Procedure - Fit-Up & Assembly

 

 

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 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 ensure continuos process 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 sent accepted to scrap area

OK Welding & assembling (assembling carried out if applicable 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 

On receipt of the drawings, priority schedules from planning ( through e-mail/

transmittal ) through DCC . 8.2 

Contractor to withdraw material from stores as per MIN received.

8.3 

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 semi-

finished 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 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 par ts shall be done sequentially sequentiall y 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 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

equipment/machine

and welding consumable

for getting

welding

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 al l 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. instrument. Assembly dimensions shall be recorded in a dimensional 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 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 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 following Procedure 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: CONTRACTO R:

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 N No o Qty

Material /Fit up / Weld ld Visu Visual al insp inspec ecti tion on Dimensional verification Preheat We temp Contractor RPL Contractor RPL

ND NDT T Repo Report rt No 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 Note against particular mark no.

Contractor SIGNATURE NAME DATE

RIL Execution Engineer

RIL QMD

Client / Third Party

Weight ( Kgs)