1 Objective

To outline the procedure that will be followed for Welding and cutting activities at the site.

2 Scope of work
 Welding and cutting are the most relevant activities for execution of work at the site.
 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.

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

6 Welding and Cutting Operations:

 Welder qualification test should be carried out with 6G positions welding. Radiography (X-
Ray) test and laboratory tests. Subject to the satisfactory report only, that particular welder
should be allowed to perform welding work for that project.
 An identity card duly signed by approval authority shall be issued.
  The fitter shall use a normal welding transformer to join pipes by tack-welding them. Joint-
gap of minimum 2-2.5 mm shall be maintained. For larger dia piping, pipe-ends of both pipes
will be chamfered to form adequate bevel at 30° - 37.5°.
 Good quality electrodes as specified for the project should only be used to fill the gap (with
molten weld-metal) and settle properly.
 The skilled welder then shall start a root weld, and wire brush the root joint so that the flux
on the joint is completely removed. Grinding machine should be used to remove flux.
 After letting the joint to solidify for a few minutes, the final weld shall be performed and the
flux is removed once again.

6.1 Gas Cutting Equipment

 Gas cutting is fusion method of cutting, in which a strong gas flame is used to raise the
temperature of work pieces so as to melt them. The following gases can be used for heating
and cutting
o Oxygen and Acetylene mixture.
o Oxygen and BMC gas mixture.
 The oxy-acetylene/ BMC gas equipment consists of two large steel cylinders; one containing
oxygen at high pressure, and the other dissolved acetylene or BMCG also at high pressure,
rubber tubes, pressure regulators and blowtorch. The oxygen and the acetylene or BMCG
are supplied to the blowtorch separately, where both of them get mixed and come out
through the nozzle of the 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. Preferably a trolley should be used to
ensure enclosure as well as mobility.
 Gauges on the cylinders should be fully functional and well-maintained.
 It is advised that flame arrestors be given at both sides of the area where cutting is being
done.
 6.2 Welding Procedure Specification

JOINT (QW-402)
Joint Type: AS INDICATED IN DRAWING / COMPONENT
Backing NONE
Backing material N.A

BASE MATERIAL (QW-403)

P. No.: N.A To N.A

Base metal IS 1239 * GRADE LIGHT (M.S) To IS 1239 * GRADE : HEAVY (M.S)

Specification: IS 1239 * GRADE : LIGHT To IS 1239 * GRADE : HEAVY

Thickness range: Groove 1.6 mm – 10 mm Fillet ANY

*Note: IS 1239 is equivalent to BS: 1387, ASTM-120, DIN-2439, 2440, 2441.

FILLER METALS (QW-404) (Filler-1) (Filler-2)

Spec No (SFA) A 5.1 N.A

AWS No. (Class) E 6013

F-No. 2

A-No. 1

Size of Filler Metals 2.5 / 3.15 mm

Weld metal Thickness range - Groove 1.6 mm – 10 mm

Weld metal Thickness range - Fillet ANY

Electrode / Flux Trade name ESAB or ADOR or equivalent

Consumable insert N.A

Other: N.A

POSITIONS (QW-405) GAS (QW-408)

Position of Groove ANY Shielding Gas N.A
Welding Progression UPHILL Composition N.A
Position of Fillet ANY Flow-rate N.A

PREHEAT (QW-406) GAS (QW-408) continued

Preheat Min. Temp. 200 C Backing Gas N.A
Interpass max. Temp. N.A Composition N.A
Preheat maintenance N.A Flow-rate N.A

POST WELD HEAT TREATMENT (QW-407) Trailing Gas N.A

Temp. range N.A Composition N.A
Soak Time N.A Flow-rate N.A
Holding Temp N.A

ELECTRICAL CHARACTERISTICS (QW-409)

Current Type (AC / DC) AC / DC Polarity SP / RP
Amps range AS BELOW Tungsten Electrode type & size N.A
Volt range AS BELOW Metal Transfer mode (GMAW) N.A
Electrode wire feed speed range N.A

TECHNIQUE (QW-410)
String or weave Bead STRING / WEAVE Method of Back gouging N.A
Initial Cleaning BRUSHING / GRINDING Orifice or Gas Cup size N.A
Interpass cleaning BRUSHING / GRINDING Gun angle (GMAW) N.A
Single or Multiple pass (per
MULTIPLE Multiple or Single electrodes SINGLE
side)
Travel Speed range N.A Oscillation N.A
Other N.A Peening N.A
Contact Tube To Work Dist. N.A

Filler Material Electrical Travel

Weld Others /
Process speed
Layer Current range Voltage range Remarks
Class Size Polarity (mm/min)
Amps Volts
1 2.5 / AC / DCSP/ 60-100/
SMAW E 6013 N.A N.A
(Root) 3.15 DCRP 100-140
2.5 / AC / DCSP/ 60-100/
2 SMAW E 6013 N.A N.A
3.15 DCRP 100-140
AC / DCSP/ 100-140/
3 SMAW E 6013 3.15/4.0 N.A N.A
DCRP 140-200

OTHER PARAMETERS AS REQUIRED