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LARSEN & TOUBRO LIMITED – ECC DIVISION

Job Procedure For Welding of Plate/Tube (C.S, S.S, AL.)


Procedure No LT/MAP/PSS/WP/002

Contents
S.No Description Page Formats
1 Scope 2
2 Reference 2
3 Material 2
4 Method 2-3
5 Risk analysis 3-4
6 Documentation 4
7 Inspection & Test plan 5

10-06- For review and


0
10 aaproval
Checked &
Prepared By Reviewed By
Rev Date Description Approved By
L&T HIL / EIL / AP
L&T

Page 1 of 5
LARSEN & TOUBRO LIMITED – ECC DIVISION
Job Procedure For Welding of Plate/Tube (C.S, S.S, AL.)
Procedure No LT/MAP/PSS/WP/002

1. Scope: This procedure covers the work method for fabrication of Pot
superstructure.
2. Reference:
NF EN 10021; NF EN 10025-2; NF EN 10028-2; NF EN 10088-2; NF EN 10088-3; NF EN
10027-1; NF EN 10029; NF EN 10163-1; NF EN 10163-2; NF EN 10164; NF EN 10216-1/1A;
NF EN 10216-5;NF E 83-100-1 ;NF E 100-4; NF EN 100-5; NF EN 287-1 ; NF EN 287-2; NF EN
288-3 ; NF EN ISO 5817 ; ISO 9606-2; ISO 10042; ISO 15607 ;ISO 15609-1; ISO15613; ISO
15614-2.6954-00-16-46-SP-011;07923-S322.00.12.012;07923.S322.34.13.002;
07923.S322.00.12.021;07923.S322.34.12.005.

3. Material: S235J0(IS: 2062 Gr. B E 250) ;S235JRG2(IS: 2062 Gr.E250-quality-B);S355J0 (IS: 2062
Gr.E410);X6CrNiTi18-10(SA240Gr.TP321 & SA240Gr.321); X2CrNi18-9(SA312Gr.TP304L &
SA312Gr.304L); P235TR2 (A106Gr.B);

4. Method :

Fit up

• Before fit-up; pipe/plate shall be checked for correct thickness,


specification, etc.
• Bevel ends shall be visually checked, if any damages are found the same
shall be repaired as mentioned below.
 Dents less than 1mm depth shall be removed by grinding
 Dents 1mm to 3mm depth shall be re-beveled by grinding
 Dents more than 3mm depth shall be gas cut and re-beveled
• Before fit-up; ends inside / outside shall be cleaned by power wire brush at
least for one inch so that the weld edges are free from rust, paint and
other foreign matters
• Repairing of the pipes/plates and beveling by welding with high current is
not allowed
• If any laminations; split ends or any other manufacturing defects in the
pipe/plate are discovered; the length of the pipe/plate shall be cut to the
extent required. Pipes/plates; which have been cut at defects; shall be
checked by DPT to extent of 25mm at the new bevel to ensure it is free
from lamination.
• During alignment & fit-up; first pipe/plate: will be rested and locked on the
pre-positioned skids and the second pipe/plate: shall be held by crane and
rested on wooden / MS supports. Maximum misalignment of same wall
thickness pipe shall not be more than 1.6mm
• Before any pipe/plate length is cut; the painted serial number / stamped
pipe number shall be transferred to either side of joint which has to be
welded.
Page 2 of 5
LARSEN & TOUBRO LIMITED – ECC DIVISION
Job Procedure For Welding of Plate/Tube (C.S, S.S, AL.)
Procedure No LT/MAP/PSS/WP/002

• In case of slight misalignment cold hammering is permissible. Hot


dressing is not permitted.
• The joint design for similar and dissimilar thickness shall be as per figure-1
• After alignment & fit-up; the joint shall be offered for inspection before
start of welding.

Similar thickness joint Dissimilar thickness joint


60º 60º
Taper 1:4

T1
T T

1.5 -3mm 1.5 -3mm


2-4mm 2-4mm

Note:
Plate material: S 235 J0
T =3mm to 45mm, T1 =
>T
Figure:1

Welding
• Earthing clamps used for welding return circuit shall be placed as near as
possible to the welding job.
• Weld joint shall be adequately protected from rain / strong winds.
Windshield shall be used wherever required. Whenever surface moisture
is observed on the pipe/plate; preheat the pipe/plate upto 80 – 100ºC with
a flame torch.
• Welding shall be carried out as per the approved WPS. Minimum no of
welders shall be two on either sides of the pipe.
• After completing of every pass; the same shall be cleaned by rotating
grinders / wire brushes
• Electrode starting and finishing points shall be staggered from pass to
pass

• Arc strike outside the bevel if any shall be grinded and checked.
• Welders shall be qualified as per the approved WPS and all the welders
shall have their identification card at site

Page 3 of 5
LARSEN & TOUBRO LIMITED – ECC DIVISION
Job Procedure For Welding of Plate/Tube (C.S, S.S, AL.)
Procedure No LT/MAP/PSS/WP/002

• After completion of welding; visual inspection shall be done and all the
surface defects shall be removed as per the standards. NDT if any shall be
carried out as per the approved procedures.
• The details of welding consumables are as per approved WPS.
5. Risk analysis

SL.NO RISK INVOLVED PRECAUTIONARY MEASURES


1 Electrical shock - Body of the welding machine should be earthed
Fire - The terminals of the welding cables should be
Explosion provided with lugs and kept tight
Health hazards - The joints in the cables should be made with
Poor illumination terminals; kept tight & well insulated with heat
Hit by object resistant tape.
- The cables should be free from joints at least
for a length of three meters from electrode
holders to avoid shock hazards
- Other electrical cables should not be kept laid
with welding cables to avoid insulation
damage.
- For return cable; proper cable should be used.
- Never change electrode with bare hands or wet
gloves; when standing on wet floors.
- Electrode holders shall be of good quality with
proper insulation.
- Welder shall never be allowed to weld when he
is wet.
- The welder shall use helmet with welding
screen. Adequate ventilation shall be ensured.
- All the combustible materials should be
removed in the welding zone
- Good housekeeping to be maintained.
- Fire extinguisher to be provided at the work
site.
- Proper illuminations must be provided at the
workplace.
- Welders must wear hand gloves; arm guard &
apron shoe.
- All the P&M equipment must be checked for
safety before putting in operation.

Page 4 of 5
LARSEN & TOUBRO LIMITED – ECC DIVISION
Job Procedure For Welding of Plate/Tube (C.S, S.S, AL.)
Procedure No LT/MAP/PSS/WP/002

6. Documentation
• Inspection & Test Plan : LT/MAP/PSS/ITP/001

No:
Inspection & Test Plan for Carbon Steel Welding LT/MAP/PSS/I
TP/001
Verification
Inspection
S.N By Records to be
Activity Description by
o Client/Consu submitted by L&T
L&T
ltant
Welding Procedure
1 W W WPS & PQR Document
Qualification
Welders Performance
2 W W WQT Document
Qualification
3 NDT Procedures W W NDT Document
4 Bevel Inspection W RM
Fit-up of pipe/plate
5 W RM
joints

Page 5 of 5
LARSEN & TOUBRO LIMITED – ECC DIVISION
Job Procedure For Welding of Plate/Tube (C.S, S.S, AL.)
Procedure No LT/MAP/PSS/WP/002

Weld Visual of
6 W RM
completed Weld
NDT of completed
7 W W Relevant NDT formats
Weld
8 Weld Repairs W RM Relevant NDT formats

Legends:

W – Witness
RM – Random
R – Review

10-06- For review


0
10 and aaproval
Checked &
Re Prepared By Reviewed By
Date Description Approved By
v L&T HIL / EIL / AP
L&T

INSPECTION REPORT FOR PIPE/PLATE WELDING


Project: HIL/MAP/PSS; SITE SINGRAULI. Report No: Date:
Spread: From: To:
Plate(thk.)/Pipe
Weather: Material: WPS No:
(Dia/Thk):
Pipe /
Plate Length Weld Weld Welder
Fit-up Remarks
bend Heat No Mtrs No Visual Id
No

Page 6 of 5
LARSEN & TOUBRO LIMITED – ECC DIVISION
Job Procedure For Welding of Plate/Tube (C.S, S.S, AL.)
Procedure No LT/MAP/PSS/WP/002

Welding Progress: Electrode Batch


No. Used

As on Previous Cumulativ Size Batch No


Today e

L&T HIL/EIL/AP

Page 7 of 5