DELHI INTERNATIONAL AIRPORT LIMITED

Phase 3A Works, IGI Airport, New Delhi

Submittal

Date: 27-Jun-2020 Submittal no. BSL-L&T-DIAL-3A-B-002-QCD-0204

INDEX

Section - I : Cover Page

Section - II : Contents
 DELHI INTERNATIONAL AIRPORT LIMITED
Phase 3A Works, IGI Airport, New Delhi

Submittal

Date: 27-Jun-2020 Submittal no. BSL-L&T-DIAL-3A-B-002-QCD-0204

Cover Page
 COVER PAGE

Method Statement for

Welding Process Specification
Contents
 CONTENTS

S. NoDescription
I Cover Sheet
II Content Sheet
1 Scope of Work
2 References
3 Project Organization
4 Pre-requisite
5 Activity Description
6 Work Methodology
7 Testing
8 In process and Final Inspection and Testing
9 Records
10 List of attachments
 PHASE-3A , DIAL PROJECT

METHOD STATEMENT

1.0 SCOPE OF WORK

This method statement describes the method of Welding process specification at DIAL ,
Phase-3 project.

2.0 REFERENCES

Approved drawing and specification .

3.0 Project Organization

Project is headed by project manager and supported by various functions i.e

construction purchase, design , quality and safety etc.
Construction Team : Roles & Responsibility :

Project Engineer :

 He is responsible for ensuring the implementation of this method statement and

assuring SHE and quality management at Site.
 He is responsible for execution of all site related work in accordance with the
approved Working Reference Drawings and Method statement..
 He is responsible for scheduling and monitoring site activities in a regular basis ,
adhering to Quality and Safety policy.
 He is responsible to reconcile material, coordinate with Work force, interface with
other system wide contractors
 Responsible to comply PTW requirement.

Site Supervisor :
 He is prime responsible for ensuring the implementation of this method statement
assuring SHE and quality management at Station.
 Ensures that tools and equipment used by Construction Sub Contractor are in safe
and workable condition.
 Conduct frequently activity supervision regarding the workers activities and ensuring
work as per approved Working Reference Drawings & method statement and initiate
corrective action if any deviation observed from system requirement.
 Works in close coordination with Station Safety Officer & takes all necessary
measures to comply and Correct all practices and condition which are deemed to be
unsafe.
 Responsible to ensure PTW prior to start the job.
 To conduct Tool Box Talk.
Safety Officer :

 Coordinate the safety activities between the customer, contractor (BSL) and sub-
contractor.
 Coordinating safety, Health & Environment implementation.
 Conduct regular safety checks to ensure that the established safety procedures are
implemented in proper manner.
 Record & report all reportable incidents to Chief SHE Manager.
 Report and investigate all near misses, incidents and accidents.
 Organizes and conducts safety trainings of Subcontractors at site.
 Organize the monthly Safety committee meeting at site.
 Ensures use of Personal Protective Equipment (PPE).
 Ensures that safety equipment (incl. Fire-fighting equipment) is always ready for use,
monitors expiry dates and inspection requirements.
 Ensure that all Safety related documents like instructions, procedures, inspection
forms and emergency plans are kept updated with the latest information.
 Assist in conducting tool box talk to workers along with site supervisor.
 Inspection of tools, tackles, lifting machines & inform the Project Engineer if any
deviations observed.
 Promoting safety consciousness at site.
 Monitoring of welfare measures for workers & staff at work site.
 EHS management system shall be followed as per Customer approved EHS plan.

4. Pre-requisite :
 Clearance of site from civil agency where installation activity to be commenced.
 Availability of approved working drawings
 Availability of required tools and tackles with safety tag ‘ safe for use’
 Availability of all material required to conduct the welding activity

5. Activity description :

5.1 Material Details

Item Description – QTY Brand /

Manufacturer
1. Welding Rod ESAB
5.2 Machine Tools Equipment

Project Engineer and site Supervisor shall ensure all necessary tools & tackles
are available at site prior to commencement of work. All tools are to be
approved by client before commencement of work. All tools test/calibration
certificates to be submitted for record .

Item Machine / Equipment Tool

1. Welding Machine ( 3Phase)
2. Hammer
3. Chisel
4. Welding Shield
5. Grinder
6. Wire Brush
7. Pipe Cutter

5.3 Manpower Deployment:

Required team of workers deputed by Subcontractor under supervision of
supervisor as per site condition and volume of work. Tool box meeting to be
conducted to the workers before start of work and properly inducted with
subcontractor by Safety personnel. All the workers must know the safety
signage & concept of work. ID card must be issued to each worker with
personal details ( including blood group ) and employers details.

5.4 Safety Gadgets

Item Description
1. Safety Helmet ( Mandatory)
2 Safety Shoes ( Mandatory)
3. Safety Jacket ( Mandatory)
4. Hand gloves- (as per activity)
5. Safety harness (as per activity)
6. Ladder (as per activity)
7. Welder apron, welding Shield
8. Fire Extinguishers
9. Fire Blanket, if required.

5.5 HANDLING AND STORAGE

- Welding rods must be stored in dry place
 6.0 WORK METHODOLOGY:

6.1 : WELDING PROCESS (ES) : SMAW

JOINT Details & Design ( QW-402) . : Single "V" BUTT (As per below sketch)

Note : Welding should be done @ 45deg.

6.2 BASE METALS (QA - 403)

Material Specification : ASTM A106

Pipe Dia & Thickness of Test Specimen : 150mm Dia , Thickness as per IS.
Type of Grade : GR - C
Thickness Range : Up to 12mm
Groove : 2.7mm to 3.2mm
Fillet : All Thickness
Pipe Dia Range : Min. 25 mm and over all size

6.3 FILLER METALS ( QS - 404 )

Spec. No. (SFA) : A. 5.1

AWS No. (Class) :E - 6010 & E - 6013
Size of Filler Metals : Root - 2.5 / Final - 3.15 mm
Weld Metal : GI /MS Pipes
Electrode - Flux (Class) : Root E - 6010 Fillup & Final E- 6013
 6.4 POSITIONS (QW - 405)

Positions : 6G
Positions of Groove : All Position
Welding Progression : Up hill

6.5 PREHEAT (QW - 406)

Preheat Temperature Min. : Ambient
Interpass Temperature Max. : 250 deg.C
Preheat Maintenance : Nill

6.6 POSTWELD HEAT TREATMENT (QW - 407)

Temperature Range : N/A
Holding Temperature Range : N/A
Holding Time Range : N/A

6.7 GAS (QW - 408)

Gases Mixture Flow rate
Shielding NA NA NA
Trailing NA NA NA
Backing NA NA NA

6.8 ELECTRICAL CHARACTERISTICS (QW - 409)

Current AC of DC : DC
Amps (Range) : 60 - 150A
Polarity : SMAW - DCEP
Volt (Range) : 10 - 16 V

6.9 TECHNIQUE (QW - 410)

Stringe or Weave Bead : Both, weaveing should not be more than 3 times of electrode dia
Orifice or Gas Cup Size : N/A
Initial & Inter pass cleaning : Wire Brushing, Grinding etc.
Method of Backgouging : Nill
Oscillation : 2.5 times electrode dia
Multiple or Single pass (Per Side) : Multiple
Multiple or Single Electrode : Single
 PHASE-3A , DIAL PROJECT

METHOD STATEMENT
Travel Speed (Range) : 65 to 120 mm Per min.

6.10 Welding Procedure

Weld Layers Process Class Diameter mm Type Polarity Ampere Range Voltage Travel speed
range
1st Layer Root E-6010 2.5mm DCEP 70 - 100 22-28 60 - 70mm/min.

2nd Layer Fill Up E-6013 3.15mm DCEP 90 - 110 22-32 65 - 120mm/min.

3rd Layer Final E-6013 3.15mm DCEP 90 - 130 22-32 65 - 120mm/min.

7.0 Testing :

NDT testing for welded joints: Radiography test shall be conducted on welded joints
as per TS requirement.

8.0 IN PROCESS AND FINAL INSPECTION AND TESTING

NOT Applicable

9. Records :

TC of Welding Rod..
NDT radiography testing of welded joints.
Procedure qualification record for tested joint shall be documented and
recorded.
Welder qualification test record shall be documented and recorded.

10. LIST OF ATTACHMENT:

1. Checklist of Welding Joint : BSL/L&T/DIAL-3A/CL/0004 Rev-0

2. Risk Analysis of Welding Process Specification
 Installation Check List- WeldingWork
Document No.: BSL/L&T/DIAL-3A/CL/0004 Rev-0
Building Name :
Location/Area/Floor/Room:
Drawing No.:
SL No CHECK POINT Observations REMARKS if any

1 Ensure certification,approval of Welder

2 Ensure Welding Surface Cleaning

3
Check proper alignment of welded sections
4 Check proper fit up of welded joints

5 Check for Welded reinforcement as per specification

not less than 1.6 mm and not more than 3.18 mm

6 Check workmanship of welded joint

Construction/QAQC -Bluestar Construction/QAQC- L&T DIAL

Sign.:

Name:
Date
 Installation Check List- WeldingWork
Document No.: BSL/L&T/DIAL-3A/CL/0004 Rev-0
Building Name :
Location/Area/Floor/Room:
Drawing No.:
SL No CHECK POINT Observations REMARKS if any

1 Ensure certification,approval of Welder

2 Ensure Welding Surface Cleaning

3
Check proper alignment of welded sections
4 Check proper fit up of welded joints

5 Check for Welded reinforcement as per specification

not less than 1.6 mm and not more than 3.18 mm

6 Check workmanship of welded joint

Construction/QAQC -Bluestar Construction/QAQC- L&T DIAL

Sign.:

Name:
Date