1. PURPOSE
1.1 This work instruction describes the methods applied to monitor and control fabrication (fit up, welding, and visual inspection) for structural and piping fabrication.

2. REFERENCES
The following project procedures will be used in this procedure:

  • Project’s Inspection Test Plan
  • Client’s specifications
  • Welding Consumable Control instruction
  • NDT procedures
  • AWS D1.1 – current revision
  • ASME B31.3 – current revision
  • Welding Procedure Specifications

3. RESPONSIBILITIES
3.1 It is the Production Manager’s overall responsibility to ensure that fabrication works are performed in accordance with this procedure.
3.2 It is the QCE’s responsibility to ensure implementation of this procedure and to ensure compliance with approved welding procedure.
3.3 QCI/QCE shall be responsible for assessing the acceptability of the fabrication, welding, and testing.
3.4 NDT Technicians shall be qualified to the required codes and standards or approved by Client. They will be responsible for the application of non-destructive testing (NDT) techniques on all welds to be tested.

4. INSPECTION PROCEDURE
4.1 Materials
4.1.1 Receipt: All the materials and equipment to be used for fabrication shall be inspected to ensure that all the materials are in good condition. Records of materials receipt inspection shall be carried out.
3.1.2 Preparation: From the isometric drawing the cutting plan shall be prepared. The heat Number of the pipe shall be transferred to each pipe section to ensure that traceability is constant.

4.2 Fabrication
4.2.1 Edge preparation and fit up: Joints fit up shall be inspected by QC inspector to ensure that it is in accordance to the approved WPS and as the requirements of ASME B.31.3 (for piping), AWS D1.1 (for structural welding) or client requirement.
4.2.2 Tack welding: Tack welding will be monitored by QC to ensure compliance with the requirements of ASME B31.3 (for piping) and AWS D1.1 (for structural welding). Tack weld may be carried out by the qualified welders or approved tack welder by Client.
4.2.3 Dimension control: Dimension control will be carried out in accordance with the project specification.

4.3 Welding
4.3.1 Welding will be carried out after acceptance of fit up.
4.3.2 QCI/QCE will be responsible for verifying the welders have qualification, Welder No., and qualification to the approved WPS.

4.3.3 QCI/QCE to ensure that correct welding consumable is used. The Welder ID, the welding joint No will be marked adjacent to the weld.
4.3.4 QCI/QCE shall carry out visual inspection.
4.3.5 Acceptance criteria shall be in accordance with ASME.B 31.3 Sec (for piping), AWS D1.1 (for structural welding) or Client’s requirement.

4.4. Non-Destructive Testing
4.4.1 Non-destructive testing to be carried out by qualified NDT Technicians. They shall be qualified in accordance with project specification.

4.5 Weld Repair
4.5.1 If the defect are identified, the weld repairs will be carried out in accordance with the welding repair procedure.
4.5.2 Welding repair guideline:

  • Remove all the defects by grinding and or arc air gouging.
  • Repair welding shall be carried out in accordance with the approved WPS.
  • Grind/gouge out weld area shall be MPI tested prior to re-welding.

4.5.3 Repaired weld area shall be checked in accordance with Section 4.3 in this instruction by QCI/QCE prior re-welding. The repaired weld shall be subject to original NDT.

 


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