Reliance

PROCEDURE

FOR

RECONCILIATION OF WELDING CONSUMABLE

AND

ASSOCIATED CONSUMABLE FOR PIPING AND

STRUCTURE

EPCMD-2-QM00-JEP-ME-029

TD/KB/MS
03 18.07.15 Field feedback incorporated SRB N/NB/CLJ SNS
/GJR
Field feedback incorporated, and
02 28.10.14 SRB TD SNS
issued for review
Field feedback incorporated,
01 01.02.13 SAPcodes added and issued for SRB TD SNS
implementation
00 05.07.12 Issued for implementation TD EMK/KSS SNS
Rev.
Date Description By Chkd. Appd.
No.

Hard copy of this procedure shall be treated as uncontrolled if not signed by approver Total pages - 24
Reliance

CONTENTS 3

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 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

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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

• 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.

4. RESPONSIBILITY AND AUTHORITY 1

SL ACTIVITY RESPONSIBILITY&
AUTHORITY
01 Enclosing this document as a part of Work Order HOD-Contract Department
02 Submission of consumption statement with final Contractor
Bill.
03 Verification and Certification of Quantity Construction Manager/EIC
04 Verification & Certification of consumption of Construction Manager/ EIC/
welding consumable and reconciliation based on Discipline engineer
the certified scope.
05 Verification & Certification of consumption and Construction Manager/EIC
reconciliation of other associated consumable
(Gas, Grinding Wheel)
06 Final Reconciliation & Certification of Bill Construction Manager/EIC
07 Maintenance of procedure HOD-QMD

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5. REFERENCE DOCUMENTS
-ASME B31.3 Process piping
1
-ASME B31.1-Power piping

6. PROCEDURE
6.1 WELDING ELECTRODES/FILLER WIRES/FLUX
- 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.

6.2 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) 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.

(C ) 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.

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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) 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,
1 - 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.

(B) 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
1 - 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,
1 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.

- For root pass welding (groove) in SMAW process (for structural fab),
consumption of electrode is considered as 317gm/RM of weld length.

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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
1 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.

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.

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7.1.2 FOR STRUCTURAL

a) Based on Weight %
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.
Consumption of gas in Cu-
Consumption of gas in Cu-M
M/KG of filler metal for
Materials /KG of filler metal for piping
piping welding at site/
welding at Shop / under shed
open yard
Carbon Steels, Low
& Alloy Steels %Cr
2.0 (without back purging)
less than or equal 3.0 (without back purging)
to 3
Stainless Steel,
Low Alloy Steels
%Cr more than 3 4.0 (with back purging) 5.0 (with back purging)
& Non ferrous
metal
Consumption of argon gas as per item code has been derived and enclosed as
Annex-V

7.2.2 CO2 GAS CONSUMPTION NORMS:

Basis of calculation is :
Practical data of CO2 gas consumption during FCAW at SFS.
1 1.5KG CO2 gas is consumed per KG FCAW electrode.

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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)

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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. CUTTING AND GRINDING WHEEL CONSUMPTION NORMS:

7.4.1 FOR PIPING FAB/WELDING AT SHOP/SHED/FIELD/YARD: 3
Following norms are derived from field data for cutting & grinding wheels considering
average thickness 12mm. Depending on thickness, consumption shall vary
proportionally.

MOC Whether Consumption Remarks

UT Joint (EA)/ Inch Dia
CS, LAS of 1.25Cr-0.5Mo & No 0.042 Including 20%
2.25Cr-1Mo type wastage
CS, LAS of 1.25Cr-0.5Mo & Yes 0.0564 Including 20%
2.25Cr-1Mo type wastage. Additional
grinding for UT joints
is considered.
LAS of 5Cr-0.5Mo, 9Cr-1Mo No 0.084 Including 20%
and 9Cr-1Mo-V type, Stainless wastage
steels
LAS of 5Cr-0.5Mo, 9Cr-1Mo Yes 0.1128 Including 20%
and 9Cr-1Mo-V type, Stainless wastage. Additional
steels grinding for UT joints
is considered.

Note-Depending on specific field situation where additional grinding is warranted, EIC

may consider on case to case basis and certify up to 20% additional consumption.

7.4.2 STRUCTURAL
The basis for calculation considered are 2
- 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

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7.4.4 CONSUMPTION OF CORE CUTTER (FOR STRUCTURE):

3
Based on data received from structural fab shop, following norms are derived:

(i)For 16-20mm thickness, 350 holes can be made with one HSS cutter.

(ii)For 16-20mm thickness, 525 holes can be made with one carbide tip cutter.

Notes: As the thickness increases, number of holes per cutter shall be proportionally
decreased.

8. RECORDS
Records of reconciliation statement shall be handed over to accounts department/QSD.

9. ATTACHMENTS 3
• 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)

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ANNEX – I : WELDING CONSUMABLE CONSUMPTION FOR PIPING WORK

WITH SINGLE V GROOVE : INCLUDED ANGLE 75 DEGREES (WALL
THICKNESS-UPTO 22MM ) 1

WALL GROOVE WELD ELECTRODE/FILLER WIRE CONSUMPTION (gm/inch dia) (root welding by
THICKE- AREA METAL E6010-consumption of E6010 will be 30 gm/inch dia)
NSS (SQ.MM) WEIGHT
(MM) gm/inch SINGLE SINGLE COMBINATION
dia COMBINATION COMBINATION
GTAW SMAW GTAW SMAW SMAW FCAW GTAW FCAW
(root (root (root
only) only) 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

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ANNEX–II : WELDING CONSUMABLE CONSUMPTION FOR PIPING WORK

(GROOVE JOINT : ABOVE 22MM WALL THICKNESS)
CONSIDERING COMBINATION OF SITUATIONS- 50% 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 GROOVE WELD ELECTRODE/FILLER WIRE CONSUMPTION (gm/inch dia)

THICK- AREA METAL SINGLE SINGLE COMBINATION COMBINATION COMBINATION
NESS (SQ.MM) WEIGHT
GTAW SMAW GTAW SMAW SMAW FCAW GTAW FCAW
(MM) gm/inch
(root (root (root
dia
only) only) only)
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

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ANNEX–II : WELDING CONSUMABLE CONSUMPTION FOR PIPING WORK

(GROOVE JOINT : ABOVE 22MM WALL THICKNESS) 1
WALL GROOVE WELD ELECTRODE/FILLER WIRE CONSUMPTION (gm/inch dia)
THICK- AREA METAL SINGLE SINGLE COMBINATION COMBINATION COMBINATION
NESS (SQ.MM) WEIGHT
(MM) gm/inch
dia GTAW SMAW GTAW SMAW SMAW FCAW GTAW FCAW
(root (root (root
only) only) only)
42 1363 870 1149 1532 19 1506 30 1254 19 1258

43 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

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ANNEX–II : WELDING CONSUMABLE CONSUMPTION FOR PIPING WORK

(GROOVE JOINT : ABOVE 22MM WALL THICKNESS) 1

WALL GROOVE WELD ELECTRODE/FILLER WIRE CONSUMPTION (gm/inch dia)

THICK- AREA METAL SINGLE SINGLE COMBINATION COMBINATION COMBINATION
NESS (SQ.MM) WEIGHT
(MM) gm/inch
dia GTAW SMAW GTAW SMAW SMAW FCAW GTAW FCAW
(root (root (root
only) only) only)
63 2697 1721 2272 3030 19 3004 30 2505 19 2509

64 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

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ANNEX – II (A): WELDING CONSUMABLE CONSUMPTION FOR GROOVE

WELDING OF SPECIAL STRUCTURES (EIC TO CERTIFY THAT THE SPECIFIED 1
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 Weld Consumption of Consumption of FCAW+SAW Consumption

Thickness metal SMAW+FCAW Combination (gm/RM of weld) of SMAW
(mm) Weight Combination (gm/RM of electrode
(gm/RM weld) (gm/RM of
of weld) SMAW FCAW FCAW SAW SAW weld)
electrode electrode electrode electrode Flux
10 880 317 1028 265 924 1385 1549
11 988 317 1187 265 1066 1599 1739
12 1104 317 1358 265 1219 1829 1943
13 1228 317 1540 265 1383 2074 2161
14 1360 317 1734 265 1557 2336 2394
15 1500 317 1940 265 1742 2613 2640
16 1648 317 2157 265 1937 2906 2900
17 1804 317 2387 265 2143 3215 3175
18 1968 317 2628 265 2360 3540 3464
19 2140 317 2881 265 2587 3880 3766
20 2320 317 3145 265 2824 4236 4083
21 2508 317 3422 265 3072 4609 4414
22 2704 317 3710 265 3331 4997 4759
23 2908 317 4010 265 3600 5401 5118
24 3120 317 4321 265 3880 5820 5491
25 3340 317 4645 265 4171 6256 5878
26 3568 317 4980 265 4472 6708 6280
27 3804 317 5327 265 4783 7175 6695
28 4048 317 5685 265 5105 7658 7124
29 4300 317 6056 265 5438 8157 7568
30 4560 317 6438 265 5781 8672 8026
31 4828 317 6832 265 6135 9202 8497
32 5104 317 7238 265 6499 9749 8983
33 5388 317 7655 265 6874 10311 9483
34 5680 317 8084 265 7260 10889 9997
35 5980 317 8525 265 7656 11483 10525
36 6288 317 8978 265 8062 12093 11067
37 6604 317 9443 265 8479 12719 11623
38 6928 317 9919 265 8907 13360 12193

EPCMD-2-QM00-JEP-ME-029 Rev.03 Page 15 of 24

Confidential @Reliance. All Rights reserved.
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ANNEX – II (A): WELDING CONSUMABLE CONSUMPTION FOR GROOVE

WELDING OF SPECIAL STRUCTURES (SINGLE BEVEL T WELD) (CONTD)
1
Wall Weld Consumption of Consumption of FCAW+SAW Consumption
Thickness metal SMAW+FCAW Combination (gm/RM of weld) of SMAW
(mm) Weight Combination (gm/RM of electrode
(gm/RM weld) (gm/RM of
of weld) SMAW FCAW FCAW SAW SAW weld)
electrode electrode electrode electrode Flux
39 7260 317 10407 265 9345 14018 12778
40 7600 317 10907 265 9794 14691 13376
41 7948 317 11418 265 10253 15380 13988
42 8304 317 11942 265 10723 16085 14615
43 8668 317 12477 265 11204 16806 15256
44 9040 317 13024 265 11695 17542 15910
45 9420 317 13582 265 12196 18294 16579
46 9808 317 14153 265 12708 19063 17262
47 10204 317 14735 265 13231 19847 17959
48 10608 317 15329 265 13764 20647 18670
49 11020 317 15934 265 14308 21462 19395
50 11440 317 16552 265 14863 22294 20134
51 11868 317 17181 265 15428 23142 20888
52 12304 317 17822 265 16003 24005 21655
53 12748 317 18474 265 16589 24884 22436
54 13200 317 19139 265 17186 25779 23232
55 13660 317 19815 265 17793 26690 24042
56 14128 317 20503 265 18411 27616 24865
57 14604 317 21203 265 19039 28559 25703
58 15088 317 21914 265 19678 29517 26555
59 15580 317 22637 265 20328 30491 27421
60 16080 317 23372 265 20988 31481 28301
61 16588 317 24119 265 21658 32487 29195
62 17104 317 24878 265 22339 33509 30103
63 17628 317 25648 265 23031 34546 31025
64 18160 317 26430 265 23733 35600 31962
65 18700 317 27224 265 24446 36669 32912
66 19248 317 28029 265 25169 37754 33876
67 19804 317 28847 265 25903 38855 34855
68 20368 317 29676 265 26648 39972 35848
69 20940 317 30517 265 27403 41104 36854
70 21520 317 31369 265 28168 42252 37875
71 22108 317 32234 265 28944 43417 38910
72 22704 317 33110 265 29731 44597 39959
73 23308 317 33998 265 30528 45793 41022
74 23920 317 34897 265 31336 47004 42099
75 24540 317 35809 265 32155 48232 43190
76 25168 317 36732 265 32984 49476 44296
77 25804 317 37667 265 33823 50735 45415
78 26448 317 38613 265 34673 52010 46548
79 27100 317 39572 265 35534 53301 47696
80 27760 317 40542 265 36405 54608 48858

EPCMD-2-QM00-JEP-ME-029 Rev.03 Page 16 of 24

Confidential @Reliance. All Rights reserved.
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ANNEX – II (B): WELDING CONSUMABLE CONSUMPTION FOR

GROOVE WELDING OF SPECIAL STRUCTURES (EIC TO CERTIFY THAT 1
THE SPECIFIED JOINT DESIGN WAS USED AGAINST THE SPECIFIC JOB).
JOINT CONFIGURATION- DOUBLE BEVEL T WELD (BEVEL ANGLE 45 DEGREE) (REFER
FIG. 2(B))

45 degree
45 degree

Fig. 2(B)

Thick Weld metal SMAW+FCAW FCAW + SAW Combination Consumption of

ness Weight Combination (gm/RM of welding) SMAW Electrode
(mm) (gm/RM of (gm/RM of welding) (gm/RM of weld
weld welding
SMAW FCAW FCAW SAW SAW
electrode electrode electrode electrode Flux
10 688 317 747 265 670 1006 1211
11 762 317 855 265 768 1152 1341
12 840 317 970 265 871 1306 1478
13 922 317 1090 265 979 1468 1623
14 1008 317 1217 265 1092 1639 1774
15 1098 317 1349 265 1211 1817 1932
16 1192 317 1487 265 1335 2003 2098
17 1290 317 1631 265 1465 2197 2270
18 1392 317 1781 265 1599 2399 2450
19 1498 317 1937 265 1739 2609 2636
20 1608 317 2099 265 1884 2827 2830
21 1722 317 2266 265 2035 3052 3031
22 1840 317 2440 265 2191 3286 3238
23 1962 317 2619 265 2352 3528 3453
24 2088 317 2804 265 2518 3777 3675
25 2218 317 2995 265 2690 4035 3904
26 2352 317 3192 265 2867 4300 4140
27 2490 317 3395 265 3049 4573 4382
28 2632 317 3604 265 3236 4854 4632
29 2778 317 3819 265 3429 5143 4889
30 2928 317 4039 265 3627 5440 5153
31 3082 317 4265 265 3830 5745 5424
32 3240 317 4498 265 4039 6058 5702
33 3402 317 4736 265 4253 6379 5988
34 3568 317 4980 265 4472 6708 6280
35 3738 317 5230 265 4696 7044 6579
36 3912 317 5486 265 4926 7389 6885

EPCMD-2-QM00-JEP-ME-029 Rev.03 Page 17 of 24

Confidential @Reliance. All Rights reserved.
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ANNEX – II (B): WELDING CONSUMABLE CONSUMPTION FOR GROOVE

WELDING OF SPECIAL STRUCTURES (DOUBLE BEVEL T WELD) (CONTD) 1
Thick Weld metal SMAW+FCAW FCAW + SAW Combination Consumption of
ness Weight Combination (gm/RM of welding) SMAW Electrode
(mm) (gm/RM of (gm/RM of welding) (gm/RM of weld
weld SMAW FCAW FCAW SAW SAW welding
electrode electrode electrode electrode Flux
37 4090 317 5747 265 5161 7741 7198
38 4272 317 6015 265 5401 8101 7519
39 4458 317 6288 265 5646 8470 7846
40 4648 317 6567 265 5897 8846 8180
41 4842 317 6853 265 6153 9230 8522
42 5040 317 7144 265 6415 9622 8870
43 5242 317 7441 265 6681 10022 9226
44 5448 317 7743 265 6953 10430 9588
45 5658 317 8052 265 7230 10846 9958
46 5872 317 8367 265 7513 11269 10335
47 6090 317 8687 265 7801 11701 10718
48 6312 317 9014 265 8094 12141 11109
49 6538 317 9346 265 8392 12588 11507
50 6768 317 9684 265 8696 13044 11912
51 7002 317 10028 265 9005 13507 12324
52 7240 317 10378 265 9319 13978 12742
53 7482 317 10733 265 9638 14457 13168
54 7728 317 11095 265 9963 14944 13601
55 7978 317 11463 265 10293 15439 14041
56 8232 317 11836 265 10628 15942 14488
57 8490 317 12215 265 10969 16453 14942
58 8752 317 12600 265 11315 16972 15404
59 9018 317 12991 265 11666 17499 15872
60 9288 317 13388 265 12022 18033 16347
61 9562 317 13791 265 12384 18576 16829
62 9840 317 14200 265 12751 19126 17318
63 10122 317 14614 265 13123 19684 17815
64 10408 317 15035 265 13500 20251 18318
65 10698 317 15461 265 13883 20825 18828
66 10992 317 15893 265 14271 21407 19346
67 11290 317 16331 265 14665 21997 19870
68 11592 317 16775 265 15063 22595 20402
69 11898 317 17225 265 15467 23201 20940
70 12208 317 17681 265 15876 23815 21486
71 12522 317 18142 265 16291 24436 22039
72 12840 317 18610 265 16711 25066 22598
73 13162 317 19083 265 17136 25704 23165
74 13488 317 19562 265 17566 26349 23739
75 13818 317 20047 265 18002 27003 24320
76 14152 317 20538 265 18443 27664 24908
77 14490 317 21035 265 18889 28333 25502
78 14832 317 21538 265 19340 29010 26104
79 15178 317 22047 265 19797 29695 26713
80 15528 317 22561 265 20259 30388 27329

EPCMD-2-QM00-JEP-ME-029 Rev.03 Page 18 of 24

Confidential @Reliance. All Rights reserved.
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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) 1
(REFER FIG. 2. (C))

75 degree

FIG. 2 ( C)

75 degree

Wall Weld Consumption of Consumption of FCAW+SAW Consumpti

Thickness metal SMAW+FCAW Combination (gm/RM of weld) on of
(mm) weight Combination (gm/RM of SMAW
(gm/RM weld) Electrode
of weld) (gm/RM of
SMAW FCAW FCAW SAW SAW
weld)
electrode electrode electrode electrode Flux

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.03 Page 19 of 24

Confidential @Reliance. All Rights reserved.
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ANNEX – II(C): WELDING CONSUMABLE CONSUMPTION FOR GROOVE

1
WELDING OF SPECIAL STRUCTURES (DOUBLE V GROOVE WELD) (CONTD)

Wall Weld metal Consumption of Consumption of FCAW+SAW Consumption

Thick weight SMAW+FCAW Combination Combination (gm/RM of weld) of SMAW
ness (gm/RM of (gm/RM of weld) Electrode
(mm) weld) SMAW FCAW FCAW SAW SAW (gm/RM of
electrode electrode electrode electrode Flux weld)

46 8367 317 12034 265 10806 16209 14726

47 8688 317 12507 265 11231 16846 15292
48 9016 317 12989 265 11663 17495 15868
49 9350 317 13479 265 12104 18156 16456
50 9690 317 13979 265 12553 18829 17054
51 10036 317 14488 265 13010 19515 17664
52 10388 317 15006 265 13475 20212 18284
53 10747 317 15533 265 13948 20922 18915
54 11111 317 16069 265 14429 21643 19556
55 11482 317 16614 265 14918 22377 20209
56 11859 317 17167 265 15416 23124 20872
57 12242 317 17730 265 15921 23882 21546
58 12631 317 18302 265 16435 24652 22231
59 13026 317 18883 265 16957 25435 22926
60 13428 317 19473 265 17486 26229 23633
61 13835 317 20072 265 18024 27036 24350
62 14249 317 20680 265 18570 27855 25078
63 14668 317 21298 265 19124 28686 25817
64 15094 317 21924 265 19687 29530 26566
65 15526 317 22559 265 20257 30385 27327
66 15965 317 23203 265 20835 31253 28098
67 16409 317 23856 265 21422 32133 28880
68 16859 317 24518 265 22016 33024 29673
69 17316 317 25189 265 22619 33928 30476
70 17779 317 25870 265 23230 34845 31290
71 18248 317 26559 265 23849 35773 32116
72 18723 317 27257 265 24476 36714 32952
73 19204 317 27964 265 25111 37666 33798
74 19691 317 28681 265 25754 38631 34656
75 20184 317 29406 265 26405 39608 35524
76 20684 317 30140 265 27065 40597 36404
77 21190 317 30884 265 27732 41598 37294
78 21701 317 31636 265 28408 42612 38194
79 22219 317 32397 265 29091 43637 39106
80 22743 317 33168 265 29783 44675 40028

EPCMD-2-QM00-JEP-ME-029 Rev.03 Page 20 of 24

Confidential @Reliance. All Rights reserved.
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ANNEX–III: WELDING CONSUMABLE CONSUMPTION FOR FILLET WELD 1

Fillet Fillet Weld Consumption of welding electrode/filler (gm/RM of weld)

size area metal wt Single Single Combination Combination Combination
(mm) (mm2) (gm/RM)
GTAW SMAW SMAW FCAW GTAW FCAW
GTAW SMAW (root (root (root
only) only) only)
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.03 Page 21 of 24

Confidential @Reliance. All Rights reserved.
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ANNEX–III: WELDING CONSUMABLE CONSUMPTION FOR FILLET WELD

(contd) 1

Fillet Fillet Weld Consumption of welding electrode/filler (gm/RM of weld)

size area metal wt Single Single Combination Combination Combination
(mm) (mm2) (gm/RM)
GTAW SMAW SMAW FCAW GTAW FCAW
GTAW SMAW (root (root (root
only) only) only)
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.03 Page 22 of 24

Confidential @Reliance. All Rights reserved.
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ANNEX–III: WELDING CONSUMABLE CONSUMPTION FOR FILLET WELD

(contd) 1

Fillet Fillet Weld Consumption of welding electrode/filler (gm/RM of weld)

size area metal wt Single Single Combination Combination Combination
(mm) (mm2) (gm/RM)
GTAW SMAW SMAW FCAW GTAW FCAW
GTAW SMAW (root (root (root
only) only) only)
41 925 7396 9763 13017 132 12841 176 10725 132 10725

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.03 Page 23 of 24

Confidential @Reliance. All Rights reserved.
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ANNEX–III: WELDING CONSUMABLE CONSUMPTION FOR FILLET WELD

(contd) 1

Fillet Fillet Weld Consumption of welding electrode/filler (gm/RM of weld)

size area metal wt Single Single Combination Combination Combination
(mm) (mm2) (gm/RM)
GTAW SMAW SMAW FCAW GTAW FCAW
GTAW SMAW (root (root (root
only) only) only)
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.03 Page 24 of 24

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