DuPont Welding Quality Manual SEO

DuPont Welding Quality Manual
Table of Contents
1. Purpose and Scope.....................................................................................................................2
2. Authority and Responsibility .....................................................................................................3
3. References...................................................................................................................................4
4. Jurisdiction, Code, and DuPont Standard Requirements and Applications .........................7
5. Design of Fabrication, Repairs and Alterations .....................................................................10
6. Material Procurement, Control and Storage...........................................................................12
7. Welding Procedure Specifications and Procedure Qualification Records..........................15
8. Welder Performance Qualification ..........................................................................................17
9. Examination, Inspection and Testing......................................................................................19
10. Non-Conformance.....................................................................................................................22
11. Job Documentation...................................................................................................................24
12. Auditing......................................................................................................................................25
Appendix A, Design Form Templates .................................................................................................29
Appendix B, Inspection and Test Plan and Traveler Form Templates ............................................47
Appendix C, Non-Conformance Form Template................................................................................53
Paper copies of this manual are uncontrolled. This copy is valid only at time of printing. The
control version of this document can be found in the DuPont Welding Technology Lotus Notes
database at this link.
Document issued October 2010

This document may be used and reproduced for DuPont business only.
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 DuPont Welding Quality Manual
1. Purpose and Scope

This manual describes the Welding Quality Assurance/Quality Control Program required for the
fabrication, repair, and alteration of welded process equipment, piping and components. This
includes, but is not limited to, pressure vessels, heat exchangers, fired boilers and boiler piping,
process piping, utility piping (such as water, air, steam, nitrogen, and refrigeration services),
storage tanks, supports, bases, frames, structural steel, and sheet metal.
A Welding Quality Assurance/Quality Control Program is implicitly required by DuPont Corporate
Standard S21A, Process Safety Management, and may be explicitly required by the regulatory
entity having jurisdiction over a plant or operating site or by local, state or national codes and
standards.
This manual shall apply to:
 The DuPont Company and its subsidiaries globally, including all affiliated companies and
joint ventures in which DuPont or a subsidiary owns a majority interest. Note: “majority
interest” means that DuPont or a subsidiary owns more than 50 percent interest in the
entity.
 Any business entity required to operate to DuPont Safety, Health, and Environmental
policies, standards, and guidelines as a condition of venture formation, lease, or other
contractual obligation (e.g., an entity in which DuPont employees are to operate the
entity’s assets).
The requirements and provisions of this manual shall apply to welding quality assurance/quality
control activities for any and all of the following workgroups: DuPont/subsidiary personnel, on-site
contractors (resident and non-resident), and off-site contractors and fabricators. These groups
perform welding functions which include design, weld procedure development and qualification,
production welding, examination, inspection, and testing of weldments.
Inclusion or exclusion of welded equipment, piping, and components in the Welding Quality
Assurance/Quality Control Program shall be determined by considering the requirements of
DuPont Corporate Standard S21A, the requirements of the regulatory entity having jurisdiction
over a plant or operating site, and the Recognized and Generally Accepted Good Engineering
Practices (RAGAGEP), such as codes and standards, which apply to that equipment, piping, or
component. See the table below for clarification.

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Type of Equipment Requirement Basis or Examples

Pressure vessels, Follow RAGAGEP and Country, state, and/or local regulations.
piping, and tanks the Welding Quality
Manual In Corporate Standard S21A,
 Pressure vessels are prescribed as
PSM Critical (for both HHP and LHO)
 Tanks and piping shall have QA (for
both HHP and LHO)
Boilers (shell, tubes, Follow RAGAGEP and DuPont Engineering Standard K14R
drums) and boiler the Welding Quality
proper piping Manual
Fire protection Follow RAGAGEP and In DuPont Corporate Standard S21A, fire
equipment the Welding Quality protection systems are prescribed as PSM
Manual Critical (for both HHP and LHO)
Structural supports for Follow RAGAGEP and In DuPont Corporate Standard S21A, MI
PSM Critical equipment the Welding Quality and QA are specifically required for these
Manual items.
Not PSM Critical, but Follow RAGAGEP and Examples: handrails, ductwork, etc. covered
covered by a the Welding Quality by a structural steel or sheet metal code
RAGAGEP Manual
PSM Critical and not Follow the Welding Examples: valves, couplings
covered by a Quality Manual
RAGAGEP
2. Authority and Responsibility

The regulatory entity having jurisdiction over a DuPont or DuPont subsidiary plant or operating
site has the authority to establish and enforce requirements for the design, fabrication, repair,
alteration, examination, inspection, and testing of welded components. It is the responsibility of
DuPont and its subsidiaries to comply with these requirements and also with DuPont Corporate
Engineering Standards, Safety Standards, and Pipe Codes. See Section 4, “Jurisdiction, Code,
and DuPont Standard Requirements and Application.”
The Management of each DuPont and DuPont subsidiary plant or operating site is responsible
and accountable for meeting the requirements of this manual.
Each DuPont and DuPont subsidiary plant or operating site shall designate a Welding Champion.
This person shall be an employee of DuPont or a DuPont subsidiary and shall be physically
located at the plant or operating site. The Welding Champion shall be responsible for insuring
that the requirements as set forth in this manual are met by that plant or operating site. He or she
shall also be the official liaison to the Welding Advancement Technology Team (WATT) for the
operating site, and shall be identified as such to WATT. For the purposes of WATT meeting
participation, one Welding Champion may represent multiple sites based on geography or
business affiliation. The site Welding Champion position shall be included in each site’s
“Management of Change – Personnel” criteria and guidelines, described in DuPont Corporate
Standard S21A.
DuPont and DuPont subsidiary plants or operating sites may perform welding using DuPont
welders and have a DuPont welding Quality Assurance/Quality Control person (henceforth called

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a DuPont Site Welding QA/QC Representative) on staff. This person is permitted, but is not
required, to be the site Welding Champion.
It is recognized that plants or operating sites may elect to have on-site contractors (resident or
non-resident) and/or off-site contractors and fabricators perform some or all welding. These
contractors and fabricators may have a Quality Assurance/Quality Control person (henceforth
called a non-DuPont welding QA/QC representative) in their employ. However, this person
cannot be a Welding Champion, as the Welding Champion must be an employee of DuPont or a
DuPont subsidiary.
The Welding Advancement Technology Team (WATT) Leadership Team is responsible for
maintaining this manual and for answering questions regarding the content and application of this
manual. Questions and comments should be directed to one of the WATT Leadership Team
members.
3. References
The following references represent common standards, specifications or guidelines for welding of
plant equipment, including but not limited to, pressure vessels, heat exchangers, fired boilers and
boiler piping, process piping, utility piping (such as water, air, steam, nitrogen, and refrigeration
services), storage tanks, supports, bases, frames, structural steel, and sheet metal.
For specific requirements and application of these references, see Section 4, “Jurisdiction, Code,
and DuPont Standards and Application.”
 ASME Boiler and Pressure Vessel Code
o Section I: Rules for Construction of Power Boilers
o Section II Parts A, B, C & D: Materials
o Section IV: Rules for Construction of Heating Boilers
o Section V: Nondestructive Examination
o Section VIII – Division 1: Rules for Construction of Pressure Vessels
o Section VIII – Division 2: Rules for Construction of Pressure Vessels, Alternate
Rules
o Section VIII – Division 3: Rules for Construction of Pressure Vessels, Alternate
Rules for Construction of High Pressure Vessels
o Section IX: Welding and Brazing Qualifications
 ASME B31
o ASME B31.1: Power Piping
o ASME B31.3: Process Piping
o ASME B31.5: Refrigeration Piping
o ASME B31.8: Gas Transmission and Distribution Piping Systems
 ASME B96.1: Welded Aluminum-Alloy Storage Tanks
 NBIC: NB-23 National Board Inspection Code

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 American Petroleum Institute

o API 510: Pressure Vessel Inspection Code – Maintenance Inspection, Rating,
Repair and Alteration
o API 570: Piping Inspection Code – In-Service Inspection, Rating, Repair, and
Alteration of Piping Systems
o API 620: Design and Construction of Large, Welded, Low-Pressure Storage Tanks
o API 650: Welded Tanks for Oil Storage
o API 653: Tank Inspection, Repair, Alteration and Reconstruction
o API 1104: Welding of Pipelines and Related Facilities
 American Welding Society
o AWS D1.1: Structural Welding Code – Steel
o AWS D1.2: Structural Welding Code – Aluminum
o AWS D1.3: Structural Welding Code – Sheet Steel
o AWS D1.6: Structural Welding Code – Stainless Steel
o AWS D1.7: Guide for Strengthening and Repairing Existing Structures
o AWS Standard Welding Procedure Specifications (SWPS)
 AISC: American Institute of Steel Construction Standards
 TEMA: Tubular Exchanger Manufacturing Association Standards
 ASTM International Standards
 MIL-STD: United States Military Standards
 SAE: Society of Automotive Engineers Standards
 National Fire Protection Association
o NFPA 22: Standard for Water Tanks for Private Fire Protection
o NFPA 25: Standard for the Inspection, Testing, and Maintenance of Water-Based
Fire Protection Systems
 American Water Works Association
o AWWA C200: Steel Water Pipe – 6 in. (150 mm) and Larger
o AWWA C206: Field Welding of Steel Water Pipe
o AWWA C220: Stainless Steel Pipe, ½ in. (13 mm) and Larger
o AWWA C300: Reinforced Concrete Pressure Pipe, Steel Cylinder Type
o AWWA C301: Prestressed Concrete Pressure Pipe, Steel Cylinder Type
o AWWA C303: Concrete Pressure Pipe, Bar-Wrapped, Steel Cylinder Type
o AWWA D100: Welded Carbon Steel Tanks For Water Storage

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 Mainland China
o GB 150: Steel Pressure Vessels
o GB 151: Tubular Heat Exchangers
o JB 4708: Welding Procedure Qualification for Steel Pressure Vessels
o JB 4744: Welding Specification for Steel Pressure Vessels
o TSG D0001-2009: Pressure Pipe Safety Technology Supervision Regulation for
Industrial Pressure Pipe
o TSG R0004-2009: Supervision Regulation on Safety Technology for Stationary
Pressure Vessels
 Europe
o PED
 Pressure Equipment Directive 97/23/EC for Pressure Equipment
 Pressure Equipment Directive 87/404/EC for Simple Pressure Vessels
o EN 13445: Unfired Pressure Vessels
o EN ISO 3834: Quality Requirements for Fusion Welding of Metallic Materials
o EN ISO 15607: Specification and Qualification of Welding Procedures For Metallic
Materials – General Rules
o PD5500: Unfired Fusion Welded Pressure Vessels
o AD2000: German Pressure Vessel Directive
 Brazil
o Regulation Standard NR-13 Boilers and Pressure Vessels
 DuPont Standards
o SG1S: Fabrication Requirements for Pressure Vessels and Similar Equipment
o SG1E: Shell and Tube Heat Exchangers for Process Service
o SG100S: Design Criteria, ASME Code Section VIII, Divisions 1 and 2
o SG101S: Fabrication Requirements for Pressure Vessels & Heat Exchangers with
Limited Design Conditions
o SG103S: Specification for Small Pressure Vessels & Heat Exchangers with Limited
Design Conditions
o SG104S: General Specification for Low-Pressure, Welded, Shop-Fabricated
Vessels
o SG105S: API Standard 650 Storage Tank Specification
o SP29M: Minimum Essential Receiving Inspection – Pipe
o SP34M: Minimum Essential Receiving Inspection – Fabricated Pipe
o SP37M: Minimum Essential Receiving Inspection – Welding Filler Metals

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o DuPont Pipe Codes

o DuPont Corporate Welding Procedures (in the “DuPont Welding Technology” Lotus
Notes database)
4. Jurisdiction, Code, and DuPont Standard Requirements and Applications

Welded fabrication, repair or alteration of process equipment, piping and components as a
minimum shall comply with all requirements of the regulatory entity having jurisdiction over a plant
or operating site (henceforth called the “Jurisdiction”) within the governmental boundaries in which
the plant site is located. Welded fabrication, repair or alteration shall also comply with DuPont
Corporate Engineering Standards, Process Safety Standards and Pipe Codes, where applicable.
When a Jurisdiction establishes requirements that are different from those in the DuPont
Corporate Engineering Standards or Pipe Codes, rules of the Jurisdiction shall prevail. If DuPont
requirements are more stringent and meet the Jurisdictional requirements, the DuPont
requirements shall take precedence.
The plant or operating site into which process equipment, piping and components are installed
and operated after fabrication or in which equipment, piping and components are located that will
be weld repaired or altered shall determine Jurisdictional requirements. The plant or operating site
is responsible for ensuring the welding on process equipment, piping and components complies
with all applicable Jurisdictional and DuPont requirements. The plant or operating site is
responsible for review and retention of all applicable documents.
The following guidelines are recommended for application of Jurisdictional and DuPont Codes
and Standards for welding:
4.1 New Equipment
4.1.1 Pressure Vessels and Heat Exchangers
4.1.1.1 Per DuPont Standard SG1S, all pressure vessels and heat exchangers
for use in the USA shall be fabricated per the requirements of the ASME
Boiler and Pressure Vessel (B&PV) Code.
4.1.1.2 For pressure vessels and heat exchangers installed in plant sites where
fabrication is not governed by the ASME B&PV Code, fabrication and
welding shall comply with the applicable construction codes, standards
and requirements of the Jurisdiction into which the equipment will be
installed and operated.
4.1.1.3 The manufacturer of the pressure vessel or heat exchanger shall supply
all the required documentation showing the equipment complies with
the requirements of the construction code.
4.1.2 Piping
4.1.2.1 New piping, as a minimum, shall be fabricated per the requirements of
the applicable DuPont Pipe Code and the applicable ASME B31 Code.
4.1.2.2 For piping installed in plant sites where fabrication is not governed by
the ASME Codes, in addition to DuPont Pipe Code requirements,
fabrication and welding shall comply with the applicable construction

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codes, standards and requirements of the Jurisdiction into which the

piping will be installed and operated.
4.1.2.3 The manufacturer of the piping shall supply all the required
documentation showing the equipment complies with the requirements
of the construction code.
4.1.3 Storage Tanks
4.1.3.1 New storage tanks, as a minimum, shall be fabricated per the
requirements of API 620, API 650 or where applicable, the requirements
of the National Fire Protection Association (NFPA) or American Water
Works Association (AWWA).
4.1.3.2 For storage tanks installed in plant sites where fabrication is not
governed by the API Codes, fabrication and welding shall comply with
the applicable construction codes, standards and requirements of the
Jurisdiction into which the tank will be installed and operated.
4.1.3.3 The manufacturer of the tank shall supply all the required
documentation showing the equipment complies with the requirements
of the construction code.
4.1.4 Fabricated Equipment and Components
4.1.4.1 Fabricated equipment or components of welded construction shall, as a
minimum, shall be fabricated and welded per the requirements of the
appropriate DuPont Standards.
4.1.4.2 Where no DuPont Standards are appropriate, fabrication and welding
shall comply with AWS D1.1, D1.2, D1.3 or D1.6 as applicable.
4.1.4.3 For equipment installed in plant sites outside of the USA, the equipment
shall comply with the applicable construction codes, standards and
requirements of the Jurisdiction into which the equipment or
components will be installed and operated. If no appropriate codes or
standards apply, fabrication and welding shall be performed to the
requirements of Sections 4.1.4.1 and 4.1.4.2.
4.1.4.4 The manufacturer of the equipment or component shall supply all the
required documentation showing the equipment or component complies
with the requirements of the construction code.
4.2 Repair or Alteration
4.2.1 Pressure Vessels and Heat Exchangers
4.2.1.1 Repair and alteration welding on pressure vessels and heat exchangers
installed in the USA shall meet the requirements of NBIC NB-23 or API
510. Companies performing repairs or alterations shall have a current
NBIC R Stamp or an API repair program approved by the local
Jurisdiction.
4.2.1.2 For process equipment installed in plant sites outside of the USA,
welding shall comply with the applicable repair and alteration codes,
standards and requirements in the Jurisdiction into which the equipment

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is installed and operated. If no appropriate codes or standards apply,

welding shall be performed to the requirements of Section 4.2.1.1
4.2.1.3 The organization performing the welding shall supply all the required
documentation showing the pressure vessel or heat exchanger
complies with the requirements of the applicable repair or alteration
codes.
4.2.2 Piping
4.2.2.1 Repair and alteration welding to piping installed in the USA shall meet
the requirements of API-570 and DuPont Pipe Codes.
4.2.2.2 For piping installed in plant sites where repair and alteration is not
governed by the API Codes, in addition to DuPont Pipe Code
requirements, welding shall comply with the applicable repair and
alteration codes, standards and requirements of the Jurisdiction into
which the piping is installed and operated. If no appropriate codes or
standards apply, welding shall be performed to the requirements of
Section 4.2.2.1.
documentation showing the piping complies with the applicable
requirements of the repair or alteration codes.
4.2.3 Storage Tanks
4.2.3.1 Repair and alteration welding on tanks installed in the USA shall meet
the requirements of API 653 or NFPA-25.
4.2.3.2 For tanks installed in plant sites outside of the USA, welding shall
comply with the applicable repair and alteration codes, standards and
requirements in the Jurisdiction into which the tank is installed and
operated. If no appropriate codes or standards apply, welding shall be
performed to the requirements of Section 4.2.3.1.
documentation showing the tank complies with the applicable
requirements of the repair or alteration codes.
4.2.4 Fabricated Equipment and Components
4.2.4.1 Repair and alteration welding of equipment and components shall, as a
minimum, shall be performed per the requirements of the appropriate
DuPont Standards.
4.2.4.2 Where no DuPont Standards are appropriate, welding shall comply with
AWS D1.1, D1.2, D1.3, D1.6 or D1.7 as applicable.
4.2.4.3 For equipment to be installed in plant sites other than the USA, in
addition to DuPont Standards, welding shall comply with the applicable
repair and alteration codes, standards and requirements of the
Jurisdiction into which the equipment or components will be installed
and operated. If no appropriate codes or standards apply, welding shall
be performed to the requirements of Sections 4.2.4.1 and 4.2.4.2.

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documentation showing the equipment or component complies with the
requirements of the repair or alteration code.
5. Design of Fabrication, Repairs and Alterations

5.1 Purpose and General Requirements
The design of weldments in process equipment, piping, and components considers such
factors as material strength, pressure containment, mechanical and thermal stresses,
corrosion resistance, inspectability, and the consequences of failure. The design of
fabrication, repairs, and alterations shall meet the requirements of the codes and standards
listed in Section 4, “Jurisdiction, Code, and DuPont Standard Requirements and
Application.”
5.2 Definitions
The following definitions should be used as general guidelines for determining the
classification of work to be done on welded equipment, piping, and components. Specific
codes and standards may define these terms differently, and those definitions take
precedence.
5.2.1 Fabrication: construction of equipment, piping, or components using only new
materials which have not previously been in service.
5.2.2 Repair: restoring equipment, piping, or components to a safe and satisfactory
operating condition, with no deviation from the original construction.
5.2.3 Alteration: a change to equipment, piping, or components described on the original
Manufacturer's Data Report or design specification which affects the allowable
temperature limits, pressure containing capability, or load-carrying capacity of the
item.
5.2.4 Rerating: a non-physical change such as an increase in the maximum allowable
working pressure (internal or external), increase in design temperature, or a
reduction in minimum temperature. In some codes, rerating is considered an
alteration.
5.3 Responsibility
5.3.1 Operating site
Each DuPont and DuPont subsidiary operating site shall have overall responsibility
for compliance with design requirements as established in the applicable codes
and standards. This responsibility includes, but is not limited to:
 Determining the fluid composition, temperature, pressure, flow rate, loadings,
special service requirements (if any), equipment history, and other specific
information required to develop the design.
 Communicating the above information to the designer.
 Reviewing and approving designs, including those prepared by third parties.
 Evaluating the design for Management of Change implications, and ensuring
that proper Management of Change documents are prepared and approved.

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Note: “Change” is not limited to alterations or rerating. Fabrication or repair

can also be a “Change” depending on application, context, and the Process
Technology. See DuPont Corporate Standard S21A.
5.3.2 Designer
The responsibilities of the designer include, but are not limited to:
 Consulting appropriate personnel, such as Jurisdiction Inspectors, Authorized
Inspectors, insurance Inspectors, licensed Professional Engineers, structural
engineers, metallurgists, welding engineers, or other persons, in order to
develop designs that are in compliance with the requirements of the
jurisdiction and applicable codes and standards.
 Assuring the DuPont or DuPont subsidiary operating site that the design
complies with the requirements of the Jurisdiction and applicable codes and
standards.
5.3.3 Approvers
Those approving the design for fabrication, repair, alteration, and rerating of
process equipment, piping, or components shall possess the proper authority to do
so. Operating sites shall consider the following when selecting those having
authority as approvers.
 The regulatory entity having jurisdiction over an operating site or local, state
or national codes and standards may have specific requirements that design
documentation be approved by a Jurisdiction Inspector, Authorized Inspector,
insurance Inspector, or Professional Engineer.
 The designer shall sign the design documentation. If the designer is not an
employee of DuPont or a DuPont subsidiary, a knowledgeable employee of
DuPont or a DuPont subsidiary shall approve the design documentation to
assume responsibility for the design.
 The organization performing the fabrication, repair, or alteration shall approve
the design.
 Operating sites may require that the DuPont Site Welding QA/QC
Representative, site Welding Champion, and/or DuPont materials engineer
approve all designs or certain types of design.
5.4 Design Form Templates
See Appendix A for Design Form templates for the following types of work:
 Pressure Vessel or Heat Exchanger Repair, Alteration, or Rerating Plan
 Piping System Fabrication Plan
 Piping System Repair, Alteration, or Rerating Plan
 Storage Tank Repair, Alteration, or Rerating Plan
 Welded Component Fabrication, Repair, or Alteration Plan
Each DuPont or DuPont subsidiary operating site shall use these forms or similar forms that
meet site-specific requirements and, at a minimum, contain the same information.

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These forms shall be used in conjunction with an Inspection and Test Plan (ITP) and
Welding Traveler. See Appendix B for an Inspection and Test Plan Form template and
Welding Traveler Form templates.
5.5 Document Retention
Design documentation shall be kept on site in a secure location and is required to be
retained for the life of the equipment. Contractor and fabricator design documentation shall
be part of the turnover package provided to the site at the completion of work. Design
documents shall be accessible for review and auditing as required by the applicable code
and PSM requirements.
6. Material Procurement, Control and Storage

6.1 Material Procurement
6.1.1 Purchasing materials to recognized standards or specifications is necessary to
assure materials meet the minimum requirements for mechanical, physical and
chemical properties required for the design.
6.1.2 Materials used for fabrication, repair or alteration of process equipment, piping or
fabricated equipment shall be purchased from an approved or preferred supplier, if
possible, and conform to a material specification or standard that is recognized and
approved by the fabrication, repair or alteration code by which the work is being
performed or governed. Unless directed otherwise by a DuPont materials
engineer, materials used for alteration or repair shall conform insofar as possible to
the material specification or standard used for the original code of construction.
Materials include, but are not limited to, wrought plate, sheet, pipe, tube, castings
and welding filler materials.
6.1.2.1 In the United States, wrought or cast materials should be purchased to
the requirements of ASTM, ASME, MIL-STD or SAE Standards.
6.1.2.2 Weld filler metals should be purchased to the appropriate AWS
Classification, UNS Number or ASME Specification.
6.1.2.3 Outside of the United States wrought or cast materials and weld filler
metals should be ordered to standards required by the local Jurisdiction,
recognized National standards or standards from the organizations
listed in Section 6.1.2.1 and 6.1.2.2.
6.1.3 Materials that do not meet the requirements of Section 6.1.2 shall not be used
unless a variance is approved by a DuPont materials engineer.
6.1.4 The project manager, project engineer, or plant site engineer shall be responsible
for verifying the original material of construction from original data, drawings, and
records or by positive metal identification (see DuPont Engineering Standard
SW6P).
6.1.5 The project manager, project engineer, or plant site engineer shall be responsible
for designating and supplying the appropriate materials standards or specifications
required for each job or project.
6.1.6 The DuPont Site Welding QA/QC Representative, site Welding Champion, or
materials engineer shall be responsible for designating and supplying the

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appropriate welding filler metal standards or specifications required for each job or
project.
6.1.6.1 Recommendations for filler metal selection can be made by a DuPont
materials engineer, the project engineer, or by the organization
performing the welding.
6.1.6.2 The final filler metal selection should be agreed upon between the
DuPont Site Welding QA/QC Representative or site Welding Champion
and the organization performing the welding before start of any welding.
6.2 Receipt Inspection
6.2.1 All incoming material shall be inspected, identified and verified that its meets the
requirements of the purchase order specification, appropriate materials
specification or standard and is accompanied by the proper documentation.
6.2.2 As a minimum material shall be supplied with a certificate of compliance, or when
required by code or contractual documents, a certified mill test report. All material
shall be properly marked according to the specification or standard with material
grade and heat number.
6.2.3 Piping shall receive receipt inspection per the requirements of DuPont Engineering
Standard SP29M or SP34M.
6.2.4 Welding filler metals shall receive receipt inspection per the requirements of
DuPont Engineering Standard SP37M.
6.3 Storage
6.3.1 Plate, Pipe and Wrought Materials
6.3.1.1 Materials shall be stored under cover whenever possible.
6.3.1.2 If storage under cover is not possible, material should be placed on
wood dunnage or metal racks to keep the material off the bare ground.
6.3.1.2.1 Wooden dunnage should be untreated.
6.3.1.2.2 Metal racks used for storage of corrosion resistant alloys,
such as copper alloys, stainless steel and nickel alloys,
should be made from stainless steel or should be covered
to prevent contamination of the corrosion resistant
materials by iron from carbon steel racks.
6.3.1.3 Materials shall be segregated to separate carbon and low alloy steel
from corrosion resistant alloys, such as copper alloys, stainless steel
and nickel alloys, to prevent possible detrimental contamination of the
corrosion resistant alloys by iron in the carbon and low alloy steels.
6.3.2 Welding Filler Metals
6.3.2.1 All filler metals, whenever possible, should be stored in the original un-
opened, un-damaged container.
6.3.2.2 Covered electrodes should be stored un-opened in their original
containers in a climate controlled area.

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6.3.2.2.1 Low hydrogen electrodes, such as AWS EXX15-x, EXX16-

x and EXX18-x, in open containers or loose electrodes
should be stored in accordance with the manufacturer’s
recommendations. When no recommendations can be
found, the electrodes should be stored in a thermostatically
controlled oven or at a temperature of 250°F – 300°F
(120°C - 150°C). Storage of these electrodes at higher
temperature may affect the welding characteristics.
6.3.2.2.1.1 If contaminated by moisture, low hydrogen
electrodes may be reconditioned per the
manufacturer’s recommendations.
6.3.2.2.2 Standard or conventional, non-low hydrogen, covered
electrodes in open container or loose electrodes should be
stored indoors in a dry area, on shelving or racks off the
floor.
6.3.2.2.2.1 If contaminated by moisture, standard or
conventional electrodes may be
reconditioned per the manufacturer’s
recommendations.
6.3.2.2.3 At the job site, covered electrodes should be stored off the
ground and kept dry until ready, stored in a sealed plastic
bags or portable drying ovens.
6.3.2.2.3.1 Covered electrodes open to atmosphere
shall be reconditioned per the
manufacturer’s recommendations prior to
use or discarded.
6.3.2.3 Bare filler metal rods, spools, and coils should be stored indoors in a
clean, dry area.
6.3.2.3.1 In as much as possible, bare filler metal should be stored
in a manner that prevents contamination from dust, dirt,
grinding particles and other shop contaminants.
6.3.2.3.2 Partially used spools and coils should be stored in a
manner to prevent contamination when not in use, such as
in a plastic bag or under a plastic cover.
6.3.2.3.3 Flux cored filler metal should be stored in a similar manner
to coated electrodes in Section 6.3.2.2.2.
6.3.2.3.3.1 If contaminated by moisture, flux cored
filler metal may be reconditioned per the
manufacturer’s recommendations.
6.3.2.3.4 When handling bare filler metal rods, spools, or coils,
gloves should be worn to prevent contamination from
moisture and oils on bare skin.
6.3.2.3.5 At the job site, bare filler metal should be stored off the
ground in a closed container or sealed plastic bag until
Page 14 of 54
ready to use to prevent contamination from dirt, oil, grease

or other job site contaminants.
6.3.2.3.5.1 If required, bare filler metal rods can be
cleaned with a non-residue, low chloride
solvent to remove contamination.
6.4 Material Identification and Control
6.4.1 All material shall, as a minimum, shall be marked with the material grade, heat
number and purchase order number.
6.4.1.1 Marking or label materials shall not contain harmful quantities of
chlorides, low-melting metals or salts, such as cadmium, lead, mercury
tin and zinc, which can cause cracking, pitting or embrittlement of some
materials of construction. See DuPont Engineering Standard SP3D,
Table 1.
6.4.2 All identification and numbering shall be transferred or carried over to each drop or
piece before cutting is performed.
6.4.3 Prior to placing the material into service, all adhesive-backed labels and tapes shall
be removed and the area covered by the adhesive cleaned with an appropriate
solvent and clean cloth.
7. Welding Procedure Specifications and Procedure Qualification Records

7.1.1 Welding Procedure Specifications (WPSs) and Procedure Qualification Records
(PQRs) shall be established for the purpose of assuring that welding practices
produce a weld with the degree of integrity specified by the project design and the
applicable DuPont and Jurisdictional codes and standards. The requirements in
these procedures and standards must be understood by DuPont and all contract
organizations associated with welding on process equipment, piping and fabricated
components for all DuPont and DuPont subsidiary sites. Each site and contractor
organization performing welding activities for DuPont on or off site is responsible
for establishing and following WPSs and PQRs.
7.1.2 WPSs and PQRs for use in the US and Canada shall meet the requirements of
ASME Section IX or the American Welding Society. For plant sites outside the US
and Canada, establishing and following of welding procedures shall comply with
the applicable codes and requirements of the site Jurisdiction.
7.2 Responsibility
This section outlines the responsibilities for control and implementation of Welding
Procedure Specifications required for welding activities at or for DuPont and DuPont
subsidiary plants or operating sites.
7.2.1 The DuPont Site Welding QA/QC representative, DuPont materials engineer, site
Welding Champion, and/or the project welding QA/QC representative (if applicable)
is responsible for approval of WPSs and PQRs for welding activities performed by
DuPont/subsidiary personnel, on-site contractors (resident and non-resident), and

Page 15 of 54
off-site contractors and fabricators at or for DuPont sites. The approver must have
adequate details of the scope of the welding job, such as drawings, weld maps or
detailed scope of work in order to approve the procedures. The approver may be
located at another DuPont site for this approval process.
7.2.2 Any contract welding or fabrication organizations performing welding activities for
DuPont, on or off site are required to submit their qualified WPSs and PQRs for
review and approval prior to any welding. The contract or fabrication organization’s
welding QA/QC representative, job supervisor, or engineer is responsible for
supplying the WPSs and PQRs for review and approval.
7.2.3 The approved WPS(s) shall be incorporated into the job plan and shall be available
at the job site for access and review by the welder(s). The First Line Supervisor
and or job planner/coordinator is responsible for supplying the WPS(s) to the
welder(s).
7.2.4 Welding shall be performed within the parameters of the approved WPS(s). The
designated DuPont or non-DuPont welding QA/QC representative shall be
responsible for auditing this process.
7.3 Standard Welding Procedure Specifications
DuPont owned Standard Welding Procedure Specifications (SWPSs), purchased from AWS,
are maintained in the “DuPont Welding Technology” Lotus Notes database.
These procedures can be used by DuPont welders at any DuPont site provided the following
requirements and limitations are followed.
 SWPSs can be used for construction, repair, and alteration in which requirements of
the ASME Boiler and Pressure Vessel Code and Section IX are specified. Any
requirements of the applicable construction, repair, or alteration Code Section
regarding SWPSs takes precedence over the requirements of Section IX.
 These SWPSs are not permitted for construction, repair, or alteration where impact
testing requirements are required by the applicable construction, repair or alteration
code.
 You cannot deviate from any of the welding parameters and conditions specified on
the SWPSs. It cannot be revised.
 Multiple process SWPSs shall be used in the order and manner specified.
 You cannot combine any of these processes with another DuPont WPS in the same
production weld joint.
 Additional instructions may be added as long as they are within the limits of the
SWPSs.

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7.4 DuPont Corporate Qualified Welding Procedures

DuPont corporate welding procedures are maintained in the “DuPont Welding Technology”
Lotus Notes database.
7.4.1 Corporate welding procedures are for use by only DuPont welders. They shall not
be used for welding by on-site contractors (resident or non-resident) nor off-site
contractors or fabricators.
7.4.2 The development and qualification of site specific WPSs and PQRs shall be
performed under the direction and control of the DuPont Site Welding QA/QC
Representative, DuPont materials engineer, or site Welding Champion. New
DuPont welding procedures shall be qualified per the applicable construction code
within the Jurisdiction or region of the site location.
7.4.3 Only DuPont approved laboratories shall perform the necessary mechanical testing
for qualification of new PQRs. All test results shall be reviewed and approved by
the Site Welding QA/QC Representative, DuPont materials engineer, or site
Welding Champion prior to acceptance. Test results shall be retained with the
master copy of the weld procedure, see Section 7.5.
Master copies of WPSs and PQRs being used on DuPont sites for welding activity shall be
kept in a secure location and are required to be retained indefinitely on site where welding
activity is being performed. Contractor and fabricator WPSs and PQRs shall be part of the
turnover package provided to the site at the completion of work, as described in Section 11,
“Job Documentation.” WPS and PQR documents shall be accessible for review and
auditing as required by the applicable code and PSM requirements.
8. Welder Performance Qualification

8.1 Purpose
The purpose of a Welder Performance Qualification (WPQ) is to determine and qualify that a
welder or welding operator possesses the skills necessary to produce a sound weld and
meets the testing requirements of the applicable code, standard or specification.
8.2 Responsibility
It is the responsibility of the DuPont Site Welding QA/QC Representative, DuPont materials
engineer, and/or site Welding Champion to insure that all DuPont/subsidiary welders, on-site
contractor welders (resident and non-resident), and off-site contractor and fabricator welders
performing welding activity on DuPont process equipment, piping and fabricated
components in, or to be installed in, the US and Canada are qualified per the requirements
of ASME Section IX and/or the American Welding Society (AWS). For plant sites outside the
US and Canada, Welder Performance Qualification shall comply with the applicable
Jurisdictional codes and requirements of the site.
8.3 DuPont Welder Performance Qualifications
8.3.1 DuPont Welder Performance Qualification testing shall be performed under the
direction of the DuPont Site Welding QA/QC Representative, DuPont materials
engineer, and/or site Welding Champion. The welder or welding operator shall be

Page 17 of 54
qualified using an approved DuPont Welding Procedure Specification (WPS) or

DuPont owned Standard Welding Procedure Specification (SWPS).
8.3.2 The DuPont Site Welding QA/QC Representative, DuPont materials engineer,
and/or site Welding Champion shall approve and document the welder or welding
operator Welder Performance Qualification Record prior to any welding activity
being performed. The Welder Performance Qualification Record shall include all
the essential variables, type of qualification tests and test results, and the variable
ranges qualified for each welder. Welders and welding operators shall be limited to
welding only in the qualified process and parameters.
8.3.3 Each qualified welder or welding operator shall be assigned an identifying number,
letter or symbol which shall be used to identify the work of the welder or welding
operator.
8.3.4 A welder or welding operator’s qualification is valid for six months from the date of
the satisfactorily passed qualification test.
8.3.5 Re-qualification of the welder or welding operator is required if any of the following
occurs:
 The welder or welding operator has not made a production weld using the
qualified process within the previous 6 months.
 A continuity log can not verify the welder or welding operator has welded in
the process within the previous six months.
 When there is a specific reason to question a welder’s or welding operator’s
ability to make satisfactory welds the qualification shall be revoked.
8.3.6 Welder Qualification Records shall be kept in a secure location and shall be
retained indefinitely on site as long as the welder or welding operator is making
production welds. Welder continuity logs shall also be maintained for all active
welders and welding operators. A blank template for welder continuity
recordkeeping is available in the “DuPont Welding Technology” Lotus Notes
database.
8.4 Contractor/Fabricator Welder Qualification
8.4.1 The contract and fabrication organization welders and welding operators
performing welding activities for DuPont shall be tested and qualified under the full
supervision and control of the manufacturer, contractor or assembler during the
production of the test weldments using an approved WPS. This responsibility
cannot be delegated to another organization. Contractor and fabricator welders
and welding operators shall be qualified per the requirements of ASME Section IX
and/or the American Welding Society (AWS) in the US and Canada. For plant sites
located outside the US and Canada qualification shall comply with the applicable
Jurisdictional codes and requirements of the site.
8.4.2 In the case where pre-qualified welders are acceptable, the initial welds made to
the WPS shall be examined per the applicable construction, repair, or alteration
code for the work. This shall be documented on the Inspection and Test Plan
and/or Welding Traveler (see Section 9, “Examination, Inspection and Testing”).

Page 18 of 54
8.4.3 All contract and fabrication organizations performing welding activities for DuPont,
on or off site are required to submit Welder Qualification Records for review and
approval by the DuPont Site Welding QA/QC Representative, DuPont materials
engineer, and/or site Welding Champion prior to any welding activity being
performed. These records shall be kept in a secure location on site as long as the
welder or welding operator is making production welds for the site and shall also be
part of the turnover package provided to the site at the completion of work, as
described in Section 11, “Job Documentation.”
8.4.4 The Welder Performance Qualification Record shall include all the essential
variables, type of qualification tests and test results, and the variable ranges
qualified for each welder or welding operator. Welders and welding operators shall
be limited to welding only in the qualified process and parameters.
8.4.5 Each welder or welding operator shall be assigned an identifying number, letter or
symbol which shall be used to identify the work of the welder or welding operator.
8.4.6 A welder or welding operator’s qualification is valid for six months from the date of
the satisfactorily passed qualification test.
8.4.7 Re-qualification of the contract or fabricator welder or welding operator is required
if any of the following occurs:
 The welder or welding operator has not made a production weld using the
qualified process within the previous 6 months.
 A continuity log can not verify the welder or welding operator has welded in
the process within the previous six months.
 When there is a specific reason to question a welder’s or welding operator’s
ability to make satisfactory welds the qualification shall be revoked.
9. Examination, Inspection and Testing

The purpose of examination, inspection and testing during the fabrication, repair, or
alteration of process equipment, piping, and components is to ensure that the work meets
the requirements of the applicable codes and standards and the engineering design. As a
minimum, examination, inspection, and testing activities shall meet the requirements of the
codes and standards listed in Section 4, “Jurisdiction, Code, and DuPont Standard
Requirements and Application.” Operating sites must carefully consider whether these
minimum requirements are indeed sufficient for a given fabrication, repair, or alteration job.
9.2 Definitions
The following definitions apply to the use of these terms within this manual. Specific codes
and standards may define these terms differently, and those definitions take precedence.
9.2.1 Examination: the use of methods, usually non-destructive, to assess weld quality.
Examples of examination methods are visual examination, radiography, and
penetrant testing. Examination results alone are not meaningful; the results must
be compared to acceptance criteria to verify that the weld is of the required quality.

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9.2.2 Inspection: the review of documents, examination results, and the physical work
itself to verify that the fabrication, repair, or alteration conforms to the applicable
codes and standards and the engineering design. Inspectors may be granted
specific authorities, rights, and responsibilities by the codes and standards and by
the regulatory entity having jurisdiction over the site.
9.2.3 Testing: specifically, leak testing using a fluid or tracer medium. Examples of leak
testing methods are hydrostatic testing, pneumatic testing, and helium-leak testing.
9.2.4 Inspection and Test Plan (ITP): also sometimes called a Quality Plan, this
document details the examination/inspection/testing tasks, acceptance criteria,
reference documents, and approval signatures for a fabrication, repair, or alteration
job. The Inspection and Test Plan may be generated by the organization
performing the welding, by the DuPont or DuPont subsidiary operating site, or by a
third party, but it must be mutually agreed upon by the organizations involved. For
small, simple jobs, especially those performed by DuPont welders or resident
contractor welders, a separate Inspection and Test Plan may not be required;
rather, examination/inspection/testing tasks may be able to be fully described in
design documentation (see Section 5, “Design of Fabrication, Repairs and
Alterations”) and the Traveler.
9.2.5 Traveler: generated by the organization performing the welding, this document
tracks a job on a weld-for-weld basis. It provides the welder identification, Welding
Procedure Specification (WPS), filler metal, and examination and inspection
requirements and approval signatures for each particular weld. A weld map,
detail/isometric drawing, or key is typically included. The Traveler can serve as a
means for verifying that the requirements of the Inspection and Test Plan have
been met.
9.3 Responsibility
9.3.1 Operating Site
for compliance with examination, inspection and testing requirements as
established in the applicable codes and standards. This responsibility includes, but
is not limited to:
 Ensuring that appropriate staffing is in place for examination, inspection and
testing activities for fabrication, repairs, and alterations. Examinations and
inspections shall be performed by qualified individuals.
o For the qualification of examination personnel employed by DuPont,
DuPont Engineering Standard SG9T shall be followed. Outside of
the United States, this standard is optional. Where national or local
government Jurisdictional requirements exist, they shall be imposed
in lieu of the requirements of this standard.
o For contracted examination personnel, DuPont Engineering
Standard SG11T shall be used to verify their technical capability.
o Inspector qualifications and certifications shall follow the specific
fabrication, repair, or alteration codes and standards that require the
use of an inspector.

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o The use of third-party examination and inspection is common for

some types of fabrication and repair performed at off-site vendor
facilities. DuPont and DuPont subsidiary operating sites shall be
responsible for verifying that the third-party personnel assigned to
the job are properly qualified and/or certified to perform the required
examinations and inspections.
 Establishing and maintaining calibration schedules for DuPont-owned
examination and testing equipment, based on manufacturers’
recommendations, codes and standards, and site written procedures.
 Developing and following both general and specific written procedures for
examination and testing methods when required by codes and standards.
DuPont Engineering Standard SG8.1T should be used for guidance.
 Determining the need for a separate Inspection and Test Plan, based on the
complexity of the job, the organization performing the welding, the
requirements of the codes and standards, and the requirements of DuPont
Corporate Standard S21A.
 Reviewing and approving Inspection and Test Plans, including those
prepared by third parties.
9.3.2 Inspection and Test Plan and/or Welding Traveler Author
The responsibilities of the Inspection and Test Plan and/or Welding Traveler Author
include, but are not limited to:
 Consulting appropriate personnel, such as Examiners, Jurisdiction
Inspectors, Authorized Inspectors, insurance Inspectors, licensed
Professional Engineers, structural engineers, metallurgists, welding
engineers, or other persons, in order to develop Inspection and Test Plans
and/or Travelers that are in compliance with the requirements of the
Jurisdiction and applicable codes and standards.
 Assuring the DuPont or DuPont subsidiary operating site that the Inspection
and Test Plan and/or Traveler complies with the requirements of the
Jurisdiction and applicable codes and standards.
9.3.3 Approvers
Those approving Inspection and Test Plans and/or Travelers for fabrication, repair,
and alteration of process equipment, piping, or components shall possess the
proper authority to do so. Operating sites shall consider the following when
selecting those having authority as approvers.
 The regulatory entity having jurisdiction over an operating site or local, state
or national codes and standards may have specific requirements that
Inspection and Test Plans and/or Travelers be approved by a Jurisdiction
Inspector, Authorized Inspector, insurance Inspector, or Professional
Engineer.
 The author shall sign the Inspection and Test Plan and/or Traveler. If the
author of the Inspection and Test Plan is not an employee of DuPont or a
DuPont subsidiary, a knowledgeable employee of DuPont or a DuPont

Page 21 of 54
subsidiary shall approve the Inspection and Test Plan to assume

responsibility for the Plan.
 The organization performing the fabrication, repair, or alteration shall approve
the Inspection and Test Plan and/or Traveler.
 Operating sites may require that the DuPont Site Welding QA/QC
Representative, site Welding Champion, and/or DuPont materials engineer
approve the Inspection and Test Plan and/or Traveler.
9.4 Form Templates
For piping fabrication, a Pipe Fabrication Agreement can be used as the Inspection and Test
Plan. The Pipe Fabrication Agreement template is owned and maintained by the DuPont
Facilities Construction and Support piping consultants.
See Appendix B of the Welding Quality Manual for form templates for:
 Inspection and Test Plan [general]
 Welding Traveler with Isometric
 Welding Traveler with Grid
Each DuPont or DuPont subsidiary operating site shall use these forms or similar forms that
meet site-specific requirements and, at a minimum, contain the same information.
The Welding Quality Manual forms shall be used in conjunction with a Design Form specific
to the type of work to be performed. See Appendix A for Design Form templates.
Examination, inspection, and testing documentation shall be kept on site in a secure location
and shall be retained for the period of time required by the applicable codes and standards,
by the regulatory entity having jurisdiction over the site, or by site specific written
procedures. For some process equipment, piping, and fabricated components, examination,
inspection and testing documentation must be retained for the life of the equipment.
Contractor and fabricator examination, inspection, and testing documentation shall be part
of the turnover package provided to the site at the completion of work. Examination,
inspection and testing documents shall be accessible for review and auditing as required by
the applicable code and PSM requirements.
10. Non-Conformance
10.1 Purpose and Scope
This section establishes a procedure for the control and disposition of non-conforming
item(s) so as to prevent unintentional use or installation. This procedure applies to all non-
conforming materials, parts, welded components, and welded equipment whether produced
in-house by DuPont, resident contractors, or alliance supply companies, or obtained from
outside vendors, contractors or contract fabricators.
10.2 Responsibility and Authority
10.2.1 The DuPont Site Welding QA/QC Representative or site Welding Champion has
responsibility and authority to ensure this procedure is followed. The DuPont Site

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Welding QA/QC Representative or site Welding Champion may delegate tasks to

qualified personnel, as needed.
10.2.2 All persons involved, including those employed by DuPont, resident contractors,
outside vendors, contractors, and contract fabricators, are responsible for knowing
and following this procedure.
10.2 Procedure
Non-conforming item detection and actions are as follows:
10.2.1 The non-conforming item(s) can be detected in many ways, by any person, at any
time, including, but not limited to, receipt inspection, in-process fabrication
inspection, random inspection or by simple observation and visual inspection.
10.2.2 When a non-conforming item is detected, it shall be immediately removed from the
normal work or fabrication flow process, work area or job site and placed in an
isolation area. The DuPont Site Welding QA/QC Representative or site Welding
Champion shall be contacted about the non-conformance.
10.2.3 The item shall be immediately identified with a NON-CONFORMANCE FORM,
which is filled out and attached to the affected item. The NON-CONFORMANCE
FORM contains part number, quantity, description, reason for being on hold, name
of the person who detected the problem, and the date. See Appendix C of the
Welding Quality Manual for a template NON-CONFORMANCE FORM. Each
DuPont or DuPont subsidiary operating site shall use this form or a similar form
that meets site-specific requirements and, at a minimum, contains the same
information.
10.2.4 Disposition of the non-conforming item can be determined by the DuPont Site
Welding QA/QC Representative, site Welding Champion, DuPont materials
engineer, project manager or manufacturing technical engineer. No non-
conforming item shall be removed from the isolated hold area except by the
DuPont Site Welding QA/QC Representative or site Welding Champion. The
resolution of the non-conformance can be any of the following:
10.2.4.1 Return: The item will be returned to the supplier/vendor’s shop for
rework or replacement
10.2.4.2 Rework: The item will be reworked or repaired at the work site by
DuPont or contract company personnel.
10.2.4.3 Usable: The item is deemed suitable for the intended application “as is”
and returned to the work process.
10.2.4.4 Scrap: The item is deemed unusable and disposed of offsite.
10.2.5 The DuPont Site Welding QA/QC Representative or site Welding Champion shall
note the resolution on the NON-CONFORMANCE FORM, remove the NON-
CONFORMANCE FORM from the item and retain the NON-CONFORMANCE
FORM on site.

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11. Job Documentation

11.1 Scope
This section provides requirements and guidelines for the collection, retention and storage
of job documentation records for welding, testing, examination, and inspection activities
performed by DuPont/subsidiary personnel, on-site contractors (resident and non-resident),
and off-site contractors and fabricators.
11.2 Responsibility
11.2.1 The DuPont Site Welding Quality QA/QC Representative is responsible for the
collection and retention of job documentation records generated for the welding of
process equipment, piping and fabricated components performed on site by
DuPont/subsidiary personnel.
11.2.2 Contract welding and fabrication organizations are responsible for the collection
and retention of job documentation records generated for the welding of process
equipment, piping and fabricated components performed by contractor or fabricator
personnel. These job documentation records shall be accumulated and submitted
to DuPont at the completion of the project or scope of work.
11.2.3 The DuPont or DuPont subsidiary employee or designate responsible for receiving
documentation submitted by contractors or fabricators shall also be responsible for
properly communicating and retaining this documentation.
11.3 Procedure
11.3.1 Job documentation records can be either electronic or hard copy files.
11.3.2 The following job documentation records are required for DuPont and on site
contract organizations performing welding, testing, examination, and inspection
activities for DuPont and shall be maintained on site by the DuPont Site Welding
QA/QC Representative or site Welding Champion.
 Design documentation packages, including drawings and calculations
 Welding Procedure Specifications and Procedure Qualification Records
 Welder Performance Qualification Records
 Non-Destructive Examination (NDE) procedures
 NDE personnel qualifications
 NDE reports and job travelers
 Weld maps
11.3.3 Contract welding and fabrication organizations that perform welding offsite on
DuPont process equipment, piping, and fabricated components are required to
retain and submit copies of job documentation records for welding, testing,
examination, and inspection activities to DuPont after the project or scope of work
is complete. These documentation records, called the “turnover package” or “data
package,” include but are not limited to the following:
 Complete set of vendor drawings
 Welding Procedure Specifications and Procedure Qualification Records
Page 24 of 54
 U-1or U-1A (manufacturers data report), if applicable

 Copy of nameplate rubbing, if applicable
 Mill test reports and or certificate of compliance on materials
 Design calculations
 Inspection reports
 NDE reports and job travelers
 Weld maps
11.4 Retention
Job documentation records for process equipment, piping and fabricated components shall
be retained for the period of time required by the applicable code of construction, repair, or
alteration, the site Jurisdiction and/or site specific written procedures. For some process
equipment, piping, and fabricated components, job documentation must be retained for the
life of the equipment.
11.5 Storage
Job documentation records shall be maintained in a secure location with a system in place
to facilitate orderly retrieval when required. Consideration should be made for electronic
versus paper storage, records retention requirements, protection from natural disasters, etc.
12. Auditing
The purpose of auditing is to ensure that all organizations performing welding functions
comply with the requirements and provisions of this manual and all applicable codes,
regulatory requirements, standards and the engineering design. As a minimum, auditing
activities shall meet the requirements of this manual and of the codes and standards listed
in Section 4, “Jurisdiction, Code, and DuPont Standard Requirements and Application.”
Auditing of external vendor organizations performed per this section is done to confirm the
abilities of vendors already on a site or corporate approved supplier list. It should not be
used for qualification of new vendors for inclusion on a site or corporate approved supplier
list.
12.2 Definitions
The following definitions apply to the use of these terms within this manual. Specific codes
and standards may define these terms differently, and those definitions take precedence.
12.2.1 Auditing: A formal methodical examination and review of an organization’s or
individual’s systems and activities. This includes audits of internal
(DuPont/subsidiary and on-site resident contractor) organizations and external (off-
site contractor and fabricator) organizations.
12.2.2 1st Party Audits: Audits conducted by on-site resources as a means to determine
gaps in welding programs, systems, and individuals, including design, weld
procedure development and qualification, production welding, examination,
inspection, and testing of weldments.

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12.2.3 2nd party Audits: Audits conducted by off-site resources from other DuPont or
DuPont subsidiary facilities.
12.2.4 3rd Party Audits: Audits conducted by non-DuPont resources such as Moody
International, Det Norske Veritas, or Bureau Veritas.
12.2.5 Non-Conformances: Items that do not meet the specifications of codes, standards
or work practices as defined.
12.2.6 Periodic Audits: audits conducted to verify compliance of DuPont/subsidiary
welding organizations, on-site contractors (resident and non-resident), and off-site
contractors and fabricators to welding program and work system requirements.
12.2.7 Qualification or Re-qualification Audits: audits conducted to assess or re-assess a
non-DuPont welding organization for inclusion on a site or corporate approved
supplier list. It shall be the responsibility of the DuET/
DuCAP/Sourcing commodity teams to schedule and execute these audits
12.3 Responsibility
12.3.1 Operating Site
for auditing and audit compliance requirements as established in this manual, the
applicable codes and standards, and any other regulatory, corporate, or site
specific documentation. This responsibility includes, but is not limited to:
 Ensuring that appropriate staffing is in place for conducting auditing. Auditing
shall be performed by qualified individuals.
o For auditing personnel employed by DuPont, at least one auditor on
the team shall have not less than 10 years experience in the design,
fabrication, or inspection of welded components. Each 20% of
satisfactorily completed work toward an engineering degree
recognized by an accredited institution shall be considered
equivalent to 1 year of experience, up to 5 years total.
o For periodic auditing for compliance, it is acceptable to use an
individual from a third party organization who meets the above
qualification requirements. The third party organization shall be
qualified by the site Welding Champion with approval from the
appropriate commodity team or from the WATT Leadership Team.
When there is no active commodity team, it shall be the
responsibility of the site Welding Champion, at the direction of the
WATT Leadership Team, to recommend an auditor or to approve
the qualification of an auditor.
 Including other appropriate personnel, such as the DuPont materials
engineer, DuPont Site Welding QA/QC Representative, and Sourcing
representatives, on audit teams or in audit communications.
 Ensuring that periodic audits of DuPont/subsidiary welding organizations, on-
site contractors (resident and non-resident), and off-site contractors and
fabricators are conducted on a scheduled frequency as defined in Section
12.4.

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 Ensuring that non-conformances and action items identified during audits are
appropriately addressed, assigned, tracked, and resolved.
12.3.2 Site Welding Champion
The responsibilities of the site Welding Champion include, but are not limited to:
 Verifying that organizations performing the welding functions within the scope
of this manual for his/her DuPont/DuPont subsidiary site(s) have received a
qualification audit and receive periodic audits.
 Planning, scheduling, and executing (or delegating execution of) periodic
audits.
 Writing or approving audit reports, and ensuring that audit reports are
communicated to the operating site.
 When required, drafting appropriate action items (including responsibility and
timing) for submission to the operating site.
12.4 Periodic Audit Frequency
It is the responsibility of the site Welding Champion to execute (or delegate execution of)
periodic audits as planned or, when there is reason to question a potential non-
conformance, conduct an un-scheduled audit. Periodic audit frequencies are as follows:
 Periodic auditing of site and resident contractor systems and personnel – Annually
 Periodic auditing of off-site contractor or fabricator facilities, systems, and personnel
Every 3 Years, or
o change of ownership, change in QA/QC management, or other significant change
or events
o if there is a reason to question the work quality or integrity
12.5 Systems to Audit
The following systems, facilities and personnel shall be subject to audit:
 Welding Quality Control/Quality Assurance Manual, and its adherence
 Welding Procedure Qualification Records and Welding Procedure Specifications
 Welder Performance Qualification Record(s)
 Welder Continuity Records
 Systems and processes for the design of fabrication, repairs and alterations
 Piping, storage tank, pressure vessel, and welded component traveler(s)
 Examination, testing and inspection records
 Non-destructive examination procedures
 Non-destructive examination personnel qualifications
 Material control systems and practices

Page 27 of 54
12.6 Suggested Audit Forms and Protocols

The following documents and resources are suggested as guidelines for conducting periodic
audits:
 DuPont Engineering Standard A3.2VL, Appendices A and B
 DuPont Facilities Construction and Support Quality System (QC) Internal Audit
12.7 Corrective Action
The audit findings requiring action will be entered into a corrective action system such as
Manage-It for execution.
Documentation of periodic off-site contractor and fabricator audits shall be filed in the
DuPont MIQANET Lotus Notes database on CDCLN80. This documentation shall be sent
to Frances Clancy-Green. Audit documentation can be viewed by clicking on the “twisty” for
the “Sourcing Page” at this link.
Documentation of periodic audits of DuPont/subsidiary and on-site resident contractor
welding organizations shall be retained in a secure location on site. Documentation shall be
retained for the period of time required by the applicable codes and standards, by the
regulatory entity having jurisdiction over the site, or by site specific written procedures.

Page 28 of 54
Appendix A, Design Form Templates

 Pressure Vessel or Heat Exchanger Repair, Alteration, or Rerating Plan
 Piping System Fabrication Plan
 Piping System Repair, Alteration, or Rerating Plan
 Storage Tank Repair, Alteration, or Rerating Plan
 Welded Component Fabrication, Repair, or Alteration Plan

Page 29 of 54
Pressure Vessel or Heat Exchanger
Repair, Alteration, or Rerating Plan
General Information:
Form Date: Form #:
Work Order #: PCR #:
Equipment #: Equipment Name:
Description:
Business: Area: Bldg #:
Area
PSM Critical: Yes No HHP LHO EHS
Classification:
Area Contact: Extension:
Equipment Design Basis Information:

BPF/Drawing #:
P&ID #: National Board #:
Manufacturer: Jurisdictional #:
Construction Code: Year Built:
Lethal Service: Yes No Special Design Required for HTM: Yes No
Existing Design Limits:
Temperature (Maximum/Minimum) Pressure (Maximum/Minimum)
Shell
Jacket
Tubeside
Original Pressure Test:
Pressure Fluid Test Position
Shell
Jacket
Tubeside
Original Joint Efficiencies, Radiography, and Post-Weld Heat Treatment:
Joint Efficiency Radiography PWHT (Yes/No) PWHT Temp. and Time
Shell
Jacket
Tubeside
Existing Materials of Construction: note substrate AND lining, weld overlay, or cladding if applicable.
Shell: Heads:
Nozzle/Flange: Jacket:
Tubes: Tubesheets:
Internals:
Original General Size:
Diameter: Length:
Head type: Welded Bolted Clamped Other
Shell Thickness: Head Thickness:
# of Tubes: Tube Wall:
Design Corrosion Allowance: Shell: Tubeside: Jacket:
Document template issued October 2010 Page 1 of 3

Repair, Alteration, or Rerating Information:
(to be completed by the organization performing the work)
Organization Performing Work:
Code for the Present Work:
Present Work Classified As: Repair Alteration Rerating
Person Responsible for Calculations:
New Design Limits:
Temperature (Maximum/Minimum) Pressure (Maximum/Minimum)
Shell
Jacket
Tubeside
New Pressure Test and/or Leak Test (if required):
Pressure Fluid Test Position
Shell
Jacket
Tubeside
New Joint Efficiencies, Radiography, and Post-Weld Heat Treatment:
Joint Efficiency Radiography PWHT (Yes/No) PWHT Temp. and Time
Shell
Jacket
Tubeside
New Materials of Construction: note substrate AND lining, weld overlay, or cladding if applicable.
Provide specification and grade.
Shell: Heads:
Nozzle/Flange: Jacket:
Tubes: Tubesheets:
Internals:
New Corrosion Allowance:
Shell: Tubeside: Jacket:
Additional or Special Examination Requirements and Details: refer to applicable construction, repair,
and/or alteration codes for minimum requirements
Prep Root Final Comments
Radiography
Magnetic Particle
Visual
Ultrasonic Thickness
Ultrasonic Shear Wave
Penetrant (list type)
Other

Detailed Description of Work:
Records and Documents to Send to the Owner Business Unit:

Supplier Certificate of Compliance Visual Examination Reports
RT Films Other Examination Reports (PT, MT, etc.)
RT Reader (Interpretive) Sheets Material Receipt Examination Records
Material Test Reports Other (list):
Pressure Test Reports
Leak Test Reports
Approved By:
Title Print Name Signature Date
Owner-User
Designer
Authorized or
Jurisdictional Inspector
Organization Performing Work
Appendices: Attach supporting documents when available. (e.g. photos, sketches, drawings,
calculations, analysis, etc...)
Appendix Number Title / Description

Piping System
Fabrication Plan
Form Date: Form #:
Line #: Ultra Pipe ID #:
Equipment #:
Description:
PSM Critical: Yes No Area Classification: HHP LHO
ASME B31.3 Class of service Normal Fluid Category M Category D
Fluid Type: Liquid Vapor Solids Specific Gravity:

P&ID Drawing #: Construction Code:
Pipe Code #:
MDMT: Tmin:
Fabrication Information:
Flexibility Analysis Required: Yes No
If No, Provide Explanation:
Design Limits:
Pressure (Max/Min): Temperature (Max/Min):
Severe Cyclic Service: Yes No
Pressure cycles/year: Temperature cycles/year:
Pressure Test and/or Leak Test:
Pressure: Fluid:
Post-Weld Heat Treatment:
Temperature: Time:
Post-Fabrication Cleaning Requirements:
Painting:
Paint Specification: Comments:

Piping System
Fabrication Plan
Materials of Construction: (Refer to Pipe Code) note if pipe is lined
Provide material grade, if applicable.
Type(s) Material Specification(s) Nominal Pipe Size(s) Schedule(s)
Pipe
Flanges
Fittings
Gaskets
Bolting
Examination Requirements and Details: refer to applicable construction codes for minimum requirements
Radiography
Magnetic Particle
Visual
Other

Piping System
Fabrication Plan
Exceptions and Limitations from the Product & Service Index:

Material Test Reports Post-Weld Heat Treatment Records
Pressure Test Reports Other (list):
Leak Test Reports
Approved By:
Owner-User
Designer
Authorized or

Piping System
Form Date: Form #:
Line #: Ultra Pipe ID #:
Equipment #:
Description:
ASME B31.3 Class of service Normal Fluid Category M Category D

Pipe Code #: Year Built:
MDMT: Tmin:
Existing Design Limits:
Existing Materials of Construction: (Refer to Pipe Code) note if pipe is lined
Material Specification Nominal Pipe Size Schedule
Original General Size:

Nominal Pipe Size: Schedule:
Design Corrosion Allowance:
Additional comments:

Piping System
Flexibility Analysis Required: Yes No
If No, Provide Explanation:
New Design Basis Information:
Pipe Code #:
MDMT: Tmin:
New Design Limits:
Pressure: Fluid:
New Post-Weld Heat Treatment:
Temperature: Time:
Post-Repair/Post-Alteration Cleaning Requirements:
Painting:
New Materials of Construction: (Refer to Pipe Code) note if pipe is lined
Provide material grade, if applicable.
Type(s) Material Specification(s) Nominal Pipe Size(s) Schedule(s)
Pipe
Flanges
Fittings
Gaskets
Bolting

Piping System
Examination Requirements and Details: refer to applicable construction, repair, and/or alteration codes for
minimum requirements
Radiography
Magnetic Particle
Visual
Other

Piping System
Exceptions and Limitations from the Product & Service Index:

Leak Test Reports
Approved By:
Owner-User
Designer
Authorized or

Storage Tank
Equipment General Information:

Form Date: Form #:
Equipment Name: Equipment #:
Description:
Business: Area: Bldg # or Location:

BPF/Drawing #: Construction Code:
Manufacturer Serial #: Year Built:
Type of Tank: Horizontal Vertical Cylindrical Other
Design Limits:
General Size:
Diameter: Length/Height:
Design Corrosion Allowance: Capacity:
Materials of Construction and General Size: note lining
Ring # Material Specification Thickness
Shell:
Flange Material Spec Size Schedule
Nozzles/Flanges/Manway:
Shell Seam Type: Butt-welded Riveted Bolted Other

Head 1 Type: Conical Elliptical Torispherical None Other
Head 2 Type: ConicalElliptical Torispherical Flat Other
Annular Plate: Yes No
Bottom Plate: Material Specification:
For Flat Bottom: Thickness:
Bottom Plate Seam Type: Butt-welded Single Lap Double Lap Other
Efficiency, basis for E

Storage Tank

New Design Limits:
Pressure: Fluid:
New Post-Weld Heat Treatment:
Temperature: Time:
New Materials of Construction: note lining
Provide specification and grade.
Ring # Material Spec and Grade Thickness
Shell:
Flange Material Spec(s) Size Schedule
Nozzles/Flanges/Manway:
Material Specification and Grade Thickness

Head 1:
Head 2:
Examination Requirements and Details: refer to applicable construction, repair, and/or alteration codes for
Radiography
Magnetic Particle
Visual
Vacuum Box
Other

Storage Tank

Leak Test Reports
Approved By:
Owner-User
Designer
Authorized or

Storage Tank
Appendices: Attach supporting documentation when available. (e.g. photos, sketches,

drawings, calculations, analysis, etc…)
Appendix Number Title/Description

Welded Component
Fabrication, Repair, or Alteration Plan
This form is to be used to design the fabrication, repair, or alteration of welded, non-pressure
containing items where weld strength is important. Examples are equipment bases and
supports not covered by pressure vessel, tank, or piping codes; handrails and walkways;
material handling equipment; and other structural and sheet metal components.
Form Date: Form #:
Equipment #:
Description:

Pipe Code #: BPF/Drawing #:
Manufacturer: Year Built:
Fabrication, Repair, or Alteration Information:

Present Work Classified As: Fabrication Repair Alteration
Preheat and Post-Weld Heat Treatment:
Preheat Temperature:
PWHT Temperature: PWHT Time:
Post-Fabrication Cleaning Requirements:
Painting:
Materials of Construction:
Provide material specification, grade, temper or hardness, etc. if applicable.
Description Material Specification(s) Size(s) Other Information

Welded Component
Examination Requirements and Details: refer to applicable construction, repair, or alteration codes for
Radiography
Magnetic Particle
Visual
Other

Welded Component

Material Test Reports Other (list):
Post-Weld Heat Treatment Records
Approved By:
Owner-User
Designer
Authorized or

Appendix B, Inspection and Test Plan and Traveler Form Templates

 Inspection and Test Plan [general]
 Welding Traveler with Isometric
 Welding Traveler with Grid

Page 47 of 54
Inspection and Test Plan
Plant: Revision Number:

Project or Work Order Number: Date:
Equipment Name: Prepared By:
Equipment Number: Date:
Organization Performing Work: Checked By:
Job Number: Date:
Key: H: Hold Point SW: Spot Witness

R: Review F: Witness First Item, Spot Witness Thereafter
W: Witness
Activity Required
Step Specific Item to Review, Examine, Acceptance Criteria and Reference Organization Documents to be
General Description of Step Third Remarks
Number Witness, or Inspect Document(s) Performing DuPont Generated
Party
Work
A Before Work Begins
B During Work
C Final Examinations, Inspections, and Tests
D Final Documentation
Form template issued October 2010 Page 1 of 1

Welding Traveler Page 1
Equipment Name: Design Form #: Work Order #: Traveler #:
Equipment #: Spool or Segment #: Reference Dwg: Date:
Isometric Sketch Specification:
Fabrication/Repair/Alteration Code
Fluid Service Category or Class
DuPont Pipe Code
Leak Test Fluid and Pressure
PWHT Time and Temperature
Post Cleaning Requirements
Paint Preparation and Specification
Welding Procedure
Filler Metal
Material: (include bolting and gaskets)

Item Qty Size, Sch, Flange Class, Dimensions Material Spec and Grade Heat #
Notes and Special Instructions:
See page 2 for hold points and signatures.

Hold points for specified examinations and inspections:

[1] Materials condition and cleanliness [4] After root pass [7] During erection
[2] At fit-up and/or tacking [5] After final weld [8] After erection
[3] Purge settings and verification [6] During leak test [9] None
Welding Examiner Hold Points Inspector Hold Points

Weld # Welder Type of Weld Filler Metal Comments
Process # NDE Initial and Date # NDE Initial and Date
Leak test conducted at (pressure) for (time) by (name) on (date).
Planning Review and Approval:

Author Date
Owner-User Date
Organization Performing Work Date
Inspector Date
Other Date
Work Completion:
Inspector Date Document template issued October 2010
Sketch Specification:
Fabrication/Repair/Alteration Code
Fluid Service Category or Class
DuPont Pipe Code
Leak Test Fluid and Pressure
PWHT Time and Temperature
Post Cleaning Requirements
Paint Preparation and Specification
Welding Procedure
Filler Metal
Material: (include bolting and gaskets)

Item Qty Size, Sch, Flange Class, Dimensions Material Spec and Grade Heat #
Notes and Special Instructions:
See page 2 for hold points and signatures.

Hold points for specified examinations and inspections:

[1] Materials condition and cleanliness [4] After root pass [7] During erection
[2] At fit-up and/or tacking [5] After final weld [8] After erection
[3] Purge settings and verification [6] During leak test [9] None
Welding Examiner Hold Points Inspector Hold Points

Weld # Welder Type of Weld Filler Metal Comments
Process # NDE Initial and Date # NDE Initial and Date
Leak test conducted at (pressure) for (time) by (name) on (date).
Planning Review and Approval:

Author Date
Owner-User Date
Inspector Date
Other Date
Work Completion:
Inspector Date Document template issued October 2010
Appendix C, Non-Conformance Form Template

Page 53 of 54
WELDING QUALITY MANUAL NON-
CONFORMANCE REPORT
Title of Non-Conformance
NCR No. Date:

Site Month Day Year
Site Welding QA/QC Representative
or Site Welding Champion
Person Finding Non-Conformance
Reason for Non-Conformance
Material Specification Project No.

Damaged As-Received BPF No.
Damaged at Site Item No.
Quality Issue P.O. No.
Design or Dimensional Issue Drwg No.
Other (Describe)
Description of Problem
Disposition of Item
(check one)
Usable
Rework
Return
Scrap
Action Taken / Organization Responsible
Name
Title
Completion Date
Month Day Year

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1. Purpose and Scope

Document issued October 2010

Type of Equipment Requirement Basis or Examples

2. Authority and Responsibility

Document issued October 2010

Document issued October 2010

 American Petroleum Institute

Document issued October 2010

Document issued October 2010

o DuPont Pipe Codes

4. Jurisdiction, Code, and DuPont Standard Requirements and Applications

Document issued October 2010

codes, standards and requirements of the Jurisdiction into which the

Document issued October 2010

is installed and operated. If no appropriate codes or standards apply,

Document issued October 2010

5. Design of Fabrication, Repairs and Alterations

Document issued October 2010

Note: “Change” is not limited to alterations or rerating. Fabrication or repair

Document issued October 2010

6. Material Procurement, Control and Storage

Document issued October 2010

Document issued October 2010

6.3.2.2.1 Low hydrogen electrodes, such as AWS EXX15-x, EXX16-

ready to use to prevent contamination from dirt, oil, grease

7. Welding Procedure Specifications and Procedure Qualification Records

Document issued October 2010

Document issued October 2010

7.4 DuPont Corporate Qualified Welding Procedures

8. Welder Performance Qualification

Document issued October 2010

qualified using an approved DuPont Welding Procedure Specification (WPS) or

Document issued October 2010

9. Examination, Inspection and Testing

Document issued October 2010

Document issued October 2010

o The use of third-party examination and inspection is common for

Document issued October 2010

subsidiary shall approve the Inspection and Test Plan to assume

Document issued October 2010

Welding QA/QC Representative or site Welding Champion may delegate tasks to

Document issued October 2010

11. Job Documentation

 U-1or U-1A (manufacturers data report), if applicable

Document issued October 2010

Document issued October 2010

Document issued October 2010

12.6 Suggested Audit Forms and Protocols

Document issued October 2010

Appendix A, Design Form Templates

Document issued October 2010

Equipment Design Basis Information:

Document template issued October 2010 Page 1 of 3

Document template issued October 2010 Page 2 of 3

Records and Documents to Send to the Owner Business Unit:

Organization Performing Work

Document template issued October 2010 Page 3 of 3

Equipment Design Basis Information:

Document template issued October 2010 Page 1 of 3

Document template issued October 2010 Page 2 of 3