CHAPTER 1

COMPANY PROFILE
H.H construction was established in the year 2010 and engaged in road and pipeline works since inception. Our Company
is engaged in the business of Pipeline laying, welding works. We also have our own vehicles for earthworks such as
excavation, backfilling, breaking and levelling of the particular area. We have vast experience in laying of MS, DI and
HDPE Pipes.

1.1 VISION
To be the best pipeline contractors delivering value in a safe, reliable and sustainable manner .

1.2 MISSION
• Carry out the transmission business complying with highest standard of safety and ethics & compliance.
• Drive reliable, efficient and competitive pipeline operations.
• Ensure best in class service to the clients
• To be the preferred contractor in the industry.
• Continuous focus on risk reduction and maintaining consistency

1.3 STRATEGIC AND ENABLING PILLARS

• Customer.

• Latest technology.
• Highly skilled workforce.

• Operational Excellence.
1.4 CAPABILITIES
• Work Force
• Highly Skilled Engineers
• Clean field work
• Quality Team
• Good field Knowledge .

1.4 CAPABILITIES
1.7 LIST OF PROJECT DONE BY COMPANY

SL PROJECT NAME COMPANY STATUS

NO NAME

1 Harihara lift irrigation SNC Completed

scheme
2 Harihara lift irrigation L&T Completed
scheme

3 Bharamsagar lift irrigation SNC Completed

scheme
4 Koppal lift irrigation scheme SNC Completed

5 24*7 Hubballi-Dharwad L&T Ongoing

continuous water supply
6 Viesvesvaraya Jala Nigham RVR project Ongoing
Limited(Upper Bhadra Pvt ltd
project)
CHAPTER 2
ABOUT THE INTERNSHIP
The main objective of the Internship was to learn and gain field knowledge regarding the various activities like Welding
and Grinding of different kinds of pipes , Ultrasonic testing , Hydro testing , and Operations of various machinaries like
Diesel Generators , Excavator , Pressure Pump , Dewatering Pump for the given spam of 4 weeks at H.H Constructions at
Sira ,Tumkur.

I received field training on Welding and Grinding of different types of pipes.I was also
trained for testing pressure of water inside pipe after filling it using Hydro testing
machine and Ultrasonic testing machine.I was also trained for operating various
machineries like Diesel Generators ,Excavator , Dewatering Pumps. Also got know
about the process in making MS,DI,HDPE Pipes.
CHAPTER 3
PIPING SYSTEM
3.1 INTRODUCTION
A pipe can be defined as a tube made of metal, plastic, wood, concrete or fiberglass. Pipes are used to carry liquids, gases,
slurries, or fine particles. A piping system is generally considered to include the complete interconnection of pipes, including
in-line components such as pipe fittings and flanges. Pumps, heat exchanges, valves and tanks are also considered part of
piping system. Piping systems are the arteries of our industrial processes and the contribution of piping systems are essential
in an industrialized society. The initial design of a piping system is established by the functional requirements of piping a
fluid from one point to another. The detailed design is decided by criteria such as type of fluid being transported, allowable
pressure drop or energy loss, desired velocity, space limitations, process requirements like free drain or requirement of straight
run, stress analysis, temperature of fluid, etc. The supporting of piping systems requires a significant engineering, design,
fabrication and erection effort. In some cases, special structures (like structural T or inverted L, cantilevers, U portals,
pedestals, etc) must be built solely for the purpose of supporting piping systems.
3.2 Piping Material
The material to be used for pipe manufacture must be chosen to suit the operating conditions of the piping system. Guidance
of selecting the correct material can be obtained from standard piping codes. As an example, the ASME Code for Pressure
Piping contains sections on Power Piping, Industrial Gas and Air Piping, Refinery and Oil Piping, and Refrigeration
Piping Systems. The objective being to ensure that the material used is entirely safe under the operating conditions of
pressure, temperature, corrosion, and erosion expected. Some of the materials most commonly used for power plant piping are
discussed in the following sections.
• Steel – Steel is the most frequently used material for piping. Forged steel is extensively used for fittings while cast steel is
primarily used for special applications. Pipe is manufactured in two main categories – seamless and welded.
• Cast Iron – Cast iron has a high resistance to corrosion and to abrasion and is used for ash handling systems, sewage lines
and underground water lines. It is, however, very brittle and is not suitable for most power plant services. It is made in
different grades such as gray cast iron, malleable cast iron and ductile cast iron.
• Brass and Copper – Non-ferrous material such as copper and copper alloys are used in power plants in instrumentation and
water services where temperature is not a prime factor.
3.3 Pipe Sizes
pipe is made in standard sizes each having several different wall thicknesses or weights. Up to and including 304.8 mm (12 inch)
 pipe, the size is expressed as nominal (approximate) inside diameter. Above 304.8 mm, the size is given as the actual outside
diameter. All classes of pipe of a given size have the same outside diameter, with the extra thickness for different weights on the
inside. For example, if a pipe was designated as 152.4 mm size this would mean that it has a nominal or approximate inside diameter
of 152.4 mm. The outside diameter is 168.28 mm. This is a constant value no matter what the wall thickness is. The actual inside
diameter of the pipe will depend upon its wall thickness. For a standard wall thickness, the actual inside diameter of 152.4 mm pipe is
154.06 mm. For an extra strong wall thickness, the actual inside diameter is 146.34 mm. There are two systems used to designate the
various wall thicknesses of different sizes of pipe. The older method lists pipe as standard (S), extra strong (XS) and double extra
strong (XXS). The newer method, which is superseding the older method, uses schedule numbers to designate wall thickness. These
numbers are 10, 20, 30, 40, 60, 80, 100, 120, 140 and 160. In most sizes of pipe, schedule 40 corresponds to standard and schedule 80
corresponds to extra strong..

3.4 Pipe Fittings

A fitting is used in pipe systems to connect straight pipe sections, adapt to different sizes or shapes and for other purposes,
such as regulating (or measuring) fluid flow. Pipe Fittings (especially uncommon types) require money, time, materials and
tools to install, and are an important part of piping and plumbing systems. The purposes of the fittings, shown in Fig. 3 may
be generally stated as follows:
• Elbows – for making angle turns in piping.
• Nipples – for making close connections. They are threaded on both ends with the close nipple threaded for its entire length.
• Couplings – for connecting two pieces of pipe of the same size in a straight line.
• Unions – for providing an easy method for dismantling piping.
• Tees and Crosses – for making branch line connections at 90º.
• Y-bends – for making branch line connections at 45º.
• Return Bends – for reversing direction of a pipe run.
• Plugs and Caps – for closing off open pipe ends or fittings.
• Bushings – for connecting pipes of different sizes. The male end fits into a coupling and the smaller pipe is then screwed
into the female end. The smaller connection may be tapped eccentrically to permit free drainage of water.
• Reducers – for reducing pipe size. Has two female connections into which the different sized pipes fit. May also be made
with one connection eccentric for free drainage of water.
3.5 Methods of Connecting Pipe
There are three general methods used to join or connect lengths of pressure piping. These are:
1. Screwed Connections.
2. Flanged Connections.
3. Welded Joints.
Each of these methods has certain advantages and disadvantages and each will be discussed in the following sections.
4. Screwed Connections:
In this method, threads are cut on each end of the pipe and screwed fittings such as unions, couplings, and elbows are used to
join the lengths. This method is generally used for pipe sizes less than 101.6 mm (4 inch) for low and moderate pressures. It
has the advantage that the piping can be easily disassembled or assembled. However, the threaded connections are
subject to leakage and the strength of the pipe is reduced when threads are cut in the pipe wall.
2. Flanged Connections:
This method uses flanges at the pipe ends which are bolted together, face to face, usually with a gasket between the two faces.
Flanged connections have the advantage over welded connections of permitting disassembly and are more convenient to
assemble and disassemble than the screwed connections. In order to prevent leakage at flanged connections, the flange faces,
which butt together, would have to be absolutely flat and smooth. While it is theoretically possible to grind the faces to this
condition, it is a time consuming and expensive proposition. Therefore gaskets are usually used between flange faces. Gaskets
are made of a comparatively soft material which, when the flanged connection is tightened, will fill in any small depressions
in the flange faces and thus prevent leakage.
3. Welded Connections:
In this method, the pipe lengths are welded directly to one another and directly to any valves or fittings that may be required.
The use of these welded joints for piping has several advantages over the use of screwed connections or flanged connections:
• The possibility of leakage is removed with the elimination of screwed or flanged joints.
• The weight of the piping system is reduced due to the elimination of connecting flanges or fittings.
• The cost of material and the need for maintenance are reduced with the elimination of flanges and fittings.
• The piping looks neater and is easier to insulate with the elimination of bulky flanges and fittings.
• Welded joints give more flexibility to the piping design as the pipes may be joined at practically any angle to each other.

The main disadvantage of using welded joints for piping is the necessity of obtaining a skilled welder whenever a connection
is to be made.
3.6 Piping Insulation
Most piping systems are used to convey substances that are at temperatures much higher than that of the surrounding
air. Examples would include the main steam piping and feedwater piping. In order to reduce the amount of heat lost to
the surrounding air from the hot substance, the piping is covered with insulation. The insulation not only retains the heat
in the hot lines but also prevents the temperature inside the process plant building from becoming uncomfortably high.
In addition, insulation of hot pipe lines will prevent injury to personnel due to contact with the bare surfaces of the
pipe.In the case of piping which carries substances at a lower temperature than that of the surrounding air, insulating the
piping will prevent sweating of the pipe and consequent dripping and corrosion.A material suitable for use as an
insulation should have the following characteristics.
• High insulating value.
• Long life.
• Vermin proof.
• Non corrosive.
• Ability to retain its shape and insulating value when wet.
• Ease of application and installation.

Some of the more common materials used for piping insulating are discussed in the following sections.
• Diatomaceous Silica – This material is bonded with clay and asbestos and is used for temperatures up to 1030ºC.
• Asbestos – Pipe covering sections are molded from asbestos fibre and are used for temperatures up to 650ºC.
• Calcium Silicate – This insulation is made from silica and lime and is suitable for temperatures up to 650ºC.
• Cellular Glass – This material is glass which has been melted and foamed and then molded into pipe covering forms. It
can be used for temperatures up to 430ºC.
• Magnesia (85%) – This material is composed of magnesium carbonate with asbestos fibre. It is available in molded
form for pipe covering and also is supplied in powdered form to be mixed with water to form an insulating cement
which is used to cover pipe fittings. Magnesia pipe covering is suitable for service up to 315ºC.
• Glass Fibre – This is glass that has been processed into fibres and then formed into pipe covering sections which are
suitable for temperatures up to 190ºC.
• Plastic Foams – These are plastics that have been processed into a foam during manufacture and then formed into pipe
covering sections. They are available for temperatures as low as -170ºC and as high as 120ºC.
CHAPTER 4
WELDING OF PIPES
Pipe welding is a method for joining two pipes together. Welding techniques used for pipes include arc welding
processes including MIG welding and TIG welding. Some make a distinction between pipe welding and pipeline
welding, with pipe welding relating to metal pipes at plants and refineries and pipeline welding referring to those used
to transport gas, water, oil and other liquids over many miles.  
Pipe and pipeline welders undertake welding jobs in the construction industry, at oil and gas fields, in the water industries,
fabrication shops and nuclear power stations, among others. Working to connect new pipes or repair old ones, pipe welding is
generally performed to conform with relevant codes and standards.
4.1 TYPES OF PIPE WELDING
1. Shielded Metal Arc Welding (SMAW):
Shielded Metal Arc Welding also known as Manual Metal Arc Welding (MMA or MMAW), Flux Shielded Arc Welding or Stick
Welding. Also known as stovepipe welding, using SMAW for pipe welding means that no flux or shielding gas are needed during
welding, making the welding equipment simple and portable.  The metal is welded by melting the electrodes through the heat generated
by an electric arc. Although SMAW has some advantages, the slow travel speed means that it is not as productive as other techniques.
2. Gas Metal Arc Welding (GMAW):
Gas Metal Arc Welding including Metal Inert Gas (MIG) Welding and Metal Active Gas (MAG) Welding.Offering greater productivity
than with SMAW, these techniques do require better control of the welding variables to deliver high quality, efficient work. Usually
performed with semi or fully automatic equipment, GMAW offers high deposition rates with low fume generation.
3. Flux-Cored Arc Welding (FCAW):
Flux-Cored Arc Welding – including self-shielded and gas-shielded FCAW. Gas-shielded FCAW uses semi-automatic machines to
provide a high productivity welding solution for pipes, although windy conditions can disturb the shielding gas and lead to porosity
defects. Self-shielded FCAW avoids this by not requiring a shielding gas, but has lower deposition rates.
4. Submerged Arc Welding(SAW):
Submerged Arc Welding is a semi-automatic process where the arc is not visible, which can make tracing difficult. However, it offers the
highest deposition rates of all the different pipeline welding methods as well as delivering defect-free surfaces.
5. Tungsten Inert Gas Welding(TIGW):
Tungsten Inert Gas Welding also known as Gas Tungsten Arc Welding (GTAW).TIG welding has low deposition rates and higher
equipment costs than the other methods for pipe welding. However, it produces very high quality welds (according to welder skill),
making it perfect for critical and high-precision welding jobs.

4.2 PIPE WELDING STEPS

As with all welding work, there are a number of steps that should be followed, starting with process selection, which involves the
consideration of factors such as:
• Pipe material
• Pipe diameter and wall thickness
• Welding location
• Weldment properties
• Welding direction (Uphill or downhill)
• Required welding quality
• Economic considerations
• Health and safety

Once these factors have been addressed, you can determine which equipment is best suited for the work by assessing:
• Output power
• Duty cycle
• Portability
• Safety

4.3 PIPE WELDING PROCESS

1. Joint Preparation: Joint preparation should follow the appropriate guidelines as set out by the relevant standard
2. Pipe End Cleaning: Remove an undesirable moisture or coatings including, oil, paint, rust or varnish. This will prevent
defects and costly repair or re-welding.
3. Welding: Having selected the correct materials (including electrodes) and parameters (preheat requirements, etc), according
to the required specifications, the welding can begin with the root passes. Hot passes follow this before the welding fill and
final cap passes.
4. Repairs: Ideally, you will be able to skip this step, but it is worth checking the weld and making any defect repairs.
 
4.4 PIPE WELDING PASSES
Pipe welds require several different weld passes:
• Root Passes: These first passes should fill the gap between the two sections of piping.
• Hot Passes: These join the root weld to both groove faces.
• Fill Passes: These passes fill out most of the groove before the final cap passes are made.
• Cap Passes: These final passes should complete the weld with as little build up beyond the surface of the pipe as possible.
You can grind this layer back if required to improve the weld beading and remove contamination before a final, finishing cap
pass.
4.4 PIPE WELDING POSITION
There are four types of pipe welding position; 1G, 2G, 5G and 6G. Each position details whether the pipe is stationary or
rotating and whether the pipe is placed horizontally, vertically, or inclined at an angle.
 1G Welding: This position places the pipe horizontally. The pipe can be rotated along the horizontal (X) axis, with the welder
remaining stationary. The weld is completed on the top of the pipe and is the most basic of the pipe welding positions.
2G Welding: This position places the pipe upright in a vertical position. The pipe can be rotated along the vertical (Y) axis,
with the welder remaining stationary. The welding is performed horizontally on the side of the pipe.
5G Welding: The 5G position places the pipe horizontally but, unlike with the 1G position, the pipe cannot be rotated. Instead,
the welder must move around the stationary pipe in a vertical direction to create the weld.
6G Welding: This position inclines the pipe at a 45° angle to create a sloping surface. The pipe is fixed, as with 5G, and the
welder must move around the pipe. This is the most advanced of the four positions and requires a greater level of expertise from
the pipe welder.
Welders will learn each type of position in turn, with 1G being the easiest to master and 6G the most difficult. A welder will need
to gain certification in each position in turn, so someone qualified in 1G positions cannot weld 2G, 5G or 6G, but if you are
qualified in 6G you can weld in any of the other positions. These standardspreserve the safety of the work environment when
performing pipe welds.

4.5 ADVANTAGES
Welding pipes has a number of advantages over other joining techniques, such as screwed fittings. These advantages include:
1. Fewer Fittings
Welding eliminates the need for fittings to join straight sections of pipe. A screwed pipe requires a fitting between every joint
while welding can quickly join pipes following end preparation of the parts to be joined.
2. Lower Costs
Welded pipe can use thinner wall pipe than with screwed connections, leading to significant cost savings for long runs and larger
jobs. Screwing pipes together can also require higher labour costs along with the higher costs of the threaded fittings themselves.
3. Improved Flow
Screwed fittings create turbulence and fluid resistance in the flow through the pipe. Welded solutions can create smooth and
streamlined surfaces to allow for improved flow.
4. Ease of Repair
Welded systems are generally easier to repair than screwed systems. Where a welded pipe can often be repaired in place, a
screwed system requires disassembly and reassembly for repair. This obviously increases labour costs and downtimes for the
pipe system.
5. Fewer Leaks
A welded pipe is generally able to handle vibration better than a screwed system, making it less prone to leaks.
6. Easier Insulation
It is easier to insulate welded pipes, as there are no threaded connections to create difficult bumps that need covering.
7. Location
Welded pipes can be placed close together but threaded pipes need extra space so that wrenches and other tools can be used.
8. Labour
While the labour required to weld or screw smaller pipes is about the same, as the pipe size is increased, so the labour costs and
time required to install the welded pipe decreases as the screwed pipe increases. A screwed pipe also requires different tooling
for different pipe sizes, while a skilled welder can use the same welding machine for a range of pipe sizes.

4.6 COMMON ISSUES

The best way to avoid common mistakes in pipe welding is to understand the process and working conditions associated with
the process.
• Firstly, the pipes to be joined need to be prepared correctly, making sure the edges to be joined a clean and straight. If this is
not done correctly there can be problems including a lack of fusion in the weld, slag trapments and hydrogen inclusion.
• Aside from the preparation, there are a number of challenges associated with welder working conditions. The process itself
can produce a risk of injury unless the correct precautions are taken. The risks include the heat created by the welding tools,
the bright light created by the arc, and the release of particles or gases.
• Pipe welding can add additional hazards due to the working conditions associated with pipes. This includes having to work in
uncomfortable or even dangerous positions and locations, including underground or underwater. Other factors may include
working in very hot or cold conditions, depending on the location of the pipe as well as hazards associated with the contents
of the pipe, whether sewage or oil.
• However, with the correct preparation, training and equipment many of these challenges can be solved.
4.7 APPLICATIONS
• Since pipe welding refers to the connecting of metal pipes, there are a wide range of applications for this skill. The number of
applications is increased further as welding is one of the most cost-effective methods for connecting several sections of pipe.
• Consequently, pipe welding is used across a range of industries including transporting natural resources to oil refineries, through cross-
country or international pipelines, and to mineral processing plants.
• Pipe welders also work in plants for chemical processing, food and beverage manufacture and power generation, as well as to provide
infrastructure for water and gas providers, the construction industry and more.

4.8 WELDING PRE START CHECKLIST

To ensure safety, several practices need to be in place before starting the actual welding work. Here is a checklist of the things that you
need to keep in mind.
1. Be familar with equipment you’re using which includes reading the operating manuals.
2. Wearing appropriate safety equipment and check to make sure its in good condition
3. Wear proper clothing for the job and button up.
4. Checking the power supply and other cables connected to welding machines.
5. Check out your welding machine to comfirm it’s not faulty.
6. Is a fire blanket available in the working area?
7. Ensure your work area is well ventilated.

4.9 WELDING EQUIPMENT SAFETY CHECKLIST

The welding industry requires you to wear appropriate equipment when performing welds. This equipment protects from unnecessary
incidents such as blindness, skin burns, or overexposures to gases and fumes. Here is a list of welding safety equipment that can protect
from welding hazards.
1.      Welding Helmet:
A welding helmet or mask can protect welders from radiation and sparks that damage the eyes and skin and are emitted by the arc. For
extra protection for your ears, hair, and head I recommend wearing a welding cap under your helmet.
2.      Eye Protection:
Welders should always wear eye protection, including goggles or safety glasses with side shields. Don’t pick up just any safety glasses
or goggles; your eye protection needs to meet the standards .
3.      Respirators:
To ensure that the welders don’t inhale harmful fumes or gases that can have a detrimental effect on their health, respirators
must be used. However, not all respirators are designed for every gas, so ensure you have the correct respirator for the fumes
that are in your workspace.
4.      Flame Resistant Welding Gloves:
During welding, your hands are in the closest proximity to the arc so you need to wear gloves designed to protect your hands
and lower arms from intense radiation, sparks, and the heat generated when welding.
5.      Protective Suits:
Since welders work in an environment where they are exposed to extreme temperatures, sparks, and flames, it is important to
wear protective suits to protect their skin from burning. This is not the case for every shop or situation. My son welds wearing
a heavy welding shirt, jeans, and square toe cowboy boots.
6.      Welding Specific Boots
Welding-specific boots are an essential piece of your work clothing as they protect the top of your feet from flames and sparks.
Most leather work boots are fine to use when welding, but be aware that sparks are likely to fall on your feet and mark them.