1.

Change In Issue
2. Purpose and Scope
2.1.

Purpose
This instruction describes the acceptance criteria for welds in Fico Indo Rekayasa, PT.
Processing equipment . Weld defects such as cracks, porosities or oxidation will increase
the chance of adhesion of product within the cavity and affect the cleanability and
corrosion resistance of the system. That is, weld joints should made so that they do not
contaminate the product or increase therisk for corrosion.

2.2.

Scope
The scope of this SOP is all welding in steel

3. Type of Welding Process (Manual or Orbital)

This SOP is applicable to all welding processes both manual and mechanized
3.1.

Type of Material to be weld

This SOP is applicable to all welds in steel materials. If any other material than steel is to
be welded, Fico Indo Rekayasa will advice on applicable standards and requirements.

4. Responbilities and Authorities

Stake holders that share the responbility for enforcement of this procedure are
Stake Holder
Project Manager
Site Manager
Site Supervisor
QAQC
Supply
Management

Responbility
Review QA Report
Review QA Report
Random Weld Joint
Site check
Random QA Report
Random QA Check
Procurement

Frequency
Monthly
Weekly

Remarks
On Site
On Site

Daily

On Site

Weekly
Monthly
For preProject/Projec

On Site
And Whenever during random site visit
Ensure it is include in the scope and
responbility

t
Site Installation
Sub Contractor

Implementation,
Enforcement and
Execution

daily

Enganged by PT. Fico Indo Rekayasa to

carry site process piping installation

5. Inspection and Testing of Welds

5.1.

External Subcontractor Task

Fico Indo Rekayasa PT will engage an external subcontractor (pre-qualified by Fico Indo Rekayasa,
PT Supply Management Audit system) to carry out the welding. Hence it is the responsibility of the
external subcontractor to prepare and perform the necessary inspection and testing to ensure the
quality of the welds. Fico Indo Rekayasa, PT will specify any mandatory inspection and testing to be
carried out. All inspection and testing shall be documented, regardless of if the inspection and testing
is required by Fico Indo Rekayasa, PT or if it is performed internally by the subcontractor.

Each individual welder shall examine his work after completion of the welding. The welder
shall have the necessary tools to make the inspection and the necessary training to be able to
assess the weld quality to the requirements in this document.
Example of basic inspection tool each welder to be equipped with:

Notes: The above are just our suggestion and its restricted to very short inspection distance of
inside weld joints
It is up to the installation contractor to ensure the weld quality regardless of the type of basic
suggested inspection tool.
That is, if boroscope inspection is require, the installation contractor has the take the
initative to be equipped and carry out the inspection.
Each weld shall be possible to trace to the welder who has done it by marking or by tracing
through Weld Map and Weld log Sheet
If permanent marker pen is used for the marking, it shall be halogen free, intended for use on
stainless steel.
Subcontractor quality personnel shall randomly inspect the weld joints on a daily basis

Fico Indo Rekayasa, PT. quality inspectors will make random inspections of the weld joints,
either at (dependant on the scope of each contract): the subcontractors premises
before delivery
or when the equipment is delivered
or at site

This procedure is intended to safeguard the quality set forth in this document. Should there, by
any chance, be unacceptable compared to the requirements in section 6, the weld joint / joints
shall be remade according to section 6.5 and re-checked and recorded when approved.

5.2.

Weld Joint Repair

Should it be necessary to cut out an unacceptable weld joint, the heat affected material on each
side of the weld (minimum 10 mm) shall be removed. If it is then necessary to put in a new piece
of material, the width of plate, or length of inserted pipe, shall be at least 100 mm.

6. Acceptance Criteria
6.1. Weld Joint Edge Acceptance Criteria
Acceptance Criteria:

No dust, no grease / oil and other contaminations

Presence of foreign scraps, including lint from cloth is not acceptable.
When tubes are fitting up, they must be perpendicular to axis and displacements and / or

gaps between tube ends are not allowed.

The cleaned surfaces must not be touched with bare hands In order to keep the surfaces
intact

6.2.

Tack Weld Acceptance Criteria:

Descriptions

Acceptance Criteria

Whereever possible, no gap. A gap less than

0.25 mm prior to welding is acceptable. For
certain materials (e.g 254SMO) and for welds in
Large gaps will cause concavity of weld and
plates, a gap is sometimes required and specified
risk of discolouration on the root side and are
in the WPS
therefore not allowed

Poor alignment between the wall of two pieces

to be welded can lead to a step in the inner
surface of the weld area which could retain
product and dirt. Misalignment shall be avoided.

( Replace with picture from ISO 5817)

For circumferential welds in pipes OD29
mm, h<0.15t 29<OD<85 mm, h<0,2t OD85
mm, h<0,6 mmf..For circumferential welds
in tanks and vessels, h0,3t, max 3 mm) For
longitudinal welds, h0,15t

Burning through tack weld is not permitted. All

tacking in pipes shall be made with root
protection gas.
Unacceptable example

Acceptable and unacceptable tack reference for

pipes as shown. If unacceptable tacks are
discovered before welding the joint must be
opened, and the joint preparation be remade.
The joint face has to be machined so all remains
of the unacceptable tacking is removed.

6.3. Requirement of Surface Oxides

Reference : Force Technology, Park Alle 345, DK-2605 Brondby, Denmark

www.forcetechnology.dk
Oxides from tacking and welding may reduce the corrosion resistance of the material. Coloring must
not exceed the requirements of Force Technology Reference Color Charts level C. An extract is
shown below. Measuring of oxygen concentrations in the ppm range requires a high accuracy
monitor. As an alternative it is possible to make test welds on similar configurations where the purge
time and flow is measured. If those test welds give consistent and acceptable results the production
welds can be made using the same purge parameters. However, regardless of how the purging
procedure is determined, if the production welds show unacceptable discoloration they must be
cleaned or remade.
Acceptance Criteria: Allowable coloring level C (32 ppm) or better

Note:
For some welds that are not in contact with food substances or not subject to corrosion, i.e. welds on
the inside of insulation cladding or where water/steam jackets are welded to the main body of the
tank/vessel, the coloring requirements may be disregarded. Such welds shall be identified in the
contract with the customer and on the drawing or in the inspection plan. .

6.4 Weld Joint Acceptance Criteria

Reference 35 Hygienic welding of stainless steel tubing in the food processing industry

(2006) http://www.ehedg.org/index.php?nr=9&lang=en&guid=37 EN ISO 5817 Welding

Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding excluded)
Quality levels for imperfections ISO 6520-1 Welding and allied processes - Classification of
geometric imperfections in metallic materials Part 1: Fusion welding.
All welds shall fulfil the requirements of EN ISO 5817, level C, and the additional requirements
below.

No

Discontinuity /
Indication

Numerical
designatio
n
acc to ISO
6520-1

Sketch / Description

Result
h0,1 t

Top side concavity

509, 511
repl
ace picture with the one used in
ISO 5817

Root side concavity

5013, 515

Convexity on the
internal diameter
(circumferential welds)

504

replace picture with the one used in

ISO 5817

replace picture with the one used in

ISO 5817

Only short
imperfections are
allowed (see note
below for definition
of
short
imperfections)
h0,1 t
Only short
imperfections are
allowed (see note
below for definition
of
short
imperfections)
OD29 mm,
h<0.15t
29<OD<85 mm,
h<0,2t
OD85 mm, h<0,6
mm

Surface pores / end

crater pipes

2017, 2025

Not Allowed
replace picture with the one used in
ISO 5817

Inclusions (e.g.
tungsten) are not
acceptable and
should be completely
avoided(Delete
whole item)

Not Accepted if the

minimum width <
50% of the
maximum width

Weld bead width

variation (root side)
6

Not accepted if
minimum width <
50% of maximum
width and root side
not accessible for
inspection
Max allowable is
25% from ideal
axis

allowable is 25 %
from ideal axis if
its not accessible
for root side
Inspection

Weld bead width

variation (top side)

Weld bead
meandering
(root side)
7
Weld bead
meandering
(top side)

Arc Strike

Not Allowed

601

To be ground
smooth +
100 % PT
inspection

Slag island

10

Icicle/burn through

Acceptable

Localized region of excessive penetration,

which usually appear as long, narrow
portions of weld metal on the weld
underbead

Not Allowed

h0,1 t

11

Undercut

5011, 5012

12

Linear misalignment
(circumferential welds
in pipes)

507

13

Thickness differential
preparation

14

Spatter

Max 1 mm.Only
short imperfections
are allowed (see
note below for
definition of short
imperfections)
Smooth transition is
required
OD29 mm, <0.15t
29<OD<85 mm,
<0,2t
OD85 mm, <0,6
mm
If the thickness
difference is > 0,5
mm

To be removed
from
the surface

602
Small droplets of weld metal adhering to
the surface

15

Grinding mark

Shall be ground to
provide a smooth
transition

604

16

Under Flash

606

17

Linear misalignmen
(circumferential
welds in tanks and
vessels)
Longitudinal welds

507

Heavy grinding, unacceptable surface

roughness
Material thickness below minimum
required

Not Allow

h0,3t, max 3 mm)

h0,15t

Note:
Short imperfections: in cases when the length of the weld is 100 mm or
longer,imperfections are considered to be short if in the 100 mm which contains the
greatestnumber of imperfections their total length is less than 25mm.
In cases when the length of the weld is less that 100 mm, imperfections are considered to
be short if their total length is less than 25% of the weld length
A smooth transition between base material and weld is required

6.5 Acceptance Criteria Quality Control

Fico Indo Rekayasa, PT will engage an external subcontractor (pre-qualified by Fico Indo
Rekayasa, PT. Supply Management Audit system) to carry out the welding. Fico Indo Rekayasa,
PT. representative will conduct random quality check. However, it is the responsibility of the
external subcontractor to ensure that the quality of all

weld joints meet (or is better than) the

requirement as stipulated in this document.

If any weld joints are found to fall outside of the acceptance criteria:Make good without delay to our project
During Manufacture or installation phase or
schedule and no cost to Fico Indo Rekayasa,
commissioning phase
PT

At inspection before
delivery
At inspection after delivery

Make good within one working day and no

cost to Fico indo Rekayasa, PT
Make good within 2 days and no cost to
Fico Indo Rekayas, PT

7 Boroscope Procedure
The boroscope inspection shall be carried out in accordance with a qualified procedure. Before
starting the inspection, the equipment shall be checked for white balance and/or colour, and for
picture quality. (possibility to see small details, usually by checking that lines of predefined
width are distinguishable). All inspections shall be reported.

8 Radiograpy Procedure
Radiographic inspection shall be carried out in accordance with a qualified procedure. The
assessment of radiographs shall be carried out by a person holding at least a Level II certificate
for radiography (according to ASNT Recommended practice No. SNT-TC-1A or EN 473)

9. Appendices
9.1 Some Example of Acceptable and Rejected Manual Weld Joints

Document

Number

Do10. Reference Document

Na
Document Number
ASME Section IX
EN 287-1
EN ISO 9606-1
EN 1418
ISO 14732
EN ISO 5817
ISO 6520-1
EN 473

Document Name
35 Hygienic welding of stainless steel tubing in
the food processing industry (2006)
http://www.ehedq.org/index.php?
nr=9&lang=en&quid-=37
Force Technology, Park Alle 345, DK-2605
Brondby, Denmark (www.forcetechnology.dk)
American Society For Mechanical Engineers
Boiler and Pressure vessel Code Sextion IX
Qualification test of welders Fusion Welding
Part 1 Steels
Qualification testing of welders Fusion Welding
Part 1 Steel
Weling personal. Qualification testing of
Welding and resistance weld setters for fully
mechanized and automatic welding of metallic
materials.
Welding Personnel Approval
Welding Fusion Welded joints in steel, nickel,
titanium and their alloys (beam welding
excluded) Quality Levels for imperfections.
Welding and allied processes Classification of
geometric Imperfections in metallic materials
Part 1. Fusion Weldiing
Non Detructive Tesing Certification of NDT
personnel General principles