INTERVENTION SOLUTIONS WLL

Methodology for Fabrication of Runway Beam and Support Structure

Appendix : 1

CONTENTS

1. Material Procurement Plan

a. Steel
b. Paint

2. Steel Structure

a. Fabrication.
b. Surface Preparation & Painting.
c. Packing & Dispatch Steel
d. Unloading & Storage Steel

3. Index for Field Quality Plan & Checklist

1|Page
STEEL STRUCTURE- PROCUREMENT

Objective To procure material as per drawing / BOQ & correct specification.

Reference Relevant Manufacturing Drawing & BOQ

Inspection & Test PT/ISWLL/C286/01

Plan

Procedure

BOQ Manufacturing Materials

Sample Approval Vendor Approval Dwg. Specification

Check

Purchase Order

GRN

Inspection

Storage /
Processing

2|Page
1. Purchase orders shall clearly describe the goods and services being ordered. The descriptions
shall include the following information as applicable to the product being purchased:

(a) Quantity
(b) Unit of Measure
(c) Product Name
(d) Manufacturer’s Description
(e) Size and Length
(f) Material Specification
(g) Finish
(h) Inspection Instructions
(i) Special Packaging or Shipping Instructions
(j) Applicable standards
(k) Attachments to the purchase order

1.1 For subcontracted work, the Fabricator is responsible to ensure that the final
product meets the customer requirements.
1.2 Specifications, drawings, process requirements, inspection instructions and
other relevant technical data shall accompany the purchase order if applicable.
1.3 Purchase orders shall clearly specify the written documentation that shall be
provided to verify conformance with purchase orders.

2. Receiving
2.1 Incoming materials shall be matched against receiving DN and purchase
orders.
2.2 Nonconformities that are identified at the receiving stage quarantined and
dealt with separately.
2.3 Material shall not be used or processed until it has been inspected and
approved for use.

Record MED-01 DN-PO Goods Receive Notes (GRN)

INTERVENTION SOLUTIONS WLL. Client Petrotec
Project c-286

3|Page
 Format no. MED-01

Rev. No. 00

Date
INWARD STEEL MATERIAL CHECK LIST

MATERIAL LOT No DC No.

BATCH HEAT No.
No.

Sr. Standard Size Actual Size. Remarks

No (mm) (mm)
.
L W B Dia Sec T L W B Dia Sec T

4|Page
QA/QC Engineer (ISWLL) Q.C Engineer (PETROTEC) CLIENT

Name : Name : Name :

Date : Date : Date :

Signature : Signature : Signature :

LEGENDS

L Length Sec Section DC Delivery Note

W Width T Thickness

B Breadth

Dia. Diameter

Client Petrotec
Project c-286
INTERVENTION SOLUTIONS WLL Format no. MED-02
Rev. No. 00
Date

INWARD PAINT CHECK LIST

MATERIAL LOT No MFG DATE
DC No. BATCH No. EXPIRY DATE
SHELF LIFE
DATE

SL. No Description YES N N.A Remarks

O
CHECK POINTS
Check for Paint inward
1 Paint supply as per Purchase Order or
Not?
2 Ensure Paint RAL No. colour, shade etc.
as per specification.
3 Check availability of MTC with Paint or
Not?
4 Check paint packing is proper or not?
5 Check leakage of paint from packing or
not?
6 Check Paint qty. as per P.O and
drawing.

5|Page
Fabrication Engineer (ISWLL) NACE LEVEL-II (ISWLL) Client Engineer

METHOD STATEMENT FOR FABRICATION OF STEEL STRUCTURE

Objective To fabricate steel structure as per drawing within approved tolerance with
surface finish to required specification.

Reference Relevant Manufacturing Drawing

Inspection & Test ISWLL/QAP/FAB/002

Plan
Procedure

1) Fabrication
Check
RM from Storage Identification

Cutting Plan Gas / Plasma Part Identification

Cutting PUG / CNC Hard Punch/Marker

Edge Preparation

Weld Visual Fit-up

Assembly DP Test Welding Fit-up Inspection 6|Page

Identification Mark
 Surface
Grinding & Preparation/ Shot Primer Application
Finishing Blasting
DFT Check Packing
Final Inspection

MOI Coat Pre-Dispatch

Application Inspection

DFT Check
Dispatch to Site
Finish Paint 1st &
2nd Coat
Application

DFT Check Each

Coat
Record

(a) Cutting Plan

The cutting plan shall be prepared for all material before commencement of fabrication
work. Material mark number shall be provided for easy identification.

(b) Cutting

Material cutting shall be carried out either by plasma, CNC Profile cutting and pug cutting
machine. The edges of all plates shall be perfectly straight and uniform throughout. Cut
edges shall be visually examined for laminations and inclusions. All corners shall be shaped
so as to be notch free. For easy identifying all part shall be marked by Paint Marker.

(c) Edge Preparation

Edge preparations for field welding shall be done in the shop. The edges or surfaces of
parts to be joined by welding shall be uniform, smooth and cleaned from all foreign
materials such as moisture, slag, oil, grease, paint, scale or rust. Edge preparation shall be
verified for proper groove angle and root face dimensions. Welding groove dimensions
shall be inspected as per shop drawings under tack-welded condition prior to welding.

(d) Fit-Up

7|Page
The Members or Plates to be welded are assembled, aligned and retained in position by
tack welding. The location of integral parts / members to be assembled shall be checked
dimensionally prior to full welding. Tack welds shall be used for secure alignment.

(e) Welding

Full welding shall be carried out as per the details given in manufacturing drawing.

The following practices shall be used for welding: -

 Run-on and run-off plates shall be welded at the ends of weld lines of crucial butt
welds.
 Prior to welding the surface to be welded and filler material to be used shall be
checked.
 Prior to welding root opening, groove angle and the crucial dimensions shall be
checked, and groove face shall be free from oil, water and dirt.
 During welding work, the most appropriate arc length, angle and welding speed
shall be maintained so that welding defects shall be avoided, and arc energy
requirements are satisfied.
 All welding area shall be clean and inspected. After completion of inspection Box
Sections will be released for further fabrication activities and assembly
identification mark done by hard punch on the job.

(f) Sand Blasting (Surface Preparation)

Abrasives for blast cleaning shall be clean, dry and free of any constituent. Surface
preparation shall be in accordance with technical data sheet of specified paint. Surface
profile shall not be less than 15 microns and more than 150 microns. Paint shall be applied
to dry, clean prepared surfaces in accordance with manufacturer data sheet.

(g) Primer

Epoxy primer is excellent for filling micro cracks and dents. It bonds very well to base
material at one side and makes a good surface on other side to which paint adheres well.
It comes in two parts base & hardener which need to be combined and mixed before they
can be applied.

Applying Epoxy Primer: -

Start by just applying a thin coat to the area you want to cover and then leave it. It doesn’t
have to be completely dry before you put on the next coat, merely sticky to the touch.

Check that all coating materials to be used are recommended by the manufacturers for the
particular surface and condition of exposure. Painting shall be carried out with skilled
workers. All coating materials shall be applied evenly in a continuous full coat free from
over-spray, dry-spray, wrinkling, sagging, curtaining, thin spot, pinholes and other film
defects.

8|Page
 Dry film thickness shall be checked prior to shipment to project site and painting inspection
report shall be maintained.

(h) Packing and Dispatch

The painted structures after fabrication shall be protected from further damage during
transportation.
The materials will be loaded on to the vehicle using timber supports and separators and
secured properly to prevent any damage to the material while transportation to site.
Fabricated items will be delivered loose. Small items (i.e. Hardware, cleats etc) will be
packed in bag.

METHOD STATEMENT FOR FABRICATION OF STEEL STRUCTURE

Objective To fabricate steel structure as per drawing within approved limits with surface
finish to required specification.

Reference Relevant Manufacturing Drawing

Inspection & Test ISWLL/QAP/FAB/002

Plan

Procedure

1) Machined Components if Any.

Check
Raw Material from
Identification
Storage

Machining as per
Drawing

Inspection

Packing

Dispatch

9|Page
  Inspected and material issued for project to be utilized.
 Check identification mark earmarked for project material.
 Machine components as per drawing.
 Inspect the job as per drawing.
 The finished jobs are to be packed for proper rust protection and avoid any damages in
transit.
 The packing to be marked with job code and quantity.
 Shipped to site with required documentation.

Record

QUALITY PLAN -Fabrication Client Petrotec

Project C-286
Doc No. MED-03
Rev. No. 00
Date
S Componen Characte Nature of Metho Quantum Reference Format of Agency Re
N t& ristics Check / d of of Check Document Record ma
Operation Test Check/ IS Pet. Clie
nt rks
Type W
of LL
Check
PROCESS-Fabrication
1. Welding 1)Brand,
Consumable 2)Grade
s (Electrode- 3)Batch no
E6013) 4)Size
100% of lot 1)BS-EN 10025
5)AWS Class MTC MTC & DN E C R
size 2)Drawing
6)F/A NO.
7)SFA NO.
8)Chemical
9)Tensile Prop etc.
2. Weld 1)Storage
Consumable 2)issue 1)Issue
Record 1)WPS
s Control 3)Balance At Random ISWWL-STD P C R
book 2)As Specified
4)Return 2)Visual
5)Reissue etc.
3. Welding 1)Welding Parameter Review
Procedure- 2)Welding Procedure & of 100% P W R
WPS Personnel Records 1) AWS D1.1
PQR 5) Tensile 2) ASME Sec. IX
WPQ 100% of 3) As Specified P W R
6) Guide Bend Test LTR
7) Radiography Test Test
Sample
4. Welder Test- 1)Welder (welding Review 100% of 1) Approved WPS 1)Welder ID
WQT operator) of Test Card P W R
2)Welder Performance Records Sample 2) AWS D1.1 2)Qualified
Welder Log P C R
3)Welder Record

10 | P a g e
LEGENDS
MT Material Test Certificate E Execute MR Material Receipt WPS Welding Procedure
C N Note Specification
M Measurement W Witness R Review PQR Procedure Qualification Record
LTR Lab Test Report SIR Site Inspection Report P Perform WPQ Welder Performance
Qualification
DC Delivery Note C Check WQT Welder Qualification Test

Client Petrotec
QUALITY PLAN -Fabrication Project C-286
Doc No. MED-04
Rev. No. 00
Date
S Componen Characteristic Nature of Method Quantum Reference Format Agency Re
N t& s Check of of Check Document of ma
Operations Check/ Record ISW PE CLIE
NT rks
/ Process Type of LL T
Check

PROCESS-Fabrication
6. Fit up 1)Marking
2)Cutting
Dimensional 3)straightness
control 4)Notches 1) AWS
5)Edge Preparation 1)Visual D1.1
100% P C R
6)Joint Preparation 2)M 2) Approved
7)Complete dim Drawing
8)Orientation
9)Offset
10)Tack weld
7. Welding 1)Weld Visual 1) AWS
2)Completeness 1)Visual D1.1
100% P C R
3)Free from Defects 2)M 3)Approved
Drawing
8. NDE of 1)NDT of Fillet weld 1) AWS
Welding 2)NDT of Butt weld 1)DP Test 1)10% of D1.1
Fillet weld 2) ASME
2)UT P C R
2)100% of Sec V
Butt weld 3) Approved
Drawing

11 | P a g e
LEGENDS
MT Material Test Certificate E Execute DP Dye Penetrant
C T Testing
M Measurement W Witness R Review
LTR Lab Test Report SIR Site Inspection Report P Perform

DC Delivery Note VT Visual Testing C Check

Client Petrotec
Project C-286
INTEVENTION SOLUTIONS WLL Format no. MED-05
Rev. No. 00
Date
WELDING ELECTRODDE ISSUE RECORD
MATERIAL LOT No DC No

Date Sr. Brand Batch No. Electrode Qty. Issue Balance Return Reissue Remarks
No. Name Dia. Qty. Qty. Qty. Qty.

12 | P a g e
Site Engineer (ISWLL) Q.C Engineer (ISWLL) CLIENT
Name : Name : Name :
Date : Date : Date :
Signature : Signature : Signature :
Client Petrotec
Project C-286
INTERVENTION SOLUTIONS WLL Format no. MED-06
Rev. No. 00
Date
WELDING PROCEDURE SPECIFICATION (WPS)
Code : AWS D1.1 WPS No. : ISWLL/WPS/01 Rev. No. : 00
Welding Process : SMAW Supporting PQR(s) No. : ISWLL/PQR/ 01
Type : Manual Proposed WPS No. : ISWLL/PWPS/ 01

JOINT DESIGN USED

Joint Deign Single “V” Groove Weld
Backing NA
Backing Material NA
Groove Angle (ɵ˚) 45 ± 5˚
Back Gouging NA
Method of Back Gouging NA

BASE METAL FILLER METAL

Material Specification : IS 4923 AWS Specification : SFA 5.1

Type or Grade: YST 310 AWS Classification : E 6013

Thickness of Groove (t) : F/A No. : 2/1

Supplier / Brand Name: ESAB India Ltd.
Thickness of Fillet :
Size of Filler Metal (dia. mm) : 2.5mm, 3.15mm &
Tube Diameter : 4mm

Filler Metal Product Form : Flux Coated Solid

Consumable Insert : NA

Flux Type : NA

POSTION PREHEAT

13 | P a g e
 Preheat Temperature
Min.(0 C ): Ambient /
Position(s) of Groove : 6G 20˚C
Weld Progression : UPHILL Inter pass Temperature Max.(0˚C ): Below 250˚C
Position(s) of Fillet : All Preheat Maintenance : NA

POST WELD HEAT TREATMENT (PWHT)

Type of PWHT : NA
GAS
PURPOSE Gas % or Mixture Flow Rate (LPM)
Shielding Gas NA NA NA
Backing Gas NA NA NA
Trailing Gas NA NA NA
Client PETROTEC
Project C-286
INTERVENTION SOLUTIONS WLL Format no. MED-06
Rev. No. 01
Date
WELDING PROCEDURE SPECIFICATION (WPS)

Code : AWS D1.1 WPS No. : ISWLL/WPS/01 Rev. No. : 00

Welding Process : SMAW Supporting PQR(s) No. : ISWLL/PQR/ 01
Type : Manual Proposed WPS No. : ISWLL/PWPS/ 01

ELECTRICAL CHARACTERISTICS
Transfer Mode (GMAW) NA

Type of Current DC

Polarity DCEP

Amps (Ranges) See Table

Volts (Ranges) See Table

Travel Speed See Table

Mode of Metal Transfer NA

Heat Input NA

TECHNIQUE
Single or Weave bead As Applicable Method of Back Gouging NA
Initial & Inter Pass Brushing / Grinding Multiple or Single Pas Multiple
Cleaning
Manual or Automatic Manual Peening NA
Use of Thermal Process NA Single or Multiple Single
Electrode
Contact Tube Distance NA Oscillation Max. 2.5 times of
Electrode dia.

WELDING PROCEDURE

14 | P a g e
 Weld Filler Metal Current Voltage Travel Speed
Processes
Layers Dia. Amp. Type Range Range (mm /
Class
(mm) Range Polarity min.)
Max. 2.5 times of
Root Pass
Electrode dia.
1st Pass &
Rest Pass
Final Pass

Change
Approved
Rev. No. Date Description marked Prepared by Checked by
By
as
Name
Signature
Date
Client PETROTEC
Project C-286
INTERVENTION SOLUTIONS WLL Format no. MED-07
Rev. No. 01
Date
PROCEDURE QUALIFICATION RECORD (PQR)
Code : AWS D1.1 WPS No. : ISWLL/WPS/01 Rev. No. : 00
Welding Process : Supporting PQR(s) No. : ISWLL/PQR/ 01
Type : Manual Proposed WPS No. : ISWLL/PWPS/ 01
JOINT DESIGN USED
Joint Deign Single “V” Groove Weld
Backing NA
Backing Material NA
Groove Angle (ɵ˚) 45 ± 5˚
Root Opening 2.5 to 4mm
Root Face 1.5 to 3mm
Back Gouging NA
Method of Back
NA
Gouging
BASE METAL FILLER METAL
AWS Specification : SFA 5.1
Material Specification : IS 4923
AWS Classification : E 6013
Type or Grade: YST 310
F/A No.
Thickness of Groove (t) : Supplier / Brand Name: 2/1

Thickness of Fillet : Size of Filler Metal (dia. mm) : 2.5mm, 3.15mm & 4mm

Pipe Diameter : Filler Metal Product Form : Flux Coated Solid

Consumable Insert : NA

Flux Type : NA

POSTION PREHEAT

15 | P a g e
 Preheat Temperature
Position(s) of Groove : 6G
Min.(0 C ): Ambient / 20˚C
Weld Progression : UPHILL
Inter pass Temperature Max.(0˚C ): Below 250˚C
Position(s) of Fillet : All
Preheat Maintenance : NA
POST WELD HEAT TREATMENT (PWHT) GAS
% or
Type of PWHT : NA Purpose Gas Mixtur Flow Rate
e
Shielding NA NA NA
Backing NA NA NA
Trailing NA NA NA
ELECTRICAL CHARECTERISTIC
Transfer Mode
NA Volts (Range) : See Table
(GMAW)
Type of Current : DC Travel speed : See Table
Mode of Metal
Polarity : DCEP NA
Transfer :
Amps (Ranges) : See Table Heat Input : NA

Client PETROTEC
Project C-286
INTERVENTION SOLUTIONS WLL Format no. MED-07
Rev. No. 01
Date
PROCEDURE QUALIFICATION RECORD (PQR)
Code : AWS D1.1 WPS No. : ISWLL/WPS//01 Rev. No. : 00
Welding Process : Supporting PQR(s) No. : ISWLL/PQR/ 01
Type : Manual Proposed WPS No. : ISWLL/PWPS/ 01
TECHNIQUE
String or Weave bead : As Applicable Method of Back Gouging : NA
Initial & Inter Pass Cleaning : Brushing /
Multiple or String Pass : Multiple
Grinding
Manual or Automatic : Manual Peening : NA
Use of Thermal Process : NA Single or Multiple electrode : Single
Oscillation: Max. 2.5 times of
Contact Tube Distance : NA
Electrode dia.
WELDING PROCEDURE
Travel Speed
Voltage
Filler Metal Current Range (mm /
Weld Processe (volt)
min.)
Layers s
Type
Class Dia. (mm) Amp.
Polarity
Root Pass
2nd Pass
3rd Pass
4th Pass
Final Pass-1
Final Pass-2
Final Pass-3
TEST RESULT
VISUAL INSPECTION
Appearance Undercut
Porosity Convexity
16 | P a g e
Witness Inspected By : Date of Inspection :
TENSILE TEST
Specimen Dimension Ultimate Load Ultimate Tensile
Area(sq. mm) Character of Failure
No. (mm) (Newton) Load (MPa)

Tensile Test Report :-

GUIDE BEND TEST
Specimen
Type of Bend Remarks Specimen No. Type of Bend Remarks
No.

Bend Test Report no. :-

RADIOGRAPHY TEST
Film Identification No. Result
Interpreted By Organization
Radiography Report No. :-
Welder Name Stamp No.
Test Conducted By Date of Welding
Change Description Checked by Approve
Rev. No. Date Prepared by
marked as d By
Name
Signature

Client PETROTEC
Project C-286
INTERVENTION SOLUTIONS WLL Format no. MED-08
Rev. No. 01
Date
WELDER PERFORMANCE QUALIFICATION RECORD (WPQ)
Report No. ISWLL/WPQ/SMAW/01
Manufacturer Location
Identification WPQ No.
Welder Name Process
Material Batch No.
Size of T.P Qty. of T.P
Welding mach. Position
Electrode Used WPS No. :

Travel
Weld Layer Welding Process Filler Metal Current Voltage
speed
mm/mi
Process Dia. Polarity Amp. Volt
n.

17 | P a g e
Visual Inspection :
Back Chipping & LPT :
Remarks :
Prepared By Reviewed By Approved By

Client PETROTEC
Project C-286
INTERVENTION SOLUTIONS WLL Format no. MED-09
Rev. No. 01
Date
IDENTITY CARD FOR WELDERS

CLIENT: BASE METAL

LOCATION: FILLER METAL
PROJECT: DIA. / THK
PROJECT Code: PROCESS
NAME OF WELDER: POSITION:
WELDER NO:
DATE OF
QUALIFICATION:
VALID UP TO:
Name
Signature
Q.C Engineer Q.C Engineer (PETROTEC)
(ISWLL)
WE CERTIFY THE QUALIFICATION IN ACCORDANCE WITH ASME SEC. IX.

Material Thickness Type of Weld Electrodes Position Date of Test Remark / Sign.
Specificatio Range Specification
n Qualified

18 | P a g e
 Client PETROTEC
Project C-286
INTERVENTION SOLUTIONS WLL Format no. MED-10
Rev. No. 01
Date
QUALIFIED WELDER’S LOG

Sr. Welder’s Welder’s ID Procedure Position Date Qualified Remarks

Welding
No Name No. Tested Up to
. Inspector
(Date)
Name Signatur
e

19 | P a g e
Site Engineer (ISWLL) Q.C Engineer (ISWLL) CLIENT
Name : Name : Name :
Date : Date : Date :
Signature : Signature : Signature :

Client PETROTEC
Project C-286
INTERVENTION SOLUTIONS WLL Format no. MED-11
Rev. No. 01
Date
FIT-UP CHECK LIST
JOB. ASSLY No. REPORT No.
DRAWING JOB No./MARK No.
WELDER No.
No.

Sr. Mark No./Part Qty. Marki Cutting Joint Tack Orient Offset DIMENTION Remarks
No No. ng & weld ation
. Edge
Prepa
ration
A B C D

20 | P a g e
Site Engineer (ISWLL) Q.C Engineer (ISWLL) CLIENT
Name : Name : Name :
Date : Date : Date :
Signature : Signature : Signature :

Client PETROTEC
Project C-286
INTERVENTION SOLUTIONS WLL Format no. MED-12
Rev. No. 01
Date
WELD VISUAL CHECK LIST
JOB. ASSLY No. REPORT No.
DRAWING JOB No./MARK No.
DATE
No.

SR. MARK QTY CHAMPHARIN GRINDING & DIMENTION DIMENTION NDT IDENTIFICATION REMARK
No. No./PART G FINISHING (as per Dwg.) (Actual (Hard Punching / S
No. dimension) Marking)

21 | P a g e
Site Engineer (ISWLL) Q.C Engineer (ISWLL) CLIENT
Name : Name : Name :
Date : Date : Date :
Signature : Signature : Signature :

22 | P a g e
 Client PETROTEC
Project C-286
INTERVENTION SOLUTIONS WLL Format no. MED-13
Rev. No. 01
Date
DP Test Report
JOB. ASSLY No. REPORT No.
DRAWING JOB No./MARK
WELDER No.
No. No.

Stage of Test Procedure NO.

Specification ASME SEC-V, Article - 6 Developer Type Wet
Acc. Criteria ASME SEC-VIII, Div-I, App -8 Illumination Day-Light
System Used Solvent Removal Method
Developer App. Method Spraying
Material
Surface Condition Smooth & Cleaned Developing Time 8-10 min.
App. Method Spraying Cleaning consumable Solvent
Dwell Time 5-10 min. Test Temp. Ambient
Method Of Wiping Post Cleaning Wiping
Cleaning
Consumable Manufactures Brand BATCH No. Conformity Remarks
Cleaner
Penetrant
Developer

SUMMERY OF TEST RESULT

Job Description Size Interpretation Result Remarks

Site Engineer (ISWLL) Q.C Engineer (ISWLL) CLIENT

Name : Name : Name :
Date : Date : Date :
Signature : Signature : Signature :

23 | P a g e
 Client PETROTEC
Project C-286
QUALITY PLAN – Painting of Steel Structure Doc No. : FQP/ISWLL/P251/
03
Rev. No. 01
Date
Sr. Compone Nature of Metho Quantu Reference Forma Agency Rema
No nt/ Check/ d of m of Document t of rk
ISWL PET LTSPL
. Process Test Check Check Recor L RO
d TEC

1. Paint 1) Brand 100% of Lot Tech. Spec/ 1) MTC E C R

2) Type size Drawing 2) DC
3) Color
4) Expiry MTC
5) Batch No.
6) Mixing
Ratio etc.
2. Primer & Putty 1) Brand 100% of Lot Tech. Spec/ 1) MTC E C R
2) Type size Drawing 2) DC
3) Expiry
MTC
4) Batch No.
5) Mixing
Ratio etc.
3. Painting 1.Surface Visual
10% job of
1)QCS 2014 C R R
preparation inspectio 2) SSPC-SA 2.5
Dispatch Lot
n 3) BS:4232
size
4) Drawing
2.Surface Visual C R R
evenness inspectio
n

3.Primer Visual C R R
application inspectio 1) DFT
n & DFT 1) QCS 2014 REPORT
10% job of
2) Drawing
4.Paint Visual Dispatch Lot C R R
3) Tech. Spec.
application- inspectio size
Number of n & DFT
coats
5.Curing Visual C R R
inspectio
n

LEGENDS
MTC Material Test E Execute MRN Material Receipt
Certificate Note
M Measurement W Witness R Review
LTR Lab Test Report SIR Site Inspection P Perform
Report
DC Delivery Note C Check

Client PETROTEC

24 | P a g e
 Project C-286
Format no. MED-14
INTERVENTION SOLUTIONS WLL Rev. No. 01
Date

CHEK LIST FOR PAINTING

SL. No Description YE N N. Remarks

S O A
PRE-CHECK
Check for Paint
1 Check surface preparation of steel
structure before proceeding for
Painting
2 Provide Touch up wherever required
3 Ensure proper masking for areas
where paint is not desired for eg.
Threads, Field Welding joints, etc
4 Carrying out the painting as per the
drawing and technical specification to
ensure even DFT coat.
5 Time interval for second coat to be
applied as specified in manufacturer
manual

POST CHECK
12 Check for waviness, cracks,
rundown,etc
13 Check DFT of Job as per specified in
MTC

Fabrication Engineer (ISWLL) NACE LEVELL (ISWLL) Client Engineer

25 | P a g e
 Client PETROTEC

INTERVENTION SOLUTIONS WLL Project C-286

Format no. MED-15

Rev. No. 01

Date

DFT REPORT

JOB. ASSLY No.

REPORT No.
DRAWING JOB No./MARK APPLICATION
No. No. Method
BATCH No. MIXING RATIO

Sr IDENTIFICATION NO./ Stage QTY. Observed DFT in micron Remarks

. MARK NO
N
o 1 2 3 4

26 | P a g e
Fabrication / Site Engineer Q.C Engineer (ISWLL) CLIENT
(ISWLL)
Name : Name : Name :

Date : Date : Date :

Signature : Signature : Signature :

Client PETROTEC
Project C-286
Format no. MED-16
INTERVENTION SOLUTIONS WLL Rev. No. 01
Date

MACHINE COMPONENT CHECK LIST

MTERIAL GRADE
JOB. ASSLY No. REPORT No.
DRAWING No. JOB No./MARK No. LOCATION

REQUIRED DIMENSION ACTUAL DIMENSION

Sr
Visual
. Descript Qt Dia. Threa Threadin Threa Dia. Threa Threadin Threa Rema
Inspecti
N ion y L d g d L d g d rks
inne oute inne oute on
o. size (LH/RH) Depth size (LH/RH) Depth
r r r r

27 | P a g e
Site Engineer (ISWLL) Q.C Engineer (ISWLL) CLIENT
Name : Name : Name :
Date : Date : Date :
Signature : Signature : Signature :

Client PETROTEC
INTERVENTION SOLUTIONS WLL Project C-286
Format No. ISWLL/EHS-
17/WM
Frequency Monthly
Date
CHECKLIST OF WELDING MACHINE
Location

Sr. Check Point Welding Welding Welding Welding Welding Remark

No. Machine Machine no. Machine no. Machine Machine no. s
no. no.

Yes No Yes No Yes No Yes No Yes No

1 Welding machine
body is in good
condition
2 On/off switches are
in good condition
3 Double Earthing is
provided or not
4 Electrical cable is
in good condition &
free from joints.
5 Is electrical
connection given
through 30mA
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 RCCB/ELCB
6 Is proper shed/
weather protection
provided or not.
7 Welding cable is in
good condition.
8 Welding Electrode
holder is in good
condition
9 Is Welding lead
provided with
proper lugs & nut
bolt?
10 Is welding lead &
electrical cable
over lapped.
Fabrication / Site EHS Engineer (ISWLL)
Engineer (ISWLL)
Name Name
Signature of Signature of Engineer
Engineer & Date & Date

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 Client PETROTEC
INTERVENTION SOLUTIONS WLL Project C-286
Format No. ISWLL/EHS-
17/GS
Frequency Monthly
Date
CHECKLIST OF GAS CUTTING EQUIPMENT
Location

Sr. Check Point Gas Cutting Gas Cutting Gas Cutting Gas Cutting Gas Cutting Remark
No. Set No. Set No. Set No. Set No. Set No. s

Yes No Yes No Yes No Yes No Yes No

1 Gas Cylinders are

in good condition

2 Are cylinders kept

in trolley in vertical
position?
3 Is there oil &
grease on the
valve of cylinders?
4 Are hose pipe in
good condition?
5 Are hose pipes
clamped with
clamp properly?
6 Are Flash back
arrestor provided
at both side?
7 Are pressure
regulators & gauge
in working
condition?
8 Is nozzle cleaned
properly?
EHS Engineer
Fabrication / Site (ISWLL)
Engineer (ISWLL)
Name Name
Signature of Signature of Engineer
Engineer
Date Date

Client PETROTEC
INTERVENTION SOLUTIONS WLL Project C-286
Format No. ISWLL/EHS-
17/EL
Frequency Monthly
Date
MONITORING CHECKLIST FOR OPERATIONS OF POWER HAND TOOL & OTHER EQUIPMENT
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Location
Sr. Check Point YES NO N.A Remarks
No.
1 Are all Power Tools of approved double insulated type or
grounded according to this procedure?
2 Are all power tools operated by skilled and authorized
persons?
3 Is the equipment is used in the correct way? (e.g. putting
reinforcement bars vertically in a cutting machine or using
grinder wheel for cutting of the bar)
4 Are all persons provided with appropriate Personal Protective
Equipment when using portable tools and equipment?
5 Are all tools and equipment inspected prior to use?
6 Are all defective portable tools and equipment replaced,
serviced or repaired prior to use?
7 Are all tools and equipment, used by employees at their
workplace, in good condition?
8 Are rotating or moving parts of equipment guarded to prevent
physical contact or injury by items worked upon (e.g. bar
cutting machine)?
9 Are power tools used with the correct shield, guard, or
attachment provided by the manufacturer?
10 Are portable fans provided with full guards or screens having
opening of 15mm or less?
11 Is the supply line to equipment / tool equipped with a working
30 mA ELCB?
12 Are users of electric hand tools instructed not to hang / hold /
lift the equipment by its electric power cord?
13 Is the equipment / tool equipped with proper plug?
14 Is the cable / equipment away from water / moisture?

Note – In case of a ‘NO’, stop using the powered equipment / hand tool, bring the status to ‘YES’, review the
equipment and then allow continuation of use.

Fabrication / Site EHS Engineer

Engineer (ISWLL) (ISWLL)
Name Name
Signature of Signature of Engineer
Engineer
Date Date
PACKING & DISPATCH

Objective Packing the material to avoid surface damages & ship the material at site

Reference Relevant Manufacturing Drawing

Inspection & Test

Plan

31 | P a g e
 Packing

Steel
 The pre-painted structural steel assemblies are to be properly protected in the
areas where the paint may get damaged during transportation for eg. The resting
points/areas of the structure in loading, unloading & transportation.
 Ensure proper wooden packing and wrapping for surface protection.

Dispatch

 Ensure that all items are properly prepared, handled and/or packed for storage
and shipping to prevent damage to the product.
 Ensure that items loaded correspond to the shipping bill.
 Maintain records of all items that have been shipped.

Record - MED-23

Client PETROTEC
Project C-286
INTERVENTION SOLUTIONS WLL Format no. MED-23
Rev. No. 01
Date

PACKING & DISPATCHING CHECK LIST

SL. No Description YES N N.A Remarks

32 | P a g e
 O
PRE-CHECK

1 Prepare the packing list & delivery

Note according to material dispatch
plan.
2 Check job is properly covered,
wrapped and protected.
3 Check part No. tagged with each
packing.
4 Check the job quantity as per packing
list.

POST CHECK
5 Check the dispatch job as per Erection
sequence or not?

Fabrication Engineer (ISWLL) QC Engineer (ISWLL) Client Engineer

UNLOADING AND STORAGE

Objective To unload material safely, arrange, and protect material.

Reference Relevant Manufacturing Drawing

Inspection & Test

Plan
33 | P a g e
Unloading

 Material to be shipped to site separately.

 They are unloaded by crane or worker manually up to the material properties
(weight & size)

Material Arrangement, Protection & Storage

 The storage place for steel parts shall be prepared in advance and to be
approved by the client as per demarcation plan submitted before the steel
structures start arriving from the shop.
 The site-in charge shall make the following verification upon receipt of material
at site.

 For Quality certificates regarding materials and workmanship according to

these general specification and drawing.
 Whether parts received are complete without defects due to transportation,
loading and unloading, if any are well within the admissible limit.
 For the above work sufficient space must be allotted in the storage area.

 The parts shall be unloaded, sorted and stored so as to be easily identified.

 Steps shall be taken to prevent warping of items during unloading.
 The parts shall be stored according to construction symbol and markings so that
these may be taken out in order of erection.
 The parts shall be set at least 150 mm clear from ground on wooden or steel
blocks for protection against direct contact with ground and to permit drainage of
water.
 The parts shall be clean when delivered for erection.
 The materials should be placed in minimum 5% slope to avoid water pond.
 The materials shall be kept free from dirt, grease, and other foreign materials
and shall be protected from road splash. Never step on the materials.
 All bolts, nuts, washers, screws, small plates and articles generally shall be
suitably packed and identified.

Record MED-24

Client PETROTEC
Project C-286
INTERVENTION SOLUTIONS WLL Format no. MED-24
Rev. No. 01
Date

UNLOADING & STORAGE CHECK LIST

SL. No Description YES N N.A Remarks

O
PRE CHECK

1 Check the delivery Note before

unloading the vehicle.
34 | P a g e
 2 Check the material size and weight
and the capacity of crane which is
used for unloading.
3 Check the material is stacked on
wooden block and not directly with
ground.(at least 150mm from ground)
4 Check materials are stored as per
erection schedule or not?
5 Check the job is damaged during
transportation or not?
6 Check the paint damage from the job
surface.
POST CHECK
7 Ensure the storage place is near to
the work place.
8 Ensure the materials placed in
minimum 5% slope or not to avoid
water pond.

Fabrication Engineer (ISWLL QC Engineer (ISWLL) Client Engineer

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