Quality control procedure

Procedure for structural work

Scope:

This specification provides procedure for inspection and testing of

equipment,
installation, supports, etc. & Fabrication and erection of piping system,
which are to be fabricated .

SPECIFICATION & STANDARDS:

Is 808 - Rolled steel beam, channel, and angel section
Is2062 - Structural Steel ( Fusion Welding Quality )
Is814 - Specification for cover electrodes for Metal Are
Welding for Weld Steel.
Is 1852 - Specification for Rolling and Cutting Tolerances for hot
Rolled steel products.
Is 2074 - Ready mixed paints, Red Oxide Zinc chromate Primer
Is 3502 - Specification for checkered plate
Is 800 - Code of practice for construction of steel.
Is 7215 - Tolerances for erection of structural steel.

ASME SECTION IX and AWS D1.1

Equipment / Machinery Erection

Levelling / alignment shall be done with the proper shims, wedges; the
pockets/ base plate grouted as suggested by the engineer in charge, In case
of machinery such as pumps, compressors, etc. The alignment should be
perfectly done using good millwright fitters and the alignment readings
properly recorded.

Payment for the equipment / machinery erected weight and shall be

inclusive of everything including consumables such as grouting materials,
special grouts, shims wedges and any other items required for completion
of the work as per the crane hiring charges, cost of all erection tolls and
tackles.
Method of working
Welded Joints.

In general flanged connection shall be used at connection to vessel/

equipment and wherever required for ease of erection / maintenance.
Proper electrodes as specified for the basic piping material shall be used in
welding. Carbon steel electrodes shall be stored in banking ovens till the
time the same would be used in welding. No welding transformer would be
allowed in welding works. The contractor need to mobilise suitable
welding generators /rectifier / transformers sets for this purpose.

All fields welds shall be pre decided and marked in the isometric. Any
deviation need to be approved by the engineer at site.

Location and designs of pipe supports shall be strictly adhered to pipe

supports such as guides, stops, anchors, etc must be in such a manner that
they will not contribute to the over-stressing of a line. Flanged connections
to pumps, blowers, compressors, etc shall not induce any undue stress on
the equipment nozzles. Any slopes provided on various lines properly be
maintained by us and shall be measured using spirit levels.

Welding.
The welding electrodes as recommended by the reputed manufacture
suitable basic piping materials shall be used in works. Root pass shall
preferable be made with 2.5mm (12SWG ) electrodes.

The root pass of butt joints should be executed properly so as to achieve

full penetration with complete fusion of the root edges. Weld projection
inside the piping shall not excess 3 mm. Welding shall be continuos and
uninterrupted during a pass. On completion of each run, crater,
irregularities / slag etc. Shall be removed by grinding and or by chisiling.
Separate clearing tools shall be used for C. S and S.S. works. welding of
pipes in general shall confirm to API 1104. the weld joints shall be free
from porosity, undercuts, lack of penetration, surface cracks and shall have
an apparent good look after the seam is completed. Similarly if a welder is
found welding in a position for which he is not qualified for, he shall be
debarred from doing further jobs immediately and we shall remove him
from the works site.
MATERIALS
1.All materials shall confirm to the requirements of the applicable
standards and approved drawings. Mill test certificate of the chemical
analysis and physical properties of the materials shall be furnished as
required in the specification for material. Materials above 25mm thick
shall be ultrasonically tested for lamination as per SA 435. IS 2062

MATERIAL VERIFICATION
Identification of the materials with the materials test certificates shall be
confirmed prior to fabrication. Also the plate materials except rolled
section which is cut into parts shall be given the identification viz. material
name, plate heat number/cast number similar to the original.

FABRICATION
The fabrication and erection of works shall be carried out generally in
accordance with IS 800 as well as the stipulation contained in these
specification. All materials shall be completely fabricated at shop or at the
shop established at project site and finished with proper connection
materials for ready assembly in the field. Check list formate inspection
certificate for fabrication, alignment of structural steel shall be submitted
to the customer. Fabrication works shall be taken up based on the approved
fabrication drawings.

Cutting plans
The cutting plan shall be prepared before commencement of fabrication for
all fabrication drawings.

Straightening :
All the steel material shall be straight and free bends or twists. If the
sections are distorted or twisted during transit, storage etc. They shall be
straightened and/or flattened by straightening machine at ambient
temperature, through minor bends may be corrected by limited heating
under supervision.

Bending :
The bending of plate and section to specially shapes shall be done on
appropriate machine.
Cutting :
Cutting shall be carried out by gas cutting, by hand or pug cutting
machine. The edges of all plates shall be perfectly straight and uniform
throughout. Cut edges shall be examined visually for laminations and
inclusions.

Holes :
When holes are being drilled in one operation through two or more
separable parts, which shall be separated after drilling and burns shall be
removed.

Finished holes shall not be more than 1.5mm or 2.0mm larger in diameter
than the diameter of the bolt passing through them. Holes for bolts shall
not be formed by a gas cutting process except in special case with
specification of the customer. Wherever a horizontal member is likely to
collect water suitable holes for drainage shall be provided.

Notches
The ends of all joints, beams and grinders shall be cut truly square unless
required otherwise all joints flanges shall be nearly cut away or notched
where necessary, the notches being kept as small as possible.

Assembly
The fabricated components shall be so prepared that the specified chamber,
if any is provided. In order to minimise distortion I a member of
components shall be positioned by using clamps, clips, jigs and other
suitable means and fasteners shall be placed in a balanced pattern.

Items like roof trussed, galleries, plate girders etc. shall be trial assembled
keeping in view the actual site condition prior to dispatch to site for
erection so that they can be conveniently pre assembled before erection or
conveniently pre assembled during erection. Necessary match marks shall
be made on these components before disassembly in the shop and
dispatching.

For columns which are fabricated in two or more parts pre-assembly shall
be carried out in the fabrication yard before dispatch to the erection site.
Bolting :
All bolt and nuts shall be used as per approved fabrication drawing and
specification.

\\

Welding :
Welding procedure qualification and welders and welding operators
performance qualification test shall be made in accordance with ASME
sec. IX/A WS DI.I

The following documents shall be submitted to customer/inspection

agency during final inspection;

a) Welding procedure specification (WPS)

b) Welding procedure qualification record (PQR)

Edge Preparation Inspection

The edges or surface if parts to be joints b welding shall be uniform,
smooth and cleaned from all foreign materials as moisture, slag, oil grease,
paints scale or rust.

Welding groove dimension shall be inspected as per fabrication drawing

under tack welded condition prior to welding.

The allowable misalignment of adjoining plates to be butt-welded shall be

in accordance with IS 7215.

Unless otherwise specified, the tolerance for welding groove dimensions

shall be as follows;
a) Groove Angle : +/-5Deg
b) Root Gap : Subject to welding procedure specification.

Back Chipping Inspection

Back Chipping inspection shall be visually checked to be from any defects
such as crack and other discontinuity.

Visuals Examination of welds

Each reinforcement height for butt welds and leg dimensions for fillet
welds shall be checked in addition to bead contour appearance. In addition,
possible presence of such service defects viz.. undercut, crack, surface,
porosity etc. shall be checked visually.

The reinforcement on each side of butt-welded joints shall be checked in

accordance with ASME Sec. VIII Div. 1 UV-35.

Temporary lunges braces, clips shall be welded in connection with WPS

and these shall be removed without damaging the base metal and the area
ground flash and smooth.

Electrodes
The electrodes used for welding shall be of suitable type and size
depending upon specification of the parent material, the method of
welding, the position of welding and quality of welds desired. However,
only low hydrogen electrode (E 7018) shall be used for plates and rolled
section with thickness above 20mm for IS; 2026 grade. A materials E 6013
electrodes shall be not be kept in the same oven.

Thermo-chalk or other approved methods shall be used for measuring the

plate temperature.

Sequence of welding
The sequence of welding shall be selected to ensure that the components
assembled by welding are free from distortion and large residual stresses
are not developed.

Butt weld in flange plate and/ web plate shall be complete before the
flanges and webs are welded together.

The ends of butt welds shall have full throat thickness. This shall be
obtained on all main butt welds by the use of run off and run on pieces
adequately secured on either pieces of main plates. Additional metal
remaining after the removal of extension pieces shall be removed by
griding or by gas cutting.
Erection
Erection marks shall be clearly painted on the work item each being
marked in at least two places. Each piece shall also have its weights
marked thereon.

DIMENSIONAL CHECK AND FINAL VISUAL

INSEPCTION :
The fabricated steel structure shall be inspected in accordance with
respective approved fabrication drawings and /or specified in standards
.dimensions shall be kept within the tolerance specified in standards /
specifications.

100% visual inspection shall be carried out for external defects.

Test and inspection are subject to witness and/or review of customer

and/or customer’s representative as per approved Field Quality Plan.
(Refer FQP;022).
 PROCEDURE FOR DYE PENETRANT TEST
SCOPE:
• This practice describes techniques for liquid penetrating testing by
solvent removable process using visible dye penetrant at room temp
(16 degree C)

• This NDT uses for detecting surface discontinues which are open to the
surface in any solid material or weld ments

REFERENCE

1. ASME Sec. V Article 6& 24

AWS D 1.2 Sec. 6.7
ASTM E165
IS3658

PERSONAL QALIFICATION:

1. The personal performing Dye penetrant examination should have

level II in
2. accordance with ASNT document SNT-TC-A or any
internationally recognised qualification.

PENETRANT MATERIALS:

1 Any one of the following combinations of various penetrant materials

of particular
make & type shall be used.

Penetrant Cleaner Developer

ASME Sec V Article 6& 24 Check Mate CL96 Checkmate

DV98
P-met/PP 15 Acetone-Commercial P-met/PD3/or
31A

1.Inter mixing of different family materials mentioned above is restricted.

2. Other makes maybe used subject to prior approval with customer.
PROCEDURE:
1. Clean the surface thoroughly with recommended cleaner.

2. Apply penetrant and leave for a contact period of 10-30 Mts. Depending
on the nature of defects sought.

3. Remove excess penetrant from surface with waste cloth.

4. With cloth with cleaner continue wiping until no red discoloration

remains.
Important – Do not spray cleaner directly on to test area.

5 .Developer must be thoroughly shaken prior to application.

6.Spray over test area developer in a thin even coating at @ 12 inch

distance

7. Allow developer to try and stands for 10 Mts. Before inspection for
indication.

8.View under lighting.

SAFETY:
1 Carry out test in conditions of adequate ventilation. Do not smoke whilst
applying.

2 Interpretation and acceptance of indications:

The evaluation of indications and the acceptance criteria shall be in

accordance
with the following standards.

AWS D1.1 Sec. 9 for plate to plate welds.

AWS B31.3 for utility & process piping welds

ASME Sec VIII Div. 1, Div, 2 for pr. Vessels.

IS 3658
 WELDING PROCEDURE SPECIFICATION

WPS NO.:

WELDING PROCESS(ES) : DATE

TYPE(S) PROJECT
SUPPORTING PQR NO. JOB/EQPT.REF.

1.Joints 3.Position
Groove Design Position of Groove
Backing Welding Pregression
Others Others

2.Filler Metals 4.Base Metals

Weld Metal P.No. To
P.No.
Analysis A No. Spec.No. To
Spec.No.
Filler Metal F No. Thicknes range
Spec.No.(SFA) Others
AWS No.(Class)
Size of Electrode 5.Preheat
Filler Preheat Temp
Electrode/Filler Interpass Temp
Composition Preheat
Maintenance
Drying of Electrode /Flux Others
a.Drying Temp
b.Duration 6.Post Weld Heat
Treatment
c.Holding Temp. Temperature
d.Others Holding Time
Heating Time
Cooling Rate
 Others

WELDING PROCEDURE SPECIFICATION

7.Gas 9.Technique
Shielded Gas String or Weave Bead
Gas Composition Initial Cleaning
Flow Rate Inter Pass Cleaning
Purging Gas Method of Back gauging
Gas Composition Oscillation
Flow Rate Contact tube to work Distance
Single/Multiple pass
8.Electrical Characteristic Single/ Multiple Electrodes
Current(AC/DC) Travel speed (Range)
Polarity Others
Others

10.Welding Procedure
a)Joint sketch & Bead sequence

Sequence Wall No. of Electrode Ro

thick Passes filler Dia

Prepared by
Approved by

WELDER QUALIFICATION TEST RECORD

Welder Stamp
Name No.
Passport Using Rev.
No. WPS Date
No.
The above welder is qualified for the following ranges
Variable Actual values used in qualifications Qualification range
Date of test
Process
Process type
Backing metal,Weld flux etc.
Material spec.
Thickness
Groove (QW 425.1)
Fillet (QW 425.6)
Dia.groove (QW 452.6)
Fillet (QW 452.6)
Filler metal
Spec. No.
Class
F No.
Deposited weld metal thk,
Groove fillet
Position (QW 461.9)
Weld Progression
Gas Type
Electrical characteristic
Current
Polarity
Guided Bend Test
Type Result

Test Results
Radiography results
Fracture test
Length & Percent of defect Inches
%
Macro test Fusion
Appearance-Fillet
,Size(Leg)
Test conducted by Laboratory test
No.
We certify that the statement in this record is correct and that the test welds were prepared
welded and tested as per Sec IX of ASME code .

Date By(Signature and stamp)