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Need of weld buildup: ID mismatch was observed during fit up stage of reducer
and CRA Cladded pipe. The root cause of the problem was identified that the
reducers were procured according the thickness of pipe without considering the
Cladded thickness. To solve this problem suggestion was made by L&T to put weld
overlay over the ID of the reducers and the methodology was approved by
COMPANY.
Methodology adopted: It was proposed to test a mock up piece according to the
Approved Method Statement. The COMPANY Approved method statement for weld
overlay is attached along with.
Execution stage of work: The various steps followed for the work execution are:1. A surplus eccentric reducer (IMIR No. 93/5) was identified for the actual
execution of the test.
2. COMPANY approved WPS was identified according to the requirements of the
job.
3. COMPANY approved welder (qualified into the required welding process i.e.
GTAW) was identified and d about the job to be done.
4. Marking was done before actual start and witnessed by GL & ADMA.
6. In the same manner with subsequent runs one layer was completed and
witnessed by GL & ADMA.
9. Then the test piece was offered for RT. RT film was witnessed by GL and found
OK. See report attached.
11. Machining was done by putting the reducer into the casing.
Machining in progress
13.
After machining all the length, thickness, ID, OD was checked and found
within the limits.
Final product after machining is as shown under.
14.
After final machining a trial fit up was shown to COMPANY and found OK.