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DuPont Welding Quality Manual PDF
DuPont Welding Quality Manual PDF
Table of Contents
1. Purpose and Scope.....................................................................................................................2
2. Authority and Responsibility .....................................................................................................3
3. References...................................................................................................................................4
4. Jurisdiction, Code, and DuPont Standard Requirements and Applications .........................7
5. Design of Fabrication, Repairs and Alterations .....................................................................10
6. Material Procurement, Control and Storage...........................................................................12
7. Welding Procedure Specifications and Procedure Qualification Records..........................15
8. Welder Performance Qualification ..........................................................................................17
9. Examination, Inspection and Testing......................................................................................19
10. Non-Conformance.....................................................................................................................22
11. Job Documentation...................................................................................................................24
12. Auditing......................................................................................................................................25
Appendix A, Design Form Templates .................................................................................................29
Appendix B, Inspection and Test Plan and Traveler Form Templates ............................................47
Appendix C, Non-Conformance Form Template................................................................................53
Paper copies of this manual are uncontrolled. This copy is valid only at time of printing. The
control version of this document can be found in the DuPont Welding Technology Lotus Notes
database at this link.
a DuPont Site Welding QA/QC Representative) on staff. This person is permitted, but is not
required, to be the site Welding Champion.
It is recognized that plants or operating sites may elect to have on-site contractors (resident or
non-resident) and/or off-site contractors and fabricators perform some or all welding. These
contractors and fabricators may have a Quality Assurance/Quality Control person (henceforth
called a non-DuPont welding QA/QC representative) in their employ. However, this person
cannot be a Welding Champion, as the Welding Champion must be an employee of DuPont or a
DuPont subsidiary.
The Welding Advancement Technology Team (WATT) Leadership Team is responsible for
maintaining this manual and for answering questions regarding the content and application of this
manual. Questions and comments should be directed to one of the WATT Leadership Team
members.
3. References
The following references represent common standards, specifications or guidelines for welding of
plant equipment, including but not limited to, pressure vessels, heat exchangers, fired boilers and
boiler piping, process piping, utility piping (such as water, air, steam, nitrogen, and refrigeration
services), storage tanks, supports, bases, frames, structural steel, and sheet metal.
For specific requirements and application of these references, see Section 4, “Jurisdiction, Code,
and DuPont Standards and Application.”
ASME Boiler and Pressure Vessel Code
o Section I: Rules for Construction of Power Boilers
o Section II Parts A, B, C & D: Materials
o Section IV: Rules for Construction of Heating Boilers
o Section V: Nondestructive Examination
o Section VIII – Division 1: Rules for Construction of Pressure Vessels
o Section VIII – Division 2: Rules for Construction of Pressure Vessels, Alternate
Rules
o Section VIII – Division 3: Rules for Construction of Pressure Vessels, Alternate
Rules for Construction of High Pressure Vessels
o Section IX: Welding and Brazing Qualifications
ASME B31
o ASME B31.1: Power Piping
o ASME B31.3: Process Piping
o ASME B31.5: Refrigeration Piping
o ASME B31.8: Gas Transmission and Distribution Piping Systems
ASME B96.1: Welded Aluminum-Alloy Storage Tanks
NBIC: NB-23 National Board Inspection Code
Mainland China
o GB 150: Steel Pressure Vessels
o GB 151: Tubular Heat Exchangers
o JB 4708: Welding Procedure Qualification for Steel Pressure Vessels
o JB 4744: Welding Specification for Steel Pressure Vessels
o TSG D0001-2009: Pressure Pipe Safety Technology Supervision Regulation for
Industrial Pressure Pipe
o TSG R0004-2009: Supervision Regulation on Safety Technology for Stationary
Pressure Vessels
Europe
o PED
Pressure Equipment Directive 97/23/EC for Pressure Equipment
Pressure Equipment Directive 87/404/EC for Simple Pressure Vessels
o EN 13445: Unfired Pressure Vessels
o EN ISO 3834: Quality Requirements for Fusion Welding of Metallic Materials
o EN ISO 15607: Specification and Qualification of Welding Procedures For Metallic
Materials – General Rules
o PD5500: Unfired Fusion Welded Pressure Vessels
o AD2000: German Pressure Vessel Directive
Brazil
o Regulation Standard NR-13 Boilers and Pressure Vessels
DuPont Standards
o SG1S: Fabrication Requirements for Pressure Vessels and Similar Equipment
o SG1E: Shell and Tube Heat Exchangers for Process Service
o SG100S: Design Criteria, ASME Code Section VIII, Divisions 1 and 2
o SG101S: Fabrication Requirements for Pressure Vessels & Heat Exchangers with
Limited Design Conditions
o SG103S: Specification for Small Pressure Vessels & Heat Exchangers with Limited
Design Conditions
o SG104S: General Specification for Low-Pressure, Welded, Shop-Fabricated
Vessels
o SG105S: API Standard 650 Storage Tank Specification
o SP29M: Minimum Essential Receiving Inspection – Pipe
o SP34M: Minimum Essential Receiving Inspection – Fabricated Pipe
o SP37M: Minimum Essential Receiving Inspection – Welding Filler Metals
4.2.4.4 The organization performing the welding shall supply all the required
documentation showing the equipment or component complies with the
requirements of the repair or alteration code.
These forms shall be used in conjunction with an Inspection and Test Plan (ITP) and
Welding Traveler. See Appendix B for an Inspection and Test Plan Form template and
Welding Traveler Form templates.
5.5 Document Retention
Design documentation shall be kept on site in a secure location and is required to be
retained for the life of the equipment. Contractor and fabricator design documentation shall
be part of the turnover package provided to the site at the completion of work. Design
documents shall be accessible for review and auditing as required by the applicable code
and PSM requirements.
appropriate welding filler metal standards or specifications required for each job or
project.
6.1.6.1 Recommendations for filler metal selection can be made by a DuPont
materials engineer, the project engineer, or by the organization
performing the welding.
6.1.6.2 The final filler metal selection should be agreed upon between the
DuPont Site Welding QA/QC Representative or site Welding Champion
and the organization performing the welding before start of any welding.
6.2 Receipt Inspection
6.2.1 All incoming material shall be inspected, identified and verified that its meets the
requirements of the purchase order specification, appropriate materials
specification or standard and is accompanied by the proper documentation.
6.2.2 As a minimum material shall be supplied with a certificate of compliance, or when
required by code or contractual documents, a certified mill test report. All material
shall be properly marked according to the specification or standard with material
grade and heat number.
6.2.3 Piping shall receive receipt inspection per the requirements of DuPont Engineering
Standard SP29M or SP34M.
6.2.4 Welding filler metals shall receive receipt inspection per the requirements of
DuPont Engineering Standard SP37M.
6.3 Storage
6.3.1 Plate, Pipe and Wrought Materials
6.3.1.1 Materials shall be stored under cover whenever possible.
6.3.1.2 If storage under cover is not possible, material should be placed on
wood dunnage or metal racks to keep the material off the bare ground.
6.3.1.2.1 Wooden dunnage should be untreated.
6.3.1.2.2 Metal racks used for storage of corrosion resistant alloys,
such as copper alloys, stainless steel and nickel alloys,
should be made from stainless steel or should be covered
to prevent contamination of the corrosion resistant
materials by iron from carbon steel racks.
6.3.1.3 Materials shall be segregated to separate carbon and low alloy steel
from corrosion resistant alloys, such as copper alloys, stainless steel
and nickel alloys, to prevent possible detrimental contamination of the
corrosion resistant alloys by iron in the carbon and low alloy steels.
6.3.2 Welding Filler Metals
6.3.2.1 All filler metals, whenever possible, should be stored in the original un-
opened, un-damaged container.
6.3.2.2 Covered electrodes should be stored un-opened in their original
containers in a climate controlled area.
off-site contractors and fabricators at or for DuPont sites. The approver must have
adequate details of the scope of the welding job, such as drawings, weld maps or
detailed scope of work in order to approve the procedures. The approver may be
located at another DuPont site for this approval process.
7.2.2 Any contract welding or fabrication organizations performing welding activities for
DuPont, on or off site are required to submit their qualified WPSs and PQRs for
review and approval prior to any welding. The contract or fabrication organization’s
welding QA/QC representative, job supervisor, or engineer is responsible for
supplying the WPSs and PQRs for review and approval.
7.2.3 The approved WPS(s) shall be incorporated into the job plan and shall be available
at the job site for access and review by the welder(s). The First Line Supervisor
and or job planner/coordinator is responsible for supplying the WPS(s) to the
welder(s).
7.2.4 Welding shall be performed within the parameters of the approved WPS(s). The
designated DuPont or non-DuPont welding QA/QC representative shall be
responsible for auditing this process.
7.3 Standard Welding Procedure Specifications
DuPont owned Standard Welding Procedure Specifications (SWPSs), purchased from AWS,
are maintained in the “DuPont Welding Technology” Lotus Notes database.
These procedures can be used by DuPont welders at any DuPont site provided the following
requirements and limitations are followed.
SWPSs can be used for construction, repair, and alteration in which requirements of
the ASME Boiler and Pressure Vessel Code and Section IX are specified. Any
requirements of the applicable construction, repair, or alteration Code Section
regarding SWPSs takes precedence over the requirements of Section IX.
These SWPSs are not permitted for construction, repair, or alteration where impact
testing requirements are required by the applicable construction, repair or alteration
code.
You cannot deviate from any of the welding parameters and conditions specified on
the SWPSs. It cannot be revised.
Multiple process SWPSs shall be used in the order and manner specified.
You cannot combine any of these processes with another DuPont WPS in the same
production weld joint.
Additional instructions may be added as long as they are within the limits of the
SWPSs.
8.4.3 All contract and fabrication organizations performing welding activities for DuPont,
on or off site are required to submit Welder Qualification Records for review and
approval by the DuPont Site Welding QA/QC Representative, DuPont materials
engineer, and/or site Welding Champion prior to any welding activity being
performed. These records shall be kept in a secure location on site as long as the
welder or welding operator is making production welds for the site and shall also be
part of the turnover package provided to the site at the completion of work, as
described in Section 11, “Job Documentation.”
8.4.4 The Welder Performance Qualification Record shall include all the essential
variables, type of qualification tests and test results, and the variable ranges
qualified for each welder or welding operator. Welders and welding operators shall
be limited to welding only in the qualified process and parameters.
8.4.5 Each welder or welding operator shall be assigned an identifying number, letter or
symbol which shall be used to identify the work of the welder or welding operator.
8.4.6 A welder or welding operator’s qualification is valid for six months from the date of
the satisfactorily passed qualification test.
8.4.7 Re-qualification of the contract or fabricator welder or welding operator is required
if any of the following occurs:
The welder or welding operator has not made a production weld using the
qualified process within the previous 6 months.
A continuity log can not verify the welder or welding operator has welded in
the process within the previous six months.
When there is a specific reason to question a welder’s or welding operator’s
ability to make satisfactory welds the qualification shall be revoked.
9.2.2 Inspection: the review of documents, examination results, and the physical work
itself to verify that the fabrication, repair, or alteration conforms to the applicable
codes and standards and the engineering design. Inspectors may be granted
specific authorities, rights, and responsibilities by the codes and standards and by
the regulatory entity having jurisdiction over the site.
9.2.3 Testing: specifically, leak testing using a fluid or tracer medium. Examples of leak
testing methods are hydrostatic testing, pneumatic testing, and helium-leak testing.
9.2.4 Inspection and Test Plan (ITP): also sometimes called a Quality Plan, this
document details the examination/inspection/testing tasks, acceptance criteria,
reference documents, and approval signatures for a fabrication, repair, or alteration
job. The Inspection and Test Plan may be generated by the organization
performing the welding, by the DuPont or DuPont subsidiary operating site, or by a
third party, but it must be mutually agreed upon by the organizations involved. For
small, simple jobs, especially those performed by DuPont welders or resident
contractor welders, a separate Inspection and Test Plan may not be required;
rather, examination/inspection/testing tasks may be able to be fully described in
design documentation (see Section 5, “Design of Fabrication, Repairs and
Alterations”) and the Traveler.
9.2.5 Traveler: generated by the organization performing the welding, this document
tracks a job on a weld-for-weld basis. It provides the welder identification, Welding
Procedure Specification (WPS), filler metal, and examination and inspection
requirements and approval signatures for each particular weld. A weld map,
detail/isometric drawing, or key is typically included. The Traveler can serve as a
means for verifying that the requirements of the Inspection and Test Plan have
been met.
9.3 Responsibility
9.3.1 Operating Site
Each DuPont and DuPont subsidiary operating site shall have overall responsibility
for compliance with examination, inspection and testing requirements as
established in the applicable codes and standards. This responsibility includes, but
is not limited to:
Ensuring that appropriate staffing is in place for examination, inspection and
testing activities for fabrication, repairs, and alterations. Examinations and
inspections shall be performed by qualified individuals.
o For the qualification of examination personnel employed by DuPont,
DuPont Engineering Standard SG9T shall be followed. Outside of
the United States, this standard is optional. Where national or local
government Jurisdictional requirements exist, they shall be imposed
in lieu of the requirements of this standard.
o For contracted examination personnel, DuPont Engineering
Standard SG11T shall be used to verify their technical capability.
o Inspector qualifications and certifications shall follow the specific
fabrication, repair, or alteration codes and standards that require the
use of an inspector.
10. Non-Conformance
10.1 Purpose and Scope
This section establishes a procedure for the control and disposition of non-conforming
item(s) so as to prevent unintentional use or installation. This procedure applies to all non-
conforming materials, parts, welded components, and welded equipment whether produced
in-house by DuPont, resident contractors, or alliance supply companies, or obtained from
outside vendors, contractors or contract fabricators.
10.2 Responsibility and Authority
10.2.1 The DuPont Site Welding QA/QC Representative or site Welding Champion has
responsibility and authority to ensure this procedure is followed. The DuPont Site
12. Auditing
12.1 Purpose and General Requirements
The purpose of auditing is to ensure that all organizations performing welding functions
comply with the requirements and provisions of this manual and all applicable codes,
regulatory requirements, standards and the engineering design. As a minimum, auditing
activities shall meet the requirements of this manual and of the codes and standards listed
in Section 4, “Jurisdiction, Code, and DuPont Standard Requirements and Application.”
Auditing of external vendor organizations performed per this section is done to confirm the
abilities of vendors already on a site or corporate approved supplier list. It should not be
used for qualification of new vendors for inclusion on a site or corporate approved supplier
list.
12.2 Definitions
The following definitions apply to the use of these terms within this manual. Specific codes
and standards may define these terms differently, and those definitions take precedence.
12.2.1 Auditing: A formal methodical examination and review of an organization’s or
individual’s systems and activities. This includes audits of internal
(DuPont/subsidiary and on-site resident contractor) organizations and external (off-
site contractor and fabricator) organizations.
12.2.2 1st Party Audits: Audits conducted by on-site resources as a means to determine
gaps in welding programs, systems, and individuals, including design, weld
procedure development and qualification, production welding, examination,
inspection, and testing of weldments.
12.2.3 2nd party Audits: Audits conducted by off-site resources from other DuPont or
DuPont subsidiary facilities.
12.2.4 3rd Party Audits: Audits conducted by non-DuPont resources such as Moody
International, Det Norske Veritas, or Bureau Veritas.
12.2.5 Non-Conformances: Items that do not meet the specifications of codes, standards
or work practices as defined.
12.2.6 Periodic Audits: audits conducted to verify compliance of DuPont/subsidiary
welding organizations, on-site contractors (resident and non-resident), and off-site
contractors and fabricators to welding program and work system requirements.
12.2.7 Qualification or Re-qualification Audits: audits conducted to assess or re-assess a
non-DuPont welding organization for inclusion on a site or corporate approved
supplier list. It shall be the responsibility of the DuET/
DuCAP/Sourcing commodity teams to schedule and execute these audits
12.3 Responsibility
12.3.1 Operating Site
Each DuPont and DuPont subsidiary operating site shall have overall responsibility
for auditing and audit compliance requirements as established in this manual, the
applicable codes and standards, and any other regulatory, corporate, or site
specific documentation. This responsibility includes, but is not limited to:
Ensuring that appropriate staffing is in place for conducting auditing. Auditing
shall be performed by qualified individuals.
o For auditing personnel employed by DuPont, at least one auditor on
the team shall have not less than 10 years experience in the design,
fabrication, or inspection of welded components. Each 20% of
satisfactorily completed work toward an engineering degree
recognized by an accredited institution shall be considered
equivalent to 1 year of experience, up to 5 years total.
o For periodic auditing for compliance, it is acceptable to use an
individual from a third party organization who meets the above
qualification requirements. The third party organization shall be
qualified by the site Welding Champion with approval from the
appropriate commodity team or from the WATT Leadership Team.
When there is no active commodity team, it shall be the
responsibility of the site Welding Champion, at the direction of the
WATT Leadership Team, to recommend an auditor or to approve
the qualification of an auditor.
Including other appropriate personnel, such as the DuPont materials
engineer, DuPont Site Welding QA/QC Representative, and Sourcing
representatives, on audit teams or in audit communications.
Ensuring that periodic audits of DuPont/subsidiary welding organizations, on-
site contractors (resident and non-resident), and off-site contractors and
fabricators are conducted on a scheduled frequency as defined in Section
12.4.
Ensuring that non-conformances and action items identified during audits are
appropriately addressed, assigned, tracked, and resolved.
12.3.2 Site Welding Champion
The responsibilities of the site Welding Champion include, but are not limited to:
Verifying that organizations performing the welding functions within the scope
of this manual for his/her DuPont/DuPont subsidiary site(s) have received a
qualification audit and receive periodic audits.
Planning, scheduling, and executing (or delegating execution of) periodic
audits.
Writing or approving audit reports, and ensuring that audit reports are
communicated to the operating site.
When required, drafting appropriate action items (including responsibility and
timing) for submission to the operating site.
12.4 Periodic Audit Frequency
It is the responsibility of the site Welding Champion to execute (or delegate execution of)
periodic audits as planned or, when there is reason to question a potential non-
conformance, conduct an un-scheduled audit. Periodic audit frequencies are as follows:
Periodic auditing of site and resident contractor systems and personnel – Annually
Periodic auditing of off-site contractor or fabricator facilities, systems, and personnel
Every 3 Years, or
o change of ownership, change in QA/QC management, or other significant change
or events
o if there is a reason to question the work quality or integrity
12.5 Systems to Audit
The following systems, facilities and personnel shall be subject to audit:
Welding Quality Control/Quality Assurance Manual, and its adherence
Welding Procedure Qualification Records and Welding Procedure Specifications
Welder Performance Qualification Record(s)
Welder Continuity Records
Systems and processes for the design of fabrication, repairs and alterations
Piping, storage tank, pressure vessel, and welded component traveler(s)
Examination, testing and inspection records
Non-destructive examination procedures
Non-destructive examination personnel qualifications
Material control systems and practices
Approved By:
Title Print Name Signature Date
Owner-User
Designer
Authorized or
Jurisdictional Inspector
Appendices: Attach supporting documents when available. (e.g. photos, sketches, drawings,
calculations, analysis, etc...)
Appendix Number Title / Description
Fabrication Information:
Organization Performing Work:
Person Responsible for Calculations:
Flexibility Analysis Required: Yes No
If No, Provide Explanation:
Design Limits:
Pressure (Max/Min): Temperature (Max/Min):
Severe Cyclic Service: Yes No
Pressure cycles/year: Temperature cycles/year:
Pressure Test and/or Leak Test:
Pressure: Fluid:
Post-Weld Heat Treatment:
Temperature: Time:
Post-Fabrication Cleaning Requirements:
Painting:
Paint Specification: Comments:
Approved By:
Title Print Name Signature Date
Owner-User
Designer
Authorized or
Jurisdictional Inspector
Organization Performing Work
Appendices: Attach supporting documents when available. (e.g. photos, sketches, drawings,
calculations, analysis, etc...)
Appendix Number Title / Description
Painting:
Paint Specification: Comments:
New Materials of Construction: (Refer to Pipe Code) note if pipe is lined
Provide material grade, if applicable.
Type(s) Material Specification(s) Nominal Pipe Size(s) Schedule(s)
Pipe
Flanges
Fittings
Gaskets
Bolting
Approved By:
Title Print Name Signature Date
Owner-User
Designer
Authorized or
Jurisdictional Inspector
Organization Performing Work
Appendices: Attach supporting documents when available. (e.g. photos, sketches, drawings,
calculations, analysis, etc...)
Appendix Number Title / Description
Nozzles/Flanges/Manway:
Nozzles/Flanges/Manway:
Approved By:
Title Print Name Signature Date
Owner-User
Designer
Authorized or
Jurisdictional Inspector
Painting:
Paint Specification: Comments:
Materials of Construction:
Provide material specification, grade, temper or hardness, etc. if applicable.
Description Material Specification(s) Size(s) Other Information
Approved By:
Title Print Name Signature Date
Owner-User
Designer
Authorized or
Jurisdictional Inspector
Appendices: Attach supporting documents when available. (e.g. photos, sketches, drawings,
calculations, analysis, etc...)
Appendix Number Title / Description
B During Work
D Final Documentation
Title of Non-Conformance
Description of Problem
Disposition of Item
(check one)
Usable
Rework
Return
Scrap
Action Taken / Organization Responsible
Name
Title
Completion Date
Month Day Year