WI02/QCD

Document: Instruction:
WI02/QCD-03 PROCEDURE FOR FABRICATION OF BOILER AND VESSEL
Revision: Prepared by: LE PHUOC PHU Date Prepared:
00 NGUYEN THI KIEU AN
Effective Date Date Reviewed:
Reviewed by: TOSHIYUKI NISHIO

Standard Date Approved:

Approved by: NOBUYUKI TATEKO
ISO 9001

Forms/Records

Form # Record/Form/Activity Name

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 WI02/QCD
Revision History

Revision # Date Description of changes Requested By

00 Initial Release Phu san

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 WI02/QCD
I. PURPOSE
This work instruction provides a guideline for the inspection for pressure boiler and
pressure vessel.
II. SCOPE
This work instruction covers the visual and dimension inspection to be performed for the
boiler, pressure vessels fabricated according ASME code section I, section VIII division 1.
Vendor must be submitted method statement, inspection plan (ITP), welding procedure
specification (WPS), certificate of equipment, material to KESV for purpose of this work
and notify to KESV inspection plan according ITP.

III. REFERENCE
ASME Code Section I
ASME Code Section II Part C
ASME Code Section V
ASME Code Section VIII Division 1
KESV’s procedure for hydro test inspection.
Fabrication Drawings
IV. DEFINITION AND ABBREVIATION
1. KESV: Kobelco Eco - Solutions Vietnam Co., Ltd.
2. BOD: Board of Directors.
3. ITP: Inspection and Test Plan.
4. WPS: Welding Procedure Specification.
V. RESPONSIBILITIES
V.1. Board of Management
The BOD is responsible for approving and allocating company resources to ensure this
work instruction is carried out throughout KESV.
V.2. KESV Staffs/Departments
All related departments are responsible for applying this work instruction: …
All KESV staffs must ensure specifications in this work instruction are applied
throughout the documentation process.
V.3. Quality control department
Check the effectiveness of the implementation of this work instruction.
Provide necessary training to the whole company and specifically to the project team on
the requirements of this work instruction.

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 WI02/QCD
Conduct regular audit with integrated audit plan to ensure the effectiveness of this work
instruction.
VI. DESIGN REQUIREMENTS
- All welding shall comply with the requirements specified in the Welding Procedure
Specification (WPS) or Welding Technique Sheets (WTS).
- Preheating above the minimum temperature specified in the Welding Procedure
Specification (WPS) or Welding Technique Sheets (WTS) may be necessary to remove
any entrapped moisture. The preheat temperature shall be maintained for a distance of at
least 3 inches on each side of the weld joint and in advance of the welding.
- Tack welds shall be made by qualified welders in accordance with the Welding Procedure
Specification (WPS) or Welding Technique Sheets (WTS). Defective tack welds shall be
removed or repaired prior to welding. Tack welds used in the assembly of vertical joints
of tank shells shall be removed and shall not remain in the finished joint when the joints
are welded manually.

VII. WORK INSTRUCTION

1) FLOW CHART

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 WI02/QCD
No Responsibility Content Form

Receive procedure
1 KESV and related
documents

2 VENDOR Cutting inspection

VENDOR, Formed head N

3 inspection
KESV

Y
N
VENDOR, Cylindrical shell
4
KESV inspection

VENDOR, N
5 Fit up
KESV inspection

Y
VENDOR,
6
KESV Dimension inspection

VENDOR,
7 Visual N
KESV Welding repair
inspection

Y
8 VENDOR
Report

9 KESV
Record

2) EXPLANATION
Stage 1: Receive procedure and related documents

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 WI02/QCD
After receiving procedure and related documents, if any ambiguities or contradictions
between these requirements and vendor standards or experience shall be notified to KESV
attention for resolution before vendor proceeds this work.
Stage 2: Cutting Inspection
- When the plates, edges of head and other part are cut by oxygen or arc cutting, the edges
shall be smooth and free of all loose scale, slag accumulation and detrimental
discoloration of material which has been molten, by the mechanical means prior to
fabrication or use.
- Exposed inside edge shall be chamfered or rounded.
- The used method of base metal preparation shall leave the welding groove with reasonably
smooth surface and free from deep notched, striations irregularities.
Stage 3: Formed head Inspection
- The inner surface of a formed head shall not deviate outside of the specified shape by
more than 1.25% of D nor inside the specified shape by more than 0.625% of D, where D
is the nominal inside diameter of the vessel shell at point of attachment. Such deviations
shall be measured perpendicular to the specified shape and shall not be abrupt. The
knuckle radius shall not be less than that specified.
- Measurements for determining the deviations specified in above shall be taken from the
surface of the base metal and not from welds.
- The skirts of heads shall be sufficiently true to round so that the difference between the
maximum and minimum diameters shall not exceed 1% of the nominal diameter.
Stage 4: Cylindrical shell Inspection
- The difference between the maximum and minimum inside diameters at any cross shall
not exceed 1% of the nominal diameter at the cross section under consideration. This
diameter may be measured on the inside or outside of the vessel. If measured on the
outside, the diameters shall be corrected for the plate thickness at the cross section under
consideration.

- When the cross section passes through an opening or within inside diameter of the
opening, the permissible difference in inside diameters give above may be increased by
2% of the inside diameter of the opening. When the cross section passes through any other

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 WI02/QCD
location normal to the axis of the vessel, including head to shell junction, the difference in
diameters shall not exceeds 1%.
- The inside diameter shall be measured at two or more position for each section at a
distance of about 100mm from each side of circumferential welded seam. When direct
measurement of the inside diameter is impractical, the external circumference may be
measured and the inside diameter calculated.
Stage 5: Fit up Inspection
- The surface of the parts to be welded shall be clean and free scale, rust, oil and other
deleterious foreign material for a distance of at least 13mm for ferrous material from the
welding joint preparation.
- Detrimental oxide shall be removed from the weld metal contact area. When weld metal is
to be deposited over a previously welded surface, all slag shall be removed by suitable
means so as to prevent inclusion of impurities in the weld metal.
- Plate that are being welded shall be fitted, aligned and retained in position prior to the
welding operation.
- Before all lugs, supporting saddles, nozzles, manhole frames, reinforcement around
openings, and other appurtenances are attached, they should be examined to certain that
they shall be properly formed and fitted.
- When fit up pressure parts, such as nozzles, manhole frames, reinforcement around
openings, such welds shall be flush for the portion of the weld to be covered.
- Tack welding shall be performed by qualified welders in accordance with qualified WPS.
- Tack welds to secure alignment, should be removed completely when they have served
their purpose and their starting and stopping ends shall be properly prepared by grinding
or other suitable means so that they may be satisfactorily incorporated into the final weld.
- The gap and alignment of section at edges to be butt welded in accordance with drawing
specification and WPS. The maximum offset is not greater than the applicable amount
listed in the following table.
Maximum allowable alignment tolerances of plate edge (For ASME section VIII div.1)

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 WI02/QCD
Illustration of welded joint locations typical of categories A, B, C, D

Maximum allowable alignment tolerances (for ASME section I)

Stage 6: Dimension after welding Inspection

Dimension inspection shall be performed in accordance with drawing and specification for
fabrication.
Stage 7: Visual Inspection
- Butt welded joints shall have complete penetration and full fusion. The surface of welds
shall be sufficiently free from grooves, spatter, porosity, overlaps, undercut, cracking,
etc... The nondestructive examinations shall be application if required.
- The reduction in thickness shall not be exceed 0.8mm or 10% the nominal thickness, or
the adjoin surface, whichever is less.
- To assure that the weld grooves are complete filled so that the surface of the weld metal at
any point does not fall below the surface of the adjoining base metals, weld metal may be
added as reinforcement on each of the weld. The thickness of the weld reinforcement on

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 WI02/QCD
each face shall not exceed the value show in the following table, this is applicable to the
butt welding of materials in all product forms.
Maximum allowable reinforcement thickness (for ASME section VIII)

Maximum allowable reinforcement thickness (for ASME section I)

Stage 8: Welding repair

- The removal of weld metal or portions of the base metal may be done by grinding or
gouging. The surfaces shall be cleaned thoroughly befor welding. All repair work shall be
done in accordance to the approved WPS.
3
- The total repair depth shall not exceed inch (38 mm) for P-No.1 Group No.1 materials
2
5
and inch (16mm) for P-No.1 Group No.2 materials.
8
- After removal of the defects, the groove shall be examined, using either the MT or PT if
required.

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 WI02/QCD
- The manual shielded metal arc process using low hydrogen electrodes shall deposit the
weld metals. The electrode shall be properly conditioned in accordance with ASME
section II Part C, SFA-5.5, appendix A5.6. The maximum bead width shall be four time
the electrode core diameter.
Stage 8: Report
Vendor shall be made report each of stage and submit to KESV.
Stage 9: Record

VIII. TRAINING
Training needs will be identified and conducted, if required, in accordance with procedure
“ADM-02 Training”.

IX. RECORDS
1. F01/QCD-03: Painting Inspection Report
2. F01/QCD-03: Dust Assessment

X. PROCESS CRITERIA
Not application

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