document.xlsx Sr.No Process Parameters Item to be checked Record Conform 1 Preparations Before Welding (4M - Man/Method/Machine/Material) 1.1 Welder (MAN) 1.1.1 Welder Qualification 1.1.2 Welder Qualification List 1.1.3 Welder Utilization 1.1.4 1.1.5 Monitor Welder Repair Rate 1.2 Welding Process ( METHOD) All welders are qualified in accordance with IBR and ASME Section IX. (Compliance to ASME Sec. IX and approved SOP) All qualified welders list is prepared and maintained along with their qualified range & validity, otherwise, the engineer will suffer form verification whether each welder is eligible to weld the particular joint. qualified range & validity is utilized so that product-wise assignment of welders can be done smoothly. On Site Arrival - Welder Check Test whether individual welder can properly perform welding even if he has the IBR certificate. utilize the information in order to improve the rate of weld defect. Depending on the rate, the welder with poor rate must be re- trained. Check point : Monitor the result of NDE and utilizing the same for re- training.
Transcript
document.xlsx
Sr.No Process Parameters Item to be checked Record Conform Non conform Remarks
1 Preparations Before Welding (4M - Man/Method/Machine/Material)1.1 Welder (MAN)
1.1.1 Welder Qualification
1.1.2 Welder Qualification List
1.1.3 Welder Utilization
1.1.4
1.1.5 Monitor Welder Repair Rate
1.2 Welding Process ( METHOD)
All welders are qualified in accordance with IBR and ASME Section IX. (Compliance to ASME Sec. IX and approved SOP)
All qualified welders list is prepared and maintained along with their qualified range & validity, otherwise, the engineer will suffer form verification whether each welder is eligible to weld the particular joint.
Qualified welders list along with their qualified range & validity is utilized so that product-wise assignment of welders can be done smoothly.
On Site Arrival - Welder Check Test
whether individual welder can properly perform welding even if he has the IBR certificate.
Rate of weld defect of each welder and utilize the information in order to improve the rate of weld defect. Depending on the rate, the welder with poor rate must be re-trained. Check point : Monitor the result of NDE and utilizing the same for re-training.
WPS/PQR and HPS is prepared according to the drawing and FWS in consideration with ASME/IBR requirements, then qualified and approved. Also shall ensure that instruction to workers is properly done. Check point : 1.Consistency between drawing, FWS, WPS/PQR, HPS, job card 2. Whether the items specified in the job card are sufficient. 3. Whether instruction is properly given to workers
PWHT is properly done through the demonstration by PWHT subvendor, including that specified width of soaking band not only at outside of pipe but also inside can be kept within the range of holding temperature. Check Point : Check the above demonstration satisfy the requirement.
Machines/Equipment and tools are properly maintained at regular intervals. The maintenance record shall include machine/tool ID, points to be checked, date, name of checker and history of check. Check Point : Machines/Equipment and tools to be maintained is identified, properly maintained and recorded with history
document.xlsx
1.3.1 Equipment Maintenance
1.3.2 Machines/Equipment Accuracy
1.4 Material - Consumables & Shield Gas
1.4.1 Electrodes - Brand Approval
Machines/Equipment and tools are properly verified at regular intervals. The verification record shall include machine/tool ID, calibration record with accuracy, traceability and history as applicable Check Point : Machines/Equipment and tools to be verified is identified, properly verified and recorded with history and traceability as applicable.
Use welding consumables which is not listed in MHI TLA document, high temp mechanical property shall be checked with MHI basically before commencement of work, i.e. high temp tensile and creep rupture test report. (excl. carbon steel)Check Point : Brand name of welding consumables likely to be used. Test report also will be checked.
document.xlsx
1.4.2 Storage/Issue of Electordes
1.4.3 Sheilding Gas
2 Boiler Pressue Parts Joint Fitup
2.1 Cleaning the Weld Groove
Identify points to be checked for welding consumables acceptance, establish acceptance procedure and ensure the same is done properly. Establish the procedure of the storage, baking, identification and issue and return of welding consumables. Check Point : Actual practice of acceptance and Procedure is sufficient
Purity of the shield gas with the inspection report/certificate.Check Point : Conformity Certificate
The surface of weld groove shall be kept clean to prevent from weld defect.Establish the management process of the cleanness of the surface of weld groove. Check Point : The status of execution of InspectionThe status of the inspection recordThe status of the actual product (including the maintenance up to welding start)Acceptance criteria : Cleanness of weld surface is specified in ASME Sec. PW-29.3ⅠThe method of base metal preparation used shall leave the welding groove with reasonably smooth surfaces and free from deep notches, striations, or irregularities. The surfaces for welding shall be free of all scale, rust, oil, grease, or other foreign materials.
document.xlsx
2.2 Foreign Material Control
2.3 Control of Fitup Lugs
The foreign materials cause the fatal damage of components during plant-operation stage.Countermeasure the foreign materials in products.The establishment of procedure to ensure the inside component is free from foreign materialAbove procedure shall include the marking of name of checker and date on components to clarify the status of check.Check Point : The status of execution of the procedureThe status of the record The status of the actual product
Fit-up lugs have to made with proper material.“Proper material” means Same Grade material with base materials of joint,Traceable material with mill certificate (Cutting record, ID marking i.e. color and hard stamp)The fit-up lug shall be welded according to WPS of the full welding. Therefore the material of lug and welding consumables shall be comply with the WPS. Check Point : The process of the preparation of lug and recordThe fit-up welding recordThe status of actual componentsThe NDE record of the lug-removed area
document.xlsx
2.4 Groove Dimension
3 Welding Process Control
3.1 Welding Instruction
The groove shall be fitted according to the drawing and the code requirement. Establish the procedure of measurement of groove dimensions, measure according to the procedure and record. Check Point : The status of execution of inspection The status of the inspection record The status of the actual product (Include the mark of the name of checker and the date on components)
Ensure the welding is properly done strictly according to the job card and relating instructions (for example issuing slip etc.).Check Point : Process is properly done through the demonstration by LMB/TPPC engineers.
document.xlsx
3.2
3.3
3.4
Welding consumables Control Ensure the welding consumables are used according to the LMB’s procedure.Check Point : Verify Actual practice
Preheat and Interpass Temperature Control
Ensure the weld joint is preheated and kept below the specified maximum inter-pass temperature according to the job card and LMB’s procedure. Check Point :Whether the procedure is sufficient.The actual practiceThe record
Controlling of shield gas
Ensure the flow rate of shield gas is within the range specified in the WPS. LMB/TPPC engineer shall ensure the back shield is done according to the WPS.Check Point : Whether the procedure is sufficient.The actual practiceThe record
document.xlsx
3.5
3.6
Welding Records Content4 REPAIR WELDING
Checks on complete welds
Ensure the weld joint is checked with the procedure of the visual inspection and marked/recorded the result on completion of weld joint.Such marking on components to release to the next process shall be done after NDE process also.Check Point : Whether the procedure is sufficient.The actual practiceThe record/marking
Pressure parts welding and attachment welding to pressure parts are recorded. Identify the items to be written in the welding record and ensure the items are properly recorded according to the procedure. Check Point : Items of the welding record and the procedure is sufficient.
document.xlsx
4.1
4.2
5 PWHT
5.1 PWHT instruction
5.2
Repair welding instruction and record
Establish the repair welding instruction and recording procedure, including work flow, items to be specified. Ensure that repair welding is done according to the above procedure and recorded properly. Check Point : Whether the procedure is sufficient.The actual practiceThe record
Repair welding of products made with 9%Cr material Establish weld defect removal procedure for 9%Cr
materials. Special care shall be taken for removal of the weld defects of 9%Cr materials.
Ensure the PWHT is properly done strictly according to job card, and HPS.Check Point : Process is properly done through the demonstration by LMB/TPPC engineers.
Record the results of PWHT
Check PWHT is performed according to the job card and record the following checking items with temperature chart. Drawing No. Joint No. Job card No. Power source/heat element/recorder device No. Base material specification Operated Date Heating/Cooling rate Holding temperature Holding time Chart feeding speed The location of thermocouple Control No. of thermocouple and Used timesCheck Point : Result of PWHT has done according to the job card.
document.xlsx
6 Scheduling of fabrication
Plan welding schedule (including preheating, PWHT, NDE) based on the erection schedule with consideration of the following points. Number of welders/fittersNumber of joints per man-shift Target of weld defect rateNumber of equipment (preheat, welding, PWHT, NDE) Effect of weather/monsoon Check the progress and the difference from the plan, and take recovery action if the difference occurred. Planning and progress check - Number of joints per man-shift Number of welders/fittersWeld defect rateNumber of equipment (preheat, welding, PWHT, NDE) Number of joints per man-shift shall be checked first then check the other parameters if necessary.Check Point : Welding planning system is properly done. Control the progress of each joint
