FABRICATION PLAN

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Fabrication Plan

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INDEX Page No.

1 Project Particulars 3
2 Sub-Contractor(Zamil) Organisation detail 4
3 List Of Codes used for Fabrication 7
4 Specification details of materials used 8
5 Mill Certificate Sample 9
6 Shop Drawing Sample 10
7 ZS Standard Quality Assurance Plan 11
8 Manufacturing Process flow chart 13
9 Inspection flow chart 14
10 ZS Weld Map 15
11 Identification & Traceability Procedure 17
12 Fabrication Tolerances 20
13 Incoming Inspection Procedure 31
14 Dimensional Inspection Procedure 34
15 Welding Inspection Procedure 36
16 NDT Procedure 39
17 Weld Repair Procedure 77
18 Surface Preparation & Painting Procedure 83
19 Paint Repair Procedure 86
20 Final Inspection Procedure 89
21 Welding Procedure Specifications 91
22 Procedure for crane bracket welding steel columns 111
23 QC Formats 112
24 Appendix
A. List of qualified welders 146

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B. List of qualified NDT Personnel 148

1. Project Particulars:
Building Parameters:

Width (m): 81.000 Width Reference: CENTERLINE TO CENTERLINE OF COLUMN GRID

Length (m): 167.000 Length Reference: CENTERLINE TO CENTERLINE OF COLUMN GRID
Height Reference: CLEAR HEIGHT: 10.100 M
Frame Type: SINGLE SLOPE
Bays Spacing’s (m): [email protected], [email protected]
Frame Profile Distribution: 18@01
Width Modules (m):

Profile No 01 GABLE 01: MS-2([email protected] , [email protected] , [email protected])

End walls

Wall Type Profile Wind Columns (m)

LEW: RIGID FRAME 01 [email protected] , [email protected] , [email protected]

REW: RIGID FRAME 01

1) There is cut off portion BX3 to BX4 in between BY29 to BY32.

2) One another area GL BX4 to BX4b in between GL BY29 to BY32 is having reverse slope. For this
clear height is 3.5m at GLBX4.
3) This area is coming GL BX3 to BX6 in between BY15-BY32.
4) Intermediate column along GL BX4 and BX5 in between GL BY16 to BY28 are full height RCC
column.
5) Connection of these columns has to be designed as pinned base. But periphery columns are PEB
columns.
6) Holes for hanging equipment in all purlins shall be provided at 1m spacing.
7) Fabrication tolerances - Flatness of end plate - H<1.0mm; J<1.0mm
8) Bottom connection of all columns fixed connection.
9) Double side welding has to be considered for all built-up sections.
10) Refer customer drawings for bracings location.
11) Column depth is limited to 1m.Refer customer drawings no. 22.
12) 54MM DIA HOLE WILL BE PROVIDED FOR THE ANCHOR BOLT AT BASE PLATE AT TOP OF RCC
COLUMN.
13) LEW WIND COLUMN SPACING AS PER DESIGN.
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14) GL BX3 has to be designed for future expansion for area 2 and it should have provision for
putting new column on existing column to match the height of area 2 height in future. Area 6 is
lower height portion.
15) Consider 3 no’s templates for each column type.
16) Provide 500 dia holes in template for concrete pouring.

Primary Members PAINTED

Primary Surface Treatment STANDARD
Primary Paint System SPECIAL
01 ZS AT SHOP 40 STANDARD GREY OXIDE PRIMERS
02 ZS AT SHOP 50 SMOKEGREY (0616) MATCHING WITH ASIAN MAKE COLOUR SHED. (SYNTHETIC
ENAMEL PAINT)

2. Sub Contractor (Zamil) Organisation Details.

Zamil Steel was established in 1977. The company specializes in the design, fabrication and supply
of Pre-Engineered steel Buildings (PEB). Over the past 30 years, it has grown from a local single
division company into a leader in the growing field of steel fabrication in Asia, Africa and Europe.

The World Leader in Steel Construction Industry:

Since its inception, Zamil Steel has supplied over 55,000 buildings to more than 90 countries
worldwide, from Panama and Mexico in the West to the Philippines, China, Japan, Australia and
South Korea in the east, this stands the proof our expertise. As an Industrial Leader, Zamil Steel
excels in engineering, fabrication, sales and project management and offers its clients a diverse
range of products to compile a total building solution. ZS supplies buildings for diverse Industrial,
Commercial, Agriculture, Aviation, entertainment, military applications and support of
infrastructure and `development projects which makes Zamil Steel one of the Largest Steel
Fabrication Company in Middle East, Asia and Europe.

Zamil Steel’s Industrial Product Verticals:

• Pre-Engineered Buildings (PEB)
• Structural Steel Division (SSD)
• Process Equipment Division (PED)
• Tower & Galvanizing (T&G)
• Buildings Components Solutions (BECOMS)
• CANAM Asia Ltd. (CAL) [Open Web Joists & Beams]

Pre Engineered Division (PEB): Manufacturing Network:

Zamil Steel manufactures a total 500,000 MT of fabricated steel per annum of low & high rise steel
buildings and structures through it’s 10 state of art manufacturing facilities in the following
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countries:
• 5 In Saudi Arabia (Dammam)
• 1 In Egypt (6th October City)
• 2 In Vietnam (Hanoi & Ho Chi Minch City)
• 1 in United Arab Emirates (Ras Al Khaimah)
• 1 in India (Ranjangaon, Pune)

Altogether these factories manufacture and supply over 6 million square meters of premium Pre-
Engineered steel buildings per annum and delivered across the world. The unique manufacturing
process of PEB buildings under factory conditions provides efficiency and high quality. Automated
welding lines and painting lines are used by major manufacturers like Zamil. Use of machines that
utilize CNC ensures very little error margin. In the end the
finished product is subjected to the quality tests to ensure error free output. This unique
manufacturing & quality control process under one facility enable us to ship 100% finished product
to the site and installed at site without any site fabrication.

Global Sales & Distribution Network:

You can experience our services through our SALES NETWORK of 63 area offices located in 39
countries. They are staffed and equipped to provide you with detailed quotations and proposal
drawings for your steel building inquiries, and site support for your ongoing projects. Apart from
our direct sales office, we have 40 certified builders
in 22 countries, 11 Agents throughout Asia, Africa & Europe who is part of our sales network ready
to support you locally.

Zamil Steel’s India Operations:

The establishment of Zamil Steel Indian operations was announced during the historic visit of the
Custodian of the Two Holy Mosques King Abdullah bin Abdul Aziz to India back in January 2006.
Zamil Steel buildings India has started its commercial production from their new factory in India
since February 2008, which is located in Pune, Maharashtra state. The factory & head office in India
is strategically located to reach our customers faster and provide better service locally. This factory
is the latest in the row of six PEB manufacturing facilities worldwide. The state-of-the-art
manufacturing facility on a total area of 87,000 square meters is capable of producing complete
pre-engineered steel buildings. This factory has an invested production capacity of 45,000MT per
annum. Pune facility is already producing and supplying high-end pre-engineered steel buildings to
various customers all over India. Since the start of commercial production in February 2008, Zamil
Steel India has supplied more than 450 projects comprised of more than 500 buildings, with an
approximate area of ‘One” million M2 of Complete PEB building including its’ related
accessories.

Zamil Steel India Corporate Head office:

Zamil Steel India's corporate head quarter is located in Kharadi, Pune, and Maharashtra. Which is
approximately 10KM from the Pune Central railway station and 8 KM from the airport. The
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executive management, HR Admin, Finance, Marketing, Customer service, Estimating, Engineering

departments are functioning from this office.

Zamil Steel India Sales network:

Our SALES NETWORK IN INDIA comprised of Ten sales offices (Pune, Mumbai, Ahmedabad, Delhi,
Ranchi, Bhubaneswar, Hyderabad, Banglore, Chennai and Cochin) and six resident Sales personnel
( in Kolkata, Chandigarh, Jamshedpur, Baroda, Madurai & Coimbatore) that can support our
potential clients at the early stages of their building project. A typical Zamil Steel sales office
consists of a Sales Manager, Sales Engineer(s), Sales support Engineer & Site Engineer(s) who are
equipped to provide speedy response to your enquires related to the Pre-Engineered steel building
project.

Our Engineering Capabilities:

Zamil Steel provides value engineering services to their customers by adopting the modern
engineering practices and methods which is the best available in the industry.
Zamil Steel has well established and ADVANCED ENGINEERING centers in
(India)
• Chennai, Tamil Nadu
• Cochin, Kerala
• Pune, Maharashtra

We are one of the few PEB companies that have a dedicated and highly experienced R&D
department for developing new products and software as well as enhancing new products. More
than 600 engineers are at work for the consistent flow of design, process and product innovation,
bolstering Zamil Steel Industries position as a Global Industry Leader by giving value added
Engineering solutions to your steel building projects.

Pre-Engineered Building (PEB) System:

Our pre-engineered building system is unmatched in its speed and value. Buildings, to suit specific
needs, are designed, engineered, manufactured and shipped in less than 8 weeks and at a cost that
is as low as 30 percent of the cost of conventional steel buildings (when compared to speed of
occupancy and space usability). Clear spans up to 93 meters wide and eave heights as high as 30
meters are possible. Zamil Steel meets & exceeds International quality and design standards.
Unless otherwise required, Zamil Steel buildings are designed and manufactured in accordance
local codes (IS) besides the US codes (MBMA, AISC, AISI, AWS),

Functional versatility of PEB’s:

There is literally no limit to the scope of application of PEB buildings. This functional versatility
makes pre-engineered steel buildings suitable and attractive for a variety of applications like;

• Agricultural • Aviation
• Commercial • Educational
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• Hospital, • Industrial,
• Institutional • Recreational

3. List of Design Codes:

The Pre-Engineered Building described in these calculations was designed according to the
latest U.S.A. Buildings and Design Codes and Indian design codes that have been referred to
in the design:

1. The loads as described in the Design Summary Sheet have been applied on
the structure in accordance with; The IS875-PartIII, Code of practice for design
loads (Other than Earthquake) for Buildings and structures. By Bureau of Indian
Standards

2. Seismic Load Calculation as per IS-1893-2002

3. Hot rolled sections and built up components have been designed in

accordance with: The Ninth Edition (1989) of the Manual of Steel Construction
– Allowable Stress Design, By American Institute of Steel Construction, Inc.
(AISC) 1East Wacker Drive, Suite 3100, Chicago, Illinois 60601-2001, USA

4. Cold formed components have been designed in accordance with:

The 1986 Edition of Cold Formed Steel design Manual, Addendum. By American Iron
and Steel Institute (AISI) 1000 16th Street, NW, Washington, DC 20036, USE.

5. Welding has been applied in accordance with: The Edition (2006) of Structural
Welding Code – Steel (AWS D1.1M: 2006) By American Welding Society (AWS)
550 NW LeJeune Road, Miami, FL 33126, USA

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4. Specification details for materials used:

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5. MILL CERTIFICATE SAMPLE

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6. SHOP DRAWING SAMPLE

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ZS QAP

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7. ZS STANDARD QAP

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8. Manufacturing Process Flow Chart

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9. Inspection Flow chart:

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ZS WELD MAP

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10.ZS WELD MAP

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IDENTIFICATION &
TRACEABILITY
PROCEDURE

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11. IDENTIFICATION & TRACEABILITY PROCEDURE:

1. TITLE:
Procedure for identification and traceability of raw material & finished
products.

2. PURPOSE :
To follow a uniform system for the identification and traceability of raw
material and finished products during all stages of manufacturing and
shipping.

3. IDENTIFICATION OF INCOMING MATERIAL:

All raw material, hot rolled plates/sections and coils shall have the following
information - Size, Specification, Heat, Coil or cast Number tagged or printed
on it

4. TRACEABILTY OF MATERIALS :

4.1 Steel Plates shall be traceable to the mill certificates received by the heat or cast
number
4.2 PEB has standardized the use of Hot Rolled Plates ASTM A 572 Gr-345 plates. Hence
the heat no is not transferred to the individual product components. If required as
per job specifications, the TC of steel plates or coils used for a particular job can be
given to customer, but individual part wise traceability cannot be maintained
4.3 QC shall review the mill certificates during inspection of the raw materials and shall
file with the TCs
4.4 Traceability can be maintained for sheetings if required as per job specifications

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11. IDENTIFICATION DURING MANUFACTURING :

5.1 All primary members shall be hard stamped / stenciled with the Job No.
Building No. Phase no. and Part mark as per following marking scheme.

Job No. Part Mark

XY - ZZZZ - AA - BB XX - XXXX - XX

Phase No. Color Code

Building No. Part No.

Job No. Member Category

Receiving Territory

5.2 All secondary members & components shall have the part mark, job no &
quantity hand written on the bundles

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FABRICATION
TOLERANCES

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12. FABRICATION TOLERANCES:

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B) BUILT-UP MEMBERS (MBMA 1986, SECTION 9.2.2)

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A) BUILT-UP MEMBERS:

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INCOMING
INSPECTION
PROCEDURE

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13. INCOMING INSPECTION PROCEDURE:

1. PURPOSE:
To establish and maintain documented procedures to ensure incoming inspection is
carried out to get the desired quality product.
2. SCOPE:
This work instruction is intended for inspection of incoming materials before using
for production. Eg. Coils, HR Plate, Welding Consumable, HR sections, buyout and
paint materials.
3. RESPONSIBILITY:
Engineer/ Inspector QC
4. INSTRUMENT USED:
Micrometer, Vernier, measuring tape, thread string etc.
5. INSPECTION FLOW CHART:

Received GRN & TC from

Stores

Review the TC as per PO & If not found OK

Job specifications

Visual & Dimensional inspection If not found OK

as per specifications

Ok
Hold / Reject
Clear the material material & Raise
for Production NCR

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Clear the GRN & forward to

Stores

6. ACCEPTANCE CRITERIA:
As per relevant specifications

7. RECORDS:
Heat / Batch Test Certificate

8. REFERENCE DOCUMENT:
QAP, Relevant Specifications

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DIMENSIONAL
INSPECTION
PROCEDURE

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14. DIMENSIONAL INSPECTION PROCEDURE:

1. PURPOSE:
To establish and maintain documented procedure to ensure that the in-process
inspection is carried out to get the desired quality product.
2. SCOPE:
This work instruction is intended for the dimensional inspection done in the sundry,
cold forming & fit up stages
3. RESPONSIBILITY:
QC Engineer / Inspector
4. INSTRUCTION:
4.1 Identify the fabricated part mark by noting the part mark stencilled or written on
the job

4.2 Ensure inspection is done by calibrated instrument

4.3 Check the dimensions as per the shop sketch
4.4 Check if all dimensions are within the ZS fabrication tolerances
4.5 If job meets the requirements, then release it for next operation, if not found OK
then raise NCR
4.6 For reworked jobs, check if the job is within the acceptable limits after the rework
& release the job if found satisfactory

5. RECORD:
ZS inspection report - ZS/QC/IR/04,05,06, 07
6. REFERENCE:
Shop Sketch, ZS Fabrication Tolerance, QAP

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WELDING INSPECTION
PROCEDURE

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15. WELDING INSPECTION PROCEDURE:

1. PURPOSE:
To establish and maintain documented procedure to ensure that welding inspection
is carried out to get the desired quality product
2. SCOPE:
This work instruction is intended for the welding inspection
3. RESPONSIBILITY:
QC Engineer / Inspector
4. INSTRUCTION:

1. Checks Before & During Welding:

1.1 Ensure qualified welder is doing the welding

1.2 Ensure welding is done as per the WPS & qualified welding position
1.3 Ensure area to be welded is free from base metal imperfections &
impurities
1.4 Ensure filler metal is appropriate & free from damages
1.5 Ensure joint preparation as per the WPS
1.6 Ensure proper joint fit up & alignment
1.7 Ensure preheating & interpass requirements are identified & maintained

2. Checks after Welding:

2.1 Check weld visual appearance as per AWS D1.1:2006, Section 6 Table 6.1
2.2 Check fillet size as per Weld Map or shop sketch
2.3 Check double side weld requirement as per Weld map or for any special job
shop sketch requirement
2.4 Perform NDT as per the QAP & NDT Procedure

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2.5 Check weld distortion & other dimensions are within the ZS Fabrication
tolerances
2.6 Ensure Weld cleaning as per AWS D1.1:2006 – 5.30

If job meets the requirements, then release it for next operation, if not found OK
then raise NCR;
For reworked jobs, check if the job is within the acceptable limits after the rework
& release the job if found satisfactory

5. RECORD:
ZS inspection reports - ZS/QC/IR/07, 08 & 10
6. REFERENCE:
Shop Sketch, ZS Fabrication Tolerance; QAP

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NDT PROCEDURES

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UT PROCEDURE

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16. NDT PROCEDURE:

UT PROCEDURE
1.0 SCOPE:
This procedure covers method for the manual Ultrasonic testing requirements,
procedures & acceptance criteria of fusion welded joints with thickness above 8 mm to
200 mm on carbon and low alloy steel hot rolled shaped/Plates, in accordance with AWS
D1.1.

2.0 REFERENCE DOCUMENTS:

The latest edition of the following documents shall be referred to in conjunction with
this procedure.
 AWS D1.1 2006- Structural welding code-steel

3.0 QUALIFICATION
3.1 Qualification of Operator / Inspector -Personnel performing Ultrasonic examination
to this procedure shall be qualified & certified in respective NDT techniques in
accordance with SNT- TC-1A latest Accepted edition published by ASNT.
3.2 All inspections indicated in this specification must be performed & assessed by
qualified Level-II /Level-III personnel only.
3.3 Abbreviation:

ASNT- American Society For NDT

SDH-Side Drill Hole FSH- Full Scale Height BWE-Back wall echo.
4.0 EQUIPMENT:

4.1 Equipment used for Ultrasonic testing shall be capable of generating frequencies in
the range of least 1 MHz to 5 MHz.
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4.2 A Scan, Pulse Echo equipment shall be used for examination (i.e. Einstein-II/EEC-
Make equivalent) with valid calibration certificate as per AWS D1.1 shall be used
with following requirements.
4.2.1 Horizontal linearity – It shall be checked with V1 block,V2 block & Straight
beam probe. A Straight beam probe shall be coupled to 25 mm thickness & five
BWE is adjusted on 1-5 division by using Delay & Range control. First BWE shall
be adjusted on second division by delay control. Fifth BWE shall be adjusted on
fifth division by range control. Each indication shall be adjusted to reference
level with the gain control for horizontal location examination.. Horizontal
linearity shall be with in ± 2% screen width. It will be checked after every 40
hrs. in each distance ranges.
4.2.2 Gain control Linearity/db accuracy- For details refer annexure-A
4.2.3 Internal reflection-Maximum internal reflection from each probe shall be
verified within 40 hrs.
After sensitivity check remove the probe & add 20 db than reference level. The
screen area beyond 12 mm sound path & above reference level height shall be
free of any indication.
4.3 Straight beam Search units- Straight beam probe shall be round & having frequency
2-4 MHz have a diameter 10- 25 mm.
4.4 Angle Beam Search unit- Angle beam probe shall be square & having frequency 2-4
MHz have a size 8 x 9 mm. & 45º, 60 º.or 70 º.
4.4.1 Angle beam transducer exit point / real angle check:
After calibrating the time base of instrument, exit point and real angle of the
transducer shall be checked. Exit point and angle of the transducer shall be
checked with the IIW block as shown Fig. 1.If the angle of the transducer is
out by more than 2°, transducer shall be replaced, and calibration starts from
the beginning.

4.5 Daily and Periodic equipments checks like range & sensitivity shall be carried out.
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4.6 db accuracy adjustment shall be done every 2 months, records shall be kept on file
in calibration log and horizontal linearity check shall be done for every 40 hours of
use.

5.0 CALIBRATION BLOCKS:

5.1 Calibration & reference blocks shall be provided so as to enable system. Calibration in
accordance with the referencing code. These blocks may include but are not limited
to the following.
a. IIW-Ultrasonic reference block (See fig.1)
b. RC Resolution reference block (See fig.2 )
c. Distance and Sensitivity (DS) block (See fig. 2)
6.0 CALIBRATION FOR TESTING:
6.1 Position of reject control-All calibration & testing shall be done with the reject control
turned off.
6.2 Technique-Calibration for sensitivity & Horizontal sweep shall be made by the UT
operator just prior to and at time of testing.

6.3 Recalibration-
Recalibration shall be made after a change in operator. Each 30 minute maximum
time Interval or when the electrical circuitry is disturbed in any way which includes
the following.
Probe change. Battery change. Electrical outlet change. Coaxial cable change. Power
outage.
6.4 Range Calibration:
6.4.1 Angle Beam: Set up the instrument for angle beam examination. Enter the
refracted angle into the instrument. The transducer shall be set at position
D(fig 4) on the IIW block and the instrument shall be adjusted to attain
indications at 100 mm and 200 mm. The distance calibration must be based
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on sound travel path and shall be made using the 125 mm or 255 mm scale
whichever is appropriate. However, if joint configuration or thickness
prevents full examination at either of these settings use the 375 mm or 500
mm scale.
6.4.2 Straight Beam: Set up the instrument for straight beam examination. Apply the
probe to face A(see fig. in Table 1) and calibrate for range such that at least
two plate are presented on the screen.

6.5 Sensitivity Calibration:

6.5.1 Angle Beam: Set the transducer at position A(fig. 4) on the IIW block and
maximize the indication from the 1.5 mm hole. Set the maximized indication
to 80% full screen height. Set the gain at this stage as the reference gain.

6.5.2 Straight Beam: Calibration for straight beam testing of base metal shall be
done as follows. Subsequent to calibration for range apply the transducer to
Face A (See fig. in Table 1) and adjust the sensitivity such that the first back
reflection is approximately between 50 to 75% FSH.
7.0 Testing Procedure:
7.1 Extent of examination
7.1.1 An “X” line for discontinuity shall be marked with respect to the centreline of
the butt joint welds.

7.1.2 An “Y” line for weld identification, face ID direction & distance from X.

7.1.3 Surface Condition-The base material surface shall be free from rust. Loose
scale. Weld spatters notches. Groove & outer surface irregularities or
substances that could interfere with the examination. Scanning surfaces &
surfaces from which the sound beam is reflected may be assumed to be
Satisfactory. Surface finish shall be minimum 125 µm. Parent material in the
scanning zone area shall be examined with straight beam probes (prior or

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after welding) in order to include presence of Imperfection or high

attenuation.

7.1.4 Couplants- A couplant material shall be used between the search unit & the
test material. The couplant shall be starch & water mixture of a suitable
consistency. A wetting agent may be added if needed or light machine oil
may be used as a couplant. Same couplant shall be used on calibration blocks
as on the item to be tested.

7.1.5 Extent of Testing-The base metal shall be scan with straight beam probe for
laminar reflector. If any Area of base metal exhibits total loss of back
reflection or any indication equal to or greater than the original back
reflection height is located in a position that will interfere with the normal
weld scanning procedure. Its size. Location & depth from the A face shall be
determined & reported on the UT report & an alternate weld scanning
procedure shall be used.

7.1.6 Reflector Size- The defect length wherever warranty by discontinuity amplitude shall be
done with 6db drop method.

7.1.7 Inaccessibility-If due to lamination weld is inaccessible for testing. The testing
shall be conducted using other search unit angles or weld surfaces shall be
ground finish or testing shall be performed from Face A & B whichever
accessible.

7.1.8 Testing of welds- Weld shall be inspected using angle beam probe. After
calibration & during testing the only instrument adjustment allowed is the
sensitivity level adjusted using gain control. Sensitivity shall be increased
from the reference level for weld scanning n conformance with Table-2
7.1.9 Scanning-Test angles & scanning level as follows:

7.9.1.1 Scanning shall be performed manually via. The contact method by

moving the test probe over the examination surface so as to scan
the entire volume and adjacent area of the weld to be examined.
7.9.1.2 Each pass of the search unit shall overlap the previous pass by a
minimum 10% of the dimension of transducer element.
7.9.1.3 The speed of scanning shall not exceed 150 mm/s.

7.1.10 All butt joint welds shall be tested from each side of the weld axis. Corner and

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T-joint welds shall be primarily tested from one side of the weld axis only. All
welds shall be tested using the applicable scanning pattern or patterns shown
in figure 3 as necessary to detect both longitudinal and transverse flaws. It is
intended that, as a minimum, passing sound through the entire volume of
the weld and the heat-affected zone in two crossing directions test all welds,
wherever practical.
7.1.11 when a discontinuity indication appears on the screen, the maximum
attainable indication from the discontinuity shall be adjusted to produce a
horizontal reference level trace deflection on the display. This adjustment
shall be made with the calibrated gain control (attenuator), and the
instrument reading in decibels shall be used as the “Indication Level,” “a,” for
calculating the “Instrument Rating.” ”d”

7.1.12 The “Attenuation Factor”,”c” on the test report shall be attaining by

subtracting 25 mm from the sound path distance and multiplying the
reminder by 2.This factor shall be rounded out nearest dB value. Fractional
Values less than 0.5 or greater increased to the higher level.

7.1.13 The “Indication rating”.”d” represents the algebraic difference dB between

the indication level and the reference level with correction for attenuation
as indicated in the following expressions:

Instrument with gain in dB: a-b-c = d

Instrument with attenuation in dB: b-a-c = d

7.1.14 The Length of the flaws shall be determined as per the procedure stated in
clause 9.2

7.1.15 Each weld discontinuity shall be accepted or rejected on the basis of its
indication rating and its length as per Table 2 for statically Loaded structures
or Table 3 for dynamically loaded structures, whichever is applicable. Only
those discontinuity, which are rejectable,need to be recorded on the test
report, except that for welds designated in the contract documents as being
“Fracture Critical,” acceptable ratings that are within 6dB,inclusive,of the
minimum reject able rating shall be recorded on the test report.

7.1.16 Each reject able discontinuity shall be indicated on the weld by a mark
directly over the discontinuity for its entire length. The depth from the
surface and indication rating shall be noted on nearby base metal.

7.1.17 Welds found unacceptable by ultrasonic testing shall be repaired by methods

permitted by AWS D1.1.Repaired areas shall be re-tested ultrasonically with
results tabulated on the original form (if available) or additional report forms.
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8.0 SCANNING PATTERN:

8.1 Longitudinal Discontinuities

8.1.1 Scanning Movement A: Rotation angle a=10

8.1.2 Scanning Movement B: Scanning distance b shall be such that the section of
weld being tested is covered.

Scanning Movement C: Progression distance c shall be approximately one-half the transducer

width.

Note: Movements A, B & C are combined into one scanning pattern.

8.2 Transverse Discontinuities:

8.2.1 Scanning Movement D is to be used when welds are ground flush.

8.2.2 Scanning Movement E is to be used when weld reinforcement is not ground

flush. Scanning angle e=15 max.

Note: The Scanning Pattern is to be such that the full weld section is covered.

9.0 FLAW SIZE EVALUATION PROCEDURE:

9.1 Straight (longitudinal) Beam Testing:

The size of lamellar discontinuities is not always easily determined, especially those
that are smaller than the transducer size. When the discontinuity is larger than the
transducer, a full loss of back reflection will occur and a 6 Db loss of amplitude and
measurement to the centerline of the transducer is usually reliable for determining
flaw edges. However, the approximate size evaluation of those reflectors, which are
smaller than the transducer, must be made by beginning outside of the
discontinuity with equipment calibrated as per Sec.5.3.2 and 5.3.5.2 of this
procedure and moving the transducer toward the area of discontinuity until an
indication on the screen begins to form. The leading edge of the search unit at this
point is indicative of the edge of the discontinuity.
9.2 Angle Beam (Shear) Testing:

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The following procedure shall be used to determine lengths of indications, which

have dB ratings more serious than for a Class 0 indication. The length of indication
shall be determined by measuring the distance between the transducer centerline
locations where the indication rating amplitude drops 50% (6dB) below the rating
for the applicable flaw classification. This length shall be recorded under”
discontinuity length" on the test report. Where warranted by flaw amplitude, this
procedure shall be repeated to determine the length of Class A, B and C flaws.

10.0 ACCEPTANCE LEVEL:

All indication with echo amplitude & length exceeding the Table-1 limit are
unacceptable.

11.0 CLEANING:

After the examination part shall be thoroughly cleaned to remove all traces of
couplant.

12.0 IDENTIFICATION OF REJECTED AREA

Following inspection, each reject able discontinuity shall be indicated on the weld by
a mark over the discontinuity for its entire length, where possible, and the depth
from the surface shall be noted nearby.
13.0 REPORTING:
The Inspector shall report findings of the Ultrasonic Test using the UT Inspection
Report – ZS/QC/IR/10 Rev 02

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APPENDIX- 1

1. EQUIPMENT QUALIFICATION:
1.1 Horizontal Linearity Procedure:

Note: Since this qualification procedure is performed with a straight beam search
unit, which produces longitudinal waves with a sound velocity of almost double,
that of shear waves, it is necessary to double the shear wave distance ranges to be
used in applying this procedure.

Example: The use of a 10 in. [250 mm] screen calibration in shear wave would
require a 20 in. [500mm] screen calibration for this qualification procedure. The
following procedure shall be used for instrument qualification (see Annex X, X3, for
alternative method):

1.1.1 A straight-beam search unit shall be coupled meeting the requirements of

6.22.6 to the IIW or DS block in Position G, T, or U (see Figure 6.26) as
necessary to attain five back reflections in the qualification range being
certified (see Figure 6.26).

1.1.2 The first and fifth back reflections shall be adjusted to their proper locations
with use of the distance calibration and zero delay adjustments.

1.1.3 Each indication shall be adjusted to reference level with the gain or
attenuation control for horizontal location examination.

1.1.4 Each intermediate trace deflection location shall be correct within 2% of the
screen width.

This test is recommended to be done at every 40 hours of instrument use.

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1.2 DB Accuracy:
Objective:
To learn how the DB controls will give a 100% increase with
every increase of 6dB
1.2.1 Couple a straight beam probe to the OS block at 'T' - set 4"
range indication should be at 2”.
1.2.2 Set the indication to exactly 40% full screen height control by moving
TX toward “U”

1.2.3 Add 6dB gain ("Indication level" should be 80%). Record dB level "a" and
"INO" amplitude "b" on the table

1.2.4 Move TX toward "U· to bring "INO" to 40% FSH.

. 1.2.5 Repeat steps 3 + 4 until the full range of the gain control is reached (60 min)
Accurate ± 1 % FSH.

Find the average % screen values from column B disregarding the first three
and ast three tabulation. Use percentage as % 2 in calculating the corrected
reading C.
dB2 = 20 x log (%2/ % 1) + dB1
dB2 = C, dB1 = a, %1 = b.
The dB error D is established by subtracting the corrected reading
from the dB reading (a) i.e. a-c = d.
Beginning in the tabulated db error’d’ nearest to 0.0, collectively
add the db error 'd' values up and down placing the subtotals in
column 'e' (collective db errors).

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Moving vertically up and down from the average % line, find the
largest vertical span in which the top and bottom collective db
error figure remains at or below 2 db. Count the No. of vertical
spaces of movement, subtract one, and multiply the remainder by
six. This db value is the acceptable range of the UNIT.
This test is recommended to be done once every two months.
1.3 Internal Reflections:
1.3.1 Calibrate the equipment as explained in "calibration for testing" -
Sec.5.3 of this procedure.
1.3.2 Remove the search unit from the calibration blocks without
changing any other equipment adjustments.

1.3.3 Increase the calibrated gain (or) attenuation 20 dB more sensitive

than reference level.
1.3.4 The CRI screen area beyond 13mm sound path and above
reference level height shall be free of any indications.

1.4 Angle beam transducer calibration:

Objective:

To learn the proper method of calibrating an angle beam contact

probe to a standard range of 10" with the IIW calibration block.
1.4.1 Verify the BIP (Beam Index Point):
Put the transducer (45, 60 or 70 degree) in position "A". Locate the echo
from the 4" radius and peak up on it. It should be the first large echo after
the main bang. It may not be the 4" mark on the CRT depending on the
previous range settings. After peaking up the echo, carefully hold the
transducer on the block and mark the side of the probe wedge (use a piece of
a tape) directly above the zero mark on the IIW block. This mark represents
the actual BIP.
1.4.2 Verify the Refracted Angle:
Put the transducer in position "B" (60- and 70 degree on the top of block &
45 and 60 on the bottom of the block for the selected angle).Peak up the
echo from the Lucite disc by moving the transducer back and forth. When
peaked, read the degree scale on the IIW block at the probe BIP point to
identify the actual refracted angle (Beta).

1.4.3 Distance Calibration:

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Put the transducer in position "A" making sure that the BIP is lined up over
the zero mark. Locate the echo from the 4" distance (first large echo after the
main bang). Increase the gain to locate a second echo (it represents 8" of
steel travel). Use the delay control to place the 4" echo at 40% FSW. Then
use the fine range/sweep control to place the 8" echo at 80% FSW. Repeat
until both signals are properly located on the CRT display. The instrument is
now calibrated for a 10" range for steel.
1.4.4 Sensitivity Calibration:
Put the transducer in position "C". Peak up on the 0.060" SDH (Side drilled
hole). Using a 70 degree probe, this echo should be 2" of sound path on the
CRT. If in doubt, use a ruler to measure from the BIP to the SDH and then
identify the echo on the CRT. When peaked, use the gain (dB) controls to
adjust the echo height to the reference line (50% FSH). Record the reference
level (dB reading).
1.4.5 Resolution:
1.4.5.1 The transducer shall be set on resolution block RC position Q for 70°
angle, position R for 60° angle, (or) position S for 45° angle. Refer fig.
4.
1.4.5.2 Transducer and instrument shall resolve the three test block holes at
least to the extent of distinguishing the peaks of the indication from
the three holes

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(A)TYPE 1(TYPICAL)

(B)TYPE 2(TYPICAL)

FIGURE 1 : IIW Block

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PT PROCEDURE

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PT PROCEDURE

1.0 SCOPE:

This procedure defines the method, technique and acceptance standard for Liquid
Penetrant examination of all the structural welds. This method can be effectively
used on weldments /Components / Raw material like Plates, Shapes etc. to detect
discontinuities or flaws which are open to the surface.

2.0 REFERENCE DOCUMENTS:

 AWS D 1.1 - 2006

Others equivalent standards/ codes/specifications also may be used with prior
approvals

3.0 PERSONNEL REQUIREMENTS:

3.1 Personnel performing the Liquid Penetrant inspection shall be qualified and certified
in accordance with a written procedure confirming to SNT –TC-1A Level-I/II or
another national standard that is acceptable to both the purchaser and the supplier.

3.2 Evaluation of test results shall be performed by the person Qualified at least as a
Level II.

4.0 SURFACE QUALITY REQUIREMENTS:

4.1 The weld and HAZ areas (13 mm) shall be free of scales, dust, rust, spatter, oil,
grease, etc.

4.2 Sand grit or shot blasting should not be carried out prior to penetrant examination
as it may close the surface discontinuities.

4.3 If shot blasting is necessary prior to liquid penetrant examination then it shall be
performed by using angular or sub-angular cutting type sand, silicon or alumina grit.

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5.0 LIQUID PENETRANT MATERIALS:

5.1 Penetrant materials are approved by GWPL shall be used on the product under
examination .Liquid penetrant materials are
5.1.1 Pentrant-Visible Dye Pentrant solvent removal type with good colour
contrast.
5.1.2 Cleaner-Solvent, It will be an organic chemical such as Acetone, or Trichloro
ethylene.
5.1.3 Developer- Non aqueous suspendible type.

The following brands of Penetrant Chemicals will be used. TABLE – 1

TABLE – 1

Penetrant Penetrant remover Developer Manufacturer

FC-911/2 SKC- IFC-711/2 FC-811/2 Ferrochem
PM-18 PM-30 PM-24 Promotech

Other brands may be used with the approval of Head / NDT.

5.2 Intermixing of penetrant materials from different systems and different

manufactures are not permitted.

5.3 Halogenated content in the penetrant shall be less than 1% of the residue by weight.

5.4 Lighting: - Visible Dye penetrant examination shall be performed in light intensity
minimum 1000 lux.

6.0 SURFACE CLEANING:

6.1 Adequate surface cleaning of job prior to liquidpenetrant examinations necessary.

Surface cleaning can be accomplished by Mechanical cleaning, solvent cleaning

6.2 Mechanical cleaning:-It includes smooth wire brushing to remove rust and scale.

6.3 Solvent Cleaning: - Cleaning can be done by solvent to remove and grease.
6.4 Temperature:- The temperature of the penetrant and material to be examined shall
not be below 60°F to 125°F

7.0 APPLICATION OF PENETRANT:

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7.1 The weld and HAZ area to be examined shall be thoroughly and uniformly coated
with penetrant by Spraying, brushing. The penetration dwell time will be 20 to 30
min.

8.0 REMOVAL OF EXCESS PENETRANT:

8.1 The excess surface penetrant is removed by wiping with dry cloths then using lint
free cloth slightly moistened with solvent and finally with dry cloths.

9.0 APPLICATION OF DEVELOPER:

9.1 Solvent suspendible wet developer shall be applied on the job surface thin uniform
layer after removal of excess penetrant. The developer shall be applied by spraying.
The development time is between 7 to 20 minutes.

10.0 INTERPRETATION OF TEST RESULT:

10.1 Only indications with major dimensions greater than 1.6mm shall be deemed as
relevant.

10.2 It is to be determined whether the indication is true indication, false indication or

non-relevant Indication.

11.0 EVALUATION:

11.1 Each defect indication linear or non-linear shall be evaluated.

11.2 Linear indication- Indication having a length greater than three times its width.
Non-linear Indication- indication having a length less than, or equal to three times its
width.

12.0 ACCEPTANCE LEVEL FOR INDICATION:

For statically and cyclically loaded non tubular connection made to AWS code, the
acceptance of any discontinuity shall be based upon a visual examination of the
discontinuity after the removal of developer medium and evaluated for its nature
and size. Where the discontinuity cannot be seen after removal of developer
medium either directly or using magnifying glass evaluation shall be based on the
size and nature of liquid penetrant indication.

12.1 Statically loaded non tubular connections:

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12.1.1 Indications from cracks, lack of penetration and lack of fusion are not
acceptable.

12.1.2 Porosity:

12.1.2.1 Complete joint penetration groove welds in butt joints transverse to

the computed tensile stress shall have no visible piping porosity.

12.1.2.2 For all other groove welds and for fillet welds, the sum of the visible
piping porosity 1.0 mm or greater in diameter shall not exceed 10
mm in any linear 25 mm of weld and shall not exceed 20 mm in any
300 mm length of weld.
12.1.3 Undercut:

12.1.3.1 For material less than 25 mm thick, undercut shall not exceed 1.0
mm expect that a maximum 2.0 mm is permitted for an
accumulated length of 50 mm in any 300 mm

12.1.3.2 For material equal to or greater than 25 mm thick, undercut shall

not exceed 2.0 mm for any length of weld.

12.2 Cyclically leaded non tubler connections:

12.2.1 Indications from cracks, lack of penetration and lack of fusion are not
acceptable.

12.2.2 Porosity:

12.2.2.1 Complete joint penetration groove welds in butt joints transverse to

the direction of computed tensile stress shall have no piping
porosity, for all other groove welds, the frequency of piping
porosity shall not exceeded one in 100 mm of length and the
maximum diameter shall not exceeded 2.5 mm.
12.2.2.2 The frequency of piping porosity in fillet welds shall not exceed one
in each 100 mm of weld length and maximum diameter shall not
exceeded 2.5 mm. Exception for fillet welds connecting stiffeners to
web, the sum of diameters of piping porosity shall not exceed 10
mm in any linear 25 mm of weld and shall not exceed 20 mm in any
300 mm length of weld..

12.2.3 Undercut:

12.2.3.1 In primary member, undercut shall not be more than 0.25 mm deep
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when the weld is transverse to tensile stress under any design

loading conditions. Undercut shall not be more than 1 mm deep for
all other cases

13.0 REPAIR AND REEXAMINATION:

13.1 Whenever an imperfection is repaired by chipping or grinding the evaluated area

shall be blended into the surrounding surfaces so as to avoid sharp notches, curves
or corners.

13.2 After a defect is thought to have been removed and where welding is required after
repair, the area shall be examined for removal of defects, area cleaned and repair
carried out. The repaired area shall be blended into the surrounding surfaces and re-
examined by the liquid penetrant or any other NDT methods originally required for
the affected areas.

14.0 POST CLEANING:

14.1 After the examination and evaluation is completed, all penetrant testing materials
shall be removed from the surface, so that it will not interface with the subsequent
processing or service requirements.

15.0 REPORTING:

15.1 The Report format no.:ZS/QC/IR/08 Rev-01 shall be used for reporting

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MPT PROCEDURE

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MPT PROCEDURE

1.0 SCOPE:

1.1 Following procedure defines minimum requirements for conducting Continuous

method, visible, wet, magnetic particle examination with a yoke on welds.
Inspection method is applicable to detect cracks, porosity, inclusions and other
discontinuities at or near the surface on the welded structures/piping fabricated
from the ferromagnetic materials; in the light of AWS D1.1 of section 6.It is not
applicable to non-ferromagnetic metals and alloys.

2.0 REFERENCE DOCUMENTS:

 AWS D1.1:2006
 ASNT Hand Book for Non-Destructive Testing.

3.0 PERSONNEL REQUIREMENTS:

3.1 Personnel performing the Magnetic particle inspection shall be qualified and certified
in accordance with SNT –TC-1A Level-I/II or another national standard that is
acceptable to both the purchaser and the supplier.

3.2 Evaluation of test results shall be performed by the person Qualified at least as a
Level II.

4.0 SURFACE QUALITY REQUIREMENTS:

4.1 The sensitivity of examination strongly depends on the surface quality.The best
results are obtained on the grinded (polished) or machined surfaces.

4.2 The test surface shall be clean and free from oil,grease,sand,loose
rust,scale,lint,thick paint, weld flux and spatter, and contamination which will
interfere with the mobility of the magnetic particles and mask relevant indication or
create false indication.

4.3 Thin nonconductive coatings such as paint or plating less than 4 mils thick will not
normally interfere with the formation of indications.

4.4 All coatings must be removed in the areas where electrical contact will be made.

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4.5 If needed, a surface may be cleaned by pressure blasting, provided this will not
interfere with subsequent tests.

4.6 If false indications are noted due surface conditions such as weld deposits or burned
in sand, the surface shall be cleaned of these conditions and the part retested.

4.7 Chemical cleaners used for surface preparation shall not contain chlorine, sulphur,
or caustics

5.0 EQUIPMENT & CALIBRATION:

5.1 Equipment/Materials:
Magnaflux make, Yoke Type Equipment –AC/HWDC or equivalent make.
Power supply – 230 volts. Amperes -5, Light meter, Gauss meter, 60 watt bulb
Magnetic Powder wet Black, Pie-shaped Field Indicator/Shims, Centrifugal tube
Cleaner- Magnaflux SKC-S (or equivalent), White contrast paint-Ferrochem make-
1204/2

5.2 Equipment :
Magnetic particle testing equipment shall produce either AC/HWDC current &
capable of supplying sufficient amperage & type of amperage as defined in the
requirements of this Instruction and the specific instruction being applied. A typical
apparatus will be a yoke type machine A built –in demagnetization circuit, or a
separate demagnetization coil. will be necessary when demagnetization is required.

5.3 Magnetic Particle testing equipment shall be checked for accuracy at the time of
purchase, at an interval not to exceed twelve months and whenever electrical
maintenance is performed which may affect the equipment accuracy. The
equipment –yoke shall be lift a weight of 4.5kg on AC & 18.1kg on DC with maximum
poles spacing of the yoke

5.4 Magnetic Particles-For visible magnetic particles. The color of the particles shall be
selected to yield the highest contrast with the part.

5.5 When using wet magnetic particle method, the particles are applied using an aerosol
spray can. All application and mobilizing of particles must be done while the current
is being applies using the true continuous method.
5.6 Lighting-for visible magnetic particles the visible light intensity shall be at least 1000
lux(100 foot candles) at the part surface

6.0 METHOD OF EXAMINATION:

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6.1 All magnetic particle inspections shall be of the wet continuous method.

6.2 The temperature of the weld surface & dry powder shall be in the range 10 -57° c

6.3 Area of Inspection:

MT shall be performed after final welding on fillet welds between the plate & flange,
and heat affected zone areas. All areas of each component shall be inspected in two
perpendicular directions. The extent area shall be 100 % as specified on the
production drawing. In addition, 100% MT shall be performed of repairs welds or arc
strike.

6.4 Magnetizing current:

MT shall be carried out with using of AC/HWDC.

6.5 Magnetization Method:

6.5.1 Direct Longitudinal magnetization shall be applied in weld area by using yoke.

6.5.2 The yoke spacing shall be kept between 3” to 8”

6.5.3 First ensure good yoke contact & that the yoke points of contact are clean &
in good condition, yoke spacing of 100 mm shall be used.
6.5.4 The effective perpendicular test area using yoke is ¼ the pole spacing from a
line which connects the two yoke.
6.5.5 Overlapping of pole spacing shall be at least one inch

6.6 Magnetic Field Adequacy:

6.6.1 The sufficient strength of magnetic field shall be checked before every
Inspection with a Pie Shaped field Indicator. The indicator shall be placed on
the surface to be examined with the copper plated side facing away from the
inspected surface. When a clearly defined line of magnetic particles is formed
at the face of indicator (When applying simultaneously magnetic force and
magnetic particles), Magnetic field has a suitable strength.

6.7 Application of Magnetic Particle:

6.7.1 The flow of magnetizing current shall be initiated prior to application of the
magnetic Particles and terminated after dry/wet powder application has
been completed. The duration of magnetizing current shall be at least 2
seconds. Magnetic wet powder shall be applied in a light, uniform coating on
the surface to be tested, aerosol spray can. Care must be taken to overlap
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inspection areas to insure complete coverage.

7.0 INTERPRETATION AND EVALUATION:

7.1 Evaluation of examined surface shall be performed under appropriate light

condition i.e. 1000 lux at the part surface. Interpretation of results shall be
performed during the magnetization time.

7.2 Interpretation shall be done immediately after current has been applied and powder
applied. Sufficient time for the formation and examination of indications shall be
permitted during the testing process. All indications shall be evaluated in terms of
the acceptance criteria defined by applicable standards and specifications. As per
this procedure, linear or non-linear indications are unacceptable.

7.3 False Indications :

False indications may be caused by irregular geometry or by surface
roughness. In case of doubt, additional inspections or improvement of surface
condition shall be performed.

7.4 Linear Indication :

An indication whose length is equal to or greater than three times its width.
However, indications (1.6mm) or less shall be considered non-linear and evaluated
with the applicable non-linear acceptance standard.

7.5 Non-Linear Indication:

An indication whose length is less than three times its width. In
addition, all indications (1.6mm) or less shall be considered non-linear indication

8.0 ACCEPTANCE LEVEL FOR INDICATION:.

For statically and cyclically loaded non tubular connection made to AWS code, the
acceptance of any discontinuity shall be based upon a visual examination of the
discontinuity after the removal of developer medium and evaluated for its nature
and size. Where the discontinuity cannot be seen after removal of developer
medium either directly or using magnifying glass evaluation shall be based on the
size and nature of liquid penetrant indication

8.1 Statically Loaded Non-tubular connections:

8.1.1 Indications from cracks, lack of penetration and lack of fusion are not
acceptable.

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8.1.2 Porosity:

8.1.2.1 Complete joint penetration groove welds in butt joints transverse to

the computed tensile stress shall have no visible piping porosity.

8.1.2.2 For all other groove welds and for fillet welds, the sum of the visible
piping porosity 1.0 mm or greater in diameter shall not exceed 10 mm
in any linear 25 mm of weld and shall not exceed 20 mm in any 300
mm length of weld.

8.1.3 Undercut:

8.1.3.1 For material less than 25 mm thick, undercut shall not exceed 1.0 mm
expect that a maximum 2.0 mm is permitted for an accumulated
length of 50 mm in any 300 mm

8.1.3.2 For material equal to or greater than 25 mm thick, undercut shall not
exceed 2.0 mm for any length of weld.

8.2 Cyclically Loaded non-tubular Connection:

8.2.1 Indications from cracks, lack of penetration and lack of fusion are not
acceptable.

8.2.2 Porosity:

8.2.2.1 Complete joint penetration groove welds in butt joints transverse to

the direction of computed tensile stress shall have no piping porosity,
for all other groove welds, the frequency of piping porosity shall not
exceeded one in 100 mm of length and the maximum diameter shall
not exceeded 2.5 mm.
8.2.2.2 The frequency of piping porosity in fillet welds shall not exceed one in
each 100 mm of weld length and maximum diameter shall not
exceeded 2.5 mm. Exception for fillet welds connecting stiffeners to
web, the sum of diameters of piping porosity shall not exceed 10 mm
in any linear 25 mm of weld and shall not exceed 20 mm in any 300
mm length of weld..

8.2.3 Undercut:

8.2.3.1 In primary member, undercut shall not be more than 0.25 mm deep
when the weld is transverse to tensile stress under any design loading
conditions. Undercut shall not be more than 1 mm deep for all other
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cases

9.0 DEMAGNETIZATION:

9.1 After examination using the yoke method, residual magnetism will removed by
demagnetization. Alternating current yoke shall be used for demagnetization by
placing the poles on the surface moving them around area & slowly with drawing
the yoke while still it is energized. The parts should be checked for any residual
magnetism with Gauss meter. If there is any, demagnetization shall be performed by
a method approved by both the customer and manufacture. A residual magnetic
field of +/- 3 gauss is considered acceptable.

10.0 POST EXAMINATION CLEANING:

10.1 Following inspection, contrast paint shall be removed from the inspected part by
subsequent process

11.0 REPORTING:

11.1 The Report format no.:ZS/QC/IR/09 Rev-01 shall be used for reporting

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2. FIGURE SHOWS EXAMINATION AREAS

Fig-I

d 75
b ≤ d/2
ß 90º

d1 75
b1 ≤ d1/2
b2 ≤ d2-50
d2 75

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13. FIGURE SHOWS EXAMINATION AREAS

Fig-III

d1 75
d2 75
b1 ≤ d1/2
b2 ≤ d2-50

Fig-IV

d1 75
b1 ≤ d1/2
b2 ≤ d2-50
d2 75

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14. FIGURE SHOWS EXAMINATION AREAS

Fig-V

Examples of effective examination area (shaded) for magnetizing

With yokes

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WELD REPAIR
PROCEDURE

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17. WELD REPAIR PROCEDURE:

1. TITLE:
Repair procedure for weld defects and straightening of bend members.

2. SCOPE:
This procedure covers is applicable to correct the defects which exceed the
limits of Zamil Steel Fabrication Tolerances or the weld visual & NDT
acceptance criteria of AWS D1.1

3. MATERIALS:
ASTM A 36, ASTM A 572 GR 50 or equivalent.

4. FILLER METALS AND PROCESS:

GMAW Process: ER 70S-6 (AWS A 5.18)

5. PRE-HEAT AND INTERPASS TEMEPRATURES:

5.1 Prior to welding, the base metal shall be pre-heated to ensure that weld
metal being deposited are above specified minimum temperature for a
distance equal to the thickness of part being welded. But not less than
75mm, in all direction form the point of welding.

5.2 The minimum pre-heat and inter-pass temperatures shall be as per table
shown below.

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Thickness of Thickest
Minimum
Material part @ the point of
Temperature °C
welding
Up to 19mm not less than 10°C
ASTM A 36 &
Over 19mm to 38mm 10°C
ASTM A 572 GR 50
Over 38mm to 64mm 65°C
or equivalent
Over 64mm 110°C

5.2.1 Pre-heat application method: Pre-heating shall be done by torch flame

heating.

5.2.2 Temperature where required shall be measured by temperature

crayons.

6. WELDING:

The welding current, arc, voltage, speed of travel, gas flow and metal
transfer shall be such that each pass will have complete fusion between the
adjacent base metal and suitable WPS shall be followed

7. WELD DEFECTS CORRECTION:

Weld defects shall be corrected as follows.

7.1 Excessive convexity or reinforcement overlap: Excessive weld metal

shall be removed by gouging or grinding.

7.2 Crater, undersize weld, undercut, excessive concavity: The surface shall
be prepared and additional weld metal shall be deposited as required.
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7.3 Unacceptable porosity, slag inclusion, lack of fusion: Unacceptable

portion of weld shall be removed and re-welded.

7.4 Cracks in weld metal and heat affected zone: The extent of crack shall
be ascertained by suitable NDE, the crack & sound weld 50 mm
beyond each end of the crack shall be removed and re welded.

7.5 Arc Strikes: Ark strikes shall be avoided on any base metal. Cracks or
blemishes caused by arc strikes shall be ground to a smooth contour
and checked to ensure soundness.

7.6 Inaccessibility of unacceptable welds:

7.6.1 If the unacceptable portion of the weld is inaccessible due to

any additional work performed, then the original conditions
shall be restored by removing weld (or) members (or) both
before the repair.

7.6.2 If this is not done, the deficiency shall be compensated for by

additional work performed according to our approved revised
design

7.7 Welded restoration of Base metal with misallocated holes:

7.7.1 Except where restoration by welding is necessary for structural

(or) other reasons, punched (or), drilled misallocated holes may
be left open (or) filled with bolts.

7.7.2 When base metal with misallocated holes are to be restored by

welding, then the technique as given in 7.7.4 is to be used. The
repair is not applicable for base metal subjected to cyclic
tensile stress.

7.7.3 All weld restored holes shall be flush ground.

7.7.4 Technique: Place the steel backing strip at one half the depth of
hole and either tack (or) seal welds around the backing strip.
Gouge a “U: shaped cavity down to the backing and fill the
cavity by welding using a stringer bead technique. After the
first side is welded, gouge another side to make an “U” shaped
cavity, completely removing the temporary backing and
complete by welding using stringer bead technique. The
backing strip material shall have similar composition of base
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metal.

7.8 Distortion Control:

7.8.1 As far as practicable, all welds shall be made in a sequence that

will balance the applied heat of welding while the welding
progresses.

7.8.2 Suitable dummy stiffeners shall be provided for unspported

lengths exceeding 300 mm to prevent distortion of the end
plates

7.8.2.1 Distortion/ Bend Correction :

i) Member distorted by welding (or) handling shall be

straightened by mechanical means (or) by application of
localized heat and accelerate cooling by spraying water
(or) by compressed air.

ii) The temperature of heated areas shall not exceed

650°C.

iii) Temperature indicating crayons shall used to measure

the temperature.

7.9 Cleaning:

7.9.1 Slag shall be removed from all completed repair welds. The
welds and adjacent base metal shall be cleaned by brushing or
suitable means.

7.9.2 Tightly adherent spatter remaining after cleaning operation is

acceptable, unless its removal is required for the purpose of
non-destructive testing.

7.9.3 Repaired welded joints shall not be coated until repair weld is
accepted.

8. QUALITY CONTROL:

8.1 The inspector shall review repair welding procedures to be used for this work

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and ensure that it is followed correctly.

8.2 The inspector shall ensure that all the welders are qualified as per AWS D1.1
before permitting them for welding.

8.3 The inspector shall monitor during welding all the welding parameters, pre-
heat, inter-pass temperature, cleaning, gouging are carried out correctly.

8.4 The inspector shall ensure the repaired portion is examined & accepted by the
same inspection method which was used to identify the defect and that the
repaired portion meets the acceptance criteria.

8.5 The inspector shall make sure that the size, length, locations of all repaired
welds conforms to the requirement of the detail drawings.

8.6 The inspector shall ensure the straightened pieces are within the Fabrication
tolerances.

9. REFERENCES:

AWS D1.1 for Structural Welding Code

Zamil Steel Fabrication Tolerances

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SURFACE
PREPARATION
& PAINTING
PROCEDURE
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18. SURFACE PREPARATION & PAINTING PROCEDURE:

1. PURPOSE:
To establish and maintain documented procedure to ensure that surface preparation
& painting inspection is carried out to get the desired quality output
2. SCOPE:
This work instruction is intended for the surface preparation & painting inspection
3. RESPONSIBILITY:
QC Engineer / Inspector
4. INSTRUCTION:

1. Surface Preparation:

1.1 Check the surface preparation requirement from Job Specifications

1.2 If job requires standard surface preparation, ensure hand tool cleaning as per
the method described below -
1.3 All visible oil, grease & contaminations are removed by Solvent Cleaning
1.4 Cleaning shall be done by hand tools to remove loose mill scales, loose rust &
dirt
1.5 If job requires Blasting, then blasting shall be done to achieve cleanliness of
Sa2.5 finish – the job surface shall be free from all visible oil, grease, dust,
dirt, mill scales, rust & oxides except that random staining shall be allowed
till 5% of the area
1.6 Check the anchor profile by touch feel with keanetator surface
comparator

2. Environment Monitoring:
Painting or blasting shall not be carried out
2.1 When the steel substrate temperature is below 10° or more than 55°.
2.2 When humidity is more than 85% (<50% for inorganic)
On wet steel.
2.3 When wind borne dust is present
2.4 When difference between steel substrate temperature and the dew

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point is less than 3°C.

3. Paint Inspection:

3.1 Ensure paint applied is that specified for the job

3.2 Ensure shade is matching with the specified RAL; Difference in batches
if visible from 6 meter distance shall not be acceptable
3.3 Ensure DFT is achieved as per job specifications as per below method

3.3.1 Ensure calibrated instrument is used; the required accuracy

level is minimum 10%
3.3.2 Individual measurements made by keeping the probe in the
surface are called gage readings; Take 3 gage readings each
within a distance of 40 mm at any location on the job; The
average of the 3 gage readings is called the spot reading
3.3.3 Take the spot readings at 5 locations on the job – 3 locations on
the web & 2 locations on each flange
3.3.4 The average of the 5 spot readings is the mean DFT measured on
the job
3.3.5 The mean DFT shall be equal to or above the specified
requirement; the spot readings can be less than the specified
requirement by 20% & the gage readings can be lesser by a
greater amount

3.4 Adhesion shall be checked after hard dry & will be minimum 4A or 4B
when checked as per ASTM D 3359
3.5 Visual Inspection shall be carried out to check visual defects like run
down, sagging, uncovered areas etc

If job meets the requirements, then release it for next operation,

if not found OK then raise NCR ;
For reworked jobs, check if the job is within the acceptable limits
after the rework & release the job if found satisfactory

5. RECORD:
ZS inspection reports - ZS/QC/IR/11, 12, 14 & 15
6. REFERENCE:
SSPC PA2, QAP, BOM, ASTM D 3359

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PAINT REPAIR
PROCEDURE

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19. PAINT REPAIR PROCEDURE

1. TITLE : Procedure for repair of painting.

2. PURPOSE : Covers repair of painting performed at Zamil Steel.

3. SCOPE : This procedure covers the methods of repairing

damaged paint on steel members.

4. GENERAL : The specification covers the requirements for

repainting damaged and defective areas of painted
members including surface preparation, painting and
inspection procedures.

5. REPAIR PROCEDURES :

5.1 : All damaged and defective members requiring repair of

rework shall be dried and cleaned to remove dust, rust, oil,
grease and loose mill scales by hand tools,
Power tools, and solvent or detergent.

5.2 : For areas less than 0.10 m², abrade to a rough metal
surface using at least an 80 grit disc sander or sand paper
to bare the steel. Abrade the edge of the coating to
50 mm beyond steel.

5.3 : Application of paint by means of a brush or roller on the

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defective areas.

5.4 : In case of multi coat system, each paint coat shall be allied.

6. Opening of container and mixing:

Before opening the container of the paints, confirm whether the quality, lot numbers
are in conformity to those specified in the documents. The container should be stirred
well to homogeneous mixture. If the paint is to be thinned, material and amount of
thinner should conform to the instruction given by the manufacturer. Complete the
coating work in the time period specified for the mixed material.

7. Prohibition of Painting Operation:

Painting is prohibited in the following cases:

7.1 : when temperature is below 5°C or humidity is over 85%.
7.2 : During rainfall except when the operation is performed
Indoor.
7.3 : When there is possibility of rainfall before the paint could
dry.
7.4 : When strong wind dust is blowing.
7.5 : When the surface to be painted are wet.
7.6 : When sand or other foreign matters are deposited on the
surface to be painted.

8. Inspection:

8.1: The degree of surface preparation of damaged areas is determined

by Inspection. Damaged and defective areas shall be inspected for
surface appearance and condition prior to paint application.
8.2: Thickness and appearance shall be inspected after completion of
painting process. Painted surface should have smooth surface.
8.3 Appropriate tests shall be carried out on the repaired areas on
random basis in order to determine the adhesion strength of applied
paint to the base metal.

IMPORTANT TECHNICAL DATA:

In addition to the requirements of these specifications the paint manufacturer’s

latest, published instruction for application shall be followed.
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FINAL INSPECTION
PROCEDURE

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20. FINAL INSPECTION PROCEDURE:

1. PURPOSE:

To establish and maintain documented procedure to ensure that final inspection is

carried out to get the desired quality output

2. SCOPE:

This work instruction is intended for the final inspection conducted in the shipping
area

3. RESPONSIBILITY:

QC Engineer / Inspector

4. INSTRUCTION:

4.1 Identify the fabricated part mark by noting the part mark stenciled or written on the
job

4.2 Ensure inspection is done by calibrated instrument

4.3 Check the dimensions as per shop sketch
4.4 Check completeness of the holes
4.5 Check for welding & painting visual defects
4.6 Check for handling & loading damages
4.7 Check if the identification / part marking are clear & correct
4.8 If job meets the requirements, then release it for next operation, if not found OK
then raise NCR
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4.9 For reworked jobs, check if the job is within the acceptable limits after the rework &
release the job if found satisfactory

5. RECORD:

ZS inspection reports - ZS/QC/IR/16

6. REFERENCE:

Shop Sketch, ZS Fabrication Tolerance; QAP

WELDING PROCEDURE
SPECIFICATION
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21. WELDING PROCEDURE SPECIFICATION:

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22. Procedure for Crane Bracket welding to steel columns

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QC FORMATS

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23. QA&QC FORMATS:

Sr.
No. Format Name Format No.
1 INCOMING INSPECTION REPORT ZS/QC/IR/01
2 DIMENSIONAL INSP. REPORT (SHEARING/GASCUTTING) ZS/QC/IR/02
3 DIMENSIONAL INSP. REPORT (DRILLING/PUNCHING) ZS/QC/IR/03
4 DIMENSIONAL INSP. REPORT (SUNDRIES / ACCESSORIES) ZS/QC/IR/04
5 DIMENSIONAL INSPECTION REPORT FOR ANCHOR BOLTS ZS/QC/IR/04A
6 DIMENSIONAL INSP. REPORT (SHEET/TRIMS/PURLIN/GUTTER) ZS/QC/IR/05
7 DIMENSIONAL INSP. REPORT (FITMENT) ZS/QC/IR/06
8 WELDING INSPECTION REPORT ZS/QC/IR/07
9 LPT TESTING REPORT ZS/QC/IR/08
10 MPI TESTING REPORT ZS/QC/IR/09
11 UT TESTING REPORT ZS/QC/IR/10
12 SURFACE PREPARATION INSPECTION REPORT ZS/QC/IR/11
13 PAINTING INSPECTION REPORT (DFT) ZS/QC/IR/12
14 NON-CONFORMITY REPORT ZS/QC/IR/13
15 PAINT ADHESION TEST REPORT ZS/QC/IR/14
16 DAILY WEATHER CONDITION REPORT ZS/QC/IR/15
17 PRE-SHIPMENT INSPECTION REPORT ZS/QC/IR/16
18 BEND TEST REPORT ZS/QC/IR/19
19 FILLET BREAK TEST REPORT ZS/QC/IR/21
20 DAILY WELDING PARAMETERS CHECK REPORT ZS/QC/IR/22
21 EXTERNAL TESTING REQUEST ZS/QC/CMTR/23
22 NON-CONFORMITY REPORT (INCOMING MATERIAL) ZS/QC/IR/24
23 WELDER, WELDING OPERATOR, OR TACK WELDER QUALIFICATION ZS/QC/WPQR/36
24 QUALITY ASSURANCE PLAN ZS/QC/QAP/44
25 HISTORY CARD OF CALLIBRATED INSTRUMENT ZS/QC/HC/45
26 CLAIM ANALYSIS FORM ZS/QC/CA/46
27 QUALIFIED WELDER CERTIFICATE ZS/QC/ZWC/47
28 CONSUMABLE TEST REPORT ZS/QC/WCTR/48
29 ASSET RETIREMENT AUTHORIZATION FORM ZS/QC/ARA/49
30 VISIT INSPECTION REPORT ZS/QC/VIR/50
31 IN-HOUSE CALIBRATION REPORT(PRODUCTION) ZS/QC/IHCM/51
32 IN-HOUSE CALIBRATION REPORT(QUALITY) ZS/QC/IHCM/52

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24. Appendix
A. List of Qualified Welders

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B.List of Qualified NDT personnel

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