PROCEDURE

FOR

RECONCILIATION OF WELDING CONSUMABLE

AND

ASSOCIATED CONSUMABLE FOR PIPING AND

STRUCTURE

Note:- This Procedure provides general information. This procedure for a project shall be valid
only when reviewed and modified as per specific project requirements and approved by authorized
person.
02 15/03/2006 Revised as per comments TD/SNS AJV HDP
Revised as per comments received and reissued for
01 16/08/2004 implementation TD/SNS AJV HDP

00 20/03/2002 Issued for implementation TD AJV SCG

Rev.
Date Description By Chkd. Appd.
No.
Department/
RELIANCE Division Quality Management
ENGINEERING ASSOCIATES (P) LIMITED Location: Jamnagar
Job Number Document No

2 Q M 0 0 J E P M E 0 2 9

Hard copy of this procedure shall be treated as uncontrolled if not signed by approver Total pages - 21
 R ELIANCE ENGINEERING ASSOCIATES (P) LIMITED

CONTENTS
1. INTRODUCTION

2. PURPOSE

3. SCOPE

4. ABBREVIATIONS AND DEFINITIONS

5. RESPONSIBILITY AND AUTHORITY

6. REFERENCE DOCUMENTS

7. FLOWCHART

8. PROCEDURE

9. NORMS

10. RECORD

11. ATTACHMENTS

? ANNEXTURE –I Welding Consumable Estimation for Piping Work upto 22 mm

? ANNEXTURE-II Welding Consumable Estimation for Piping Work above 22 mm

? ANNEXTURE-III Welding Consumable Estimation for fillet Welding

? ANNEXTURE-IV W.O. item code wise consumption for welding electrode & filler wire

? ANNEXTURE-V W.O. item code wise consumption for argon gas

? ANNEXTURE-VI W.O. item code wise consumption for Cutting gases and grinding wheels

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and associated items for piping and structure
Doc. No.: 2QM00JEPME029 Rev.02 Date 15/03/2006
Jamnagar
 R ELIANCE ENGINEERING ASSOCIATES (P) LIMITED

1. INTRODUCTION
1
Depending on contract conditions, welding consumable and other associated consumable are
being issued free of cost to many a contractors. In order to reconcile the items, one standard
reconciliation norm of the company becomes necessary to avoid individual approach.

2. PURPOSE 1
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.

3. SCOPE 1
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, dissolved acetylene, oxygen and grinding wheels are also covered
under the present scope under associated consumable part.
The scope of this procedure is applicable only to all concerned working in REAL, Jamnagar
Complex, wherever Welding & Associated consumable are issued as free issue items.

4. ABBREVIATIONS AND DEFINITIONS 1

- Associated Consumable- Argon gas, dissolved acetylene, oxygen and grinding wheels
- Welding consumable-Welding consumable cover welding electrodes (including Tungsten
electrode), filler wire, flux used in GTAW, SMAW, FCAW and SAW processes.
- SMAW-Shielded Metal Arc Welding
- MMAW-Manual Metal Arc Welding
- GTAW-Gas Tungsten Arc Welding
- TIG-Tungsten Inert Gas (Arc) Welding
- GMAW-Gas Metal Arc Welding
- FCAW-Flux Cored Arc Welding
- SAW-Submerged Arc Welding
- QMD- Quality Management Department
- QSD- Quantity Survey Department
- HOD- Head of Department

5. RESPONSIBILITY AND AUTHORITY 1

SL ACTIVITY RESPONSIBILITY &

AUTHORITY
01 Enclosing this document as a part of Work HOD-Contract Department
Order
02 Submission of consumption statement with Contractor
final Bill.
03 Verification and Certification of Quantity Construction Manager/Engineer In-
charge
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 R ELIANCE ENGINEERING ASSOCIATES (P) LIMITED

SL ACTIVITY RESPONSIBILITY &

AUTHORITY
04 Verification & Certification of consumption Construction Manager/ QMD
of welding consumable and reconciliation Leads/HOD-QMD
based on the certified scope.

04 Verification & Certification of consumption Construction Manager/Engineer In-

and reconciliation of other associated charge
consumable (Gas, Grinding Wheel)
05 Final Reconciliation & Certification of Bill Construction Manager/Engineer In-
charge
06 Maintenance of procedure HOD-QMD

6. REFERENCE DOCUMENTS
Nil

7. FLOWCHART
Nil

1
8. PROCEDURE
8.1 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/QMD
during the closure of Work Order.

8.2 DEVIATIONS
The consumption shall be calculated based on the billing quantities and the norms as above
with the following deviation.
2
(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

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 R ELIANCE ENGINEERING ASSOCIATES (P) LIMITED

As application of SAW process is limited to Fabrication Shops only, consumption of flux & wires
of SAW shall be verified based on the statement of 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/QMD 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.

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.

8.3 PROCESS OF RECONCILIATION

8.3.1 Piping welding consumable 1

(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,
- 24-30mm,
- 30-25mm, 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.

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 R ELIANCE ENGINEERING ASSOCIATES (P) LIMITED

A separate matrix has been enclosed as Annexure-IV with the W.O. item code for the ease of
certification

(B) For consumption calculation, the following joint configurations combinations is neglected for
pipe wall thickness of 22 mm and greater
- Single bevel V pipe joint to compound bevel fitting
- Fitting to fitting joint of compound groove
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.

8.3.2 Structural Work welding consumable

Certification of consumption for structural work shall be based on the actual scope.
8.3.3 ASSOCIATED CONSUMABLE
Site/ Shop Engineer will certify the consumption of gases, grinding wheels, based on the actual
scope.

9. NORMS
Following are the norms for welding consumable:

9.1. WELDING ELECTRODE AND FILLER WIRE 1

9.1.1 For Piping
The basis of calculation considered are :
- Weld groove details as per ASME B31.3
- Actual area of cross section involved .
- Annexure – I applicable for thickness up to 22 mm and Annexure – II is applicable for above
22 mm.
- Table directly gives the SMAW electrode and GTAW filler wire consumption.
- Annexure – III for Fillet Welding applicable for all thickness as applicable.
- Weight of electrode/filler wire/flux consumption is estimated based on the following:

Welding process Wastage considered Weight of electrode/filler wire consumed

2
(to take care of (including wastage)
practical conditions
at site)
GTAW 10% Filler wire consumption= 1.32 times weight of
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
deposited

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 R ELIANCE ENGINEERING ASSOCIATES (P) LIMITED

FCAW 10% 1.47 times weight of corresponding weld metal

deposited
SAW wire 10% 1.32 times weight of corresponding weld metal
deposited
SAW flux 50% 1.5 times consumption of wire

- For groove welding root pass in GTAW process, consumption of filler wire is considered as
21gm/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 42gm/inch dia.
- For fillet welding root pass in GTAW process, consumption of filler wire is considered as
144gm/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.

9.1.2 FOR STRUCTURAL

a) Based on Weight % 1
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 weight 1.23% of structural 1.1% of structural
weight weight
Heavy 1.4% of structural weight 1.07% of structural 0.96% of structural
weight weight
Extra Heavy 1.2% of structural weight 0.92% of structural 0.83% of structural
weight weight
b) Based on Actual Fillet Size
Annexure – III for Fillet Welding applicable for all thickness as applicable.

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.

9.2 ARGON GAS CONSUMPTION NORMS :

Basis for calculation considered are:
- WPS argon flow rate.
- 50% wastage for practical difficulties in the site.

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 R ELIANCE ENGINEERING ASSOCIATES (P) LIMITED

Materials Cu-M of Gas / Kg of Cu-M of Gas / Kg of

1 Filler Metal at Shop Filler Metal at site
Carbon Steels, Low & Alloy 2.0 (With out back 3.0 (With out back
Steels %Cr less than or equal to 3 purging) purging)
Stainless Steel, Low Alloy Steels 5.0
4.0
%Cr more than 3 & Non ferrous (With back purging)
(With back purging)
metal
Consumption of argon gas as per item code has been derived and enclosed as Annexure-V

9.3 DISSOLVED ACETYLENE AND OXYGEN CONSUMPTION NORMS

9.3.1 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

Consumption of DA and Oxygen as per item code has been derived and enclosed as Annexure-VI

9.3.2 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

9.3.3 SUPPORT FABRICATION AT SHOP

Basis for calculation are: 1
-Structural fabrication shop’s actual consumption
Items Consumption / MT
Dissolved Acetylene (D.A.) 3.5 Cu-M
Oxygen (O2) 12 Cu-M
9.4. GRINDING WHEELS CONSUMPTION NORMS INCLUDING CUTTING
WHEELS

9.4.1 PIPING
The basis for calculation considered are :
- Pipe Shop’s actual consumption
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 R ELIANCE ENGINEERING ASSOCIATES ( P) LIMITED

- Craft Training Centre’s experimental data

- A contractor’s site act ual 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 pip es and fittings supplied in
machined condition.

Items Consumption / Inch.Dia.

Grinding Wheel for fabrication 0.035 Numbers 1
Grinding Wheel for joint grinding 0.012 Numbers
for UT

9.4.2 STRUCTURAL
The basis for calculation considered are
- Structural Fab. Shop’s actual consumption
Items Consumption / MT
Grinding Wheel AG 7 (7"*7MM) 0.75 Numbers 2
Grinding Wheel AG 5 (5"*5MM) 0.25 Numbers

9.4.3 SUPPORT FABRICATION AT SHOP

Basis for calculation are: 1
-Structural fabrication shop’s actual consumption

Items Consumption / MT
Grinding Wheel 2 Numbers

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

1
11.ATTACHMENT
Annexure –I Welding Consumable Estimation for Pipi ng Work upto 22 mm

Annexure-II Welding Consumable Estimation for Piping Work above 22 mm

Annexure-III Welding Consumable Estimation for fillet Welding

Annexure-IV W.O. item code wise consumption for welding electrode & filler wire

Annexure-V W.O. item code wise consumption for argon gas

Annexure-VI W.O. item code wise consumption for Cutting gases and grinding wheels

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 R ELIANCE ENGINEERING ASSOCIATES ( P) LIMITED
2
ANNEXURE – I
WELDING CONSUMABLE ESTIMATION FOR PIPING WORK WITH SINGLE V HAVING
INCLUDED ANGLE OF 75 DEGREES
WALL GROOVE WELD ELECTRODE/FILLER WIRE CONSUMPTION
THICKENSS AREA METAL (where root welding by E6010 -consumption of E6010 will be
(MM) (SQ.MM) WEIGHT 30 gm/inch dia)
gm/inch dia gm/inch dia
SINGLE SINGLE COMBINATIONAL
GTAW SMAW GTAW SMAW
4 23 15 20 26 0 0

5 33 21 28 37 19 11

6 46 29 38 51 19 25

7 59 38 50 67 19 41

8 75 48 63 84 19 59

9 91 58 77 102 19 76

10 110 70 92 123 19 98

11 130 83 110 146 19 120

12 151 97 128 171 19 145

13 174 111 147 195 19 170

14 198 127 168 224 19 198

15 224 143 189 252 19 226

16 252 161 213 283 19 258

17 281 180 238 317 19 291

18 311 199 263 350 19 325

19 343 220 290 387 19 362

20 377 241 318 424 19 398

21 412 264 348 465 19 439

22 449 287 379 505 19 479

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 R ELIANCE ENGINEERING ASSOCIATES ( P) LIMITED

2
ANNEXURE – II
WELDING CONSUMABLE ESTIMATION FOR PIPING WORK WITH SINGLE V HAVING INCLUDED ANGLE
OF 75 DEGREES
WALL GROOVE WELD METAL ELECTRODE/FILLER WIRE CONSUMPTION (gm/inch dia)
THICKNESS AREA (SQ. WEIGHT SINGLE SINGLE COMBINATIONAL
(MM) MM) (gm/inch dia) GTAW SMAW GTAW SMAW
23 464 297 392 523 19 497
24 479 307 405 540 19 515
25 495 317 418 558 19 532
26 512 327 432 576 19 550
27 529 339 447 597 19 571
28 547 350 462 616 19 590
29 566 362 478 637 19 611
30 586 375 495 660 19 634
31 607 388 512 683 19 657
32 628 402 531 708 19 682
33 650 416 549 732 19 706
34 673 431 569 759 19 733
35 697 446 589 785 19 759
36 722 462 610 813 19 787
37 747 478 631 841 19 816
38 773 495 653 871 19 846
39 800 512 676 901 19 875
40 828 530 700 933 19 907
41 857 548 723 964 19 939
42 886 567 748 998 19 972
43 916 586 774 1031 19 1006
44 947 606 800 1067 19 1041
45 979 627 828 1104 19 1078
46 1012 647 854 1139 19 1113
47 1045 669 883 1177 19 1152
48 1079 691 912 1216 19 1190
49 1114 713 941 1255 19 1229
50 1150 736 972 1295 19 1270
51 1187 759 1002 1336 19 1310
52 1224 783 1034 1378 19 1352
53 1262 808 1067 1422 19 1396
54 1301 833 1100 1466 19 1440
55 1341 858 1133 1510 19 1484
56 1382 884 1167 1556 19 1530
57 1423 911 1203 1603 19 1578
58 1465 938 1238 1651 19 1625
59 1508 965 1274 1698 19 1673
60 1552 993 1311 1748 19 1722
61 1597 1022 1349 1799 19 1773
62 1642 1051 1387 1850 19 1824
63 1688 1080 1426 1901 19 1875
64 1735 1111 1467 1955 19 1930
65 1783 1141 1506 2008 19 1982

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 R ELIANCE ENGINEERING ASSOCIATES ( P) LIMITED

2
ANNEXURE – III
WELDING CONSUMABLE ESTIMATION FOR FILLET WELDING
FILLE FILLE WELD ELECTRODE/FILLER WIRE CONSUMPTION
T SIZE T META
AREA L
WEIGH
T
MM SQ MM gm/ gm/meter
meter SINGLE SINGLE COMBINATIONAL
GTAW SMAW GTAW SMAW
2 8 64 84 113 0 0
3 13 100 132 176 0 0
4 18 144 190 253 132 77
5 25 196 259 345 132 169
6 32 256 338 451 132 275
7 41 324 428 570 132 394
8 50 400 528 704 132 528
9 61 484 639 852 132 676
10 72 576 760 1014 132 838
11 85 676 892 1190 132 1014
12 98 784 1035 1380 132 1204
13 113 900 1188 1584 132 1408
14 128 1024 1352 1802 132 1626
15 145 1156 1526 2035 132 1859
16 162 1296 1711 2281 132 2105
17 181 1444 1906 2541 132 2365
18 200 1600 2112 2816 132 2640
19 221 1764 2328 3105 132 2929
20 242 1936 2556 3407 132 3231
21 265 2116 2793 3724 132 3548
22 288 2304 3041 4055 132 3879
23 313 2500 3300 4400 132 4224
24 338 2704 3569 4759 132 4583
25 365 2916 3849 5132 132 4956
26 392 3136 4140 5519 132 5343
27 421 3364 4440 5921 132 5745
28 450 3600 4752 6336 132 6160
29 481 3844 5074 6765 132 6589
30 512 4096 5407 7209 132 7033
31 545 4356 5750 7667 132 7491
32 578 4624 6104 8138 132 7962
33 613 4900 6468 8624 132 8448
34 648 5184 6843 9124 132 8948
35 685 5476 7228 9638 132 9462
36 722 5776 7624 10166 132 9990
37 761 6084 8031 10708 132 10532
38 800 6400 8448 11264 132 11088
39 841 6742 8899 11866 132 11690
40 882 7056 9314 12419 132 12243

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2
ANNEXURE – III
WELDING CONSUMABLE ESTIMATION FOR FILLET WELDING
FILLE FILLE WELD ELECTRODE/FILLER WIRE CONSUMPTION
T SIZE T META
AREA L
WEIGH
T
MM SQ MM gm/ gm/meter
meter
41 925 7396 9763 13017 132 12841
42 968 7744 10222 13629 132 13453
43 1013 8100 10692 14256 132 14080
44 1058 8464 11172 14897 132 14721
45 1105 8836 11664 15551 132 15375
46 1152 9216 12165 16220 132 16044
47 1201 9604 12677 16903 132 16727
48 1250 10000 13200 17600 132 17424
49 1301 10404 13733 18311 132 18135
50 1352 10816 14277 19036 132 18860

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 Annexure-IV

Consumption Norms for Welding Electrode & Filler Wires 2

TUNGSTEN TUNGSTEN
ELECTRODE CONSUMPTION (gms/UOM.) ELECTRODE ELECTRODE
Weld SINGLE SINGLE COMBINATION COMBINATION CONSUMPTI CONSUMPTI
Item Code DESCRIPTION OF JOB UOM metal GTAW SMAW GTAW SMAW SMAW FCAW ON (EA/UOM) ON (EA/UOM)
weight
gms/
UOM Remarks
Full GTAW Root GTAW
Piping-Shop welding
CS-NIBR ---
6011001 T < 10 mm (FULL TIG) ID 48 63 - - - - - 0.06336
6011002 10 mm < = t < 12 mm(Full Tig)) ID 83 110 - - - - - 0.10956
6011003 12 mm < = t < 15 mm(Full Tig) ID 127 168 - - - - - 0.16764
6010901 t < 10 mm ( TIG+SMAW) ID 48 - - 19 59 - - 0.019
6010902 10 mm < = t < 12 mm(Tig+SMAW) ID 83 - - 19 121 - - 0.019
6010903 12 mm < = t < 15 mm(Tig+SMAW) ID 127 - - 19 198 - - 0.019
6010101 t < 10 mm (BY SMAW/SSFCAW) ID 48 - 84 - - 26 49 NA
6010102 10 mm < = t < 12 mm(BY SMAW/SSFCAW) ID 83 - 146 - - 26 100 NA
6010103 12 mm < = t < 15 mm(BY SMAW/SSFCAW) ID 127 - 224 - - 26 165 NA
6010104 15 mm < = t < 19 mm(BY SMAW/SSFCAW ID 180 - 317 - - 26 243 NA
6010105 19 mm < = t < 24mm(BY SMAW/SSFCAW ID 287 - 505 - - 26 400 NA
6010106 24 mm < = t < 30 mm(BY SMAW/SSFCAW) ID 339 - 597 - - 26 477 NA
6010107 30 mm < = t < 37 mm(BY SMAW/SSFCAW) ID 431 - 759 - - 26 612 NA
CS-IBR ---
6012001 t < 10 mm (FULL TIG) ID 48 63 - - - - - 0.06336 NA
6012004 10 mm < = t < 12 mm(Full Tig)) ID 83 110 - - - - - 0.10956 NA
6012005 12 mm < = t < 15 mm(Full Tig) ID 127 168 - - - - - 0.16764 NA
6013001 t < 10 mm ( TIG+SMAW) ID 48 - - 19 59 - - NA 0.019
6011101 t < 10 mm (BY SMAW/SSFCAW) ID 48 - 84 - - 26 49 NA NA
6011102 10 mm < = t < 12 mm(BY SMAW/SSFCAW) ID 83 - 146 - - 26 100 NA NA
6011103 12 mm < = t < 15 mm(BY SMAW/SSFCAW) ID 127 - 224 - - 26 165 NA NA
6011104 15 mm < = t < 19 mm(BY SMAW/SSFCAW ID 180 - 317 - - 26 243 NA NA
6011105 19 mm < = t < 24mm(BY SMAW/SSFCAW ID 287 - 505 - - 26 400 NA NA
6011106 24 mm < = t < 30 mm(BY SMAW/SSFCAW) ID 339 - 597 - - 26 477 NA NA
6011107 30 mm < = t < 37 mm(BY SMAW/SSFCAW) ID 431 - 759 - - 26 612 NA NA
LTCS :
6010201 t < 10 mm ID 48 63 84 19 59 - - 0.06336 0.019
6010202 10 mm < = t < 12 mm ID 83 110 146 19 121 - - 0.10956 0.019
6010203 12 mm < = t < 15 mm ID 127 168 224 19 198 - - 0.16764 0.019
6010204 15 mm < = t < 19 mm ID 180 238 317 19 291 - - 0.2376 0.019
6010205 19 mm < = t < 24mm ID 287 379 505 19 480 - - 0.37884 0.019
6010206 24 mm < = t < 30 mm ID 339 447 597 19 571 - - 0.44748 0.019
6010207 30 mm < = t < 37 mm ID 431 569 759 19 733 - - 0.56892 0.019
SS-NIBR
6010301 t < 10 mm ID 48 63 84 19 59 - - 0.06336 0.019
6010302 10 mm < = t < 12 mm ID 83 110 146 19 121 - - 0.10956 0.019
6010303 12 mm < = t < 15 mm ID 127 168 224 19 198 - - 0.16764 0.019
6010304 15 mm < = t < 19 mm ID 180 238 317 19 291 - - 0.2376 0.019
6010305 19 mm < = t < 24mm ID 287 379 505 19 480 - - 0.37884 0.019
6010306 24 mm < = t < 30 mm ID 339 447 597 19 571 - - 0.44748 0.019
6010307 30 mm < = t < 37 mm ID 431 569 759 19 733 - - 0.56892 0.019
AS-NIBR
6010401 t < 10 mm ID 48 63 84 19 59 - - 0.06336 0.019
6010402 10 mm < = t < 12 mm ID 83 110 146 19 121 - - 0.10956 0.019
6010403 12 mm < = t < 15 mm ID 127 168 224 19 198 - - 0.16764 0.019
6010404 15 mm < = t < 19 mm ID 180 238 317 19 291 - - 0.2376 0.019
6010405 19 mm < = t < 24mm ID 287 379 505 19 480 - - 0.37884 0.019
6010406 24 mm < = t < 30 mm ID 339 447 597 19 571 - - 0.44748 0.019
6010407 30 mm < = t < 37 mm ID 431 569 759 19 733 - - 0.56892 0.019
AS-IBR
6010601 t < 10 mm ID 48 63 84 19 59 - - 0.06336 0.019
6010602 10 mm < = t < 12 mm ID 83 110 146 19 121 - - 0.10956 0.019
6010603 12 mm < = t < 15 mm ID 127 168 224 19 198 - - 0.16764 0.019
6010604 15 mm < = t < 19 mm ID 180 238 317 19 291 - - 0.2376 0.019
6010605 19 mm < = t < 24mm ID 287 379 505 19 480 - - 0.37884 0.019
6010606 24 mm < = t < 30 mm ID 339 447 597 19 571 - - 0.44748 0.019
6010607 30 mm < = t < 37 mm ID 431 569 759 19 733 - - 0.56892 0.019
Page 14 of 21

Procedure No.-2QM00JEPME029
Rev.-02
Date :- 15/03/2006
 Annexure-IV

Consumption Norms for Welding Electrode & Filler Wires 2

TUNGSTEN TUNGSTEN
ELECTRODE CONSUMPTION (gms/UOM.) ELECTRODE ELECTRODE
Weld SINGLE SINGLE COMBINATION COMBINATION CONSUMPTI CONSUMPTI
Item Code DESCRIPTION OF JOB UOM metal GTAW SMAW GTAW SMAW SMAW FCAW ON (EA/UOM) ON (EA/UOM)
weight
gms/
UOM Remarks
Full GTAW Root GTAW
Piping - Field welding
CS-NIBR ID
6031001 t < 10 mm (FULL TIG) ID 48 63 - - - - - 0.06336
6031002 10 mm < = t < 12 mm(Full Tig)) ID 83 110 - - - - - 0.10956
6031003 12 mm < = t < 15 mm(Full Tig) ID 127 168 - - - - - 0.16764
6030901 t < 10 mm (TIG+SMAW) ID 48 - - 19 59 - - 0.019
6030902 10 mm < = t < 12 mm (TIG+SMAW) ID 83 - - 19 121 - - 0.019
6030903 12 mm < = t < 15 mm(Tig+SMAW) ID 127 - - 19 198 - - 0.019
6030101 t < 10 mm (BY SMAW/SSFCAW) ID 48 - 84 - - 26 49 NA
6030102 10 mm < = t < 12 mm(BY SMAW/SSFCAW) ID 83 - 146 - - 26 100 NA
6030103 12 mm < = t < 15 mm(BY SMAW/SSFCAW) ID 127 - 224 - - 26 165 NA
6030104 15 mm < = t < 19 mm(BY SMAW/SSFCAW ID 180 - 317 - - 26 243 NA
6030105 19 mm < = t < 24mm(BY SMAW/SSFCAW ID 287 - 505 - - 26 400 NA
6030106 24 mm < = t < 30 mm(BY SMAW/SSFCAW ID 339 - 597 - - 26 477 NA
6030107 30 mm < = t < 37 mm(BY SMAW/SSFCAW) ID 431 - 759 - - 26 612 NA
CS-IBR
6032001 t < 10 mm (FULL TIG) ID 48 63 - - - - - 0.06336 NA
6032004 10 mm < = t < 12 mm(Full Tig)) ID 83 110 - - - - - 0.10956 NA
6032005 12 mm < = t < 15 mm(Full Tig) ID 127 168 - - - - - 0.16764 NA
6030513 t < 10 mm (TIG+SMAW) ID 48 - - 19 59 - - 0.019 NA
6030501 t < 10 mm (BY SMAW/SSFCAW) ID 48 - 84 - - 26 49 NA NA
6030502 10 mm < = t < 12 mm(BY SMAW/SSFCAW) ID 83 - 146 - - 26 100 NA NA
6030503 12 mm < = t < 15 mm(BY SMAW/SSFCAW) ID 127 - 224 - - 26 165 NA NA
6030504 15 mm < = t < 19 mm(BY SMAW/SSFCAW ID 180 - 317 - - 26 243 NA NA
6030505 19 mm < = t < 24mm(BY SMAW/SSFCAW ID 287 - 505 - - 26 400 NA NA
6030506 24 mm < = t < 30 mm(BY SMAW/SSFCAW) ID 339 - 597 - - 26 477 NA NA
6030507 30 mm < = t < 37 mm(BY SMAW/SSFCAW) ID 431 - 759 - - 26 612 NA NA
LTCS :
6030201 t < 10 mm ID 48 63 84 19 59 - - 0.06336 0.019
6030202 10 mm < = t < 12 mm ID 83 110 146 19 121 - - 0.10956 0.019
6030203 12 mm < = t < 15 mm ID 127 168 224 19 198 - - 0.16764 0.019
6030204 15 mm < = t < 19 mm ID 180 238 317 19 291 - - 0.2376 0.019
6030205 19 mm < = t < 24mm ID 287 379 505 19 480 - - 0.37884 0.019
6030206 24 mm < = t < 30 mm ID 339 447 597 19 571 - - 0.44748 0.019
6030207 30 mm < = t < 37 mm ID 431 569 759 19 733 - - 0.56892 0.019
SS-NIBR ---
6030301 t < 10 mm ID 48 63 84 19 59 - - 0.06336 0.019
6030302 10 mm < = t < 12 mm ID 83 110 146 19 121 - - 0.10956 0.019
6030303 12 mm < = t < 15 mm ID 127 168 224 19 198 - - 0.16764 0.019
6030304 15 mm < = t < 19 mm ID 180 238 317 19 291 - - 0.2376 0.019
6030305 19 mm < = t < 24mm ID 287 379 505 19 480 - - 0.37884 0.019
6030306 24 mm < = t < 30 mm ID 339 447 597 19 571 - - 0.44748 0.019
6030307 30 mm < = t < 37 mm ID 431 569 759 19 733 - - 0.56892 0.019
AS-NIBR ---
6030401 t < 10 mm ID 48 63 84 19 59 - - 0.06336 0.019
6030402 10 mm < = t < 12 mm ID 83 110 146 19 121 - - 0.10956 0.019
6030403 12 mm < = t < 15 mm ID 127 168 224 19 198 - - 0.16764 0.019
6030404 15 mm < = t < 19 mm ID 180 238 317 19 291 - - 0.2376 0.019
6030405 19 mm < = t < 24mm ID 287 379 505 19 480 - - 0.37884 0.019
6030406 24 mm < = t < 30 mm ID 339 447 597 19 571 - - 0.44748 0.019
6030407 30 mm < = t < 37 mm ID 431 569 759 19 733 - - 0.56892 0.019
AS-IBR ---
6030601 t < 10 mm ID 48 63 84 19 59 - - 0.06336 0.019
6030602 10 mm < = t < 12 mm ID 83 110 146 19 121 - - 0.10956 0.019
6030603 12 mm < = t < 15 mm ID 127 168 224 19 198 - - 0.16764 0.019
6030604 15 mm < = t < 19 mm ID 180 238 317 19 291 - - 0.2376 0.019
6030605 19 mm < = t < 24mm ID 287 379 505 19 480 - - 0.37884 0.019
6030606 24 mm < = t < 30 mm ID 339 447 597 19 571 - - 0.44748 0.019
6030607 30 mm < = t < 37 mm ID 431 569 759 19 733 - - 0.56892 0.019
Page 15 of 21

Procedure No.-2QM00JEPME029
Rev.-02
Date :- 15/03/2006
 Annexure-IV

Consumption Norms for Welding Electrode & Filler Wires 2

TUNGSTEN TUNGSTEN
ELECTRODE CONSUMPTION (gms/UOM.) ELECTRODE ELECTRODE
Weld SINGLE SINGLE COMBINATION COMBINATION CONSUMPTI CONSUMPTI
Item Code DESCRIPTION OF JOB UOM metal GTAW SMAW GTAW SMAW SMAW FCAW ON (EA/UOM) ON (EA/UOM)
weight
gms/
UOM Remarks
Full GTAW Root GTAW
U/G piping ---
2121806 U/G piping CS T<10 mm ID 48 63 84 19 59 0.06336 0.019
Fillet welding ---
2012501 CS Fillet of Size 6 mm Mtr 256 338 451 132 275 - - 0.33792 0.132
2012502 CS Fillet of size 8 mm Mtr 400 528 704 132 528 - - 0.528 0.132
2012503 CS fillet of size 10 mm Mtr 576 760 1014 132 838 - - 0.76032 0.132
2012504 CS fillet of size 12 mm Mtr 784 1035 1380 132 1204 - - 1.03488 0.132
2012505 CS fillet of size 14 mm Mtr 1024 1352 1802 132 1626 - - 1.35168 0.132
2012506 CS fillet of size 16 mm Mtr 1296 1711 2281 132 2105 - - 1.71072 0.132
2012508 CS fillet of size 20 mm Mtr 1936 2556 3407 132 3231 - - 2.55552 0.132
2012400 Erection of Structure
Erection of Structure from ground level to 10M
2012425
height MT NA NA 600 NA NA NA NA NA NA
Erection of Structure from ground level to 10M
2012426
to 20M height MT NA NA 600 NA NA NA NA NA NA
Erection of Structure from ground level to 20M
2012427
to 30 M height MT NA NA 600 NA NA NA NA NA NA

2012500 Modification of Structure in erected position

2012502 CS fillet size 8mm Mtr 400 NA 704 NA NA NA NA NA NA

2012503 CS fillet size 10mm Mtr 576 NA 1013.76 NA NA NA NA NA NA
2080804 Steam Tracing in ISBL Racks Mtr NA 37 NA NA NA NA NA NA 0.037
2160700 Fabrication of pipe supports
2160701 CS Material MT NA NA NA 20000 NA NA NA
2160800 Erection of Pipe Supports
2160801 CS Material MT NA NA NA 1000 NA NA NA
Strengthening of rolled steel section by
2011700
welding plates
2011701 Fillet of 6mm size Mtr 256 NA 451 NA NA 176 229.32 NA NA
2011702 Fillet of 8mm size Mtr 400 NA 704 NA NA 176 441 NA NA
2012100 Fabrication of Structure
Fabrication of Light Steel Shapes (Wt. 25 Kg or
2012144
less/RM or Plate upto 10mm thk). MT NA NA 20000 NA NA NA NA NA NA
Fabrication of Medium Steel Shapes (Wt. Above
2012145 25 Kg upto and including 75 Kg/RM or Plate
above 10mm thk upto 20mm thk).. MT NA NA 16000 NA NA NA NA NA NA

Fabrication of Heavy Steel Shapes (Wt. Above

2012146 75 Kg upto and including 150 Kg/RM or Plate
above 25mm thk upto 50mm thk)..
MT NA NA 14000 NA NA NA NA NA NA

Fabrication of Extra Heavy Steel Shapes (Wt.

2012147
Above 150 Kg /RM or Plate above 50mm thk)..
MT NA NA 12000 NA NA NA NA NA NA
2012151 Welding of Nuts for fireproofing SQM NA NA 26 NA NA NA NA NA NA
2012154 Fabrication of channel boxes MT NA NA 16000 NA NA NA NA NA NA
2013806 Handrailing & Standards Lin Mtr NA NA 125 NA NA NA NA NA NA
2013807 Ladders and Cages Lin Mtr NA NA 125 NA NA NA NA NA NA
Note
1. For erection of structure, 0.6 Kg (i.e. 5% of average MT wise consumption) electrode consumption have been considered. This is in
addition to the consumption against item code available for the modification of erected structure.
2. For steam tracing, equivalent to 100 mm weld, 6mm fillet per meter has been considered.
3. For welding of nuts for fire proofing, 5 nuts/Sq Feet with single welding 3mm fillet, 4mm length has been considered.
4. For handrailing, ladders & Cages erection, consumption norms has been converted to linear meter considering 25Kg/Meter weight. 50%
has been considered for field welding.
5. Where root welding is carried out by E6010, consumption of E6010 shall be 30 gm/Inch Dia
Page 16 of 21

Procedure No.-2QM00JEPME029
Rev.-02
Date :- 15/03/2006
 Annexure-V

Consumption Norms for Argon Gas

Consumption of

Consumption of

Kg of Filler Wire
Purging) / Kg of

(With Purging)/
Argon Gas

Argon Gas
Filler Wire
SL Item Code DESCRIPTION OF JOB

(Without
Remarks
1.0.0 Piping-Shop welding
1.1.0 CS-NIBR ---
1.1.1 6011001 T < 10 mm (FULL TIG) 2 4 (See Remarks) Wherever purging is required
1.1.2 6011002 10 mm < = t < 12 mm(Full Tig)) 2 4 (See Remarks) Wherever purging is required
1.1.3 6011003 12 mm < = t < 15 mm(Full Tig) 2 4 (See Remarks) Wherever purging is required
1.1.4 6010901 t < 10 mm ( TIG+SMAW) 2 4 (See Remarks) Wherever purging is required
1.1.5 6010902 10 mm < = t < 12 mm(Tig+SMAW) 2 4 (See Remarks) Wherever purging is required
1.1.6 6010903 12 mm < = t < 15 mm(Tig+SMAW) 2 4 (See Remarks) Wherever purging is required
1.2.0 CS-IBR ---
1.2.1 6012001 t < 10 mm (FULL TIG) 2 0
1.2.2 6012004 10 mm < = t < 12 mm(Full Tig)) 2 0
1.2.3 6012005 12 mm < = t < 15 mm(Full Tig) 2 0
1.2.4 6013001 t < 10 mm ( TIG+SMAW) 2 0
1.3.0 LTCS :
1.3.1 6010201 t < 10 mm 2 4 (See Remarks) Wherever purging is required
1.4.0 SS-NIBR
1.4.1 6010301 t < 10 mm 0 4
1.4.2 6010302 10 mm < = t < 12 mm 0 4
1.4.3 6010303 12 mm < = t < 15 mm 0 4
1.4.4 6010304 15 mm < = t < 19 mm 0 4
1.4.5 6010305 19 mm < = t < 24mm 0 4
1.4.6 6010306 24 mm < = t < 30 mm 0 4
1.4.7 6010307 30 mm < = t < 37 mm 0 4
1.5.0 AS-NIBR
1.5.1 6010401 t < 10 mm 2 4 (See Remarks) only for % Cr >3%
1.5.2 6010402 10 mm < = t < 12 mm 2 4 (See Remarks) only for % Cr >3%
1.5.3 6010403 12 mm < = t < 15 mm 2 4 (See Remarks) only for % Cr >3%
1.5.4 6010404 15 mm < = t < 19 mm 2 4 (See Remarks) only for % Cr >3%
1.5.5 6010405 19 mm < = t < 24mm 2 4 (See Remarks) only for % Cr >3%
1.5.6 6010406 24 mm < = t < 30 mm 2 4 (See Remarks) only for % Cr >3%
1.5.7 6010407 30 mm < = t < 37 mm 2 4 (See Remarks) only for % Cr >3%
1.6.0 AS-IBR
1.6.1 6010601 t < 10 mm 2 4 (See Remarks) only for % Cr >3%
1.6.2 6010602 10 mm < = t < 12 mm 2 4 (See Remarks) only for % Cr >3%
1.6.3 6010603 12 mm < = t < 15 mm 2 4 (See Remarks) only for % Cr >3%
1.6.4 6010604 15 mm < = t < 19 mm 2 4 (See Remarks) only for % Cr >3%
1.6.5 6010605 19 mm < = t < 24mm 2 4 (See Remarks) only for % Cr >3%
1.6.6 6010606 24 mm < = t < 30 mm 2 4 (See Remarks) only for % Cr >3%
1.6.7 6010607 30 mm < = t < 37 mm 2 4 (See Remarks) only for % Cr >3%
2.0.0 Piping - Field welding
2.1.0 CS-NIBR
2.1.1 6031001 t < 10 mm (FULL TIG) 3 5 (See Remarks) Wherever purging is required
2.1.2 6031002 10 mm < = t < 12 mm(Full Tig)) 3 5 (See Remarks) Wherever purging is required
2.1.3 6031003 12 mm < = t < 15 mm(Full Tig) 3 5 (See Remarks) Wherever purging is required
2.1.4 6030901 t < 10 mm (TIG+SMAW) 3 5 (See Remarks) Wherever purging is required
2.1.5 6030902 10 mm < = t < 12 mm (TIG+SMAW) 3 5 (See Remarks) Wherever purging is required
2.1.6 6030903 12 mm < = t < 15 mm(Tig+SMAW) 3 5 (See Remarks) Wherever purging is required
2.2.0 CS-IBR
2.2.1 6032001 t < 10 mm (FULL TIG) 3 5 (See Remarks) Wherever purging is required
2.2.2 6032004 10 mm < = t < 12 mm(Full Tig)) 3 5 (See Remarks) Wherever purging is required
2.2.3 6032005 12 mm < = t < 15 mm(Full Tig) 3 5 (See Remarks) Wherever purging is required
2.2.4 6030513 t < 10 mm (TIG+SMAW) 3 5 (See Remarks) Wherever purging is required
2.3.0 LTCS :
2.3.1 6030201 t < 10 mm 3 5 (See Remarks) Wherever purging is required
Page 17 of 21

Procedure No.-2QM00JEPME029
Rev.-02
Date :-15/03/2006
 Annexure-V

Consumption Norms for Argon Gas

Consumption of

Consumption of

Kg of Filler Wire
Purging) / Kg of

(With Purging)/
Argon Gas

Argon Gas
Filler Wire
SL Item Code DESCRIPTION OF JOB

(Without
Remarks
2.4.0 SS-NIBR ---
2.4.1 6030301 t < 10 mm 0 5
2.4.2 6030302 10 mm < = t < 12 mm 0 5
2.4.3 6030303 12 mm < = t < 15 mm 0 5
2.4.4 6030304 15 mm < = t < 19 mm 0 5
2.4.5 6030305 19 mm < = t < 24mm 0 5
2.4.6 6030306 24 mm < = t < 30 mm 0 5
2.4.7 6030307 30 mm < = t < 37 mm 0 5
2.5.0 AS-NIBR ---
2.5.1 6030401 t < 10 mm 3 5 (See Remarks) only for % Cr >3%
2.5.2 6030402 10 mm < = t < 12 mm 3 5 (See Remarks) only for % Cr >3%
2.5.3 6030403 12 mm < = t < 15 mm 3 5 (See Remarks) only for % Cr >3%
2.5.4 6030404 15 mm < = t < 19 mm 3 5 (See Remarks) only for % Cr >3%
2.5.5 6030405 19 mm < = t < 24mm 3 5 (See Remarks) only for % Cr >3%
2.5.6 6030406 24 mm < = t < 30 mm 3 5 (See Remarks) only for % Cr >3%
2.5.7 6030407 30 mm < = t < 37 mm 3 5 (See Remarks) only for % Cr >3%
2.6.0 AS-IBR ---
2.6.1 6030601 t < 10 mm 3 5 (See Remarks) only for % Cr >3%
2.6.2 6030602 10 mm < = t < 12 mm 3 5 (See Remarks) only for % Cr >3%
2.6.3 6030603 12 mm < = t < 15 mm 3 5 (See Remarks) only for % Cr >3%
2.6.4 6030604 15 mm < = t < 19 mm 3 5 (See Remarks) only for % Cr >3%
2.6.5 6030605 19 mm < = t < 24mm 3 5 (See Remarks) only for % Cr >3%
2.6.6 6030606 24 mm < = t < 30 mm 3 5 (See Remarks) only for % Cr >3%
2.6.7 6030607 30 mm < = t < 37 mm 3 5 (See Remarks) only for % Cr >3%
3.4.0 U/G piping ---
3.4.1 2121806 U/G piping CS T<10 mm 2 0 For Site 3 CUM/Kg of filler wire
4.6.0 Fillet welding ---
4.6.1 2012501 CS Fillet of Size 6 mm 2 0 For Site 3 CUM/Kg of filler wire
4.6.2 2012502 CS Fillet of size 8 mm 2 0 For Site 3 CUM/Kg of filler wire
4.6.3 2012503 CS fillet of size 10 mm 2 0 For Site 3 CUM/Kg of filler wire
4.6.4 2012504 CS fillet of size 12 mm 2 0 For Site 3 CUM/Kg of filler wire
4.6.5 2012505 CS fillet of size 14 mm 2 0 For Site 3 CUM/Kg of filler wire
4.6.6 2012506 CS fillet of size 16 mm 2 0 For Site 3 CUM/Kg of filler wire
4.6.7 2012508 CS fillet of size 20 mm 2 0 For Site 3 CUM/Kg of filler wire
Page 18 of 21

Procedure No.-2QM00JEPME029
Rev.-02
Date :-15/03/2006
 Annexure-VI

Consumption Norms for Cutting Gas and Grinding Wheels

Consumption of Cutting Consumption of Grinding wheel Remarks
Gas per UOM (Numbers) per UOM

Item Code DESCRIPTION OF JOB UOM

D.A. (Cu Oxygen (Cu

M) M) Non UT Joint UT Joints
Piping-Shop welding
CS-NIBR ---
6011001 T < 10 mm (FULL TIG) ID 0.011 0.041 0.028 0.038
6011002 10 mm < = t < 12 mm(Full Tig)) ID 0.015 0.056 0.039 0.052
6011003 12 mm < = t < 15 mm(Full Tig) ID 0.019 0.069 0.047 0.063
6010901 t < 10 mm ( TIG+SMAW) ID 0.011 0.041 0.028 0.038
6010902 10 mm < = t < 12 mm(Tig+SMAW) ID 0.015 0.056 0.039 0.052
6010903 12 mm < = t < 15 mm(Tig+SMAW) ID 0.019 0.069 0.047 0.063
6010101 t < 10 mm (BY SMAW/SSFCAW) ID 0.011 0.041 0.028 0.038
6010102 10 mm < = t < 12 mm(BY SMAW/SSFCAW) ID 0.015 0.056 0.039 0.052
6010103 12 mm < = t < 15 mm(BY SMAW/SSFCAW) ID 0.019 0.069 0.047 0.063
6010104 15 mm < = t < 19 mm(BY SMAW/SSFCAW ID 0.024 0.087 0.060 0.080
6010105 19 mm < = t < 24mm(BY SMAW/SSFCAW ID 0.029 0.107 0.074 0.098
6010106 24 mm < = t < 30 mm(BY SMAW/SSFCAW) ID 0.038 0.138 0.095 0.127
6010107 30 mm < = t < 37 mm(BY SMAW/SSFCAW) ID 0.046 0.168 0.116 0.155
CS-IBR ---
6012001 t < 10 mm (FULL TIG) ID 0.011 0.041 0.028 0.038
6012004 10 mm < = t < 12 mm(Full Tig)) ID 0.015 0.056 0.039 0.052
6012005 12 mm < = t < 15 mm(Full Tig) ID 0.019 0.069 0.047 0.063
6013001 t < 10 mm ( TIG+SMAW) ID 0.011 0.041 0.028 0.038
6011101 t < 10 mm (BY SMAW/SSFCAW) ID 0.011 0.041 0.028 0.038
6011102 10 mm < = t < 12 mm(BY SMAW/SSFCAW) ID 0.015 0.056 0.039 0.052
6011103 12 mm < = t < 15 mm(BY SMAW/SSFCAW) ID 0.019 0.069 0.047 0.063
6011104 15 mm < = t < 19 mm(BY SMAW/SSFCAW ID 0.024 0.087 0.060 0.080
6011105 19 mm < = t < 24mm(BY SMAW/SSFCAW ID 0.029 0.107 0.074 0.098
6011106 24 mm < = t < 30 mm(BY SMAW/SSFCAW) ID 0.038 0.138 0.095 0.127
6011107 30 mm < = t < 37 mm(BY SMAW/SSFCAW) ID 0.046 0.168 0.116 0.155
LTCS :
6010201 t < 10 mm ID 0.011 0.041 0.028 0.038
6010202 10 mm < = t < 12 mm ID 0.015 0.056 0.039 0.052
6010203 12 mm < = t < 15 mm ID 0.019 0.069 0.047 0.063
6010204 15 mm < = t < 19 mm ID 0.024 0.087 0.060 0.080
6010205 19 mm < = t < 24mm ID 0.029 0.107 0.074 0.098
6010206 24 mm < = t < 30 mm ID 0.038 0.138 0.095 0.127
6010207 30 mm < = t < 37 mm ID 0.046 0.168 0.116 0.155
SS-NIBR
6010301 t < 10 mm ID NA NA 0.028 0.038
6010302 10 mm < = t < 12 mm ID NA NA 0.039 0.052
6010303 12 mm < = t < 15 mm ID NA NA 0.047 0.063
6010304 15 mm < = t < 19 mm ID NA NA 0.060 0.080
6010305 19 mm < = t < 24mm ID NA NA 0.074 0.098
6010306 24 mm < = t < 30 mm ID NA NA 0.095 0.127
6010307 30 mm < = t < 37 mm ID NA NA 0.116 0.155
AS-NIBR
6010401 t < 10 mm ID 0.011 0.041 0.028 0.038
6010402 10 mm < = t < 12 mm ID 0.015 0.056 0.039 0.052
6010403 12 mm < = t < 15 mm ID 0.019 0.069 0.047 0.063
6010404 15 mm < = t < 19 mm ID 0.024 0.087 0.060 0.080
6010405 19 mm < = t < 24mm ID 0.029 0.107 0.074 0.098
Use of Qxygen and DA is
6010406 24 mm < = t < 30 mm ID 0.038 0.138 0.095 0.127 permitted only on AS
6010407 30 mm < = t < 37 mm ID 0.046 0.168 0.116 0.155 material where %Cr<3%
AS-IBR
6010601 t < 10 mm ID 0.011 0.041 0.028 0.038
6010602 10 mm < = t < 12 mm ID 0.015 0.056 0.039 0.052
Use of Qxygen and DA is
6010603 12 mm < = t < 15 mm ID 0.019 0.069 0.047 0.063 permitted only on AS
6010604 15 mm < = t < 19 mm ID 0.024 0.087 0.060 0.080 material where %Cr<3%
Page 19 of 21

Procedure No.-2QM00JEPME029
Rev.-02
Date :-15/03/2006
 Annexure-VI

Consumption Norms for Cutting Gas and Grinding Wheels

Consumption of Cutting Consumption of Grinding wheel Remarks
Gas per UOM (Numbers) per UOM

Item Code DESCRIPTION OF JOB UOM

D.A. (Cu Oxygen (Cu

M) M) Non UT Joint UT Joints
AS-IBR
6010605 19 mm < = t < 24mm ID 0.029 0.107 0.074 0.098
Use of Qxygen and DA is
6010606 24 mm < = t < 30 mm ID 0.038 0.138 0.095 0.127 permitted only on AS
6010607 30 mm < = t < 37 mm ID 0.046 0.168 0.116 0.155 material where %Cr<3%
Piping - Field welding
CS-NIBR
6031001 t < 10 mm (FULL TIG) ID 0.011 0.041 0.028 0.038
6031002 10 mm < = t < 12 mm(Full Tig)) ID 0.015 0.056 0.039 0.052
6031003 12 mm < = t < 15 mm(Full Tig) ID 0.019 0.069 0.047 0.063
6030901 t < 10 mm (TIG+SMAW) ID 0.011 0.041 0.028 0.038
6030902 10 mm < = t < 12 mm (TIG+SMAW) ID 0.015 0.056 0.039 0.052
6030903 12 mm < = t < 15 mm(Tig+SMAW) ID 0.019 0.069 0.047 0.063
6030101 t < 10 mm (BY SMAW/SSFCAW) ID 0.011 0.041 0.028 0.038
6030102 10 mm < = t < 12 mm(BY SMAW/SSFCAW) ID 0.015 0.056 0.039 0.052
6030103 12 mm < = t < 15 mm(BY SMAW/SSFCAW) ID 0.019 0.069 0.047 0.063
6030104 15 mm < = t < 19 mm(BY SMAW/SSFCAW ID 0.024 0.087 0.060 0.080
6030105 19 mm < = t < 24mm(BY SMAW/SSFCAW ID 0.029 0.107 0.074 0.098
6030106 24 mm < = t < 30 mm(BY SMAW/SSFCAW ID 0.038 0.138 0.095 0.127
6030107 30 mm < = t < 37 mm(BY SMAW/SSFCAW) ID 0.046 0.168 0.116 0.155
CS-IBR
6032001 t < 10 mm (FULL TIG) ID 0.011 0.041 0.028 0.038
6032004 10 mm < = t < 12 mm(Full Tig)) ID 0.015 0.056 0.039 0.052
6032005 12 mm < = t < 15 mm(Full Tig) ID 0.019 0.069 0.047 0.063
6030513 t < 10 mm (TIG+SMAW) ID 0.011 0.041 0.028 0.038
6030501 t < 10 mm (BY SMAW/SSFCAW) ID 0.011 0.041 0.028 0.038
6030502 10 mm < = t < 12 mm(BY SMAW/SSFCAW) ID 0.015 0.056 0.039 0.052
6030503 12 mm < = t < 15 mm(BY SMAW/SSFCAW) ID 0.019 0.069 0.047 0.063
6030504 15 mm < = t < 19 mm(BY SMAW/SSFCAW ID 0.024 0.087 0.060 0.080
6030505 19 mm < = t < 24mm(BY SMAW/SSFCAW ID 0.029 0.107 0.074 0.098
6030506 24 mm < = t < 30 mm(BY SMAW/SSFCAW) ID 0.038 0.138 0.095 0.127
6030507 30 mm < = t < 37 mm(BY SMAW/SSFCAW) ID 0.046 0.168 0.116 0.155
LTCS :
6030201 t < 10 mm ID 0.011 0.041 0.028 0.038
6030202 10 mm < = t < 12 mm ID 0.015 0.056 0.039 0.052
6030203 12 mm < = t < 15 mm ID 0.019 0.069 0.047 0.063
6030204 15 mm < = t < 19 mm ID 0.024 0.087 0.060 0.080
6030205 19 mm < = t < 24mm ID 0.029 0.107 0.074 0.098
6030206 24 mm < = t < 30 mm ID 0.038 0.138 0.095 0.127
6030207 30 mm < = t < 37 mm ID 0.046 0.168 0.116 0.155
SS-NIBR ---
6030301 t < 10 mm ID NA NA 0.028 0.038
6030302 10 mm < = t < 12 mm ID NA NA 0.039 0.052
6030303 12 mm < = t < 15 mm ID NA NA 0.047 0.063
6030304 15 mm < = t < 19 mm ID NA NA 0.060 0.080
6030305 19 mm < = t < 24mm ID NA NA 0.074 0.098
6030306 24 mm < = t < 30 mm ID NA NA 0.095 0.127
6030307 30 mm < = t < 37 mm ID NA NA 0.116 0.155
AS-NIBR ---
6030401 t < 10 mm ID 0.011 0.041 0.028 0.038
6030402 10 mm < = t < 12 mm ID 0.015 0.056 0.039 0.052
6030403 12 mm < = t < 15 mm ID 0.019 0.069 0.047 0.063
6030404 15 mm < = t < 19 mm ID 0.024 0.087 0.060 0.080
6030405 19 mm < = t < 24mm ID 0.029 0.107 0.074 0.098
Use of Qxygen and DA is
6030406 24 mm < = t < 30 mm ID 0.038 0.138 0.095 0.127 permitted only on AS
6030407 30 mm < = t < 37 mm ID 0.046 0.168 0.116 0.155 material where %Cr<3%
Page 20 of 21

Procedure No.-2QM00JEPME029
Rev.-02
Date :-15/03/2006
 Annexure-VI

Consumption Norms for Cutting Gas and Grinding Wheels

Consumption of Cutting Consumption of Grinding wheel Remarks
Gas per UOM (Numbers) per UOM

Item Code DESCRIPTION OF JOB UOM

D.A. (Cu Oxygen (Cu

M) M) Non UT Joint UT Joints
AS-IBR ---
6030601 t < 10 mm ID 0.011 0.041 0.028 0.038
6030602 10 mm < = t < 12 mm ID 0.015 0.056 0.039 0.052
6030603 12 mm < = t < 15 mm ID 0.019 0.069 0.047 0.063
6030604 15 mm < = t < 19 mm ID 0.024 0.087 0.060 0.080
6030605 19 mm < = t < 24mm ID 0.029 0.107 0.074 0.098
Use of Qxygen and DA is
6030606 24 mm < = t < 30 mm ID 0.038 0.138 0.095 0.127 permitted only on AS
6030607 30 mm < = t < 37 mm ID 0.046 0.168 0.116 0.155 material where %Cr<3%
U/G piping ---
2121806 U/G piping CS T<10 mm ID 0.011 0.041 0.028 0.038
2012300 Cutting & Grinding of plates

2012308 Cutting & Grinding of CS plates thk. < 10mm

Mtr 0.056 0.20 0.04
Cutting & Grinding of CS plates thk. > 10mm <
2012309
20mm Mtr 0.084 0.30 0.06
2012400 Erection of Structure
Erection of Structure from ground level to 10M
2012425
height MT 0.22 0.8 0.04
Erection of Structure from ground level to 10M to
2012426
20M height MT 0.22 0.8 0.04
Erection of Structure from ground level to 20M to
2012427
30 M height MT 0.22 0.8 0.04
2080804 Steam Tracing in ISBL Racks RM 0.015 0.053 0.036
2160700 Fabrication of pipe supports
2160701 CS Material MT 3.5 12 2
2160800 Erection of Pipe Supports
2160801 CS Material MT 0.22 0.8 0.04
6101000 Cutting of pipes
6101001 CS/LTCS Material In Dia mm 0.0014 0.0051 NA
6101100 Bevelling of pipes
6101101 CS/LTCS Material In Dia mm 0.0014 0.0051 0.0035
2012100 Fabrication of Structure
AG 7(7"*7MM)-
0.75 Nos and AG 5
2012142 Cutting of flats from plates
(5"*5MM)- 0.25 2
MT 2.2 8 Nos
AG 7(7"*7MM)-
Fabrication of Light Steel Shapes (Wt. 25 Kg or 0.75 Nos and AG 5
2012144
less/RM or Plate upto 10mm thk). (5"*5MM)- 0.25 2
MT 2.2 8 Nos

Fabrication of Medium Steel Shapes (Wt. Above AG 7(7"*7MM)-

2012145 25 Kg upto and including 75 Kg/RM or Plate 0.75 Nos and AG 5
above 10mm thk upto 20mm thk)..
(5"*5MM)- 0.25 2
MT 2.2 8 Nos

Fabrication of Heavy Steel Shapes (Wt. Above AG 7(7"*7MM)-

2012146 75 Kg upto and including 150 Kg/RM or Plate 0.75 Nos and AG 5
above 25mm thk upto 50mm thk).. (5"*5MM)- 0.25 2
MT 2.2 8 Nos
AG 7(7"*7MM)-
Fabrication of Extra Heavy Steel Shapes (Wt. 0.75 Nos and AG 5
2012147
Above 150 Kg /RM or Plate above 50mm thk).. (5"*5MM)- 0.25 2
MT 2.2 8 Nos
AG 7(7"*7MM)-
2012154 Fabrication of channel boxes 0.75 Nos and AG 5
(5"*5MM)- 0.25 2
MT 2.2 8 Nos
2013806 Handrailing & Standards Lin Mtr 0.05 0.18 0.009
2013807 Ladders and Cages Lin Mtr 0.05 0.18 0.009
Note
1. Present norms for piping Cu-M/ID for cutting gas and No/ID for grinding wheel have been converted and linked with
thickness assuming 10 mm thickness.
2. Present norms for structural Cu-M/MT converted to linear meter for the cutting of plates considering 10 mm thickness and
one sq. meter cutting (cutting length 3M)
3. For structural erection including pipe supports erection 10% of the fabrication norms considered.
4. For handrailing, ladders & Cages, consumption norms has been converted to linear meter considering 25Kg/Meter weight
for field erection part.
5. For steam tracing, equivalent norms of cutting & grinding norms considering 100 mm weld per RM has been considered.
Page 21 of 21

Procedure No.-2QM00JEPME029
Rev.-02
Date :-15/03/2006