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    Welding Manual for Power Sector Bhel

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    41 views150 pages

    Welding Manual For Power Sector Bhel

    Uploaded by

    ABINASH BEHERA

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 150
    WELDING MANUAL FOR POWER SECTOR xy SS ee rae ae ee ee ae ee ee ee ee ee ee ee eee perry BHARAT HEAVY ELECTRICALS LIMITED Li = POWER SECTOR - CORPORATE QUALITY Qa oe WELDING MANUAL FOR POWER SECTOR NAME ‘DESIGNATION / DIVISION ‘V.KANDHSAMY ‘AGM/ PSSR -QLY, Chennai UM DESHPANDE AGM/ CQ, SECUNDRABAD PREPARED BY Dr. K.P.DHANDAPANI ‘DGM / WTC-TIRUCHY P.ELANGOVAN DGM /PC- Chennai ‘A.SUKUMARAN ‘Manager/ SAS Cell - TIRUCHY D.DEVASAHAYAM. Manager/ PSSR-QLY, Chennai |ANARTHANAN ‘Dy. Manager/ PC-Chennai APPROVED BY | A.V.KRISHNAN GENERAL MANAGER / CQ, NEW DELHI PSQ-WDM-COM ISSUE DATE ROL/ 11-06 AD No. : DATE OF ISSUE CONTROLLED COPY/ INFORMATION COPY (ator ur) TT BHARAT HEAVY ELECTRICALS LIMITED POWER SECTOR / CORPORATE QUALITY ISSUED BY ISSUED TO: ‘THIS WELDING MANUAL PROVIDES BROAD BASED GUIDELINES FOR WELDING WORK AT SITES. HOWEVER, SITES MUST ENSURE ADHERENCE TO THE PRIMARY DOCUMENTS LIKE CONTRACT DRAWINGS, ERECTION WELDING SCHEDULE, PLANT / CORPORATE STANDARDS, WHEREVER SUPPLIED, STATUTORY DOCUMENTS, WELDING PROCEDURE SPECIFICATIONS, CONTRACTUAL OBLIGATIONS, IF ANY AND SPECIAL INSTRUCTIONS ISSUED BY MANUFACTURING UNITS SPECIFIC ‘TO THE PROJECT. WELDING MANUAL ‘Al. WELDING-GENERAL STATUS OF AMENDMENTS Reference of Sheet(s) ‘Amended ‘Amendment No. & Date WELDING MANUAL ‘Al, WELDING-GENERAL ‘Description Welding - General Base Materials Welding Material Specification and Control | Procedure for Welder Qualification [inspection of Welding fae Welding |[ Safe Practices in Welding Ct a PART-B Table of contents (Part-B) is shown in page no. 80 a WELDING MANUAL. Al. WELDING-GENERAL, a ee Welding - General | Base Materials | Welding Material Specification and Control Procedure for Welder Qualification Inspection of Welding Repair Welding Safe Practices in Welding Se WELDING MANUAL ‘Al. WELDING-GENERAL Al. WELDING-GENERAL 1.0 SCOPE: This manual deals with activities and information related to welding for site ‘operations including P91 material. Where specific documents are supplied by the manufacturers, the same shall be adopted. 2. DOCUMENTS REFERRED: 2.1. The following documents are referred in preparation ofthis manual AWS D1.1 ASME sections I, II (A&C), V & IX ASME B31. I. BR 5. BHEL Manufacturing Units’ Standards & practices 3 PROCEDURE: 3.1 The following documents shall be referred as primary documents = Contract drawings + Erection Welding Schedule or equivalent - Plant / Corporate standards, where supplied - Statutory documents Welding Procedure Specifications + Contractual obligations, i any. 3.2 Welder Qualification: 3.2.1 Ensure, personnel qualified as per statutory requirements are engaged, where required. 3.22 For welding not under the purview of statutory requirements, qualification of welders shall be as in this manual. 3.3 Monitor performance of qualified butt welders as in this manual 3.4 Ensure selection, procurement, storage, drying & issue of welding consumables, as detailed in this manual, List of approved vendors of general purpose welding electrodes as provided by BHEL, Tiruchy Unit web site (wivw-bheltry.co.in) shall be used for selection of brands at sites . ‘Alternatively specific contractual requirements, it any may be followed. WELDING MANUAL At. WELDING-GENERAL Where Tiruchy list does not cover site requirements, such specific cases may be’ referred to Head(Qly) of the region. Welding in-charge shall assign a unique identification for all the butt welds coming under the purview of statutory regulations. Such identification may be traceable through documents like drawings, sketches etc. ‘A welding ‘job card” incorporating the welding parameters and heat treatment requirements is recommended to be issued for all critical welds like pressure part ‘welds, piping welds, ceiling girder welds. A format of the job card is enclosed for ilustration.. Heat Treatment: Preheat, inter pass, post heat and Post Weld Heat Treatment (PWHT) requirements shall be as per applicable documents; where these are not supplied, reference may be ‘made to this manual. Prior to PWHT operation, a ‘job card” containing material specification, weld reference, size, rate of heating, soaking temperature, soaking time and rate of cooling shall be prepared referring to applicable documents, and issued. (On completion of PWHT, temperature recorder details (like SI.No., make, range, chart speed) chart number, date of PWHT, start and end time of operation shall be entered ‘on the job card. The PWHT chart shall contain the chart number. ‘The chart shall be evaluated and results recorded. Refer Heat Treatment Manual (Document No. PSQ-HTM-COM) for details. Equipment & Instruments: Equipment/accessories used shall be assessed for fitness prior to use. Use calibrated temperature recorders. ‘Thermal chalks shall be batch tested prior to use. Inspection: Inspection of welding may be done as per Chapter AS and records maintained as appropriate. WELDING MANUAL ‘Al, WELDING-GENERAL, Weld log containing the following information shall be prepared for all completed systems. = Project / Unit reference = Drawing No. Weld designation EWStequivalent Material specification Welder code Date of welding NDE ret. and results (including repair details) PWHT ref. and results + Remarks, if any. Safety: Safe aocess to weld area shall be provided. ‘Adequate protection shall be provided against excessive wind and rain water entry during welding, Records : All records, as required, shall be maintained by welding in-charge. WELDING MANUAL Al, WELDING-GENERAL, Page 1 of 2 Project Unit No. ‘Area: Boiler /'TG / PCP Job Card No. : Date: Joint No. Drawing No. System Description Size (Dia. x thick) Material Specification t Welder No.) : Date of welding Filler wite Specification Electrode Specification Preheat temperature Inter pass temperature PWHT temperature WELDING JOB CARD. HILLER WIRE / ELECTRODE CONSUMPTION GTAW Filler wire Page 2 of 2 SMAW 62.5 mm 93.15 mm 94.0 mm. Date of LPI for RG Plug Remarks Date of Return ‘At. WELDING-GENERAL Card No.: | Project System: Drawing No. PGMA: DU No. ‘Material Specification: OD (mm): | Filler craw smaw | Joint fitup: | Min. WT = Root Log sheet mismatch: filled: No. of TICs: Distance from EP edge: | ‘Welders’ ID: Mic No Preheat Temp.: °C Minimum, Rate of heating: Purging flow rate: Litres / mi Purging time: I Shielding flow rate: SP as Interpass Temp.: °C Maximum, Rate of cooling: | °C per hour Holding Temp.: ®C for min. 1 hour. for post heating PWHT: 7c Rate of heating / cooling: °C per hour ‘Soaking time inutes (2.5 minutes per mm) | Cooling to: | 350° reheating started at His. on Root welding started at Firs. Preheating completed at Root welding completed at Welding started at Hrs. Welding completed at Interpass temp, maintained between °C and

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