Inspection For Fabrication & Welding

OCS Engineering & Construction (I) Pvt Ltd
INSPECTIONOF
INSPECTION OF
FABRICATIONAND
FABRICATION ANDWELDING
WELDING
 Pressure Vessels and Piping Industry

 Pressure Vessels and Piping Industry
Doc. No: OCS-QMS-SOP-001

Doc. No: OCS-QMS-SOP-001
INSPECTIONS OF MATERIALS
 the materials used in the construction of a pressure vessel

AllAllthe materials used in the construction of a pressure vessel
shall be identified to the relevant specification
shall be identified to the relevant specification
 the materials used in any pressure vessel shall conform to

AllAllthe materials used in any pressure vessel shall conform to
the Specifications as given in drawing
the Specifications as given in drawing
Material to a specification shall have a manufacturer’s test

Material to a specification shall have a manufacturer’s test
certificate and Marking and/or stamping as mentioned in test
certificate and Marking and/or stamping as mentioned in test
certificate.
certificate.
 Carbon percentage shall be less than or equal to 0.25% for

 Carbon percentage shall be less than or equal to 0.25% for
pressure parts No negative tolerance on plate thickness.
pressure parts No negative tolerance on plate thickness.

 the absence of mill test certificate, check testing shall be carried
InInthe absence of mill test certificate, check testing shall be carried
out in agreement with the inspecting authority. Check testing
out in agreement with the inspecting authority. Check testing
normally will be allowed only in the case of structural quality
normally will be allowed only in the case of structural quality
material and pipes and tubes of certain grades. Boiler quality
material and pipes and tubes of certain grades. Boiler quality
material will be accepted only against mil marking and mill T.C.
material will be accepted only against mil marking and mill T.C.

Carbon steel Dished end material shall be of low sulfur (0.01%
Carbon steel Dished end material shall be of low sulfur (0.01%
max.) if the dished is undergoing Spinning after Cold Pressing
max.) if the dished is undergoing Spinning after Cold Pressing
INSPECTIONS OF FABRICATION
When plates are shaped by oxygen or arc cutting, the edges to be welded and grind
When plates are shaped by oxygen or arc cutting, the edges to be welded and grind
smoothed shall be free of all loose scale and slag accumulations before welding.
smoothed shall be free of all loose scale and slag accumulations before welding.
 The surfaces to be welded and 25mm on both sides shall be clean free of scale,
 The surfaces to be welded and 25mm on both sides shall be clean free of scale,
rust, oil, grease, slag, detrimental oxides and other deleterious foreign material.
rust, oil, grease, slag, detrimental oxides and other deleterious foreign material.
 End of nozzles or manhole necks which are to remain unwelded in the completed
 End of nozzles or manhole necks which are to remain unwelded in the completed
vessel may be cut by shearing, but exposed inside edges shall be chamfered or
vessel may be cut by shearing, but exposed inside edges shall be chamfered or
rounded.
rounded.
Tack welds used to secure alignment shall either be removed completely when they
Tack welds used to secure alignment shall either be removed completely when they
have served their purpose or their stopping and starting ends shall be properly
have served their purpose or their stopping and starting ends shall be properly
prepared by grinding or other suitable means so that they may be satisfactorily
prepared by grinding or other suitable means so that they may be satisfactorily
incorporated into the final weld.
incorporated into the final weld.
 Butt-welded joints shall have complete penetration and full fusion.

 Butt-welded joints shall have complete penetration and full fusion.
 All welded surfaces are acceptable provided the surface is free from coarse
 All welded surfaces are acceptable provided the surface is free from coarse
ripples, grooves, overlaps and ridges and valleys to permit proper interpretation of
ripples, grooves, overlaps and ridges and valleys to permit proper interpretation of
non destructive examinations.
non destructive examinations.
 In making fillet welds, the weld metal shall be deposited in such a way that
 In making fillet welds, the weld metal shall be deposited in such a way that
adequate penetration into the base metal at the root of the weld is secured.
adequate penetration into the base metal at the root of the weld is secured.
 Fillet welds should have adequate root and side wall fusion. The legs of fillet
 Fillet welds should have adequate root and side wall fusion. The legs of fillet
welds should be equal and its profile somewhat concave rather than convex.
welds should be equal and its profile somewhat concave rather than convex.
In butt welds root run should be chipped back to sound metal before welding on
In butt welds root run should be chipped back to sound metal before welding on
the reverse side. In multi pass welding de- slagging after each pass is necessary.
the reverse side. In multi pass welding de- slagging after each pass is necessary.
 Butt welds should neither be under-flush nor with excessive reinforcement. Arc strikes,
 Butt welds should neither be under-flush nor with excessive reinforcement. Arc strikes,
undercuts, porosity, slag and surface cracks are not acceptable. Spatters should be avoided.
undercuts, porosity, slag and surface cracks are not acceptable. Spatters should be avoided.
 Longitudinal seams should be welded prior to circumferential seams, Run on and run off
 Longitudinal seams should be welded prior to circumferential seams, Run on and run off
plates attached at both ends of long seams will avoid defective weldments at these ends.
plates attached at both ends of long seams will avoid defective weldments at these ends.
 All surfaces of parent metals should be dressed free from injury and blemishes.
 All surfaces of parent metals should be dressed free from injury and blemishes.
Temporary welded hooks should be chipped off (not hammered out), and the area ground
Temporary welded hooks should be chipped off (not hammered out), and the area ground
and DP/MPT checked for flaws.
and DP/MPT checked for flaws.
 All plates for shell sections and for heads shall be formed to the required shape by any
 All plates for shell sections and for heads shall be formed to the required shape by any
process that will not unduly impair the physical properties of the material. Local hammering
process that will not unduly impair the physical properties of the material. Local hammering
is not permitted.
is not permitted.

If the plates are to be rolled, the adjoining edges of longitudinal joints of
If the plates are to be rolled, the adjoining edges of longitudinal joints of
cylindrical vessels shall first be shaped to the proper curvature by
cylindrical vessels shall first be shaped to the proper curvature by
preliminary rolling or forming in order to avoid having objectionable flat
preliminary rolling or forming in order to avoid having objectionable flat
spots along the completed joints.
spots along the completed joints.
When non pressure parts such as lugs, bracket saddles, etc. extend over
When non pressure parts such as lugs, bracket saddles, etc. extend over
pressure refraining parts, such welds shall be ground flush and DP tested
pressure refraining parts, such welds shall be ground flush and DP tested
before further attachments. or such parts shall be notched to clear those
before further attachments. or such parts shall be notched to clear those
welds.
welds.
 All Sharp edges shall be round off at the time of full welding, so as to
 All Sharp edges shall be round off at the time of full welding, so as to
take care of Aesthetics & to improve the life of applied coating.
take care of Aesthetics & to improve the life of applied coating.

WELDING INSPECTION
WELDING INSPECTION
BEFORE WELDING
BEFORE WELDING
 Safety:
 Safety:
Ensure that all operations are carried out in complete compliance with local, company
Ensure that all operations are carried out in complete compliance with local, company
or national Safety legislation.
or national Safety legislation.
 Documentation:
 Documentation:
Specification, Drawings, WPS & WPQ approvals, Calibration certificates, Material and
Specification, Drawings, WPS & WPQ approvals, Calibration certificates, Material and
consumables certificates availability
consumables certificates availability
 Welding Process and ancillaries:

 Welding Process and ancillaries:
Welding equipment and related ancillaries like cables, regulators, torches, ovens etc.
Welding equipment and related ancillaries like cables, regulators, torches, ovens etc.

WELDING INSPECTION
WELDING INSPECTION
BEFORE WELDING
BEFORE WELDING
 Incoming Consumables:
 Incoming Consumables:
All pipe/plate and welding consumables for Size, Type and condition
All pipe/plate and welding consumables for Size, Type and condition
 Marking, Preparation & Set up:

 Marking, Preparation & Set up:
Correct method of cutting weld preparation
Correct method of cutting weld preparation
Correct preparation (relevant bevel angles, root face, root gap, root radius, land etc)
Correct preparation (relevant bevel angles, root face, root gap, root radius, land etc)
Correct pre-welding distortion control (tacking, bridging, jigs, and line up clamps)
Correct pre-welding distortion control (tacking, bridging, jigs, and line up clamps)
Correct preheat applied prior to tack welding.
Correct preheat applied prior to tack welding.
All tack welding to be monitored and inspected
All tack welding to be monitored and inspected

WELDING INSPECTION
WELDING INSPECTION
DURING WELDING
DURING WELDING
 Preheat values (heating method, location and control)
 Preheat values (heating method, location and control)
 In process distortion control (Sequence or balanced welding)
 In process distortion control (Sequence or balanced welding)
 Consumable control (Specification, size, condition)
 Consumable control (Specification, size, condition)
 Process type and all related variable parameter (Voltage, amperage, travel speed)
 Process type and all related variable parameter (Voltage, amperage, travel speed)
 Purging gases
 Purging gases
 Welding conditions for root run/hot pass and all subsequent run and inter run cleaning.
 Welding conditions for root run/hot pass and all subsequent run and inter run cleaning.
 Minimum preheat or maximum Inter pass temperature control
 Minimum preheat or maximum Inter pass temperature control

WELDING INSPECTION
WELDING INSPECTION
AFTER WELDING
AFTER WELDING
 Visual inspection of the welded joint including dimensional aspects

 Visual inspection of the welded joint including dimensional aspects
 NDT requirements.(method, qualification of operator, and execution )

 NDT requirements.(method, qualification of operator, and execution )
 Identify repairs from assessment of visual or NDT reports. Repair procedure for repair
 Identify repairs from assessment of visual or NDT reports. Repair procedure for repair
 PWHT (heating method and temperature recording system)

 PWHT (heating method and temperature recording system)
 Re-inspect with visual/NDT after PWHT if applicable.

 Re-inspect with visual/NDT after PWHT if applicable.
 Pneumatic, hydrostatic test

 Pneumatic, hydrostatic test

INSPECTION
INSPECTION
 Ensure use of Calibrated Instrument during all Inspection.
 Ensure use of Calibrated Instrument during all Inspection.
 During inspection insist on availability of following documents before Inspection
 During inspection insist on availability of following documents before Inspection
 WTS/ Welder History Certificates & Process to be used Purchase Order for the particular Job.
 WTS/ Welder History Certificates & Process to be used Purchase Order for the particular Job.
 Requirements of Hold points, Extent of Inspection
 Requirements of Hold points, Extent of Inspection
 Material Control Requirement
 Material Control Requirement
 Drawing availability
 Drawing availability
 Follow the Quality Assurance Plan Cum Route sheets / Quality Assurance Check
 Follow the Quality Assurance Plan Cum Route sheets / Quality Assurance Check
 Sheet for Further instructions & hold Points
 Sheet for Further instructions
& hold Points

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OCS Engineering & Construction (I) Pvt Ltd

 Pressure Vessels and Piping Industry

Doc. No: OCS-QMS-SOP-001

 the materials used in the construction of a pressure vessel

 the materials used in any pressure vessel shall conform to

Material to a specification shall have a manufacturer’s test

 Carbon percentage shall be less than or equal to 0.25% for

 Butt-welded joints shall have complete penetration and full fusion.

 Welding Process and ancillaries:

 Marking, Preparation & Set up:

 Visual inspection of the welded joint including dimensional aspects

 NDT requirements.(method, qualification of operator, and execution )

 PWHT (heating method and temperature recording system)

 Re-inspect with visual/NDT after PWHT if applicable.

 Pneumatic, hydrostatic test

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