Reconcilation of Welding Consumable and Associated Consumable for Piping and Structure
March 30, 2017 | Author: Rakesh Ranjan | Category: N/A
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Reliance CONTENTS 1.
PURPOSE
2.
SCOPE
3.
ABBREVIATIONS AND DEFINITIONS
4.
RESPONSIBILITY AND AUTHORITY
5.
REFERENCE DOCUMENTS
6.
PROCEDURE
7.
NORMS
8.
RECORD
9.
ATTACHMENTS
ANNEX –I
Welding Consumable Estimation for Piping Work upto 22 mm
ANNEX-II Welding Consumable Estimation for Piping Work above 22 mm ANNEXII(A) Welding consumable Estimation for Special Structure (Single Bevel T weld)
ANNEX-II(B) Welding consumable Estimation for Special Structure (Double Bevel T weld)
ANNEX-II(C) Welding consumable Estimation for Special Structure (Double V groove weld)
ANNEX-III
Welding Consumable Estimation for fillet Welding
ANNEX-IV
W.O. item code wise consumption for welding electrode & filler wire
ANNEX-V
W.O. item code wise consumption for argon gas
ANNEX-VI
W.O. item code wise consumption for Cutting gases and grinding wheels
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
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Reliance 1.
PURPOSE Purpose of this document is to provide outline for having a unique approach for certifying the consumption of welding consumable and other associated consumable supplied to contractors as free issue items. The procedure covers the methodology of consumption certification and norms of consumption derived based on practical experience.
2.
SCOPE Present scope of consumption norms cover welding electrodes, filler wires and flux used in GTAW(TIG), SMAW(MMAW), FCAW, SAW process for piping and structural work. Consumption of argon gas, CO2, oxygen, dissolved acetylene, LPG, and grinding wheels are also covered under the present scope under associated consumable part. The scope of this procedure is applicable for Reliance, EPCM, wherever Welding & Associated consumable are issued as free issue items.
3.
ABBREVIATIONS AND DEFINITIONS
4.
Associated Consumable- Argon gas, dissolved acetylene, oxygen and grinding wheels AS-Alloy steel (i.e. low alloy steel family) CS-Carbon steel (including low temperature carbon steel) CO2-Carbon di oxide D.A.-Dissolved Acetylene EIC-Engineer In Charge FCAW-Flux Cored Arc Welding GTAW-Gas Tungsten Arc Welding GMAW-Gas Metal Arc Welding HOD- Head of Department LPG-Liquefied Petroleum Gas MMAW-Manual Metal Arc Welding QMD- Quality Management Department QSD- Quantity Survey Department SAW-Submerged Arc Welding SMAW-Shielded Metal Arc Welding SS-Stainless steel TIG-Tungsten Inert Gas (Arc) Welding Welding consumable-Welding electrodes (including Tungsten electrode), filler wire, flux used in GTAW, SMAW, FCAW and SAW processes.
RESPONSIBILITY AND AUTHORITY
1
SL
ACTIVITY
01
Enclosing this document as a part of Work Order
02
Submission of consumption statement with final Bill. Verification and Certification of Quantity Verification & Certification of consumption of welding consumable and reconciliation based on the certified scope. Verification & Certification of consumption and reconciliation of other associated consumable (Gas, Grinding Wheel) Final Reconciliation & Certification of Bill Maintenance of procedure
03 04
05 06 07
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
RESPONSIBILITY& AUTHORITY HOD-Contract Department Contractor Construction Manager/EIC Construction Manager/ EIC/ Discipline engineer Construction Manager/EIC Construction Manager/EIC HOD-QMD Page 3
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Reliance 5.
REFERENCE DOCUMENTS -ASME B31.3 Process piping -ASME B31.1-Power piping
1
6. 6.1
PROCEDURE WELDING ELECTRODES/FILLER WIRES/FLUX -
6.2
The norms for welding consumables have been developed & Issued by QMD with inputs from Fabrication Division welding Team. All contractors shall submit consumption of all welding consumable & associated consumable against the executed work quantities along with final bill. Final reconciliation of the total scope of work shall be submitted and certified by EIC during the closure of Work Order.
DEVIATIONS The consumption shall be calculated based on the billing quantities and the norms as above with the following deviation.
(A) -
-
Deviations due to welding process (Carbon Steel). Full GTAW: - This qty is billed separately and hence no deviation. GTAW ROOT + SMAW FILLER: - This qty is billed separately and hence no deviation. Others: Billing qty and the unit rate is same, which will have all the following process combinations, separate break-up may not be available with the contractor. E6010+E7018+SAW As application of SAW process is limited to Fabrication Shops only, consumption of flux & wires of SAW shall be verified based on the contractor’s statement duly certified by the shop welding team. Consumption of FCAW will be verified based on the statement given by contractors and certified by shop welding team/discipline engineer for fieldwork. Based on the consumption of FCAW, SAW wire, equivalent inch dia work shall be calculated. This will be subtracted from total inch dia. The subtraction value will be treated as welding work in SMAW. From norms, consumption in SMAW consumable shall be calculated which will be compared with actual consumption of SMAW electrode. Accordingly consumption shall be certified.
(B)
(C )
Deviations due to welding process (Other than Carbon Steel). For Alloy Steel and S.S. non-ferrous welding, Root pass will be treated as GTAW process. For filler passes with SAW & FCAW, same methodology of carbon steel shall be followed for consumption certification. Deviation due to enabling works/ temporary supporting etc. There are some non-unit rate billable works executed in shop & site ( few examples are given below). Contractors shall quantify the same in terms of equivalent inch diameter in case of piping and equivalent MT in case of structure and use the same consumption norms as above to account for the welding consumables used. (1)Procedure qualification (2)Works executed on manpower basis (3)Welder qualification (4)Enabling works – like Hydro test arrangements etc.
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
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Reliance All quantity for the above works shall be checked and certified by shop/site production engineer. (D)
Based on the consumption statement and proper justification submitted by contractor, EIC may accept deviation from the norms for exceptional cases on case-to-case basis.
6.3 PROCESS OF RECONCILIATION 6.3.1 Piping welding consumable (A)
1
(B)
1
The billing data available in contractor bills are for ranges of thickness. - (i.e.) up to 10 mm. - 10-12mm, - 12-15mm, - 15-19mm, - 19-24mm, - 24-30mm, - 30-37mm, etc. For consumption certification purpose,: - 8mm thickness shall be considered for the first range, i.e. up to 10mm thickness. - For other cases, average thickness within the range shall be taken. For consumption calculation, the following joint configurations combinations is considered: (i)Up to 22mm wall thickness-Single V (included angle 75 degree ) (ii)Above 22mm wall thickness- Single V (included angle 75 degree ) pipe to pipe joint welding -50% cases - Fitting to fitting joint of compound groove-fitting to fitting-50% cases - An average consumption of the above two types of joint configurations is considered against each wall thickness to take care of practical considerations. (refer Annex -II for details) Based on the present procedure, the consumption will be treated as it in all the cases. The reconciliation statements prepared by shop welding engineer/site engineer shall be discussed with the contractors for any major deviations. After the initial two-month, contractors shall be advised to prepare reconciliation statements totally on the same basis and submit for checking and approved. Note- A separate matrix has been enclosed as Annex-IV with the W.O. item code for the ease of certification.
6.3.2 Structural Work welding consumable Certification of consumption for structural work shall be based on the actual scope. For special groove designs under structural fabrication (single bevel T joint, double bevel T joint, double V groove joint- welding consumable calculation details are shown in Annex-II (A), Annex – II (B) and Annex-II(C). EIC to certify scope and certify that the specific joint configuration is used at site to facilitate reconciliation.
1
-
For root pass welding (groove) in SMAW process (for structural fab), consumption of electrode is considered as 317gm/RM of weld length.
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
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Reliance 6.3.3 ASSOCIATED CONSUMABLE Site/ Shop Engineer will certify the consumption of gases, grinding wheels, based on the actual scope.
7.
NORMS Following are the norms for welding consumable:
7.1. WELDING ELECTRODE , FILLER WIRE, FLUX 7.1.1 For Piping The basis of calculation considered are : Weld groove details as per ASME B31.3 Actual area of cross section involved . Annex–I applicable for thickness up to 22 mm. Annex–II is applicable for above 22mm. - Table directly gives the SMAW electrode and GTAW filler wire consumption. - Annex – III for Fillet Welding applicable for all thickness as applicable. - Weight of electrode/filler wire/flux consumption is estimated based on the following: Welding Wastage (to Weight of electrode/filler wire consumed consumable take care of site (including wastage) conditions) GTAW filler 10% Filler wire consumption= 1.32 times weight of wire corresponding weld metal deposited. For the consumption estimation of full GTAW process of any thickness, the weld metal against the table of annexure-1 shall be multiplied by the above mentioned factor (1.32) Tungsten electrode consumption shall be 1 EA (number) (2.4x 150mm) against 1Kg of filler wire consumed SMAW 10% 1.76 times weight of corresponding weld metal electrode deposited FCAW 10% 1.47 times weight of corresponding weld metal electrode deposited SAW 10% 1.32 times weight of corresponding weld metal electrode deposited SAW flux 50% 1.5 times consumption of SAW electrode -
-
For groove welding root pass in GTAW process, consumption of filler wire is considered as 19gm/inch dia for root pass only. Wherever root and hot pass welding is carried out with GTAW process, consumption of filler wire shall be taken as 38gm/inch dia.
-
For fillet welding root pass in GTAW process, consumption of filler wire is considered as 132gm/meter for root pass only.
1
This consumption is estimated for Carbon Steel, Low Alloy Steels and stainless steels. For the estimation of Nickel and Nickel based alloys (Monel, Inconel etc), a factor of 1.12 shall be multiplied with the final weight of welding consumable to compensate the mass density difference.
7.1.2 FOR STRUCTURAL a) Based on Weight % EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
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Reliance The basis of calculation is actual consumption trend at Structural Fabrication Shop for the past three months for covered Electrode Considering total fabrication at shop, following is the welding consumable consumption in different welding processes as follows against different structures: Type of Welding process structure SMAW FCAW GMAW Light 2% of structural weight 1.53% of structural 1.38% of structural weight weight Medium 1.6% of structural 1.23% of structural 1.1% of structural weight weight weight Heavy 1.4% of structural 1.07% of structural 0.96% of structural weight weight weight Extra 1.2% of structural 0.92% of structural 0.83% of structural Heavy weight weight weight
b) Based on Actual Fillet Size Refer Annex –III for details.
c) Pipe Supports Saddle supports-Reconciliation of welding consumable shall be carried out based on the weld length for saddle supports. For other supports, reconciliation shall be carried out on the weight of the supports in the light weight structure category.
7.2 SHIELDING GAS CONSUMPTION NORMS: 7.2.1 ARGON GAS CONSUMPTION NORMS: -
Basis for calculation considered are: WPS argon flow rate. 50% wastage for practical difficulties in the site. Materials Carbon Steels, Low & Alloy Steels %Cr less than or equal to 3 Stainless Steel, Low Alloy Steels %Cr more than 3 & Non ferrous metal
Consumption of gas in Cu-M /KG of filler metal for piping welding at Shop / under shed
2.0 (without back purging)
4.0 (with back purging)
Consumption of gas in CuM/KG of filler metal for piping welding at site/ open yard
3.0 (without back purging)
5.0 (with back purging)
Consumption of argon gas as per item code has been derived and enclosed as Annex-V
7.2.2 CO2 GAS CONSUMPTION NORMS: 1
Basis of calculation is : Practical data of CO2 gas consumption during FCAW at SFS. 1.5KG CO2 gas is consumed per KG FCAW electrode.
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
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Reliance 7.3 CUTTING GAS CONSUMPTION NORMS : 7.3.1 DISSOLVED ACETYLENE AND OXYGEN CONSUMPTION NORMS 7.3.1.1 Piping The basis for calculation considered are : Pipe Shop’s actual consumption Craft Training Centre’s experimental data A contractor’s site actual consumption 50 % added as wastage at sites . Requirement of dissolved acetylene and oxygen gases are not considered for stainless steels and LAS steels of 5 Cr - 0.5 Mo / 9 Cr – 1 Mo / 9 Cr – 1 Mo ( Modified Steel ) - Requirement of dissolved acetylene and oxygen gases are not considered for pipes and fittings supplied in machined condition. Items Consumption / Inch.Dia. Dissolved Acetylene (D.A.) 0.0140 Cu-M Oxygen (O2) 0.0510 Cu-M -
7.3.1.2 STRUCTURAL -
The basis for calculation considered are: Structural Fab. Shop’s actual consumption 50% excess to suit site conditions Items Consumption / MT Dissolved Acetylene (D.A.) 2.2 Cu-M Oxygen (O2) 8.0 Cu-M
7.3.1.3 SUPPORT FABRICATION AT SHOP Basis for calculation are: -Structural fabrication shop’s actual consumption Items Consumption / MT Dissolved Acetylene (D.A.) 3.5 Cu-M Oxygen (O2) 12 Cu-M
Note- Consumption of DA and Oxygen as per item code has been derived and enclosed as Annex-VI 7.3.2 LPG AND OXYGEN CONSUMPTION NORMS FOR CUTTING 7.3,2.1Piping The basis for calculation considered are : Contractor’s experimental data 50 % added as wastage at sites . Requirement of and oxygen gases are not considered for stainless steels and LAS steels of 5 Cr - 0.5 Mo / 9 Cr – 1 Mo / 9 Cr – 1 Mo ( Modified Steel ) - Requirement of LPG and oxygen gases are not considered for pipes and fittings supplied in machined condition. Items Consumption / Inch.Dia. LPG 0.02865 Kg Oxygen (O2) 0.1263 Cu-M (Note- i.e. Against per Kg LPG, 4.4Cu-M Oxygen shall be consumed) -
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
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Reliance 7.3.2.2 STRUCTURAL -
The basis for calculation considered are : Structural Fab. Shop’s actual consumption 50% excess to suit site conditions Items Consumption / MT LPG 3Kg Oxygen (O2) 13.2 Cu-M (Note- i.e. Against per Kg LPG, 4.4Cu-M Oxygen shall be consumed)
7.4. GRINDING WHEELS CONSUMPTION NORMS INCLUDING CUTTING WHEELS 7.4.1 PIPING The basis for calculation considered are : Pipe Shop’s actual consumption Craft Training Center’s experimental data A contractor’s site actual consumption 50 % added as wastage at sites . 100 % extra grinding wheels shall be considered for Stainless Steels / LAS Steels of 5 Cr – 0.5 Mo / 9 Cr – 1 Mo / 9 Cr – 1 Mo ( Modified Steel ) - 50% of the consumption shall be reduced in case of the pipes and fittings supplied in machined condition. Items Consumption / Inch. Dia. Grinding Wheel for fabrication 0.035 Numbers Grinding Wheel for joint grinding for UT 0.012 Numbers -
7.4.2 STRUCTURAL -
2 The basis for calculation considered are Structural Fab. Shop’s actual consumption Items Consumption / MT Grinding Wheel AG 7 (7"*7MM) 2.0 Numbers Grinding Wheel AG 5 (5"*5MM) 1.0 Numbers Cutting Wheel AG 7 (7"*7MM) 0.5 Numbers Cutting Wheel AG 5 (5"*5MM) 0.3 Numbers
7.4.3 SUPPORT FABRICATION AT SHOP Basis for calculation are: -Structural fabrication shop’s actual consumption Items Consumption / MT Grinding Wheel 2 Numbers Note- Consumption of Grinding wheels as per item code has been derived and enclosed as Annex-VI
8.
RECORDS Records of reconciliation statement shall be handed over to accounts department/QSD.
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
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Reliance 9.
1
ATTACHMENTS
ANNEX –I
Welding Consumable Estimation for Piping Work up to 22 mm
ANNEX-II
Welding Consumable Estimation for Piping Work above 22 mm
ANNEX-II(A): Welding consumable Estimation for Special Structure (Single Bevel T weld)
ANNEX-II(B): Welding consumable Estimation for Special Structure (Double Bevel T weld)
ANNEX-II(C):Welding consumable Estimation for Special Structure (Double V groove weld)
ANNEX-III
Welding Consumable Estimation for fillet Welding
ANNEX-IV
W.O. item code wise consumption for welding electrode & filler wire
ANNEX-V
W.O. item code wise consumption for argon gas
ANNEX-VI
W.O. item code wise consumption for Cutting gases and grinding wheels
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
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Reliance ANNEX – I : WELDING CONSUMABLE CONSUMPTION FOR PIPING WORK WITH SINGLE V GROOVE : INCLUDED ANGLE 75 DEGREES (WALL THICKNESS-UPTO 22MM ) 1 WALL THICKENSS (MM)
GROOVE AREA (SQ.MM)
WELD METAL WEIGHT gm/inch dia
ELECTRODE/FILLER WIRE CONSUMPTION (gm/inch dia) (root welding by E6010-consumption of E6010 will be 30 gm/inch dia) SINGLE
SINGLE
GTAW
SMAW
GTAW (root only)
COMBINATION SMAW
COMBINATION SMAW FCAW (root only)
COMBINATION GTAW FCAW (root only)
4
22
14
18
25
0
0
0
0
0
0
5
34
22
29
39
19
13
30
7
19
11
6
44
28
37
50
19
25
30
17
19
21
7
63
40
53
70
19
45
30
34
19
38
8
77
49
65
86
19
61
30
47
19
51
9
92
59
78
104
19
78
30
61
19
65
10
109
70
92
123
19
97
30
77
19
81
11
128
82
108
144
19
118
30
95
19
99
12
148
94
125
166
19
141
30
114
19
118
13
170
108
143
191
19
165
30
134
19
138
14
206
132
174
232
19
206
30
169
19
172
15
232
148
195
260
19
235
30
193
19
196
16
259
165
218
291
19
266
30
218
19
222
17
287
184
242
323
19
298
30
245
19
249
18
318
203
268
357
19
332
30
273
19
277
19
349
223
294
392
19
367
30
303
19
307
20
382
244
322
430
19
404
30
334
19
338
21
417
266
352
469
19
443
30
366
19
370
22
453
289
382
509
19
484
30
400
19
404
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
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Reliance ANNEX–II : WELDING CONSUMABLE CONSUMPTION FOR PIPING WORK (GROOVE JOINT : ABOVE 22MM WALL THICKNESS) CONSIDERING COMBINATION OF SITUATIONS50% OF WELD JOINT CONFIGURATION- SINGLE V (GROOVE ANGLE 75 DEGREE, PIPE TO PIPE JOINTS), BALANCE 50% JOINT CONFIGURATION COMPOUND V (UPTO 19MM THICK, INCLUDED ANGLE IS 75 DEGREE AND ABOVE 19MM, INCLUDED ANGLE IS 22.5 DEGREE- FITTING TO FITTING JOINTS) WALL THICKNESS (MM)
GROOVE AREA (SQ.MM)
WELD METAL WEIGHT gm/inch dia
SINGLE GTAW
ELECTRODE/FILLER WIRE CONSUMPTION (gm/inch dia) SINGLE SMAW
23
479
306
403
538
19
513
30
424
19
428
24
514
328
433
577
19
552
30
457
19
461
25
550
351
464
618
19
593
30
491
19
495
26
626
400
528
704
19
678
30
563
19
567
27
665
425
561
748
19
722
30
599
19
603
28
705
450
594
792
19
767
30
637
19
641
29
746
476
629
838
19
813
30
675
19
679
30
788
503
664
885
19
860
30
714
19
718
31
831
530
700
933
19
908
30
754
19
758
32
874
558
737
982
19
957
30
795
19
799
33
919
587
774
1033
19
1007
30
837
19
841
34
965
616
813
1084
19
1058
30
880
19
884
35
1011
645
852
1136
19
1111
30
924
19
928
36
1059
676
892
1189
19
1164
30
968
19
972
37
1107
707
933
1244
19
1218
30
1014
19
1018
38
1156
738
974
1299
19
1274
30
1060
19
1064
39
1207
770
1017
1356
19
1330
30
1107
19
1111
40
1258
803
1060
1413
19
1388
30
1155
19
1159
41
1310
836
1104
1472
19
1446
30
1204
19
1208
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
COMBINATION GTAW SMAW (root only)
COMBINATION SMAW FCAW (root only)
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COMBINATION GTAW FCAW (root only)
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Reliance ANNEX–II : WELDING CONSUMABLE CONSUMPTION FOR PIPING WORK (GROOVE JOINT : ABOVE 22MM WALL THICKNESS) WALL THICKNESS (MM)
GROOVE AREA (SQ.MM)
42
1363
43
WELD METAL WEIGHT gm/inch dia
ELECTRODE/FILLER WIRE CONSUMPTION (gm/inch dia) SINGLE
SINGLE
COMBINATION
COMBINATION
COMBINATION
GTAW
SMAW
GTAW (root only)
SMAW
SMAW (root only)
FCAW
GTAW (root only)
FCAW
870
1149
1532
19
1506
30
1254
19
1258
1417
905
1194
1592
19
1567
30
1305
19
1309
44
1472
940
1241
1654
19
1629
30
1356
19
1360
45
1528
976
1288
1717
19
1692
30
1409
19
1413
46
1585
1012
1336
1781
19
1756
30
1462
19
1466
47
1643
1049
1384
1846
19
1820
30
1517
19
1521
48
1702
1086
1434
1912
19
1887
30
1572
19
1576
49
1761
1124
1484
1979
19
1954
30
1628
19
1632
50
1822
1163
1535
2047
19
2022
30
1685
19
1689
51
1884
1202
1587
2116
19
2091
30
1743
19
1746
52
1946
1242
1640
2187
19
2161
30
1801
19
1805
53
2010
1283
1693
2258
19
2233
30
1861
19
1865
54
2074
1324
1748
2330
19
2305
30
1921
19
1925
55
2140
1366
1803
2404
19
2379
30
1983
19
1987
56
2206
1408
1859
2478
19
2453
30
2045
19
2049
57
2273
1451
1915
2554
19
2529
30
2108
19
2112
58
2341
1495
1973
2631
19
2605
30
2172
19
2176
59
2411
1539
2031
2708
19
2683
30
2237
19
2241
60
2481
1584
2090
2787
19
2762
30
2303
19
2307
61
2552
1629
2150
2867
19
2842
30
2369
19
2373
62
2624
1675
2211
2948
19
2922
30
2437
19
2441
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
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1
Reliance ANNEX–II : WELDING CONSUMABLE CONSUMPTION FOR PIPING WORK (GROOVE JOINT : ABOVE 22MM WALL THICKNESS) 1 WALL THICKNESS (MM)
GROOVE AREA (SQ.MM)
63
2697
64
WELD METAL WEIGHT gm/inch dia
ELECTRODE/FILLER WIRE CONSUMPTION (gm/inch dia) SINGLE
SINGLE
COMBINATION
COMBINATION
COMBINATION
GTAW
SMAW
GTAW (root only)
SMAW
SMAW (root only)
FCAW
GTAW (root only)
FCAW
1721
2272
3030
19
3004
30
2505
19
2509
2771
1769
2335
3113
19
3087
30
2575
19
2579
65
2845
1816
2398
3197
19
3171
30
2645
19
2649
66
2921
1865
2461
3282
19
3257
30
2716
19
2720
67
2998
1914
2526
3368
19
3343
30
2788
19
2792
68
3076
1963
2592
3455
19
3430
30
2861
19
2865
69
3154
2013
2658
3544
19
3518
30
2935
19
2939
70
3234
2064
2725
3633
19
3608
30
3009
19
3013
71
3314
2116
2793
3723
19
3698
30
3085
19
3089
72
3396
2168
2861
3815
19
3790
30
3161
19
3165
73
3478
2220
2931
3907
19
3882
30
3239
19
3242
74
3561
2273
3001
4001
19
3976
30
3317
19
3321
75
3646
2327
3072
4096
19
4070
30
3396
19
3400
76
3731
2382
3144
4191
19
4166
30
3476
19
3480
77
3817
2437
3216
4288
19
4263
30
3557
19
3561
78
3904
2492
3290
4386
19
4361
30
3638
19
3642
79
3992
2548
3364
4485
19
4460
30
3721
19
3725
80
4081
2605
3439
4585
19
4560
30
3804
19
3808
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
Page 14
of 44
Reliance ANNEX – II (A): WELDING CONSUMABLE CONSUMPTION FOR GROOVE WELDING OF SPECIAL STRUCTURES (EIC TO CERTIFY THAT THE SPECIFIED JOINT DESIGN IS USED AGAINST THE SPECIFIC JOB). JOINT CONFIGURATION- SINGLE BEVEL T WELD (BEVEL ANGLE 45 DEGREE) (REFER FIG. 2(A))
45 degree FIG. 2A Wall Thickness (mm)
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
Weld metal Weight (gm/RM of weld)
880 988 1104 1228 1360 1500 1648 1804 1968 2140 2320 2508 2704 2908 3120 3340 3568 3804 4048 4300 4560 4828 5104 5388 5680 5980 6288 6604 6928
Consumption of SMAW+FCAW Combination (gm/RM of weld) SMAW FCAW electrode electrode
317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
1028 1187 1358 1540 1734 1940 2157 2387 2628 2881 3145 3422 3710 4010 4321 4645 4980 5327 5685 6056 6438 6832 7238 7655 8084 8525 8978 9443 9919
Consumption of FCAW+SAW Combination (gm/RM of weld) FCAW electrode
SAW electrode
SAW Flux
265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265
924 1066 1219 1383 1557 1742 1937 2143 2360 2587 2824 3072 3331 3600 3880 4171 4472 4783 5105 5438 5781 6135 6499 6874 7260 7656 8062 8479 8907
1385 1599 1829 2074 2336 2613 2906 3215 3540 3880 4236 4609 4997 5401 5820 6256 6708 7175 7658 8157 8672 9202 9749 10311 10889 11483 12093 12719 13360
Page 15
Consumption of SMAW electrode (gm/RM of weld)
1549 1739 1943 2161 2394 2640 2900 3175 3464 3766 4083 4414 4759 5118 5491 5878 6280 6695 7124 7568 8026 8497 8983 9483 9997 10525 11067 11623 12193
of 44
1
Reliance ANNEX – II (A): WELDING CONSUMABLE CONSUMPTION FOR GROOVE WELDING OF SPECIAL STRUCTURES (SINGLE BEVEL T WELD) (CONTD) Wall Thickness (mm)
39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
Weld metal Weight (gm/RM of weld)
7260 7600 7948 8304 8668 9040 9420 9808 10204 10608 11020 11440 11868 12304 12748 13200 13660 14128 14604 15088 15580 16080 16588 17104 17628 18160 18700 19248 19804 20368 20940 21520 22108 22704 23308 23920 24540 25168 25804 26448 27100 27760
Consumption of SMAW+FCAW Combination (gm/RM of weld) SMAW FCAW electrode electrode
317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
10407 10907 11418 11942 12477 13024 13582 14153 14735 15329 15934 16552 17181 17822 18474 19139 19815 20503 21203 21914 22637 23372 24119 24878 25648 26430 27224 28029 28847 29676 30517 31369 32234 33110 33998 34897 35809 36732 37667 38613 39572 40542
Consumption of FCAW+SAW Combination (gm/RM of weld) FCAW electrode
SAW electrode
SAW Flux
265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265
9345 9794 10253 10723 11204 11695 12196 12708 13231 13764 14308 14863 15428 16003 16589 17186 17793 18411 19039 19678 20328 20988 21658 22339 23031 23733 24446 25169 25903 26648 27403 28168 28944 29731 30528 31336 32155 32984 33823 34673 35534 36405
14018 14691 15380 16085 16806 17542 18294 19063 19847 20647 21462 22294 23142 24005 24884 25779 26690 27616 28559 29517 30491 31481 32487 33509 34546 35600 36669 37754 38855 39972 41104 42252 43417 44597 45793 47004 48232 49476 50735 52010 53301 54608
Page 16
Consumption of SMAW electrode (gm/RM of weld)
12778 13376 13988 14615 15256 15910 16579 17262 17959 18670 19395 20134 20888 21655 22436 23232 24042 24865 25703 26555 27421 28301 29195 30103 31025 31962 32912 33876 34855 35848 36854 37875 38910 39959 41022 42099 43190 44296 45415 46548 47696 48858
of 44
1
Reliance ANNEX – II (B): WELDING CONSUMABLE CONSUMPTION FOR GROOVE WELDING OF SPECIAL STRUCTURES (EIC TO CERTIFY THAT THE SPECIFIED JOINT DESIGN WAS USED AGAINST THE SPECIFIC JOB).
1
JOINT CONFIGURATION- DOUBLE BEVEL T WELD (BEVEL ANGLE 45 DEGREE) (REFER FIG. 2(B))
45 degree 45 degree Fig. 2(B)
Thick ness (mm)
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
Weld metal Weight (gm/RM of weld
688 762 840 922 1008 1098 1192 1290 1392 1498 1608 1722 1840 1962 2088 2218 2352 2490 2632 2778 2928 3082 3240 3402 3568 3738 3912
SMAW+FCAW Combination (gm/RM of welding)
FCAW + SAW Combination (gm/RM of welding)
SMAW electrode
FCAW electrode
FCAW electrode
SAW electrode
SAW Flux
317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317
747 855 970 1090 1217 1349 1487 1631 1781 1937 2099 2266 2440 2619 2804 2995 3192 3395 3604 3819 4039 4265 4498 4736 4980 5230 5486
265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265
670 768 871 979 1092 1211 1335 1465 1599 1739 1884 2035 2191 2352 2518 2690 2867 3049 3236 3429 3627 3830 4039 4253 4472 4696 4926
1006 1152 1306 1468 1639 1817 2003 2197 2399 2609 2827 3052 3286 3528 3777 4035 4300 4573 4854 5143 5440 5745 6058 6379 6708 7044 7389
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
Consumption of SMAW Electrode (gm/RM of weld welding
1211 1341 1478 1623 1774 1932 2098 2270 2450 2636 2830 3031 3238 3453 3675 3904 4140 4382 4632 4889 5153 5424 5702 5988 6280 6579 6885
Page 17
of 44
Reliance ANNEX – II (B): WELDING CONSUMABLE CONSUMPTION FOR GROOVE WELDING OF SPECIAL STRUCTURES (DOUBLE BEVEL T WELD) (CONTD) Thick ness (mm)
37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
Weld metal Weight (gm/RM of weld
4090 4272 4458 4648 4842 5040 5242 5448 5658 5872 6090 6312 6538 6768 7002 7240 7482 7728 7978 8232 8490 8752 9018 9288 9562 9840 10122 10408 10698 10992 11290 11592 11898 12208 12522 12840 13162 13488 13818 14152 14490 14832 15178 15528
SMAW+FCAW Combination (gm/RM of welding)
FCAW + SAW Combination (gm/RM of welding)
SMAW electrode
FCAW electrode
FCAW electrode
SAW electrode
SAW Flux
317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317
5747 6015 6288 6567 6853 7144 7441 7743 8052 8367 8687 9014 9346 9684 10028 10378 10733 11095 11463 11836 12215 12600 12991 13388 13791 14200 14614 15035 15461 15893 16331 16775 17225 17681 18142 18610 19083 19562 20047 20538 21035 21538 22047 22561
265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265
5161 5401 5646 5897 6153 6415 6681 6953 7230 7513 7801 8094 8392 8696 9005 9319 9638 9963 10293 10628 10969 11315 11666 12022 12384 12751 13123 13500 13883 14271 14665 15063 15467 15876 16291 16711 17136 17566 18002 18443 18889 19340 19797 20259
7741 8101 8470 8846 9230 9622 10022 10430 10846 11269 11701 12141 12588 13044 13507 13978 14457 14944 15439 15942 16453 16972 17499 18033 18576 19126 19684 20251 20825 21407 21997 22595 23201 23815 24436 25066 25704 26349 27003 27664 28333 29010 29695 30388
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
Consumption of SMAW Electrode (gm/RM of weld welding
7198 7519 7846 8180 8522 8870 9226 9588 9958 10335 10718 11109 11507 11912 12324 12742 13168 13601 14041 14488 14942 15404 15872 16347 16829 17318 17815 18318 18828 19346 19870 20402 20940 21486 22039 22598 23165 23739 24320 24908 25502 26104 26713 27329
Page 18
of 44
1
Reliance ANNEX – II(C): WELDING CONSUMABLE CONSUMPTION FOR GROOVE WELDING OF SPECIAL STRUCTURES (EIC TO CERTIFY THAT THE SPECIFIED JOINT DESIGN IS USED AGAINST THE SPECIFIC JOB). JOINT CONFIGURATION- DOUBLE V GROOVE WELD (GROOVE ANGLE 75 DEGREE) (REFER FIG. 2. (C)) 75 degree FIG. 2 ( C)
75 degree Wall Thickness (mm)
Weld metal weight (gm/RM of weld)
Consumption of SMAW+FCAW Combination (gm/RM of weld)
Consumption of FCAW+SAW Combination (gm/RM of weld)
SMAW electrode
FCAW electrode
FCAW electrode
SAW electrode
SAW Flux
Consumpti on of SMAW Electrode (gm/RM of weld)
20
2159
317
2909
265
2612
3918
3800
21
2321
317
3147
265
2826
4239
4085
22
2489
317
3394
265
3048
4572
4381
23
2664
317
3650
265
3278
4917
4688
24
2844
317
3916
265
3516
5274
5006
25
3031
317
4190
265
3763
5644
5334
26
3223
317
4473
265
4017
6025
5673
27
3422
317
4766
265
4279
6419
6023
28
3627
317
5067
265
4550
6825
6384
29
3839
317
5377
265
4829
7243
6756
30
4056
317
5697
265
5116
7673
7138
31
4279
317
6025
265
5410
8116
7531
32
4509
317
6363
265
5714
8570
7935
33
4744
317
6709
265
6025
9037
8350
34
4986
317
7065
265
6344
9516
8776
35
5234
317
7429
265
6671
10007
9212
36
5488
317
7803
265
7007
10510
9660
37
5749
317
8185
265
7350
11025
10118
38
6015
317
8577
265
7702
11553
10586
39
6287
317
8977
265
8061
12092
11066
40
6566
317
9387
265
8429
12644
11556
41
6851
317
9806
265
8805
13208
12058
42
7142
317
10233
265
9189
13784
12570
43
7439
317
10670
265
9581
14372
13092
44
7742
317
11116
265
9981
14972
13626
45
8051
317
11570
265
10390
15585
14170
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
Page 19
of 44
1
Reliance ANNEX – II(C): WELDING CONSUMABLE CONSUMPTION FOR GROOVE WELDING OF SPECIAL STRUCTURES (DOUBLE V GROOVE WELD) (CONTD) Wall Thick ness (mm)
Weld metal weight (gm/RM of weld)
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
8367 8688 9016 9350 9690 10036 10388 10747 11111 11482 11859 12242 12631 13026 13428 13835 14249 14668 15094 15526 15965 16409 16859 17316 17779 18248 18723 19204 19691 20184 20684 21190 21701 22219 22743
Consumption of SMAW+FCAW Combination (gm/RM of weld) SMAW FCAW electrode electrode
317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317 317
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
12034 12507 12989 13479 13979 14488 15006 15533 16069 16614 17167 17730 18302 18883 19473 20072 20680 21298 21924 22559 23203 23856 24518 25189 25870 26559 27257 27964 28681 29406 30140 30884 31636 32397 33168
Consumption of FCAW+SAW Combination (gm/RM of weld)
1
FCAW electrode
SAW electrode
SAW Flux
Consumption of SMAW Electrode (gm/RM of weld)
265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265 265
10806 11231 11663 12104 12553 13010 13475 13948 14429 14918 15416 15921 16435 16957 17486 18024 18570 19124 19687 20257 20835 21422 22016 22619 23230 23849 24476 25111 25754 26405 27065 27732 28408 29091 29783
16209 16846 17495 18156 18829 19515 20212 20922 21643 22377 23124 23882 24652 25435 26229 27036 27855 28686 29530 30385 31253 32133 33024 33928 34845 35773 36714 37666 38631 39608 40597 41598 42612 43637 44675
14726 15292 15868 16456 17054 17664 18284 18915 19556 20209 20872 21546 22231 22926 23633 24350 25078 25817 26566 27327 28098 28880 29673 30476 31290 32116 32952 33798 34656 35524 36404 37294 38194 39106 40028
Page 20
of 44
Reliance ANNEX–III: WELDING CONSUMABLE CONSUMPTION FOR FILLET WELD Fillet size (mm)
Fillet area (mm2)
Weld metal wt (gm/RM)
1
Consumption of welding electrode/filler (gm/RM of weld) Single Single Combination Combination Combination SMAW (root only)
FCAW
GTAW (root only)
FCAW
SMAW
GTAW (root only)
SMAW
GTAW
2
8
64
84
113
0
0
0
0
0
0
3
13
100
132
176
0
0
0
0
0
0
4
18
144
190
253
132
77
176
65
132
65
5
25
196
259
345
132
169
176
141
132
141
6
32
256
338
451
132
275
176
229
132
229
7
41
324
428
570
132
394
176
329
132
329
8
50
400
528
704
132
528
176
441
132
441
9
61
484
639
852
132
676
176
564
132
564
10
72
576
760
1014
132
838
176
700
132
700
11
85
676
892
1190
132
1014
176
847
132
847
12
98
784
1035
1380
132
1204
176
1005
132
1005
13
113
900
1188
1584
132
1408
176
1176
132
1176
14
128
1024
1352
1802
132
1626
176
1358
132
1358
15
145
1156
1526
2035
132
1859
176
1552
132
1552
16
162
1296
1711
2281
132
2105
176
1758
132
1758
17
181
1444
1906
2541
132
2365
176
1976
132
1976
18
200
1600
2112
2816
132
2640
176
2205
132
2205
19
221
1764
2328
3105
132
2929
176
2446
132
2446
20
242
1936
2556
3407
132
3231
176
2699
132
2699
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
Page 21
of 44
Reliance ANNEX–III: WELDING CONSUMABLE CONSUMPTION FOR FILLET WELD 1 (contd) Fillet size (mm)
Fillet area (mm2)
Weld metal wt (gm/RM)
Consumption of welding electrode/filler (gm/RM of weld) Single Single Combination Combination Combination SMAW (root only)
FCAW
GTAW (root only)
FCAW
SMAW
GTAW (root only)
SMAW
GTAW
21
265
2116
2793
3724
132
3548
176
2964
132
2964
22
288
2304
3041
4055
132
3879
176
3240
132
3240
23
313
2500
3300
4400
132
4224
176
3528
132
3528
24
338
2704
3569
4759
132
4583
176
3828
132
3828
25
365
2916
3849
5132
132
4956
176
4140
132
4140
26
392
3136
4140
5519
132
5343
176
4463
132
4463
27
421
3364
4440
5921
132
5745
176
4798
132
4798
28
450
3600
4752
6336
132
6160
176
5145
132
5145
29
481
3844
5074
6765
132
6589
176
5504
132
5504
30
512
4096
5407
7209
132
7033
176
5874
132
5874
31
545
4356
5750
7667
132
7491
176
6256
132
6256
32
578
4624
6104
8138
132
7962
176
6650
132
6650
33
613
4900
6468
8624
132
8448
176
7056
132
7056
34
648
5184
6843
9124
132
8948
176
7473
132
7473
35
685
5476
7228
9638
132
9462
176
7903
132
7903
36
722
5776
7624
10166
132
9990
176
8344
132
8344
37
761
6084
8031
10708
132
10532
176
8796
132
8796
38
800
6400
8448
11264
132
11088
176
9261
132
9261
39
841
6724
8876
11834
132
11658
176
9737
132
9737
40
882
7056
9314
12419
132
12243
176
10225
132
10225
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
Page 22
of 44
Reliance ANNEX–III: WELDING CONSUMABLE CONSUMPTION FOR FILLET WELD (contd) 1 Fillet size (mm)
Fillet area (mm2)
Weld metal wt (gm/RM)
Consumption of welding electrode/filler (gm/RM of weld) Single Single Combination Combination Combination SMAW (root only)
FCAW
GTAW (root only)
FCAW
SMAW
GTAW (root only)
SMAW
GTAW
9763
13017
132
12841
176
10725
132
10725
41
925
7396
42
968
7744
10222 13629
132
13453
176
11237
132
11237
43
1013
8100
10692 14256
132
14080
176
11760
132
11760
44
1058
8464
11172 14897
132
14721
176
12295
132
12295
45
1105
8836
11664 15551
132
15375
176
12842
132
12842
46
1152
9216
12165 16220
132
16044
176
13401
132
13401
47
1201
9604
12677 16903
132
16727
176
13971
132
13971
48
1250
10000
13200 17600
132
17424
176
14553
132
14553
49
1301
10404
13733 18311
132
18135
176
15147
132
15147
50
1352
10816
14277 19036
132
18860
176
15753
132
15753
51
1405
11236
14832 19775
132
19599
176
16370
132
16370
52
1458
11664
15396 20529
132
20353
176
16999
132
16999
53
1513
12100
15972 21296
132
21120
176
17640
132
17640
54
1568
12544
16558 22077
132
21901
176
18293
132
18293
55
1625
12996
17155 22873
132
22697
176
18957
132
18957
56
1682
13456
17762 23683
132
23507
176
19633
132
19633
57
1741
13924
18380 24506
132
24330
176
20321
132
20321
58
1800
14400
19008 25344
132
25168
176
21021
132
21021
59
1861
14884
19647 26196
132
26020
176
21732
132
21732
60
1922
15376
20296 27062
132
26886
176
22456
132
22456
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
Page 23
of 44
Reliance ANNEX–III: WELDING CONSUMABLE CONSUMPTION FOR FILLET WELD (contd) Fillet size (mm)
Fillet area (mm2)
Weld metal wt (gm/RM)
Consumption of welding electrode/filler (gm/RM of weld) Single Single Combination Combination Combination GTAW
SMAW
GTAW (root only)
SMAW
SMAW (root only)
FCAW
GTAW (root only)
FCAW
61
1985
15876
20956 27942
132
27766
176
23191
132
23191
62
2048
16384
21627 28836
132
28660
176
23937
132
23937
63
2113
16900
22308 29744
132
29568
176
24696
132
24696
64
2178
17424
23000 30666
132
30490
176
25466
132
25466
65
2245
17956
23702 31603
132
31427
176
26248
132
26248
66
2312
18496
24415 32553
132
32377
176
27042
132
27042
67
2381
19044
25138 33517
132
33341
176
27848
132
27848
68
2450
19600
25872 34496
132
34320
176
28665
132
28665
69
2521
20164
26616 35489
132
35313
176
29494
132
29494
70
2592
20736
27372 36495
132
36319
176
30335
132
30335
71
2665
21316
28137 37516
132
37340
176
31188
132
31188
72
2738
21904
28913 38551
132
38375
176
32052
132
32052
73
2813
22500
29700 39600
132
39424
176
32928
132
32928
74
2888
23104
30497 40663
132
40487
176
33816
132
33816
75
2965
23716
31305 41740
132
41564
176
34716
132
34716
76
3042
24336
32124 42831
132
42655
176
35627
132
35627
77
3121
24964
32952 43937
132
43761
176
36550
132
36550
78
3200
25600
33792 45056
132
44880
176
37485
132
37485
79
3281
26244
34642 46189
132
46013
176
38432
132
38432
80
3362
26896
35503 47337
132
47161
176
39390
132
39390
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
Page 24
of 44
1
Reliance 1 Tungsten electrode consumption (EA/UOM) (Root GTAW)
FCAW
COMBINA TION
GTAW
FCAW
COMBINA TION
SMAW
SMAW
GTAW
SINGLE SMAW
COMBINA TION SINGLE GTAW
Weld metal wt gm/ UOM
UOM
ELECTRODE CONSUMPTION (gm/UOM.) DESCRIPTION OF JOB
Item Code
Tungsten electrode consumption (EA/UOM) (Full GTAW)
ANNEX- IV : Consumption Norms for Welding Electrode & Filler Wires
0.019 0.019 0.019 0.019 0.019
0.019
0.065 0.065 0.108 0.174
51 51 99 172
0.242
19 19
0.382
245 400
Page 25
of 44
249
30 30
EPCMD-2-QM00-JEP-ME-029 Rev. 02 Confidential @Reliance. All Rights reserved.
404
19 19 19
298 484
19
NA 47 95
19 19
169
NA 30 30
323 509
30
61 61 118
242 382
206
19 19 19
184 289
19
ID ID ID ID
ID
NA
19 mm
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