Project Detail
Project: Saddle Mountain Carbon Plant
Equipments: Carbon Rotary Kiln
Date: April 2013 to to June 2013
Vendor Location: Fabricator of Rotary Kilns in Nuevo Leon, Mexico.
Visual Inspection on CS Kiln Casing per ITP-432659 Item 3 and Drawing 432659R062-00-13 Rev 4.
Items Inspected: Carbon Steel Kiln Casing Fitted Up.
Findings: Splices on External Angle Stiffeners not properly weld prepared (Not Bevel preparation and Not root gap) in order to make sure a complete joint penetration as specified.
Re-inspection: Referenced splices have been weld prepared with proper bevel and proper root opening as well they have been complete joint penetration welded in accordance with Drawing Requirements referenced above. See photo on described Issue as originally found.
Visual Inspection on CS Kiln Casing per ITP-432659 Item 3 and Drawing 432659R062-00-13 Rev 4.
Item Inspected: Carbon Steel Kiln Casing Fitted Up.
Findings: Observed a weld preparation of External Channel Stiffener with an excessive root gap at ends connecting to surrounding items.
Re-Inspection: Referenced location have been corrected to achieve a proper weld preparation and welded in accordance with referenced drawing. See photo on referenced Issue.
Review on Status of WPSs for SS Rotary Drum per ITP-432660 Item 2 and Drawing 432659R063-01-14 Rev 2.
Item Inspected: Stainless Steel Kiln Drum Sections.
Findings: Welding Procedure WPS RD-Y-78 Rev 1, as per Reviewed Supporting PQR, No Volumetric NDE Examination was conducted on Welded Coupon used for the Qualification of mentioned WPS as specified on AWS D1.6 Code.
Re-Inspection: Per observation from Fraza Team, Referenced WPS has been subsequently re-qualified in accordance with AWS D1.6 Code requirements, included the specified Volumetric NDE Examination.
Review on Qualification Status of WPSs for Stainless Steel Rotary Drum per ITP-432660 Item 2 and Drawing 432659R063-01-14 Rev 2.
Item Inspected: Stainless Steel Kiln Drum Sections.
Findings: Vendor has started the Fabrication, however a Welding Procedure to weld dissimilar joints of Stainless Steel Kiln Shell to External Carbon Steel Clips had not yet been Qualified per AWS Code Requirements.
Re-Inspection, per observation from Fraza Team, Welding Procedure WPS SS-07 Rev 0 in GMAW Process for Dissimilar Fillet Joints of Stainless Steel parts to Carbon Steel parts has been qualified by Vendor in accordance with AWS D1.6 Code Requirements.
Review on Engineering Documents for Stainless Steel Rotary Drum per ITP-432660 Item 1.1.
Item Inspected: Stainless Steel Rotary Drum
Findings: Fraza Team has detected the following Engineering Issue, Detail Drawing 432659R065-02-12 Rev 1, does not show welding symbol to specify if internal vanes are to be fillet welded or are to be welded by complete joint penetration to Drum Shell and accordingly Fraza Team has informed to Vendor on it.
Re-Inspection: Per observation from Fraza Team, Vendor Engineering Team has issued a Revision 2 of referenced Drawing confirming, the internal vanes must be welded by complete joint penetration to Drum Shell. This timely observation from Fraza Team has prevented making a wrong fillet weld on referenced internal vanes.
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, engineering, weld preparations and welding procedures not qualified in accordance with Project Requirements, If Not Corrected/Repaired in timely manner at Vendor Shop.
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