Project Detail
Project: South High Mountain Energy Project.
Equipment: Steam Drum, Heat Exchanger, Lower Drum, Pre-Heater and Steam Super Heater.
Date: April 2016 - October 2016
Vendor Location: Fabricator of Heat Exchangers and Pressure Vessels in Nuevo Leon, Mexico.
Visual Inspection per ITP-3471 Rev 1 Sec Nr 8.7, Drawing 3471-01 Rev 3.
Item Inspected: Heat Exchanger Tag-Y-9502.
Findings: Fraza Team had requested to Vendor to make sure Pre-Heat is being properly applied before tack welding on Fit Up of Flanges Studding Outlets R1, R2, R3, T2 and T3 to Shell, as per answer from Vendor Production Team, preheat had been applied and measured, however not checked by Vendor QC Team. During inspections conducted later, cracks were observed on tack welds applied on Fit Up of referenced Flanges, which reflects a Pre-Heat Not conducted properly before tack welding or Not Performed. Fraza Team has requested Vendor to prevent on such issues making sure on Compliance to Pre-Heat Requirements per Approved WPSs.
Re-Inspection: Per Fraza Team observation, Vendor has removed all cracked tack welds, applying new tack welds per Approved WPS, as well conducted PT Examination on referenced Weld Preparations and found all of them free of cracks. See Photos as illustration on Referenced Issue.
Witness on Welding Application per ITP-4371 Rev 1 Sec Nr 7.5, Drawing 3471-03 Rev 1, Spec 19502-HE-03 Rev 2 and Approved WPS GT-237 Rev 1.
Item Inspected: Heat Exchanger Tag-Y-9502.
Findings: Welding Application of Nozzle K7(Material SA-335 P11) to Inlet Chamber(Material SA-387 Gr 11 Cl 2) P4 to P4. During welding a lot of Electrodes E-7018 and only one electrode specified E8018 B2 were found in the Portable Stove being used by welder Mr Raul Rodriguez, existing a serious risk Mr Rodriguez has applied welding using wrong Electrodes E-7018 in place of the Specified E-8018 B2 per approved WPS GT-237 Rev 1. Fraza Team has requested to Vendor QC to issue an Internal NCR on this critical Issue of Control of Welding Materials.
Re-Inspection: Vendor Production Team has decided to remove completely the weld applied with wrong filler metal E-7018 as well has Examined by PT the weld preparation and found it free of defects. Later Welding Application with Correct Filler metal E-8018 B2 in accordance with Approved WPS Referenced above has been completed. See Photo as Illustration on Referenced Issue.
Dimensional Inspection per ITP-1473 Rev 1 Sec Nr 4.0, Drawing 1472-02 Rev E and Spec 19502-HE-03 Rev 2.
Item Inspected: Steam Drum Tag S-8804.
Findings: Nozzle N19, Dimensions of internal Flange Item 4-23 such as Diameter of Boltholes Circle and Outside Diameter do not match with dimensions of connecting flange installed in piping continuous blowdown item 4-9 per drawing 1471-04 Rev G. Apparently this is a mistake in drawing since the dimensions of referenced flange item 4-23 correspond to a size NPS 2” 150# and the connecting flange item 4-9 corresponds to a size NPS 1 1/2” 150#.
Re-Inspection: Vendor Engineering team has confirmed on this Issue produced during the Drawing preparation as well a new flange item 4-9 with similar dimensions as connecting flange item 4-23 will be fabricated from plate material and this change will be reflected on revised drawings. Addressed by Vendor. See Photos as Illustration on Referenced Issue.
Visual Inspection on Surface Preparation per Inspection Plan 1472 Rev 2 Sec Nr 16.0, Drawing 1472-03 Rev 2 and Paint Spec 19504-HE-01 Rev 2.
Item Inspected: Blasted Lower Drum Tag-Z-4594.
Findings: Nozzle T20 observed with finish of gasket seat totally damaged by Blasting during the Surface Preparation.
Re-Inspection: Vendor has replaced the damaged flange by other new flange with aceptable finish on gasket seat. See Photo as Illustration on Referenced Issue.
Witness on Welding per Inspection Plan 4276 Rev 2 Sec Nr 6.6, Drawing 594-02-34981-04 Rev D, Customer Specification 19401-SH-02 Rev 2 and Approved WPS GT-499 Rev 2.
Item Inspected: Super Heater Tag F-3502.
Findings: Fit-Up and Weld Prep on Joints of Return Bends to Tubes(SA 213-347H Material).Wrong Filler Metal ER 308/308L had been provided and placed at Work Station to tack weld on Fit-Up of referenced Return bends to Tubes. Fraza Team has requested to Vendor to prevent on use of wrong ER308L making sure only the Right Filler Metal ER-347H(ER-347) be used in accordance with Approved WPS referenced above.
Re-Inspection: Vendor has removed from Work Station all Wrong Filler Metal Rods ER 308/308L to prevent their use. See Photo as illustration on Referenced Issue.
Witness on Welding Application per Inspection Plan 2146 Rev 1, Sec Nr 6.3 and Drawing 19401-39204 Rev D.
Item Inspected: Steam Drum Tag S-7704.
Findings: Monitoring on Handling and Control of Welding Material. Several times during this Week Low Hydrogen Electrodes E-7018 found left out from their original container for an extended time not in accordance with ASME Code Requirements.
Re-Inspection: Addressed by Fabricator QC Team per referenced Project Requirements. See Photos on Referenced Issue.
Dimensional Inspection per Inspection Plan 1473 Rev 1 Sequence Nr 6.5 and Drawing 1462-01 Rev 2.
Item Inspected: Lower Drum Tag-Z-4594.
Findings: Dimension from Centerline of Nozzle T20 to Main Centerline of Equipment, Specified Dimension, 429mm, Actual as Measured 464mm(Plus 35mm), Not Acceptable to Tolerances per Drawing Referenced Above.
Re-Inspection: Correction conducted by vendor to bring the referenced dimensión to within tolerance per Drawing Requirements. See Photo on Referenced Issue.
Final Visual Inspection on all Equipments per Inspection Plan 2146 Rev 1, Sec Nr 6.3 and Drawing 19401-39203 Rev C.
Item Inspected: All Equipments.
Findings: Issues Observed, weld defects such as arc strikes, unacceptable undercuts, lack of fusion, overlaps, weld preparations with excessive root gap and bevel angle not in accordance with approved WPSs, undersized fillet welds on joints of nozzles, support saddles and shell/tubesheets, pre-heat temp not in accordance with approved WPSs, major repairs on base metal not previously approved from customer as specified per Project Requirements.
Re-Inspection: All referenced issues corrected/repaired by Vendor in accordance with Project Requirements. See photos on typical issues.
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 Wrong Connecting Flanges, Control of Welding Materials, Dimensions, Welding, Surface Preparation, Damaged Gasket Seating on Nozzle flanges for Field Connections and Not Compliance to Project Specifications, If Not Corrected/Repaired in timely manner at Vendor Shop.
Project Detail
Project: Long Beach Unit 02
Equipments: LBU-9 8" Bun C-D LBA-PYL-13ST-Y/E
Date: January 2018 - February 2018
Vendor Location: Fabricator of Pressure Vessels in Tamaulipas, Mexico.
Visual Inspection on Welds per Vendor ITP T463313 Rev 1 Item C-1 and Vendor Fabrication Drawing LB-463313-02 Rev A.
Item Inspected: Outlet Elbow Assembly 6” LBU(Four Pieces).
Findings: All Joints specified to be welded by Complete Joint Penetration, however a piece identified as 1-4 observed with incomplete joint penetration at a spot of 1” length on seam of Reducer item 1 to Elbow item 2.
Re-Inspection: Repair completed properly by Vendor to achieve CJP as confirmed by Visual Inspection. See Photos as Illustration on Referenced Issue before and after Repair.
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 Welding, If Not corrected/Repaired in timely manner at Vendor Shop.
Project Detail
Project: New Valley Energy
Equipments: Vaporizer Pot/Start-Up Pot/Condensate Pot.
Date: June 2013 - November 2013
Vendor Location: Fabricator of Pressure Vessels in Nuevo Leon, Mexico.
Visual Inspection per ITP-5971-08 Rev 1 Item 4, Drawing 7916-03 Rev 3 and Customer Specification MJPWSS-02 Rev 5
Item Inspected: Condensate Pot Tag-7502-0122-02.
Findings: Lack of fusion observed on two locations of weld of Top Head to Shell. As well specified radius on internal edge of Nozzles not yet Done as specified on Customer Specification MJPWSS-02 Rev 5 Section 10.
Re-Inspection: All corrections and repairs conducted by Vendor in compliance to Referenced Projects Requirements. See Photos as Illustration on referenced Issues.
Visual Inspection per ITP-5971-08 Rev 1 Item 4, Drawing 7916-03 Rev 3 and Customer Specification MJPWSS-02 Rev 5.
Item Inspected: Vaporizer, Start Up and Condensate Pots Tag-7801-0134-01.01/02/03.
Findings: Per Customer Specification MJPWSS-02 Rev 5 Section 8.1.2, plate layouts shall be arranged so that Longitudinal and Circumferential weld seams do not cross through any Nozzles, however this requirement has not been complied on Three Referenced Vessels at this Vendor, since two connection nozzles have been located over Circumferential Seams of Shell to Heads.
Re-Inspection: Per Customer Direction,Vendor has RT Examined 100% the referenced weld seams in order to get compliance to Requirements per Referenced Customer Specification Sections 8.1.2 and 8.1.3. Addressed by Vendor. See Photos as Illustration on referenced Issue.
Visual Inspection per ITP-5971-08 Item 4, Drawing 7916-03 Rev 3 and Customer Specification MJPWSS-02 Rev 5.
Item Inspected: Vaporizer, Start Up and Condensate Pots Tag-7801-0134-01.01/02/03.
Findings: Per Customer Specification MJPWSS-02 Rev 5 Section 8.1.4, Structural Attachments shall clear weld seams by a minimum of 2”. This Requirement has not been complied on the Three Vessels at this Vendor since the reinforcing pads of the Four Support Legs have been located over the Circumferential Seam of Shell to Bottom Head.
Re-Inspection: Per Customer Direction, In order to get Compliance to Requirements per Customer Specification MJPWSS-02 Rev 5 Sections 8.1.4 and 8.1.5, Vendor has removed the referenced Support Pads, grinding flush the portions of the seams originally covered and Examining by RT on them, Addressed by Vendor as per Project Requirements. See Photos as Illustration on referenced Issue.
Visual Inspection per Inspection and Test Plan ITP-5971-08 Item 4, Drawing 9812-04 Rev 3 and Customer Specification MJPWSS-02 Rev 5.
Item Inspected: All Referenced Pressure Vessels.
Findings: Issues Observed, lack of penetration and root concavity observed on root side of the joint of nozzles necks to Shell and undersized fillet welds.
Re-Inspection: Repairs completed by Vendor in accordance with Project 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 Reworks at field site per unacceptable issues on welding and Not Compliance to Project Requirements if Not Corrected/Repaired in timely manner at Vendor Shop.
Project Detail
Project: High Forest Unit 01
Equipments: Steam Stripper Column, Steam Receiver, Vent Seal Pot, Knock Out Pot
Date: September 2015 - October 2015
Vendor Location: Fabricator of Pressure Vessels in Nuevo Leon, Mexico.
Review on Project Requirements per ITP-1786-01 Rev 1 Item 3 and Documents as referenced below.
Item Inspected: Steam Receiver Tag HF1-RT884.
Findings: Fraza Team has recommended to Vendor QC Team to clarify on right Painting System to be applied since per Drawing 121832-HF1-01 Rev 0, a Paint System per Paint Code T330N with just Primer coating High Temp 1027 is specified, as Done originally by Vendor, however in accordance with Vendor Drawing HF-832-01 Rev 1 Note 25, a paint system per Paint Code T330U from Specification 8HFQ-7603 Rev 3 with a Primer Hi Temp plus a Top Coating 500VS is specified and finally confirmed as right from Customer.
Re-Inspection: Vendor has applied later the specified Top Coating, found missing originally. See Photo on Equipment Top Coated.
Visual Inspection on Paint per ITP-1786-02 Rev 1 Item 12 and Documents as referenced below.
Item Inspected: Knock Out Pot-Tag HF1-RT886.
Findings: Paint system per Paint Code T330U from Specification 8HFQ-7603 Rev 3 with Primer Hi Temp and subsequent Top Coating 500VS had been completed, however a lot of days have passed after paint application and the applied coating has not cured since it has not hardened, showing a surface excesively soft easy to remove.
Re-Inspection: Vendor QC Team has decided to reject the referenced painting. Later this vessel has been re-blasted and re-painted in accordance with project requirements. See Photos on referenced issue.
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 Painting and Wrong Paint System, If Not Corrected/Repaired in timely manner at Vendor Shop.
Project Detail
Project: Beauty Forest Unit 01
Equipments: Splitter Tower
Date: September 2015 - October 2015
Vendor Location: Fabricator of Pressure Vessels in Nuevo Leon, Mexico.
Visual and Dimensional Inspection per ITP-1954-01 Rev 1 Item 3 and Vendor Drawing BF-1954-01 Rev 2.
Item Inspected: Splitter Tower.
Findings: Welds of connection clips item 25 to Tower shell specified to be Complete Joint Penetration welded, however such welds observed just single fillet welded. Also, Inspection for location of Nozzle N3, specified Dimension 8233mm, Actual dimensión as Measured, 8223mm(minus 10mm), out of tolerance per Referenced Drawing.
Re-Inspection: Vendor has conducted needed corrections and repairs to bring all dimensions to within tolerances as well all welds done in accordance with Welding Symbols per Drawings. See Photos on typical issues as found.
Visual Inspection on Painting per Inspection and Test Plan ITP-1954-01 Rev 1 Item 16 and Customer Paint Specification BFQ-1954 Rev 2.
Item Inspected: Splitter Tower.
Findings: Several locations observed with paint defects such as low DFT, sags, runs and excessive overspray.
Re-Inspection: Vendor has conducted needed repairs on Paint on all áreas previously observed with defects in compliance with Customer Paint Specification referenced Above. See Photos on typical issues as originally found.
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 Dimensions, Welding and Painting, If Not Corrected/Repaired in timely manner at Vendor Shop.
Project Detail
Project: Forest Mountain Unit 01
Equipments: Wet Steam Separator
Date: August 2017 - November 2017
Vendor Location: Fabricator of Pressure Vessels in Tamaulipas, Mexico.
Visual Inspection on Finished Painting per Customer ITP-FM-993-01 Rev 0 Item 10.3 and Painting Spec FM-T24993-01 Rev A.
Item Inspected: Wet Steam Separator Tag Number Y-3742.
Findings: Observed scale inside boltholes on Inlet/Outlet Flanges and at other areas, such scale was Not Removed by Blasting during Surface Preparation. Not Acceptable to Specified SSPC-SP 10 Near-White Metal Blast Cleaning.
Re-inspection: Per Customer Direction, Vendor has re-blasted the equipment to remove completely any scale indications, in compliance with Specified SSPC-SP 10 Cleaning. See Photos on Referenced Issue before and after Re-Blasting.
Audit on Blasting/Painting per Customer ITP-FM-993-01 Rev 0 Item 9.2 and Paint Spec FM-T24993-01 Rev B.
Item Inspected: Wet Steam Separator Tag Number FM-3743.
Findings: Primer Coating being applied, Inorganic Zinc Primer Interzinc 22HS. Vendor does not use a Paint Pot with integrated Continuous Agitator, They just fill the mixed primer in the deposit of the Gun and apply the Primer Coating. Under these conditions with no continuous agitation the powder in suspension is settled on the bottom of the gun deposit, therefore an application very poor in Zinc Powder is done. Not Acceptable to Manufacturer Data Sheet of Inorganic Zinc Primer Interzinc 22HS and Customer Spec FM-T24993-01 Rev B Protective Coatings, Section 4.5-3, which requires for Continuous Agitation during Spray Application.
Re-Inspection: Per Customer Direction, Vendor has removed by blasting the applied Primer Coating and has started to use a Paint Pot with integrated continuous agitator for inorganic zinc application, Fraza Team has witnessed and confirmed the agitator works properly powered by the compressed air line from Vendor Painting Station. See Photos as Illustration on Referenced Issue.
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 Surface Preparation and Painting, If Not Corrected/Repaired in timely manner at Vendor Shop.
Project Detail
Project: Forest Mountain Unit 03
Equipments: Exhaust Heads
Date: August 2015
Vendor Location: Fabricator of Exhaust Equipments and Pressure Vessels in Tamaulipas, Mexico.
Visual Inspection per ITP-FM-559-02 Rev 2 Item 3.2 and Vendor Drawing FM-A7835-02 Rev B.
Item Inspected: Exhaust Heads Tag-BM-RC-A7835, Serial Numbers R65673 and R65674.
Findings: Gasket Seating of Nozzle S3 Flange observed seriously damaged by the welding and grinding during fabrication process.
Re-Inspection: Vendor has replaced the damaged flanges by other new flanges with aceptable finish on gasket seat. See Photo on Referenced Issue.
Visual Inspection on Welds per ITP-FM-559-02 Rev 2 Item 3.1 and Vendor Drawing FM-A7835-02 Rev B.
Item Inspected: Exhaust Heads Tag-BM-RC-A7835 Serial Numbers R65673 and R65674.
Findings: Longitudinal and Circumferential Seams of SS Internal Pipe, Specified to be CJP welded, however, several áreas of referenced seams observed with lack of penetration.
Re-Inspection: Repairs completed by Vendor in Compliance with Drawing Requirements referenced Above. See Photos as Illustration on referenced Issue.
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 Welding and Damaged Gasket Seating on Nozzle flanges for Field Connections, If Not Corrected/Repaired in timely manner at Vendor Shop.
Project Detail
Project: White Beach Unit 03
Equipments: T309-IB In Bun Man
Date: November 2017
Vendor Location: Fabricator of Pressure Vessels in Tamaulipas, Mexico.
Visual Inspection on Welds per Vendor Inspection and Test Plan ITP R55996 Rev 2 Item 05 and Vendor Drawing WB-96704 Rev C.
Item inspected: Equipment T309-IB-In-Bun-Man Inlet Header.
Findings: Joint of Nozzle(Item 3) to Main 6” Pipe item 1, Specified to be Complete Joint Penetration Welded per referenced Drawing, however, such joint observed with Incomplete Joint Penetration.
Re-Inspection: Repair completed by Vendor to achieve CJP as specified. See Photo as Illustration on Referenced Issue.
Review on CMTRs of Stainless Steel Material Items per Vendor ITP R55996 Rev 2 Item 02 and Drawing WB-96704 Rev C.
Item Inspected: Equipment T309-IB-In-Bun-Man Inlet Header.
Findings: Per CMTR Reviewed for Pipe Item 3, a Pipe 2 ½” Schedule 5S, SA 312-316/316L Welded, Heat Number 501930 has been used by Vendor, however per Drawing WB-96704 Rev C a pipe 2 ½” Schedule 10S is specified for referenced pipe item 3 (Thicker Wall Thickness).
Re-Inspection: NCR-WB-01 has been open on this issue, Fortunately the Disposition from Customer for Referenced NCR has been “To be used as is”. See Photo on CMTR as reviewed.
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 Welding and Wrong Wall Thickness of Pipes, If Not Corrected/Repaired in timely manner at Vendor Shop.
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