Silo-1 Fit-Up Cone to Shell(Transition Piece) Inspection observations Dated:22/08/2018:

1. Groove Joint surface totally rusted and not suitable for welding.

2. Groove joint Fit-Up root gap observed more than 6mm and it should be within 3mm.

3. All gas cutted edged must be grinded to visible steel and perform DPT prior to welding (NDT must
be witnessed by TPI).

4. Additional plates installed to rectify Improper fit-up in between Cone to Shell. Full Welding is not
possible. Hence it is recommended to install anchor bolts for Shell (Transition Piece).

5. Cone piece anchor bolts not installed in 90 degree angle. Hence nuts are NOT properly seated.
(Wedge washers/Taper washers are preferred where ever required as per site Condition.)

6. Cone piece holes observed oversize and improperly covered with additional plate which is not
acceptable.
(Additional washer plate to be installed beneath the nut and washer and it should cover the hole
fully where ever required as per site condition.)

7. Some bolts not fully tightened, hand tightening to be done and must be witnessed by TPI.

8. After installing nuts, the bolt end threads are NOT exposed at some locations.
(At least three turns of the thread should be visible at the end of the bolt to ensure that nut will
maintain full tension.)

8. Shell stiffener plates gouging observed DPT to be performed prior to re-welding.

9. Unqualified welders are working for critical joints like cone to shell joint, Hopper to hopper ,SS
liner plates and Hydraulic piping, Qualified welders to be mobilized and certificates to be produced.

10. Welding Electrodes (E7018) must kept in portable ovens.

(Temperature to be maintained as per manufacturer Recommendations.)

11. MTCs is not available for Anchor Bolts and Nuts.

 Witnessed By
Mr. K Siva Kumar(TUV-SUD South Asia Pvt. Ltd.)

Mr. D Hari Kishore(KPCL)