WORK INSTRUCTION

FOR
PLUGGING OF REDUNDANT HOLES
IN STRUCTURAL MEMBERS

Job Number

Document No
2

FABRICATION DIVISION
RELIANCE INDUSTRIES LIMITED, JAMNAGAR

Department:

Location:

Quality Management

Jamnagar

Revision Number
E

00

Date

16.06.2013

Prepared
By

MM

Reviewed
By

Approved
By

TD
CPB
SSS
SNS

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

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. WORK INSTRUCTION
9. RECORDS

Work instruction for Plugging of Redundant holes in

Structural members
Document No. 2QAWINME014 Rev.00

Page 2 of 5
Quality Management Department

FABRICATION DIVISION
RELIANCE INDUSTRIES LIMITED, JAMNAGAR

1.

INTRODUCTION
RIL Fabrication division is providing construction service for various projects. Based on
design requirements, structural steel components are provided with a number of holes on
flange/web of beam or column for bolting purpose. Due to revision in fabrication drawings or
due to fabrication mistake, sometimes holes in structural members becomes redundant and new
holes are required to be drilled at new locations. In order to avoid of wastage of material,
redundant holes are required to be plugged by welding and new holes are drilled at new
locations. During plugging, a step by step control mechanism is required to be followed so as
to ascertain soundness of plugged area.

2.

PURPOSE
The purpose of this work instruction is to provide step by step instruction for plugging of
redundant hole in structural members by welding.

3.

SCOPE

The scope of this work instruction is limited to plugging of redundant holes by welding in
statically loaded Structural members only.

For cyclically loaded structure, SER shall be raised and approval shall be obtained from
engineering on a case to case basis.

4.

ABBREVIATIONS & DEFINITIONS

HOD

Head of Department

QMD

Quality Management Department

SER

Site Engineer request

WPS

Welding procedure specification

5.

RESPONSIBILITY & AUTHORITY

Respective Area construction Manager is responsible for the implementation of this procedure
in his area.

HOD - QMD is responsible to maintain this procedure.

6.

REFERENCE

7.

AWS D1.1 Structural welding code- steel

FLOW CHART
Nil

Work instruction for Plugging of Redundant holes in

Structural members
Document No. 2QAWINME014 Rev.00

Page 3 of 5
Quality Management Department

FABRICATION DIVISION
RELIANCE INDUSTRIES LIMITED, JAMNAGAR

8.

WORK INSTRUCTION

8.1.

Welding shall be done by qualified welders and job specific WPS.

8.2.

Backing strip material of same grade/type with minimum thickness of 5 mm shall be provided
to ensure complete penetration (as shown in sketch). Shall be verified by Reliance execution
prior to welding.

8.3.

Before welding, dirt, oil and grease etc. shall be completely removed from hole.

8.4.

Root pass welding shall be carried out by 2.5 electrodes. Subsequent passes shall be welded
with 3.15 electrodes. Inter pass cleaning shall be carried out. After welding completion,
weld shall be flush ground.

8.5

Backing strip shall be removed by grinding. In case of any minor damage during removal of
strip, affected area shall be checked by PT and filled up by welding using the same procedure.

8.6

New location of holes shall not overlap with plugged hole.

8.7

Plugged hole area shall be visually inspected for clearance.

Flush grind
Weld
metal

Backing strip (to be removed

after welding)

Work instruction for Plugging of Redundant holes in

Structural members
Document No. 2QAWINME014 Rev.00

Page 4 of 5
Quality Management Department

FABRICATION DIVISION
RELIANCE INDUSTRIES LIMITED, JAMNAGAR

9. RECORDS
Structural steel Fabrication Inspection Report (FORM NO: 2 QA FMT ME 003).

Work instruction for Plugging of Redundant holes in

Structural members
Document No. 2QAWINME014 Rev.00

Page 5 of 5
Quality Management Department