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Content
1.0 Purpose And Scope ......................................................................................................................... 2
2.0 Reference ........................................................................................................................................... 2
3.0 General ....................................................................................................................................................... 2
4.0 PROCEDURES .................................................................................................................................. 4
5.0 Safety Control............................................................................................................................................ 9
6.0 QUALITY CONTROL..................................................................................................................... 10































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1.0 Purpose And Scope
1.1 CALACA 2150MW
CFB
The purpose of this procedure is to make sure the welding works of aluminium bus being in
compliance with the related standards, codes, design drawings, technical documents and inspection
of Philippines Calaca 2150 MW CFB Power Plant Project.
1.2
This procedure applies to all aluminium bus welding work
2.0 Reference
2.1 F2421S-D0505
Design Construction Drawings. Drawing NO. : F2421S-D0505
2.2DL/T 869-2004
Technical Code for Welding of Thermal Power Plant (DL/T 869-2004)
2.3DL/T 754-2013
Code of the welding technique for aluminium bus (DL/T7542013)
2.3 ITB 2 2.2.1.5
Clause 2.2.1.5 in volume 2 of ITB.
2.4 ASME
3.0 General
3.1
IE


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Welders for aluminium bus welding shall obtain the welders qualification certificate of
corresponding items they are going to work. All welders shall be tested on site and get to work after
welding parts qualified. Their qualification must be certified by third party and reviewed by Owner
and IE.
3.2
All facilities and equipments used for welding of aluminium bus shall be in good condition.
3.3 ASME
The material for aluminium bus shall be in compliance with requirements of design drawings and
ASME codes.
3.4 ITB 2
2.2.1.5
Each batch of welding material used on site shall have manufacturer quality certificate. The
storage of welding material shall satisfy the requirements of ITB Clause 2.2.1.5.
3.5
Welding material shall be provided only with the welding material requisition issued by foreman
or technicians.
3.6
Welders shall be familiar with the construction drawings, well delivery the technique instruction,
carry out construction according to approved construction drawings and code.
3.7 GMAW
Aluminium bus welding adopts GMAW, and choose welding method according to site condition.
3.8
Measures for weather-proofing such as rain and gale shall be provided in the welding operation
area.
3.9
Welders shall wear badges indicating their qualified item in site welding test while working.

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4.0 PROCEDURES
4.1
Aluminium bus welding procedure:


Groove cleaning fit up fit up inspection spot welding welding slag remove
visual inspection post weld heat treatment non-destructive test recording
4.1.1
Groove cleaning and inspection before fit up
A.
Bus surface shall be clean and flat without crack, crumple, slag inclusion, deformation,
distortion and mechanical damage.
B. 5%
The contact surface of bus joint shall have no oxidation film, the fabrication shall be flat and
section shall not exceed 5% of primary section.
C.
Before fitting up the bus, the oil, paint, rust and dirt on or around the groove shall be cleaned.
D.
30mm50mm30mm50mm
E. Welding cleaning area includes groove and its two side. The cleaning area of butt joint and
angle joint is within the range of 30mm~50mm at the two sides of welding joint, the
overlap joint includes not only the mating surface but also extend outward 30mm~50mm.
F.
The bus can be welded only after the positioning was adjusted in correspondence with the
requirements.

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4.1.2 fit up and fitting up checking
A.
The connector type and size of bus should be in correspondence with the drawing design.
B.
If the partial clearance of joint is too large, it should be adjusted to the designed size without
use of metal object.
C.
The aluminium bus welding and fitting up should fix the welding cushion in case of the
deformation and crack of weldment during welding.
D.
When the structures geometric dimensioning has stringent requirements, checking shall be
carried out in case of structure deformation during the welding.
4.1.3 spot welding and pre-heating

Tack welding requirements of weldment are as follows:
A.
Welding material, technology, preheating temperature and welders qualification needed for
spot welding shall be the same as those for official welding operation.
B.
The setting and size of tack welding are as follows:
(a) ()
the points setting of tack welding are as follows:
300mm1203 300mm
500mm35 500mm60
Pipe fitting: when the diameter is not more than 300mm, every 120 should be tack welded one
point, generally not less than 3 points. When the diameter is within 300mm~500mm, it can be tack
welded at 3~5 points. When the diameter is more than 500mm, tack weld every 60 along the

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circle.
(b) 30mm50mm 80mm 2/3
4mm
Length of tack welding is 30mm~50mm generally, specialty can reach 80mm. The thickness
should be 2/3 of that of weldment and not less than 4mm.
(c)
Tack welding is one part of formal welding which is not needed to be chipped during welding.
C.
If tack welds are to be included in the final weld they must be repaired before formal welding
and weld after qualified without defects.
D.
When doing angle welding or lap type weldment spot welding, the welding seam shall be tight.
It can be knocked tightly by mallet then spot welding.
E.

Main facilities and equipments to be used are shown in table as follows:
4.1.4 A.
4.1.4
welding
A space required It is forbiddened to ignite electric arc and test current on the surface of
weldment. The suitable welding current should be chosen correctly which should be in compliance
with requirements and specifications of welding procedure qualification and welding material
specification referring to table 4.1.4.

4.1.4
Table 4.1.4 MIG-Welding Specification

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(mm)

(mm)

(A)

(V)

(m/min)

(Lmin)

8 1.6 170220 2426 4.56.2 2528 2
12 1.6 190230 2527 4.86.5 2730 2
20 1.6 200230 2527 5.06.5 2730 3
10A15A
weldmen
t
thickness
(mm)
welding
wire
diameter
(mm)
Welding
current
(A)
Welding
voltage
(V)
Wire feed rate
(m/min)
Argon gas flow
(Lmin)
welding
layer
8 1.6 170220 2426 4.56.2 2528 2
12 1.6 190230 2527 4.86.5 2730 2
20 1.6 200230 2527 5.06.5 2730 3
Remarks: current can be reduced by 10A~15A when doing inverted welding.

B.300mm
In order to reduce welding deformation and joint defects, tubing butt joint with more than
300mm diameter had better employ symmetry welding.
C.
Welding under restrained condition should be avoided to reduce the welding stress to prevent
cracking.
D.
When the defects of weld joints exceed the standard, reasons should be found out to take
measurements for rework.
(a)
Grinding can be adopted to repair the appearance defect. Repair welding should be adopted

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timely under the condition that conductive area reduces.
(b)
The method of cut and repair can be adopted for rework for cracks or inner defects.
(c) 30mm50mm
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Completely remove the defects and extend 30mm~50mm from two sides of defects and make
sure that the defects were removed. Then repair welding. And the rework application shall not
exceed 3 times for one place.
4.1.5

Quality inspection: the welding seam quality inspection for aluminium bus is mainly the
appearance inspection. The inspection method of welded joint appearance is visual observation and
using seam detecting ruler.
A.

After completed the aluminium bus welding, welding joint appearance self-inspection should be
made by welder firstly. After self-inspection is qualified, appearance quality inspection should be
made inspectors and quality inspection department of teams.
B.
The appearance quality of welding seam shall be in compliance with requirements of design
drawings. If drawings have no reuirements, the following requirement should be followed:
(a)
The external dimensions of welding seam shall be in compliance with specifications and standard
requirements.
(b)
The edge transition of welding seam shall be smoothing and the joint shall be good.
(c) .

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The welding seamshall be clean without crack, lack fusion, surface porous hole or surface
slag.
(d) 10%1mm20%
The welding seams undercut depth shall be no more than 10% of weldments thickness and
less than 1mm, length no more than 20% of welding seams length.
5.0 Safety Control
5.1

Ware helmet when entering into the site and fix safety belt for high place works. Self-lock
devices shall be used for vertical climbing works and the safety shall be fixed on the place overhead
the working point.
5.2
Footboard and scaffold used in the welding performance place shall be firmly fixed for the
convenience of squatting.
5.3

Welders shall ware the protective articles such as work clothes, special shoes and welding gloves
for the welding performance. The buckles let the cloth opening and sleeve rolling is prohibited.
5.4
The welding cable shall have property of good insulation, replace broken cables and the joint or the
broken shall be wrapped with insulating tape to avoid the power shock.
5.5
Welding machine shell shall be reliably grounding, whose grounding in series connection is
prohibited.
5.6

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Welding workpiece and equipment which hanged on the lifting hook is prohibited.
5.7
The welding slag shall be prevented from hurting people when in cleaning after the welding
operation is finished.
5.8
Civilization Construction & Environmental Protection
5.8.1
The welding is prohibited to be implemented in the rainy day when no necessary measure is
available.Fire blankets to catch any weld spatter and sparks for third party protection.
5.8.2
Sufficient lighting for the night works.
5.8.3
The cleaning and recovery works shall be implemented in time after the welding operation finished.
6.0 QUALITY CONTROL

6.1
The construction workers shall participate in safety and technology discussion before work
commencement, and carry out the works specifically in accordance with the work plan procedures.
6.2
Reinforce the control upon the welding process and carry out three-level (Work teams, specialized
company and Quality Dept.) quality inspection and acceptance system.