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8/12/2019 Guidline Welding & Heat Treatment
1/69
GUIDELINES FOR
WELDING, NDE
AND
HEAT TREATMENT
THIS BOOKLET IS GIVEN AS A GENERAL GUIDELINE TO THE TENDERERS
ABOUT WELDING, NDE & HT FOR THE PIPING SYSTEMS, HOWEVER
INSTRUCTIONS GIVEN IN THE DRAWINGS & WELDING SCHEDULE ISSUED
DURING EXECUTION OF THE WORK SHALL BE FINAL AND BINDING OF
THE CONTRACTOR.
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BASE MATERIALS
1.0 Scope:
1.1 This chapter contains tabulations of chemical compositions &mechanical properties of various materials generally used in BHELsites.
2.0 Contents:
Table 1 - Pipes (ASME)
Table 2 - Tubes (ASME)
Table 3 - Forgings (ASME)
Table 4 - Castings (ASME)
Table 5 - Plates / Sheets (ASME)
Table 6 - Pipes (Other specifications)
Table 7 - Tubes (Other specifications)
Table 8 - Forgings (Other specifications)
Table 9 - Barstock
3.0 The data are for general information purposes. The corresponding PNumbers are also indicated.
4.0 For materials not covered in this chapter, the supplier shall becontacted.
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CHEMICALCOMPOSITIONANDMECHANICAL
PROPERTIES
Ta
ble
2Tu
bes
Chem
ica
lCompos
ition
(%)
Mec
h.P
ropert
ies
(Min
.)
Sl.
No
P.N
O/
Group
No.
Ma
teria
l
Spec
ificat
ion
(ASME)
C
Mn
P
S
Si
Ni
Cr
Mo
T.S.
kg
/mm
2
Y.S.
kg
/mm
2
%E
Min
1
P1/1
SA192
0.0
6-
0.1
8
0.2
7-
0.6
3
0.0
48
Max.
0.0
53
Max.
0.2
5
Max.
-
-
-
33
18
35
2
P1/1
SA210Gr
A1
0.2
7
0.1
8
0.9
3
Max
0.0
48
Max.
0.0
58
Max.
0.1
0
Max.
-
-
-
42
26
30
3
P1/1
SA179
0.0
62-
Max.
0.2
7-
0.6
3
0.0
48
Max.
0.0
58
Max.
-
-
-
-
-
-
-
4
P1/2
SA210Gr.
C
0.3
5
Max.
0.2
9-
1.0
6
0.0
48
Max.
0.0
58
Max.
0.1
0
Max
-
-
-
49
28
30
5
P1/2
SA556Gr
C2
0.3
Max.
0.2
9
Max.
0.0
48
Max.
0.0
48
Max.
0.1
0
Max
-
-
-
49
28
25
6
P3/1
SA209T1
0.1
0
0.2
0
0.3
-
0.8
0.0
45
Max.
0.0
45
Max.
0.1
0-
0.5
0
-
-
0.4
4-
0.6
5
39
21
30
7
P3/1
SA209T1a
0.0
5
0.2
5
0.3
-
0.8
0.0
45
Max.
0.0
45
Max.
0.1
0-
0.5
0
-
-
0.4
4-
0.6
5
42
22
.4
30
8
P3/1
SA209T1b
0.1
4
Max.
0.3
-
0.8
0.0
45
Max.
0.0
45
Max.
0.1
0-
0.5
0
-
-
0.4
4-
0.6
5
37
20
30
9
P4/1
SA213T11
0.1
5
Max.
0.3
0-
0.6
0
0.0
3
Max.
0.0
3
Max.
0.5
-
1.0
-
1.0
-
1.5
0.4
4-
0.6
5
42
21
30
10
P4/1
SA213T12
0.1
5
Max.
0.3
0-
0.6
1
0.0
45
Max.
0.0
45
Max.
0.5
Max.
-
0.8
-
1.2
5
0.4
4-
0.6
5
42
21
30
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CHEMICALCOMPOSITIONANDMECHANICAL
PROPERTIES
Ta
ble
2Tu
bes
(Con
td..
)
Chem
ica
lCompos
ition
(%)
Mec
h.P
ropert
ies
(Min
.)
Sl.
No
P.N
O/
Group
No.
Ma
teria
l
Spec
ificat
ion
(ASME)
C
Mn
P
S
Si
Ni
Cr
Mo
T.S.
kg
/mm
2
Y.S.
kg
/mm
2
%E
Min
11
P5/1
SA213T22
0.1
5
Max.
0.3
0-
0.6
0
0.0
3
Max.
0.0
3
Max.
0.5
0
Max.
-
1.9
-
2.6
0
0.8
7-
1.1
3
42
21
30
12
P5/1
SA213T5
0.1
5
Max.
0.3
0-
0.6
0
0.0
30
Max.
0.0
3
Max.
0.5
0
Max.
-
4.0
-
6.0
0.4
5-
0.6
5
42
21
30
13
P5/2
SA213T9
0.1
5
Max.
0.3
0-
0.6
0
0.0
3
Max.
0.0
3
Max.
0.2
5-
1.0
0
-
8.0
-
10
.0
0.9
-
1.1
0
42
21
30
14
P8/1
SA213TP32
1H
(TiStabilised)
0.0
4-
0.1
0
2.0
Max.
0.0
4
Max.
0.0
3
Max.
0.7
5
Max.
9.0
-
13
.0
17
.0-
20
.0
-
53
21
35
15
P8/1
SA213TP
304H
0.0
4-
0.1
0
2.0
Max.
0.0
4
Max.
0.0
3
Max.
0.7
5
Max.
8.0
-
11
.0
18
.0-
20
.0
-
53
21
35
16
P8/1
SA213TP30
4
0.0
8
Max.
2.0
Max.
0.0
4
Max.
0.0
3
Max.
0.7
5
Max.
8.0
-
11
.0
18
.0-
20
.0
-
53
21
35
17
P8/1
SA249TP30
4
0.0
8
Max.
2.0
Max.
0.0
4
Max.
0.0
3
Max.
0.7
5
Max.
8.0
-
11
.0
18
.0-
20
.0
-
53
21
35
18
P8/1
SA688TP30
4
0.0
8
Max.
2.0
Max.
0.0
4
Max.
0.0
3
Max.
0.7
5
Max.
8.0
-
11
.0
18
.0-
20
.0
-
53
21
35
19
P8/1
SA213TP31
6H
0.0
4-
0.1
0
2.0
Max.
0.0
4
Max.
0.0
3
Max.
0.7
5
Max.
11
.0-
14
.0
16
.0-
18
.0
2.0
-
3.0
53
21
35
20
P8/1
SA213TP34
7H
(Cb+Ta
Stabilise
d)
0.0
4-
0.1
0
2.0
Max.
0.0
4
Max.
0.0
3
Max.
0.7
5
Max.
9.0
-
13
.0
17
.0-
20
.0
-
53
21
35
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CHEMICALCOMPOSITIONANDMECHANICAL
PROPERTIES
Ta
ble
3Forg
ings
Chem
ica
lCompos
ition
(%)
Mec
h.P
ropert
ies
(Min
.)
Sl.
No
P.N
O/
Group
No.
Ma
teria
l
Spec
ificat
ion
(ASME)
C
Mn
P
S
Si
Ni
Cr
Mo
T.S.
kg
/mm
2
Y.S.
kg
/mm
2
%E
Min
1
P1/2
SA105
0.3
5
Max
0.6
-
1.0
5
0.0
4
Max.
0.0
5
Max.
0.3
5
Max.
-
-
-
49
25
.2
30
2
P4/1
SA182F12
0.1
0-
0.2
0
0.3
-
0.8
0.0
4
Max.
0.0
4
Max.
0.1
-
0.6
-
0.8
-
1.2
5
0.4
4-
0.6
5
49
28
20
3
P5/1
SA182F22
0.1
5
Max.
0.3
-
0.6
0.0
4
Max.
0.0
4
Max.
0.5
Max.
-
2.0
-
2.5
0.8
7-
1.1
3
52
.5
31
.5
20
4
P8/1
SA182F321
H
(TiStabilised)
0.0
4-
0.1
0
2.0
Max.
0.0
4
Max.
0.0
3
Max.
1.0
0
Max.
9.0
-
12
.0
17
.0-
Min
-
52
.5
21
30
5
P8/1
SA182F304
H
0.0
4-
0.1
0
2.0
Max.
0.0
4
Max.
0.0
3
Max.
1.0
0
Max
8.0
-
11
.0
18
.0-
20
.0
-
52
.5
21
30
6
P8/1
SA182F316
H
0.0
4-
0.1
0
2.0
Max.
0.0
4
Max.
0.0
3
Max.
1.0
0
Max
10
.0-
14
.0
16
.0-
18
.0
2.0
-
3.0
52
.5
21
30
7
P8/1
SA182F347
H
(Cb+Ta
Stabilise
d)
0.0
4-
0.1
0
2.0
Max.
0.0
4
Max.
0.0
3
Max.
1.0
0
Max
9.0
-
13
.0
17
.0-
20
.0
-
52
.5
21
30
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CHEMICALCOMPOSITIONANDMECHANICAL
PROPERTIES
Ta
ble
4Cas
tings
Chem
ica
lCompos
ition
(%)
Mec
h.P
ropert
ies
(Min
.)
Sl.
No
P.N
O/
Group
No.
Ma
teria
l
Spec
ificat
ion
(ASME)
C
Mn
P
S
Si
Ni
Cr
Mo
T.S.
kg
/mm
2
Y.S.
kg
/mm
2
%E
Min
1
P1/2
SA216WCB
0.3
Max.
1.0
Max.
0.0
4
Max.
0.0
45
Max.
1.6
0
Max.
0.5
Max.
0.5
Max.
0.2
0
Max.
49
25
.2
22
2
P1/2
SA216WCC
0.2
5
Max.
1.2
0
Max.
0.0
4
Max.
0.0
45
Max.
0.6
0
Max.
0.5
Max.
0.5
Max.
0.2
0
Max.
49
28
22
3
P3/1
SA217WC1
0.2
5
Max.
0.5
-
0.8
0.0
4
Max.
0.0
45
Max.
0.6
Max.
-
-
0.4
5-
0.6
5
45
.5
24
.5
24
4
P4/1
SA217WC6
0.2
Max.
0.5
-
0.8
0.0
4
Max.
0.0
45
Max.
0.6
Max.
-
1.0
-
1.5
0.4
5-
0.6
5
49
28
20
5
P5/2
SA217C5
0.2
Max.
0.4
-
0.7
0.0
4
Max.
0.0
45
Max.
0.7
5
Max.
-
4.0
-
6.5
0.4
5-
0.6
5
63
42
18
6
P5/1
SA217WC9
0.1
8
Max.
0.4
-
0.7
0.0
4
Max.
0.0
45
Max.
0.6
Max.
-
2.0
-
2.7
5
0.9
-
1.2
0
49
28
20
7
P8/1
SA351CF8
0.0
8
Max.
1.5
Max.
0.0
4
Max.
0.0
4
Max.
2.0
Max.
8.0
-
11
.0
18
.0-
21
.0
0.5
Max.
49
21
35
8
P8/1
SA351CF8M
0.0
8
Max.
1.5
Max.
0.0
4
Max.
0.0
4
Max.
1.5
Max.
9.0
-
12
.0
18
.0-
21
.0
2.0
-
3.0
49
21
30
9
P8/1
SA351CF8C
0.0
8
Max.
1.5
Max.
0.0
4
Max.
0.0
4
Max.
2.0
Max.
9.0
-
12
.0
18
.0-
21
.0
0.5
Max.
49
21
30
10
P8/2
SA351CH20
0.2
0
Max.
1.5
Max.
0.0
4
Max.
0.0
4
Max.
2.0
Max.
12
.0-
15
.0
22
.0-
26
.0
0.5
Max.
49
21
30
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CHEMICALCOMPOSITIONANDMECHANICAL
PROPERTIES
Ta
ble
5Plates
/Shee
ts
Chem
ica
lCompos
ition
(%)
Mec
h.P
ropert
ies
(Min
.)
Sl.
No
P.N
O/
Group
No.
Ma
teria
l
Spec
ificat
ion
(ASME)
C
Mn
P
S
Si
Ni
Cr
Mo
T.S.
kg
/mm
2
Y.S.
kg
/mm
2
%E
Min
1
P1/1
SA516Gr
60
0.2
1-
0.2
5
1.8
5-
1.2
0
0.0
35
Max.
0.0
4
Max.
0.1
5-
0.4
0
-
-
N 0.0
09
56
26
25
2
P1/2
SA516Gr
70
0.3
5
Max.
0.8
5-
1.2
0
0.0
35
Max.
0.0
4
Max.
0.1
5-
0.4
0
-
-
N 0.0
09
49-
63
27
21
3
P1/3
SA299
0.3
0
Max.
0.8
4
Max.
0.0
35
Max.
0.0
4
Max.
0.1
3-
0.4
5
-
-
-
52
.5-
66
.5
29
.4
19
4
P1/2
SA515Gr
70
0.3
5
Max.
1.3
Max.
0.0
35
Max.
0.0
4
Max.
0.1
3-
0.4
5
-
-
-
49
.2-
63
26
.6
21
5
P4/1
SA387Gr
12
0.1
7
Max.
0.3
5-
0.7
3
0.0
35
Max.
0.0
4
Max.
0.1
3-
0.4
5
-
0.7
4-
1.2
1
0.4
0-
0.6
5
38
.5-
56
.0
23
.1
22
6
P5/1
SA387Gr
22
0.1
5
Max.
0.2
5-
0.6
6
0.0
35
Max.
0.0
35
Max.
0.5
Max.
-
1.8
8-
2.6
2
0.8
5-
1.1
42-
59
.5
21
18
7
P8/1
SA240TYPE
321
(TiStabilised)
0.0
8
Max.
2.0
Max.
0.0
45
Max.
0.0
3
Max.
1.0
Max.
9.0
-
12
.0
17
.0-
19
.0
-
52
.5
21
40
8
P8/1
SA240
TYPE304
0.0
8
Max.
2.0
Max.
0.0
45
Max.
0.0
3
Max.
1.0
Max.
8.0
-
10
.5
18
.0-
20
.0
-
52
.5
21
40
9
P8/1
SA240
TYPE316
0.0
8
Max.
2.0
Max.
0.0
45
Max.
0.0
3
Max.
1.0
Max.
10
.0-
14
.0
16
.0-
18
.0
2.0
-
3.0
52
.5
21
40
10
P8/1
SA240
TYPE347
Ca
+Ta
Stabilise
d
0.0
8
Max.
2.0
Max.
0.0
45
Max.
0.0
3
Max.
1.0
Max.
9.0
-
13
.0
17
.0-
19
.0
-
52
.5
21
40
-
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CHEMICALCOMPOSITIONANDMECHANICAL
PROPERTIES
Ta
ble
6Pipes
(Other
Spec
ifica
tions
)
Chem
ica
lCompos
ition
(%)
Mec
h.
Propert
ies
(Min
.)
Sl.
No
P.N
O/
Group
No.
Ma
teria
l
Spec
ifica
tion
C
Mn
P
S
Si
Ni
Cr
Mo
V
T.S.
kg
/mm
2
Y.S.
kg
/mm
2
%E
Min
1
P1/1
DINSt35
.8
0.1
7
Max.
0.4
-
0.8
0.0
4
Max.
0.04
Max.
0.1
0-
0.3
5
-
-
-
-
36
.7-
48
.96
24
25
2
P1/1
DINSt45
.8
0.2
1
Max.
0.4
5-
1.2
0
0.0
4
Max.
0.04
Max.
0.1
0-
0.3
5
-
-
-
-
41
.8-
54
.1
26
21
3
P1/1
BS3602410
0.2
1
Max.
0.4
0-
1.2
0
0.0
45
Max.
0.045
Max.
0.3
5
Max.
-
-
-
-
41
.82-
56
.1
25
22
4
P1/1
BS3602/460
0.2
2
Max.
0.8
0-
1.4
0
0.0
45
Max.
0.045
Max.
0.3
5
Max.
-
-
-
-
46
.9-
61
.2
28
.6
21
5
P4/1
BS3604620-
460HFS
or
0.1
0-
0.1
5
0.4
0
Max.
0.0
4
Max.
0.04
Max.
0.1
0-
0.3
5
-
0.7
0-
0.4
5-
1.1
0
0.6
5
-
46
.9-
62
.22
18
.36
22
CDS
620-4
40
0.1
0-
0.1
8
0.4
0-
0.7
0
0.0
4
Max.
0.04
Max.
0.1
0-
0.3
5
-
0.7
0-
0.4
5-
1.1
0
0.6
5
-
44
.9-
60
.2
29
.58
22
6
P5/1
BS3604
622
HFSor
CDS
0.0
8-
0.1
5
0.4
0-
0.7
0
0.0
4
Max.
0.04
Max.
0.5
Max.
-
2.0
-
2.5
0.9
-
1.2
-
48
.8
26
.8
17
7
-
BS3604
HFS660
or
CDS660
0.1
5
Max.
0.4
-
0.7
0.0
4
Max.
0.04
Max.
0.1
0-
0.3
5
-
0.2
5-
0.5
0
0.5
-
0.7
0.2
2-
0.3
0
47
.3
30
17
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CHEMICALCOMPOSITIONANDMECHANICAL
PROPERTIES
Ta
ble
7Tu
bes
(Other
Spec
ifica
tions
)
Chem
ica
lCompos
ition
(%)
Mec
h.
Properties
(Min
.)
Sl.
No
P.N
O/
Group
No.
Ma
teria
l
Spec
ifica
tion
C
Mn
P
S
Si
Cr
Mo
V
T.S.
kg
/mm
2
Y.S
.
kg/m
m2
%EMin
1
P1/1
DINSt35
.8
0.1
7
Max.
0.4
0-
0.8
0
0.0
4
Max.
0.04
Max.
0.1
0-
0.3
5
-
-
-
36
.70-
24
48
.96
25
2
P1/1
DINSt45
.8
0.2
1
Max.
0.4
0-
1.2
0
0.0
4
Max.
0.04
Max.
0.1
0-
0.3
5
-
-
-
41
.80-
26
54
.06
21
3
P1/1
BS3059/360
0.1
7
Max.
0.4
-
0.8
0.0
45
Max.
0.045
Max.
0.3
5
Max.
-
-
-
36
.70-
22
51
.00
24
4
P1/1
BS3059/440
0.1
2-
0.1
8
0.9
-
1.2
0
0.0
40
Max.
0.035
Max.
0.1
0
0.3
5
-
-
-
44
.88-
25
59
.2
21
5
P3/1
DIN15Mo
3
0.1
2-
0.2
0
0.4
0
0.8
0
0.0
35
Max.
0.035
Max.
0.1
0-
0.3
5
-
0.2
5-0
.35
-
45
.9-
61
.2
27
.5
22
6
P4/1
DINBGr.
Mo
4
0.1
0-
0.1
8
0.4
-
0.7
0.0
35
Max.
0.035
Max.
0.1
0-
0.3
5
0.7
-
1.1
0
0.4
5-0
.65
-
44
.88-
60
.18
29
.6
22
7
P4/1
BS3059/620
0.1
0
0.1
5
0.4
-
0.7
0.0
4
Max.
0.04
Max.
0.1
0-
0.3
5
0.7
-
1.1
0.4
5-0
.65
-
46
.9-
62
.2
18
.4
22
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CHEMICALCOMPOSITIONANDMECHANICAL
PROPERTIES
Ta
ble
9Bars
toc
k
(Other
Spec
ifica
tions
)
Chem
ica
lCompos
ition
(%)
Mec
h.
Propert
ies
(Min
.)
Sl.
No
P.N
O/
Group
No.
Ma
teria
l
Spec
ifica
tion
C
Mn
P
S
Si
Ni
Cr
Mo
V
T.S.
kg
/mm
2
Y.S.
kg
/mm
2
%E
Min
1
P1/1
IS1570
-1508
0.1
-
0.2
0.6
-
0.9
0.0
55
Max.
0.055
Max.
0.0
5-
0.3
5
-
-
-
-
43
-
25
2
P1/1
IS226
(St42)
0.2
3
Max.
-
0.0
55
Max.
0.055
Max.
-
-
-
-
-
42-
54
25
23
3
P1/1
CSN11416
.1
0.2
Max.
0.6
5
Max.
0.0
45
Max.
0.045
Max.
0.3
5
Max.
0.3
0
Max
0.3
0
Max.
-
-
41-
50
24
25
4
-
VX22
Cr
Mo
V121V
0.1
8-
0.2
3
0.3
-
0.8
0.0
35
Max.
0.02
Max.
0.1
-
0.5
0.3
-
0.5
11
.5-
11
.9
0.8
-
1.2
0.2
5-
0.3
5
95
60
15
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RECEIPT INSPECTION OF WELDING
ELECTRODES / FILLER WIRES
1. All electrodes / filler wires received at site stores shall be segregated for type and sizeof electrode.
2. Ensure that electrode packets received are free from physical damage.
3. Where electrodes are damaged, the same shall be removed from use.
4. Only electrodes indentified in the Rationalised List of Electrodes are to be accepted.
5. Where filler metals are supplied by manufacturing unit, inspect for damages, if any.
6. Ensure availability of relevant test certificates. Refer tables of chemical compositionsand mechanical properties for acceptance.
7. Endorse acceptance / rejection on the test certificate.
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STORAGE & IDENTIFICATION OF WELDING
ELECTRODES / FILLER WIRES
1.0 Scope
1.1 This procedure is applicable for storage of welding electrodes / filler wires used atsites.
2.0 Procedure:
2.1 Only materials accepted (based on receipt inspection) shall be taken into account forstorage.
2.2 Storage Facility:
2.2.1 The storage facility shall be identified.
2.2.2 Access shall be restricted to authorized personnel.
2.2.3 The storage area shall be clean and dry.
2.2.4 Steel racks may be used for storage. Avoid storing wood inside the storage room.
2.2.5 Maintain the temperature of the storage facility above the ambient temperature. Thiscan be achieved by the use of appropriate heating arrangements.
2.3 The electrodes / filler wire shall be segregated and identified for
a. Type of electrode e.g. E7018.b. Size of electrode e.g. Dia 3.15 mm.
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BAKING AND HOLDING OF WELDING ELECTRODES
1.0 Purpose:
1.1 This section details activities regarding baking and holding of welding electrodesused at sites.
2.0 Procedure:
2.1 While handling, avoid contact of oil, grease with electrodes. Do not use oily or wetgloves.
2.1.1 It is recommended that not more than two days requirements are baked.
2.2 GTAW Filler Wires:
2.2.1 These wires do not require any baking.
2.3 Covered Electrodes:
2.3.1 Baking and holding:
2.3.1.1 Identify baking oven and holding oven.
2.3.1.2 They shall have a temperature control facility upto 3500C for baking oven and 200Deg. C for holding oven.
2.3.1.3 A calibrated thermometer shall be provided for monitoring temperature.
2.3.2 On opening a packet of electrodes, segregate and place them in the baking oven.Avoid mix up.
2.3.2.1 After loading, raise the baking oven temperature to the desired range as per Table in2.3.2.5.
2.3.2.2 Note the time when the temperature reaches the desired range. Maintain thistemperature for the duration required as per Table in 2.3.2.5.
2.3.2.3 On completion of baking, transfer the electrodes to holding oven, maintain aminimum temperature of 1000C till issue.
2.3.2.4 The electrode shall not be subjected to more than two cycles of baking.
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2.3.2.5 Maintain a register containing following details :
a) Brand name (e.g. Supratherme)
b) Size (e.g Dia 4.0 mm)
c) Quantity (e.g. 110 pieces)
d) Time at required temperature ie. Above 2500C
e) Time of Transfer to holding oven. Activities a,b,c to be recorded beforeloading into the oven.
Baking and Holding Parameters
BakingAWSClassification(*)
Temperature 0C Time (Hours)HoldingTemperature0C (@ )
E7018
E7018-1
E7018-A1
E8018-B2
E9018-B3
E8018-B2L
E9018-B3L
E309 & E347
250 300
250 300
250 300
250 300
250 300
250 300
250 300
250 - 300
2
2
2
2
2
2
2
1
100 min
100 min
100 min
100 min
100 min
100 min
100 min
100 min
Note : (*) For other electodes, suppliers recommendations shall be followed.
(@) Maintain the temperature in the oven till issue.
2.3.2.6 After issue, maintain the electrodes in a portable oven at a minimum temperature of650C till use (not applicable for E6013, E309 & E347 electrodes).
2.3.3 Unused, returned electrodes shall be segregated and kept in the holding oven.
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SELECTION AND ISSUE OF WELDING
ELECTRODES / FILLER WIRES
1.0 Purpose:
1.1 This procedure details methods for selection and issue of welding electrodes / fillerwires for site operations.
2.0 Procedure:
2.1 Selection:
2.1.1 The type of filler wire / electrode for welding shall be based on the details given inthe contract documents like Erection Welding Schedules, drawings, WeldingProcedure Specifications as supplied by the Manufacturing Units.
2.1.2 Where not specified by the Manufacturing Units, selection shall be based on thetables enclosed.
2.1.3 Where electrodes / filler wire are not covered in the documents mentioned in 2.1.1,2.1.2, refer to manufacturing Units.
2.2. Issue:
2.2.1 Issue of welding electrodes / filler wires shall be based on authorized WeldingElectrodes Issue Voucher.
2.2.2 It is recommended to restrict quantity issued to not more than 4 hours requirements.
2.2.3 Redried low hydrogen electrodes shall be carried to the work spot in a portableoven.
2.2.4 Maintain the temperature in the portable oven at the work spot above 65 Deg. C.
2.2.5 Unused electrodes shall be returned and kept in the holding oven till reissue.
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TABLE
1SELECTIONOFGTAW
FILLERWIRE
,SM
AW
ELECTRODE
FORBUTTWELDSINTUBES
,PIPES
,HE
ADERS
MATERIAL
WELD
ING
PROC
ESS
P1GROUP1
P1GROUP2
P3G
ROUP1
P4GROUP1
P5GROUP1
P8
Cr
Mov
P1Group
1
P1Group
2
GTAW
SMAW
RT1/2Mo
E7018(ATT)
No
te
1
P3Group
1
GTAW
SMAW
RT1/2Mo
E7018(ATT)
RT1
/2Mo
E701
8A1
P4Group
1
GTAW
SMAW
RT1/2Mo
E7018(ATT)
RT1
/2Mo
E701
8A1
RT
1Cr
1/2
Mo
E8018-
B2
P5Group
1
GTAW
SMAW
RT1/2Mo
E7018(ATT)
RT1
/2Mo
E701
8A1
RT
1Cr
1/2
Mo
E8018-
B2
RT21/4Cr
1
Mo
E9018
B3
PS
GTAW
SMAW
ERMiCr3
ERNiCr3
ENiCrFe
2
ENiCrFe
2
RT347
E347
Cr
Mo
V
No
te-
2
GTAW
SMAW
RT21/4Cr
1
Mo
E9018-B
3
RT21/4Cr
1Mo
E9018-
B3
No
te
1E7018-
A1
For
P1Gr
2+P1Gr
2an
dD
ia>127mm.
No
te
2DIN14MoV
63orequ
iva
len
t.
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TABLE3
SELECT
IONOFELECTRODES,PR
EHEAT,PWHT
FORATTACH
MENTTOATTACHMENTW
ELDS
(Sea
lban
ds,
Highcrown
bars,
En
dba
rs,
En
dbar
lifting
lugsan
dCo
llec
torp
lates
etc
.)
MATERIAL
W
ELDING
REQUIREMENTS
P1
P4
P5
P8GRUP1
P8GROUP2
P1
Electro
de
Pre
hea
t
PWHT
E7018
Nil
Nil
P4
Electro
de
Pre
hea
t
PWHT
E7018(Note-2
)
Nil(No
te2
)
Nil(No
te2
)
E8018-B
2
Nil
Nil
P5
Electro
de
Pre
hea
t
PWHT
E7018
No
te1&2
Nil(No
te-2)
E8018-B
2
No
te-1
Nil
E9018
-B3
No
te-1
Nil
P8
Electro
de
Pre
hea
t
PWHT
E309
Nil
Nil
E309
Nil
Nil
E309
Nil
Nil
E347
Nil
Nil
E309
Nil
Nil
No
te:
1.
WhenP
5ma
teria
lthickness
ismore
than
10mm,
150Deg.C
preh
ea
tisrequ
ire
d.
2.
Elec
trode,
Pre
hea
tan
dPWHTrequiremen
tforwe
ldingen
dbarli
fting
lugareas
follows:
ENDBAR
LIF
TING
L
UG
ENDBAR
ELECTRODE
PREHEAT
D
EG
.C
PWHTDEG
.C
P1
P1
P4
P5
E8018-B
2
E9018-B
3
120
150
650
680
680-7
20
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TABLE4SELECTIONOFELE
CTRODESFORWELDINGNOZZLEATTACHMENTS,
HANDHOLEPLAT
E,RGPLUGETCTOHEAD
ERS,PIPES
ATTACHMENTMAT
ERIAL
HEADER
,PIPE
MATERIAL
P1
P3
P4
P5
P8
P1
P4
P5
Cr
Mo
V
No
te-1
E7018(ATT)
- - -
- - - -
E7018(ATT)
E8018-B
2
- -
-
E8018-B
2
E9018-B
3
E9018-B
3
ENiCrFe
2
-
ENiCrFe
2
ENiCrFe
2
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TABLE5
SELECTIONO
FELECTRODESFORNON
-PRESSUREPARTS
(INC
LUDINGSTRUCTURES)
MATERIAL
ELECTRODES
P1+P1
Carton
Stee
l+P1
Carton
+Carton
Stee
l
Stee
l
a.
For
bu
ttwelds,
up
to6mm
inc
luding
:E6013
Over
6mm
:E7018
b.
For
fillets
,upto
8mm
inc
luding
:E6013
Over
8mm
:E7018
E6013or
E7018
E8018-B
2
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WELDER QUALIFICATION
1.0 Scope:
1.1 This chapter details the procedure for qualification of welder at site.
2.0 Contents:
1. Qualification of Welders at Site.
2. Table-1 Welder qualification Requirements.
3. Record of Welder Performance Qualification Tests.
4. Figure- 1 Fillet Weld Break Specimen.Figure-2 Method of Rupturing.
Figure-3 Positions.
Figure-4 Plate Butt Weld specimen.
Figure-5 Pipe Butt Weld Specimen.
Figure-6 Bend Specimen.
Figure-7 Bend Jig.
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QUALIFICATION OF WELDERS AT SITES
1.0 Base Metal:
1.1 For selection refer tables in chapter II.
2.0 Test coupon:
2.1 Depending on the range to be qualified, choose the appropriate test couponfrom table-1.
2.2 For plate butt welds, details of edge preparation shall be as per Figure-4.
2.3 For pipe butt welds, details of edge preparation shall be as per Figure-5.
2.4 For structural tack welds, refer Figure-1.
3.0 Requirement of Tests:
3.1 For Structural Tack Welders:
3.1.1 Break Test as per Figure-2.
3.2 For Plate Butt Welds:
3.2.1 Minimum of 2 specimens for bend test; one for root bend and other for facebend. Width of specimen shall be 38 mm for plate thickness upto 9.5 mm. Forthickness greater than 9.5 mm, width of specimens shall be 10 mm and theyshall be side bend tested.
3.3 For Pipe Welder:
3.3.1 The order of removal of test specimens shall be as per Figure-6.
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Example: vee bevel to u bevel.
4.1.3 Base Metal:
A change in thickness or pipe diameter beyond the limits prescribed inTable-1.
4.1.4 Filler Metal:
A change from one F number to another F number, except as specified intable-1,
4.1.5 Positions:
Note: This procedure envisages qualification of welders to perform in all
positions. Deviation to this are not recommended.
4.1.6 Gas:
Note: This procedure envisages test to pre-prescribed gas as forproduction welds.Deviation to this are not recommended.
4.1.7 Electrical Characteristics:
a. AC to DC and vice versa.
b. In DC, DCEN (Electrode Negative) to DCEP (Electrode Positive) andvice versa.
4.1.8 Technique:
Note:- This procedure envisages only use of uphill progression technique.
5.0 Acceptance Criteria:
5.1 Structural Tack Welding:
5.1.1 No cracks.
5.1.2 No lack of fusion.
5.1.3 Undercut not exceeding 1 mm.
5.1.4 Not more than 1 porosity (max. diameter of porosity 2 mm).
5.2 Plate / pipe Welding:
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5.2.1 Visual Inspection:
a. No cracks.b. No lack of fusion or incomplete penetration.c. Not more than 1 porosity in a length of 100 mm of length of weld (max.
porosity diameter 2 mm).
5.2.2 Bend Test results:
The convex surface of the bend test specimen shall be visually examinedfor surface discontinuities. For acceptance, the surface shall contain nodiscontinuities exceeding the following dimensions.
1. 3 mm measured in any direction on the surface.
2. The sum of the greatest dimensions of all discontinuities exceeding 1mm but less than or equal to 3 mm, shall not exceed 10 mm.
3. The maximum corner crack of 6 mm, except when that corner crackresulted from visible slag inclusion or other fusion typediscontinuities, then the 3 mm maximum shall apply. Specimens withcorner cracks exceeding 6 mm with no evidence of slag inclusions orother fusion type discontinuities shall be disregarded, and areplacement test specimen from the original weldment shall betested.
6.0 Retests :
6.1 A welder who fails to meet the acceptance criteria for one or more testspecimens, may be retested as per this procedure after adequate practice.
7.0 Validity :
7.1 When a welder meets the requirements of this procedure, the validity willbe for a maximum of 2 years from the date of test, limited to Validityspecified by statutory authority, as applicable.
7.2 The validity may be extended by one year each time, based onsatisfactory performance.
8.0 Requalification :
8.1 Requalification is required for the following :
a. Where there is a specific reason to doubt the skill of the welder.b. Due to non-engagement of the welder for a continuous period of 6
months.
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9.0 Records ;
9.1 The welding in charge at site shall maintain the following records.
A. Record of welder performance Qualification Test (as per format).
B. Register of qualified welders (employer-wise) containing the followingdetails :
1. Name of welder.2. Age.3. Tested for pipe / plate / tack.4. Performance Test No.5. Validity.6. Welder Code.7. Remarks.
The above register shall be updated for deletions also.
9.2 Copies of welder identity card (including details as in 9.1 B and relevantvariables qualified).
9.3 Pertinent radiography reports.
10.0 Enclosures :
1. Table 1 - Welder qualification Requirements.
2. Record of Welder Performance Qualification Test.
3. Figure-1 - Structural Tack weld specimen.
4. Figure 2 - Break Test.
5. Figure 3 Weld Positions.
6. Figure 4 - Plate Butt Weld Specimen.
7. Figure 5 - Pipe Butt Weld Specimen.
8. Figure 6 - Order of Removal of Test Speciemen.
9. Figure 7 - Bend Jig
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WELDERS
QUALIFICATIONREQUIREMEN
TS
TABLE1
S L.N O
T
ESTFOR
BASE
METAL
Note-1
TEST
COUP
ON
DIMENSION
OD,t
ELECTRODE
TOBE
USED
Note2.4
WELD
POSITIONS
REFEREN
CEFIGURE
RANGE
QUALIF
IED
DIA.&T
POSI
TION QUA
LIFI
ED
ELECTROD
E QUALIFIED
Note2,4
REMARKS
1.
Structural
T
ack
P1Gr1
t=10m
mOR
12mm
(E6013
F2)
(E7018)
F4
3F&
4F
3F&
4F
Fig.1&2
-do-
T=Unlimited
T=Unlimited
ALL
ALL
F2,F1
F4&Below
Refer
Fig.1,3
2.
Plate
W
elder
(Structural)
-do-
t=>25
mm
t>25m
m
F4
F4
3G&
4G
3G&
4G
Fig.3
-do-
T=>3.2
mm
T>3.2m
m
25
mm
t>25m
m
F4
F4
2G3G&
4G
2G3G&
4G
-do-
-do-
T=Unlimited
OD=>600mm
T6
00mm
ALL
ALL
F4&Below
F4&Below
4.
PipeWelder
-do-
OD=>
25mm
OD=>
25mm
&=
73mm
t=19
mm
F4
F4
F4
F4
F4
6G
6G
6G
6G
6G
-do-
-do-
-do-
-do-
-do-
OD=>A
bove
OD&25mm
OD>73
mm
T16mm
(No
te3)
SRa
t650
7000C
P5
Alls
heare
d
edge
s
at680-7
300Cfor1
5
mts
.
t25
,2000C
(No
te4)
All
---
150
Allwe
lds
(No
te5
&6)
SRa
t680-7
300C
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Note 1: Clip angles above 10 mm, used for beam connections, which are shearedto length, shall required heat treatment.
Note 2 : All tension members, when thickness is above 50 mm, the entire assembly
shall be post weld heat treated.
Note 3 : All fabricated structural components of P-4 material, with any memberabove 16 mm thickness, the entire assembly shall be post weld heattreated.
Note 4: All gas cut edges of P-5 material shall be heat treated at 680-7300C for 15
mts. As an alternative to this heat treatment, the gas cut edges may bechipped off, ground or machined to remove the HAZ with 6 mm minimumremoval.
Note 5 : All welds of P-5 material shall be post heated at 2500C for 2 hours or1500C for 4 hours immediately following welding.
Note 6 : All fabricated structural members of P-5 material, the entire assembly shallbe post weld heat treated after completion of fabrication.
Note 7: For soaking time details refer Annexure I.
