Welding Cost Reduction & Productivity Improvement through

Advanced Welding Technologies Implementation

D.U. Ramakrishnan
Deputy General Manager – QM & QA
Hydrocarbon Construction & Pipelines (HCP)
Larsen & Toubro Limited
P.B. No. 979, Mount Poonamallee Road,
Manapakkam, Chennai- 600089
durk@lntecc.com

Key words: Productivity, Flux Cored Arc Welding, Surface Tension Transfer, Metal Inert
Gas Welding, Gas Tungsten Arc Welding

Abstract:
As the country has embarked upon an ambitious expansion in the Oil, Gas & Power sector, the
Construction majors in this sector are facing enormous challenges in meeting the demands of their
customers both domestic and international. Bold initiatives and risk taking are the order of the day,
as the old conventional practices are found no more useful in meeting the present demands of this
sector. As Welding is the back bone of Mechanical Construction, Technology up gradation in the
same is of great importance and interest ever mainly because of the industry’s needs for
Productivity and Cost competitiveness. Achieving the objective of installing higher productive
welding processes, with affordable costs is the real challenge faced. L&T - HCP, being the key
Mechanical construction SBG, has been experimenting towards meeting this challenge by adopting
new welding techniques in its journey of Quality Management in Welding for quite some time and
this paper shares its experience in the adoption of latest Semi-Automatic & Automatic Welding
process as below:

 Flux Cored Arc Welding (FCAW) & Surface Tension Transfer (STT) in Piping works
 Advanced Stainless Steel welding techniques &
 Automated double tandem Submerged Arc Welding (SAW) & Automated Metal Inert Gas
(MIG) for Tankage welding

Also this paper demonstrates Productivity & Cost study of subject processes in construction.
Introduction:
When L&T was awarded the prestigious Guru Gobind Singh Refinery project, a joint venture of
M/s HPCL & Mittal Energy, Singapore at Bathinda, it found itself with the onerous task of welding
14 lakhs Inch dia in Piping fabrication & erection in a very stiff target period of 16 months. The
organization had its own compulsions from within to differentiate itself from its competitors and
decided to spearhead a new era in Fabrication methodology, which entailed deployment of new
automated techniques. The revolution was made by deployment of advanced technologies (FCAW –
Semi – Automatic & Orbital) in welding minimizing the conventional methods, large manpower
and long work time cycles which eventually offset the cost incurred for this new initiative. On
successful implementation at GGSRP sites, these projects were extended to our other projects such
as NFL Bathinda, NFL Panipat, DCU Paradip & BPCL Kochi sites.
Also advancement in SS Welding techniques were taken-up in our GGSRP, Bathinda & OMPL,
Mangalore projects so as to achieve increased productivity & reduced SS welding cost.
Automatic Double Tandem SAW & Automated MIG Welding processes are also being taken-up for
the upcoming Ethylene Storage Tank package at RIL, Jamanagar.
This paper herein details the success story of the company on implementing the above latest
welding technologies and enhancing it to other Project sites, which has won accolades from its
customers, peers and the industry alike, setting the trends for high productivity and reduced welding
costs for the future projects.

1.0 Implementation of FCAW & STT

1.1 Implementation of FCAW in place of SMAW

1.1.1 Conventional Welding Processes (GTAW & SMAW)

Construction projects are being executed under a very high competitive environment as the time
schedule is playing a key role in successful completion of these projects. Here, the scope for time
reduction in civil works of construction activities is less. Hence mechanical work cycle time needs
to be reduced in which welding plays a major role. Welding, with the advent of many newly
automated technologies has a huge scope for introducing cost effective methodologies to gain
competitive advantage in the Construction industry. In Construction industry, the widely used
welding processes are Gas Tungsten Arc Welding (GTAW) & Shielded Metal Arc Welding
(SMAW). GTAW is used for root welding of the Piping works, where radiographic quality of weld
is essential. SMAW is used for welding of structural works and fill & final welding for piping
works.

1.1.2 Semi-Automatic FCAW

It is a semi-automatic arc welding process which requires a continuously-fed consumable tubular
electrode containing a flux and a constant-voltage or less commonly a constant-current welding
power supply. An externally supplied shielding gas is sometimes used, but often the flux itself is
relied upon to generate the necessary protection from the atmosphere. FCAW was considered the
entitlement of Production Shops and was alien to Construction welding since L&T implemented the
same in large scale and that too for C.S. pipes welding. The use of Self Shielded wires called for
utmost care and skills in welding RT quality pipes whereas use of Gas shielded wires was
considered taboo owing to perceived higher costs in comparison with SMAW. We took detailed
procedure studies in order to leverage the speed advantage of this process with the capital and
operating costs to gain higher productivity.
 Fig.1 - Self-Shielded FCAW Fig. 2 - Gas-Shielded FCAW

1.1.3 Semi-Automatic FCAW Machine Identification

As M/s Lincoln is the forerunner and pioneer in the manufacturing of FCAW machines, welding
machines (Invertec Pro V350) – 20 Nos of M/s Lincoln have been identified for our process.
However, the wire feeder and gun available with these machines is suitable for self-shielded type
only and hence study on suitable wire feeder for gas shielded type had been developed.
Accordingly, wire feeder & suitable gun for gas shielded type has been identified with Lincoln
make & detailed compatibility study has been done. The existing wire feeder with the machine has
been removed and new wire feeder was taken and found suitable for pipe welding. Upon successful
trial, all machines were installed with this new wire feeder and made suit for pipe welding process.

Fig. 3 - Lincoln FCAW Machine

1.1.4 Welding Consumable Identification

As this process is not yet widely established in Indian construction, availability of consumables
from the approved Manufacturers plays a key role to proceed further. As different grades of
materials are coming in carbon Steel, NACE, Alloy Steel & Stainless Steel, each grade require
specific consumable for welding. Hence consumables from Manufacturers like M/s ESAB, Bohler,
Hobart, ADOR & D&H were advised to provide their product details (catalogue) for each grade to
suit with FCAW process. Detailed study on their products was made and the below consumables
were shortlisted.
A. Carbon Steel-E 71 T1
 Dual shield 7100-M/s Esab
 Royal Fil GS-12R-M/s Royal Arc
 Automig FC-M/s Ador
B. Carbon Steel-NACE
 OK TUBROD 15.14A-M/s Esab
C. Alloy Steel
 Dual shield 8002 B2-E 81T1 B2-M/s Esab
 Dual shield 9000 B3-E91T1 B3-M/s Esab
 D. Stainless Steel
 Shield Bright 347L-E347T1-1-M/s Esab

These manufacturers were advised to supply the subject consumables as per AWS specification and
consumables qualification tests are conducted and qualified through NDT & Destructive testing.

1.1.5 Challenges in Implementation

 As the FCAW equipment is 2.5 times costlier than SMAW equipment, company did not want to
take initiative for the Capital Investment.
 The jobs were always taken through bids in tender. Unless the new processes are clearly put
forth to the Customer at this stage, it was always impossible to take up the same in the Project
execution phase.
 Welders for FCAW called for training, which the Contractors found to be difficult.
 The Consumable production from the Manufacturers, as well as qualifying the same on time,
with customers called for Pro-active leadership and greater initiatives from the Company.
 FCAW equipment has limitations with longer distance accessibility and hence there is need for
special arrangements in Erection field.
 Customer mindset for old established processes as a safe way of project execution was an
obstacle. Proper knowledge / orientation on the advantages of new technologies were required.
 Feasibility on the new processes with Customer involved time and money.
 Abolishing established processes meant redundancy of concerned equipment and accessories
and suitable means of disposing the same had to be worked out.

1.1.6 Semi-Automatic FCAW Deployment

However the above challenges were taken with utmost care and the subject process was
implemented at GGSRP – Bathinda site through EIL were most suitable condition prevails. Though
initially EIL was reluctant to approve this process as the same was not included in their Project
Specification, all it’s merits and in specific about its productivity to cater the needs of huge quantum
of scope were explained in detail and got approved. Different wires were used according to the
merit of the piping classes to ensure optimum use. As this process operates with high welding speed
and high deposition efficiency of 85% as compared to 55% in conventional welding processes and
also requires less inter-pass cleaning as compared to SMAW process, this leads to significant
increase in productivity and decrease in consumable cost. The quality of welding achieved through
this process is also very high as compared to conventional SMAW as defects due to improper
baking of electrodes and slag inclusions are avoided. Training and orientation on FCAW to Sub
contractors and workmen were meticulously done and their performance in Radiography carefully
monitored before converting the whole of SMAW fill up welding to FCAW. Average productivity
achieved through this process was 90 inch dia per welder day as compared to 35 inch dia per day
through SMAW process with huge savings on manual SMAW welders’ deployment.

1.1.7 FCAW – Orbital Welding

In addition to semi-automatic FCAW, fully automatic Orbital welding was also tried to further
enhance the productivity as deposition rate is high. M/s Liburdi & M/s Magnatech welding
machines were taken for study. M/s Magnatech was found technically superior as compared to M/s
Liburdi per following reasons:

 M/s Magnatech is primarily designed for FCAW application, whereas M/s Liburdi is primarily a
Gas Metal Arc Welding (GMAW) design with FCAW capability.
 No water cooled torch in M/s Liburdi which is mandatory for FCAW.
 No rigid track system in M/s Liburdi which is mandatory for FCAW.
 Separate wire feeder & usage of 16 Kg spool in M/s Magnatech, whereas M/s Liburdi is having
the limitation of usage upto 5 kg spool.
  Heavy weld head in M/s Liburdi makes welding difficult.
 Unique Push-Pull system which is not in the case of M/s Liburdi.

Fig. 4 - Magnatech Orbital Machine

Hence considering the above advantages, 2 Nos of M/s magnatech make Orbital welding machines
were procured. Due efforts were put to identify & train the welding operators for this process.
This process was highly productive and used to weld pipes from 8” to 36” dia. easily. As manual
involvement in this process is restricted to welding operator, unlike a welder in semiautomatic
FCAW process, quality of welding achieved is very high with smooth and uniform weld ripples. We
determined the process application well in advance and made the welding arrangements on tailor
made jigs as the process had weld position limitations. Also, the challenge of orienting our Plant &
Machinery (P&M) and welding team with the foreign Expat and the needful training and
qualification of the welding operators and procedures was a great challenge which was overcome.
Eventually, the process yielded productivity of 150” dia / day / machine which is 5 times of
conventional welding process thus enabling a much accelerated welding progress at site.

1.1.8 Productivity & Weld Cost Analysis - FCAW

The above automation processes ensured the target productivity of 4000 inch dia per day at the
Fabrication shop with RT repair % as low as 0.8% which involved a labour force of 150 man-days
against 280 man-days in the conventional fabrication set ups earlier deployed.

1.2 Surface Tension Transfer (STT)

1.2.1 Need for STT

However these semi-automatic & automatic welding processes were used only for Fill-up & Final
passes & the root welding was still done with Manual welding only (GTAW or SMAW). It makes
the industry to augment more machineries / welders to increase the production of root run to provide
adequate work front for subsequent automation process. It is also to note that 80% of our project
scope requires TIG process for root welding which is highly costlier and faces Welders scarcity
problem due to heavy demand for them in Industries. To arrive a competitive solution, semi-
automatic process (Steel root) is implemented at ONGC, Uran which not only yields high
productivity but also economical without any compromise in meeting quality requirements.

1.2.2 Process Characteristics - STT

STT is a new approach to what has to been known as the Short Arc transfer mode or Short Arc
welding. STT uses sophisticated electronic technology to combine the best characteristics of the
Short Arc & TIG processes. The Key to STT technology is its ability to control the current
independent of wire feed speed. This means that more or less current can be applied without adding
more wire. It was named after the way this technology monitors & controls the surface tension of
the weld droplet as it adheres to the weld puddle. It is done through a high speed inverter that
precisely adjusts the output current waveform during the entire shorting cycle. This unique high
frequency inverter technology is known as Waveform Control Technology. This shall be used as a
substitute for GTAW.

Fig. 5 - STT Characteristics

Unless GTAW, STT uses solid welding wire (ER70S6) & the shielding is given by CO2 gas which
is more economic when compared to that of Argon gas which is used in GTAW welding.

1.2.3 STT Welding Machine

Initially, trials were carried out with M/s Lincoln welding machine (Invertec STT II) and results
were found satisfactory. However the subject welding machine is designed for root welding alone
which will force to put other welding machine (Invertec Pro V350) for subsequent passes with
FCAW. It severely affects the Welding productivity due to more time is getting consumed for
changeover of machines for both root and fill & cap welding. As M/s Lincoln has ruled out the
possibility of providing dual purpose machines, it made us to search suitable machines in the market
which will cater both root & subsequent passes. After detailed search & analysis Pipe Pro system
(M/s Miller make) & Transteel 3500 (M/s Fronius make) were identified & taken for the study.
Trials were conducted with both the machines. As far as performance is concerned, both were
observed to be at par. However, Transteel 3500 has been preferred over pipe Pro system due to its
simplicity & economical nature.

Fig. 6 - Miller Machine Fig. 7 - Fronius Machine

Despite the above challenges, we were ahead confidently with the feasibility and cost study of the
new processes at our Pilot projects, as we were fully aware of the overall benefits, our organization
reap in to, once these are streamlined.

1.3 Trial and cost study of FCAW & STT in place of SMAW & GTAW
Trial & Cost study were carried out by comparing GTAW & STT for root welding and FCAW &
SMAW for fill up and final welding. Trial test were conducted on pipes of 6” (7.11mm thk), 8”
(18.25mm thk) & 10”(9.27mm thk). Several welding parameter were taken into considerations at
the time of study. Major parameters considered during Cost analysis of these processes & the cost
work sheets are shown in the appendix below (Appendix – I).

Fig. 8 - STT & FCAW Trial

1.4 Study Results
Results of the study shows that average savings of Rs. 12.81/inch dia shall be achieved by
deploying STT in place of GTAW for root welding & an average savings of Rs 15.24 / inch dia
shall be achieved by deploying FCAW in place of SMAW for fill up & final welding. These study
results were validated in the presence of Project & Planning Managers at ONGC, Uran site.

Table. 1 - Validated Costing Savings in 6” Table. 2 - Validated Cost Savings in 8”

Table. 3 - Validated Cost Savings in 10”

1.5 Validation of Welding Procedures with Customers

Procedure Qualification on carbon Steel - Initially the Welding Procedure Qualification is carried
out on carbon Steel at our ONGC, Uran site. Customer of this project is M/s ONGC, Project
Management Consultant (PMC) is M/s Triune Energy Services Pvt. Ltd. & Third Party inspection
(TPI) is M/s Velosi Certification Services (I) Pvt. Ltd. Several constraints were faced initially at the
time of Procedure Qualification. Customers were reluctant for Qualification of these processes as
these were not mentioned in the Tender document. Also pre-established WPS/PQRs approved by
Elite Customers were also not available to convince the Customer as the same processes were not
yet established in Indian Construction. Hence Customers were explained about the technologies in
detail & successful trails were conducted to create the confidence & approval has been got.
Welding Consumable for root welding is identified from M/s ESAB and for fill up & final is from
M/s Royal Arc. The Procedure was successfully established on CS – A 106 Gr.B – 8” NB / WT –
18.25mm & 4 PQRs qualified for carbon steel & duly approved by Customer (Appendix – II).
Procedure Qualification on Alloy Steel - Once the PQR is successfully qualified on carbon steel,
then the process Qualification was extended to alloy Steel material. Alloy Steel Qualification was
carried out at our NFL, Bathinda site. Customer of this project is M/s Nagarjuna Fertilizers Limited.
Welding Consumable for root welding is identified from M/s D&H and for fill up & final is from
M/s ESAB. The Procedure was established on ASTM A 335 Gr. P22 – 10” NB / WT – 33mm.
(Appendix – III)

1.6 Welder Training & Qualification for STT+FCAW

The real challenge was to identify, train & Qualify welders for these processes in quick time and to
maintain required quality as availability of STT+FCAW welders in market is scarce. Hence we have
put special efforts to identify Welders through previous project references, welder databank and to
groom/train ability SMAW welders available at site on STT+FCAW process and succeeded. Once
the welding procedure has been successfully approved, the welder Qualification was done
immediately. GTAW & SMAW welders with good welding performance are oriented towards this
process and sufficient training was provided to them. On successful completion of training, Welders
are provided Welder Qualification Test (WQT).

1.7 Combined (STT+FCAW) Welding Productivity

As appraised earlier the average Welding productivity by FCAW is 90” dia/shift when compared
with productivity by SMAW achieved is 35” dia/shift & average Welding Productivity achieved by
STT is 150” dia/shift when compared with productivity by GTAW achieved is 60” dia/shift.

1.8 Implementation at Erection

Once the welding processes are established at fabrication, then the challenge was to take the
processes to erection welding. Unlike fabrication welding, implementing these welding technologies
at erection had certain constraints. Special scaffolding arrangements are required so to
accommodate the welding machines near the joint position itself. These constraints are resolved and
these technologies are implemented at erection.

Fig. 9 – Erection Welding

1.9 Weld Repair Analysis

As the process for both root Welding (STT) and Fill up & final welding (FCAW) are semi-
automatic processes the chance of repair was very less. Also unlike full manual welding these
welding processes do not have too many starts and stops so that the arc strike, a potential defect
does not occur.
These processes were implemented at ONGC, Uran and NFL, Bathinda sites and studied for process
improvements. On study it was found that by implementing these processes, weld repair is reduced
by almost 1% when compared to GTAW+SMAW combination (Appendix-IV).
After successful implementation at ONGC, Uran & NFL, Bathinda projects, these processes were
extended to our DCU, Paradip & BPCL, Kochi projects (Appendix – V).

2.0 Advanced Stainless Steel (SS) welding Techniques

In SS welding, usually the weld is back purged with Argon before and during welding to prevent
oxidation. To achieve this back purge, purging set-up has to be made before making the fit-up of the
joint to be welded. This makes the weld set-up time longer than that for carbon steel joints. The cost
of argon required for back purging is also a major contributor of the welding cost for SS joints. Also
provision of complete purging & purity of Argon are also some of the factor which influences the
Quality of SS weld. In order to meet the present demand of increased productivity with necessary
Quality and reduced cost in construction, the need for exploring the possibility of eliminating the
back purging raised.

2.1 Fi- Back Fiber Glass Weld backing tape

In the process of eliminating the back purging, we found Weld backing tape made by M/s Aquasol,
USA as an alternative for Argon purging. It is composed of two adhesive areas on the outer edges
and a centre strip of flexible fiber glass fabric which is heat resistant upto 1022⁰F.
Trial & Outcome - Trials were conducted on ASTM A358 TP316 Class 1 pipes of 10” & 8” dia at
our OMPL, Mangalore site. Good Quality welds were achieved during these trials & the welds were
cleared visually & by Radiographic Testing.

Fig. 10 - SS Welding with Fi-Back Tape

Since the use of this tape requires access from the back side of the joint, it’s use is restricted to
Fabrication joints alone and could not be used for erection joints. Hence it is implemented at our
Fabrication works alone.

2.2 SS Welding with Flux Cored Wire

The next trial was performing SS welding with a Flux cored filler wire instead of a bare filler wire
which is the conventional one. It produces a slag to protect reverse-side bead from oxidation by
atmosphere, thus eliminating the use of argon for back-purging the weld. The removal of the slag
produced will be easier in the fabrication joints & impossible for the erection joints. Hence it’s
implementation was restricted with Fabrication joints and planned to used it on erection works for
shut down jobs.
 Fig. 11 - SS Welding with Flux Cored Wire
Elimination of Argon-back purging automatically reduces the weld set-up time drastically. Thus
increased productivity & reduced welding cost will be achieved by using this filler wire. Trials were
conducted at our OMPL, Mangalore & GGSRP, Bathinda sites on ASTM A312 TP 304 & detailed
cost analysis is made between conventional Argon Purging & Welding with Flux cored wire.
Results revealed cost reduction of around Rs 6/inch dia of welding with a reduced weld set-up time.

Cost Analysis of Flux Cored Wire with Conventional Purging

S. No. Parameter Consumption / ID Unit Rate Cost

Conventional – With Argon purging

3 3 3
1. Purging Gas (m ) 0.08m Rs.105/ m Rs.8.40
2. Filler wire (Kg) 0.011 Kg Rs.757/ Kg Rs.8.30
2 2 2
3. Soluble dam(m ) 0.01 m Rs.575/ m Rs.6.75
Total cost / ID Rs.23.45
STF F316L – Flux Cored wire
3 3
1. Purging Gas (m ) 0 Rs.105/ m 0
2. Filler wire 0.01 Rs.1795/Kg Rs.17.95
Total cost / ID Rs.17.95
Table. 4 - Cost Analysis of Flux Cored Wire in SS Welding

Subsequently Electrode Qualification Test EQT (per ASME Sec II C) & Welding Procedure (per
ASME sec IX) using this Flux cored filler wire has been conducted at site with the witness of
clients. Necessary Destructive and Non-Destructive test have been conducted for the test pieces and
successful results achieved. Upon this new Welding Procedure for SS joints with this flux cored
wire (Appendix – VI) have been qualified and implemented at site with reduced welding cost and
increased productivity.
3.0 Automated welding Processes for Ethylene Cryogenic Storage Tank
L&T has won the order from RIL for the construction of Ethylene Cryogenic Storage Tank at
Jamnagar. There will be two tanks- inner and outer. Outer tank will be a concrete tank and the inner
tank will be of Cryogenic Steel (ASTM A 553/A553M Type 1 Q&T). Diameter of the inner tank is
around 60 mtrs and the height is around 25 mtrs. The welding of cryogenic material is one of the
most critical one as the weld procedure has to pass the impact value of 70 Joules at -196⁰C. Hence
the Heat Input during the welding of these materials is an important factor for deciding the welding
process. But on the other hand, the productivity should also be taken care as huge amount of
welding to be completed within the stipulated time.
In this context, we explored the advanced welding technologies being used for this cryogenic
welding at abroad and found them as below:

 Automated MIG Welding for vertical joints

 Automated Tandem SAW for horizontal joints

Deploying of Automated Tandem SAW for Horizontal shell joints of tank eliminates back chipping
and a separate back side welding which would save huge amount of time in the construction
schedule. But the challenge is that in India till now these processes are not popular for these
applications, as huge efforts are involved in weldability study and Welder orientation. We took this
as a challenge and started with the weldability study for these processes with leading Welding
Automation firm viz. ESAB, Memco, Primo Automations, Future Automations etc.

3.1 Automated MIG Trial

As a part of it, initial trials of Automated MIG Welding was carried out at our LTEW
Kancheepuram Workshop on 11.11.2013. Initially the welding parameters provided by the vendor
were not yielding a good quality weld. So we modified those parameters to our requirement and
welded again which gave a good quality weld with comparatively shorter duration.

Fig. 12 - Vertical MIG Welding Trial

3.2 Automated Double Tandem SAW Trial

Also trials were conducted for Automated Tandem SAW at M/s MEMCO shop at Mumbai on 28th&
29th of Nov’13. Upon several trials necessary good quality weld is achieved .The weld was cleared
visually and by Radiographic testing. Both these Automated vertical MIG welding and Automated
Tandem SAW trials were conducted on CS plates only. Trials on actual material ASTM A
553/A553M Type 1 Q&T) will be scheduled once we receive the material from overseas. Upon
successful results, L&T – HCP would be the first Indian Construction company to implement these
Automated Welding processes for Cryogenic Welding Applications.
 Fig. 12 - Automated Double Tandem SAW Trial

Conclusion

Thus welder dependency is reduced to greater extent by deploying these Semi-automatic &
Automatic welding processes, which yielded higher productivity. Also the quality of weld is
improved through reduction in repair rate which ultimately reduced the quantum of re-work too.
This in-turn resulted in the reduction of project cycle time which helped to expedite the Project
completion per schedule.
 APPENDIX – I

Welding Cost Working Sheet for 6” GTAW Vs STT

Larsen & Toubro Limited

APU- PROJECT, ONGC URAN
Welding Cost Working sheet for Welding Processes / ID

(A) CONSUMABLE COST FOR VARIOUS WELDING PROCESSES

Welding Consumables Consumed Per inch Welding consumables cost per inch dia
Welding Consumable Cost
dia. (Rs.)
Sl. No. Process Filler Wire Total cost
CO2 Gas Argon Gas Filler Wire/ CO2 Gas Argon Gas Filler Wire/
/ Roll CO2 Gas Argon Gas
(Rs/Kg) (Rs/M3) Roll (Kg) (KG) (M3) Roll
(Rs/Kg.)
1 STT (ER70S6) 84.94 30 - 0.0217 0.065 - 1.84 1.95 - 3.79
2 GTAW (ER70S2-2.5mm)- Root + Hotpass 180 - 105 0.019 - 0.0752 3.42 - 7.896 11.32
(B) Average cost of welder per inch dia.
GTAW
Sl No. Activity STT (Root &
Hotpass)
1 Productivity per Shift ( ID) 150 60
2 Avg. Salary per Month (Rs) 20000 20312.5
Productivity per Month
3 2600 1560
(26 days)( ID)
Average cost of welder per inch
4 7.69 13.02
dia.(Rs)
(C) Grinder and Grinding wheel cost
GTAW
Sl No. Description STT (Root &
Hotpass)
1 Grinder wheel cost per inch dia. (Rs.) 1.68 1.14
(D) Welding M/c Cost

Avg.
Monthly Daily Hire Avg. cost of
Productivity
Sl. No. Description Qty Hire charge charge* Machine / ID Remarks
per day
(Rs) (Rs) (Rs)
(ID)
1 Welding generators 1 3000 115.38 60 1.92
2 STT MACHINE 1 5600 215.38 150 2.15

(E) Power Cost

Average Average
Total Energy Cost per Total Cost
UNITS Productivity Welding Cost of Power
Sl.NO MACHINE DESCRIPTION CURRENT KW Consumed unit From of Power
(KWH) / 12 hr Shift time per ID (Rs)
(Unit) MSEB (Rs) (Rs)
(ID) (hr)
1 GTAW MACHINE 11 6.800 6.800 60 5 34.00 5 169.99 2.83
2 STT MACHINE 8 4.945 4.945 150 5 24.73 5 123.63 1.24
 Process Validation Sheet for 6” GTAW Vs STT

METHODOLOGY FOR PROCESS VALIDATION (FOR ROOT WELDING)

Study 1:

Dia. of Pipe: 6" NB Material: ASTM A 106Gr.B

Thickness of Pipe: 7.11mm

Welder Name: Manish .M.J (GTAW) & Bir Bahadur (STT)

Consumable brand name: Ador (TIGFIL ER70S2), ROYAL Arc (ROYAY 70S6)

1. Filler wire consumption

GTAW STT
Size of Filler wire: 2.5mm Size of filler wire: 1.2mm

Weight of single Filler wire (gms): 37.14 Initial weight of spool (Kgs): 15.05

No. of Filler wire consumed: 3 Final weight of spool after welding (Kgs): 14.92

Total weight of filler wire (Kgs): 0.111 Weight of filler wire consumed in actual (Kgs): 0.13

Consumption / inch dia.(Kgs) 0.019 Consumption / inch dia.(Kgs): 0.0217

2. Argon / CO2 consumption (New cylinder with full load to be taken)

GTAW STT
Initial weight of argon cylinder (Kg): 64.18 Initial weight of CO 2 cylinder (Kg): 80.32

Final weight of cylinder after welding(Kg): 63.52 Final weight of cylinder after welding(Kg): 79.93

Actual consumption of gas (M3): 0.4514 Actual consumption of gas (Kgs): 0.39

Consumption / inch dia.(M3) 0.0752 Consumption / inch dia.(Kgs) 0.065

3. Welder productivity / Day

GTAW STT
Starting time of weld: 0 Starting time of weld: 0

Finishing time of weld (min): 25.75 Finishing time of weld (min): 18.13

Tentative welder productivity (ID): 60 Tentative welder productivity (ID): 100

4. Grinding wheel Consumption / ID

GTAW STT
Size of grinding wheel: 5 Initial Size of grinding wheel: 5

No. of wheels consumed: 0.1 No. of wheels consumed: 0.15

Actual consumption of wheel / inch dia 0.017 Actual consumption of wheel / inch dia 0.025

5. Welding machine Productivity

GTAW STT
Welding Machine Productivity : 60 ID Welding Machine Productivity : 150 ID

Welding current to be measured during different passes and average current to be noted. Calculation
6. Power cost:
of power shall be done per Welding Cost Working sheet.

110 Amps. 80 Amps.

 Welding Cost Working Sheet for 6” SMAW Vs FCAW

Larsen & Toubro Limited

APU- PROJECT, ONGC URAN
Welding Cost Working sheet for Welding Processes / ID

(A) CONSUMABLE COST FOR VARIOUS WELDING PROCESSES

Welding Consumables Consumed Per inch Welding consumables cost per inch dia
Welding Consumable Cost
dia. (Rs.)

Sl. No. Process Argon +CO2 Filer Wire/ Argon +CO2 Mix Total cost
Filler Wire Filler Wire/ Argon +CO2
Electrode (Rs) Mix GAS Electrode GAS Filler Wire Electrode
(Rs/Kg.) Roll (Kg) Mix GAS
(Rs/M3) (Nos.) 3
(M )

1 FCAW (E71T1-1) 115.8 - 105 0.05 - 0.048 5.79 - 5.07 10.86

2 SMAW (E7018-2.5mm) - 2.89 - - 2.83 - - 8.18833333 - 8.19
(B) Average cost of welder per inch dia.
FCAW
SMAW
Sl No. Activity (Semi auto Fill up
(Fill Up Passes)
Passes)
1 Productivity per Shift ( ID) 40 100
2 Avg. Salary per Month (Rs) 16250 20000
Productivity per Month
3 1040 2600
(26 days)( ID)
Average cost of welder per inch
4 15.63 7.69
dia.(Rs)
(C) Grinding wheel cost
Grinding Wheel Grinding Wheel
Grinding Wheel
Sl No. Process Consumed / inch Cost / inch dia
Cost (Rs)
dia Rs
1 SMAW 0.11 7.38
67.09
2 FCAW 0.017 1.14
(D) Welding M/c Cost

Avg.
Avg. cost of
Monthly Hire Daily Hire charge* Productivity
Sl. No. Description Qty Machine / ID Remarks
charge (Rs) (Rs) per day
(Rs)
(ID)
1 Welding generators 1 3000 115.38 40 2.88 (Smaw)
2 FCAW MACHINE 1 5600 215.38 100 2.15 Only fill up passes

(E) Power Cost

Average Average
Total Energy Cost per Total Cost
Productivity Welding Cost of Power
Sl.NO MACHINE DESCRIPTION CURRENT KW UNITS (KWH) Consumed unit From of Power
/ 12 hr Shift time per ID (Rs)
(Unit) MSEB (Rs) (Rs)
(ID) (hr)
SMAW WELDING MACHINE (Fill up
1 11.0 6.80 6.80 40 5 34.00 5 170.0 4.25
& Final)
2 FCAW MACHINE 16.5 10.20 10.20 100 5 51.00 5 255.0 2.55
6 Baking OVEN(1.5 KW)** 1.5 1.5 1000 12 18.000 5 90.00 0.09
** Oven capacity (1500 nos of electrodes / 3 hr)
For 1" dia. and 10 mm thk. No of electrode consumed is 6 nos. ( 3.15 mm 3 nos. and 2.5 mm 3 nos.)
For 1500 nos we shall weld=1500/6=250" dia.
 Process Validation Sheet for 6” SMAW Vs FCAW

METHODOLOGY FOR PROCESS VALIDATION (FILL & FINAL)

Study 1:

Dia. of Pipe: 6" NB Material: ASTM A 106Gr.B

Thickness of Pipe: 7.11mm

Welder Name: Manish .M.J (SMAW) & Bir Bahadur (FCAW)

Consumable brand name: Royaltherm, ROYAL FIL GS-12R

1. Filler wire / Electrodes consumption.

SMAW FCAW
Size of electrode: 2.5 Size of filler wire: 1.2

Weight of single electrode (gms) 23.25 Initial weight of spool (Kgs): 14.22

No. of electrodes consumed: 17 Final weight of spool after welding (Kgs): 13.92

Total weight of electrodes (Kgs): 0.395 Weight of filler wire consumed in actual (Kgs): 0.300

Consumption / inch dia. (Kgs) 0.066 Consumption / inch dia. (Kgs): 0.05

2. Argon + CO2 consumption

SMAW: FCAW (New cylinder with full load to be taken)

Initial weight of Argosheild cylinder (Kg): 62.66

Final weight of cylinder after welding(Kg): 62.22

Actual consumption of gas (M3): 0.2895

Consumption / inch dia. (M3) 0.0483

3. Welder productivity / Day

SMAW FCAW

Starting time of weld: 0 Starting time of weld: 0

Finishing time of weld: 32 Finishing time of weld: 17.12

Tentative welder productivity: 40 Tentative welder productivity: 90

4. Grinding wheel consumption

SMAW FCAW

Size of grinding wheel: 5 Size of grinding wheel: 5

No. of wheels consumed: 0.65 No. of wheels consumed: 0.1

Actual consumption of wheel 0.11 Actual consumption of wheel 0.0167

5. Welding machine Productivity

SMAW FCAW

Welding Machine Productivity : 40 ID Welding Machine Productivity : 90 ID

Welding current to be measured during different passes and average current to be noted.
6. Power cost:
Calculation of power shall be done per Welding Cost Working sheet.

70 Amp 175Amps
 APPENDIX –II

WPS /PQR – CARBON STEEL

PQR on CS with PWHT – STT with Argon+ CO2 / FCAW

PQR on CS with PWHT – STT with CO2 / FCAW

PQR on CS without PWHT – STT with Argon+CO2/ FCAW

PQR on CS without PWHT – STT with CO2/ FCAW

 APPENDIX –III

WPS /PQ R – ALLOY STEEL

PQR on Alloy Steel P22

 APPENDIX –IV

WELD REPAIR ANALYSIS

Welded by SMAW Welded by FCAW

Total Welding Overall
S.No. Project scope completed repair Remarks
(Inch dia) (Inch dia.) %
% Inch
Inch dia % Repair
Repair dia

GGSR
1 Composite, 1647982 934311 646409 1.65 287902 0.79 1.66
Bathinda

2 DCU, Paradip 514000 48229 42059 0.77 6170 0.00 0.72

APU-ONGC,
3 210000 59523 53634 0.71 3864 0.00 0.63
Uran
Below 4"
4 MFF, Hazira 49772 49772 44427 1.97 3172 0.23 1.91 dia. not
considered.
AFC PROJECT, (Uran &
5 207000 146200 93900 0.54 52300 0.35 0.89
NFL-Bathinda Paradip is
at starting
6 NFL, Panipat 197500 135786 57936 0.45 77580 0.62 1.07 stage)

TOTAL 1373821 938365 1.01 430988 0.33 1.15

 APPENDIX –V

WELDING PROCEDURE SPECIFICATION – DCU, PARADIP

WELDING PROCEDURE SPECIFICATION – CDU, VDU & DCU BPCL, KOCHI
 APPENDIX –VI

PROCEDURE QUALIFICATION RECORD (PQR) OF SS PQR WITH FLUX CORED

WIRE