CHAPTER ERECTION WELDING PRACTICE FOR SA335 P91 MATERIAL

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: "%5

WELDING MANUAL

B&. ERECTION WELDING PRACTICE FOR SA 335 P91 MATERIAL

1." 1.1 SCOPE This document details salient practices to be adopted during erection of SA335 P91 material. &." MATERIAL Materials shall be identified as follows. 1 & 3 &.1 !olour !ode " #rown $ %ed 'ard Stamping " Specification( 'eat )o( Si*e. Paint + Stencil " ,- ./( as per the rele0ant drawing $ document.

,hen an1 defect li2e crac2( lamination( deposit noticed during 0isual e3amination the same shall be confirmed b1 4i5uid Penetrant 6nspection. 6f confirmed( same shall be referred to unit.

3." 3.1 3.1.1

ERECTION 7dge Preparation and fit up !utting of P891 material shall be done b1 band saw + hac2saw + machining + grinding onl1. 7dge preparation 97P shall be done onl1 b1 machining. 6n e3treme cases( grinding can be done with prior appro0al of ,elding 7ngineer+:ualit1 Assurance 7ngineer. .uring machining +grinding( care should be ta2en to a0oid e3cessi0e pressure to pre0ent heating up of the pipe edges.

3.1.&

All 7dge Preparations done at site shall be sub;ected to 4i5uid Penetrant 6nspection 94P6 . ,eld build8up on 7dge Preparation is prohibited.

3.1.3

The weld fit8up shall be carried out properl1 to ensure proper alignment and root gap. )either tac2 welds nor bridge piece shall be used to secure alignment. Partial root weld of minimum &<mm length b1 =TA, and fit8up b1 a clamping arrangement is recommended. /se of site manufactured clamps for fit up is acceptable .The necessar1 preheat and purging shall be done as per clause >.1 and 3.&.& The fit8up shall be as per drawing. %oot gap shall be & to > mm? root mismatch shall be within 18mm. Suitable %eference punch mar2s shall be made on both the pipes 9at least on three a3is 9a At &<< mm from the 7P for /T. 9b At 1<<< mm from the 7P for identif1ing weld during P,'T.

3.1.>

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: "%'

WELDING MANUAL

3.&." 3.&.1

FI(ING OF THERMOCOUPLE )T*C+ AND HEATING ELEMENTS DURING PREHEATING AND PWHT )o Preheating is re5uired for fi3ing T + ! with resistance spot welding. @ollowing are the e5uipment + facilities for heating c1cles. 91 'eating methods " 6nduction heating 9& Thermo couples 93 " )i8!r + )i8Al of <.5 mm gauge si*e. Temp.%ecorders " A Points + 1& Points.

3.&.&

ARRANGEMENT FOR PURGING :Argon gas with re5uisite 5ualit1 shall be used for purging the root side of weld. The purging dam 9blan2 shall be fi3ed on either side of the weld be0el prior to pre8 heating. The dam shall be fi3ed inside the pipe and it shall be located awa1 from the heating *one. Purging is to be done for root welding 9=TA, followed b1 two filler passes of SMA, in case of butt welds. Purging is not re5uired in the case of no**le and attachment welds( when the1 are not full penetration ;oints. The Argon to be used shall be dr1. The flow rate is to be maintained during purging is 1< to &A litres + minute and for shielding during =TA, is B to 1> litres + minute. 9A minimum flow rate as per welding Procedure specification shall be maintained . Start purging from inside of pipe when root temperature reaches &&<deg !. Pro0ide continuous and ade5uate Argon =as to ensure complete purging in the root area. The minimum pre8flushing time for purging before start of welding shall be 5 minutes( irrespecti0e of the pipe si*e. ,here0er possible( solid purging gas chambers are to be used which can be remo0ed after welding. 6f not possible( onl1 water8soluble paper is to be used. Plastic foils that are water8soluble are )-T acceptable.

3.&.3

USING ALUMINIUM DAM ARRANGEMENT:

6n order to retain the Argon gas at the inside of the pipe near root area of the weld ;oint( the purging dams made of Aluminium and permanite gas2ets ma1 be pro0ided during the weld fit8up wor2 as indicated in the s2etch.

The Aluminium discs shall be firml1 secured with a thin wire rope. After completion of the root welding followed b1 two filler passes( the disc ma1 be pulled outwards softl1.

CAUTION: ENSURE REMO,AL OF PURGE DAM ARRANGEMENT AFTER WELDING

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: "%%

WELDING MANUAL

3.&.>

USING OF WATER SOLUBLE PAPER : The dams can be made of water8soluble paper for creating the purging chamber. The ad0antage in such dam arrangement is that dissol0ing in water can flush the dams. The following are different methods used.

-."

WELDING * WELDERS QUALIFICATION : -nl1 :ualified welding procedures are to be used. ,elders :ualified as per ASM7 Sec 6C and 6#% on P91 material shall onl1 be engaged. ,elders log boo2 to be maintained and welders performance to be monitored b1 site welding engineer + :ualit1 assurance engineer. The applicable ,PS for P91DP91 shall be ,PS )<.1<3>.

-.1

PREHEATING:

Prior to start of pre heating ensure that surfaces are clean and free from grease ( oil and dirt. Preheating temp shall be maintained at &&< deg ! 9min b1 using 6nduction heating The Temperature shall be ensured b1 using a !alibrated autographic recorder and two calibrated thermo couples fi3ed at < deg and 1B< deg positions on both pipes 5< mm awa1 from the 7P. The thermocouple shall be welded with the condenser discharge portable spot welding machine. The pre heating arrangements shall be inspected and appro0ed b1 welding engineer + :ualit1 Assurance 7ngineer. 9 %ef @ig 8 1

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: "%.

WELDING MANUAL

Alternate arrangements shall be made during power failure. Two additional spare thermocouple to be fi3ed9as described abo0e for emergenc1 use. =as burners shall be emplo1ed to maintain the Temperature until the power resumes.

-.&

WELDING: %oot ,elding shall be done using =TA, process 9 as per ,PS fi0e minutes after the start of argon purging. @iller wire shall be clean and free from rust or oil. Argon Purging shall be continued minimum two filler passes of SMA,.

-.3

STORAGE OF WELDING CONSUMABLES : a. ,elding consumables are recei0ed with proper pac2ing and mar2ing which includes the rele0ant batch number for eas1 identification. b. 7lectrodes are stored in their original sealed containers + pac2ages until issued and 2ept in dr1 and clean en0ironment as per the instructions of electrode manufacturers( ta2ing care of shelf life. c. ,elding filler wires are recei0ed with proper pac2ing and mar2ing which includes the rele0ant batch number for eas1 identification. d. The filler wires are stored in their original pac2ages until issue and 2ept in dr1 and clean en0ironment.

>.3.1

The electrode =TA, wires issued to the welders should be controlled through issue slips. SMA, electrodes used must be dried in dr1ing o0ens with calibrated temperature !ontroller. The dr1ing temp shall be as recommended b1 the electrode manufacturer. The dr1ing Temp shall be &<< 8 3<< deg ! for two hours if it is not specified b1 the manufacturer. Portable flas2s shall be used b1 the welders for carr1ing electrodes to the place of use. The electrodes shall be 2ept at minimum1<< deg ! in the flas2. ,elding shall be carried out with short arc and stringer bead techni5ue onl1.

>.>

The inter8pass temperature shall not e3ceed 35< deg !. After completion of ,elding bring down the temp to B< 8 1<< deg ! and hold it at this temp for one hour minimum. The P,'T shall commence after completing one hour of soa2ing. CAUTION:- No LPI * W / MPI 01#22 3 c#445 6 o7/ o8 9 26 3 :o4 PWHT.

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: "%9

WELDING MANUAL

5."

POST WELD HEAT TREATMENT : Arrangements" 8 A minimum of four thermocouples shall be placed such that at least two are on the weld and the other two on the base material on either side of the weld within the heating band at 1B< degrees apart about 5<mm from the weld ;oint. Two standb1 thermocouple shall also be pro0ided on the weld in case of an1 failure of the thermocouple.

The width of the heated circumferential band on either side of the weld must be at least 5 times the thic2ness of the weld. 6n case of fillet ;oints the heating band shall be si3 times the thic2ness of the base material. 9%ef @ig 8 & . An insulation of about 1<mm thic2ness shall be pro0ided between the cable and weld ;oint. 5.1 -btain the clearance for post weld heat treatment c1cle from :A7 + ,elding 7ngineer. The P,'T temp for P91 with P91 material shall be EA< D 1<! and the soa2ing time shall be &.5 minutes per mm of weld thic2ness( sub;ect to a M6)6M/M -@ T,'-/%S. All records shall be re0iewed b1 ,elding 7ngineer prior to P,'T clearance. 'eating shall be done b1 6nduction heating onl1. The rate of heating + cooling" 8 Thic2ness 9Abo0e 35<! Thic2ness upto A<mm 8 11<!+ hr.9ma3 F A<mm 8 55!+ hr.9ma3

Thic2ness G Actual thic2ness as measured.

5.&

6)S/4AT6-)" The width of the insulation band be1ond the heating band shall be at least two times the heating band width on either side of the weldment. The recording of time $ temp shall be continuousl1 monitored with a calibrated recorder right from preheating. This will be ensured at e0er1 one hour b1 site authori*ed personnel.

3.B

P%7H7)T6H7 M7AS/%7S ./%6)= P-,7% @A64/%7 A). )-)8@/)!T6-)6)= -@ 7:/6PM7)TIS. )o interruption is allowed during welding and P,'T. 'ence all the e5uipment for the purpose of power suppl1( welding ( heating etc.( shall ha0e alternati0e arrangements. 9diesel generator for pro0iding power to the welding and heating e5uipments( standb1 welding and heating e5uipments( reser0e thermocouple connections( gas burner arrangement for maintaining restored " temp etc. @ollowing pre0enti0e measures shall be adopted until normal power suppl1 or bac2up power suppl1 through diesel generator is

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: "."

WELDING MANUAL

)#+ D7458$ 0/#4/ o: ;4 1 #/58$: 6n case of an1 power failure+interruption during preheating( the weld fit8up shall be insulated and brought to room temperature. After the electric suppl1 resumes the ;oint shall be preheated as per !lause )o" >.1. 9 %ef " @ig 3 )3+ D7458$ GTAW * SMAW: /se gas burner arrangement to maintain the temperature at B< to 1<<! upto a length of 5<mm on either side from weld centre line along the complete circumference of the pipe. %oot welding shall be continued after power is restored and preheating temperature is raised to &&<!. .uring the abo0e period temperature shall be recorded through contact t1pe Thermometer. 9 %ef " @ig> 9c .uring cooling c1cle after SMA, welding to holding temperature at B< to 1<<! for one hour. 9 %ef " @ig 5 !are shall be ta2en to a0oid faster cooling rate b1 ade5uate insulation. The re5uired temp B< to 1<<! shall be maintained b1 gas burner arrangements till power resumes + start of P,'T. 9d .uring post weld heat treatment? The following shall be followed" J1 J& .uring heating c1cle The whole operation to be repeated from the beginning. 9 %ef " @ig A .uring soa2ing 'eat treat 9soa2 subse5uentl1 for the entire duration. 9complete period . 9 %ef " @ig E The heating rate shall be as per the chart. 3 .uring cooling 9abo0e 35<! . %eheat to soa2ing temperature and cool at the re5uired rate. 9 %ef " @ig B J Temp should not be allowed to fall below B< to 1<<!. =as burner arrangement shall be used to maintain the temperature. >.B 6n all the abo0e cases 9a to d the temp. measurement on the weld ;oint b1 means of contact t1pe calibrated temp. =auges shall be emplo1ed to record the temper8 ature at regular 6nter0als of 15 minutes in the logboo2 b1 :ualit1 Assurance 7ngineer + ,elding 7ngineer.

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: ".1

WELDING MANUAL

5.5

TEMPERATURE MONITORING: The welding and heat treatment chart gi0en in @igure 9 shall be followed for the following details. The actual P,'T chart shall be monitored for the following" a b c Preheat 6nter pass Temperature 9=TA, D SMA, !ontrolled cooling and 'olding at B< to 1<<! for minimum one hour under insulation. Start P,'T after minimum one hour of soa2ing. d e f g 'eating to P,'T Soa2ing at P,'T !ooling to 35<! !ooling to %oom Temperature 9under insulation

5.A

!A/T6-) T'7 P,'T T7MP. S'A44 )-T .7H6AT7 @%-M T'7 HA4/7S SP7!6@67. 6) T'7 !'A%T %A)=7 S6)!7 A)K .7H6AT6-)S T- T'7 SP7!6@67. '-4.6)= T7MP7%AT/%7 %A)=7( ,644 A.H7%S4K A@@7!T T'7 M7!'A)6!A4 P%-P7%T67S -@ T'7 ,74.M7)T A). MAK 47A. T- %7L7!T6-) -@ T'7 ,74.M7)T. T'7 ,74. L-6)TS S'-/4. #7 M7PT .%K. /).7% )!6%!/MSTA)!7S A)K ,AT7% + 46:/6. 6S A44-,7. T- !-M7 6) !-)TA!T ,6T' ,74. AS ,744 AS P%7'7AT7. P-%T6-) -@ P6P7.

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: ".&

WELDING MANUAL

6)./!T6-) '7AT6)= 9for all Thic2ness

TOP

5<mm 6nduction !able

3
>

&

3<mm

6nsulation > C T Min -% as recommended b1 e5uipment supplier.

1$& Measurement T!( 3$> Spare T!

T'7%M-!-/P47 9T! (P%7'7AT6)=

A%%A)=7M7)T @ig 8 1

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: ".3

WELDING MANUAL

A%%A)=7M)T @-% P-ST , 74. '7AT T%7ATM7)T 6nsulate & Times 'eating #and , idth 'eating #and , G B C T min or as recommended b1 the e5uipment supplier T!1 fibre glass cloth or !eramic wool

6nduction !able

5<mm

5<mm
T!&

T! 3 T! > at 1B<N apart

T!5( T!A 9 Spare T! shall be fi3ed at 9<N( &E<N to T!3 @ig 8 &

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: ".-

WELDING MANUAL

Power @ailure during Preheating

Temp in deg c T heoretical cur0e Actu al 35<

&&< 1<< B< %T

P-,7% !/T

After power r esu

Time

6mmediatel1 co0er the ;oint b1 insulation( if welding has not been started. Start preheat as per !l.>.1 after power resumes @ig83

Power @ailure during =TA,+SMA,

Temp in deg c T heoretical cur0e 35< Actu al

&&< 1<< B< %T .uring powe r cut

After power resu mes Maintain B< 8 1<<Nc b1 imme diate insulation and h eating b1 bu

Time

@ig 8 >

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: ".5

WELDING MANUAL

Power @ailure during cooling + holding

Tem p in deg c Theoretical cur0e

35< &&< 1<< B< .uring power cut %T

Actual cur0e

After power resum es Maintain B< 8 1<<N! for a min period one hour b1 imm ediate insulation and heating b1 gas

Tim

@ig 8 5

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: ".'

WELDING MANUAL

Power @ailure during P,'T heating c1cle

Temp in deg c Theoretical cur0e EA< O 1<

Actual cur0e

35< &&< 1<< B< %T Power cut Time

%ate of heating shall be adhered

@ig 8 A

Power @ailure during P,'T soa2ing c1cle

Temp in deg c EA< O 1< T T1

Actual cur0e

35< &&< 1<< B< %T

Power cut

Theoretical cur0e

T1 GT

Time

@ig 8 E

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: ".%

WELDING MANUAL

Power @ailure during P,'T cooling

Temp in deg c Theoretical EA< O 1< Actual

35< &&< 1<< B< %T @ree fall 9,hile heat insulated

%ate of cooling shall be

Time

@ig 8

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: "..

WELDING MANUAL

Preheating and P,'T b1 induction heating

Temp in deg c

EA< O 1<

35<

&&<
1<<

B< %T 1 & 3 > 5 Time

A E B

@ig 8 9 Sln operation Temp Nc

%ate of

1 N!+hr & 3

Preheat

&&<N ! &&<N!835<N! B< 8 1<< N!

1<<

=TA,DSMA, !ooling

1<<

> 5

'olding at B<81<< N! for min 1 hr.'olding shall continue till the start of P, 'T 'eating to P, 'T Soa2ing at P, 'T %each EA< O1< N! for P91 D P91 EA< O 1< at &.5minutes +mm 9 minimum & hrs
As per clause 5.1

E B

!ooling !ooling

!ooling to 35<N! !ooling to %oom temperature under insulation

As per clause 5.1

NOTE 1.Purging shall be ensured for minimum root and two further passes of SMA, . &.7nsure remo0al of all purging dam arrangements after welding.. 3.@or electrodes details strictl1 follow , PS+7,S.

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: ".9

WELDING MANUAL

5.%

CALIBRATION All e5uipments li2e recorder( thermocouple( compensating cable( o0en thermostat etc. should ha0e 0alid calibration carried at #'74 appro0ed labs. The calibration reports shall be re0iewed and accepted b1 !alibration 6n8charge at site prior to use.

'." A.1

NONDESTRUCTI,E E(AMINATION: All ).7 shall be done after P,'T onl1. Prior to testing all welds shall be smoothl1 ground. All weld s 9fillet $ butt shall be sub;ected to MP6 9MP6 shall be done b1 K-M7 t1pe onl1 . 6n addition to MP6( butt8 welds and all full penetration welds shall be e3amined b1 /T. 4P6 procedure shall be #'7" ).T " P# " PT " <18 %e0 11 and MP6 procedure shall be #'7" ).T " P# " MT" <5 8 %e0 <& The penetrant materials 9.1e Penetrant( Sol0ent cleaner $ .e0eloper and medium 9dr1 + wet particles used in MP6 shall be of #'74 appro0ed brands onl1. /T procedure shall be as per #'7").T"P#" /T&1 8 %e0 <> re5uirements as in 9a through 9e a with additional

The calibration bloc2s used shall be of same material specification 9P91 dia $ thic2ness.

The /T e5uipment shall be calibrated prior to use and should be of Pdigital t1peQ 8 Mraut2ramer Model /S) 5< of e5ui0alent( capable of storing calibration data as well as ultrasonic test results as per /T8&1 %e0 <>.

All recordable indications will be stored in memor1 of either the digital flaw detector or a P! for re0iew at a later period. The e5uipment calibration data for specific weld as well as the hard cop1 of PStatic echo8trace patternQ 8 Showing the flaw8echo amplitude with respect to .A!( flaw depth( pro;ection surface distance 9probe position and beam8path shall be attached to /T test report. This hard8cop1 of echo8trace with e5uipment calibration data will form part of test documentation.

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: "9"

WELDING MANUAL

The e3amination as well as e0aluation will be performed b1 a 5ualified 4e0el 66 personnel( and a test report will be issued. An1 defect noticed during ).T shall be mar2ed with mar2er.

%."

REPAIR OF WELD <OINTS: )A+ WELD REPAIR AT ROOT. -n 0isual e3amination during root welding if it re0eals an1 surface defects( the same shall be remo0ed b1 grinding maintaining temperature B< 8 1<<N! and rewelded with =TA, maintaining &&< N! before starting SMA,.

)B+ WELD REPAIR ON COMPLETION: An1 defect obser0ed on the weld shall be brought to the notice of :ualit1 assurance engineer. The si*e and nature of defect shall be re0iewed. An1 repair on weld to be carried on their appro0al onl1.

6f an1 defects are noticed on the full1 completed weld while performing /.T after completion of P,'T( the same ma1 be assessed in order to find the seriousness of the defect and to locate where e3actl1 the defect lies from the weld outside surface. The defect area shall be mar2ed and repaired as below"

The weld shall be remo0ed b1 grinding 9gouging not permitted such that the area for repair welding is free from sharp corners and pro0ided with sufficient slope towards the weld face sides. 6ncase of cut $ weld ;oints 'AR 9 5mm will ha0e to be remo0ed b1 grinding. Surface e3amination 9MP6+4P6 on the ground and welded area to be performed to ensure a sound base metal before depositing weld la1ers using SMA,.

c d e

The temp. of the weld is to be maintained at preheat temp. !arr1 out SMA, using the same procedure as that of welding. All the specified precautions w.r.t to welding consumables( heating c1cles( post weld heat treatment etc. as followed for original welding( shall be strictl1 adhered.

f g

The ).7 shall be conducted for the entire weld ;oint. 6f an1 further defects are obser0ed on the repaired weld( the same ma1 be further rewor2ed as mentioned abo0e.

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: "91

WELDING MANUAL

.."

HARDNESS SUR,EY The e5uipment recommended to measure the hardness are 7:/-T6P or M6!%-./% ma2e or e5ui0alent portable e5uipment. The e5uipment used for the hardness measurement shall be calibrated as recommended b1 the manufacturer and also on a P91 calibration bloc2 pro0ided b1 P!.

The surface shall be cleaned and prepared as per hardness test instrument manufacturerQs recommendation prior to hardness sur0e1. 'ardness sur0e1 shall be done at each ;oint at three locations along the circumference. At each location three readings on weld and parent metal 9both pipes shall be carried out.

All the hardness 0alues shall be recorded. The ma3 allowable hardness at weld and parent metal shall be 3<< 'H1<. Loints ha0ing hardness abo0e 3<< 'H shall be reheat treated and hardness shall be chec2ed again. 6f hardness is still more refer to unit. PM 1 ,74. PM & &E< 1B< @igure 8 1<
LOCATION READINGS 0 90 180 270 1 2 PM 1 3 AVE 1 2 WELD 3 AVE 1 2 PM 2 3 AVE

< 9<

PM " PA%7)T MAT7%6A4 9." COMBINATION WELDING

AH7 " AH7%A=7

@or other combination of material li2e P&& with P91( and C&& with P91 the applicable ,PS for the in0ol0ing material shall be obtained from e5uipment supplier + ,T! + P! and the same shall be used .

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: "9&

WELDING MANUAL

9.1

SOA=ING TIME FOR COMBINATION WELDING. ,PS )<. 1<35 Material P91DP&& Temp.( E>515! E5<1<! Soa2ing time &.5mts + mm minimum one hour &.5mts + mm minimum two hour for thic2ness upto 5< mm and minimum four hours for thic2ness abo0e 5< mm. Ho9 ! 4 /1 ;4 c#7/5o80 #0 4 >754 6 :o4 P9101#22 3 :722? /#@ 8 c#4 o:.

MS ,<>5>. P91DC&&

1"."

DEMAGNETISATION 6n case magnetisation is noticed on the pipes( the following procedure shall be followed during welding. /se %esidual field8indicator at one end of pipe and measure the residual field. )ote reading and direction of field 9D 0e or S 0e $ )o units

TTTTTTTTTATTTTTTTTTTT D1< < 81< 5 turns8 6ndicator ma1 show readings greater than D or 81< .i0isions. A small si*e electrode or gem8clip will get attracted $ stic2 to pipe. ,rap insulated welding cable cloc2wise on the -. surface or pipe. ,rapped cable to be 5< to 1<< mm awa1 from ;oint end. -ne cable end connect to D0e terminal of welding generator and the other to 8 0e terminal. !omplete electrical circuit $ pass ><< amps current for 3 to > seconds. Measure residual field now at the same end of pipe. 6f demagnetisation is effecti0e the reading will come closer to `-Q @or eg. 6f it is formerl1 F D 1< .i0isions( it ma1 show 85 .i0ision. The electrode or gem8clip will not stic2 to pipe8end. 6f will still stic2 to pipe( Then repeat the following. )ow wrap the insulated cable 95 turns in anti8cloc2wise direction pass current slightl1 e3cess of ><< Amps %educe the current graduall1 to < amps in one minute when current is on. !hec2 for demagneti*ation using gem8clip + electrode. The gem8clip + electrode ,644 )-T =7T re0erse the turns. attracted. 6f the reading is shifted to opposite direction( de8magnetisation is )-T effecti0e The readings will be greater in the same direction The gem clip+electrode

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Doc.No.:PSQ-WDMCOM R !.No.:R"" P#$ No.: "93

WELDING MANUAL

11." 11.1

TRAINING The personnel engaged in P91 piping fabrication shall be trained in the following areas. a. b. c. d. e. Method and !are during fit8up. Argon gas root purging arrangement. @i3ing of thermocouple and wires. Arrangements for Pre+Post heating re5uirements and methods. Ad;ustment of heating pads+cables at the time of controlling the temperature within specified tolerance limits during welding or P,'T in case of induction heating. f. g. h. i. ;. =ood appreciation of the ,PS re5uirements. 'andling of P91 welding consumables and re8dr1ing conditions. Special precautions during the power+e5uipment failure. ,eld ;oints of dissimilar thic2ness + material specification. ,eld defect control and weld repair s1stems.

11.&

SPECIFIC TRAINING FOR WELDERS a. b. c. d. The 5ualified welders who will be engaged in P91 welding shall be gi0en training on pipe ;oints simulated with P91 welding and heating c1cle conditions. The ac5uaintance on welding positions( as applicable shall be gi0en using P91 pipes and P91 welding consumables. ,elding techni5ues and instructions on .os and .-)QTs of P91 welding. ,elders onl1 who are 5ualified on P91 welding alone shall be engaged. ,hene0er new welders ha0e to be engaged the1 shall undergo all the training as abo0e and shall be 5ualified with P91 material onl1.

11.3

CONTROL ON WELDERS The welder during welding at site follow the following procedures. The welder shall interact with the 'T operator 96nduction e5uipment operator to ensure that preheat and interpass temperature during welding are maintained as per re5uirements. The welder shall not mi3 the welding electrodes with that of the other welder. At the end of the shift( the unused electrodes shall be returned to the stores.

11.-

PERSONNEL * CONTRACTORS ENGAGED FOR HEATING CYCLES )HT O; 4#/o4+

11.>.1 The Personnel + !ontractor shall ha0e ade5uate heat treat e3perience on P91 or similar material.

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11.>.& 'T operator shall be aware of the following" a b c d e The e5uipment used and its wor2ing principle and operation. The procedures to be followed in using heating e5uipments. Procedure to be followed in case of power failure or e5uipment non8functioning so that heating c1cle is not disrupted. !alibration of e5uipments. Method of fi3ing thermocouples and compensating cables leading to 'T recorder. @i3ing of heating pads or elements on the pipe ;oints and also in maintaining the temperature within the specified limits. 11.5 NDE PERSONNEL QUALIFICATIONS All ).7 personnel performing ).T li2e /T $ MP6+4P6 shall be 5ualified in accordance with #'74 Procedure meeting the re5uirements of recommended practice S)T8T!8 6A. MP6 $ 4P6 shall be carried out be le0el 6 5ualified personnel and shall be e0aluated b1 le0el 66 5ualified personnel. 'owe0er /T e3amination and e0aluation shall be done b1 le0el 66 5ualified personnel.

11.'

LE,EL OF SUPER,ISION Site 6ncharge shall be responsible for the completion of all acti0ities from weld fit8up to final clearance of weld ;oints after satisfactor1 ).7 and acceptance b1 #'74 + !ustomer + 6#%.

1&." 1&.1

DOB0 #86 DONBTB 0 67458$ P 91 9 2658$C 1 #/ /4 #/D 8/ #86 NDE #/ co80/47c/5o8 05/ . DOBS .
a b c d e !utting b1 #and saw+'ac2 saw+Machining . Pipes 7dge Preparation b1 machining. Machining shall be done without e3cessi0e pressure to pre0ent heating up of pipe =rinding ma1 be done on e3ceptional cases after appro0al and ta2ing ade5uate care to pre0ent o0erheating. Thermocouple wire 9hot+!old ;unctions shall be welded with condenser discharge portable spot8welding e5uipment. %eser0e Thermocouples shall be made a0ailable ( incase of failure of connected thermocouple elements.

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WELDING MANUAL

f g h

7nsure ade5uate Argon =as for complete purging of air inside the pipe before starting =TA, root welding. 7nsure Preheating at &&<N! minimum before =TA, root welding. Start preheating onl1 after clearance from ,elding engineer + :ualit1 assurance engineer for weld fit8up and alignment of the ;oint as well as fi3ing of Thermocouple connections 9 for 6nduction heating

i ; 2 l m n o p 5 r s t u 0

.o 0isual inspection on root weld maintaining weld preheating temp. !ontinue Argon purging until the =TA, root welding followed b1 minimum two filler passes of SMA,( is completed. Perform partial root welding to facilitate fit8up if necessar1. 7nsure that onl1 one la1er of root welding using T=S &!M filler wire 9& U !r 1 Mo is deposited. 9where0er specified . 7nsure proper use of T6= wires as identified b1 colour coding or suitable hard punching. Meep the =TA, wires in absolutel1 clean condition and free from oil ( rust( etc. .r1 the SMA, electrodes before use. 7nsure the interpass temperature is less than 35<N!. 'old at B< to1<<N! for a period of Minimum 1 hour before the start of P,'T. %ecord entire heating c1cle on !hart through recorders. 73ercise control during grinding of weld and ad;oining base metal while remo0ing surface+sub8surface defects or during preparation for ).7. 7nsure no contact with moisture during preheat( welding( post heat and P,'T of ,eld Loints. 7nsure remo0al of argon purging arrangements after welding. /se short Arc onl1. The ma3imum wea0ing shall be limited to 1.5 times the dia of the electrode.

13."

DONBTB0
a b c d e f A0oid -318Acet1lene flame cutting. A0oid ,eld8build up to correct the weld end8d1 or to set right the lip of the weld be0el. A0oid Arc stri2e on materials at the time of weld fit up or during welding. .o not Tac2 weld the Thermocouple wires with Manual Arc+T6= welding. )- =TA, root welding without thorough purging of root area. .o not use -318acet1lene flame heating for an1 heating re5uirements.

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g h i ; 2 l

.o not use Thermal chal2s on the weld groo0e. .o not stop argon purging till completion of =TA, root welding and two la1ers of SMA,. )o Tac2 welding or #ridge piece welding is permitted. .o not use unidentified T6= wires or electrodes. .o not e3ceed the ma3imum interpass temperature indicated in ,PS. .o not allow moisture( rain( water( cold wind( cold draft etc. to come in contact with the weld *one or heating *one during the entire c1cle from preheat to P,'T.

m n o

.o not e3ceed the limits of P,'T soa2ing temperature. .o not 6nterrupt the ,elding+heating c1cle e3cept for una0oidable power failures. .o not use un calibrated e5uipment for temperature measurement during heating( welding( post weld( heat treating etc.(

1-."

NDE CONSUMABLES
TECHNICALLY APPRO,ED BRANDS BY BHEL HPBP. 1 4i5uid Penetrant( Penetrant %emo0er 9Sol0ent cleaner and Aerosol .e0eloper from the same manufacturer considered as a famil1 group.

#%A). H7).-% 6T, S6=)-.7 6).6A 46..( P8M7T !-.( !'7!M MAT7 !'7M6!A4S 9P 4T..( P%A.77P M7TA4 T%7ATM7)T !'7M6!A4 9P @7%%-!'7M P7)7T%A)T SP-T !'7!M SM48SP @4A, !'7!M a PP815 b PP811< !'7!M MAT7 S/P7% PT 9E @4A, =/6.7 =P !%A!M !'7!M @! 911 P7)7T%A)T %7M-H7% SP-T !'7!M SM!81 @4A, !'7!M a PP8&1 b PP81&< !'7!M MAT7 S/P7% !4 9A @4A, =/6.7 !%A!M !'7!M @! 911 .7H74-P7% SP-T !'7!M SM.8S& @4A, !'7!M a P.831A b P.8131A !'7!M MAT7 S/P7% .H 9B @4A, =/6.7 =P !%A!M !'7!M @! 911

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WELDING MANUAL

&

.r1 Magnetic powder" 9a 9b 9c MA=)A@4/C 8 P%-./!T =%7K? BA S %7. @7%%-!'7M P%-./!T )- " &AA M8747!T%-)6!S P%-./!T S %.8 &<< 9SP7!6A4

)on8fluorescent magnetic in2" 9Prepare bath as instructed b1 supplier 9a 9b 9c MA=)A@4/C S Product 9! %7. with MC+M= carrier 66 oil 0ehicle. @7%%-!'7M S P%-./!T )- " 1>A A with oil 0ehicle 9with high flash point 9&! SA%.A MA=)A !'7!M 6)M with oil 0ehicle 9with high flash point 9&!

>

@luorescent magnetic in2" 9Prepare bath as instructed b1 supplier 9a 9b MA=)A @4/C 8 Product 1>A with MC+M= carrier 66 oil 0ehicle. MA=)A @4/C 8 Product 1> AM 8 Prepared bath of 1>A and M=+MC carrier 66 read1 to use without measuring and Mi3ing in aerosol container with MC+M= carrier 66 oil 0ehicle.

15." The documentation shall be as per the customer appro0ed #'74 :ualit1 Plan.