Run-in and Run-out Plate, and proper Earthing

Recommendation for good Quality in Fabrication /welding

Material:
Material selection should be strictly as per the
service requirements only. If possible use a
material with low Carbon and high ductility, for
easy forming/ Rolling and crack free welding.
(High Carbon requires special welding
techniques including pre- heating of plates
before welding to avoid cracking of weld and
plate during welding and after completion of
welding.

 Members Design

For LDO tank- instead of stiffener/

insulation ring made from Angle,- use of
rolled flat (double flat with welded spacers)
may be a better choice from the point of
easy fabrication, low cost better stability
and appearance.
Cross weld joints should be avoided to
avoid cracking, due to stress concentration

 Saddle plate- pad should be at least 120 deg in

circumference for avoiding any distortion and
providing sufficient support to the tank. as per the
good engineering practice.
Horizontal support plate should be at least 8 mm
outside from the vertical support pads for both
sides welding as per the required size and to avoid
burning of edges.
All pads welded on shell should have a 6 mm Dia
hole for escape of hot gases during welding and
operation, otherwise it may cause cracking of
welds between pad and shell.

 Designer should specify

required weld size in
Drawing itself, so that
welding supervisor and
welders can check the
weld size during welding

 Marking and cutting of plates and

other members.
Plates should be cut length wise to keep rolling direction in
favorable fiber direction of plate to avoid cracking.
Edge preparation in plate, for welding, should be made at the
time of gas cutting of plates -to avoid extra time and Labour
for making edge preparation afterwards. This wills also help in
getting the required edge preparation of defect free welding.

 Rolling and Shaping of

members
Desired shape should be obtained by
proper rolling and by other means to
avoid any extra efforts during fit up and
avoiding undesirable stresses in the
member which can cause cracking of
material

 Fit up of members
Edge preparation of members should be done
before

set up of members
Proper groove angle, root face and root gap, as
mentioned by the design department should be
made to get full penetration, full fusion and crack
free weld joint.
Cleaning of plates or other members, which are to
be welded, should be fully cleaned -at least 2
inches, on both side of weld joint.

 Minimum possible number of cleats and tacks should be used to

make setup.
Tacks size should be at least 1 inch in length.
If pre- heating is required ,as per the qualified WPS, it should be
done, even for tacking of plates.
Only Qualified welder should tack the plates as per the required
welding electrodes.
After tacking tacks should be ground smooth and checked for any
porosity/ crack. If there is any crack/porosity it should be removed
before carrying out before any subsequent welding operation. If
possible DP Test should be carried out on tacks welds.
Proper stiffeners/spiders should be provided to avoid any ovality
after welding

 Welding
welding should be done only by qualified welders as peer the qualified WPS
(Welding Procedure Specification)
Low hydrogen electrode (E 7018) should be baked at 300deg C for 1 hour and
then maintained in oven a t 100 deg C(or as per the recommendation of
electrode manufacturer) .
In shop floor electrode should be carried, only in carry oven in which
temperature is maintained 70 deg C ,by electrical heating
Welding Cables length should be as small as possible,

To avoid electricity wastage and better welding.

Welding machine should be kept as near as possible

From the job. to avoid current loss.

 Earthling of the job should be made directly to the

job which is to be welded,for avoiding any damage
by sparking and obtaining good quality welds.
Insulated electrode holder should be used, to avoid
sparking.
Pre heating of the material, at least 6 inch on both
sides of weld joints should be done, if required as
per the qualified weld procedure.

 After first side welding ,back grooving of the weld

joint should be done to remove the oxidized and
defective weld metals. If possible, DP test should
be carried out to ensure full penetration and fusion.
Proper welding techniques should be used to
minimize undercutting, spatters, under filling and
excessive reinforcement.
Removal of cleats by grinding and then hammering
to avoid damage of base material

 Surface
preparation of
before painting
All spatters notches should
be removed /prepared before
shot blasting before painting

 7.0 GENERAL RECOMMENDATION

7.1 Electrode should be stored only in original packing; if packet
is open it should be re-packed.
7.2 After welding no hammering should be done to avoid tracking.
7.3. All plates should be 100% clean before welding. no moisture
should be present to avoid hydrogen cracking. (Delayed
cracking)
7.4. In all material Carbon and sulphur should be checked before
cutting of the plates as high carbon and sulphur can cause
cracking of weld.

Defect removal