MECHANICAL PLANT

FABRICATION & INSPECTION PROCEDURE

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

SECTION NO TITLE

1.0 SCOPE

2.0 REFERENCE & CODE STANDARD

3.0 GENERAL FABRICATION REQUIREMENTS

4.0 PRODUCTION WELDING

5.0 INSPECTION AND TESTING

1.0 SCOPE

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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 standards and code shall be considered part of this

procedure :

- 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.

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4.0 PRODUCTION WELDING

4.1 WELDING MATERIALS

Welding material to be used shall be as follows:

a) For SMAW shall conform to low hydrogen E-70XX classification of SFA 5.1
b) 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 µ 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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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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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.
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The Production Dept. shall repair the defect in accordance with the
approved welding specification and Company’s 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 personnel’s

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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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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 Shop’s
radiographic examination procedure to ensure that the
procedure meets Construction of Code requirements.

The shop’s 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 shop’s / sub-contractor shall comply with the safety

requirements of current Indonesian National Safety Regulation
for Atomic Energy (BATAN). In particular , the shop’s 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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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 shop’s/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 Code’s 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-TC-

1A 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 Shop’s Standard
Procedures. Acceptance level shall be in accordance with related
ASME Construction Code.

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QC and TPI reserves the right to test the shop/sub-contractor’s

procedure to ensure that the procedure meets Code’s
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).

Attachment 1
Acceptable and Unacceptable Weld Profiles

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