AIM: To weld build up over the reducer ID for proper matching with the connecting

CRA Cladded pipe.

Need of weld buildup: ID mismatch was observed during fit up stage of reducer

and CRA Cladded pipe. The root cause of the problem was identified that the

reducers were procured according the thickness of pipe without considering the

Cladded thickness. To solve this problem suggestion was made by L&T to put weld

overlay over the ID of the reducers and the methodology was approved by

COMPANY.

Methodology adopted: It was proposed to test a mock up piece according to the

Approved Method Statement. The COMPANY Approved method statement for weld

overlay is attached along with.

Execution stage of work: The various steps followed for the work execution are:-

1. A surplus eccentric reducer (IMIR No. 93/5) was identified for the actual

execution of the test.

2. COMPANY approved WPS was identified according to the requirements of the

job.

3. COMPANY approved welder (qualified into the required welding process i.e.

GTAW) was identified and d about the job to be done.

4. Marking was done before actual start and witnessed by GL & ADMA.

Marking on the reducer.

5. First run was overlaid and shown to GL & COMPANY.

First run overlaid.

6. In the same manner with subsequent runs one layer was completed and

witnessed by GL & ADMA.

First layer Completed

7. On completion of first layer DP test was carried out in presence of GL & ADMA.

Result of DP was found OK. Report attached

DP testing being carried out

8. After DP and Cleaning Second layer was overlaid in the same manner and DP

was carried out. Result of the testing was found OK. Report attached

Second layer completed & DP being carried out.

9. Then the test piece was offered for RT. RT film was witnessed by GL and found

OK. See report attached.

RT marking shown on the test piece.

10. After successful completion of RT the test piece was sent for machining.

Machining of the reducer was a great hurdle for which Mr. J K Das (Machine

shop foremen) found out a solution and a casing was made as shown in figure.

Reducer & the casing made for machining

In this casing any type of reducer (Concentric/Eccentric) can be easily fixed and

machined which reduces the job set up time as well. SS bolts were used and

packing of SS sheets was used for tightening the reducer into the casing.

11. Machining was done by putting the reducer into the casing.

Reducer fitted into casing Machining in progress

12. After machining all the length, thickness, ID, OD was checked and found

within the limits.

13. Final product after machining is as shown under.

14. After final machining a trial fit up was shown to COMPANY and found OK.