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L&W CONSTRUCTION PVT LTD

RMZ PLOT-A, BLOCK-4AB & 4C

TECHNICAL SPECIFICATION OF
WELDING AND CUTTING

Total no. of sheets including this sheet :08

FILE NO: LW/FIP/RMZ/FPS/4AB/WMS/003

NOT-APPROVED – COMMENTS AS INDICATED / ATTACHED
APPROVED WITH MINOR COMMENTS
APPROVED
TICK BOX DATE DOCUMENT/DWG STATUS

R1 14/07/14 For Approval FIREPRO L&W RMZ
R0 26/06/14 For Approval FIREPRO L&W
REVISION DATE REASON FOR ISSUE ORIGINATOR CHECKED APPROVED
PROJECT : RMZ ECOWORLD PLOT A – 4AB

DESIGN & BUILT
SUB-CONTRACTOR OWNER
CONTRACTOR

...........4 Welding Procedure Specification................................1 Arc Welding Machine.......................5 Welder Performance Test Report........................................3 5 Manpower:.....................................................................................................................................2 Arc Welding Electrodes.....................: LW/FIP/RMZ/FPS/4AB/WMS/003 for Welding and Cutting 01 Rev......................................................3 2 Scope of work.............................. No.....6 6.......................................................................................................................3 4 Tools:.... 2014 Contents 1 Objective...................................4 6...... : Date 05th July...................................4 6...........3 Gas Cutting Equipment............................................................................... Page 2 of 8 METHOD STATEMENT Doc No.................................................................................................................................................3 6 Welding and Cutting Operations:.............................................................................8 PREPARED BY & DATE REVIEWED BY & DATE APPROVED BY & DATE FOR FIREPRO SYSTEMS PVT LTD FOR L and W FOR RMZ ECOWORLD ...........................4 6..........................................................................3 3 Materials:............................................................................................................................................................................................................................................................................................................4 6.......................

2 Scope of work  Welding and cutting are the most relevant activities for execution of work at the site. No.  The process steps herein aim to outline execution of work enabling the resultant welding to meet quality requirements while remaining within the normal work requirements so as to reduce encumbrances to work as a result of too many constraints. 2014 1 Objective To outline the procedure that will be followed for Welding and cutting activities at the site. Page 3 of 8 METHOD STATEMENT Doc No. : Date 05th July.: LW/FIP/RMZ/FPS/4AB/WMS/003 for Welding and Cutting 01 Rev. 3 Materials:  GI/ MS C Class Pipes as per tender coated with one coat of primer and paint  Threaded ‘U’ Bolt  MS ISMC Channel 100 X 50 X 6mm  M12 Anchor fastener with bolt nut washer  Water for Hydro-testing  Dummy flanges and plugs for Hydro-testing  Cylinders for oxygen and BMC gases 4 Tools:  Welding Machine  Drilling machine  Gas-cutter  Cutting Machine  Ladder(s)  Chain-Pulley Block  Ropes  Hydro-testing pump  Radiography testing apparatus 5 Manpower:  One or more team(s) consisting of: o One welder (cum-fitter) o One fitter (if welder is not capable of fit-up) o One cutter (if reqd.) o Two unskilled labourers as helpers PREPARED BY & DATE REVIEWED BY & DATE APPROVED BY & DATE FOR FIREPRO SYSTEMS PVT LTD FOR L and W FOR RMZ ECOWORLD .

6.  An identity card duly signed by approval authority shall be issued.2 Arc Welding Electrodes  Consumable-coated electrodes shall be used to fill the joints.3 Gas Cutting Equipment  Gas cutting is fusion method of cutting.  The addition of alloying element.1 Arc Welding Machine  For fitment purpose. either rectifier or welding generator should be used. 2014 6 Welding and Cutting Operations:  Welder qualification test should be carried out with 6G positions welding. Grinding machine should be used to remove flux. in which a strong gas flame is used to raise the temperature of work pieces so as to melt them. The transformer receives the A. pipe-ends of both pipes will be chamfered to form adequate bevel at 30° .  The skilled welder then shall start a root weld.  After letting the joint to solidify for a few minutes. Subject to the satisfactory report only.  The fitter shall use a normal welding transformer to join pipes by tack-welding them.C supply between 200 and 440 volts and transforms it to the required low voltage in the range of 80 to 100 volts. .  The protection of molten metal from oxygen and nitrogen of the air by providing a gas shield around the arc and the molten pool of metal. A high current of 100A to 400A will be suitable for general arc welding work. Page 4 of 8 METHOD STATEMENT Doc No. a step down transformer is used. o Oxygen and BMC gas mixture. Joint- gap of minimum 2-2.: LW/FIP/RMZ/FPS/4AB/WMS/003 for Welding and Cutting 01 Rev. : Date 05th July. PREPARED BY & DATE REVIEWED BY & DATE APPROVED BY & DATE FOR FIREPRO SYSTEMS PVT LTD FOR L and W FOR RMZ ECOWORLD .  For welding process.5°.5 mm shall be maintained. 6. Radiography (X- Ray) test and laboratory tests.  To establish and maintain the arc throughout welding. that particular welder should be allowed to perform welding work for that project. The following gases can be used for heating and cutting o Oxygen and Acetylene mixture.  The formation of slag over the joint thus protects from rapid cooling. 6. and wire brush the root joint so that the flux on the joint is completely removed.  AWS E-6013 class welding electrodes shall be used  Welder should be qualified and skilled to perform the welding joints and follow all safety procedures during the performance of welding sequence.  Good quality electrodes as specified for the project should only be used to fill the gap (with molten weld-metal) and settle properly. No.37. the final weld shall be performed and the flux is removed once again.  The electrodes are made of either soft steel wire or alloy steel. For larger dia piping.

No. where both of them get mixed and come out through the nozzle of the blowtorch.  Gauges on the cylinders should be fully functional and well-maintained. The oxygen and the acetylene or BMCG are supplied to the blowtorch separately.: LW/FIP/RMZ/FPS/4AB/WMS/003 for Welding and Cutting 01 Rev.  It is advised that flame arrestors be given at both sides of the area where cutting is being done. rubber tubes. one containing oxygen at high pressure. PREPARED BY & DATE REVIEWED BY & DATE APPROVED BY & DATE FOR FIREPRO SYSTEMS PVT LTD FOR L and W FOR RMZ ECOWORLD . Preferably a trolley should be used to ensure enclosure as well as mobility. : Date 05th July. Page 5 of 8 METHOD STATEMENT Doc No. and the other dissolved acetylene or BMCG also at high pressure. pressure regulators and blowtorch.  Precaution needs to be taken that the cylinders are standing vertically at all times in a properly enclosed area and tied to secure them. 2014  The oxy-acetylene/ BMC gas equipment consists of two large steel cylinders.

A To N. 2014 6.: N. DIN-2439. BANGALORE (INDIA) Welding Procedure Specification No. 2 A-No.4 Welding Procedure Specification Company Name: FIREPRO SYSTEMS PVT.A PREPARED BY & DATE REVIEWED BY & DATE APPROVED BY & DATE FOR FIREPRO SYSTEMS PVT LTD FOR L and W FOR RMZ ECOWORLD .A Base metal IS 1239 * GRADE LIGHT (M.Fillet ANY Electrode / Flux Trade name ESAB or ADOR or equivalent Consumable insert N. No.: FP/WPS/ 01 Rev: 01 Date Supporting Procedure Qualification Record FP/PQR/01 Rev: 01 Date No(s) Welding Process: SMAW Type MANUAL JOINT (QW-402) Joint Type: AS INDICATED IN DRAWING / COMPONENT Backing NONE Backing material N.6 mm – 10 mm Fillet ANY *Note: IS 1239 is equivalent to BS: 1387. LTD. 2441.5 / 3..S) Specification: IS 1239 * GRADE : LIGHT To IS 1239 * GRADE : HEAVY Thickness range: Groove 1. (Class) E 6013 F-No.A Position of Fillet ANY Flow-rate N.A Other: N. : Date 05th July. ASTM-120. 1 Size of Filler Metals 2.A Welding Progression UPHILL Composition N. FILLER METALS (QW-404) (Filler-1) (Filler-2) Spec No (SFA) A 5.S) To IS 1239 * GRADE : HEAVY (M.Groove 1.15 mm Weld metal Thickness range . No. Page 6 of 8 METHOD STATEMENT Doc No.A POSITIONS (QW-405) GAS (QW-408) Position of Groove ANY Shielding Gas N.A AWS No.: LW/FIP/RMZ/FPS/4AB/WMS/003 for Welding and Cutting 01 Rev.6 mm – 10 mm Weld metal Thickness range . 2440.1 N.A BASE MATERIAL (QW-403) P.

: LW/FIP/RMZ/FPS/4AB/WMS/003 for Welding and Cutting 01 Rev. range N.A Oscillation N.A Temp.A (Root) 3. N.A Flow-rate N.A N.A Volt range AS BELOW Metal Transfer mode (GMAW) N.A N.A N. AC / DCSP/ 100-140/ 3 SMAW E 6013 N.A Interpass max.A Composition N.A Preheat maintenance N.A Initial Cleaning BRUSHING / GRINDING Orifice or Gas Cup size N.15 DCRP 100-140 3. N.A Other N.A Peening N. Temp.A Interpass cleaning BRUSHING / GRINDING Gun angle (GMAW) N. 2014 PREHEAT (QW-406) GAS (QW-408) continued 0 Preheat Min.A Electrode wire feed speed range N. No.A ELECTRICAL CHARACTERISTICS (QW-409) Current Type (AC / DC) AC / DC Polarity SP / RP Amps range AS BELOW Tungsten Electrode type & size N.5 / AC / DCSP/ 60-100/ SMAW E 6013 N.A Composition N.A Holding Temp N.A 0 DCRP 140-200 OTHER PARAMETERS AS REQUIRED PREPARED BY & DATE REVIEWED BY & DATE APPROVED BY & DATE FOR FIREPRO SYSTEMS PVT LTD FOR L and W FOR RMZ ECOWORLD .5 / AC / DCSP/ 60-100/ 2 SMAW E 6013 N. 20 C Backing Gas N.A Filler Material Electrical Travel Others / Weld Process speed Remark Layer Current range Voltage range Class Size Polarity (mm/min) s Amps Volts 1 2.A Single or Multiple pass (per MULTIPLE Multiple or Single electrodes SINGLE side) Travel Speed range N.A TECHNIQUE (QW-410) String or weave Bead STRING / WEAVE Method of Back gouging N. Temp. Page 7 of 8 METHOD STATEMENT Doc No.15/4.A Flow-rate N.15 DCRP 100-140 2.A 3.A Soak Time N. : Date 05th July.A POST WELD HEAT TREATMENT (QW-407) Trailing Gas N.A Contact Tube To Work Dist.

8 mm 4 FILLER MATERIAL: ESAB Classification E6013 Filler / Electrode size 3. VARIABLES ACTUAL VALUES REMARKS 1 BACKING STRIP (if any): n/a 2 MATERIAL SPECIFICATION: IS: 1239 Pt-1 C Class Material GI Size / Pipe Diameter 3”  Wall Thickness 4. : Date 05th July. 2014 6. Colour Photograph Welding Process: SMAW Type: Manual Sl.15 mm 5 WELD DEPOSIT THICKNESS: 5 mm 6 WELD POSITION: 6G 7 WELD PROGRESSION: Uphill 8 GAS TYPE: n/a 9 BACKING GAS: n/a 10 ELECTRICAL CHARACTERISTICS: AC Transformer Current / Polarity 40-90 Amps / AC VISUAL INSPECTION Surface appearance : Cap width & height : Undercut : Root Defects : Result : Inspected by : COMMENTS (if any): TEST CONDUCTED BY: APPROVED BY (QC): WITNESSED BY: Signature: Signature: Signature: Date: Date: Date: Name: Name: Name: Organization: FIREPRO Organization: FIREPRO Organization: PREPARED BY & DATE REVIEWED BY & DATE APPROVED BY & DATE FOR FIREPRO SYSTEMS PVT LTD FOR L and W FOR RMZ ECOWORLD .: LW/FIP/RMZ/FPS/4AB/WMS/003 for Welding and Cutting 01 Rev. Page 8 of 8 METHOD STATEMENT Doc No.5 Welder Performance Test Report WELDER NAME: Project Name: Location / Region: BLR Employed by:(Sub-Contractor name) Sub-Contractor contact person Affix Joint type: Butt (with Groove) Passport size. No.