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Standard

Group Technology

Title:

Control of Plant Construction, Repair and Maintenance Welding Activities

Unique Identifier:

36-775

Alternative Reference Number:

N/A

Area of Applicability:

Engineering

Documentation Type:

Standard

Revision:

Total Pages:

22

Next Review Date:

November 2014

Disclosure Classification:

CONTROLLED DISCLOSURE

Compiled by

Functional Responsibility

Authorized by

.. P Doubell Chief Engineer Welding, IWE

.. BS MacColl Acting General Manager Research, Testing & Development Date:

.. MM Koko Divisional Executive Group Technology Date:

Date:

Control of Plant Construction, Repair and Maintenance Welding Activities

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CONTENTS
Page FOREWORD ................................................................................................................................................................ 4 1. SCOPE ..................................................................................................................................................................... 6 2. NORMATIVE REFERENCES .................................................................................................................................. 6 3. DEFINITIONS AND ABBREVIATIONS ................................................................................................................... 7 3.1 DEFINITIONS .................................................................................................................................................... 7 3.1.1 Classification ............................................................................................................................................. 8 3.2 ABBREVIATIONS .............................................................................................................................................. 8 4. REQUIREMENTS ..................................................................................................................................................... 8 4.1 GENERAL.......................................................................................................................................................... 8 4.1.1 Welding Requirements .............................................................................................................................. 8 4.1.2 Welders and welding operators ................................................................................................................. 9 4.1.3 WPS .......................................................................................................................................................... 9 4.1.4 WPQR/PQR............................................................................................................................................... 9 4.1.5 WPS verification ........................................................................................................................................ 9 4.1.6 Eskom welding coordinator/administrator ............................................................................................... 10 4.1.7 Welding supervision ................................................................................................................................ 10 4.1.8 Welding Inspector .................................................................................................................................... 10 4.1.9 Technical capability assessment of contractors ...................................................................................... 10 4.2 WELD QUALITY SYSTEM .............................................................................................................................. 11 4.2.1 SANS ISO 3834 ...................................................................................................................................... 11 4.2.2 Welding Quality Requirements ................................................................................................................ 11 4.2.3 Quality assurance function ...................................................................................................................... 11 4.2.4 Project quality audits ............................................................................................................................... 12 4.2.5 Reporting of non-conformances .............................................................................................................. 12 4.3 WELDING PROCEDURES ............................................................................................................................. 12 4.3.1 Construction of new plant ........................................................................................................................ 13 4.3.2 Weld repairs on old plant......................................................................................................................... 13 4.3.3 Modification work to existing plant........................................................................................................... 13 4.3.4 Refurbishment and/or repair work to existing plant ................................................................................. 13 4.3.5 Acceptance levels for Imperfections ....................................................................................................... 13 4.3.6 Quality levels and assessment class for imperfections ........................................................................... 13 4.3.7 Basic requirements of the weld procedure specification ......................................................................... 13 4.4 WELDER QUALIFICATION............................................................................................................................. 14 4.5 MATERIAL CONTROL .................................................................................................................................... 14 4.5.1 Material to be used for fabrication or for weld repairs ............................................................................. 14 4.5.2 All Unidentified material ........................................................................................................................... 14 4.5.3 Marking of removed material ................................................................................................................... 15 4.5.4 Protection of sectioned faces .................................................................................................................. 15 4.6 WELDING CONSUMABLE CONTROL ........................................................................................................... 15 4.6.1 Consumable approval ............................................................................................................................. 15 4.6.2 Consumable identification ....................................................................................................................... 15 4.6.3 Consumable storage ............................................................................................................................... 15 4.6.4 Damaged or contaminated consumables ................................................................................................ 15 4.6.5 Identification on consumables ................................................................................................................. 15 4.6.6 Baking/drying of consumables ................................................................................................................ 15 4.6.7 Holding of baked/dried consumables ...................................................................................................... 15 4.6.8 Hot boxes for consumables ..................................................................................................................... 16 4.6.9 Unused consumables .............................................................................................................................. 16 4.6.10 Permitted re-baking cycles .................................................................................................................... 16 4.6.11 Welding and cutting gasses .................................................................................................................. 16 4.7 HEAT TREATMENT ........................................................................................................................................ 16 CONTROLLED DISCLOSURE
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4.7.1 Heat treatment procedures ...................................................................................................................... 16 4.7.2 Heat treatment equipment ....................................................................................................................... 16 4.7.3 Operation and monitoring of heat treatment equipment ......................................................................... 17 4.7.4 Measurement and maintenance of temperature for pre-heating and interpass temperature ................ 17 4.7.5 Heat treatment parameters for service-aged materials ........................................................................... 17 4.7.6 Substantiation of heat treatment ............................................................................................................. 17 4.7.7 Heat treatment information ...................................................................................................................... 17 4.7.8 Multiple heat treatments .......................................................................................................................... 17 4.7.9 Unplanned events during heat treatment ................................................................................................ 17 4.8 CALIBRATION OF EQUIPMENT .................................................................................................................... 18 4.8.1 Equipment identification .......................................................................................................................... 18 4.8.2 Calibration of temperature measuring equipment ................................................................................... 18 4.8.3 Calibration of furnaces, holding ovens and hot boxes ............................................................................ 18 4.8.4 Calibration of chart recorders for heat treatments................................................................................... 18 4.8.5 Proof of calibration .................................................................................................................................. 18 4.9 NON DESTRUCTIVE TESTING...................................................................................................................... 18 4.9.1 Independence of NDT contractor ............................................................................................................ 18 4.9.2 Eskom approval of NDT contractor ......................................................................................................... 18 4.9.3 NDT safety............................................................................................................................................... 19 4.10 WELDING COORDINATOR/ADMINISTRATOR ........................................................................................... 19 5. RECORDS AND DATA PACKAGES .................................................................................................................... 19 6. APPENDIX ............................................................................................................................................................. 21 A.1 SUMMARY OF SANS ISO 3834 QUALITY REQUIREMENTS ...................................................................... 21

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FOREWORD
Revision History This revision cancels and replaces Revision No. 1 of Specification or Standard No. GGS1407.
Date November 2011 December 2011 February 2012 Rev. 0 0.1 1 Remarks This is the first issue developed Issued for comments Final Document for Publication

Authorization This document has been seen and accepted by:


Name and Surname Pius Oba Sumaya Nassiep Barry MacColl Titus Mathe Dhiraj Bhimma Anthony Kuzelj Bheki Nxumalo Bruce Moyo Chris Schutte Christo van Niekerk Christopher Nani Deon Beukes Des Sheppard Ertjies Bierman Gladman Mkwai Hennie van Staden Johan Du Preez Johan Prinsloo John Dean Julian Fourie Julian Nair Kiren Maharaj Lebo Serekwa Leon Booyens Mandla Mtembu Marcus Nemadodzi Mark Breetzke Marthinus Bezuidenhout Designation Acting Section Manager: Welding & NDE, Welding Engineer Acting Senior Manager: Plant Performance and Optimisation Acting General Manager: Research, Testing & Development Engineering Power Plant Manager Engineering Account Executive Power Station Manager Power Station Manager Power Station Manager Senior General Manager Senior General Manager Power Station Manager Chief Technologist Senior Manager: Projects and Outages Senior Manager Engineering Power Station Manager Senior Manager: Projects and Outages Boiler Senior Consultant Power Station Manager Power Station Manager Senior Manager Engineering Power Station Manager Senior General Manager Boiler Senior Consultant Senior Consultant Boiler Tube Failure Reduction Senior Manager Engineering Boiler Senior Consultant Corporate Consultant: Boilers Corporate Consultant: Materials

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Name and Surname Morris Maroga Piet Veldman Russel Tarr Ryno Lacock Shamiel Jappie Shireen Prince Thava Govender Thomas Conradie Louise Petrick Andrew Downes Hennie Coetzer Werner Smit Michael Mkhize Frans Havenga Thobeka Pete Leslie Too

Designation Chief Engineer Outage Integration Manager: Coal Operating Unit 1 Senior Consultant: Fleet Technology Power Station Manager Acting Power Station Manager Power Station Manager Divisional Executive: Generation Power Station Manager Senior Advisor Welding Senior Consultant Senior Advisor Projects Chief Engineer Chief Engineer Section Manager Physical Metallurgy Chief Engineer Senior Advisor

Applicability This standard is applicable to all Eskom plant during procurement, reviewing and placing construction, maintenance and repair contracts with vendors for welding and related activities on Eskom plant by the relevant Eskom procurement departments. Routine weld repair and maintenance work by Eskom personnel also fall within the requirements of this document. It will serve as the standard to support Eskoms position on all welding related issues and disputes. Any disputes that fall outside this standard or that appear to be in conflict with it, may be resolved with the proper weld engineering and/or metallurgical inputs. Contractors that fail to meet these requirements may be assessed to determine the nature and significance of the shortcomings, after which they may be considered for the contract with the necessary concessions which shall be documented and submitted to Eskom during the course of the contract as required by the Eskom Quality Standard GGS 0462. Development Team The following people were involved in the development of this document: Philip Doubell

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1. SCOPE
This standard defines uniform, fit-for-purpose requirements for performing construction, repair and/or maintenance welding and related activities on Eskom plant. The objective is to impose good basic welding practices of high quality levels while conforming to the construction code and welding specifications, thereby improving and preserving the integrity of Eskom assets. To ensure a safe and healthy working environment as required by the Chief Inspector, the Occupational Health and Safety Act is another principal objective through compliance with the applicable requirements of the PER in the case of pressurised equipment.

2. NORMATIVE REFERENCES
Parties using this document shall use the most recent editions of the documents listed in this section. [1] [2] [3] [4] [5] [6] [7] [8] [9] ASME Boiler and Pressure Vessel Construction Code: Section IX: 2010 (Including Addenda) BS EN 1011: 2009 Welding- Recommendations for welding of metallic materials Part 1 General guidance for arc welding BS EN 1011: 2001 Welding- Recommendations for welding of metallic materials Part 2 Arc welding of ferritic steels BS EN 1011: 2000 Welding- Recommendations for welding of metallic materials Part 3 Arc welding of stainless steels BS EN ISO 15607:2003 Specification and qualification of welding procedures for metallic materials - General rules BS EN ISO 15613: 2004 Specification and qualification of welding procedures for metallic materials Qualification based on pre-production welding test BS EN ISO 5817: 2003 Welding - Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding excluded) Quality levels for imperfections BS EN ISO 17663 (2009): Welding Quality requirements for heat treatment in connection with welding and allied processes BS 2633:1987 Specification for Class I arc welding of ferritic steel pipework for carrying fluids

[10] EN 10204: 2004 Metallic products: Types of inspection documents [11] EN ISO 13916: Welding guidance on the measurement of preheating temperature, interpass temperature and preheat maintenance temperature [12] ISO/TR 15608: 2005 Welding Guidelines for a metallic material grouping system [13] ISO 14731:2006 Welding co-ordination. Tasks and responsibilities [14] SANS 15614-1 Specification and qualification of welding procedures for metallic materials Welding procedure test Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys [15] SANS 15614-7 Specification and qualification of welding procedures for metallic materials Welding procedure test Part 7: Overlay welding [16] SANS 15609-1 Specification and qualification of welding procedures for metallic materials Welding procedure specification Part 1: Arc welding [17] SANS 9606-1 Approval testing of welders - Fusion welding Part 1: Steels

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[18] SANS ISO 3834-1:2005 Quality requirements for Welding Part 1 Guidelines for selection and use [19] SANS ISO 3834-2:2005 Quality requirements for Welding Part 2 Comprehensive quality requirements [20] SANS ISO 3834-3:2005 Quality requirements for Welding Part 3 Standard quality requirements [21] SANS ISO 3834-4:2005 Quality requirements for Welding Part 4 Elementary quality requirements [22] SANS 10269:2002 Welding of thermoplastics Testing and approval of welders [23] SANS 10270:2004 Welding of thermoplastics Approval of welding procedures and welds [24] SANS 10268:2005 Welding of thermoplastics Welding Processes Part 10: Weld defects [25] Pressure Equipment Regulations, 2009 (PER) [26] SANS 347: 2010 Specification for categorization and assessment criteria for all pressure [27] 32-632 Requirements for NDT on Eskom plant [28] 32-631 Eskom approval of personnel performing quality related special processes on Eskom plant [29] GGS0462, Quality requirements for engineering and construction works in generation [30] N.PSZ 45-223: High pressure pipework for fossil fired power stations [31] 36-504: Welding of high temperature and pressure tube and pipework [32] 36-505 Personnel and Entities Performing Welding Related Special Processes on Eskom Plant

3. DEFINITIONS AND ABBREVIATIONS


3.1 DEFINITIONS 3.1.1 Procedure Qualification Record: A record comprising all relevant data from the welding of a test piece needed for the approval of a welding procedure specification as described in the ASME Boiler and Pressure Vessel Code Section IX. 3.1.2 Welding Procedure Qualification Record: A record comprising all relevant data from the welding of a test piece needed for the approval of a welding procedure specification as described in the welding specification BS EN ISO 15614. 3.1.3 Welding Procedure Specification: A document meeting the requirements of BS EN 15609 or ASME Boiler and Pressure Vessel Code Section IX and derived from the WPQR/PQR that sets out in detail the required variables for a specific application to assure repeatability. 3.1.4 Welder Qualification Record: A document meeting the requirements of BS EN 287 or ASME Boiler and Pressure Vessel Code Section IX, that presents the results of the approval testing of a welder to perform a fusion welding process. 3.1.5 Eskom Welding Co-ordinator: A Welding Engineer/Technologist appointed by the Eskom Chief Executive Officer or his designate to oversee all welding activities within Eskom Holdings Ltd. 3.1.6 High pressure equipment: Pressure Equipment with design pressure 50 kPa which include a steam generator, pressure vessel, pressure accessory and piping.

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3.1.1 Classification a. Controlled disclosure: controlled disclosure to external parties (either enforced by law, or discretionary). 3.2 ABBREVIATIONS
Abbreviation AIA ASME AWS BS EN ISO ITP IW IWE IWS IWT NDT OHS Act PER PWHT QCP TCA TPI WA Approved Inspection Authority American Society of Mechanical Engineers American Welding Society British Standard European Norm International Organization for Standardization Inspection and test plan International Welder registered with the International Institute of Welding International Welding Engineer registered with the International Institute of Welding International Welding Specialist registered with the International Institute of Welding International Welding Technologist registered with the International Institute of Welding Non-destructive testing Occupational Health and Safety Act of 1993 Pressure Equipment Regulations of 2009 Post weld heat treatment Quality control plan Technical capability assessment Third Party Inspector Welding administrator / coordinator Description

4. REQUIREMENTS
4.1 GENERAL 4.1.1 Welding Requirements The governing rules, clauses and requirements (in order of precedence) related to welding as described in: PER; Relevant plant design and /or construction codes; Eskom Standards;

Shall be followed during application of welding activities, disposition of defects and engineering interventions for solving anomalies.

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In addition to this, welding shall be performed to the requirements of BS EN 1011 Parts 1, 2 and 3 which provide general guidance on how to achieve and control basic good quality weldments in ferritic and stainless steels with emphasis on:

Welding principles Requirements on welding production Parent metals and welding consumables Planning of welding activities Welding fabrication Elimination of distortion or inherent stresses Post-weld heat treatment Surface cleaning and treatment Inspection and documentation.

More specific to tube and pipe welding activities, basic principles stipulated in BS 2633 shall be followed where applicable. This specification details arc welding using manual, semi-automatic or automatic processes; parent metals, welding consumables, preparation for welding, butt joints, branches, attachments, flanges, inspection, acceptance criteria, procedure and welder approval tests. 4.1.2 Welders and welding operators Welders and welding operators working within the scope of this guideline shall be coded in-accordance with the requirements of the latest construction code relevant to the plant and have the minimum IW qualifications specified in Eskom Standard 36-505. Execution of the WPQR / PQR activities shall be witnessed by a suitably qualified TPI employed by the Eskom appointed AIA company if qualification activities are not witnessed by the responsible IWE or IWT. 4.1.3 WPS Welding performed on plant built to a code or standard of manufacture shall be done in accordance with a valid WPS reflecting the requirements of the applicable code. 4.1.4 WPQR/PQR A WPS shall be supported by a valid WPQR/PQR for all Level I and II plant work, while this is recommended in the case of Level III plant work as set out in Table 1 of Appendix A. The PQR/WPQR shall be approved by a registered IWE or IWT with minimum qualifications as defined in Eskom Standard 36-505. Any other qualification from another country that is considered to be equivalent shall be evaluated by the Eskom Welding Co-ordinator or his delegate for relevance. Execution of the procedure qualification activities shall be witnessed and/or verified by a suitably qualified TPI if qualification activities are not witnessed by the responsible IWE or IWT. 4.1.5 WPS verification A suitably qualified TPI employed by an Eskom appointed AIA company shall verify that the information on the WPS accurately reflects the parameters reported on the WPQR/PQR before use on Eskom

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equipment. Although approval of this document by an IWE/IWT is not mandatory, it is recommended practice. 4.1.6 Eskom welding coordinator/administrator The appointed welding coordinator/administrator at the Eskom Site for the control of repair and maintenance welding on Eskom plant, shall as a minimum be qualified as required by Eskom standard 36-505. Any other qualification from another country that is considered to be equivalent shall be evaluated by the Eskom Welding Co-ordinator or his delegate for relevance. It is recommended that his tasks contain the basic elements of ISO 14731. 4.1.7 Welding supervision Supervisors for controlling welding activities at site level shall have the necessary practical experience with supervising contracts relating to the components relevant to the contract and as a minimum qualification be a certified IWS as required by Eskom Standards 36-775 and with the requirements specified in Eskom Standard 36-505. 4.1.8 Welding Inspector The Eskom or contractor welding inspector responsible for inspection of welding set-ups, welding preparations and completed weldments shall have a minimum qualification as stipulated in Eskom Standard 36-505. Any other qualification acquired from another country that is considered to be equivalent shall be evaluated by the Eskom Welding Coordinator for maintenance and repair projects or his delegate during the time of contract placement negotiations. 4.1.9 Technical capability assessment of contractors Contracted companies (main and subcontracted) performing work on high value and safety critical Level 1 and 2 Eskom plant shall be evaluated for acceptance on the Eskom vendor list for selected contracts through a technical capability assessment (TCA) convened and coordinated by the Eskom Quality Department. The assessment team shall as a minimum consist of: IWE / IWT NDT specialist Quality specialist Relevant Eskom plant engineer

Subsequent to each TCA a full report with findings shall be compiled for future reference by the relevant Eskom plant line groups. The list of approved Level 1 and 2 vendors shall be maintained by the Eskom Quality Department and distributed to the Eskom procurement departments. Follow up TCAs should ideally be conducted at 3 year intervals, or when a contractor company is subjected to major structural changes. In cases where a major breakdown in a contracting companys capabilities is suspected, a TCA can be motivated at any time by the responsible Eskom plant engineer.

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4.2 WELD QUALITY SYSTEM 4.2.1 SANS ISO 3834 SANS ISO 3834 provides the framework for quality levels pertinent to the welding process. All weld quality related activities on Eskom plant shall use a system based on the requirements of SANS ISO 3834. Exemptions from this requirement will be acknowledged for plant built in accordance with the ASME Boiler and Pressure Vessel Code in which cases a quality system related or referenced to this construction code may be used as stated in the ASME BPV Code, Section VIII Division 1 Appendix 10. The vendor shall clearly define the welding function, its control and interaction with the rest of the companys production functions in the quality manual. 4.2.2 Welding Quality Requirements The welding quality requirements will depend on: The category level of Eskom plant being worked on The contract requirements as agreed on between Eskom and contracting party Any unusual conditions such as emergency repairs.

The different quality requirements as described in ISO 3834 are summarised in Table 1 of Appendix A. Repair and maintenance work on Level 1 Category components shall be supported by ISO 3834-2 for comprehensive quality requirements where BS or AD Merkblatt (TRD) construction rules apply. This by implication requires the contractor to be an SANS ISO 3834 Part 2 certified company. For components built to the ASME Boiler and Pressure Vessel Code, the requirements applicable to that code shall apply. For work on Level 2 and Level 3 components a quality level will be decided on by the Eskom project manager or his delegate. 4.2.3 Quality assurance function 4.2.3.1 Minor repairs and maintenance The appointed site welding co-ordinator / welding administrator shall perform the quality assurance function at this level. 4.2.3.2 Major repairs and maintenance The authorised principal contractor shall employ a suitably qualified person to perform the quality assurance function. The appointed site welding co-ordinator/administrator or his delegate shall maintain a monitoring presence and report any concerns to the Eskom project manager or the senior person responsible for quality at the plant.

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Quality of welding activities performed on pressure Equipment, particularly pipework and boiler components, shall be monitored and verified by the Eskom appointed AIA as required by the PER and Eskom Standard N.PSZ 45-223. The authorised principal contractor shall appoint an AIA for any off-site repair and or refurbishment done on pressure equipment if required by SANS 347. The contractor shall prepare quality control documentation as required by Eskom Quality Standard GGS 0462 and submit it to the welding co-ordinator for approval before commencing with any contract or welding work. 4.2.4 Project quality audits The Eskom welding co-ordinator or his delegate shall carry out spot checks on the overall welding activities of a major contract with emphasis on: Compliance with the Eskom Generation standard GGS0462 and SANS ISO 3834 quality level requirements as stated in the contract documents Conformance of the contractor to the welding quality system as presented to the Eskom Corporate Audit team during the vendor approval phase. Application of sound welding principles Adherence to PERs NDT

These checks should also form part of technical capability assessments follow-ups when vendor companies are evaluated for acceptance on the Eskom vendor list for selected contracts on Eskom Level 1 and 2 plants. 4.2.5 Reporting of non-conformances All issues shall be addressed through the reporting system as required by the contract. Issues that might jeopardise the integrity of Eskom plant, transgressing the requirements of the applicable construction code and/or the OHSAct and/or the rules set out by the Chief inspector of Machinery in the PER shall be investigated as required by these authorities. 4.3 WELDING PROCEDURES Welding procedure qualification for metallic weldments shall be in accordance with the appropriate combination of EN and ISO/EN family codes of specification; BS EN ISO 15607, SANS 15609, SANS 15614-1, SANS 15614-7, BS EN ISO 15613 and ISO 15608; as is applicable to the relevant plant and to the Eskom quality Level requirements stipulated in Table 1 of Annexure A. An exception to this shall apply to Eskom plant at sites constructed to the ASME Boiler and Pressure Vessel codes in which case the requirements stipulated in Section IX of the code shall be met. Any other possible exceptions shall be motivated for approval by the responsible Eskom plant engineer.

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Welding procedure qualification for thermoplastic weldments shall be in accordance with SANS 10270. 4.3.1 Construction of new plant Construction of new plant shall be performed to welding procedures qualified to the requirements of the latest version of the applicable construction code. 4.3.2 Weld repairs on old plant Weld repairs to be performed on old plant shall conform to the latest version of the construction code. Any deviations from the requirements resulting from technological advancement of equipment, processes and techniques shall be noted and submitted for approval by Eskom. For this type of application the original welding procedure can be used but must be re-written to reflect the latest weld specification format. Only old procedures with the required supporting documents such as the heat treatment chart and report from the mechanical test laboratory will be eligible for use. 4.3.3 Modification work to existing plant Modification work to existing plant shall be performed to welding procedures qualified to the requirements of the latest version of the applicable construction code. 4.3.4 Refurbishment and/or repair work to existing plant Refurbishment and/or repair work on existing plant that require non-standard weld preparations shall be supported by suitably qualified welding procedures that accommodate the geometry of the intended repairs. In the majority of cases this will require overlay or built-up type welding techniques. It is recommended that the basic rules stipulated in SANS 15614 Part 1 be complemented by elements of SANS 15614 Part 7 and BS EN 15613. For this approach the welding procedure will closely reflect the geometry, sequence and technique required for the production weld. 4.3.5 Acceptance levels for Imperfections Acceptance levels for imperfections B,C or D as described in BSENISO 5817 as required for specific weldments shall be prescribed to the contractor before production commences, preferably at the inquiry or order stage. In case no requirements are specified, by default the most stringent quality Level B shall apply. For special purposes additional conditions and details may be prescribed. The quality levels refer to production quality and not to fitness for purpose of the situation. 4.3.6 Quality levels and assessment class for imperfections Quality levels and assessment class for imperfections as described in SANS 10268 for thermoplastic weldments shall be prescribed to the contractor before production commences, preferably at the inquiry or order stage. For special purposes additional conditions and details may be prescribed. The quality levels refer to production quality and not to fitness for purpose of the situation. 4.3.7 Basic requirements of the weld procedure specification 4.3.7 Pertinent to welding procedure qualifications, the following information shall always be recorded in addition to the basic requirements of the weld specification:

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Heat input: the speed of weld progression shall be recorded in mm/s; the weld current range shall be measured with a clip-on gauge/ tong tester; the open circuit voltage of the welding machine and the weld voltage range shall be measured with a volt-meter (multi meter). Commercial trade name of the welding consumable. The yield strength and tensile strength of the coupons shall be recorded during the tensile tests. A copy of the actual graph generated during execution of the tensile tests shall be part of the record package. The heat treatment chart (where applicable) shall form part of the permanent record of the WPQR / PQR. Material certificates for both filler and parent material(s) shall be part of the permanent record of the WPQR / PQR. The mechanical test samples shall be retained and preserved for at least six months after completion of the tests for evaluation/examination by Eskom when required.

4.4 WELDER QUALIFICATION WPQR / PQR testing for metallic materials shall be performed in accordance to SANS 9606. For welding activities on plant constructed to the ASME Boiler and Pressure Vessel Code Section IX of the code applies. Welder qualification pertinent to thermoplastic materials shall be performed in accordance to SANS 10269. 4.5 MATERIAL CONTROL Prescriptions of the Quality Standard relevant to the contract shall be adhered to including the following basic requirements that are pertinent to all welding related tasks 4.5.1 Material to be used for fabrication or for weld repairs Material to be used for fabrication or for weld repairs shall be identified by a material test or mill test certificate. All high pressure valves, fittings, tubes and pipe work must be supplied with an EN 10204: 2004 Type 3.2 material certificate. All other components may be supplied at least with an EN 10204: 2004 3.1 material certificate. 4.5.2 All Unidentified material Unidentified material shall be isolated / quarantined and identified by a full chemical analysis and mechanical testing as required by the relevant material specification, before being considered for further use.

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4.5.3 Marking of removed material Any pieces or parts removed from original material shall be clearly marked with low stress hard stamps in the presence of the WA/TPI before any cutting is performed. 4.5.4 Protection of sectioned faces Sectioned faces shall be inspected for material defects and then protected from atmospheric conditions and contamination and stored in a clean and dry environment until required for use. 4.6 WELDING CONSUMABLE CONTROL The prescriptions of the Quality Standard relevant to the contract shall be adhered to including the following basic requirements that are pertinent to all welding related tasks. 4.6.1 Consumable approval Consumables shall be approved by the national standard requirements of the country of origin as a minimum. It is recommended that consumables with approval according to AWS A5.X family of specifications and/or BSEN family of consumable specifications be used on Level 1 and 2 Eskom plant. 4.6.2 Consumable identification Batch identification numbers shall be clearly marked on each individual package. 4.6.3 Consumable storage Consumables shall be stored in a clean atmosphere with humidity kept below 50% and a minimum of at least 30C above atmospheric dew point shall be maintained inside the original packaging as long as possible. 4.6.4 Damaged or contaminated consumables All consumables showing signs of damage to coatings, rust or contamination by any carbonaceous (paint, oil, polymers etc.) substance shall be promptly removed from storage or circulation and properly disposed of. 4.6.5 Identification on consumables Consumable grade markings/ stamps shall be visible on each individual wire or rod. There shall be no mixing of different class/grade consumables in one container. 4.6.6 Baking/drying of consumables Baking or drying temperature and duration shall be at least in accordance with the suppliers minimum requirements. 4.6.7 Holding of baked/dried consumables After baking/drying, the consumables shall be promptly transferred to a holding oven and stored at 120 C to 150 C for a maximum of one week prior to u se.

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4.6.8 Hot boxes for consumables Consumables shall be issued to welding personnel in hot boxes and the temperature shall be maintained above 70 C. 4.6.9 Unused consumables After each working shift the unused electrodes shall be accounted for by the welding supervisor or a properly trained delegate and returned to the holding oven until issued for a next working shift. These unused consumables shall be the first to be issued on the next working shift. 4.6.10 Permitted re-baking cycles The number of permitted re-baking cycles shall be in accordance with the supplier recommendations. If this is not clearly specified, the maximum number of baking cycles shall be three. 4.6.11 Welding and cutting gasses All gases used for welding and cutting tasks shall be clearly identifiable and accompanied by an analysis certificate. 4.7 HEAT TREATMENT Heat treatment procedures shall be compiled to meet the requirements of BS EN ISO 17663. The prescriptions of this quality standard and the contractors works instructions relevant to the contract shall be adhered to including the following basic requirements pertinent to all welding related tasks. 4.7.1 Heat treatment procedures Heat treatment procedures shall be compiled strictly in accordance with the WPS. A clear and concise drawing indicating the position and orientation of the heating source (resistance heating mats, induction coils, gas flame) as well as the positions for the controlling and monitoring thermocouples shall form part of the heat treatment method statement. This document shall be kept by the heat treatment technician at the work site. For PWHT on Eskom plant the temperature variation between set and actual measured shall be maximum or better than quality Class III in Table 1 of BS EN ISO 17633. 4.7.2 Heat treatment equipment Equipment used for heat treatment shall be in a well maintained condition, in particular: Valid calibration certificates for the power source and the control units shall be available for scrutiny at the work site All connections for thermocouples and heating elements shall be mechanically sound. No bare wires wedged into connection points on the power source and control panel will be allowed on Eskom plant No bare wire connections between lengths of compensating cable, and between compensating cables and the thermocouple wires are permissible. Proper connectors designed for this purpose shall be used.

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4.7.3 Operation and monitoring of heat treatment equipment Heat treatment equipment shall be attended to by suitably qualified operators at all times, including automated units which shall also be monitored continuously. 4.7.4 Measurement and maintenance of temperature for pre-heating and interpass temperature Measurement of temperature for preheating and interpass maintenance shall be in accordance with EN ISO 13916. Unless otherwise indicated by Eskom, the controlling thermocouple shall be positioned at the perceived point of lowest temperature during the heat treatment operation. This position will be determined by factors such as the effect of gravity on radiant heat flow, insulation techniques and conduction heat flow effects due to the close proximity of heavy walled components. Thermocouples, in particular the controlling one, shall be insulated from the direct radiant heat flux caused by the heating mat/coil/element (by recognised means such as heat resistant putty) in order to ensure true metal temperature is measured. 4.7.5 Heat treatment parameters for service-aged materials When welding is performed on service-aged materials, heat treatment parameters may have to be reviewed/revised to accommodate the material condition. Typical requirements are reduced heating and cooling ramp rates, flush grinding of weld reinforcements before PWHT commences. Additional measures to reduce cooling rates in the event of power source failure shall be in place. As a minimum, insulation of the affected component shall extend at least 1 meter either side of the heating source. A back up power generator is strongly recommended. 4.7.6 Substantiation of heat treatment Each heat treatment performed shall be substantiated by chart recordings or accurately kept hand written recordings of time versus temperature 4.7.7 Heat treatment information These heat treatment graphs shall form part of the welding data package. 4.7.8 Multiple heat treatments Multiple heat treatments of the same area on a component must be avoided. If this is unavoidable, the effect of multiple heat cycles on material metallurgical properties as well as on complicated geometries shall be investigated by the contractors suitably qualified engineering department. This investigation may also be contracted out to a suitably qualified metallurgical consultant. 4.7.9 Unplanned events during heat treatment Unplanned events that may occur during execution of the heat treatment procedure such as: Loss of power to the power source and/or controlling unit and/or data recorder Detached thermocouples Detached insulation Electrical shorts on thermocouple compensation cables

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These events shall be investigated immediately after being discovered by the project team, with the qualified metallurgical engineering input to determine the course of remedial action. A written report with recommendations shall be issued by the contractor for Eskom records. 4.8 CALIBRATION OF EQUIPMENT The prescriptions of the Quality Standard relevant to the contract shall be adhered to including the following basic requirements that are pertinent to all welding related tasks. 4.8.1 Equipment identification Each welding machine, heat treatment power source and plasma cutter shall be identifiable by an unique number. Machines shall be serviced and calibrated at least once a year when in constant use and proper records shall be kept. In case of infrequent use longer inspection and calibration cycles may be motivated by the vendor. Periodic checks by using a calibrated tong tester shall be performed to ensure that a reasonable level of accuracy is maintained. 4.8.2 Calibration of temperature measuring equipment Temperature measuring equipment shall be calibrated at least once a year and a record shall be kept. Other inspection and calibration cycles may be motivated and agreed between Eskom and the vendor. 4.8.3 Calibration of furnaces, holding ovens and hot boxes Consumable baking furnaces, holding ovens and hot boxes shall be calibrated at least once a year and a record shall be kept. In case of infrequent use longer inspection and calibration cycles may be motivated by the vendor. 4.8.4 Calibration of chart recorders for heat treatments Chart recorders used for heat treatment shall be calibrated at least once a year and a record shall be kept. In case of infrequent use longer inspection and calibration cycles may be motivated by the vendor. 4.8.5 Proof of calibration Proof of calibration status of the calibration and test equipment itself shall be included on each calibration certificate. 4.9 NON DESTRUCTIVE TESTING 4.9.1 Independence of NDT contractor Non-destructive testing (NDT) shall be performed by an entity suitably independent from the welding operation to ensure unbiased inspection. 4.9.2 Eskom approval of NDT contractor All Technicians performing NDT shall be Eskom approved and shall be employed by an Eskom approved company in accordance with the requirements of Eskom Standards 32-631 and 32-632.

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4.9.3 NDT safety Safety measures required by radiographic testing shall be strictly adhered to by the welding personnel. 4.10 WELDING COORDINATOR/ADMINISTRATOR The site welding co-ordinator / administrator shall be appointed by the relevant Eskom Power Station Manager, this function will depend on the Eskom site personnel structure and his/her job model shall at least include the following: 1. Assuring that all welding and related activities are performed in accordance with this guideline. 2. Any welding activity that could affect Eskom plant detrimentally in any way that is not specifically addressed in this guideline shall be investigated, reported and/or referred for in depth investigation. 3. Quality control of all welding and NDT activities as per relevant site procedures. 4. Compile repair procedures, Quality Control Plan (QCPs) and witness mandatory inspection hold points or witness points as required by the QCP 5. Accepts contractors repair procedures and QCPs. 6. Issue non-conformance reports on non-compliant materials, spares and workmanship. 7. Liaise with the TPI working for the Eskom appointed AIA on all repairs. 8. Interpret radiographs (if qualified to do so) and determine compliance to acceptance criteria. 9. Setting of quality criteria for special material requirements. 10. Check quality of special materials when delivered. 11. Ensure that only approved and qualified NDE personnel are employed on site. 12. Ensure that special processes controlling or verifying weld quality, heat treatment and NDT are performed by qualified personnel using qualified procedures in accordance to specified requirements. 13. Preparing, recording, maintaining and issuing welder performance qualification records and ensuring all Eskom and Contractor welders are qualified in accordance with the specified construction code. 14. Ensure all welding equipment is calibrated and maintained and records kept up to date.

5. RECORDS AND DATA PACKAGES


Records pertaining to any manufacture, repairs or modifications shall be compiled and /or updated and stored as required by Regulation 14 of the PER. All documents required by the applicable codes, standards and specifications shall be included in the contract/project data package. Eskom shall retain all original documentation. As a minimum, the following shall be present: 1. WPQR/PQR register. 2. WPS register. 3. WQR register. 4. Register with calibration certificates for welding, measuring and recording equipment.

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5. Welding consumable and material test certificates. 6. Heat treatment recorded data. 7. NDT certificates/records and radiographs stored in accordance with Eskom requirements. 8. Weld record sheet/weld map relating all the above records to each individual weld, for example, which welder performed the welding to which WPS with which batch of consumables and what were the NDT results for that joint. 9. Record of non-conformances. 10. Record of performance of each individual welder with regard to repair rates and exceptional performance for future reference. 11. Inspection reports 12. Repair recommendations/instructions 13. QCP / ITP 14. Release certificate

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6. APPENDIX
A.1 SUMMARY OF SANS ISO 3834 QUALITY REQUIREMENTS

ELEMENTS

SANS ISO 3834-2 (Comprehensive quality requirements) ESKOM LEVEL 1 PLANT Full documented review

SANS ISO 3834-3 (Standard Quality requirements) ESKOM LEVEL 2 PLANT Less extensive review

SANS ISO 3834-4 (Elementary quality requirements) ESKOM LEVEL 3 PLANT Establish that capability and information is available Shall comply with standard

CONTRACT REVIEW DESIGN REVIEW SUB-CONTRACTOR WELDERS, OPERATORS WELDING COORDINATION INSPECTION PERSONNEL PRODUCTION EQUIPMENT EQUIPMENT MAINTENANCE PRODUCTION PLAN WPS

Design for welding can be reviewed Treat like main contractor

Approved to SANS 9606 (Metallic weldments); SANS10269 (Thermoplastics) Welding co-ordination personnel with appropriate technical knowledge according to ISO14731, or persons with similar knowledge Sufficient and competent personnel to be available Required to prepare, cut, weld, transport, lift, together with safety equipment and protective clothes Has to be carried out, maintenance plan necessary Necessary No specific demand. Shall be adequate Restricted plan necessary Not demanded but responsibility of contractor Sufficient and competent, access for third parties, as needed No specific demand

No demands No demands No specific demands

Instructions to be available to welder (BS EN 15609) In accordance with BS EN15614 series(for metallics), approved as application standard or contract demands For thermoplastic weldments refer to SANS 10270 WPS or dedicated work instructions to be available Necessary Only if specified in contract Not specified Not specified

WELDING PROCEDURE APPROVAL WORK INSTRUCTIONS DOCUMENTATION BATCH TESTING OF CONSUMABLES STORAGE AND HANDLING OF WELDING CONSUMABLES

No demands

No demands No demands No demands

In accordance with supplier recommendation as minimum

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STORAGE OF PARENT MATERIALS POST WELD HEAT TREATMENT INSPECTION BEFORE, DURING, AFTER WELDING NONCONFORMANCES CALIBRATION IDENTIFICATION TRACEABILITY QUALITY RECORDS

Protection required from influence by the environment Specification and complete record necessary Confirmation to specification necessary

No demands No demands Responsibilities as specified in contract

As required for specific operations Procedures shall be available Procedures shall be available Required when appropriate

Not specified Required , when necessary Not specified Not specified As required by contract

Shall be available to meet the rules for product liability

Retained for five years minimum 5 years (or as contractually required)

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