rs/hour)
Labor cost (Rs/m)
Labor cost (Rs/m)
Consumable cost (Rs/m)
Total cost Gas cost (Rs/m)
Electricity cost (Rs/m)
Backchipping & DPT cost

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17.Reference Standards and codes

a. ASME section I : Rules for Construction of Power Boilers
This Code covers rules for construction of power boilers, electric boilers, miniature
boilers, high-temperature water boilers, heat recovery steam generators and certain
fired pressure vessels to be used in stationary service and includes those power
boilers used in locomotive, portable, and traction service.
The scope of jurisdiction of Section I applies to the boiler proper and to the boiler
external piping. Superheaters, economizers, and other pressure parts connected
directly to the boiler without intervening valves shall be considered as parts of the
boiler proper,

b. ASME Sec II : Material Specifications

The American Society of Mechanical Engineers (ASME) and the American
Society for Testing and Materials (ASTM) have cooperated for more than fifty
years in the preparation of material specifications adequate for safety in the
field of pressure equipment for ferrous and nonferrous materials, contained in
Section II
Part A — Ferrous Materials and
Part B — Nonferrous Materials
Part C -Welding Rods, Electrodes, and Filler Metals for both ferrous and
Non-ferrous materials
of the ASME Boiler and Pressure Vessel Code.

c. ASME Sec V : Non-destructive Testing

This Code describes the requirements and methods for nondestructive
examination (NDE), which are Code requirements to the extent they
are specifically referenced and required by other Code Sections or
referencing document. These NDE methods are intended to detect
surface and internal imperfections in materials, welds, fabricated parts,
and components. They include radiographic examination,
ultrasonic examination, liquid penetrant examination, magnetic
particle examination, eddy current examination, visual
examination, leak testing, and acoustic emission examination.

d. ASME section VIII div.1: Rules for construction of pressure vessels

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This Division contains mandatory requirements, specific prohibitions, and

nonmandatory guidance for pressure vessel materials, design, fabrication,
examination, inspection, testing, certification, and pressure relief.

For the scope of this Division, pressure vessels are containers for the
containment of pressure,either internal or external. This pressure may be
obtained from an external source, or by the application of heat from a direct or
indirect source, or any combination thereof.

e. ASME section IX : Welding and Brazing Qualification

Section IX of the ASME Boiler and Pressure Vessel Code relates to
the qualification of welders, welding operators,brazers, and brazing
operators, and the procedures employed in welding or brazing in
accordance with the ASME Boiler and Pressure Vessel Code and the ASME
B31 Code for Pressure Piping.

Section IX establishes the basic criteria for welding and brazing which are
observed in the preparation of welding and brazing requirements that affect
procedure and performance.

The procedure qualification test is to establish the properties of the weldment

or brazement and not the skill of the personnel performing the welding or
brazing. In addition, special consideration is given when notch toughness is
required by other Sections of the Code.The notch-toughness variables do not
apply unless referenced by the construction codes.

In Welder or Brazer /Brazing Operator Performance Qualification, the basic

criterion is to determine the ability to deposit sound weld metal, or to make a
sound braze. In Welding Operator Performance Qualification, the basic
criterion is to determine the mechanical ability of the welding operator to
operate the equipment.

f. ASME B31.1 : Power Piping

Rules for this Code Section have been developed considering the needs for
applications which include piping typically found in electric power generating

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stations, in industrial and institutional plants, geothermal heating systems, and

central and district heating and cooling systems.

This Code prescribes requirements for the design, materials, fabrication,

erection, test, inspection,operation, and maintenance of piping systems.Piping
as used in this Code includes pipe, flanges,bolting, gaskets, valves, relief
devices, fittings, and the pressure containing portions of other piping
components.

g. API 650 : Welded steel tanks for Oil storage

This standard covers material, design, fabrication, erection, and testing
requirements for vertical, cylindrical, aboveground, closed- and open-top,
welded steel storage tanks in various sizes and capacities for internal
pressures approximating atmospheric pressure (internal pressures not
exceeding the weight of the roof plates), but a higher internal pressure is
permitted when additional requirements are met . This standard applies only
to tanks whose entire bottom is uniformly supported and to tanks in non-
refrigerated service that have a maximum operating temperature of 90°C

h. AWS D1.1 : Strructural Welding code-Steel

This code contains the requirements for fabricating and erecting welded steel
structures. When this code is stipulated in contract documents, conformance
with all provisions of the code shall be required, except for those provisions
that the Engineer or contract documents specifically modifies or exempts.

This includes general requirements, design of welded connections,

prequalification and qualification of WPS, Fabrication, inspection, stud
welding, strengthening and repair of welded structures.

i. IBR : Indian Boiler Regulations

THE INDIAN BOILERS ACT, 1923 & Indian Boiler Regulations , 1950
IBR Code is very important in the Construction of Pressure Parts and
Power Piping. It is a legal code which is to be necessarily followed by
Everyone in the Power sector in INDIA .It is applicable to Boiler and

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Steam lines
Boiler – closed vessel exceeding 22.75 Litres capacity and generating
steam under pressure
“Steam-pipe" means any pipe through which steam passes from a boiler
to a prime-mover or other user or both, if- (i) the pressure at which steam
passes through such pipe exceeds 3.5 Kg/Cm2 above atmospheric
pressure; or (ii) such pipe exceeds 254 millimetres in internal diameter

IBR Liasioning Process- Responsibility Matrix and Sequence

Document Approval /
Forms or Documents required Responsibility Sequence
Inspection Completion

Drawing Scrutiny as per Manufacturer Manufacturer Before Erection

Previous site IBR
Erection Approval (one Approvals , IBR Welder
Contractor Before Erection
Time) certificates, Staff List , Eqpts
and Tools List
Approved drawings, Design
Material Ground calculation approvals,
Inspection Release forms (Final Manufacturer Before Erection
(Periodic) inspection before Despatch
by IBR or Third Party)
Material Ground Call Letter for ground Contractor /
Before Erection
Inspection (Periodic) inspection Manufacturer
Welder Test (for New
Welder / Sub- Before Starting
welders requires IBR Test Form-XII & Chellan
cont welding
at site)
Welder Endorsement
Before Starting
(other state welders having Form-XIII & Chellan Contractor
welding
validity)
Before Form-
Welder Certificate
XIII Expiry
Renewal ( for all existing Form-XIII Contractor
(Every 24
IBR welders)
months)
Approval of Radiography
10% for RT films and 100% Before
Films & PWHT Charts Contractor
for SR charts Hydrotest
(Periodic)

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Inspecting Authority's
Before
Certificate of Inspection Form-II Manufacturer
Hydrotest
during Construction
Material Test cert Steam Before
Form-III A Manufacturer
Pipes Hydrotest
Before
Material Test cert Tubes Form-III B Manufacturer
Hydrotest
Material Test cert Boiler Before
Form-III C Manufacturer
mounting And Fittings Hydrotest

Steel Marker's Certificate of Before

manufacture and results of Test
Form-IV Manufacturer
Hydrotest
Boiler Registration,
Chellan Paid up for Heating Before
Inspection & HT Fee Client
surface in m2 Hydrotest
(Pressure Parts)
Boiler Registration, Chellan Paid up for length of
Before
Inspection & HT Fee Pipeline in Metre , No of Client
Hydrotest
(Piping) Mountings & Fittings
Calibration of Pressure Before
Calibration T.C Contractor
gauges Hydrotest
Before
Reg.Fee Chellan Client
Hydrotest
Material T.C, Drawing Before
Manufacturer
scrutiny Fee chellan Hydrotest
Hydrotest Package
Draft Protocol for HT,
Marked P&ID for HT
Before
Circuit, Compilation of Contractor
Hydrotest
Ground insp report,
Approval for NDT& SR
Approval of Radiography 100% for RT and 100% for
Before
Films & SR for HT non-conductable Contractor
Hydrotest
PWHT Charts areas
Constructor's Certificate of Maker / Before
Form- VIII
Manufacture and Test manufacturer Registration
Steam Test & Safety valve Client / Before Prov.
Steam test certificate
floating Manufacturer order
Issue of Provisional order Berore Form-
Provisional order Client
for Boiler working VI
Engraving Registry within 1month
Receipt of Registry Number Manufacturer
number of receipt

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Registration and Certificate

Before
for use of a Boiler (Renew Form- VI Client
commercial
Every 12month)
Inspecting Authority's
Before Safety
Certificate of Inspection Form- VII Client
Valve Floating
under Construction
Certificate for the use of an Before
Form- XI Client
Economiser commercial

Inspection of Installed After

Client
Boilers (every12 months) commercial

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18 Special Welding & NDT Practices

18.1 P91 Welding & PWHT
The purpose of te following table is to define the basic requirements
& Sequence to be used for Fitup, welding ,purging /shielding, Heat treatment,
NDT requirements, Hardness of T91/P91 material intented for Pressure parts
and Piping area in accordance with the referred documents.

TUBE (T91) PIPE (Upto PIPE (Above

13mm 13mm Thk)
Thk)

Purging By using soluble dam By using soluble dam paper or

Arrangement paper Mechanical dam of removable type
Before Fitup

Filler metals ER90S-B9 and E9015-B9 or E9018-B9 (Approved brands only

to be used)
Required

Filler metal Colour code : White for ER90S-B9

identification

Baking of Baking @ 250 0C for 2 hours and holding @ 100 0C. Then issue
Electrodes of the electrodes on portable oven for E9015-B9/ E9018-B9

Welders (IBR Qualified in Alloy Qualified in Alloy steel Tube /Pipe

steel Tube
welders only )

Cutting &Edge Cutting of Materials and Edge preparation to be done by band

Preparation saw/hacksaw/machining/grinding only. Gas cutting not allowed.

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FITUP Direct Tacking By using Mechanical clamps or P91 bridge

pieces

PREHEATIN Flame - 205°C Resistance Induction –220 to 250°C (as per

- 205°C WPS)
G (Min)

Purging Argon gas with 99.997% Purity (before Welding&

During Root pass / Hot pass)

WELDING Flame heating with Resistance with Induction with

Interpass Interpass Interpass
Temperature - Temperature - Temperature -
300°C 300 °C 300°C

Shielding Argon gas with 99.997% Purity (During Welding)

HYDROGEN 325°C for 1 Hour, controlled 325°C for 2

DIFFUSION cooling till 90°C Hour, controlled
cooling till 90°C

Intermediate Not required 80-90°C for 1

COOLING Hour

PWHT Resistance Resistance Induction

Method

Loading Temp. Free Rise Free Rise Rate -220°C/Hour

(Upto 300°C)

Heating Rate 120°C/Hour 120°C/Hour 120°C/Hour/Inch Thk

Max Max Max

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(300 to 750°C)

SOAKING 2.4 Minutes/ MM or 1 hour whichever is higher. 90

(750±10°C) Minutes for Thk 25~37.9mm 120minutes
for thk 38~ 50mm 1 Hour per
inch thk or Minimum 2 hours for Pipe with thickness
more than 50 mm

Cooling Rate 120°C/Hour 120°C/Hour 120°C/Hour/Inch Thk

(up to 300°c) Max Max Max

Unloading to Free cooling with insulation

Room Temp.

NDT & Hardness Survey

NDT (% as per By RT (100% By RT By RT or UT (as

Weld schedule or in Pressure per weld schedule)
Contract)
Parts)

Hardness survey- Atleast one Atleast 2 Avg- reading on Pipes

100% Avg- reading 4”to 14” , Atleast 3 Avg-reading
(Acceptance base
on Parent on pipes above 14” on Parent
metal 1&2 , metal 1&2 , HAZ 1&2 , Weld
metal = 180 ~250,
HAZ 1&2 ,
weld < 290HB) Weld

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Typical P91 Setup for Heat treatment by induction.

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18.2 Titanium Welding

• Gas Tungsten Arc Welding (GTAW) process used to weld the Titanium
to Titanium lap welding joints given here for the strip size and welding
rod size & welding parameters as follows
Ti Clad plate thickness = 1.2mm
Ti strip thick ness & width = 2mm & 30mm
Ti 2 filler wire diameter = 2mm
Nozzle diameter = 16mm
Argon Flow volume = 10 to 14 L/min
Welding current = 70 to 80 Amps or as per approved WPS
• Prior to start the welding the joint area shall be cleaned to avoid oxidation
in the weldment. Dirt, oil, grease and moisture shall be removed in and
around 30mm from the joint.
• Welding shall not be continued in the following conditions,
If wind speed is more than 1.5m/s, If relative humidity is more than 80%,If
it is raining, If the temperature of the joint is less than 10°C.
• Prior to start the welding both the base metal & filler wire should be
cleaned and apart from that maintaining a cleaner work area also assist to
achieve good quality welds.
• To prevent contamination entering from filler wire, a lint free
cloth with acetone shall be used to clean the filler wire. If welding
is not performed immediately the filler wire shall be kept in an
airtight container.
• Between each stoppage during welding, filler wire shall be
checked for discoloration and if any found the same area shall be

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removed prior to welding.

• Use a hand grinding machine to remove the layer of titanium oxide.
Proper care shall be taken to avoid the over-heating of the base metal.
• After removing the oxide layer, once again wipe the area to be
welded using acetone, and allow it to dry completely before
welding
• 5mm intermittent (80 to 100mm) spot weld shall be done in a staggered
manner at both side of the Ti strip by using the GTAW welding process
with Ti2 filler wire
• Proper trailing gas arrangement shall be made available to shield
the weld metal after the welding.
• SS wire brush shall be used for post cleaning activities.
• If required interpass temperature shall be checked and maintained as per
the approved WPS.
• Weld visual shall be carried out and main inspection shall be focused on
the color of the weldment. Different colors and the quality indications
are listed in the below table.
• If the surface color of the titanium welds and the heat affected
zone shall be white, faint yellow and pale bule are acceptable.
• Depth yellow. Blue black and purple blue color of the surface
should be permitted and length of these colors shall not exceed
the 20% of the total length of each welds.
• Gray color & white powder in weld surface are not acceptable.
SL. No Weld Color Quality Indication
1 Bright Silver Acceptable

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2 Silver Acceptable
3 Light Straw Acceptable
4 Dark Straw Acceptable
5 Bronze Acceptable
6 Brown Acceptable
• Discoloration must be removed prior to additional welding on the
weld and HAZ.
• Violet, Blue and green discoloration is rejectable if additional
welding is to be performed. Blue and green coloration is
acceptable on finished welds and must be removed prior to
subsequent process.
• DPT shall be carried out in the specified spots / full length of the
welding depending upon the requirement.
• Crack, pore , lack of fusion, slag and other defects are not accepted in
the welding and shall be repaired immediately.
• Pore and lack of fusion shall be rectified by re-welding but crack
shall be completely removed by grinding and the same shall be
welded by using filler wire.

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18.3 PAUT Inspection for Tubes

This procedure is to be used to ensure the quality of weld by Phased Array
ultrasonic method (PAUT) for Pressure Parts Tube welding joints .PAUT is
done in-lieu of Radiography.
This procedure is comprising of PAUT equipment using phased array
probe, computer imaging technique is utilized and includes flaw sizing system

.
18.3.1 Personnel Requirement :
Level-II in UT as ASNT and sufficiently trained in PAUT and PAUT data
package will be reviewed by Level-III
18.3.2 Surface Preparation & Couplants
Water, coupling gels or pastes, cellulose gum can be used. Forced circulation of
water is preferable between probe and Job
18.3.3 Equipment
Contain minimum 32 independent pulse echo channels, Have gain
control stepped in increments of 1 dB or less, Ability to display A,B,C,E and S

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scan images, Capable of operation at frequencies of 1 MHz to 10 MHz,

Capable of varying Pulse Repetition Frequency.

Any control which affects instrument linearity shall be in same

position for calibration, calibration checks, instrument linearity checks and
examination similar to conventional UT.
Phased array wedges shall be of a design to accommodate phased array
search unit. Nominal refracted-wedge angles shall be used 45, 55, 60 or 70
degrees to ensure coverage of the weld and heat affected zone.The curvature
wedge shall be used for each nominal pipe size to be examined.

18.3.4 Calibration and Focal Law

Single (fixed angle) is a focal law applied to a specific set of active elements
for a constant angle beam, emulating a conventional single element probe.

E-scan (also termed an electronic raster scan) is a single focal law multiplexed,
across a grouping of active elements, for a constant angle beam stepped along
the phased array probe length in defined incremental steps.

S-scan (also called a Sector, Sectorial, or Azimuthal scan) may refer to either
the beam movement or the data display.

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(a) Beam movement is the set of focal laws that provides a fan-like series
of beams through a defined range of angles using the same set of
elements.
(b) Data display is the two-dimensional view of all A-scans from a
specific set of elements corrected for delay and refracted angle.

Volume-corrected S-scan images typically show a pie-shaped display with

defects located at their geometrically correct and measurable positions.

Verification of focal law:

Find the index point of transducer, By using the perpex on the IIW V1
block, peak the signal on the A-scan display, Read the values of beam path &
surface distance & calculate angle of the transducer.Transducer angle shall be
within the limits of +/- 2 degrees.Focal law used for the examination shall be
used for calibration

18.3.5 Screen shot of Scanning

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18.3.6 Acceptance criteria

Flaws shall be evaluated for acceptance using the applicable criteria of
Table 7.8 (for thick between 13 to 25mm) and with the following additional
requirements. Unacceptable flaws shall be repaired and the repaired welds shall
be re-evaluated for acceptance.

Surface Flaws – Flaws identified as surface flaws during the UT

examination may or may not be surface connected. Therefore, unless the UT
data analysis confirms that the flaw is not surface connected, it shall be
considered surface connected or a flaw open to the surface, and is
unacceptable unless surface examination is performed. If the flaw is surface
connected, the requirements above still apply.

For multiple flaws refer respective standard for further details

18.3.7 Sample Test Report

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18.3.8 Reference standards of PAUT

ASME Section VArticle 4, Appendix IV &V:Non-destructive examination
ASME Section VIII Div.1,2 :Rules for construction of pressure vessel
ASNT SNT-TC-1A : Personnel Qualification and Certification in. NDT
ASME B31 Code case 181 : Use of alternative UT Acceptance criteria
ASME B31 Code case 179 : Use of UT in lieu of RT for B31.1 applications in
materials ½ inch and less in wall thickness
Asme code case 2235-9 : Use of UT in lieu of RT in ASME Sec I, ASME Sec
VII DIV.1,2

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19 Project Specfic Technical Data

19.1Pressure Parts Joint details
Total

Tube/ No. of
Material Equivalent Major Systems involved (no.of jts in
Pipe Joints
bracket)
PIPE CC2353(WB36) 1 84 Eco inlet
PIPE CS.Gr.B 665 5334 Riser pipes, RH Con.pipe
Downcomer, Eco OL, Exit IL, SH Link
PIPE CS.Gr.C 180 5292
(LTSH OL), Headers, Handholes
PIPE CS+P12 2 198 SH Links (LTSH OL)
PIPE T12/P12 18 1139 SH Links(SH Divn, LTSH OL) , Handhole
PIPE T22/P22 24 1784 SH Links(SH Platen OL), Handhole
PIPE T91/P91 10 176 SH Links(SH Finish OL), Handhole
SUB TOTAL 900 14007
Furnace water walls, BP water walls &
TUBES CS.Gr.B 13773 13078
Roof,Economiser, LTSH Hanger
TUBES CS.Gr.C 86 173 Rear water wall hanger
RH Rad tube(1032), LTSH Lower(720),
TUBES CS+T12 2019 1619
Roof tube(267)
LTSH up&Mid(1464), SH Divn(480), Roof
TUBES T12 2754 2594
tube(292),RH Rad(516), FC Spacers
SH Platen IL (512), SH Divn(960), RH
TUBES T12+T22 2336 2065
Platen(864)
TUBES T22 1152 1266 SH Finish IL(576), RH Cross(576)
TUBES SS 870 594 RH Cross(792), FC Spacers
SH Finish OL(576), RH Finish(792), SH
TUBES T91/P91 2246 1838
Platen OL(512), RH Cross(360)
SUB-TOTAL 25082 25236 23227

Grand Total 26136 37234

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19.2Flue can
Flue can welding scope
(for 2 Nos- Sea side+ Boiler side)
Weld length
Sl. No Remark
Weld size (mm) (RM)
Longitudional weld joint-Butt
1 8 62 SS
2 10 1125 CS
3 16 159 CS
4 20 103 CS
5 2 2898 Ti
Circumferential weld joint-Butt
1 8 460 SS
2 10 4460 CS
3 16 552 CS
4 20 230 CS
5 2 11404 Ti
4347 (long)
TOTAL +17106 (cir) =21453
(cs = 7151, Titanium =14302)

19.3Ducting

Weld Fillet Size Welding Scope

Description
Type (mm) (RM)
AFTER IDF FILLET 7 1325
AFTER IDF BUTT 7 1690

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APH INLET DUCT BUTT 8 528

APH INLET DUCT FILLET 8 276
APH INLET DUCT FILLET 2 16
APH INLET DUCT FILLET 6 1058
APH OUTLET DUCT BUTT 8 37
APH OUTLET DUCT BUTT 5 3
APH OUTLET DUCT FILLET 3 126
APH OUTLET DUCT FILLET 5 180
APH OUTLET DUCT FILLET 6 394
APH OUTLET DUCT FILLET 8 457
BEFORE IDF FILLET 8 2950
BEFORE IDF BUTT 8 3750
BEFORE IDF FILLET 8 1472
BEFORE IDF BUTT 8 1880
BURNER CONNECTED DUCT FILLET 6 64
BURNER CONNECTED DUCT FILLET 5 140
BURNER CONNECTED DUCT FILLET 3 26
BURNER CONNECTED DUCT FILLET 4 28
BURNER CONNECTED DUCT FILLET 1.5 180
BURNER CONNECTED DUCT FILLET 2 42
BURNER CONNECTED DUCT BUTT 6 240
COLD PRIMARY AIR DUCT FILLET 6 1850
COLD PRIMARY AIR DUCT BUTT 6 1460
COLD SECONDARY FILLET 6 1528
COLD SECONDARY BUTT 6 1800
ECONOMISER DUCT FILLET 6 158
ECONOMISER DUCT FILLET 5 451
ECONOMISER DUCT FILLET 8 442
ECONOMISER DUCT FILLET 10 62
ECONOMISER DUCT BUTT 8 626

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HOT PRIMARY AIR DUCT FILLET 6 1870

HOT PRIMARY AIR DUCT BUTT 6 2360
HOT SECONDARY AIR DUCT FILLET 6 1383
HOT SECONDARY AIR DUCT FILLET 5 1405
HOT SECONDARY AIR DUCT FILLET 8 231
HOT SECONDARY AIR DUCT BUTT 6 785
SEAL AIR DUCT FILLET 5 200
SEAL AIR DUCT BUTT 5 30
temporary support hook etc. FILLET 6 4900
temporary support hook etc. FILLET 6 2100
Grand Total 40503

19.4DM Tank

DM TANK-A,B,C (EACH TANK)

Item Welding Type of
Sl.No
Description Scope (RM) Welding

1 Annular Plate 8 Butt

2 Shell L.S Joint 94 Butt
3 Shell C.S Joint 296 Butt
4 T-Joints 20 Butt
5 Bottom Plate 190 Butt
6 Tank roof 555 Fillet
TOTAL 1163

19.5Condenser

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HP/LP CONDENSER HOT WELL WELDING (EACH)

WELDING TYPE OF
S.NO DESCRIPTION
SCOPE (RM) WELDING
1 Condenser Bottom Plate 24 BUTT
2 Condenser Side plate 108 FILLET
3 Condenser Support Plate 83 FILLET
Condenser hot well support pipe &
4 249 FILLET
support rod
5 hotwell pipe seat plate 64 FILLET
Manway,,top support plate,side locking
6 111 FILLET
plate, hotwell side landing bar
7 tube end plate to support rod rop plate 2 BUTT
8 baffle plate to hotwell top plate 27 FILLET
TOTAL 667

HP /LP CONDENSER TUBE SHEEL(EACH)

WELDING TYPE OF
S.NO DESCRIPTION
SCOPE (RM) WELDING
1 Condenser Side Plate 24 GROOVE
2 Condenser Landing bar 130.2 FILLET
3 Tube sheet Support pipe 129 FILLET
4 Corner Plate 86 FILLET
Connecting Plate & landing
5 44 FILLET
Bar
6 Condenser Tube sheet Plate 329 FILLET
7 Baffel & tube support plate 311 FILLET
8 tube to tube support 3109 FILLET
TOTAL 4162

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HP/LP CONDENSER NECK PLATE(EACH)

WELDING TYPE OF
S.NO DESCRIPTION
SCOPE (RM) WELDING
1 Condenser Neck Plate 28 GROOVE
2 Condenser neck Plate corner 43 FILLET
Condenser neck plate
3 95 FILLET
landing bar
4 Rip Plate & Support pipe 89 FILLET
5 HP upper Exhaust Neck 30 FILLET
TOTAL 285

19.6 Coal Bunker

Coal bunker welding Scope
( for 7 no's A,B,C,D,E,F,G)
Sl. Weld size Weld length
Remark
No (mm) (m)
Longitudional weld joint-Butt
1 12 244 CS
2 14 232 CS
3 28 104 CS
Circumferential weld joint-Butt
1 12 992 SS
2 14 829 CS
3 28 200 CS
TOTAL 2601

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19.7Power cycle piping

POWER CYCLE PIPING JTS SCOPE (per Unit)
System description Material Total Jts Inch Dia
Cold Re-heat steam piping CS 52 1676
Feed water re-circulating piping CS 12 84
Feed water re-circulating piping WB36 27 162
Hot Re-heat steam piping A335 P22 76 2470
HP Bypass de-super heating piping WB36 18 90
HP Bypass piping A335 P91 2 28
HP Bypass piping CS 6 248
HP Bypass piping P12 6 264
HP feed water piping WB36 138 2020
Main steam piping A335 P91 49 824
Grand Total 386 7866

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20 Quality Management system

Eventhough the procedures & Specifications are available , the
awareness creation and implementation is the major part of the system.
Unless the knowledge is applied on the work and synchronised through
team work , the task of achieving quality will be imminent only.

To spread the awareness deep into the system and to make

accountability and responsible, management systems are very much
important. To achieve the above FQP-Field quality plans and SOP-
Standard operating procedures are implemented in view of large scale.
But as a part of continuous improvement , some specific task oriented
systems in line with FQP and Procedures also necessary to support the
quality management system.

The following are the major systems followed in the project for the
successful implementation of quality management system in Welding
related discipline.

20.1 Welding consumable Procurement, Receipt,

Storage and Issue control system
L&T POWER-TPPC BU
2x600MW ITPCL Power Project
Welding Consumables Procurement, Receipt, Storage & Issue control system

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Responsibil
Activity Time limit Ref/Acc Documents
ity
Sub- Atleast 2 weeks
Tech.assistance may
Electrode / Filler wire contractor prior to work
be obtained from
calculation for Procurement QC start (6weeks
L&T for calculation
supervisor for alloy steel)
As per weld
Within 2 days
Specification & Brand of filler L&T schedule, Drawing,
of Electrode
metal Engineer Approved list of
calculation
consumables
Purchase order for filler Sub- Within a day of
metals contractor Electrode plan
Sub- 1 week before
Baking oven / Holding oven Calibration certificate
contractor workstart
S/C QC
Portable oven and List of 1 week before Internal calibration/
supervisor/
portable ovens workstart Numbering by L&T
L&T Engineer
S/C QC Within a day of IMIR Report
Incoming material inspection supervisor/ Consumable Batch Test certificate
L&T Engineer plan PO/LR Copy
Welding consumable storage
Separate Rack for Each
S/C QC Immediately Receipt cum Issue
specification, Rigid Store.
supervisor after receipt Register
Halogen Lamp,Hygrometer or
Suitable Moisture control
S/C QC 1 day before As per colourcode
colourcode for fillerwires
supervisor issue system
Baking / Holding of electrodes
S/C QC 1 day before Baking / Holding
as per Baking instructions or
supervisor issue Register
Manufact. recommendation
Every day
Issue of consumables through S/C QC Random witness by
morning or
Issue slip by checking Right supervisor/ L&T Engineer
Before shift
consumable for Right job Store Keeper (atleast 1/day)
starts
S/C QC Issue slip
Issue of Electrodes through supervisor Baking / Holding
(Random Every Time of
Baking register by store Register
witness by L&T the issue
keeper w.r.to Issue slip Engineer (atleast Receipt cum Issue
1/day)) Register
Baking / Holding
Returning of consumables by
S/C Every Time of Register
reconciling the Bitrods and
Storekeeper return Receipt cum Issue
Balance unused consumables
Register

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20.2 Welder qualification and ID Card control

system
L&T POWER-TPPC BU
2x600MW ITPCL Power Project
Welder qualification Test & ID Card control System

Activity Responsibility Time Limit Remarks

Welder test IBR Certificate
arrangement and other
Sub-contractor
Previous experience As required for Test requirements will
QC supervisor
List ,Show be additional for
piece(sample) test IBR welder
Test piece arrangement
Within a day of Show
Voucher for Test piece L&T Engineer
piece approval
or Location traceability
Test piece
Within a day for exist
transportation and Sub-contractor
test piece or 2days
preparation like Fit-up QC supervisor
for New specimen
and Grinding
S/C QC
Welder test Witness As per client and L&T
supervisor/ L&T
Along with the client Mutual discuss
Engineer
NDT , Destructive test,
S/C QC Within a day of Test
Etching of test piece as
supervisor witness
applicable
Within a day after
Test result L&T Engineer
NDT
S/C QC Within a day of Test
Photos for ID Card
supervisor Result
to be returned
Within a day of Photo
Temporary ID card L&T Engineer once permanent
receipt
card given
Until 6 months
Permanent ID card Minimum 7 days :
L&T Engineer another copy will
(Copy) Maximum 15 days
not be given
Retrenchment to
Permanent ID card only After 6 month
L&T Engineer be approved by
(Original) service.
SectionHead

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20.3 Welding, NDT & SR Job card system

Pressure Parts JOB CARD

SH FINISH F001CHD001D1
DESCRIPTION
OL 61
WELD NO SHFO Joint Nos (1-96)-(1-6)
No.of
Material SA-213T91 576
Joints
SIZE : Dia 57 mm Thk (mm) 8

Welding
Process GTAW
Colour
Filler Material ER90SB9 BLUE
code
Extend of NDT
RT /UT 100%

Pre- 0
205 C
Heating(minimum)
PWHT
0
C/
Heating Rate (Max) 220
Hr
Soaking 0
740-760 C
Temperature
Soaking Time 120 Minutes
0
C/
Cooling Rate (Max) 220
Hr
ARGON Flow rate ( Ltr /minute )

Shilding 8 -12 Backing 8-9

Purity (if used) 99.99% 99.997%

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20.4 Issue slip

Weld Rod Issue Slip

S/C : UNIT :
Welder I.D Number – Date :
Filler Size Colour
Location Weld Joint No. Quantity
Spec (Dia.) Code

Issue Return
Issued Qty BATCH No. Unused Remarks
Time Time

S/C Supervisor
L&T Engineer

Issued by (Weld Rod Controller):

20.5 Weld Map & Weld joint code system

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L&T POWER-TPPC BU, ITPCL POWER PROJECT CUDDALORE
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20.6 Preheating, SR Requisition system

UNIT -
DATE :

PREHEATING & SR REQUISITION SLIP

DATE TIME
PREHEATING :

DATE TIME
SR :

SUB CONT SIGN SR AGENCY SIGN

NOTE ; Today Night Shift And Tomorrow Day

Shift Requisition Shall be given

Xxxxx-----xxxxx-----xxxxx-----xxxxx-----xxxxx-----xxxxx-----xxxxx

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