Fabrication

IN-PROCESS INSPECTION

The following activities shall be performed during in-process inspection:

1. QC inspector shall check the cleaning of fit-ups prior to start of welding.
2. QC inspector shall check the preheating requirement as per WPS.
3. QC inspector shall check the correct WPS, welder and welding consumables required for the joint to be welded.
4. QC inspector shall check the purging requirement for SS welding.
5. Each welder shall check the inter-pass temperature with the tempil stick, and the QC inspector shall monitor the inter-pass temperature.
6. QC inspector shall monitor the requirement of protection due to weather conditions.
7. QC inspector shall record the welder number adjacent to each joint.
8. QC inspector shall monitor the baking, holding, issue and return of welding electrodes.
9. QC inspector shall monitor the use of specific SS tools and wire brushes for the welding of SS materials.
10. QC inspector shall verify the identification tag of each piping spool.

Reference Procedures

• PCR-QCP-11 : Carbon Steel & Stainless Steel Piping Fabrication and Installation Procedure
• PCR-QCP-12 : Welding Consumable Control Procedure
• PCR-QCP-13 : Welding Control Procedure

Fabrication 23

NDE

1. NDE shall be carried out in accordance with the approved procedure of WPS and NDE piping matrix.
2. NDE shall be carried out after 24 hours of welding completion.
3. The NDE technicians shall prepare the NDE reports, which shall be endorsed by the welding inspector.
4. Should NDE examination reveal weld defect, weld repair shall be carried out using the approved WPSR. The repaired weld shall be re-radiographed. Repair shall be limited to a maximum of two attempts. Third repair shall be subject to cutout.
5. The welding inspector shall keep a summary record of the welder’s performance. The frequencies of weld repair rate shall be monitored on a weekly basis, based on individual performance and the project overall.

Quality Assurance and Quality Control

1. Inspection records shall be properly recorded and maintained with proper identification for each welded joint.
2. Inspection shall be carried out as per approved procedure, and the results shall be recorded properly.
3. Safety procedures shall be strictly followed in each inspection procedure, and in handling the inspection equipment and work environment.
4. Checklist for spool release:
   1. Conformance to construction and installation specifications.
   2. Identification and control of materials.
   3. Personnel are adequately qualified by certification, experience or training.
   4. Conformance to inspection (QC) and work performance procedures.
   5. Conformance to record-keeping requirements.
   6. Control of non-conforming items.