SURIA ENGINEERING

SURIA ENGINEERING
DOSSIER FOR GF-304CR STRUCTURE

EDC/VCM EXTENTION

05TH Oct 2020

CLIENT:

M/S ENGRO POLYMER & CHEMICALS PVT LTD.,

PORT QASIM, KARACHI - PAKISTAN

D – 50 TEXTILE AVENUE S.I.T.E

KARACHI – PAKISTAN.
Call: 92 2 1 32584377
Fax: 92 21 32588802
Cell: 92 300 8238213 / 92 321 2159684
Suriaengineering@yahoo.com

www.suriaengineering.com 1
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TABLE OF CONTENTS
DOC NO.:-QC-FIL-001

Sr. No. DOCUMENTS DESCRIPTION

1. QUALITY INSPECTION PLAN (QIP) 4

2. SUMMARY FOR BILL OF MATERIAL 6

3. MATERIAL TEST CERTIFICATES 8-10

4. WPS & WQT 12-16

5. DPT PROCEDURE REPORT 18-20

6. DPT TESTING REPORT 22

7. DIMENSIONAL INSPECTION REPORT. 24-25

8. SAND BLASTING AND PAINT APPLICATION PROCEDURE 27-30

9. FIT UP LAYOUT AND RANDOM PICTURES 32-36

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1. QUA
LITY
QUALITY INSPECTION PLAN OF STRUCTURE WORK FOR

INPE
Rev. : 2
EDCVCM DE-BOTTLENECKING PLANT-GF304C/R Date : 21-Apr-20

EPCL MANUFACTURER
ITEM ACTIVITY ACCEPTANCE CRITERIA VERIFYING DOCUMENTS REMARKS
Status Sign Status Sign
1 DOCUMENTATION

CTIO
1.1 Drawings Drawings H H
1.2 Welding Procedures Specification,WQT ASME Sec-IX DWGS WPS/PQR R -
1.3 Marking and Cutting Plan As per Drawing - R R
1.4 Material Identification/ Verification & Control of Heat Number Material Test Certificate MTCs H H
2 Material Identification/ Verification & Control of Heat Number PO/ ASME II Part A/ DWGS MTCs H W
2.1 Column As per Drawing Specs. R
2.2 Base Plates As per Drawing Specs. R

N
2.3 Corner Beams As per Drawing Specs. R
2.4 Mid Beams As per Drawing Specs. R
2.5 Mid Support Beams As per Drawing Specs. R
2.6 Gusset Plates As per Drawing Specs. R
2.7 Bracings of Structure As per Drawing Specs. R
2.8 Internal and External Direct Attachments As per Drawing Specs. R

PLA
2.9 Supporting Saddles As per Drawing Specs. R
3 FABRICATION Drawings QIP W H
3.1.1 Marking Inspection Before Cutting of All Parts As per Drawing W H
3.1.2 Cutting of marked parts As per Drawing W H
3.2 MACHINING AND DRILLING As per Dwg.Specifciation QIP/Insp Report W H
3.2.1 Inspection of hole marking before drilling As per Drawing W H

N
3.2.2 Drilling of Plates / Hole diameter measurement As per Drawing W H
3.2.3 Extra edges flushing and Burr Removal As per Drawing W H
3.3 FIT-UP Drawings QIP H H
3.3.1 Fit-up check of each weld as per Drawing
3.4 WELDING ASME Sec:IX & QIP W R
3.4.1 Welding of each weld as per WPS Dwgs.
4 FINAL INSPECTION ASME SEC-V,Drawings Inspection & Test Reports H H
4.1 Visual & Dimensional inspection according to last revised drawing H W
4.2 Surface preparation for painting W W
4.3 Painting and DFT as per specifications R R
5 NDE
5.1 100% DPT of all column joints W H
5.2 20% DPT of bracings W H
5.3 100% VT of all Joints W H
ROUTE PREPARED BY REVIEWED BY APPROVED BY
NAME ALTAF KHAN NAUMAN SURIA
SIGNATURE
DATE
Legends
H = Hold Point (Mandatory)
M = Monitor
R = Review (Documentation)
W = Witness

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2. BOQ SUMMARY REPORT

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MATERIAL FOR FILTER-GF-304C R (Dated:20/6/2020)

S.NO PROFILE DIMENSION QTY. KG/M WEIGHT(KG) UOM Qty.in 12M Pcs Remarks
1 HEA120 125x125 36 26 936 Meter 3
2 HEA100 100x100 36 21.32 768 Meter 3 6.53 M
3 IPE160 150x75 24 13.3 319 Meter 2
4 CT100 (IPE200) 200x100 12 12.5 150 Meter 1 4M
5 L70 75x75 12 6.75 81 Meter 1
6 Flat Bar 50x5 12 2.5 30 Meter 1
7 Rod-25mm Dia-25mm 4.86 3.75 18 Meter
8 10MM 10 2.69 78.5 211 SQ.M
9 20MM 20 1.05 157 165 SQ.M
Weight (KG) 2678

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3. MATERIAL TEST CERTIFICATE

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10MM PLATE

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20MM PLATE

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SURIA ENGINEERING
Welder Qualification
WPS NO. SE-QC-WPS-MS36B-03F Test Date 19-11-2019

Name:M.Naveed S/O Abdul Satter NIC#43402-0460376-1

Project: De-Bottel Necking of EDCVCM PLANT(PORT QASIM,KARACHI)

ACTUAL VALUES
VARIABLE 4. WPS & WQT USED IN
QUALIFICATION
QUALIFICATION RANGE
ASME IX
Process SMAW SMAW
Process Type MANUAL MANUAL
Backing Yes Yes
Material Specification SA-36 SA-36
P No. & Group No. (QW-423) P.No 1 & Gr.1 P.No.1 to 15F
Thickness 10mm 20mm
Diameter N/A N/A
Groove 60 DEGREE 60 DEGREE
Fillet ALL ALL
Filler Metal Space SFA No. 5.1 5.1
Filler Metal Class E-7018 E-7018
Filler Metal No. 4 3&4
Deposited Weld Thickness 10MM 10MM
Position 3G 3G
Welding Progression UPHILL UPHILL
Shielding Gas N/A N/A
Backing Gas N/A N/A
Current Amp 105-155 105-155
Polarity DC+VE DC+VE

For SURIA ENGINEERING:QA/QC ENGINEER For SURIA ENGINEERING:

NAME: Altaf Khan NAME: Noman Suria
Signature: Signature:
Date: Date:

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SURIA ENGINEERING
Welder Qualification
WPS NO. SE-QC-WPS-MS36B-03F Test Date 03-12-2019

Name:Salman S/O Niaz Muhammad NIC#42401-2947214-7

Project: De-Bottel Necking of EDCVCM PLANT(PORT QASIM,KARACHI)

ACTUAL VALUES
QUALIFICATION RANGE
VARIABLE USED IN
ASME IX
QUALIFICATION
Process SMAW SMAW
Process Type MANUAL MANUAL
Backing Yes Yes
Material Specification SA-36 SA-36
P No. & Group No. (QW-423) P.No 1 & Gr.1 P.No.1 to 15F
Thickness 10mm 20mm
Diameter N/A N/A
Groove 60 DEGREE 60 DEGREE
Fillet ALL ALL
Filler Metal Space SFA No. 5.1 5.1
Filler Metal Class E-7018 E-7018
Filler Metal No. 4 3&4
Deposited Weld Thickness 10MM 10MM
Position 3G 3G
Welding Progression UPHILL UPHILL
Shielding Gas N/A N/A
Backing Gas N/A N/A
Current Amp 105-155 105-155
Polarity DC+VE DC+VE

For SURIA ENGINEERING:QA/QC ENGINEER For SURIA ENGINEERING:

NAME: Altaf Khan NAME: Noman Suria
Signature: Signature:
Date: Date:

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SURIA ENGINEERING
Welder Qualification

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WPS NO. SE-QC-WPS-MS36B-03F Test Date 04-09-2020

Name: Kashif Iftikhar S/O Iftikhar Ahmad NIC#31302-67148841-5

Project: De-Bottel Necking of EDCVCM PLANT(PORT QASIM,KARACHI)

ACTUAL VALUES
QUALIFICATION RANGE
VARIABLE USED IN
ASME IX
QUALIFICATION
Process SMAW SMAW
Process Type MANUAL MANUAL
Backing Yes Yes
Material Specification SA-36 SA-36
P No. & Group No. (QW-423) P.No 1 & Gr.1 P.No.1 to 15F
Thickness 10mm Unlimited
Diameter N/A N/A
Groove 60 DEGREE 60 DEGREE
Fillet ALL ALL
Filler Metal Space SFA No. 5.1 5.1
Filler Metal Class E-7018 E-7018
Filler Metal No. 4 3&4
Deposited Weld Thickness 12MM 20MM
Position 3G 3G
Welding Progression UPHILL UPHILL
Shielding Gas N/A N/A
Backing Gas N/A N/A
Current Amp 105-155 105-155
Polarity DC+VE DC+VE

For SURIA ENGINEERING:QA/QC ENGINEER For SURIA ENGINEERING:

NAME: Altaf Khan NAME: Nauman SURIA
Signature: Signature:
Date: Date:

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5. DPT PROCEDURE REPORT

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1.0 Scope.

This Procedure Provides a System of general conditions and Specific Instructions to perform Liquid
Penetrant Examination in accordance with the applicable ASME code edition for Examination of
Carbon Steel, Stainless Steel, Welds and on Porous Material.

2.0 Equipment and Material.

2.1 Penetrant Material used Shall be water Washable, Visible Colour contrast of the
Following Specifications
2.1.1 Brand
Magnaflux Spot Check
2.1.2 Material Specifications
Penetrant SLK-SPI in aerosol can.
Cleaner SKC-S in aerosol can.
Developer SKD-S2 in aerosol can.
2.2 Any change in Material from the above list shall require requalification of Procedure
2.3 Intermixing of Penetrant Materials of different manufacturers is not permitted.

3.0 Procedure.

3.1 Surface Preparation.

Surfaces to be Examined may be in the as Welded, as rolled condition Grinding may be

necessary in certain cases where surface Irregularities Could Mask unacceptable
Discontinuities.

3.2 Pre-Examination Cleaning.

3.2.1 Prior to Penetrant application the Surface to be Examined and all the adjacent Areas
Within 25mm Shall be Cleaned by Mechanical Means and Solvent to remove dirt, grease
Scale, Welding flux or other matter which could interfere with the Examination
3.2.2 Operations that may Close the opening and Compromise the integrity of the Examination
Such as sand blasting are not recommended when these operations are being performed.
3.2.3 A Minimum of five minutes Shall be allowed for drying the surface to be Examined
Accomplished by evaporation before applying Penetrant.

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3.3 Techniques for Standard Temperature.

3.3.1 The Temperature of the Penetrant and the Surface of the part to be Examined Shall
not be below 5˚c nor above 52˚c, Local Heating or Cooling is permitted.

3.3.2 Penetrant Application.

The Penetrant Shall be Applied by Spraying, so that all Surface under Examination
Shall be Thoroughly and uniformly covered by Penetrant.

3.3.3 Penetrant Dwell Time.

After Application excess Penetrant is drained out from the part allowing suitable Dwell
Time of minimum 5 minutes. The area to be examined Shall remain covered by Penetrant
throughout the Dwell time.

3.4 Penetrant Removal.

3.4.1 After Dwell time the Penetrant on the Surface Shall be Removed by using Clean with
Cloth This operation Shall Continue until most traces of Penetrant on the surface is
Removed.
3.4.2 The Remaining Traces of Penetrant Shall be Removed be wiping the Surface Clean
with Cloth moistened with solvent remover, to Minimize removal of Penetrant from
discontinues, care Shall be taken to avoid excess Solvent Remover.
3.4.3 Flushing the surface with solvent remover following application of the penetrant and
prior to developing is strictly prohibited.

3.5 Application of Developer.

3.5.1 The developer is of Solvent, Suspended wet type and shall be applied as soon as possible
after excess penetrant has been removed and part is dried Developer Shall be Sprayed in
such a manner to assure complete coverage with a thin uniform film. The Second coat
may be applied across the first coat.

4.0 interpretation of indication.

4.1 All examination Shall be performed in ordinary sun light

4.2 Observation of the formation of indications Shall be performed during the application of
Developer. If defects are present they will show up as red indications on white Developer
Coating.

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5.0 Acceptance standards

5.1 The Following acceptance standards shall apply which have been referred from ASME
Sec-I, Sec VIII Division -I
5.2 All Welds Such as Longitudinal and Circumferential seams, including fillet weld
Pressure Parts. Joining of Nipples. Header Shall be Free of all relevant Indication
5.2.1 All Cracks. Lack of fusion and relevant imperfections

x______________________________________x

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6. DPT TESTING REPORT

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7. DIMENSIONAL INSPECTION
REPORT

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ELEVATION.102.950
Beam to beam distance found as per drawing.

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LINE FRAME-A & B

Beam to beam distance found as per drawing.

LINE FRAME-01
Beam to beam distance found as per drawing.

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8. SAND BLASTING AND

PAINTING APPLICATION
PROCEDURE

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.
Purchaser: Engro Polymer & Chemical
PO:
Limited. S a n d B l a s ti n g a n d P a i n ti n g A p p l i c a ti o n
Doc. No.: SE/EPCL/001
Project: EDC/VCM EXTENSION P ro ce d u re
Rev.:00

Painting Procedure

DOCUMENT CHANGE RECORD

Page Rev. Date Rev: Description Reviewed by A p p ro v e d b y

M .R G.M

0 04-01-2020 As per client comments

Name Designation Signature

Prepared By Altaf Khan QC Engineer

Approved By Nauman Suria

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Purchaser: Engro Polymer & Chemical

PO:
Limited. Sand Blasting and Painting Application
Doc. No.: SE/EPCL/001
Project: EDC/VCM EXTENSION Procedure
Rev.:00

1) General:

This procedure covers the outline of procedure adapted for the sand blasting
and primer application for structure.

2) Surface Preparation:

 Surface preparation shall be carried out by sand blasting and shall be

carried out after completion of fabrication.

 Sand blasting method shall be adopted for surface preparation. Before

blasting it shall be ensured that all weld spatters, flux and slag are removed
from weld beads.

 It shall be ensured that blasting nozzle pressure is suitable for achievement of

require profile of the blasted surface.

 Sand blasting could be done in late hours of a day but subject to weather condition.
Sand blasting shall not be done when surface temperature is less than 3°C above
the dew point and relative humidity is greater than 85% or there is a possibility that
blasted surface shall be subject to wetting before application of primer.

 Before blasting, oil, grease or other oily objects, if any, shall be removed with the
help of any detergent wash.

 All painted identification marks on parts of equipment shall be marked

permanently with the help of “Hard Punching”.

 To prevent the appearance of rust on blasted surface, primer shall be applied

within 3-4 hrs time.

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Purchaser: Engro Polymer & Chemical

PO:
Limited. Sand Blasting and Painting Application
Doc. No.: SE/EPCL/001
Project: EDC/VCM EXTENSION Procedure
Rev.:00

3) PAINT APPLICATION:

Before starting of painting activities, "Manufacturer’s Data Sheets" will be reviewed

for type of components and their mixing ratio, pot life, coverage against DFT,
recommended thinner and drying time for over coating.

Activities involved in primer application are as below:

3.1) Primer Mixing:

Base will be stirred thoroughly to homogenize. Then hardener will be added to base
in recommended ratio as mentioned in “Manufacturer's Data Sheet” with constant
stirring. A
recommended solvent shall be mixed for required thinning of primer.

3.2) Primer Application:

3.2.1) Primer Application Method:

Roller and or brush shall be used for application of Primer, if not restricted by Primer
Specification Sheets” by manufacturer.

3.2.2) Production Painting (Primer Coats):

 After sand blasting primer shall be applied within 3 to 4 hours of blasting activity.

 After each coat, surface will be left for a period recommended for drying and recoating.

 Such quantity of primer shall be removed from containers and mixed with
hardeners and thinner, which must be consumed same day and with-in the Pot-life
time.

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 Recommended quantity of thinner shall be added to achieve required flow ability of

primer.

 While applying the primer care shall be taken that paint should not be dripped,
sagged, skipped or dripped-off during application or immediately after application, if
these defects are detected then immediately be dressed with brush. If defect is not cured
then primer shall be removed completely and re-coated with the same system.

Purchaser: Engro Polymer & Chemical

PO:
Limited. Sand Blasting and Painting Application
Doc. No.: SE/EPCL/001
Project: EDC/VCM EXTENSION Procedure
Rev.:00

4) INSPECTIONS:

During surface preparation and primer application following inspection shall be carried out.

 For Surface Preparation:

Profile to be checked with the help of profile gauge. Profile reading

shall be as recommended for Sa. 2.5 standard.

 DFT of each coat:

DFT of each coat shall be 80-100 Microns and should be measured at 5 spots per 9
SQ.M, and for area less than 9 SQ.M; at least 3 spots shall be measured.

Average of these readings shall be with in range of average DFT recommendation

by paint manufacturer.

5) Paint System:

Following paint system shall be adopted for structure including (ladder /Platforms):

S.No. Description Make

1 RED OXIDE PRIMER NIPPON

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7. FIT UP LAYOUT & RANDOM

PICTURES

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