11017, Sheetmetal Fabrication 0f Genset Canopy, Baseplate & Fuel Tank

11017
COMPANY STANDARD – SHEETMETAL FABRICATION/WELDING 0F

GENSET CANOPY, BASEPLATE & FUEL TANK
_____________________________________________________________
1. Scope:
1.1 This standard is intended to provide guidelines for the manufacture of structural &
sheet metal fabrication. AWS D1.1/D1.3 (American Welding Society) shall be used as
a reference standard
1.2 Copies of this standard shall be circulate to:-
a. Application Engg.
b. Production
c. Materials
d. Quality Assurance
e. Manufacturing Engg
f. AGOEMS .
Each revision of this shall be duly intimated to all above recipients.
2. Welding processes:
2.1 Welding may be done by GMAW (Gas Metal Arc Welding), GTAW (Gas Tungsten Arc
Welding) or SMAW (Shielded Metal Arc Welding)
2.2 All welding procedures & welders shall be pre-qualified as per requirement of AWS
D1.1 & /D1.3
2.3 The validity of welder’s qualification shall be verified & monitored by concerned
Process Owner / Q.A. Department
2.4 Joints shall be made by single or multiple pass welding, from one or both sides
3. Base Metal:
3.1 The base metal used for fabrication of Genset Canopy, Base frame & Fuel tank is CR
(Cold rolled) sheets & HR (Hot rolled) steel sheets
3.2 All the base-metal shall confirm to following standards -
3.2.1 For CR sheets -IS 513 1994 Grade D
3.2.2 For HR sheets -IS 1079 1994 Grade DD / IS 2062-E-250 (FE-410) Grade-A
3.3 The base metal thickness used for fabrication of components is having thickness
range from 1.2 mm to 30 mm, thickness for all the processes
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Page | 1
Released By : Rev No : 01 ECN NO:- 28578
KOEL R & E Release Date : 26–05-2021
11017
_____________________________________________________________
4. Electrical parameters:-
4.1 The filler metal specified in WPS shall be used for respective base metals
4.2 Welding equipment shall be procured from reputed manufacturers & broadly shall
have capacities as follows:-
4.2.1 For GMAW 400 amps capacity
4.2.2 For GTAW 230/300 amps capacity
4.2.3 For SMAW Rectifier 400 amps capacity
4.3 The recommended data sheet for Filler Metal parameters:-
Sr. For GTAW For SMAW

Parameter For GMAW Welding
No. Welding Welding
1 Wire size 0.8 mm & 1.2 mm 1.6 & 2 mm 3.2 & 4 mm
Shielding
2 CO2 gas/Argon- CO2 Argon gas …….
Gas
3 Gas flow rate 10 -20 l/min 10-20 l/min …….
90-140 amps for 0.8 mm
wire size
4 Current 70-90 amps 90-110 amps
150-250 amps for 1.2 mm
wire size
5 Voltage 18-25 volts 10-20 volts …….
 Company may fallow the process validation system at their end and ensure parameters
are set as per process validation report to fulfill welding requirement. Use above table as
reference for Welding process Validation
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11017
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5. Storage & Preservation Of welding consumables:-
5.1 All consumables (Electrodes) are stored in clean & dry area
5.2 Consumables shall be stored in stores, after getting clearance from Q.A.
5.3 QA shall check all quality parameters as per consumable test certificate with reference
standard ASME–Sec II Part C (American Society of Mechanical Engineers). In addition
to verifying the manufacturer’s test certificates
5.4 Welding consumable should be tested for material composition once in a year / It
should be cleared on the basis of consumable test certificate provided by vendor
5.5 Consumables should be issued on first in first out basis
5.6 Store in-charge will issue the consumables on receipt of requisition from welding shop
5.7 Persons authorized to sign the requisition shall be designated by Manager- Production
5.8 Authorized persons from production for requisition sign are –
5.8.1 Team leader / Group Leader (Line Managers at Kagal)
5.8.2 Equivalent person at AGOEM
6. Shielding Gas:
6.1 The shielding gas shall be welding grade CO2, Argon, Helium, and Argon-CO2 or
Argon-Helium mixture as per process required
6.2 Shielding gases shall be stored in and used from the containers in which they are
supplied or from a central storage tank distribution system which is replenished by
the gas supplier
6.3 The distribution system shall be free from leaks to prevent air or other contaminants
from entering
7. Position of Welding:
7.1 The welding shall be done preferably in the flat position or alternately in any position,
provided the welder is qualified for that position
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11017
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8. Preparation of base metal:
8.1 The edges or surfaces and edges shall be free from fins, tears, cracks or any other
defects which would adversely affect the quality of the weld
8.2 All loose or thick scale, rust, moisture, grease or other foreign material that would
prevent proper welding or produce objectionable fumes, shall be removed
8.3 If required, surfaces shall be wire brushed prior to welding. Also in multi-pass welds,
the weld bead may be wire brushed between passes depending upon requirement.
8.4 All other equipment such as grinding discs shall be kept exclusively for use on sheet
steels
8.5 Wherever applicable , back gouging of welds shall produce a groove having a profile
and a depth adequate to ensure fusion with the adjacent base metal and penetration
into the root of the previously deposited weld metals
8.6 Edge preparation when required may be done by grinding/machining. If gas cutting is
used for edge preparation, the gas cut surface shall be ground back to a bright
appearance
9. Weld Quality Assurance:
9.1 All the welds shall be subjected to visual inspection

9.2 All the welds shall exhibit neat & uniform appearance
9.3 Defects noticed during visual inspection shall be rectified using the same process
9.4 ISO 5817 should be used as acceptance criteria of weld defects. Alternately the
inspector may accept the welding by using the comparators or workmanship models
9.5 If the major changes in process parameters, strength of welded joints should be
validated
9.6 For process validation make welding samples from qualified welder & check all
aspects on sample with the approved agency
9.7 Cracks or blow holes that appear on the surface of any pass shall be removed
before depositing the next covering pass
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11017
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9.8 The procedure and technique shall be such that undercutting of base metal or
adjacent passes is minimized
9.9 First piece inspection record shall be maintained by process owner / Q.A. in a batch
quantity for Canopy & Base frame
9.10 Job-wise records shall be maintained by Process Owner/QA with full traceability
regarding welder employed, date of welding & date of clearance for Fuel tank
9.11 All welds shall be free of cracks, porosity & spatter
10. Types Of Welding Joints & symbols:
10.1 Standard ANSI (American National Standards Institute) / AWS A 2.4 shall be
referred for joint-type
10.2 Any specific & requirements shall be specified in General notes on drawing
10.3 Refer Annexure A for Welding joints and symbols
10.4 Refer Annexure B for Welding details of Canopy
10.5 Refer Annexure C for Welding details of Base frame
10.6 Refer Annexure D for Welding details of Fuel tank
11. Approved Sources:
As per common sourcing data of KOEL
Prepared by: Reviewed & Approved by:

Mr. Chinchale P.R. Mr. Chatla P.A.
Sr. Engineer Associate General Manager
APPL. ENGG. APPL. ENGG.
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11017
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Annexure - A
Welding Joints and Symbols
Elementary Welding symbols
Sr. No. Designation Illustration Symbol
Butt weld between
plates with raised
1 edges(the raised
edge being melted
down completely
2 Squire butt weld
3 Single - V butt weld
Single - bevel butt

4
weld
Single - V butt weld

5
with broad root face
Single - bevel butt

6 weld with broad root
face
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11017
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Single - U butt weld

7 (parallel or slopping
side)
Single - U butt weld

8 (parallel or slopping
side)
Backing run; back or

9
weld
10 Fillet weld
Plug weld; plug or

11
slot weld
12 spot weld
13 Seam weld
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Page | 7
11017
COMPANY STANDARD – SHEETMETAL FABRICATION/WELDING 0F GENSET CANOPY, BASEPLATE &
FUEL TANK
_____________________________________________________________
Annexure - B
Guidelines for Canopy Fabrication
Canopy Sub-
Sr. No. Welding Guidelines Reference Photo Reference For welding
assembly Description
Door frame corner top side Stitch length around

flange should be stitch welded at 20mm & regular pitch
regular pitch not more than 20mm
Spot pitch distance

Door frame corner should be
1 Door Frame not more than around
spot welded at regular pitch
30mm
Regular pitch
Door frame stiffeners should be
distance not more
than around 100mm
_______________________________________________________________________
Released By : Rev No : 01
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Door frame Z chill are full welded Regular pitch for plug
at corner & plug welded at welding not more
regular pitch than 100mm
Door frame box for bolting

-----
should be spot welded
Door frame Sliding bracket Stitch length around

should be stitch welded at 20mm & regular pitch
Stitch length around

Fuel pipe box should be stitch
----- 30mm & regular pitch
welded at regular pitch
not more than 50mm
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Partition support on door frames
30mm & regular pitch
should be stitch welded at -----
not more than
regular pitch
100mm

Mounting channel on door frame
should be stitch welded at -----
not more than
regular pitch
100mm
Lamp bracket should be spot Spot distance not

-----
welded more than 50mm
Door frame weld nut & bush

should be spot welded at two -----
opposite sides
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Door corners must be full welded -----
Door stiffener should be spot Regular pitch for spot

welded at regular pitch at welding not more
bottom side edges to door than 100mm
2 Door
Joining of stiffeners should be

-----
full welded at center
Door box for lock should be spot

-----
welded
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Door lock box should be spot Spot distance not

welded more than 30mm
Door latch catcher should be

stitch welded at both sides as
20mm
shown
Spot distance not

Extra foaming plate corners more than around
should be spot welded at regular 30mm, Stitch length
pitch & corner top flange should around 20mm &
be stitch welded at regular pitch regular pitch not
more than 30mm
Tower bolt bracket should be

stitch welded at both sides as
30mm
shown
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Follow Plain door instructions for

----- -----
stiffener & box for lock welding
3 Cut-out door
Cut-out door frame should be Pitch for spot welding
spot welded at regular pitch not more than 75mm
Top cover must be full welded at

-----
corner
4 Top Cover
Top cover stiffener should be
Pitch for spot welding
spot welded with regular
not more than 75mm
intervals on edge side only
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Top cover exhaust cut-out flange

-----
should be full welded
Top cover cut-outs for Radiator

water fill flange should be full -----
welded
Top cover weld stud should be

-----
spot welded at two sides
Mesh top cover box corner Stitch length around

flange should be stitch welded at ----- 20mm & regular pitch
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Silencer support bracket should

be stitch welded at bottom side
20mm
edge as shown
Silencer bracket should be stitch Stitch length around

Silencer/EGT/Catalyst
5 welded at top, bottom & middle 30mm & regular pitch
Bracket
of rib as shown at regular pitch less than 70mm
Radiator partition should be spot

-----
welded at corner
6 Radiator Partition
Radiator partition corner top Stitch length around

side should be stitch welded at ----- 20mm & regular pitch
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Radiator partition Z -channel Regular pitch for plug

should be full welded at corner ----- welding pitch around
& plug welded at regular pitch 100mm

Radiator partition stiffeners &
cut-out frame should be spot
not more than
100mm
Louver Assly should be spot Do spot weld at top &

welded bottom of louver
7 Louver Assly
Radiator and Alternator side
louver corner top side flange
----- 20mm & regular pitch
should be stitch welded at
not more than 20mm
regular pitch
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Spot distance not

Louver box should be spot
more than around
welded at corner
30mm
Spot distance not

alternator partition should be
8 Alt Partition more than around
spot welded at corner
30mm
Regular pitch for spot

Alternator duct should be spot
9 Alternator Duct welding around
75mm
Panel corner side top flange Stitch length around

10 Vertical Panel should be stitch welded at ----- 20mm & regular pitch
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Spot distance not

Vertical Panel corner should be
more than around
30mm
Vertical panel stiffeners should Pitch for spot welding

be spot welded at regular pitch around 75mm
Vertical panel box for bolting

-----
should be spot welded
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Annexure - C
Guidelines for Base frame Fabrication
Sr. Base frame Sub- Reference For
Welding Guidelines Reference Photo
No. Assembly Description welding
Front & rear hor channel rib should be

Stitch length
stitch welded from front side in zigzag
around 75-
manner & full welded at top & bottom
90mm
on only one side as shown
1 Base frame
Base frame lifting plates & hooks must

-----
be full welded
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Channel welded joints must be full

-----
welded
Baseplate channel joint plates should be Stitch length

stitch welded around 75mm
Base frame Breather box should be full

-----
welded to channel
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KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Stitch length
Base frame side cover plates should be around 50mm &
-----
stitch welded at regular pitch regular pitch
less than 70mm
Breather pipe should be full welded to

-----
channel
Engine mounting support must be full

2 Base frame -----
welded at joints
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Alternator mounting support must be

-----
full welded at joints
Radiator mounting support must be full

-----
welded at joints
For welded Engine & alternator

mounting support channels & alternator Stitch length
bottom plate should be uniform stitch around 50mm
welded
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Battery bracket & control panel support

-----
channels must be full welded
Pitch for spot

Base frame Bottom sheet should be spot
welding around
100mm
Stitch length
Lube oil drain support angle should be
around 20-
stitch welded at both vertical edges
30mm
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Fuel tank support angle should be stitch Stitch length

welded at uniform pitch around 50mm
Full welding at
horizontal
channel side &
Mounting Plates for engine, alternator & stitch welding
3 Base frame radiator should be stitch welded on remaining
sides. Stitch
length around
50mm.
For integrated fuel tank, bottom tank

-----
tray must be full welded from inside.
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
For integrated fuel tank, Tank tray joint

-----
plates must be full welded
For integrated Fuel tank, Tank tray joint

-----
must be full welded
Alt support should be stitch welded at Stitch length

4 Alt Support
two ends & middle around 50mm
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Stitch length
around 50mm &
Alt support bottom plate should be
regular pitch
stitch welded at regular pitch.
less than
100mm
Support channel rib should be stitch Stitch length

5 Support Channel ribs
welded around 50mm
Engine support should be stitch welded Stitch length

6 Engine Support
at two ends & middle around 50mm
Stitch length
Battery bracket rib should be stitch
7 Battery Bracket around 15-
welded
20mm
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Battery bracket should be stitch welded Stitch length

at bottom support channels around 50mm
Stitch length
Battery clamp should be stitch welded around 15-
20mm
Stitch length
around 50mm &
Engine Mounting Engine mounting bracket should be
8 regular pitch
Bracket stitch welded at regular pitch
less than
100mm
Stitch length
Silencer/EGT/supply around 50mm &
Silencer/EGT mounting support channels
9 module/Adblue tank regular pitch
should be stitch welded at regular pitch
Mounting less than
100mm
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Stitch length
around 50mm &
Support plates with ribs should be stitch
10 Support plates regular pitch
less than
100mm
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Annexure - D
Guidelines for Fuel tank Fabrication
Sr. Fuel tank Sub- Reference For
Welding Guidelines Reference Photo
No. Assembly Description welding
Bottom tray must be full welded from

1 Bottom tray -----
inside
2 Top Cover All flanges & bushes must be full welded -----
_______________________________________________________________________
KOEL R & E
11017
FUEL TANK
_____________________________________________________________
Spot welding
Use stiffeners for war page control on
pitch not more
top cover with spot welding at uniform
than around
pitch
60mm
-----
Fuel tank top & bottom must be full

3 Fuel tank
welded
-----
_______________________________________________________________________
KOEL R & E

11017, Sheetmetal Fabrication 0f Genset Canopy, Baseplate & Fuel Tank

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11017

COMPANY STANDARD – SHEETMETAL FABRICATION/WELDING 0F

Each revision of this shall be duly intimated to all above recipients.

Sr. For GTAW For SMAW

5. Storage & Preservation Of welding consumables:-

9. Weld Quality Assurance:

9.1 All the welds shall be subjected to visual inspection

10. Types Of Welding Joints & symbols:

11. Approved Sources:

As per common sourcing data of KOEL

Prepared by: Reviewed & Approved by:

2 Squire butt weld

3 Single - V butt weld

Single - bevel butt

Single - V butt weld

Single - bevel butt

Single - U butt weld

Single - U butt weld

Backing run; back or

Plug weld; plug or

Door frame corner top side Stitch length around

Spot pitch distance

Door frame box for bolting

Door frame Sliding bracket Stitch length around

Stitch length around

Stitch length around

Lamp bracket should be spot Spot distance not

Door frame weld nut & bush

Door corners must be full welded -----

Door stiffener should be spot Regular pitch for spot

Joining of stiffeners should be

Door box for lock should be spot

Door lock box should be spot Spot distance not

Door latch catcher should be

Spot distance not

Tower bolt bracket should be

Follow Plain door instructions for

Top cover must be full welded at

Top cover exhaust cut-out flange

Top cover cut-outs for Radiator

Top cover weld stud should be

Mesh top cover box corner Stitch length around

Silencer support bracket should

Silencer bracket should be stitch Stitch length around

Radiator partition should be spot

Radiator partition corner top Stitch length around

Radiator partition Z -channel Regular pitch for plug

Stitch length around

Louver Assly should be spot Do spot weld at top &

Spot distance not

Spot distance not

Regular pitch for spot

Panel corner side top flange Stitch length around

Spot distance not

Vertical panel stiffeners should Pitch for spot welding

Vertical panel box for bolting

Front & rear hor channel rib should be

Base frame lifting plates & hooks must

Channel welded joints must be full

Baseplate channel joint plates should be Stitch length