Project Detail
Project: North III Unit 04 ¨Reheater Replacement”.
Equipment: Re-Heater
Date: July 2010-October 2011
Vendor Location: Boiler Parts Fabricator in Nuevo Leon Mexico.
Witness on welding application per Main ITP Rev 2 Item 19.
Item Inspected: Elements P5-U2-E- 16 to 27.
Findings: Electrode AWS Classification E-10018-D2 was being applied on welds between parts of base metals P1(Carbon Steel) to P5A(Low Alloy Steel) in place of the specified one E-9018 B3. Not in accordance with approved WPS- SMAW-58(P5A-P1).
Re-Inspection: Per Customer Direction, Repairs to remove the weld material applied with wrong Filler Metal and re-weld in accordance with approved WPS have been completed by Fabricator.See Photo.
Witness on welding application per Main ITP Rev 2 Item 19.
Item Inspected: Wall Panels N9-U1-E- 13 to 16.
Findings: Witness on FCAW Welding, on Fillet Welds of Joints Plate Membranes to Tubes (P1 to P1 Materials). Shielding GAS being used, 100%-CO2. Not Acceptable to Approved WPS FCAW-34A(P1-P1) which specifies for a Mixture 75%-25% AR-CO2.
Re-Inspection: Per Customer Direction, repairs to remove the weld material applied with wrong shielding gas and re-weld in accordance with approved WPS have been completed by Fabricator. See photo on referenced issue.
Witness on welding application per Main ITP Rev 2 Item 19.
Item Inspected: Intermediate Re-Heater Element-Tube S5-U2-E-45.
Findings:Fit-Up of Alignment Straps(P8 to P8 Stainless Steel Materials), Used Electrode E-308, right to Approved WPS, however in the Portable Oven being used by tack welder to keep the Austenitic E-308 electrodes(E-308 is Not a Low Hydrogen Electrode) were found mixed electrodes E308, E309 as well low Hydrogen Electrodes E8018 B2 and E7018 with the serious risk to take a Carbon Steel/Low Hydrogen Electrode and tack weld wrongly on the stainless steel material.
Re-Inspection: Per Customer Direction, repairs to remove the tack welds applied with filler metal in doubt completed by Fabricator. See photos as illustration on referenced Issue.
Dimensional Inspection per Main ITP Rev 2 Item 21.
Item Inspected: Intermediate Re-Heater Element-Tube M5-U1-E-43, Bends-180 deg, 7.5¨ Radius.
Findings: 8.20% Ovality as Mesaured, Not Acceptable to Customer Spec MN45U Section 8.4.
Re-Inspection: Per customer direction, repairs conducted by Vendor to bring the referenced Bends 180 deg to within tolerance in Ovality per Spec MN45U referenced above. See Photos as illustration on dimensional inspection.
Review on RT Examination per Main ITP Rev 2 Item 56.
Item Inspected: Intermediate Re-Heater Element-Tube V6-U3-Element-186.
Findings: Tube Element Number 186 already assembled within Assembly KS1-80 was found with omitted RT Examination in Butt Welds.
Re-Inspection: Vendor has disassembled the referenced Tube Element-186 and conducted the specified RT Examination with satisfactory results.
Benefits to Our Customer: By using Fraza Inspection Team, Customer saved a lot of of time and money preventing excessive expenses per back charges for Extra-RT Examination and Reworks at field site, per unacceptable issues on Omitted NDE Examination, Dimensions and Welding, if Not Corrected/Repaired in timely manner at Vendor Shop.
Project Detail
Project: South Saudi Petrochemical Co
Equipments: Boiler Parts(Convection Bank/Bank Side Wall/Bank Rear Wall/ Furnace Side Wall/Furnace Baffle Wall/ Front Wall/Rear Wall).
Date: October 2011
Vendor Location: Fabricator of Boiler Parts in Nuevo Leon, Mexico.
Review of Project Requirements per Vendor ITP-MITP-Q1391-01-07 Rev 1.
Item Inspected: Offset Tubes of Furnace Wall.
Findings: The following items were added or changed in Revision 1 of Referenced ITP per Customer Observations: Change of RT Requirement for Buttwelds of Offset Tubes on Furnace Wall, from 10% to 100%, however per review on RT Reports and RT Films all referenced buttwelds were just Single Shotted, Not Acceptable since per Requirements from ASME Code Section V, Article 2, paragraph T-271.2(b)(1), when complete coverage is required, a mínimum of two exposures taken 90 deg to each other shall be made for each joint.
Re-Inspection: Vendor has completed on specified RT Examinetion taking a second exposure for every referenced buttweld in accordance with ASME Code referenced requirements.
Benefits to Our Customer: By using Fraza Inspection Team, Customer saved a lot of of time and money preventing excessive expenses per back charges for Re-works at field site per unacceptable issues on Extent of NDE Examination Not in Compliance to Customer Project Requirements if Not Corrected/Repaired in timely manner at Vendor Shop.
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