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MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE


GEM/XXX.XXX-PROC-XX 0 Rev.

CONTENTS

SECTION NO
1.0 2.0 3.0 4.0
5.0

TITLE

SCOPE REFERENCE & CODE STANDARD GENERAL FABRICATION REQUIREMENTS PRODUCTION WELDING INSPECTION AND TESTING

1.0

SCOPE
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Fabrication & Inspection Procedure

MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE


GEM/XXX.XXX-PROC-XX 0 Rev.

This procedure details the requirements for the welding and inspection in the shop fabrication of Piping and Pressure Vessel.

2.0

REFERENCED DOCUMENTS
The following procedure : standards and code shall be considered part of this

ASME Section VIII Div. 1, 2007 Ed. Add. 2008 ASME Section II, 2007 Ed. Add. 2008 ASME Section V, 2007 Ed. Add. 2008 ASME Section IX, 2007 Ed. Add. 2008 - American Welding Society (AWS) D1.1, Latest Edition - ASME B31.1 / B31.3, Latest Edition

3.0

GENERAL FABRICATION REQUIREMENTS


Fabrication welding includes the inspection of material, equipments, workmanship, testing, and other items required to weld and inspect vessel fabrication. Each fabrication technique shall be in accordance with accepted current good engineering practice and shall be in accordance with requirements of all applicable specifications. Material shall be kept free from dirt , grease and other foreign matter, and shall be protected from corrosion. Fabrication shall take place at shop location to the greatest extent possible. All Code welding shall be in accordance with ASME Section IX and related Construction Code and specification and to qualified welding procedures. Unless otherwise specified, all welds shall be full penetration welds except where noted on drawings. All welds shall be continuous. Butt welds between materials of different thickness shall be tapered by grinding the thicker parent material at a taper of 1 in 3 and not by the use of additional weld outside the width of the joint. When the different of thickness is less than 3/8 (10mm) the transition may be formed by adding addition weld metal and MT upon adequate surface dressing of the weld. Welding shall be done by Shielded Metal Arc Welding (SMAW), Submerged Arc Welding (SAW) & Gas Tungsten Arc Welding (GTAW). Weaving shall be limited to a maximum of 2.5 times core wire diameter or 12.7 mm, whichever is the smaller.

Fabrication & Inspection Procedure

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MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE


GEM/XXX.XXX-PROC-XX 0 Rev.

4.0

PRODUCTION WELDING
4.1

WELDING MATERIALS
Welding material to be used shall be as follows:

a) b)

For SMAW shall conform to low hydrogen E-70XX classification of SFA 5.1 For SAW shall conform to classification of SFA 5.17 & SFA 5.23 c) For GTAW shall conform to classification of SFA 5.18 & SFA 5.9 d) For FCAW shall conform to classification of SFA 5.20 & SFA 5.22 e) For GMAW shall conform to classification of SFA 5.18 & SFA 5.9

4.2 WELDING EQUIPMENT


To ensure the production of sound welds, welding machines, line-up clamps, beveling machines, cutting torches, tools, supplies and other equipment used in conjunction with the welding work shall be kept in good mechanical condition. Equipment shall be inspected at regular intervals. Equipment, tools, or supplies that are not satisfactory shall be rejected and replaced with satisfactory equipment and supplies. Welding machines shall have adequate controls for making the current adjustments as necessary for all welding requirements. Sufficient meters, portable or permanent, shall be provided to calibrate machines and to regulate voltage and amperage on a regular basis.

4.3 WORKMANSHIP
Shearing, flame cutting, beveling and chipping shall be done carefully and accurately with an automated or mechanically guided tool, where possible. Any beveled edge that has been damaged shall be restored prior to welding. The cutting line shall be marinated to allow the back dressing of 0.5 mm (minimum). Beveled edge of carbon steel material to be stored for more that two weeks may be protected by a lead free primer coat, such as deoxialuminate of about 10 m. Surfaces of metal to be welded and 2 inches to either side of the weld, shall be free of fins, tears, cracks, mill scale, slag, rust, oil, paint, and other defects or contaminants which might adversely affect the quality or strength of the weld. Run On - Run Off tabs , used in welding of longitudinal seams and plate splices, shall be of the same thickness, specification , grade and edge preparation as the plate being welded. Tabs shall be of a minimum length of 200 with a width of 150 to permit complete
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MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE


GEM/XXX.XXX-PROC-XX 0 Rev.

freezing of the puddle on the tab before extinguishing the arc. Material for the Run On - Run Off tabs shall be furnished from original. The welding shall proceed in a manner that minimizes residual stresses or distortions. The welding arc shall only be struck within the weld preparation or onto already deposited weld metal. Should arc strikes occur outside the joint, they shall be removed, flushed and NDE by MT or PT. It is advisable to use Striking plate . When more than one weld pass is deposited on a joint , each pass shall be thoroughly cleaned by wire brushing and chipping before the next pass is applied. Welding shall not be discontinued until half weld is completed. If interruption occurs after this stage, such as for inspection etc., then the minimum preheat shall be ensured before restarting Weld shall not be quenched or unnaturally cooled and shall be protected from rapid cooling caused by rain, wind, or inclement weather. Suitable wind breaks / shields shall be provided during high wind velocity exceed 10 mph. Completed weld shall be cleaned of any slag residue to permit inspection. Completed welds shall be clearly marked with welders stamp every 3 ft. to allow proper documentation of weld or recorded in welding map.

4.4 WELD PROFILE


Where shown on the Specification Drawing or required by the Code Requirement, weld profile control shall be carried out to improve the fatigue life of the vessel. The surface reinforcement profile shall be in accordance with ASME Construction Code acceptance criteria. See Attachment 1 for Acceptable and Unacceptable Weld Profiles .

4.5 FIT-UP AND ALIGNMENT


When required, stiffeners shall be fitted accurately, neatly, and tightly to transmit bearing loads. Stiffener end shall be or ground smooth to conform to the geometry of the stiffener member to assure 100 percent fusion in the root of the weld. Excess root opening at welds my be repaired by depositing weld
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MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE


GEM/XXX.XXX-PROC-XX 0 Rev.

metal from one side only , by applying weld buildup to their side of the joint (i.e. through member). The maximum weld buttering deposit thickness shall be limited to 3/8 inch (10 mm) total for any weld joint. The corrected root opening shall be capable of closure with a single pass of an approved electrode weaving techniques shall not employed to close excessively wide root openings. In the event that joint fit-up tolerances for production welds exceed permitted values, buildup of the joint surfaces via weld buttering is permissible, using a qualified, approved, weld buttering procedure (see Sect. IX for qualification of Buttering / Built-up and Construction Code).
4.6

TACK WELDING
Tack welding, seal welding, and welding of temporary attachments (Including scaffolding supports and tie -downs) shall be performed in accordance with the welding parameters in approved welding procedures. Tack welds shall have a minimum length of four times the plate thickness, or 2 inches, whichever is less, be ground to a feather edge, and completely fuse with the root run should they be part of the completed weld. And only qualified welder shall making tack weld.

4.7

TEMPORARY WELDS
Temporary welds on items such as handling attachments and lugs, shall be minimized. When temporary welding is necessary the welding shall be performed with the same care, materials, processes, minimum preheat and welding procedures as permanent welds. The temporary weld shall subsequently be removed with an oxy-acetylene torch or arc gouging, by severing the attachment no closer than 1/8 inch (3.2 mm) from the surface of the vessel part and grinding the remainder of the weld deposit flush with the vessel part. Temporary weld shall not be removed by hammering. After grinding, the surface shall be inspected by dye penetrant test and repaired as specified herein, if defects are discovered. Temporary welds are prohibited on elements of the vessel part which have been post weld or relief heat treated.

4.8

WELD REPAIR
A weld repair specification, including the method for removal of defects preparation of weld area, subsequent nondestructive testing, and the minimum and maximum repair length/depth shall be prepared by Production Supervisor and submitted to Q.C. Supervisor for approval and Client for major repair for his concurrence. The weld repair specification shall be approved before any welding is performed.

Fabrication & Inspection Procedure

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MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE


GEM/XXX.XXX-PROC-XX 0 Rev.

The Production Dept. shall repair the defect in accordance with the approved welding specification and Companys Standard Operating Procedure No. QP-02-05 (STANDARD PROCEDURE WELDING DEFECTS REPAIR). The Production Dept. shall notify QC Inspector and Client about any repair welds performed to correct weld defects, weld bevel imperfection and/or base material defects or imperfections. The repair of defects in weld deposits or base metal shall be approved by QC and Client prior to executing the repair and Client shall have right to witness such repair. Removal of the defect may be by any method which produces a clean surface for the installation of the repair weld deposit. Details of all defects and their subsequent repair shall be documented, for insertion in the inspection reports. Cracks, plus approximately 2 (two) inches (50 mm) of sound metal at each end, shall be removed (by grinding) to sound metal. Dye penetrant test or magnetic particle examination of the excavated and ground cavity, prior to welding, is required to verify complete removal of the crack. The entire weld joint shall be removed if, in the opinion of QC Inspector or Client, the vessel part can not be properly inspected or repaired or if the weld is rejected. For detail refer to Standard Operating Procedure No. QP-02-05 (STANDARD PROCEDURE WELDING DEFECTS REPAIR).

5.0

INSPECTION AND TESTING


5.1 GENERAL The Client reserves the right to request testing of any welding samples at any time as necessary to maintain verification of the quality of welding work. 5.2 QUALITY CONFORMANCE INSPECTIONS 5.2.1GENERAL This section defines the minimum technical requirements for the inspection of the Piping & Pressure Vessel structural. The QC. Dept. Shall inspect and documented all work during fabrication and assembly through the utilization of qualified quality control inspectors and NDE personnels

Fabrication & Inspection Procedure

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MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE


GEM/XXX.XXX-PROC-XX 0 Rev.

The Q.C. Dept. shall provide Client access to fabrication facility at all times of work at any stage and to reject any part not complying with this specification. When, in the opinion of Client, any section requires inspection, the Production Dept. shall thoroughly clean the section of all excess and waste materials (such as sand, slag, or welding electrodes) and shall provide for the section to be properly inspected by Client. The latest edition of the specifications and codes referred to in this specification shall be available. The production shall furnish, install, and maintain in a safe operating condition, all scaffolding, ladders, walkways and lighting as necessary for the safe and through inspection of work by Client and provide adequate office space during surveillance visits. 5.2.2STAGE OF INSPECTION As a minimum, the inspection stages employed by the QC Inspector for welded joints shall be as follows : - Fit-up prior to first pass and where required during thru root pass. - Following any back grinding operation - Following completion of weld. Inspection at fit-up prior to first pass shall be visual and dimensional, checking tack welds and pre-heat applied. Inspection following root pass or back grinding shall normally be visual only, unless one or more of the other techniques described in Para. 5.2.3 are require to explore the extent of visually observed flaws, or unless previous production performance indicates that unacceptable flaws may be presented. Inspection at weld completion shall be carried out, as instructed in this specification, by one of the methods listed in 5.2.3. Welds in High Strength Material (50 ksi yield and above), due to the possibility of delayed hydrogen cracking, shall be Non Destructive Examination no less than 48 hours after welding. If difficulty is experienced in evaluating defects revealed by radiography, then ultrasonic test may be as an alternative
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MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE


GEM/XXX.XXX-PROC-XX 0 Rev.

means, subject to Client approval.


5.2.3 METHODS OF NONDESTRUCTIVE INSPECTION OF WELDS

Visual Inspection Visual Inspection of the stages listed 5.2.2, shall include, but not limited to the following : - Each weld appearance shall be in accordance with the requirement of the related Code Construction. - Each weld surface profile shall be in accordance with Section 4.5 - Each weld attaching internal ring stiffeners - Other welds in addition to the above, as specified by QC. Inspector or Client Radiographic Examination The QC Dept. shall submit the Radiographic examination procedures to ASNT/NDT Level III for review and acceptance. ASNT/NDT Level III reserves the right to test the Shops radiographic examination procedure to ensure that the procedure meets Construction of Code requirements. The shops radiographic examination procedure shall be capable of detecting the welds flaws permitted by the acceptance criteria of the ASME Construction Code. X-Ray or gamma ray techniques may be used. Film exposure techniques and processing shall provide a film free from defects, which will show a 1.8% X-Ray and 2% Gamma Ray sensitivity based on the nominal wall thickness. The shops / sub-contractor shall comply with the safety requirements of current Indonesian National Safety Regulation for Atomic Energy (BATAN). In particular , the shops shall record the quantity of radiation received by radiographers, their helper and any others personnel near sources of radiation. Upon completion of the work, or earlier, the shop/sub-contractor shall return all radioactive material to the place (s) of origin and shall not otherwise dispose of such material by any method, time any place. Radiographers shall be qualified as a minimum in accordance
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MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE


GEM/XXX.XXX-PROC-XX 0 Rev.

with SNT -TC-1A Level II or equivalent. All films shall be identified by job number, weld number, thickness, diameter and welder stamp as a minimum to allow full traceability. Film shall be held for storage in a film safe box. as part of inspection records, and retain for at least for 5 (five) years. For detail refer to Standard Operating Procedure No. QP-04-02 (STANDARD PROCEDURE FOR RADIOGRAPHIC TESTING).

Ultrasonic Examination The shops/sub-contractor ultrasonic examination procedure shall be submitted to QC. Dept. and ASNT/NDT Level III for review and acceptance. As a minimum, the shop sub-contractor procedure shall be capable of defecting any weld flaw permitted by acceptance criteria stated in the related ASME Construction Code. QC. Inspector and ASNT/NDT Level III reserves the right to test the shop sub-contractor ultrasonic examination procedure, to ensure that the procedure meets the Codes requirement. If the shop sub-contractor procedure proves inadequate, QC / ASNT/NDT Level III reserves the right to change the procedure to one that gives required weld flaw sensitivity. Ultrasonic operators shall be qualified in accordance with SNT-TC1A Level II or equivalent. Refer to Standard Operating Procedure No. QP-04-03 (STANDARD PROCEDURE FOR ULTRASONIC TESTING). Magnetic Particle Inspection & Dye Penetrant Test The shop sub-contractor shall submit the MT/PT procedure to QC and ASNT/NDT Level III for review and acceptance. The MT/PT procedure shall be in accordance with Shops Standard Procedures. Acceptance level shall be in accordance with related ASME Construction Code.
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MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE


GEM/XXX.XXX-PROC-XX 0 Rev.

QC and TPI reserves the right to test the shop/sub-contractors procedure to ensure that the procedure meets Codes requirements. Inspectors using MT/PT shall be qualified as a minimum in accordance with SNT-TC-1A Level II or equivalent. Refer to Standard Operating Procedure No. QP-04-04 (STANDARD PROCEDURE FOR MAGNETIC PARTICLE TEST) and QP-04-05 (STANDARD PROCEDURE FOR LIQUID PENETRANT TEST).

Acceptable and Unacceptable Weld Profiles

Attachment 1

Fabrication & Inspection Procedure

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MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE


GEM/XXX.XXX-PROC-XX 0 Rev.

Fabrication & Inspection Procedure

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