國外工程現(xiàn)場管理規(guī)范性文件-焊接檢驗Welding-Inspection

WeldingInspection

TableofContents

Scope

ApplicableCodes

WeldingProceduresandWeldersQualifications

InspectionRequirements

WeldJointPreparation

HeatTreatment

RadiographicRequirements

References

FORMS(TypicalExampleAttached)

26C30InspectionRecordforSiteWelding

26C31WeldRepairReport

26C32InspectionRecordforFieldWelds

26C33RadiographInspectionReport

26C34RadiographyRecordSheet

26C35RecordofWelderPerformanceQualificationTestonGrooveWelds

1.Scope

ThepurposeofthissectionistoprovideguidelinestoCompanypersonnel,inparticulartotheWeldingEngineer,concerningthewelding,heattreatmentandweldinspectionof:

Prefabricatedpiping.

Fieldweldingofprefabricatedpiping.

Fieldweldingofrandomlengthpiping.

Fieldweldingofpipetovesselstub-ends(e.g.furnacesorinsomecasesvesseltovesselstub-endsduetotransportlimitations).

(Whilstthissectioniswrittenintermsofweldingassociatedwithpiping,thesamegeneralprinciplesapplytoweldingofstructuralsteelworkandofstoragetanks).

Primaryresponsibilityforqualityisthatofthesubcontractorwhoshallsatisfyhimselfthroughhisownqualitysystemthatspecifiedrequirementsaremet.

ItistheresponsibilityoftheWeldingEngineertoensurethatthesubcontractorisinfacteffectivelyapplyinghisqualitysystemandobtainingacceptableresults.

Thefollowingspecialistorganizationsarealsoimplicated:

Nondestructiveanddestructivetestingfirms.

PossiblythirdpartyinspectortomeetAuthoritiesrequirements.

Dependingontheparticularproject,theirservicesmaybeincludedinthepipingsubcontractor'sscopeoralternativelytheymaybedirectlycontrolledbyCompany.

Pipinggenerallyinvolvesonsiteoroffsiteprefabricationofspools.Thisactivitymayinsomecircumstancesbepartofaconstructionsubcontractandcontrolledfromsite.

Itisimportantthatthequalitysystemsputintoplaceforweldingandheattreatmentofpipingadequatelycovertheactivitiesofthesespecialistorganizationsandoftheprefabricationshops.Responsibilityfortheirday-to-daysupervisionisthatoftheWeldingEngineer.

Subsequentsections17.3to17.7areineffectchecklistsofpointsrequiringsurveillance,inspectionortesting.TheyareintendedasareminderandahelptotheWeldingEngineer.However,theyarenosubstituteforreadingandfamiliarizingoneselfwiththesubcontract,requisitions,specifications,standardsanddrawings.Incaseofconflictitistheseprojectspecificdocumentswhichprevail.

Thesubcontractorcreateshisownqualitysystem,whichincludesproposingtheinspectionandtestingrecordformstobeused.TheirsuitabilityshallbejudgedbytheQualityAssuranceManagerinconsultationwiththeWeldingEngineer(seeReference17.8.1).

Thesetofinspectionandtestrecordformsattachedtothissection:

Maybeusedasabasistoreviewthesubcontractor'sforms.

Maybeimposedonthesubcontractorshouldthelatter'sformsbeconsideredtobeunsuitable.

2.ApplicableCodes

ASMEBoilerandPressureVesselCode,SectionVIII,latestissue,orspecifiedequivalent.

AmericanNationalStandardCodeforPressurePipingANSIB31.3,orspecifiedequivalent.

ASMEBoilerandPressureVesselCode,SectionIX,latestissue,orspecifiedequivalent.

Specificationsapplicabletothejobinquestion.

Clientsspecificationsandadditionalrequirements.

Authorityrequirements(e.g.T.U.V.,Stoomwezen,etc.)

3.WeldingProceduresandWeldersQualifications

Allweldingprocedurespecificationsandprocedurequalificationrecordsshallbesubmittedbythesubcontractor(s)toCompanyforreviewandapproval.

Weldersperformancequalificationsshallbeinaccordancewithapplicableprocedures,codes,etc.aslaiddownin17.2ofthisprocedure.Acopyoftheperformancequalificationtestrecordshowingthenameoftheemployerbywhomthewelderorweldingoperatorwasqualified,thedate(s)ofsuchqualificationandthedatethewelderlastweldedpressurepipingcomponentsundersuchqualificationmustbeobtainedfromthepreviousemployer.

Renewalofqualificationofaperformancespecificationisrequired:

Whenawelderorweldingoperatorhasnotusedthespecificprocess,i.e.,metal-arc,gassubmergedarc,etc.foraperiodofthree(3)monthsormore.

Whenthereisspecificreasontoquestionhisabilitytoproduceweldsthatmeetthespecification.

Whenwelderqualificationsarenotavailableoronrequestofclient,itisallowabletohavethewelderperformatestweld.ItisnecessaryinthiscasetoperformaguidedbendtestasdescribedinASTME190-64.TheperformanceofeverywelderwhoisnewlyqualifiedshallbecheckedinitiallymorethanotherweldersbymeansofNDE(seeReference17.8.2).

TheCompanyWeldingEngineercanauthorizechangesinnon-essentialvariablesinaccordancewithsectionIXoftheASMEcodeand/orothergoverningcodesafterapprovalbyclient'sinspectionrepresentative.Suchchangesdonotrequirethequalificationoftheprocedureinquestion.However,changesinessentialvariablesnotonlyrequirerequalificationbutalsopriorapprovalbyhomeofficeEngineeringDepartmentandclient.

4.InspectionRequirements

Definitionofweldinginspection:Aphaseofqualitycontrolwhichbymeansofexamination,observation,ormeasurementdeterminestheconformanceofmaterials,supplies(gases,electrodesand/orotherconsumables)parts,components,systems,processestopredeterminedqualityrequirements.

TheWeldingEngineershallensurethatweldinginspectionpersonnel,whetherofthepipingsubcontractor,ofthelatter‘sownsubcontractororofathirdpartyshallbeadequatelyqualifiedandexperiencedtoarecognizedstandard.

Thefollowingisalistofitemstobecheckedorverifiedtoassurecorrectfieldwelding.TheWeldingEngineershallcheckthefollowing:

a.Qualificationofwelders

Validityofwelders'certificates.

Namesofwelderswhilstatworkandifidentificationmarksalongcompletedweldscheckwithqualification.

b.Weldnumbering

WeldsarenumberedaccordingtoapprovednumberingsystemandthatISO'sanddrawingsaremarked-upwiththisnumber.

c.Requirementstobemetbeforeweldingstarts

Properstorageandhandlingofweldingmaterials.

Useofcorrectweldingrodsorwires.

Useofhot-boxesforlow-hydrogenweldingrods.

Assignmentofqualifiedweldersasperabove.

ApplicationofadequateWPS(weldingprocedurespecification).

Protectionagainstweatherconditions.

Backpurgingforalloysteel.

Pre-heating.

Checkthatproperequipmentwillbeused.(e.g.weldingmachines,purgegasesandtheirassociatedequipment,heatpre-andaftertreatmentincludingtemperaturerecordingapparatus).

Materialchecki.e.materialsonbothsidesofweldcomplywiththatinWPS(forfurtherdetailsseeReference17.8.2).

Propertransferofheatnumbers(ifrequiredbyspecificationand/orauthorities).

d.Examinationofweldingworkandweldpreparations

1.Rootopening

-rootfaceandshapeofgroove

-cleanliness

-misalignment

-removaloftackweld

2.Rootpass

-checkforcracks,porosity

-removeslag

-removesharpridges(grindingtoavoidlackoffusion

-repairsifnecessary

-dyepenetranttestand/orotherNDEifrequiredbyWPS(e.g.forheavywallpipe)

3.Subsequentweldlayers

4.Visualfinalchecks

-undercut

-configurationofcoverpasses

-craterdefects

-surfaceporosity

-slagremoval

-stampofwelderandfieldweldno.isinplacenearweld

-repairsifrequired

5.NDEasprescribedinspecification

6.Postweldheattreatment(alloyandheavywallpiping)

7.NDEasprescribedinspecification(alloyandheavywallpiping)

-hardnesstests

Theworkasdescribedunderd.1throughd.7abovewillbedoneinthesequencegivenandbetweenthepointsd.1throughd.5therewillnormallybeaholdpointofthesubcontractorbetweeneachpointtillinspectionhastakenplacebeforeproceedingwiththenextitem.TheWeldingEngineerwilldeterminewhichitemsconstituteCompanyholdpoints.

Butt-weldsshall,whenfeasible,alsobevisuallyinspectedinside,payingparticularattentionto:

cracks

undercutting

overcrownand

lackofpenetration

Branch-weldsshallbevisuallyinspectedasspecifiedforbutt-welds.

Allweldsofdummypipesupportsshallbeinspectedforproperbevelingandfit-upafterfullpenetrationtackwelding,priortostartofrootandfillerpasses.

5.WeldJointPreparation

Weldbevelsshallbemadebymachining,grindingorthermalcuttingandgrinding.

Thesurfacesshallbereasonablysmoothandtrueforgoodfit-up.

Spacersshallbeusedwhiletackweldingpipeandfittingsinpositiontoensurepropergapandfullpenetrationinwelding.

Smalltackweldsshallbeusedwithfullrootpenetration.Makesurethatifpre-heatingisrequiredthatitsrequirementsaremetduringtackwelding.

6.HeatTreatment

TheWeldingEngineershallensurewiththesubcontractorthatallnecessaryprecautionsaretakentopreventdistortionduringheattreatment.

Heattreatmentoperationsshallbecheckedforcompliancewithapprovedprocedures.

TheproposedstressrelievingmethodandlocationofthermocouplesshallbedefinedinawrittenproceduresubmittedbythesubcontractortotheWeldingEngineerforapproval.

Thermocouplesandatemperaturechartrecordershallbeusedtoprovideapermanentrecordofallpostweldheattreatments.Observethegradientoftemperatureincreaseaslaiddowninthespecifications.

Thermocouplesshallnotbeindirectcontactwithelectricalheatingelementsorsubjectedtoflameimpingementbygasburners.

Thermocouplesshall,ifapplicable,beplacedontheinsideofobjectsbeingheatedfromtheoutsideandviceversa,ifinternallyheated.

Atleasttwothermocouplesshallbeusedforcircumferentialweldsonpipediametersof24in.andsmaller.Theseshouldbeplacedatthetopandbottomofthepipe.Pipesofdiameterlargerthan24in.shallhaveatleastfourthermocouples.

Threadsandgasketsurfacesshallbeprotecte