Procedure - Fit-Up & Assembly [PDF]

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Procedure For Fit-up and Assembly



Job Number



Document No 2



S



F



Q



S



P



G



FABRICATION DIVISION RELIANCE INDUSTRIES LIMITED, JAMNAGAR



Revision Number E



0



0



6



00



01



02



Date 〉



06/09/0 3



20/0 7/06



03/01/0 7



Prepared By



GR/SE



RR



RR



Department:



Structural Fabrication Shop



Checked By



CLJ



CLJ/ CPB



GR/CP B



Location:



Jamnagar



Approved By



KR



VKS



VKS



Hard copy of this document shall be treated as uncontrolled if not signed by approver For latest revision please check with soft copy.



Total No. of Pages :08



FABRICATION DIVISION RELIANCE INDUSTRIES LIMITED, JAMNAGAR



CONTENTS 1.



INTRODUCTION



2.



PURPOSE



3.



SCOPE



4.



ABBREVIATIONS & DEFINITIONS



5.



RESPONSIBILITY AND AUTHORITY



6.



REFERENCE



7.



FLOW CHART



8.



PROCEDURE



9.



RECORDS



10.



ATTACHMENTS



Procedure for fit-up and assembly Doc. No.: 2 SFQSP GE 006 Rev. 02 Dt:03-01-2007



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Structural fabrication shop Jamnagar



FABRICATION DIVISION RELIANCE INDUSTRIES LIMITED, JAMNAGAR



1.



INTRODUCTION Fabrication division fabricates structures for various clients. Fit up and assembly is an important activity for fabrication of structure. In order to ensure that effective functioning of a quality system requirements are fulfilled, there is a need to establish a quality system involving the functions of fit up and assembly and to ensure the activities are in controlled condition.



2.



PURPOSE The purpose of this procedure is to establish a documented procedure for fit-up and assembly of structural steel to ensure that the specified quality requirements are fulfilled with international quality system and to ensure continuos process stability and to achieve the customer need in time.



3.



SCOPE This procedure is applicable to all the activities related to fit-up and assembly of structural steel at structural fabrication shop



4.



5.



ABBREVIATIONS & DEFINITIONS AM



:



Area Manager



CM



:



Construction Manager



HOD



:



Head of Department



SFS



:



Structural Fabrication Shop



PE



:



Production Engineer



DCC



:



Document Control Cell



NCR



:



Non-conformance Report



NDT



:



Non-destructive Testing



QMD



:



Quality management department



RESPONSIBILITY & AUTHORITY Activity



Responsibility and Authority Manage



Construction Manager Structural fabrication division



Establishing Fit-Up & Perform Assembly Procedure and its implementation



Production Engineer as per departmental QP



Verify



6.



Lead engineer Production as per departmental QP



REFERENCE



Procedure for fit-up and assembly Doc. No.: 2 SFQSP GE 006 Rev. 02 Dt:03-01-2007



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Structural fabrication shop Jamnagar



FABRICATION DIVISION RELIANCE INDUSTRIES LIMITED, JAMNAGAR



Quality Manual (100MAN GE 001) Procedure for Traceability of structural steel works (2SF QSP GE007)



7.



FLOW CHART Receiving priority schedule from planning



Receiving drawings from DCC



Preparing material cutting requisition and cutting plan for splicing of material if required. Preparing additional requirement of material if required



Issuing material cutting requisition & cutting plan of prefabrication in machine shop



Pre fabricated material or steel from machine shop



Fit-up



Fit up inspection with respect to drawings (accepted/ rejected )



NOT OK



Rework as per drawing specification .If accepted sent for welding .



NOT OK



Not accepted sent to scrap area



OK Welding & assembling (assembling carried out if applicable)



Accepted fabricated material sent



to Lay down Area



Procedure for fit-up and assembly Doc. No.: 2 SFQSP GE 006 Rev. 02 Dt:03-01-2007



NOT OK



Rework carried out as per welding Specification (accepted)



NOT OK Not accepted sent to scrap area



OK



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Structural fabrication shop Jamnagar



FABRICATION DIVISION RELIANCE INDUSTRIES LIMITED, JAMNAGAR



8.



PROCEDURE 8.1 8.2 8.3



On receipt of the drawings, priority schedules from planning ( through e-mail/ transmittal ) through DCC . Contractor to withdraw material from stores as per MIN received. a) Physical verification of raw material shall be carried out before issuing the raw material to Engineer (CNC). If any discrepancy was found PE shall raise MDR (Material Discrepancy Report) / FOR (Field Observation Report ) / SER (Site Engineering Request) b) Preparing material cutting requisition format No. 2SF FMT ME041 and same shall be hand over to Engineer (CNC) for pre-fabrication i.e., cutting and drilling operations to be performed by Lead Engineer (CNC).



8.4



Preparing additional requirement of material if any required and same shall be forwarded to Material Controller through e-mail.



8.5



PE (Fit & Assembly) shall co-ordinate with Engineer (CNC) for availability of semifinished material after cutting and drilling.



8.6



Normally PE (Fit & Assembly) shall receive pre fabricated material / steel from machine shop and verify the mark number and material specification (Identification of material specification for plates other than IS 2062 and ASTM A36 shall be done ) with drawing number and ensure the compliance before proceeding for further work. But in some cases & extra ordinary circumstances the under mentioned procedure shall be followed. a) Raw steel / painted steel shall be used directly according to machine load availability. b) Raw steel / painted steel shall be used directly in order to minimize the scrap percentage and utilization of material.



c) Raw steel / painted steel shall be used directly if the available material is less than 2.5 meters ( less than 2.5 meters length can not be processed in cnc machines for drilling. d) For identification and Traceability refer Departmental Procedure no. 2SF QSP GE 007. 8.7



PE (Fit & Assembly) shall responsible for allocating the pre fabricated material for FIT-UP to sub-contractors and inspect the fit-up material for dimensions with respect to drawings/tolerances. If found acceptable shall transfer the item part no/ mark number, drawing number on the item by hard punching for identification.



8.8



In case the dimensions are not acceptable, PE (Fit & Assembly) shall make decision for rework and identified as Rejected by permanent marker.



8.9



Acceptable material shall be processed for weld preparation and fit-up of the parts as per the drawing requirements. Fit-up of the parts shall be done sequentially so as to ensure welding accessibility



8.10 PE (Fit & Assembly) shall check the fit-up dimensions and orientation with drawing. Full penetration joints shall be provided with notch cutting as required by Procedure for fit-up and assembly Doc. No.: 2 SFQSP GE 006 Rev. 02 Dt:03-01-2007



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Structural fabrication shop Jamnagar



FABRICATION DIVISION RELIANCE INDUSTRIES LIMITED, JAMNAGAR



drawings or applicable project specifications to ensure full penetration. If fit-up is found acceptable, PE (Fit & Assembly) shall release the fit-up for welding by signing the inspection report format no. 2 QA FMT ME 003.One copy inspection report is handed over to QMD engineer , one copy inspection report with sub-contractor and one copy sent to planning for updating. After updating the copy shall be retained back from planning. 8.11



In case the fit-up is not found to be acceptable, it shall be rectified and re-inspected



8.12 PE (Fit & Assembly) shall co-ordinate with contractor for getting welding equipment/machine and welding consumable if it is not under the scope of sub contractor. Arranging Qualified welder as per the applicable qualified WPS is under sub contractors scope. 8.13 Control of welding process activities shall be taken by Welding engineer as per procedure No. 2 SF QSP GE011. Weld visual inspection, NDT examination shall be conducted by QMD Engineer as per the requirements of Inspection and test plan and shall release the structural members, if there is no final assembly of the members involved. 8.14 In case of final assembly of the parts is required to be done as per the production plan/drawings, PE (Fit-up & Assembly) shall review the Assembly drawing and list out all member required for assembly and check-up the Inspection and test status of the members with QMD. Only accepted structural steel members shall be taken-up for assembly. 8.15 PE (Fit-up & Assembly) shall ensure that the parts are properly leveled and aligned as per the drawing requirements and shall then verify the assembly dimensions using standard measuring instrument. Assembly dimensions shall be recorded in a dimensional protocol of assembly. 8.16 In case there welding involvement in final assembly, fit-up shall be inspected by PE (Fit-up & Assembly) and Points 8.10 to 8.13 shall be followed. Assembly dimensions shall be rechecked after welding and it shall be recorded in the protocol duly. 8.17 In case of final assembly, PE (Fit-up & Assembly) shall verify if holes are matching and are within the acceptable limit. In case it is found that holes are not matching rework shall be carried out and same shall be registered in rework / Rejection log note. 8.18 Rectification shall verified as per the Inspection and test plan by QMD. Final assembly dimension shall be recorded in protocol format by PE ( Fit-up and assembly ) 8.19 Delivery of fabricated structure / material shall be taken care by production engineer, for external job in co-ordination with stores. If packing is specified by client the following Procedure for Packing 2SF QSP GE 008 shall be followed by production engineer.



Procedure for fit-up and assembly Doc. No.: 2 SFQSP GE 006 Rev. 02 Dt:03-01-2007



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Structural fabrication shop Jamnagar



FABRICATION DIVISION RELIANCE INDUSTRIES LIMITED, JAMNAGAR



9.



RECORDS



Inspection report (2 QA FMT ME 03)



10. ATTACHMENTS NOT-APPLICABLE



Procedure for fit-up and assembly Doc. No.: 2 SFQSP GE 006 Rev. 02 Dt:03-01-2007



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Structural fabrication shop Jamnagar



FORM NO.: 2 QA FMT ME 003 Rev. No.: 00 FABRICATION DIVISION RELIANCE INDUSTRIES LIMITED, JAMNAGAR



CONTRACTOR:



Structural Steel Fabrication Inspection Report



SHEET: 1 OF 1



UNIT / JOB NO.:



REPORT NO: DATE:



Sl. No.



Drawing No.



Rev .No Mark No. .



Mat. grade



WPS No Qty



Material /Fit up / Preheat Weld Visual inspection Dimensional verification temp Contractor RPL Contractor RPL



NDT Report No



Date



Touch up painting



Section Deviation if any :



Splice Detail if any:



Remarks : Note: Welding Inspection shall be certified after completion of all the weld joints against particular mark no.



Contractor SIGNATURE NAME DATE



RIL Execution Engineer



RIL QMD



Client / Third Party



Weight ( Kgs)