Group Technology
Standard
Title:
Personnel and Entities
Performing Welding Related
Special Processes on Eskom
Plant
Unique Identifier:
36-505
Alternative Reference Number:
N/A
Area of Applicability:
Engineering
Documentation Type:
Standard
Revision:
1
Total Pages:
14
Next Review Date:
September 2014
Disclosure Classification:
CONTROLLED
DISCLOSURE
.
Compiled by
Functional Responsibility
Authorized by
…………………………………..
…………………………………..
…………………………………..
MM Maroga
BS MacColl
MM Koko
Chief Engineer, IWE
Acting General Manager:
Research, Testing &
Development
Divisional Executive: Group
Technology
Date: ……………………………
Date: ……………………………
Date: ……………………………
Personnel and Entities Performing Welding Related Special
Processes on Eskom Plant
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CONTENTS
Page
FOREWORD ................................................................................................................................................................ 3
1. SCOPE ..................................................................................................................................................................... 5
2. NORMATIVE REFERENCES .................................................................................................................................. 5
3. DEFINITIONS AND ABBREVIATIONS ................................................................................................................... 5
3.1 DEFINITIONS .................................................................................................................................................... 5
3.2 CLASSIFICATION ............................................................................................................................................. 6
3.3 ABBREVIATIONS .............................................................................................................................................. 6
4. PERSONNEL PERFORMING WELDING AND WELDING RELATED ACTIVITIES .............................................. 6
4.1 WELDERS ......................................................................................................................................................... 6
4.2 WELDING COORDINATOR .............................................................................................................................. 7
4.3 WELDING SUPERVISOR ................................................................................................................................. 8
4.4 WELDING INSPECTOR .................................................................................................................................. 10
4.5 WELDING INSTRUCTOR ............................................................................................................................... 11
4.6 SENIOR WELDING INSTRUCTOR/HEAD OF WELDING SCHOOL ............................................................. 12
4.7 WELDING ENGINEER/TECHNOLOGIST ...................................................................................................... 13
5. ENTITIES PERFORMING WELDING AND WELDING RELATED ACTIVITIES .................................................. 13
5.1 TRAINING SCHOOL FACILITIES ................................................................................................................... 13
5.2 WELDING PERSONNEL TRAINING FACILITIES .......................................................................................... 14
5.3 COMPANY ACCREDITATION – ISO 3834..................................................................................................... 14
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FOREWORD
Revision History
Date
Rev.
Remarks
September 2011
0
This is a new document.
December 2011
0.1
First Revision for Review Comments
February 2012
1
Final Revision for Publication
Authorization
This document has been seen and accepted by:
Name and Surname
Designation
Philip Doubell
Welding Engineer
Pius Oba
Welding Engineer
Sumaya Nassiep
Acting DM: Plant Performance and Optimisation
Barry MacCol
Acting GM: Research, Testing & Development
Titus Mathe
Engineering Power Plant Manager
Dhiraj Bhimma
Engineering Account Executive
Anthony Kuzelj
Power Station Manager
Bheki Nxumalo
Power Station Manager
Bruce Moyo
Power Station Manager
Chris Schutte
Senior General Manager
Christo van Niekerk
Senior General Manager
Christopher Nani
Power Station Manager
Deon Beukes
Chief Technologist
Des Sheppard
Senior Manager: Projects and Outages
Ertjies Bierman
Senior Manager Engineering
Gladman Mkwai
Power Station Manager
Hennie van Staden
Senior Manager: Projects and Outages
Ian Redpath
Consultant: Fleet Technology
Johan Du Preez
Boiler Senior Consultant
Johan Prinsloo
Power Station Manager
John Dean
Power Station Manager
Julian Fourie
Senior Manager Engineering
Julian Nair
Power Station Manager
Kiren Maharaj
Senior General Manager
Lebo Serekwa
Boiler Senior Consultant
Leon Booyens
Senior Consultant Boiler Tube Failure Reduction
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Name and Surname
Designation
Mandla Mtembu
Senior Manager Engineering
Marcus Nemadodzi
Boiler Senior Consultant
Mark Breetzke
Corporate Consultant: Boilers
Matshela Koko
Divisional Executive: Group Technology
Piet Veldman
Outage Integration Manager: Coal Operating Unit 1
Russel Tarr
Senior Consultant: Fleet Technology
Ryno Lacock
Power Station Manager
Shamiel Jappie
Acting Power Station Manager
Shireen Prince
Power Station Manager
Thava Govender
Divisional Executive: Generation
Thomas Conradie
Power Station Manager
36-505
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Applicability
This standard is applicable to all personnel and entities performing welding and welding related activities
on Eskom plant. It is also applicable when procuring, reviewing and placing manufacturing, maintenance
and repair contracts with vendors working on Eskom plant.
Development Team
The following people were involved in the development of this document:
•
Morris Maroga
Overview
Welding is a special process, which requires the coordination of welding operations in order to establish
confidence in welding and reliable performance in service. The tasks and responsibility of personnel
involved in welding-related activities (e.g. planning, executing, supervising and inspection) is defined in
this standard. The standard also prescribes the minimum requirements for companies or entities
performing welding and welding related activities on Eskom plant.
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1. SCOPE
This standard is applicable when procuring, reviewing and placement of erection, maintenance and
repair contracts for welding and related activities on Eskom plant. The standard also covers the
manufacturing and fabrication of equipment or components for Eskom plant. A concession period of
three years will be used to phase this in from the time of publication.
2. NORMATIVE REFERENCES
Parties using this document shall use the most recent edition(s) of the document(s) listed in this section.
[1]
Insert normative document references here.BS EN ISO 14731: 2006 Welding Coordination –
Tasks and responsibilities.
[2]
ISO 3834-1, Quality requirements for fusion welding of metallic materials – Part 1
[3]
ISO 3834-2, Quality requirements for fusion welding of metallic materials – Part 2
[4]
ISO 3834-3, Quality requirements for fusion welding of metallic materials – Part 3
[5]
ISO 3834-4, Quality requirements for fusion welding of metallic materials – Part 4
[6]
ISO 3834-5, Quality requirements for fusion welding of metallic materials – Part 5
3. DEFINITIONS AND ABBREVIATIONS
3.1 DEFINITIONS
3.1.1 Welding coordination: coordination of welding operations for all welding and welding-related
activities.
3.1.2 Welding coordinator: person responsible and competent to perform welding coordination and is
appointed in writing for a specific business unit or project.
3.1.3 Welding inspection: conformity evaluation of welding-related matters by observation and
judgement accompanied as appropriate by measurement or testing.
3.1.4 Welding supervisor: person responsible and competent to perform welding supervision in
accordance with this standard and is appointed in writing for a specific business unit or project.
3.1.5 Welding inspector: person responsible and competent to perform welding inspection in
accordance with this standard and is appointed in writing for a specific business unit or project.
3.1.6 Welding instructor: person responsible and competent to conduct and administer theoretical and
practical training to welder trainees in accordance with IIW guidelines..
3.1.7 Senior welding instructor: person responsible and competent to supervise the welding teaching
staff and trainees, and administer the welding training and facilities.
3.1.8 Welding technologist: person qualified and registered as International Welding Technologist in
line with IIW and also registered with ECSA as Professional Engineering Technologist.
3.1.9 Welding engineer: person qualified and registered as International Welding Engineer in line with
IIW and also registered with ECSA as Professional Engineer.
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3.2 CLASSIFICATION
a. Controlled disclosure: controlled disclosure to external parties (either enforced by law, or
discretionary).
3.3 ABBREVIATIONS
Abbreviation
Description
AIA
Approved Inspection Authority
ANB
Approved National Body in accordance with IIW
ATB
Approved Training Body in accordance with IIW
ECSA
Engineering Council of Southern Africa
IIW
International Welding Institute
ISO
International Organization for Standardization
IWE
International Welding Engineer registered with IIW
IWP
International Welding Practitioner registered with IIW
IWS
International Welding Specialist registered with IIW
IWT
International Welding Technologist registered with IIW
NCR
Non Conformance Record
NDE
Non Destructive Examination
PQR
Procedure Qualification Record
PWHT
Post Weld Heat Treatment
SAIW
Southern African Institute of Welding
WPQR
Welding Procedure Qualification Record
WPS
Welding Procedure Specification
4. PERSONNEL PERFORMING WELDING AND WELDING RELATED ACTIVITIES
The authorization for the following tasks and responsibilities for each site, project and manufacturing
shall be accorded to the person in writing and accepted by signature. Any other qualification from
another country that is considered to be equivalent shall be evaluated by the Eskom IWE/IWT for
relevance.
4.1 WELDERS
Welders and welding operators working on Eskom plant shall be qualified in accordance with the latest
applicable code. Welders shall have at least one of the following minimum requirements.
•
International Tube Welder
•
International Plate Welder
•
International Fillet Welder
•
International Welding Practitioner (IWP) in line with IAB-005-2002/EWF-451 Rev 1
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The welder training shall be based on IIW document IAB-089-2003/EWF-452-467-480-481/SV-01 and
ISO 9606. The ISO 9606-series of International Standards provides a scheme for qualification testing of
welders, to evaluate their skill for limited ranges of welding conditions.
4.2 WELDING COORDINATOR
Welding coordinator shall have one of the following minimum requirements for education, examination
and qualification.
•
International Welding Engineer (IWE) in line with document IAB-002-2000/EWF-409
•
International Welding Technologist (IWT) in line with document IAB-0003-2000/EWF-410
The tasks and responsibilities assigned to the welding coordinator are as follows:
4.2.1
Review the product standard to be used, together with any supplementary requirements
4.2.2
Ensure that all welding and related activities are performed in accordance with all applicable
Eskom standards
4.2.3
Maintain register of all WPS’s and PQR’s and maintain validity
4.2.4
Identify need for new WPS’s and arrange compilation and qualification
4.2.5
Welding problem investigation
4.2.6
Provide technical advice to supervisory and inspection staff
4.2.7
Ensure all welders performing welding operations are correctly coded to the applicable code
4.2.8
Maintain and update a register of welder’s qualifications using a separate identification
number for each welder
4.2.9
Select the appropriate WPS and qualified welder for each welding operation
4.2.10 Ensure conformance to approved WPS’s for all welding operations
4.2.11 Coordinate training of welders to meet site/workshop specific conditions
4.2.12 Coordinate refresher training programs for welders and arrange recoding
4.2.13 Test new welders
4.2.14 Ensure that all welding work is inspected by competent and qualified personnel
4.2.15 Maintain appropriate records of all welding work as per requirements of the databook
4.2.16 Review all heat treatment procedures
4.2.17 Witness the execution of WQR activities if qualification activities are not witnessed by AIA
4.2.18 Approval of PQR/WPQR
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4.2.19 Verify that the information on the WPS accurately reflects the parameters reported on the
PQR/WPQR before use on Eskom equipment/plant
4.2.20 Report any welding activity that could affect Eskom plant detrimentally in any way
4.2.21 Review repair procedure
4.2.22 Issuing of NCR
4.2.23 Technical review of
•
The parent material(s) specification and welded joint properties
•
The joint location with relation to the design requirements
•
Quality and acceptance requirements for welds
•
The location, accessibility and sequence of welds, including accessibility for inspection and
non-destructive testing
•
Other welding requirements, e.g. batch testing of consumables, ferrite content of weld metal,
ageing, hydrogen content, permanent backing, use of peening, surface finish, weld profile
•
The dimensions and details of joint preparation and completed weld
4.2.24 Review the suitability of any sub-contractor for intended welding operations
4.2.25 Review the compatibility, delivery conditions, storage and handling of welding consumables
4.2.26 Review materials for:
•
Any supplementary requirements in the material purchasing specifications, including the type
of inspection document for the material
•
The storage and handling of parent material
•
Traceability
4.3 WELDING SUPERVISOR
Welding supervisor shall have one of the following minimum requirements for education, examination
and qualification.
•
SAIW Welding Fabrication Supervisor Level II
•
SAIW Welding Fabrication Supervisor Level III
•
SAIW Welding Fabrication Inspector Level II
•
International Welding Inspector (Comprehensive)
•
International Welding Inspector (Standard)
•
International Welding Specialist (IWS) in line with document IAB-004-2000/EWF-411
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The tasks and responsibilities assigned to the welding supervisor are as follows:
4.3.1
Plan, organise and control the work load of welders
4.3.2
Exercise general control over all welders and welding operations
4.3.3
Ensure conformance to approved WPS’s for all welding operations
4.3.4
Ensure all welders welding in his/her area of responsibility are correctly coded
4.3.5
Train welders to meet site/workshop conditions
4.3.6
Supervise all welding work performed in his/her area of responsibility
4.3.7
Exercise control of materials and consumables for welding operation in accordance with the
applicable code and standard.
4.3.8
Ensure the control for drawing, issuing, storage and baking of all welding consumables in
accordance with the applicable code and standard
4.3.9
Ensure that all consumables used conform to the relevant WPS used
4.3.10
Supervise all heat treatment processes
4.3.11
Ensure all equipment used in welding operations is calibrated in accordance with the applicable
requirements
4.3.12
Monitor all NDE carried out and liaise with personnel performing NDE
4.3.13
Equipment
4.3.14
•
The suitability of welding and associated equipment
•
Auxiliaries and equipment supply, identification and handling
•
Personal protective equipment and other safety equipment, directly associated with the
applicable welding process
•
Equipment maintenance
•
Equipment verification and validation
Production Planning
• Reference to the appropriate procedure specifications for welding
• The sequence in which the welds are to be made
• Environmental conditions (e.g. protection from wind, temperature and rain)
• The allocation of qualified personnel
• Equipment for preheating and post-heat treatment, including temperature indicators
• The arrangement for any production test
4.3.15
Evaluate the issuing and use of work instructions
4.3.16
Compile repair procedures
4.3.17
Ensure identification and traceability
•
The identification of production plans
•
The identification of routing cards
•
The identification of weld locations in construction
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•
The identification of non-destructive testing procedures and personnel
•
The identification of the welding consumable (e.g. designation, trade name, manufacturer of
consumables and batch or cast numbers)
•
The identification and/or traceability of parent material (e.g. type, cast number)
•
The identification of the location of repairs
•
The identification of the location of temporary attachments
•
Traceability for fully mechanized and automatic welding units to specific welds
•
Traceability of welder and welding operators to specific welds
•
Traceability of welding procedure specifications to specific welds
4.4 WELDING INSPECTOR
Welding inspector shall have one of the following minimum requirements for education, examination and
qualification.
Minimum requirements for level 1 and 2 Eskom plant
•
SAIW Welding Fabrication Inspector Level II
•
International Welding Inspector (Comprehensive)
•
International Welding Inspector (Standard)
•
International Welding Specialist (IWS) in line with document IAB-004-2000/EWF-411
Minimum requirements for level 3 Eskom plant
•
SAIW Welding Fabrication Inspector Level I
•
International Welding Inspector (Basic)
The tasks and responsibilities assigned to the welding inspector are as follows:
4.4.1 Inspection and testing before welding
•
The suitability and validity of welders’ and welding operators’ qualification certificates
•
The suitability of the welding procedure specification
•
The identity of the parent material
•
The identity of welding consumables
•
Joint preparation (e.g. shape and dimensions)
•
Fit-up, jigging and tacking
•
Any special requirements in the welding procedures specification (e.g. prevention of distortion)
•
The suitability of working conditions for welding, including environment
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4.4.2 Inspection and testing during welding
•
Essential welding parameters (e.g. welding current, arc voltage and travel speed)
•
The preheating/interpass temperature
•
The cleaning and shape of runs and layers of weld metal
•
Back gouging
•
The welding sequence
•
The correct use and handling of welding consumables
•
Control of distortion
•
Any intermediate examination (e.g. checking dimensions)
4.4.3 Inspection and testing after welding
•
The use of visual inspection (for completeness of welding, weld dimensions, shape)
•
The use of non-destructive testing
•
The use of destructive testing
•
The form, shape, tolerance and dimensions of the construction
•
The results and records of post-operations (e.g. post-weld heat treatment, ageing)
4.4.4 Ensure that Post-Weld Heat Treatment (PWHT) is performed in accordance with the specification.
4.4.5 Non-Conformance and Corrective Actions
•
Ensure that the necessary measures and actions (e.g. weld repairs, re-assessment of repaired
welds, corrective actions) are implemented.
4.4.6 Ensure that only calibrated and validated measuring, inspection and testing equipment are used.
4.4.7 Ensure that all quality records including databook are prepared and maintained as per applicable
specification.
4.5 WELDING INSTRUCTOR
Welding instructors for practical training shall have International Welding Practitioner (IWP) as minimum
requirements for education, examination and qualification.
The tasks and responsibilities assigned to the welding instructor are as follows:
4.5.1 Present International Welder Training (both theory and Practical)
4.5.2 Maintain Welding Facilities and Equipment
4.5.3 Facilitating the Training needs analysis
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4.5.4 Administer the practical training of the trainees
4.5.5 Administer the on-job training of the trainees
4.6 SENIOR WELDING INSTRUCTOR/HEAD OF WELDING SCHOOL
Courses leading to IIW qualifications are closely related to industrial practice, and it is essential for
teaching staff to have continuing contact with industry. Teaching staff needs to combine:
•
Teaching ability – evidence of training in lecturing, public speaking or verbal communication
•
Competence in the subjects being taught
•
Knowledge and experience of current industrial practice in the subjects being taught
•
Practical skills in the demonstration of welding practice
Welding Training Specialist shall one of the following as the minimum requirements for education,
examination and qualification.
•
International Welding Engineer (IWE) in line with document IAB-002-2000/EWF-409
•
International Welding Technologist (IWT) in line with document IAB-0003-2000/EWF-410
•
International Welding Specialist (IWS) in line with document IAB-004-2000/EWF-411
The tasks and responsibilities assigned to the welding training specialist are as follows:
4.6.1
Oversee the welding training staff
4.6.2
Learner Assessments
4.6.3
Development of Training Material
4.6.4
Administer the assessments and examinations in line with International Institute of Welding
requirements
4.6.5
Administer the testing of trainees
4.6.6
Provide the resource which is adequate for the development, updating and monitoring of the
training programme
4.6.7
Updating of the syllabus
4.6.8
Maintain the current industrial practice
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4.7 WELDING ENGINEER/TECHNOLOGIST
Welding Engineer/Technologist shall have one of the following minimum requirements for education,
examination and qualification.
•
International Welding Engineer (IWE) in line with document IAB-002-2000/EWF-409
•
International Welding Technologist (IWT) in line with document IAB-0003-2000/EWF-410
In addition the Welding Engineer/Technologist shall be registered with ECSA as professional
engineer/technologist
The roles and responsibility of welding engineer/technologist shall be:
4.7.1 Formulate welding policy and practices within Eskom
4.7.2 Technical advice on welding related activities
4.7.3 Review and compile welding standards and practices within Eskom
4.7.4 Review the capacity of the site, project or manufacturer to meet the prescribed welding
requirements
4.7.5 Conduct audit/surveillance to ensure that welding management systems are operating correctly in
all the site, project or manufacturer.
4.7.7 Evaluate qualification from other countries that is considered to be equivalent to any qualification
mentioned in this standard.
4.7.8 Investigate any welding activity that could affect Eskom plant in a detrimentally way.
5. ENTITIES PERFORMING WELDING AND WELDING RELATED ACTIVITIES
5.1 TRAINING SCHOOL FACILITIES
The ATB shall provide an appropriate complement of teaching staff which has, collectively, the
knowledge and skills necessary to deliver the course in an effective manner. The number of such staff
shall be sufficient to ensure that the essential specialist knowledge and industrial experience to cover the
syllabus is adequately represented in the team of teachers and visiting lectures. In order to effectively
deliver the course, one instructor is required for each 10 trainees.
The facilities should be clean, well lit and comfortable. For practical work each student should have
ample bench space and good access to test specimens. Classrooms should have adequate desks or
tables, and be equipped with suitable teaching aids, such as blackboards, overhead projectors, closed
circuit television, slide projectors and video equipment, as appropriate to the course.
The lectures must be supported by good quality visual aids, for example: slides, overheads,
transparencies and/or videos.
The ATB shall maintain a reference library of key material available to students for background study.
This library shall include a comprehensive collection of standards relevant to welding.
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A full set of good quality course notes should be maintained in order to ensure consistency between
courses and in the event of any change of staff. Lectures should be supported by good quality
handbooks issued to students containing key information for reference.
A final examination to assess student performance, in accordance with the relevant IIW guideline will be
conducted by a Board of Examiners appointed by the Governing Board of the ANB. This examination is
mandatory, and is independent of any assessment procedure conducted by the ATB.
5.2 WELDING PERSONNEL TRAINING FACILITIES
The training facilities for all welding personnel shall be accredited by IIW and use the IIW training
programme as the basis for its training and qualification programme.
5.3 COMPANY ACCREDITATION – ISO 3834
All companies performing welding related activities on Eskom plant shall have accreditation to ISO 3834
as follows.
Equipment Group
Minimum Quality Level
Type
Eskom Level 1 Plant
IS0 3834 Part 2
Comprehensive
Eskom Level 2 Plant
IS0 3834 Part 3
Standard
Eskom Level 3 Plant
IS0 3834 Part 4
Elementary
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