Nota Kuliah 2: 3.1 - 3.7 (Rujuk Silibus) 4.1-4.4 (Rujuk Silibus)

BAHAGIAN TEKNIK DAN VOKASIONAL

KEMENTERIAN PENDIDIKAN MALAYSIA
ARAS 5 & 6, BLOK E14, KOMPLEKS E,
PUSAT PENTADBIRAN KERAJAAN PERSEKUTUAN
62604 PUTRAJAYA
NOTA KULIAH 2
SEMESTER 4
SEMESTER SESI 2016/2017
DVM
JABATAN JABATAN TEKNOLOGI MEKANIKAL & PEMBUATAN
PROGRAM DIPLOMA TEKNOLOGI KIMPALAN / DVM
KOD/KURSUS MTK 8033 METAL FABRICATION ACTIVITIES
3.0 PREDICTIVE & CORRECTIVE ACTION METHOD RELATED TO PRE-

KOMPETENSI PREPARATION OF FABRICATION WORK
4.0 CORRECTIVE ACTION REPORT
KOMPETENSI UNIT 3.1 -3.7 (Rujuk silibus)

4.1-4.4 (Rujuk silibus)
Trainee must be able to:

1. Determine metal fabrication design and specification related to work
requirement (C4, PLO3 )
KOMPETENSI
2. Assemble jigs and fixture for metal fabrication according to BS/AWS
PEMBELAJARAN
standards. ( P3, PLO2)
3. Prepare work report in non-conformance in accordance to corrective action
report specification standard (A3, PLO5)
MTK 8033/K 03,04/

NO KOD NK 02-06
EDISI 1/JUNE 2017
MUKA : 01 DARIPADA 16
H-024-4
NO KOD JPK DUTY05/
TASK 5.03,5.04
MTK 8033/K 03,04/ NK 02-06 Muka Surat / Page : 2
NO. KOD / CODE NO.
EDISI 1/JUNE 2017 Drpd / of : 16
CORRECTIVE ACTION REQUIREMENT
When something breaks, you acknowledge the shock, scratch your head, take stock of the
situation, and look for the fastest way to repair the item and put it back into operation. The
pressure to repair quickly is understandable, but common sense suggests stopping for a
moment and trying to understand what caused the break before attempting the repair.
Failure Analysis
Almost anything can fracture. The science investigating the origins of fractures is called failure
analysis, and it is used to establish responsibilities for fractures and to determine preventive
measures for avoiding future occurrences. An introductory, interesting book on this subject was
written by Donald J. Wulpi and is titled Understanding How Components Fail. 1
Service Failures
This article discusses only in-service weldment breakage, also described as service failures.
Weldments are assemblies with parts joined by welding. Failures occurring during or
immediately following welding are easier to deal with, because all conditions are known.
So if the item was welded originally, it should be weldable again for repair, right?
Yes, but only if you know the materials and their conditions and whether they still are exactly as
they were at fabrication timeâ€”no heat treatment or other surface conditioning has been
introduced. You also must know the precise process and welding procedure that were used in
the first place, which usually isnâ€™t the case.
What Caused the Break?
Before attempting any repair, you must determine why the break occurred. If you restore the
item exactly to its original condition, chances are another breakage will occur. (At that time it
may well be none of your concern, but you must operate professionally at all times).
While a fully implemented professional investigation by an experienced metallurgist would be

the best recourse, this usually is justifiable only in selected casesâ€”for example, for presenting
claims to the manufacturer or to the insurance company. It is mandatory, however, if injury to
persons or property loss was or could have been involved.
Left to involved people, the human urge to clear oneself and to find fault in someone elseâ€™s
actions or inactions can interfere with an investigation.
The main reasons that weldments fail are:

 Inadequate material or properties.
 Poor design.
 Poor workmanship.
 Excessive unanticipated service conditions.
The Investigation Process

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Even if the person in charge is not specifically trained as a failure analyst, a few investigative
steps should always be taken:
1. First take care that nothing be moved, manipulated, reassembled, or fixed.
2. Document the condition of the weldment when the breakage was found.
3. Write down all that is known, and question all who were present.
4. Note the ambient temperature at the time of occurrence.
5. Take pictures, both general and close-ups.
6. Protect the place from rain and other environmental disturbing factors
Firmly resist the pressing urge (your own and of those around you) to supply a theory for the
breakage, especially before having assembled all the information.
A description of the weld profile as visible under low-power magnification should include such
details as dimensions and fit-up as much as they can be determined visually. If possible, these
details should be compared with design requirements.
When the structure operates normally at elevated temperature, it is probably under some code
legislation that may request an official investigation.
A weld breakage usually is a crack or a fracture. Much information can be drawn from an exact
description of the failure. A crack should be characterized by its dimensions, by its orientation
(longitudinal, along the weld bead, or transversal), and by its position relative to the weld itself
(on the weld bead or on its sides, in the heat-affected zone, or in the base metal).
If the fracture is open, do not reassemble the mating parts. Doing so can obliterate important
clues. Inspect the fractured surfaces with a low-power lens or microscope that can show internal
defects like gas holes or pores, nonmetallic inclusions, or indications of fatigue failure in the
form of concentric beach marks.
The presence of macroscopic deformations and the fibrous or glassy aspect of the surfaces
should be assessed to reveal if the failure was ductile (with deformation) or brittle (without
deformation).
Specific colors on the surfaces should be remarked; they might be clues about local heating and
oxidation. The extent of corrosion, if present, has to be determined and documented.
The presence of arc strikes on the surface, improper starting conditions, or accidental contact
may be at the origin of considerable damage.
Hardness testing is a very informative, simple, nondestructive test. However, selecting the
proper locations, especially if the weldment must be sectioned for testing, may be beyond what
can be expected from a technician not specifically trained for this kind of investigation.
The materials involved should be known and their properties checked for conformance to
specifications. No weld repair should be attempted without this essential knowledge. Having this
information allows you to select the proper repair procedures and filler metal.
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If materials are not known, an effort should be made to provide at least qualitative information.
This information can be obtained by X-ray fluorescence, a nondestructive test readily available
from many metal-related services.
What Next?
Having assembled and organized all the facts, you now should be able to formulate an
educated guess as to the possible causes of the failure.
Was faulty workmanship the culprit? A professional investigation service uses metallographic
examinations of weld sections to look for weld defects in the original weldment. Obviously, faulty
welds should have been detected by inspection after manufacturing, but nobody is perfect. If the
original weld was faulty, a repair weld performed with utmost care should improve the future in-
service performance of the repaired item.
A design change is not normally applicable for repair. However, if it is clear a faulty design
caused the failure, an improvement might be introduced. But you should be aware that adding
stiffness may make the matter worse, by increasing internal stresses and paving the way for the
next fatigue fracture.
If the breakdown was sudden but caused by a progressively deteriorating condition of certain
components (as in the case of fatigue fractures or corrosion), a corrective action program
should be initiated. The plan has to incorporate periodic examination of the parts involved, after
the structure is repaired, to detect dangerously spreading cracks before much damage occurs
again.
Cracks must be removed completely by careful grinding before rewelding. If the base metal is in
acceptable condition, weld repair may be attempted with suitable ductile filler metal or low-
hydrogen electrodes.
The process selected should introduce minimum heat and residual stresses, and possibly
should be followed by light hammer peening. Preheat and/or postheat, if necessary.
If separation has occurred, then a proper joint has to be designed and prepared, possibly by
introducing a transition element to make up for the volume of metal to be discarded.
Experience and common sense always are important, and even more so when dealing with
weld repairs.
CORRECTIVE ACTION GENERAL CONSIDERATIONS
1.0 Scope
The purpose of this procedure is to establish a general welding procedure for the repair of some
casting components of Vulcan Foundation Equipment Inc. hammers. It will cover only the
fundamental parameters of the welding process. The welding techniques are well established
and generally standardized.
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2.0 Qualification
It is recommended that welding operators be certified in accordance with the requirements of

Section IX of the ASME Boiler Code or ASTM A-488. Performance Qualification of Welders
under these documents is simple, testing the ability of the welder to produce a "sound" weld in
small carbon-steel plate.
3.0 The Welding Process
There are many welding processes available today, from completely automatic "electroslag"
processes to semi- automatic "Metal-Inert-Gas" (MIG) process. In this procedure only one
process will be considered; the "Shielded-Metal-Arc- Welding" (SMAW) process. This is the
oldest, simplest and most versatile process available today.
3.1 Welding Current
The current for the SMAW process is usually DC Positive (Reverse Polarity). Any type of
welding current generators may be used. Most welding machines have "rectifiers" with a
capacity of at least 400 amps and a 100% duty-cycle.
3.2 Electrodes
Only low-hydrogen electrodes should be used for this process. In the AWS-ASTM Classification
the approved electrodes would be: EXX15, EXX16, and EXX18. It is important to keep these
electrodes moisture-free after removing from the container. They should be stored in an oven at
250° F (120° C) and used within one (1) hour after removal. The absorption of moisture in the
electrode coating will result in hydrogen pick-up in the weld deposit and likely produce cracking.
3.3 Techniques
Standard welding techniques are used in this procedure. The bead should be of the "stringer"
type. Heat input should always be kept as low as is practical. The welding pass sequence
should be selected with the idea of keeping welding stresses to a minimum. This can be done
by controlling the heating and cooling rate of the process. The welding sequence passes should
be separated as much as is practical; the interpass should be kept low by the use of small-
diameter electrodes and low welding current.
4.0 Welding Parameters
The keys to high quality welding can be summarized in three (3) factors: (1) the selection of the
proper electrode for the particular base metal to be repaired, (2) the establishment of the correct
preheat temperature to (a) maintain a low hardness in the Heat-Affected-Zone (HAZ) and (b)
minimize welding stresses, (3) the selection and use of a suitable interpass temperature to
reduce the effects of heating and cooling on the components. This is important since post-
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welding heat treatment is not always practical and thus, excessive hardness and stresses must
be minimized by the correct selection of the welding parameters.
4.1 Electrode Selection
The selection of the proper electrode is based on the composition and mechanical properties of
the metal to be welded.
The composition of welding electrodes contains the same alloys as the casting; i.e. manganese,
nickel, chromium, molybdenum and vanadium. However, the carbon and silicon contents are
lower than the base metal. Therefore, the alloy content of the rod must be higher to achieve the
same mechanical properties.
Ideally, the composition and mechanical properties of the electrode should match the casting.
When this is not possible, it is more important to coordinate the mechanical properties than the
composition. This is true of carbon/low alloy steels, but not of corrosion and heat-resisting high-
alloy steels.
4.2 Preheat Temperature
The selection of the preheat temperature should be based on three (3) factors, listed in order of
importance:
1. Composition and hardenability of the base or parent metal. 2. The feasibility of post welding
heat treatment 3. The size and configuration of the part to be welded.
All of these factors require a higher preheat temperature. The preheat can range from 100° F
(40° C) for unalloyed steel to 400° F (200° C) for steels of high hardenability. The temperature is
always listed as "minimum" and may be higher, if desired. If possible, the entire part should be
preheated in a temperature-controlled furnace. Otherwise, localized heating with torches may
be used. There are several precautions that must be observed: (1) the heating must be done
slowly (100° F) (38° C/hr), (2) the part must be heated throughout the section, (3) the area
preheated should be at least 12" (30 cm) from the edge of the cavity.
The temperature of the part can be checked by use of "Temp- Sticks", a temperature-sensitive
marker that melts at the designated temperature. The temperature of both sides of the part
should be checked to insure complete heating throughout the section.
4.3 Interpass Temperature
The interpass temperature is the temperature of the base metal measured 2" (5cm) from the
weld, between weld passes in a multi-pass welding operation. It is always listed as a maximum,
and is usually less than 200° F (95°C) above the preheat temperature.
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The primary purpose of controlling the interpass temperature is to minimize the welding induced
stresses. A reasonable interpass temperature will also prevent the parent metal from becoming
so hot that it "anneals" the weld deposit, causing lower hardness and strength.
5.0 Post Welding Heat Treatment
Heat treatment after welding accomplishes two (2) things: (1) relieves the stresses incurred
during welding; (2) reduces the hardness in the HAZ. For these reasons it is advantageous to
heat-treat all parts after welding. Unfortunately, this is not always possible.
There have been many attempts to stress-relieve parts without using a heat treating furnace.
Most of these methods are ineffective. The amount of stresses relieved is dependent on the
temperature of the part and the time at that temperature. Since the temperature of these make-
shift operations is usually in the range of 700°-800°F (370-430°C) the holding times would have
to be in the 10-12 hour range. These methods are not recommended.
6.0 Choosing A Welding Procedure
The choice of a particular welding procedure is strictly dictated by the material composition of
the piece being repaired. As VULCAN FOUNDATION EQUIPMENT INC. is constantly
improving its material specifications, it is necessary that the end user of the product or the repair
facility doing the welding contact the factory to determine the exact material composition of the
particular casting involved.
INSPECTION AND WELDING REPAIRS OF PRESSURE VESSELS
Repairs are required for pressure vessels in order to restore its original / intended operating
condition, safe operation and to prolong trouble free service life. The vessel condition
deteriorate due to various factors mainly Mechanical Problems, Process Related Problems and
Corrosion Problems. Repairs are required to be planned and carried out under the strict
supervision and control of a competent Inspector.
The paper briefs the various steps involved in:
1 • Decision making for the repairs depending on location and nature of defect within the
pressure vessel as per ASME as well as API 510 code.
2
3 • Welding procedure qualifications.
4 • Materials and Welding consumables to be used for procedure qualification.

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5 • Requirements and limitations of controlled deposition welding as an alternative to PWHT,

or where Impact testing is a requirement.
6 • By using preheating methods where Impact testing is not a requirement.
7 • Method of “Temper bead techniques”.
8 • Method of “Half bead technique”.
9 • NDT that can be employed before, during and after welding.
10 • Necessity of PWHT and Hydrostatic tests.
11 • Repairs and precautions during overlay weld repairs.
12 • Methods and precautions to be taken during alterations and re-rating of pressure vessels.
13 • Aspects of reporting and re-inspection.
The Paper aims to brief the interested audience involved in welding inspection and repairs of
pressure vessels that can be conducted in Shut downs within Chemical, Refinery,
Petrochemicals and Fertilizer industries; various methods of weld repairs and related activities
such as testing after welding.
Key Words:
1 • Owner user : Owner or a user organization of the equipment.
2 • Repairer : The agency or organization, appointed by the
owner user for repairs of the equipment.
3
4 • Inspector : A competent inspection engineer having full
knowledge of the pressure vessel construction, in-service inspection
welding etc.
5 • Designer : A competent Pressure Vessel Design Engineer.

6
7 • Code : Code or standard used for design / construction and
Inspection of Pressure vessel.
8
9 •NDT inspector : A competent NDT inspector having thorough
knowledge and experience of NDT techniques involved in
Construction and repairs.
10
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11 • PWHT : Post Weld Heat Treatment given to the Pressure

vessel during construction or repairs.
REPAIRING FLOW
Repair and maintenance of parts and components is a major activity in any process industry.
Repair welding can be carried out as a logical procedure that ensures the part is usable and
safe. If repairs are done with proper care or precautions, it can avoid premature failures, large
warranty claims, safety of property and personnel and result in satisfied customers. Failures of
pressure vessels are still observed, which result in a costly down time of production and product
losses also sometimes it results in environmental hazards and unsafe working conditions or
disasters. Every owner user wants to extract highest possible safe service life from equipment.
The pressure vessel repairs also cannot be an exception this philosophy. Modern pressure
vessels are constructed in accordance to a recognized code and established fabrication and
welding practice.
Method of Inspection and decision for repairs.

Pressure vessels are designed to any recognized code of design and construction. We
must understand that the design thickness can be considerably lower than the actual Fabricated
. During design itself corrosion allowance is added in the base metal thickness and the
manufacturer fabrication chooses the next available thickness. Thereby we have a excess
thickness available for the service which result in a considerably lower operating stress value.
Steps involved in the decision making for repairs.
1 • Operating conditions, Inspection history, Material of construction of pressure vessel .
2 • Reasons for failure .
3 • Location of the damaged area by visual inspection and evaluation by NDTs.
4 • Re-evaluate the need for repairs (Back to design calculations).
5 • Repair Methods, (For pressure retaining parts) .
6 • Preparation of repair procedures.
7 • Replacement of major components.
Operating conditions, Inspection history, Material of construction of Pressure vessel:

A careful study of the operating parameters and inspection history and properly
maintained internal inspection reports, materials of construction, its behavior with the process
fluid, welding techniques used during construction, design consideration etc, also gives an
adequate confidence level about the use of pressure vessel. Such information is also useful for
making the repair decision.
Carefully selected material of construction and the fabrication procedures, welding procedures
as well as inspection and certification by the competent inspection authorities during fabrication
stage, always intend to give such information.
Reasons for failures:

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Undesirable premature failures can occur due to any one or more of the following
reasons . Faulty design, faulty workmanship, wrongly selected material of construction, wrong
welding techniques such premature failures generally occur in an early service period, where as
the normal service failures are attributed to corrosion, changes in the working parameters,
operation of the vessel for which it is not designed, impurities in the operating fluids,
metallurgical changes in the base metal etc. Once the damage is identified the pressure vessels
must be thoroughly inspected to evaluate the extent of damage, need for repair and the repair
method. Thorough visual inspection of the pressure vessel can be supplemented by a suitable
NDT examination, to locate the defects and the extent.
Location of the damaged area by visual inspection and evaluation by NDT.

On opening the equipment it is necessary to make it safe for entry as the remaining fluid
or fumes of gases could be dangerous for human life. The personnel may be required to stay for
internal inspection there could be possible repairs where hot work is involved, therefore a safe
entry permit from a competent authority i.e from the safety and operation departments. During
internal inspection, some responsible operator should always be accessible to the inspector
performing internal inspection. Such assistance can always be handy for any critical situation.
The external surface should be checked for any corrosion below the insulation, obvious
leakages, structural attachments, connections, foundations, leak proof tightness of pressure
relief valves etc.
The internal surface should be reasonably cleaned so as to visually verify its condition,
condition of threaded connections, Flange connections, closures, internal sand damage due to
corrosion. Different corrosion problems anticipated are pitting, line corrosion, general uniform
corrosion, grooving, galvanic corrosion, fatigue, creep, temperature, hydrogen attack /
embritterment, Stress corrosion cracking, Inter-granular corrosion, etc.
The identified damage can be supplemented by NDT for the extent, where by decision
for repairs can be taken confidently, various NDT possible, are UT thickness measurement, UT
scanning, RT, MPI and LPT.
Re-evaluate the need for repairs (Back to design calculations)

Based on the NDT results obtained, the same can be verified by the designer and
inspector by performing design calculations, to ensure that the remaining thickness is still safe,
and whether the repairs are warranted or not. Based on the remaining thickness corrosion rates
are calculated and the MAWP at the available thickness also calculated. If the MAWP required
is lower that the calculated MAWP then the repairs are not warranted provided the owner user is
ready to carry out internal inspection as per next scheduled interval. Location of defect is also
important. On base metal away from the weld metal, a monitor thinning can be left unattended.
In event there are borderline case the thickness can be recalculated by carrying our full RT and
thereby revising the Joint efficiency.
Following design considerations are reviewed during re-evaluation

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 Patch repairs welded by fillet welding can be used on temporary basis. Such repairs
shall be checked and verified by the design Engineer. The same should be replaced with
permanent measure at the next available maintenance opportunity. A fully encirclement
lap joint may be considered as a permanent repair method. Such full encirclement
patches shall also be designed to meet the code requirements.
 Minimum thickness observed shall be evaluated for MAWP and the corrosion rate, so as
to decide the next inspection interval.
 Location of localized corrosion, such as on the base metal, away from L seam, Away
from C seam, on the weld joints, on crown portion of the head, etc. thereby, comparing
the original design requirement. e.g. by carrying out L seam Radiography, the joint
efficiency can be revised to 1 and the remaining thickness acceptable can be revised.
 The Inspector should think out all such possibilities and advise the owner user, so as to
take a precise judgment on the repair.
Repair methods: (For pressure retaining parts)

 The cracks are gouged out or removed and weld repairs can be carried out from both
sides, if approach is available,
 The deep pits or localized corrosion can be weld built to restore the original thickness.
 The larger area, which cannot be welded by build up, can be replaced with patch or a
shell course or a head.
So far SMAW or GTAW has been the most widely accepted welding processes in the
industry, for its availability of welding equipment and skilled welders. However FCAW or GMAW
processes can also be used if sufficient expertise and equipment are available. Needless to
state that any code requirements, contractual requirements or any statutory / regulatory
requirement must be complied during weld repairs. Original construction drawing, calculation
data and inspection records are important for repairs. If the original construction data is not
accessible, then an analysis of the base material, including previous weld deposits, becomes
mandatory. If dimensions require close tolerances or if flatness is critical, then benchmarks that
will aid the repair without causing excessive and expensive damage to the work piece must be
established. The crack in weld joint or a defect in the base metal can be repaired by preparing a
“U” or a “V” groove to the full depth and length of crack and then fill up by weld metal deposit as
described here. If the crack exists in the stress concentration region then consult a competent
pressure vessel design Engineer. Corroded area may be restored by weld metal deposition as
described here.
Preparation of a repair procedure:

The repair procedure should take care of the requirements of the base metal, welding
consumables, sequential weld deposits, requirements of preheat, Interpass temperature, post
weld heating, PWHT, impact test and the NDT requirements. The repair procedure shall be
qualified as per the recognized code such as ASME sec IX, using an experienced welder.
Maintain the records of procedure qualification as well as performance qualification. If PWHT is
required in original construction and it is not practicable or advisable during repairs, then the
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Inspector and the Pressure Vessel Design Engineer shall review the reason for original PWHT
of the equipment.
Considerations for repair Procedures:

i. Repair procedure alternative to PWHT, Pre heating method, where impact testing is not
done on the original equipment.
 Impact testing is not required when this welding method is used.
 This procedure is limited to P1-Gr. 1 & 2; P3 –Gr. 1 & 2 (Excluding Mn-Mo steels)
 The weld area is pre heated and maintained at a minimum 150 deg C, during
welding. The temperature is measured to ensure 4” material or 4 times thickness
( whichever is greater) from the each edge of weld is maintained during welding.
 The maximum Interpass temperature does not exceed 315 deg C
 Carry out welding as per the qualified procedure.
ii. Repair procedure alternative to PWHT, where impact testing is performed on the original
equipment.
When the original construction required impact test, Notch toughness testing as
required by the code of construction is required. A procedure need to be qualified
separately by using a groove welding on the plate Some additional requirements that
can be considered over and above the supplementary essential variable are:
 This procedure is limited to P1; P3 and P4 steels.
 All supplementary essential elements of ASME Section IX para QW-250 are
applied.
 The weld area is pre heated and maintained at a minimum 150 deg C, during
welding. The temperature is measured to ensure 4” material or 4 times thickness
(whichever is greater) from the each edge of weld is maintained during welding.
 The maximum Interpass temperature does not exceed 315 deg C .
 Maximum heat input shall be calculated and implemented during repairs. The
maximum heat inputs as per qualified procedure must not exceed during welding.
 Qualification thickness for the plate material and the grooves are as per the table 1.
 If the welding is to be done under NACE standard, MR 0175, then additional test for
hardness measure to be applied.
 For SMAW welding process, electrodes with additional supplemental diffusible
hydrogen designator H8 or lower shall be used. The gas used in GTAW or GMAW
or FCAW shall exhibit a dew point no higher than minus 50 deg C.
 Welding shall be carried out as per controlled deposition, temper bead or Half bead
technique.
 After completion of welding, without allowing to reduce the preheat, the temperature
is raised to 230 to 280 Deg C. and held for minimum period of about 2 Hrs to assist
as Hydrogen bake out treatment.
 The Hydrogen bake out treatment can be omitted if electrodes having supplemental
diffusible hydrogen designator H4 are used.
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 After cooling the weld metal, the excess layer of reinforcement is ground off to
match the surface contour of base metal.
Non-Destructive Examination and testing of repaired location.

 The prepared surface can be checked by using MPI or LPT before welding.
 After completion of welding, NDE acceptable to the Authorized Inspector or the
owner user are selected and applied to ensure soundness of the weld.
 After repairs the need for pressure test is to be decided by the Inspector. The test
temperature and the minimum design metal temperature of Pressure vessel shall be
carefully evaluated.
 If Hydrostatic test is impracticable, then pneumatic test should be considered with
appropriate safety consideration.
Repair to Stainless steel overlays and clad.

 In event any overlay or cladding area is removed, then the base metal gets exposed
to the service environment.
 The Inspector should give consideration to remove the possible entrapped
hydrogen if the service and the base metal is prone to hydrogen entrapment,
hydrogen embrittlement, Temper embrittlement etc. A heating treatment such as
Hydrogen bake out at 230 to 280Deg C, for about 2 Hrs. shall be given.
Execution of welding repairs:

 The repairer, under close supervision and surveillance of the Inspector, executes
actual repairs. The written and qualified procedures are strictly followed. In case the
Impact testing is specified, the welding parameters are also monitored and ensured
to be within the range at which the procedure is qualified.
 Specified NDE before welding repairs and after welding repairs are carried out and
shall be approved by the Inspector.
 After repairs the inspection record and the history of equipment, giving details of
repairs, is updated and next inspection schedule shall be recommended to the
owner user.
Welding techniques:
i. Temper bead welding technique:
The heat affected zone of the bottom bead due to the top bead applied with lower size
electrode, leaves less than 20 to 30 % of the weld metal cross sectional area as a “
typical columnar grains” and the balance is a normalized structure. The top layer of the
reinforcement mainly consisting of columnar grains, is required to be ground out, to
match the surface contour.
ii. Half bead welding technique,
After every pass, the top half of the weld bead is ground off before applying the next
layer. Such half bead technique also achievs the similar effect of temper bead technique,
but then the consumption of welding electrodes can shoot up.
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Conclusion:
 Repairs of pressure vessels are not always warranted, the decision of welding
repairs must be taken with due consideration to the location of defect, carefully
evaluated and interpreted NDE results, Design Calculations, Construction condition
such as PWHT and Impact test.
 Once the decision of welding repairs is taken then it is necessary to document the
repair procedure giving details of NDT test necessary, Per heat and PWHT, welding
sequence, monitoring the welding parameters, pressure test requirements etc.
 Prepare the inspection reports and follow up inspection at a predefined inspection
interval.
References:
1 • API 510 - Pressure vessel inspection code.
2 • ANSI NB 23 – National Board Inspection code.
Nonconformity (quality) ... In quality management, a nonconformity (also known as a

defect) is a deviation from a specification, a standard, or an expectation
nonconformance costs
Costs incurred from failure to meet product quality requirements. Nonconformance

costs results from production imperfections and encompasses both internal and failure
costs.
what
A Non Conformance Report or Non Conformity Report, is a construction related
document that keeps track of deviation and work that fails to meet standards and specs.
Non Conformance Report Items

A Non Conformance Report shall be used prepared and must include at a minimum the
following information:
 What is the main reason or what when wrong
 Why the work doesn't meet specs
 What can be done to prevent it from happening again
 Explanatory corrective action taken
 Key players involved in the NCR and specs affected under the NCR
When to Issue a Non Conformance Report

 Work that was not built as indicated in the approved Issued for Construction
Drawings
 Work that fails to meet specified tolerances as established in the project specs.
NO. KOD / CODE NO.
 Work that is being performed using non-approved methods or standards

 When the testing and inspection plan is not followed as agreed
 When testing results demonstrate that the product does not meet established
and approved standards
 When a material is used and has not been approved as a substitute (equal or
similar)
 When design is not accurate and does not represents actual field conditions
 When the approved procedure was not followed and quality defects have been
identify by the project team
Who Is Responsible to Issue the Non Conformance Report

The Non Conformance Report, depending on the situation, can be issued by any of the
project team members.
It shall present a non-debatable fact, clear and with sufficient back up information that
supports the claim. It is important to establish since day one, what conditions shall be
met in order to issue the NCR. Once the rules are established and limits have been set,
then it is safe to issue NCR's but most important to maintain track of it and be able to
close the NCR. Non Conformance Reports shall be used as learning and training tools
to avoid those situations from happening again.
Non Conformance Report Consequences
What to Do When You Receive a NCR?
If you are the recipient of the NCR, you must act promptly and at a minimum follow
these steps for a quickly resolution:
Meet with the person issuing the NCR

Implement the corrective action and make sure through an inspection process that the
issue has been solved adequately.
Reply through formal letter or document the process on what was the action that
triggered the NCR, document the action to solve the issue, explain the steps taken to
prevent this from happening and last but not least, make sure that your counterpart
agrees and signs off on your action plan.
NO. KOD / CODE NO.
Corrective vs. Preventive Action (CAPA)

corrective action deals with a nonconformity that has occurred,
preventive action addresses the potential for a nonconformity to occur.
Corrective Action Process

 Locate and document the root cause of the nonconformity.
 Scan the entire system to ensure no other similar nonconformity could occur.
 Analyze the effect such a nonconformity may have had on a product or service
produced before the nonconformity was discovered, and take action appropriate
to the severity of the situation by either recalling the product, notifying the
customer, downgrading or scrapping product.
 Establish thorough follow-up to ensure the correction is effective and recurrence
has been prevented.
Preventive Action Process
 Take proactive steps to ensure a potential nonconformity does not occur.
 Employ process and system analysis to determine how to build in safeguards
and process changes to prevent nonconformance. For example, use a failure
mode and effects analysis to identify risks and potential deficiencies and to set
priorities for improvement.
NO. KOD / CODE NO.

Nota Kuliah 2: 3.1 - 3.7 (Rujuk Silibus) 4.1-4.4 (Rujuk Silibus)

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Nota Kuliah 2: 3.1 - 3.7 (Rujuk Silibus) 4.1-4.4 (Rujuk Silibus)

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BAHAGIAN TEKNIK DAN VOKASIONAL

JABATAN JABATAN TEKNOLOGI MEKANIKAL & PEMBUATAN

PROGRAM DIPLOMA TEKNOLOGI KIMPALAN / DVM

KOD/KURSUS MTK 8033 METAL FABRICATION ACTIVITIES

3.0 PREDICTIVE & CORRECTIVE ACTION METHOD RELATED TO PRE-

KOMPETENSI UNIT 3.1 -3.7 (Rujuk silibus)

Trainee must be able to:

MTK 8033/K 03,04/

CORRECTIVE ACTION REQUIREMENT

What Caused the Break?

While a fully implemented professional investigation by an experienced metallurgist would be

The main reasons that weldments fail are:

The Investigation Process

CORRECTIVE ACTION GENERAL CONSIDERATIONS

It is recommended that welding operators be certified in accordance with the requirements of

3.0 The Welding Process

3.1 Welding Current

4.0 Welding Parameters

4.1 Electrode Selection

4.2 Preheat Temperature

4.3 Interpass Temperature

5.0 Post Welding Heat Treatment

6.0 Choosing A Welding Procedure

INSPECTION AND WELDING REPAIRS OF PRESSURE VESSELS

4 • Materials and Welding consumables to be used for procedure qualification.

5 • Requirements and limitations of controlled deposition welding as an alternative to PWHT,

6 • By using preheating methods where Impact testing is not a requirement.

7 • Method of “Temper bead techniques”.

8 • Method of “Half bead technique”.

9 • NDT that can be employed before, during and after welding.

10 • Necessity of PWHT and Hydrostatic tests.

11 • Repairs and precautions during overlay weld repairs.

13 • Aspects of reporting and re-inspection.

5 • Designer : A competent Pressure Vessel Design Engineer.

11 • PWHT : Post Weld Heat Treatment given to the Pressure

Method of Inspection and decision for repairs.

Operating conditions, Inspection history, Material of construction of Pressure vessel:

Reasons for failures:

Location of the damaged area by visual inspection and evaluation by NDT.

Re-evaluate the need for repairs (Back to design calculations)

Following design considerations are reviewed during re-evaluation

Repair methods: (For pressure retaining parts)

Preparation of a repair procedure:

Considerations for repair Procedures:

Non-Destructive Examination and testing of repaired location.

Repair to Stainless steel overlays and clad.

Execution of welding repairs:

Nonconformity (quality) ... In quality management, a nonconformity (also known as a

Costs incurred from failure to meet product quality requirements. Nonconformance

Non Conformance Report Items

When to Issue a Non Conformance Report

 Work that is being performed using non-approved methods or standards

Who Is Responsible to Issue the Non Conformance Report

Non Conformance Report Consequences

What to Do When You Receive a NCR?

Meet with the person issuing the NCR

Corrective vs. Preventive Action (CAPA)

Corrective Action Process

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