SURIA ENGINEERING

DOSSIER FOR SUBSTATION STRUCTURE

EDC/VCM EXTENTION

22ND JAN 2021

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

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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 8-11

4. WPS & WQT 13-17

5. DIMENSIONAL INSPECTION REPORT. 19-23

6. SAND BLASTING AND PAINT APPLICATION PROCEDURE 26-29

7. FIT UP LAYOUT AND RANDOM PICTURES 31-33

2
3
 1. QUA
LITY
INPE
CTIO QUALITY INSPECTION PLAN OF STRUCTURE WORK FOR
EDCVCM DE-BOTTLENECKING PLANT-SB Structure
Rev. :
Date :
2
21-Apr-20

ITEM

1
1.1
DOCUMENTATION
Drawings
N ACTIVITY ACCEPTANCE CRITERIA VERIFYING DOCUMENTS

Drawings
Status

H
EPCL

Sign
MANUFACTURER

Status

H
Sign
REMARKS

1.2 Welding Procedures Specification,WQT ASME Sec-IX DWGS WPS/PQR R -

PLA
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
2.3 Corner Beams As per Drawing Specs. R
2.4 Mid Beams As per Drawing Specs. R
2.5
2.6
2.7
2.8
Mid Support Beams
Gusset Plates
Bracings of Structure N
Internal and External Direct Attachments
As per Drawing Specs.
As per Drawing Specs.
As per Drawing Specs.
As per Drawing Specs.
R
R
R
R
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
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 11/12/2020 11/12/2020
Legends
H = Hold Point (Mandatory)
M = Monitor
R = Review (Documentation)
W = Witness

4
2. BOQ SUMMARY REPORT

5
 BILL OF MATERIAL FOR S.B STRUCTURE (REV-04)
S.NO PROFILE DIMENSION QTY. UOM KG/M WEIGHT(KG) Qty.in 12M Pcs Remarks
1 HEA200 200x200 12 Meter 50 600 1 One Spare Available
2 IPE300 300x150 24 Meter 50 1200 2
3 IPE240 250x125 24 Meter 40 960 2
4 UPN200 200x75 48 Meter 26 1224 4
5 UPN150 150x75 12 Meter 13 160 1
6 L70 75x75 12 Meter 6 77 1
7 MS Plate-10mm 10 3 SQ.M 236 707
8 MS Plate-20mm 20 3 SQ.M 471 1413
Weight (KG) 6340

6
3. MATERIAL TEST CERTIFICATE

7
8
IDENTIFICATION MARK ON BEAM-200x200

MTC Document:

9
10MM Plate

MTC Document:

10
20MM PLATE

11
.

4. WPS & WQT

12
 S U R IA E N G IN E E R IN G

W E L D IN G P R O C E D U R E S P E C IF IC A T IO N (W P S )

11-December-2020
C lie n t : EPCL D a te :
W e ld in g P r o c e d u r e S p e c if ic a t i o n N o . : SE-QC-WPS-MS36B-03F Project: EPCL (SB STRUCTURE)
R e v is io n : S u p p o rtin g P Q R N o .: S E -Q C -P Q R -M S 3 6 B -0 1 A
W e ld in g P r o c e s s ( e s ) : SM A W T y p e (s ) : M anual
C ode / STD : A s p e r A S M E S e c tio n IX

N o te :
R o o t , F illin g a n d c a p p in g to b e d o n e b y S M A W p r o c e s s
P la te T h ic k n e s s M a x im u m 4 0 m m
S h e ll to S h e ll a n d F ille t w e ld a ll th ic k n e s s e s .

to P .N o . 1 G ro u p N o . 1
P .N O . 1 G ro u p N o . 1
B A S E M E T A L (Q W .4 0 3 ) O R

S p e c ific a tio n ty p e a n d G r a d e A S T M S A -3 6 G ra d e B
to S p e c ific a tio n ty p e a n d G r a d e A S T M S A -3 6 G ra d e B
O R

B a s e M e ta l : G roove 2~4m m F ille t F ille t A ll th ic k n e s s

B a s e P la t e SA36 16m m F ille t
O th er: P ip e D i a r a n g e u n l im it e d F ille t

F IL L E R M E T A L S PO STW E LD H E AT TR E A TM E N T
(Q W .4 0 4 ) ( Q W .4 0 7 )
SM AW SM AW
R O O T H O T PA SS F IL L /C A P R O O T F IL L C A P T e m p eratu re R an g e : N /A
S p e c . N o . (S F A ) 5 .1 5 .1 T im e R a n g e : N /A
A W S N o . ( C la s s ) E -7 0 18 E -7 0 18 S o a k in g T im e a t M a x T e m p : N /A
F .N o . 4 4
A . N o. 1 1
S iz e o f F ille r M e t a ls 3 .2 m m / 4 m m 3 .2 m m / 4 m m G A S
W e ld M e ta l F /C -E 70 18 E 7018 (Q W -4 0 8 )
F ille t A ll T h ic k n e s s A ll T h ic k n e s s S h ie ld in g G a s ( e s ) :
E le c tr o d e F lu x (C la s s ) P ercen t :
F lu x T r a d e N a m e F lo w :
C o n s u m a b le I n s e r t ` G as : N /A
O th er T r a ilin g S h ie ld in g G a s C o m p o s itio n : N /A
E a c h b a s e & f ille r m e ta l c o m b in a tio n s h o u ld r e c o r d in d iv id u a lly

P O S I T I O N S ( Q W .4 0 5 ) P O S T W E L D H E A T T R E A T M E N T ( Q W .4 0 7 )
P o s itio n ( s ) o f G r o o v e V e r tic a l T e m p e r a tu r e R a n g e
W e ld in g P o s it io n : U p 3 G T im e R a n g e
P o s itio n ( s ) o f F ille t A L L

P R E H E A T ( Q W .4 0 6 ) G A S ( Q W .4 0 8 )
P e r c e n t C o m p o s itio n
P r e h e a t T e m p . M in . 55 D eg C G a s (e s ) (M ix tu r e ) F lo w R a te
I n t e r p a s s T e m p M a in t a in . 250 D eg C S h ie ld in g
P r e h e a t M a in te n a n c e (I f R e q u ir e d ) B y P r o p a n e T o rc h T r a ilin g - - -
B a k in g o f e le c t r o d e 250 D eg C B a c k in g - - -

E L E C T R I C A L C H A R A C T E R I S T I C S ( Q W .4 0 9 )
C u rren t A C or D C D C SM AW S T -(E N )
P o la r ity
A m p s . (R a n g e ) SM AW 8 0 -2 0 0 R E V (E P )
V o lts (R a n g e ) 1 8 -2 8

E le c t r o d e w ir e fe e d s p e e d 4” – 6”
E le c t r o d e S i z e a n d T y p e 2 .3 m m -4 m m

T E C H N I Q U E ( Q W .4 1 0 )
S trin g o f W e a v e B e a d A ll S tr in g
O r ific e o r G a s C u p S iz e N /A
I n i tia l a n d in t e r p a s s C le a n in g (B r u s h in g , G r i n d in g , e tc .) B r u s h in g & G r in d in g / P o w e r g rin d in g

M e th o d o f B a c k G o u g in g P o w er B ru sh
O s c i lla t io n P o w e r G r in d in g
C o n ta c t T u b e to W o r k D is ta n c e N /A
M u lt i p le o r S in g le P a s s ( p e r s id e ) M u lti p le s
M u lt i p le o r S in g le E le c t r o d e s S i n g le
T ra v e l S p e e d (R a n g e ) 4 " -6 "
P e n n in g
O th e r

F ille r M e ta l C urren t
W e ld T ype A m p V o lt T ravel O th e r
L ayers P ro cess C la s s D ia . P o la r R ange R ange Sp eed
R O O T SM A W E 7018 3 .2 / 4 D .C 8 0 -2 0 0 18 -2 8 4 "- 6 "
H O T P A S S (I f R e q .) SM A W E 7018 3 .2 / 4 D .C 8 0 -2 0 0 18 -2 8 4 "- 6 "
F IL L IN G 1 SM A W E 7018 3 .2 / 4 D .C 8 0 -2 0 0 18 -2 8 4 "- 6 "
FILLING 2(If Req.) SM A W E 7018 3 .2 / 4 D .C 8 0 -2 0 0 18 -2 8 4 "- 6 "
C A P P IN G SM A W E 7018 3 .2 / 4 D .C 8 0 -2 0 0 18 -2 8 4 "- 6 "

Prepared By Approved By
SURIA ENGINEERING SURIA ENGINEERING
Name: Altaf Khan Name: Nauman Suria
Signature: Signature:

Date: Date:

13
 SURIA ENGINEERING
Welder Qualification
WPS NO. SE-QC-WPS-MS36B-03F Test Date 04-11-2020

Name:M.Waqas S/O Abdul Ghaffar NIC#43402-0460376-1

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 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: Noman Suria
Signature: Signature:
Date: Date:

14
15
 SURIA ENGINEERING
Welder Qualification
WPS NO.SE-QC-WPS-MS36B-03F Test Date 12-09-2020

Name: Muhammad Rashid S/O Muhammad Yousuf NIC#41104-6636420-7

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

ACTUAL VALUES
QUALIFICATION
VARIABLE USED IN
RANGE 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 40mm
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 For SURIA ENGINEERING:

ENGINEER
NAME: Altaf Khan NAME: Nauman Suria
Signature: Signature:
Date: Date:

16
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7. DIMENSIONAL INSPECTION
REPORT

18
ELEVATION.102.970
Beam to beam distance found as per drawing.

ELEVATION.105.970
Beam to beam distance found as per drawing.

19
ELEVATION.108.970
Beam to beam distance found as per drawing.

ELEVATION.109.670
Beam to beam distance found as per drawing.

20
LINE FRAME-2
Beam to beam distance found as per drawing.

21
LINE FRAME-16A
Beam to beam distance found as per drawing.

22
LINE FRAME-15G
Beam to beam distance found as per drawing.

23
 DOCUMENT NO – DVD-010-016
REV- 00
DATE- 15-11-2019
PAGE- 01 of 01

DIMENSIONAL INSPECTION REPORT

CLIENT- ENGRO POLYMER ITEM DESCRIPTION – STEEL STRUCTURE
DRAWING NO- 8326-06-006-D1340-001 STAGE INSPECTION – CONNECTIONS DIMENSION
SHOP MANUFACTURE NO.- SB STRUCTURE FINAL INSPECTION - YES
REV NO- 04 INSPECTION AGENCY: ENGRO POLYMER
ATTACHMENT: SKETCH: DRAWING: DIMENSION UNITS- MILLIMETERS INCHES

Size (mm)
Serial No. Location Description QTY. Remarks
Drawing Accepted Rejected
01 EL-102.970 TOS UNO. IPE240/SSC1 01 2320 Accepted
02 EL-105.970 TOS UNO. IPE240/SSC1 01 2320 Accepted
03 EL-108.970 TOS UNO. IPE240/SS/SS 01 7220 Accepted
04 EL-108.970 TOS UNO. IPE240/SS/SS 01 7220 Accepted
05 EL-108.970 TOS UNO. IPE240/SSC1 01 1245 Accepted
06 EL-108.970 TOS UNO. IPE240/SSC1 01 2320 Accepted
07 EL-108.970 TOS UNO. L70/LT/LT 01 1414 Accepted
08 EL-108.970 TOS UNO. L70/LT/LT 01 1414 Accepted
09 LINE FRAME 2 CT150/LT/KRC1 01 3520 Accepted
10 LINE FRAME 2 CT150/LT/KRC1 01 3520 Accepted
11 SECTION-14A CT150/LT/KRC1 01 1920 Accepted
12 SECTION-14A CT150/LT/KRC1 01 1920 Accepted
13 EL-109.670 TOS UNO. IPE300/SS1 01 8735 Accepted
14 EL-109.670 TOS UNO. IPE300/SSC2/SSC3 01 8720 Accepted
15 EL-109.670 TOS UNO. UPN120/SS/SS 01 1720 Accepted
16 EL-109.670 TOS UNO. UPN120/SS/SS 01 1720 Accepted
17 EL-109.670 TOS UNO. UPN120/SS/SS 01 1720 Accepted
18 EL-109.670 TOS UNO. L70/LT/LT 01 2439 Accepted
19 EL-109.670 TOS UNO. L70/LT/LT 01 1219.5 Accepted
20 EL-109.670 TOS UNO. L70/LT/LT 01 609.75 Accepted
21 EL-109.670 TOS UNO. L70/LT/LT 01 2439 Accepted
22 EL-109.670 TOS UNO. L70/LT/LT 01 1219.5 Accepted
23 EL-109.670 TOS UNO. L70/LT/LT 01 609.75 Accepted
24 SECTION-15G HEA200/PST-1 01 3735 Accepted
25 Detail ST-01 UPN200 01 4740 Accepted
26 Detail ST-01 UPN200 01 4740 Accepted
27 Detail ST-01 UPN200/SS 01 1305 Accepted
28 Detail ST-01 UPN200/SS 01 1305 Accepted
29 Detail ST-01 UPN200 01 5073 Accepted
30 Detail ST-01 UPN200 01 5073 Accepted
31 Detail ST-01 UPN200/SS 01 1824 Accepted
32 Detail ST-01 UPN200/SS 01 1824 Accepted
33 Detail ST-01 UPN200 01 5026 Accepted
34 Detail ST-01 UPN200 01 5026 Accepted
35 Detail ST-01 UPN200/SS 01 1385 Accepted
36 Detail ST-01 UPN200/SS 01 1385 Accepted

QC INSPECTOR SURIA QUALITY DEPT.

SIGNATURE SIGNATURE
NAME SHAKEEL ABBASI NAME ALTAF KHAN
DATE 04-01-2021 DATE 04-01-2021

24
Limited. 8. SAND BLASTING AND
Purchaser: Engro Polymer & Chemical
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
PO:
Doc. No.: SE/EPCL/001
Project: EDC/VCM EXTENSION P ro ce d u re
Rev.:00

PAINTING APPLICATION Painting Procedure

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

25
26
 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.

27
 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.

 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.

28
 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 within 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

29
7. FIT UP LAYOUT & RANDOM
PICTURES

30
31
32
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