What is the
use of a diary, to note down your thoughts or note down your meetings and
appointments or note down a days important points or note down anything which
you feel important and notable.
'Site diary' will contain site observations. The observations may
be a new idea or a picture or anything that felt as 'to be noted'. The main aim
of the series is to support and train newbies in this trade.
This post is the output of general quality / procedure
violations at site. This can be used as a daily checklist for
supervisors and trainee engineers at site.
Common Procedure / Quality Violations at site.
1. Portable electrode oven (Quiver) not properly heated.
This may be due to the damage of the quiver or
not connecting it to the power source or the power source is accidentally switch
off. Many a times welder miss this as he is busy in welding and he always use
hand gloves for taking electrode out of quiver. Site engineer has to randomly
check the heating of the quivers using thermochalk or digital thermometers.
2. No identification cards with Welders.
How do you
confirm that a qualified welder is doing the job? We have to ask for his /her welding approval card or welder identification card, where the welder name, the
welder identification number, material qualified, thickness and diameter qualified
and approval dates are given. If any of the welders are doing the job and there
is no welder identification card is with them, you have to stop the welder and
allow to continue only if he produces the identification card. Sometimes after
producing the welder identity card you may come to know that he done a weld
which he is not qualified. Then the rectification procedure for the job or
re-qualification procedure for the welder has to be conducted.
3. Welding is not done by a welder.
There are many
instance where we can see that welding are done by 'others'. It may be a
fabricator, a helper to a welder or anyone who feel that it is a simple job. It
may be a situation that welding is done by the instruction of a welder, where
welder is training his assistant on the job.
welder pool can be maintained only when youngsters are on the
job. It is the duty of each organisation, to give opportunities for new welders.
But the training should not be on the production job. It should be done with
scrap pieces of material. To my opinion if you are seeing that someone is
trying to weld on scrap pieces, educate them, train them and if properly
trained, test them and allow them to do the production job.
4. Welders welding in positions for which they are not qualified.
This happens due to the unawareness of welders. It is better to qualify welders for all position welding (6G) in piping. Special surveillance is required to avoid this. Every day special tool box talk is required for limited position qualified welders.5. Use of unapproved electrodes.
This issue is purely from the issue side of the electrodes. Unapproved electrodes if any has to be stored in separate locations and with proper tags.
6. Baking registers not properly maintained.
This is the lapse from the electrode store keeper. Regular monitoring can eliminate this issue. One supervisor/engineer should be assigned to monitor the electrode issue and review of baking register.
7. Stainless steel materials mixed with carbon steel materials.
This issue can be eliminated by continue awareness only.
8. Stainless steel materials placed on the ground.
This issue can be eliminated by continue awareness only.
9. Stainless steel materials supported by stones from rolling.
This issue can be eliminated by continue awareness to rigging team.10. Using improper grinding wheel for Stainless steel materials.
Toolbox to grinders can eliminate the issue.
11. Flange face protection was not done not.
All the fabrication teams and rigging teams are to be made aware about the issues that may happen when the serration in the flange face are damaged.
12. Unapproved materials used in the site.
This issue arises due to lack of demarcation for the unapproved items.
14. Clits, used for fit-up purposes are not properly color coded.
Clits are to made and specially punches are to made on each one. This will avoid the mix-up of clits.
Though tool box talk and other awareness methods eliminate most of the issues, surveillance has to be made for these issues. If it is intentionally done, strict action against the defaulters has to be taken such as suspension for one day from the job, financial penalty or any other moral actions.
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