QUALITY CONTROL REPORT QCR FORM NUMBER DATE APPROVED QR NUMBER

In-Process Welding Inspection QCR-W-2006 WELD-

PROJECT TITLE PACKAGE NUMBER CONTRACTOR / SUBCONTRACTOR
JER PACKAGE # 3, Aromatics Unit 3 SAMSUNG
EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.

LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.

SCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME

COMPANY USE ONLY

JERITP NUMBER COMPANY ACTIVITY NUMBER WORK PERMIT REQUIRED?

COMPANY INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
A Joint preparation & cleanliness:
JERES-W-011
Weld number and weld symbol are marked adjacent to the weld joint.
A1 (NOTE: Markings shall be made with a suitable weather-proof marking
material. ) Para.
17.1
JERES-W-011
Weld joint idenntification markings conformed with the requirements of
the approved Weld Joint Identification System per QCR-W-2008.
A2
(NOTE: Project QA/QC and Company Representative may attach the
Para.
weld numbering system as Attachment 1 to this checklist.)
17.2
JERES-W-011
An approved Welding Procedure (WPS) is available at the weld site.
A3 (NOTE: Page A1of the welding procedure approval request requires
signature by the Company Inspector. ) Para.
8.1.8
Welder(s) have been issued Job Clearance Card, and that range of
A4 WPQTP
qualification shown matches the aplication of WPS being used.

JERES-W-011
Oil, moistures, scale, rust, paint, (except an approval weldable primer),
metallic coatings (e.g. Zinc) or other foreign matter, has been removed
A5
from the weld surface and at least 25mm of the adjacent base metal
Para.
surface.
12.3.1
JERES-W-011
Coated and clad or overlaid surfaces are protected from the welding arc,
A6 associated weld spatter, and damage from ground clamps or other
associated equipment. Para.
12.11
JERES-W-011
Stainless steel and nonferrous material is cleaned with grinding wheels
A7
or stainless steel brushes, not previously used on other materials.
Para.
12.4.3
B Welding Environment:
JERES-W-011
Wind shields or tents are installed when the wind is strong enough to
B1
affect arc stability or sheilding gas coverage.
Para.
JERES-W-011
12.2.1 & 12.2.3
The wind velocity in the weld area for GTAW, GMAW, or gas shielded
B2
FCAW shall not exceed 8 kph (2.2 m/s). JERES-W-011
Para.
Welding is not done duriing inclement weather e.g., wind blown sand, 12.2.1
B3
rain etc.
Para.
12.2.2
JERES-W-011
For field welding, remote Current controls shall be used if the welding is
B4 more than 30 m from the welding power source or when the welders are
working in "remote" locations (e.g., on an elevated piperack). Para.
20.1

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QUALITY CONTROL REPORT QCR FORM NUMBER DATE APPROVED QR NUMBER

In-Process Welding Inspection QCR-W-2006 WELD-

PROJECT TITLE PACKAGE NUMBER CONTRACTOR / SUBCONTRACTOR
JER PACKAGE # 3, Aromatics Unit 3 SAMSUNG
JERES-W-011
Welding power supplies for use in welding where in impact toughness
B5 test is required by the code or standard are verified to have been
validated within 1 year in accordance with BS 7570. Para.
20.2
C Welding Consumables
Filler metal size, type and classification conform with the WPS. JERES-W-011
(NOTE: A change in filler metal or deposit chemistry from A-number 1
C1 (based on ASME SEC IX) to A-number 2 and vice-versa is not permitted
without approval.) Para.
8.4.5
Filler metal and other weld consumables at weld site are maintained as Project Quality
C2
per QCR-W-2032. Plan

Welding Consumables shall be of the same brand, type and maximum

size as indicated on the WPS for the following welding processes:
a. GMAW JERES-W-011
electrode to be used for procedures with impact toughness
C3 requirements
b. SAW flux Para.
c. FCAW electrode 8.4.4
d. WPS/PQR using any consumable with a
"G" desingnation (ASME SEC II C) per JERES-W-011, Para. 7.4.8.

D Preheat
JERES-W-011
Wet or damp weld joints are surface dried by heating to a distance of
D1
100mm from the toe, and are hand warm before welding.
Para.
13.3

The actual preheat temperature was selected and used by the

fabricated that is sufficient to prevent cracking and to achieve the
required hardness, or, shall not be less than the greater of the following:

a) 10°C
b) The required or recommended preheat listed in
JERES-W-011
ASME B31.3. c) Pre-
heat temperatures from Std. Drg. W-AE-.036451 for all ASME P-No. 1
D2
materials, incliding API grades up to and including X60.
Para.
d) The
13.1 & 13.2
preheat listed in Tables 3A and 3B for the SMAW process. e)
Temperature determined by Company repersentative for steels with
specified minimum yield strengths above 60 ksi, (including API grades
X65 or greater) or for materials not listed as an ASME P-number.
f)
Temperature as specified in the approved welding procedure.

JERES-W-011
The preheat temperature shall be established over a minimum distance
D3
of 75mm on each side of the weld.
Para.
JERES-W-011
13.5
Temperature-indicating crayons, thermocouples, or contact pyrometers
D4
shall be used to measure preheat and interpass temperatures.
Para.
13.4
JERES-W-011
Temperature-indicating crayons have not been used for any weld joint
D5
that is to be coated, or that will have a heat-shrink sleeve installed on it.
Para.
13.4
JERES-W-011
On wall thickness exceeding 25mm, preheat is done from the same side
D6 as the welding and heat source removed fro 1 minute prior to measuring
the temperature. Para.
13.6
E Back Purging & Sheilding Gas

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QUALITY CONTROL REPORT QCR FORM NUMBER DATE APPROVED QR NUMBER

In-Process Welding Inspection QCR-W-2006 WELD-

PROJECT TITLE PACKAGE NUMBER CONTRACTOR / SUBCONTRACTOR
JER PACKAGE # 3, Aromatics Unit 3
JERES-W-011
SAMSUNG
Inert gas is used for GTAW or GMAW root passes on single-sided
E1
groove welds, on ASME P-No.5 materials and higher.
Para.
JERES-W-011
12.14.1
For P-No. 5 materials and higher, back purging is mailtained until at
E2
least 10mm of the weld deposit thickness is completed.
Para.
JERES-W-011
12.14.2
E3 Nitrogen as a backing gas for austentic stainless steel, is not used.
Para.
Sheilding gases conformed to the following requirements: a. 12.14.3
Carbon dioxide (CO2): Federal specification BC-C-101, Type B or JERES-W-011
Compressed Gas AssociationCGA G-6.2, Type F.
E4 b. Argon (Ar): Compressed Gas Association CGA G-11.1,Grade A.
Para.
c. Other gases and gas mixtures with approval from Company. 7.7

JERES-W-011
Back purge fir carbon and loe alloy steel has reduced the oxygen level
E5 to below1%
(NOTE: Verification is made by the use of oxygen analyzer. ) Para.
JERES-W-011
12.14.4
Back purge for stainless steel and nickel alloys has reduced the oxygen
E6 level to below 0.05%.
Para.
F Root Pass 12.14.5
JERES-W-011
The direction of welding conforms with the WPS.
F1 (NOTE: If the WPS is not qualified in the vertical position, then the
direction of welding shall be vertical-up.) Para.
JERES-W-011
8.4.7.1
Each weld pass is throughly cleaned and all slag or other foreign matter
F2 removed before the next pass is deposited. NOTE: See WPS remarks
for cleaning method, e.g. mechanical brush. Para.
JERES-W-011
12.4.1
F3 Root pass is deposited without backing for WPS qualified for single-
sided groove welds without backing. Para.
8.4.10
JERES-W-011
The GTAW process shall be used for the root pass of butt welds without
backing in piping and nozzles of 50.8mm nominal diameter or less.
F4
Para.
(NOTE: Exempted are vent and drain piping open to the atmosphere or
6.5.3
Category D piping. )

G Hot Pass & Weld-Out

JERES-W-011
The direction of welding conforms with the WPS.
G1 (NOTE: If the WPS is not qualified in the vertical position, then the
direction of welding shall be vertical-up.) Para.
8.4.7.1
JERES-W-011
Each weld pass is throughly cleaned and all slag or other foreign matter
G2 removed before the next pass is deposited. NOTE: See WPS remarks
for cleaning method, e.g. mechanical brush. Para.
12.4.1
JERES-W-011
SAW Flux fused during welding shall not be reused (i.e., fluxes that use
G3
recrushed slag are not acceptable).
Para.
7.5.2
The maximum allowable SMAW electrodes sizes that can be used are JERES-W-011
given below.
G4 a) Low hydrogen electrodes - 5mm for the 1G/1F poosition; 4mm for all
other positions. Para.
b) Non-low hydrogen electrodes - 5mm for all positions. 12.1
JERES-W-011
Remote Current controls are used if the welding is more than 30m from
G5 the welding power source or when the welders are working in "remote"
locations (e.g., on an elevated pipe rack). Para.
20.1
The heat input (HI) of each production weld is calculated (using the JERES-W-011
formula below) if nottch-toughness tests are specifid, and then
G6 confirmed not to exceed the heat input limits listed in theWPS's.
HI (kj/cm)=Voltage X Para.
Amperage X 60/Travel Speed (cm/min) 20.4

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QUALITY CONTROL REPORT QCR FORM NUMBER DATE APPROVED QR NUMBER

In-Process Welding Inspection QCR-W-2006 WELD-

PROJECT TITLE PACKAGE NUMBER CONTRACTOR / SUBCONTRACTOR
JER PACKAGE # 3, Aromatics Unit JERES-W-011
3 SAMSUNG
Adjacent weld beads shall be staggered and not started from the same
G7
location.
Para.
12.13

All full penetration joints requiring double sided welding shall be ground
or gouged to sound metal and inspected by penetrant testing (PT) or
magnetic particle testing (MT) prior to welding the reverse side, unless JERES-W-011
exempted by JERES-W-011, Para. 8.4.11 as follows:
G8 a) For automatic or
mechanized processes if additional PQR testing is conducted. Para.
b) For other 12.3.4
special processes, approved by Company Representative, on butt joints
where the production weld will be radiographed.

JERES-W-011
Unless specified otherwise, the maximum interpass temperature are:
G9 a. 177°C for P-No.8 and P-No.4x materials and
b. 315°C for p-1 steels. Para.
JERES-W-011
13.7
G10 Unless specified in the WPS, back welding is done using the same
process, consumables and preheat as the fill passes. JERES-W-011
Para.
Forced or accelerated cooling of welds is prohibited without the specific 12.17
G11
approval of Company. JERES-W-011
Para.
All slag, flux, weld spatters, and undercuts are removed from the 12.18
G12
completed weld and surrounding areas. Para.
REMARKS: 12.4.2

ATTACHMENTS:
Attachment 1 - Weld Joint Identification/Markings (NOTE: This will be attached by the Project QA/QC & Company).
REFERENCE DOCUMENTS:
1. JERES-W-011, Welding Requirements for On-Plot Piping (10'February'2010)
2. ASME SECTION IX,Welding and Brazing Approval (2008)
3. ASME B31.3, Process Piping,2008
4. Std Dwg for Pre-Heat for Welding Carbon Steel, Rev 2
6. Welding Performance Qualification Testing Procedure.
Contractor / Third-Party SATORP
Construction Representative* PMT Representative
Work is Complete and Ready for Inspection: T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:

QC Inspector CQT Representative

Performed Inspection Work / Rework May Proceed T&I Witnessed QC Record Reviewed Work Verified
Name, Initials and Date: Name, Initials and Date:

QC Supervisor Proponent and Others

Quality Record Approved: T&I Witnessed QC Record Reviewed Work Verified
Name, Organization,
Name, Sign and Date:
Initials and Date:

*Person Responsible for Completion of Quality Work / Test Y = YES N = NO F = FAILED

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