Work Instruction

Petron/WI /03 Issue No. 01 Rev. No. 0

Welding Process

Purpose The purpose of this procedure is to describe the method of control and inspection required for ensuring that the welding is carried out by Petron in accordance with relevant Codes, Standards, Specifications and Client Requirements.

Scope This procedure shall be applicable for welding of Structures, Piping, Equipments, Pressure Vessels, Storage Tanks, ESP, Silos etc etc.

Reference Applicable Codes & Standards Design Drawings ASME Sect. IX or BS EN 287-1 and Requirements of Applicable code. Applicable Welding Procedure Specification ( WPS ). Welding Consumables Control procedure PU/WI/02.

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Petron/WI /03 Issue No. 01 Rev. No. 0

Procedure Responsibility The QC Manager and QC Engineer are responsible for: Preparation of WPS Procedure Qualification Welder Performance Qualification Welder Identity Card. Overall Quality Control and Inspection of Welding as per Contract requirements and Specifications. Post Weld Heat Treatment outsourcing

NDT like Radiography, Ultrasonic and Magnetic particle testing outsourcing.

The QC Inspector and Welding Foreman are responsible for :

Carrying out welding by Welders Qualified in accordance with ASME Sec. IX / BS EN 287-1 and applicable standards and Certified by Third Party Inspection Agency.

Qualified welders are also responsible for the Quality of welding.

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Petron/WI /03 Issue No. 01 Rev. No. 0

Welding Procedure All welding works shall be carried out strictly as per approved WPS and by Qualified Welders only. All welding works shall be carried out only after ensuring that fit-ups have been cleared by QC Inspector / Third Party Inspection agency for Welding as applicable.

The Welding Foreman shall ensure that the job is adequately arrested to prevent any distortions that may occur. Fixtures/Spiders, as required, shall be fabricated by Production Supervisors to prevent distortions during welding. Welding techniques like Step Back method, Zigzag method shall be used to prevent the distortions. All welding consumables shall be handled as per Welding Consumables Control procedure PU/WI/02. The Welding Foreman shall ensure that all the welding fit-up is thoroughly cleaned and is free from oil, grease, contamination and defects.

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Petron/WI /03 Issue No. 01 Rev. No. 0

After completion of Welding, Visual inspection shall be carried out before offering for NDT and recorded in Welding Inspection Report. As applicable, PWHT, NDT tests like RT, MPT, UT will be requested by QC Manager. The same will be carried out by Third Party. Liquid Penetrant Examination shall be carried out in-house by ASNT Level II qualified and written procedure No. PUES/NDT/LPT/QMS/OOI, Issue No.1, Rev. 0. The results will be obtained by QC Manager and will be submitted to the Client / records maintained as applicable. Any defects detected by NDT (or) Visual, will be repaired in accordance with the Repair Welding Procedure. Repair Welding Procedure QC Inspector shall ensure that all Repair Welding are carried out as per as per Repair Welding Procedure.
o As applicable Client /Third Party Inspection Agency / Petron QC dept.

should be informed of repair welding work.

o Defective welding portions shall be identified from NDT reports and

marked on the weldment.

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o

Petron/WI /03 Issue No. 01 Rev. No. 0

Defect to be removed by grinding.

o Minimum repair length shall be defect length plus 2.5 mm each side as per

standard practice/client requirement. o The grinding portions should be smooth.

o The repair area shall be inspected visually by QC Engineer / QC Inspector

prior to re -welding.
o For welding parameters, refer to original welding WPS. o All repairs will be subject to PWHT and NDT as applicable.

o Further attempts at repair will be carried out as per standard practices/client requirements. 5 Documentation and records Piping Welding Inspection Report. Form No. PUES/QMS/014 Piping Welding Summary Sheet. Form No. PUES/QMS/015 Equipment Welding Inspection Report. Form No. PUES/QMS/016 Welding procedure specification. Form No. PUES/QMS/005 Procedure Qualification Record . Form No. PUES/QMS/006 Welder Performance Qualification Record . Form No. PUES/QMS/007 Liquid Penetrant Test Report. . Format No. PUES/QMS/029 NDT , PWHT Records by External Party. ******

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Petron/WI /03 Issue No. 01 Rev. No. 0

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