Welding Plan for

Pressure Parts

DOC
NO:UBEL/WPCPL/521/
WLD-001 Rev.0
Page 1 of 6

PROJECT: 4 X 135 MW WPCPL, WARORA.

WELDING PLAN
FOR
PRESSURE PARTS
Doc No: UBEL/WPCPL/521/WLD-001 Rev.0

Welding Plan for

Pressure Parts
CONTENTS

Title Clause

Sr. no.
1

SCOPE

BASE METAL

WELDING CONSUMABLES

SHIELDING GAS

EQUIPMENT & ACCESSORISE

WELDING PROCESS

EDGE PREPARATION

CLEANING

ALIGNMENT & SPACING

10

WHEATHER CONDITION

11

WELDING TECHNIQUE

12

CLEANING

13

INSPECTION

14
15

1.0

REPAIR OF WELDS
RECORD

SCOPE:-

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WLD-001 Rev.0
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Welding Plan for

Pressure Parts

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WLD-001 Rev.0
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The scope of this procedure covers the general requirements to perform

the Pressure Part welding including attachments. The extant of the
procedure shall be as per approved drawings /applicable code /project
specifications.
2.0

3.0

4.0

5.0

BASE METAL:2.1

Base metal shall be used as per approved drawings.

2.2

Base material shall be free from rust, oil, grease, earth and other
foreign matter which affect the quality of welding.

WELDING CONSUMABLES:3.1

All welding consumables shall be used as per ITPL /Project

Specification.

3.2

All welding consumables shall be purchased in sealed containers &

stored properly to prevent deterioration. All welding consumables shall
be handled with care to avoid any damage to the flux covering.

3.3

All low hydrogen type electrode shall be rebaked as per

recommendation of the electrode manufacturers/project specification.

3.4

The electrodes, filler wires and flux used shall be free from rust, oil,
grease, earth and other foreign matter which affect the quality of
welding.

SHIELDING GAS:4.1

Argon gas used in GTAW process for shielding purposes shall be

99.995% pure. The purity of the gas shall be certified by manufacturer.

4.2

The rate of flow for shielding purposes shall be as per project

specification.

EQUIPMENTS & ACCESSORIES :5.1

6.0

Ensure the sufficient number of welding & cutting equipments,

auxiliaries and accessories of sufficient capacities at site.

WELDING PROCESS:6.1
Welding of the various materials shall be carried out using following
processes.
- Gas Tungsten Arc Welding Process (GTAW)
- Shielded Metal Arc Welding Process (SMAW).

Welding Plan for

Pressure Parts
6.2
7.0

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WLD-001 Rev.0
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Welding processes to be employed as per ITPL /Project Specification.

EDGE PREPARATION:7.1
The edges to be welded shall be prepared to meet the joint design
requirements by any of the following methods recommended:
a) Carbon Steel : Gas cutting, machining or grinding methods shall be
used. After gas cutting, oxides shall be removed by chipping or
grinding.
b) Low alloy steel (Containing up to 5% Cr.): Gas cutting, machining
or grinding methods shall be used. After gas cutting, oxides shall be
removed by chipping or grinding.
c) High alloy steel (> 5% Cr.): machining or grinding methods shall
be used. After gas cutting, oxides shall be removed by chipping or
grinding.

8.0

CLEANING:8.1
The ends to be welded shall be properly cleaned to remove paint, oil,
grease, oxides, sand, earth and other foreign matter. The ends shall be
completely dry before the welding commences.
8.2

9.0

10.0

On the completion of each run, craters, welding irregularities, slag etc

shall be removed by grinding and chiselling.

ALIGNMENT & SPACING:9.1

Components to be welded shall be aligned and spaced(Fit-up) as per

approved drawings/project specification.

9.2

Tack welds, for maintaining the alignment of joints shall be made only
by qualified welders. Since the tack welds become part of the final
weldment they shall be executed carefully and shall be free from
defects. Defective tack welds must be removed prior to the actual
welding of the joints.

9.3

Tack should be equally spaced.

9.4

Welding shall commence only after approval of fit-up by client

representative.

WEATHER CONDITIONS:10.1 The parts being welded and the welding personnel should be
adequately protected from rain and strong winds. In the absence of
such a protection no welding shall be carried out.

Welding Plan for

Pressure Parts
10.2
11.0

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WLD-001 Rev.0
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During field welding using GTAW process, particular care shall be

exercised to prevent any current affecting the welding process.

WELDING TECHNIQUE :11.1

Welding shall be made with electrodes/filler wires recommended as per

ITPL/Project Specification.

11.2

The root pass of butt joints should be executed so as to achieve full

penetration with complete fusion of the root edges.

11.3

Welding shall not be uninterrupted.

11.4

While the welding is in progress care should be taken to avoid any kind
of movement of the components, shocks, vibration and stresses to
prevent occurrence of weld cracks.

11.4

Butt joints shall be completed with a cover layer that would affect
good fusion at the edges and a gradual notch free surface.

11.5

Each weld joint shall have a workmanship like finish.

11.6

Rust preventive/ protective painting on weld joint shall be as per

project specification.

12.0

CLEANING:12.1 All weld joints shall be free from adherent weld spatters, slag, sward,
dirt or foreign matter. This can be achieved by brushing or brushing.

13.0

INSPECTION:13.1 No welder shall be permitted to work without the possession of

Identity Card.
13.2

14.0

Inspection of all welds shall be carried out as per applicable code and
specifications. The entire finished weld shall be visually inspected for
parallel and axial alignment of work, excessive reinforcement, and
concavity of welds, shrinkage cracks, inadequate penetration, and
unrepaired burn-through, under cuts, surface porosity and other surface
defects.

REPAIR OF WELDS:14.1 Defect ascertained, through the inspection methods, which are beyond
acceptable limits shall be removed by the process of chipping &
grinding.
14.2

No repair shall be carried out without prior permission of client

Welding Plan for

Pressure Parts

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WLD-001 Rev.0
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representative.
15.0

RECORD:
15.1 For each weld joint examination, Welding inspection report shall be
prepared.