L&W CONSTRUCTION PVT LTD

RMZ PLOT-A, BLOCK-4AB & 4C

TECHNICAL SPECIFICATION OF
WELDING AND CUTTING

Total no. of sheets including this sheet :08

FILE NO: LW/FIP/RMZ/FPS/4AB/WMS/003

NOT-APPROVED COMMENTS AS INDICATED / ATTACHED

APPROVED WITH MINOR COMMENTS
APPROVED
TICK BOX DATE DOCUMENT/DWG STATUS

R1 14/07/14 For Approval FIREPRO L&W RMZ

R0 26/06/14 For Approval FIREPRO L&W
REVISION DATE REASON FOR ISSUE ORIGINATOR CHECKED APPROVED
PROJECT : RMZ ECOWORLD PLOT A 4AB

DESIGN & BUILT

SUB-CONTRACTOR OWNER
CONTRACTOR
 Page 2 of 8
METHOD STATEMENT Doc No.:
LW/FIP/RMZ/FPS/4AB/WMS/003
for Welding and Cutting 01
Rev. No. :
Date 05th July, 2014

Contents
1 Objective........................................................................................................................................3
2 Scope of work................................................................................................................................3
3 Materials:.......................................................................................................................................3
4 Tools:.............................................................................................................................................3
5 Manpower:....................................................................................................................................3
6 Welding and Cutting Operations:...................................................................................................4
6.1 Arc Welding Machine.............................................................................................................4
6.2 Arc Welding Electrodes..........................................................................................................4
6.3 Gas Cutting Equipment..........................................................................................................4
6.4 Welding Procedure Specification...........................................................................................6
6.5 Welder Performance Test Report...........................................................................................8

PREPARED BY & DATE REVIEWED BY & DATE APPROVED BY & DATE

FOR FIREPRO SYSTEMS PVT LTD FOR L and W FOR RMZ ECOWORLD
 Page 3 of 8
METHOD STATEMENT Doc No.:
LW/FIP/RMZ/FPS/4AB/WMS/003
for Welding and Cutting 01
Rev. No. :
Date 05th July, 2014

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

PREPARED BY & DATE REVIEWED BY & DATE APPROVED BY & DATE

FOR FIREPRO SYSTEMS PVT LTD FOR L and W FOR RMZ ECOWORLD
 Page 4 of 8
METHOD STATEMENT Doc No.:
LW/FIP/RMZ/FPS/4AB/WMS/003
for Welding and Cutting 01
Rev. No. :
Date 05th July, 2014

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 Arc Welding Machine

For fitment purpose, a step down transformer is used. The transformer receives the A.C
supply between 200 and 440 volts and transforms it to the required low voltage in the range
of 80 to 100 volts. A high current of 100A to 400A will be suitable for general arc welding
work.
For welding process, either rectifier or welding generator should be used.

6.2 Arc Welding Electrodes

Consumable-coated electrodes shall be used to fill the joints.
The protection of molten metal from oxygen and nitrogen of the air by providing a gas shield
around the arc and the molten pool of metal.
To establish and maintain the arc throughout welding.
The formation of slag over the joint thus protects from rapid cooling.
The addition of alloying element.
The electrodes are made of either soft steel wire or alloy steel. .
AWS E-6013 class welding electrodes shall be used
Welder should be qualified and skilled to perform the welding joints and follow all safety
procedures during the performance of welding sequence.

6.3 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.

PREPARED BY & DATE REVIEWED BY & DATE APPROVED BY & DATE

FOR FIREPRO SYSTEMS PVT LTD FOR L and W FOR RMZ ECOWORLD
 Page 5 of 8
METHOD STATEMENT Doc No.:
LW/FIP/RMZ/FPS/4AB/WMS/003
for Welding and Cutting 01
Rev. No. :
Date 05th July, 2014

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.

PREPARED BY & DATE REVIEWED BY & DATE APPROVED BY & DATE

FOR FIREPRO SYSTEMS PVT LTD FOR L and W FOR RMZ ECOWORLD
 Page 6 of 8
METHOD STATEMENT Doc No.:
LW/FIP/RMZ/FPS/4AB/WMS/003
for Welding and Cutting 01
Rev. No. :
Date 05th July, 2014

6.4 Welding Procedure Specification

Company Name: FIREPRO SYSTEMS PVT. LTD., BANGALORE (INDIA)

Welding Procedure Specification No.: FP/WPS/ 01 Rev: 01 Date

Supporting Procedure Qualification Record
FP/PQR/01 Rev: 01 Date
No(s)

Welding Process: SMAW Type MANUAL

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

PREPARED BY & DATE REVIEWED BY & DATE APPROVED BY & DATE

FOR FIREPRO SYSTEMS PVT LTD FOR L and W FOR RMZ ECOWORLD
 Page 7 of 8
METHOD STATEMENT Doc No.:
LW/FIP/RMZ/FPS/4AB/WMS/003
for Welding and Cutting 01
Rev. No. :
Date 05th July, 2014

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

0
Preheat Min. Temp. 20 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 Others /

Weld
Process speed Remark
Layer Current range Voltage range
Class Size Polarity (mm/min) s
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
3.15/4. AC / DCSP/ 100-140/
3 SMAW E 6013 N.A N.A
0 DCRP 140-200

OTHER PARAMETERS AS REQUIRED

PREPARED BY & DATE REVIEWED BY & DATE APPROVED BY & DATE

FOR FIREPRO SYSTEMS PVT LTD FOR L and W FOR RMZ ECOWORLD
 Page 8 of 8
METHOD STATEMENT Doc No.:
LW/FIP/RMZ/FPS/4AB/WMS/003
for Welding and Cutting 01
Rev. No. :
Date 05th July, 2014

6.5 Welder Performance Test Report

WELDER NAME:
Project Name: Location / Region: BLR
Employed by:(Sub-Contractor name)
Sub-Contractor contact person Affix
Joint type: Butt (with Groove) Passport size,
Colour Photograph
Welding Process: SMAW

Type: Manual

Sl. VARIABLES ACTUAL VALUES REMARKS

1 BACKING STRIP (if any): n/a
2 MATERIAL SPECIFICATION: IS: 1239 Pt-1 C Class
Material GI
Size / Pipe Diameter 3
Wall Thickness 4.8 mm
4 FILLER MATERIAL: ESAB
Classification E6013
Filler / Electrode size 3.15 mm
5 WELD DEPOSIT THICKNESS: 5 mm
6 WELD POSITION: 6G
7 WELD PROGRESSION: Uphill
8 GAS TYPE: n/a
9 BACKING GAS: n/a
10 ELECTRICAL CHARACTERISTICS: AC Transformer
Current / Polarity 40-90 Amps / AC

VISUAL INSPECTION
Surface appearance :

Cap width & height :

Undercut :

Root Defects :

Result :

Inspected by :

COMMENTS (if any):

TEST CONDUCTED BY: APPROVED BY (QC): WITNESSED BY:

Signature: Signature: Signature:
Date: Date: Date:
Name: Name: Name:
Organization: FIREPRO Organization: FIREPRO Organization:

PREPARED BY & DATE REVIEWED BY & DATE APPROVED BY & DATE

FOR FIREPRO SYSTEMS PVT LTD FOR L and W FOR RMZ ECOWORLD