ROOT CAUSE ANALYSIS.

Possible cause which we identify after performing root cause analysis for welding during are as follows.

ACTION PLAN IMPLEMENTED TO COUNTER THE WELD JOINTS

Sr. No. 1

Reason which we ear marked after performing RCA Bevel areas not free from contaminant like rust mill scale grease etc, which eventually results in to Porosty.

4M cause effect region Method

Occurrence of cutting kerfs during preparation of bevel edges were not removed which lead to Porosity.

Method

Irregular and excess root gaps which is varying from the WPS stated requirement

Method

Improper techniques used at the time of root welding and weaving of the electrodes of subsequent passes Lack of in process check points ( Internal) by welding inspectors

Men

Men

Lack of 100% Non evasive check points( DPI of the root welding) 100% severity level Lack of customer requirements for utilization of codes like EN/ISO 5817 classes for the visual weld imperfection evaluations

Method

ACTION PLAN IMPLEMENTED AFTER RCA 1.0 Mill scales removed by buffing to about 25mm either side of the weld centre 2.0 Grease removed by thinner, plugged the cause of oil spillage on plate material by tightening the Maintenance of Drilling machines, Cranes ( Source of oil spillage/ Grease) 3.0 Quality check points implemented with QC to monitor the cleanliness of the bevel surface during fit up stage 1.0 All cutting activities done by CNC supported by Nesting software . 2.0 Quality check points implemented with QC to monitor the occurrence cutting kerf on the bevel surface during fit up stage. 3.0 Maintaining correct O2 pressure and cutting speed ( Process parameter) 1.0 Maintenance of correct root gap through stringent check points by the qc inspector during fit up stage. 2.0 By providing root gap gauge to the fitters for checking gap and profile at the time of gap preparation 1.0 Qualification of welders against ISO 9606-1 2.0 Constant orientation to grass root level stage by training 1.0 Qualification of welding inspectors against IIW / ISO 5817 requirement. 2.0 Quality check points and weld process checks through log sheet. 1.0 Checking of root weld coming under wet joints by 100% DPI 1.0 Oriented internal QC personnel to the requirement of ISO 5817 Class

Method

Lack of awareness of the visual weld imperfection standards among the inspectors and supervisors related to standards like ISO 5817 Human error at the time of weld inspection Lack of monitoring of the process parameters like current, voltage and inter pass temperature Non adherence to the repair procedure such as (Through excavations of defective region and not maintaining minimum size of the repair area 25mm length. Use of improper or damaged electrodes

Men

2.0 Check list developed against the requirement of ISO 5817 3.0 Internal training program conducted for ISO 5817 1.0 Hired external party to train internal inspectors and supervisors

Men

1.0 Inspector identified as expert in weld checking is deputed for the inspection. 1.0 Log sheet already implemented daily basis 1.0 Monitored though checklist for welding.

Machine

10

Men

11

Material aterial

1.0 FIFO and IMIR implemented

Cause effect analysis

METHOD MEN MATERIAL MACHINE