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Shane Fluharty

Eric Martin

ENG101 (1074)

20 February 2022

Field Inspection Checklist Form

In the following essay we will be covering the requirement to notify the Authorized Inspector

(AI) of a welding repair and how to properly document and record this by completing the Field

Inspection Checklist (FIC). All welded repairs that fall within code boundaries must have AI

approval before starting. This document will give the site superintendents and quality assurance

personnel who are required to complete the FIC form the guidance and information to properly

complete this documentation. The FIC is an important part of the final Quality Record Book

(QRB) that will be presented to the AI for final approval and ultimately presented to the

customer as the final completion document per contract requirements. See a copy of the FIC at

the end of this document.

First you should have received a link to a file on the Babcock &Wilcox Construction Co.,

LLC (BWCC) OneDrive site that will contain the QRB file, if not contact your quality assurance

personnel assigned to your project and they can assist you. Next you will need locate and open

the .pdf document titled Field Inspection Checklist using Adobe Acrobat or Adobe Pro. If you do

not have one of the Acrobat programs on your computer, you will need to contact the service

desk to have the program installed.

Now that you have the FIC open, in section 1. you will need to Enter the project number and

pan. This number can be acquired from the project’s contract manager. The specific customer,

unit, and location will next need to be installed in section 2. using the following format:
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Customer / Unit / Location. You will then need to write a brief description of the Scope of Work

in the first bulleted cell of section 4. One example would be ‘install 3 dutchman in right hand

water wall.’ In your description you need enough information to clarify what the work will be, so

you can explain clearly when you contact the AI.

In the next bullet cell, you will enter the Material Specification-OD, thickness, & material

type as identified on the project drawings, material test reports and/or code data reports. These

documents should be provided by either the contract manager, customer contact, and/or BWCC

quality assurance. An example of a specification would be a 2”OD x .165”thk SA213T11.

Having identified the material for the repair you can move on to the next bullet where you will

identify the ‘Welding process and electrode.’ In this cell the welding processes that will be used

to make the repair will be listed. The abbreviations for the 4 standard processes BWCC uses are

as follows; SMAW- Shielded Metal Arc Welding; GTAW Gas Tungsten Arc Welding; FCAW

Flux Core Arc Welding; and GMAW Gas Metal Arc Welding. The welding consumables are

designated as EXXXX-XX for SMAW electrodes and ERXXX-XX for GTAW, FCAW, and

GMAW welding wires. The specific data on what process and consumables can be retrieved off

of the Welding Data Sheet (WDS) that will be completed for the QRB.

The next bullet listed is Preheat and PWHT. This data will also be found on the WDS. It will

list the minimum preheat required and the required Post Weld Heat Treatment (PWHT) if

required. If none is required note that no PWHT is required, if required you will note the

temperature and length of time required for the soak at temp as listed on the WDS.

Technical / Jurisdictional Responsibility is the next bullet that will need to be documented.

The AMSE code that covers the repair is what will be listed here. For a boiler proper repair it

will be an ASME Section I. If the repair is performed on piping attached to the boiler it can be
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one of two designations, Boiler External Piping (BEP) or Non-Boiler External Piping (NBEP).

The former, BEP piping, will require the FIC form to be completed and is listed as ASME

B31.1/ASME Section I, the NBEP does not require the FIC to be completed and also does not

need the AI to be contacted. This data can be found on the customer drawings, process and

instrument diagrams specifically can help in denoting the code boundaries; Boiler Proper, Boiler

External Pipe, Non-Boiler External Pipe. There are boundary diagrams associated with each of

the codes that can help determine the code boundary. If unsure of the code that the repair falls

under contact your field quality control personnel or the Quality Assurance department in Akron.

The next bullet, Code Required NDE, will get its data from the WDS form also. It will be

noted on the NDE (nondestructive examination) section of the WDS as to the type of

examination required. Visual examination is required for every weld repair.

The next bullet, Photos Available, is an obvious requirement. The answer to this should

always be yes. The photos may not be available at the time of contact with the AI, but photos of

the damage and repair should be taken to be included in the final QRB package. If unavailable at

time of contact with the AI, it can be noted that photos will be included with the final package.

The next bullet ‘Will pressure test be performed . . .’ will require the BWCC site personnel to

discuss with the customer representative if the site has the capability to perform a pressure test

that will cover the location of the repair. If yes, delete ‘If not what alternative method has been

agreed upon by AI.’ from the bullet section and enter Yes with the planned pressure and the

length of time that the pressure will be held. If the answer is no a form of NDE in lieu of

pressure testing will need to be performed. This will require AI concurrence. When the AI is

notified of the repair the BWCC personnel will need to give the AI a reason that the pressure test

cannot reasonably be performed. An example would be valves that are damaged and unable to
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hold the required pressure. The alternate NDE will need to be presented to the AI and noted on

the document. As noted above delete ‘If not what alternative method has been agreed upon by

AI.’ And enter the following NDE in lieu of pressure testing will be performed using ______.

The various forms of NDE testing will be; dye penetrant testing (PT); magnetic particle

testing(MT); ultrasonic testing (UT); radiographic testing (RT); and phased array testing

(PAUT).

At this point you should be ready to contact the AI and discuss the planned repair. Using the

FIC to inform the AI of what all is planned. The AI may have questions or concerns about the

repair. Answer any questions you can for the AI. Depending on the repair the AI may want to set

inspection points, these will need to be described in the next blank bullet on the sheet. If there are

multiple inspection points such as weld fit up, or final visual weld inspection note in separate

bullets. Also, if inspection points are set by the AI you will need to check the box in section 3

addressing inspection points. At this time, you can also check the box in section 3 for the

notification(s) used to contact the AI, email or phone conversation.

Now that you have had a conversation with the AI and covered the details of the repair

hopefully you have gotten consent to proceed with the repair noting on the FIC any changes the

AI may have require. In the bullet point containing, ‘Has AI approved the repair plan?’, you will

need to document the approval with the following statement. (AI Name) AI has approved this

repair plan on (Date) @ (Time). This document will need to be presented to the AI either upon

the next site visit, or upon the presentation of the final document for review and signature.

This outline should of the process and requirements for the FIC report should allow the

BWCC field personnel to complete their documentation and meet the requirements for

notification of the AI. This step by step gives you a reference for what documents and
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information will be needed to complete the document. By following these steps your interactions

with AI should be simple conversation and help you to transition from planning to the actual

repair process. If at any time in the process you have a question or concern contact the BWCC

Quality Assurance department.