PROCEDURE FOR WELDING OF PP LINING OF PP-FRV TANKS AT TDP

1.0 Introduction
This document lay down the procedure for welding of PP Lining of PP-FRV Tanks at TDP.
This procedure shall be used for welding new PP to PP sheets and for repairing of existing
PP-PP sheets.
2.0 Type of Welding: Freehand Hot Gas Filler Welding
3.0 Required Tools:
3.1 Hot Air Welding Gun (General Arrangement as indicated in Figure 1)
3.2 Files for Preparation of Weld Edges
3.3 Hose to connect compressed air to the nozzle.
3.4 Measuring tools
3.5 Accessories for surface cleaning
3.6 Personal Protective Equipment (PPEs)
3.7 Other tools & tackles as per the requirement.
4.0 Weld Design: Welding of PP to PP sheets at TDP involves two major types of weld joints
viz. Butt Weld and Fillet Weld. The design for both of these joints is indicated at Figure 2.
5.0 Welding Procedure: For welding of PP to PP sheets, following procedure is to be followed:
5.1 Preparation of Weld Area: The part to be welded shall be free of any impurities such as
dirt, oil, etc and shall be cleaned properly. For this purpose, grinding or scraping of the weld
area shall be carried out. Any dust shall be wiped off with a clean cloth. The welding rod that
is required during the welding process shall also be cleaned properly.

5.2 Edge Preparation: Edge preparation shall be carried as per the joint design. File
shall be used for this purpose. Required angle as per the joint design shall be suitably
measured and confirmed. After edge preparation, edges all the area near the edges
shall be cleaned to wipe out any left over.
5.3 Welding then shall be carried out with the help of filler wire and Hot Air Welding
Gun. Prior to commencement of welding, the welding gun shall be checked for the air
temperature emanating out of the welding tip. The air temperature shall be in the
range of 800C to 900C.
5.4 The size of the welding tip of the gun is to be kept small (1/8) to concentrate the heat
at a spot. A smaller diameter (-----) welding rod is used for easier and faster control of
the weld.
5.5 To put the parts to be welded at place, aligned properly & to prevent slippage of the
material during the structural welding process; tack weld shall be provided first, at
different places along the length of the parts to be joined.
5.6 Tack weld is carried out with the help of welding gun by softening the parent material
and the filler wire at a spot.
5.7 After providing tack weld continuous structural welding shall be carried out.

5.8 During continuous welding, the Welding Gun is brought in contact with the parent
material first and then the filler wire. The welding gun shall precede the movement of
filler wire as indicated in Figure 3
5.9 The welder shall wave the welding gun at the base material and the welding rod with
an "up and down" and "side to side" motion (Fanning motion) in order to bring them
both into the plasticized state.
5.10 The necessary pressure on the welding rod shall be applied by hand by pushing
down on it vertically at a 90 angle.
5.11 When the pressure and heat are applied to the rod and base material, a small wave
of molten material gets formed in front of the welding rod. This forms the welding
bead.
5.12 The first welding pass forms the root pass. Before proceeding for subsequent weld
passes, the root pass weld shall be inspected visually. If possible, spark testing shall
also be carried out to detect any discontinuity in the root weld.
5.13 If any defect in the root weld is observed, the same shall be rectified and tested
again before proceeding further.
5.14 Subsequent weld passes shall be carried out and each pass shall be inspected
visually.
6.0 Inspection & Testing
6.1 Visual Inspection of the welds shall be carried out as per DVS Code DVS_____. The
type of defect and its acceptance shall be as per DVS_____.
6.2 If possible, spark testing of the welds shall be carried out to detect any discontinuity.
6.3 After the welding is completed, water fill test of the tank shall be carried out to detect
any leakage from the welds.

FIGURE 1 General Arrangement Drawing for Hot Air Welding Gun

FIGURE 2 Weld Design for Butt Weld & Fillet Weld

FIGURE 3 General Procedure for carrying out Free Hand Hot Gas Filler Welding