Quality Hand Book

QUALITY HAND BOOK
MECHANICAL
QUALITY HAND BOOK – MECHANICAL WORKS
MECHANICAL WORKS
1|P ag e ISSUE: MARCH- 2020

Table of Contents - Mechanical Works

1. Receipt and Storage --------------------------------------------------- 3
2. Calibration of Inspection Measuring and Test Equipment (IMTE) -------- 7
3. Welding Inspection --------------------------------------------------- 8
3.1 Welding Consumables ----------------------------------------------------- 8
3.2 Before Welding ------------------------------------------------------ 9
3.3 During Welding ------------------------------------------------------ 9
3.4 After Welding ----------------------------------------------------- 10
4. Non Destructive Testing ------------------------------------------------ 16
4.1 Radiography Test ------------------------------------------------------ 16
4.2 Magnetic Particle Test ----------------------------------------------------- 17
4.3 Liquid Penetrant Test ------------------------------------------------------ 18
4.4 Ultrasonic Test ----------------------------------------------------- 19
5. Post Weld Heat Treatment ------------------------------------------------ 21
6. Pressure Testing -------------------------------------------------- 23
7. Pneumatic Testing ------------------------------------------------------ 24
8. Inspection – Structures ------------------------------------------------------ 25
8.1 Fabrication ------------------------------------------------------ 25
8.2 Trial Assembly at Shop ----------------------------------------------------- 28
8.3 Erection ------------------------------------------------------ 30
8.4 Bolting and Tightening ----------------------------------------------------- 32
8.5 Torqueing and Camber of Steel Girders ---------------------------------- 33
8.6 Launching of Steel Girders ------------------------------------------------- 34
9. Inspection – Piping ------------------------------------------------------ 36
9.1 Fabrication ------------------------------------------------------ 36
9.2 Erection ------------------------------------------------------ 37
10. Inspection - Storage Tanks ------------------------------------------------------ 40
11. Inspection - Static Equipment ----------------------------------------------------- 42
12. Inspection - Rotary Equipment ---------------------------------------------------- 44
13. Inspection – Surface Preparation & Painting --------------------------------- 46
14. Inspection - Insulation ------------------------------------------------------ 49

1.0 Receipt and Storage
Do’s: -
1.1 Receipt: -
 Ensure necessary arrangements for unloading and handling Materials
before receipt of Material / Equipment.
 Ensure to verify the Quantity & Condition of Materials received at Site
 Ensure inspection as per approved QAP / FQP.
 Check the material and equipment conforms to size, type, quantity, and
configuration specified in the purchase order and as per drawings.
 Verify all the documents from supplier viz. DC/ LR copy / IRN / MDCC and
inspection and testing reports as per approved Quality plan.
 Verify the identification details and correlate with the documents received
along with consignment.
 Check for transit damages to material / equipment.
 Verify items are free of damages caused by fire / high temperatures /
Inundation / weather exposure / damage due to tie down or rough
handling.
 Review supplier documentation for special identification, marking and
tagging required by the purchase order or contract.
 Promptly identify and report all Over /Shortage / Rejected / Damage of
items and initiate necessary actions.
RECEIPT INSPECTION

1.2 Storage: -
 If storage type and preservation class is not mentioned for any
items/components, the same shall be done as per OEM
guidelines/manual.
 After inspection, before storing the equipment, it should be checked for
any damage to packing.
 Handling of equipment should be done with utmost care without
damaging package/equipment and only by authorised manpower &
requisite tools & tackles.
 All equipment / material should be placed appropriately in the pre-
designated area / location (under cover / open yard) of storage
immediately after arrival at Site. Adequate care shall be taken to
protect Material, if placed in open yard during the summer / rainy
season.
 Verify and ensure the storage condition/stock status of the customer
supplied material.
 The store houses and surrounding areas should have proper drainage
facility for the sub-soil, surface and rain water. The water should not be
allowed to accumulate in these areas, especially where the material is
stored.
 The store houses and surrounding areas shall not have any unwanted
vegetation to avoid situations of Fire incidents.
 Level should be maintained for all the packages and equipment and
should be uniformly supported to avoid distortion. The long packages
should be supported at intermediate places also, so as to avoid sagging
during storage.
 Store houses should preferably be equipped with proper lifting devices
to ensure normal handling of equipment.

 For storage of heavy equipment, the roof/walls may be suitably

constructed / fabricated in such a manner to facilitate easy storage and
retrieval.
 Ensure that the Equipment / Material is kept on levelled and raised
ground with concrete / brick paving below.
 Ensure to keep the steel members on the wooden sleepers or concrete
blocks to maintain distance from ground. Spacers of wood or steel to be
provided as per standards / specification.
 In case of damage or peeling off of the paints/primers and rust
formation, materials to be cleaned appropriately and reapplied with
paint/primer.
 Galvanised structures shall be stored in prescribed manner to prevent
formation of white rust.
PIPES STACKED WITH END CAPS PIPES STACKED ABOVE GROUND
PLATES STACKED ABOVE GROUND

Please refer Material Management Manual for more details on Storage &
Preservation of Material.
Don’ts: -
 Don’t receive the material without proper supporting documents.

 Don’t Store the materials outdoor, which are to be stored inside or vice-
versa, contradictory to manufacturer’s instructions.
 Don’t Store the material directly on the ground.
 Don’t stack the Carbon Steel (CS)/Alloy Steel (AS) / Stainless Steel (SS)
materials together.
 Don’t Store the welding consumables in humid environment.
 Don’t use inappropriate / inadequate lifting devices for loading/unloading
of materials.
TRANSIT DAMGES ON
TUBES
PIPES STACKED ON PIPES STACKED WITHOUT

GROUND END CAPS

2.0 Calibration of Inspection Measuring and Test

Equipment (IMTE)
Do’s: -
 Ensure the availability of Master List for IMTE along with Valid Calibration
Certificates for all IMTE including Master Instrument / Equipment used for
IMTE.
 Ensure calibration of IMTE done before due date, by approved Agencies
and ensure identification number together with next due date sticker is
affixed.
 Identify the Un calibrated IMTE as “NOT IN USE” and keep separately.
 Identify surplus IMTE and arrange to transfer to other site through Facility
Management / Materials Management.
 Identify faulty / defective IMTE and arrange to dispose off through Facility
Management / Materials Management.
CALIBRATION OF
PRESSURE GAUGES
Don’ts: -
 Don’t use IMTE for inspection and testing without valid calibration /
identification.
 Don’t use faulty / defective IMTE, even if the calibration date is valid.
 Don’t use repaired IMTE without re-calibration done.
3.0 Welding Inspection
Do’s: -
3.1 Welding Consumables: -

 Ensure new electrodes are stored in unopened packets and labelling is
clearly visible.
 Ensure proper storage and Issue of Electrodes, Filler wires and Gases for
GTAW.
 Ensure the purity of argon in cylinder prior to start of welding.
 Ensure Welding Consumables to be used are as specified in WPS /
Manufacturer’s instructions.
 Ensure baking of Electrodes as per manufacturer recommendation.
 Ensure that loose electrodes which are recommended for drying/baking
are stored in holding ovens till their use.
 Ensure that electrodes which are already dried / baked but un-used are
returned to oven for drying before use.
 Ensure Welding consumables are color coded with paint on the stub-ends
to avoid mixing of different types of electrodes.
STORAGE OF ELECTRODES BAKING OF ELECTRODES

3.2 Before Welding: -

 Ensure the Parent Material is in accordance with drawing / WPS
 Ensure the Materials are identified and traced to relevant test certificate.
 Ensure the Materials are free from damage and contamination.
 Ensure availability of WPS / PQR, approved Quality plan and drawings.
 Ensure approval of WPS and made available to Welders and inspectors.
 Verify that welders are qualified for required position and welding process.
 Ensure identification of Qualified Welders for each WPS to be used and all
welder Qualification certificates are valid.
 Check that welding machines, welding cables, flow meters, regulator, and
support tools for welding activities are defect free.
 Ensure that Welding Machines are calibrated.
 Ensure provision of run-in and run-out plates prior to the start of welding.
3.3 During Welding: -

 Ensure all works are performed as per applicable welding codes or
standard as required by the Customer specifications.
 Ensure Weather conditions are suitable / comply with Code requirements.
 Verify that the welder assigned for welding is qualified for the process,
position and Material as per applicable code.
 Ensure to provide protective cover or shelter to protect the welding process
from weather conditions.
 Ensure to provide the welding screens and / or blankets to protect
personnel, material, and equipment from weld flashes and weld splatters.
 Check that edge or surfaces to be welded are correctly prepared, shaped
as per drawing.
 Ensure that weld surfaces are clean and free form Dirt, rust, oil and grease.
 Verify that members of specified Joints are tack welded / held together
prior to welding.
 Ensure welding consumables used are of the correct type and size, as per
approved WPS.
 Ensure the welding parameters i.e., Current, Voltage and Travel speed are
in accordance with approved WPS.
 Ensure minimum pre-heat temperature prior to welding as per approved
WPS.
 Ensure Post heat requirements as per approved WPS.
 Check that each layer of the weld is free from flux, slag and surface
defects.
 Ensure maximum inter-pass temperature as per approved WPS.
 For full penetration welds, ensure quality of Root weld by proper back
gouging prior to second side weld, as applicable.
 Ensure adequate shrinkage allowance to avoid distortion during and after
welding.
 Completed welds shall be inspected / examined as specified.
 Weaving shall not exceed 3 times of electrode diameter.
 Each weld is marked with Welder’s identification, joint identification,
drawing number in accordance with approved drawing / Weld map.
 Temporary welds / cleats shall be removed and properly ground.
3.4 After Welding: -
 Ensure the illumination during inspection is minimum of 1000 Lux including
at confined spaces.
 Ensure readiness of welds for required Non Destructive Testing (NDT) (Profile,
Cleanliness etc.,).
 Check fillet welds for leg and throat size as per drawing.
 Check dimensions are in accordance with Drawing / Code
 Check butt / grove welds for excessive or insufficient reinforcement.
 Check for defects such as undercut, overlap, slag inclusions, cracks,
pinholes, sharp edge and incomplete fusion and exposed porosity.
 Report any weld defects for disposition/repair.
 Verify removal of weld metal for the full length of any cracks prior to re -
welding.
10 | P a g e ISSUE: MARCH- 2020
 Monitor Repairs in accordance with the approved repair procedure.

 Ensure all NDT is complete and reports are available for records.
 Ensure and Monitor PWHT (if required) in accordance with the approved
procedure (Check Temperature and Time chart).
MEASUREMENT OF REINFORCEMENT
MEASURING FILLET WELD ON GROOVE BUTT WELD
WELD JOINT FIT-UP FOLLOWED BY CLEANLINESS OF BOTH SIDES OF JOINT
RUN-IN AND RUN-OUT PLATES ARE USED TO PREVENT THE CRATERS AT THE END OF
WELD PASS (SUBSEQUENTLY REMOVED AFTER COMPLETION OF WELDING)

LOW HYDROGEN ELECTRODES KEPT IN PORTABLE OVEN

.
CALIBRATED WELDING MACHINES BAKING & HOLDING OVENS
AFTER VISUAL & NDT, JOINTS PROTECTED WITH TAPE TILL HYDRO TEST TO
AVOID RUST FORMATION ON WELD JOINTS

CLEANED PROPERLY BEFORE FITUP STICH WELDED AT STIFFNER LOCATION
DISPLAY OF APPLICABLE WPS CLAMPS USED DURING FIT-UP
WELDED JOINTS CLEARLY MARKED FOR JOINT RUST PREVENTIVE COAT APPLIED
NO & WELDER NUMBER IMMEDIATELY AFTER INSPECTION

INTERMEDIATE STIFFENER PLATES IN GRID BEAMS AND COLUMNS KEPT IN

TACK WELDED CONDITION TO FACILITATE ERECTION OF FLOOR BEAMS
Don’ts: -
 Don’t allow use of wet electrodes.

 Don’t allow use of electrodes without baking as per requirements.
 Don’t allow welding, if Joint is not prepared as the requirement.
 Don’t allow storage of welding consumables in uncontrolled environment.
 Don’t allow unqualified welders even for tack welds.
 Don’t allow usage of non-calibrated Welding machines.
 Don’t use contaminated or mild steel grinding wheels, files, or tools on
stainless steel materials.
 Don’t allow unapproved methods like heating to align piping, structures
and equipment.
 Don’t allow welding without protection from wind, rain, or blowing sand.
DON’T CUT HOLES USING GAS DON’T USE CARTON TO CARRY LOW
CUTTING TORCH HYDROZEN ELECTRODES

IMPROPER CLEANING LEADS NOT PROVIDING INTERMIDIATE

TO WELD DEFECTS STIFFNERS LEADS TO DISTORTION
TYPICAL WELD DEFECTS
EXCESS ROOT PENETRATION POROSITY
INCOMPLETE ROOT FUSION UNDERCUT

4.0 Non-Destructive Testing
Do’s: -
 Ensure availability of approved procedures and personnel qualification

(Level II / III) certification records.
 Determine the location, area, and extent of required NDT as per applicable
specification.
 Determine the equipment, material, and technique to be used as per
requirement.
 Verify the sequence and timing of NDT related to welding and heat
treatment.
 Verify required preparation and cleaning of test surface.
 Verify that weld and base metal surface conditions and external
cleanliness are restored after testing (complete removal of grease,
contrasting medium and developer).
4.1 Radiography Test: -

 Check source strength.
 Ensure that requisition for RT is signed by authorized TPL personnel.
 Verify type and number of films required.
 Check the type and thickness of intensifying screens.
 Check minimum required distance from source to film.
 Check type, number and location of pentameter / Image Quality
Indicators (IQI).
 Ensure use of location markers and type of film processing.
 Ensure the type of techniques as per approved technic sheet.
 Check and ensure the density of the Films as per the requirement with
Calibrated Density meters.
 Ensure the availability of controlled Dark room for Film processing as per the
requirements

 Ensure the availability of Film Viewer for review of RT Films

 Check for required details on the films (like joint no., welder no., description,
drawing no., X-ray no.)
 Verify exposed radiographic film properly identified (both film and film
jacket) to avoid any double exposure.
 Verify NDT agency’s evaluation report for film quality (technique, density,
sensitivity), result as per relevant Code & Standard.
 Ensure that no unauthorised personnel are in the vicinity of RT.
RT EQUIPMENT DENSITY METER RT FILM VIEWER
4.2 Magnetic Particle Test: -

 Verify the lifting power of the Yoke once in a week (Will be done by NDT
coordinator).
 Monitor sequence of operation, examination medium, surface
preparation (Weld ripples and valleys are to be removed), temperature
and adequate lighting.
 Check magnetizing current (only DC to be used), Yoke spacing and
adequacy of magnetic field (with the help of field indicator).
 Always magnetize in two directions 900 to each other in the same area
to detect all probable defects in any direction.
 Ensure the coverage of the entire area of test.

 Review indications, evaluate whether it is a relevant / non-relevant

indication as per applicable Codes & Standards.
 Ensure demagnetization after test to remove the residual magnetism.
MAGNETIC PARTICLE TESTING
4.3 Liquid Penetrant Test: -

 Verify Penetrant material type / brand (only approved brand shall be used)
 Check surface temperature, lighting, surface cleaning, Penetrant
application.
 Ensure Maximum Penetrant Dwell time shall not exceed 15 minutes.
 Ensure Penetrant removal and drying as per approved procedure.
 Check the application of developer with thin layer and not too excessive
layer.
 Ensure maximum Developer dwell time of 30 Minutes.
 Temperature of the penetrant and the test surface shall be in the range of
16C to 52C throughout the examination period. Local heating and
cooling is permitted, provided that test surface temperature remains in the
required range.
 During developer application, the nozzle shall be kept at a distance not
less than 300 mm.
 Evaluation and interpretation of results shall be as per applicable Codes &
Standards.

LIQUID PENETRANT TESTING
4.4 Ultrasonic Test: -

 Ensure personnel qualification and performance requirements as per
approved procedure
 Ensure weld configuration to be examined including thickness, dimensions
and base material product form.
 Ensure availability of required Equipment and Material i.e., Ultrasonic
Equipment, Probes, Wedges, Shoes, couplant etc.,
 Ensure availability of required Calibration blocks
 Ensure calibration of Ultrasonic Equipment prior to testing as per approved
procedure
 Ensure technique and extent of scanning as per approved procedure and
specification.
 Ensure scanning with straight beam and angle beams as per approved
procedure and specification
 Evaluation and interpretation of results shall be as per applicable Codes &
Standards

ULTRASONIC TESTING
Don’ts: -
 Don’t carry out Radiography testing, If the area is not Cordoned off and
radiation caution board is not displayed.
 Don’t carry out Radiography testing, If calibrated survey meter is not
available at site.
 Don’t carry out Radiography testing, If pocket dosimeter is not available
with radiographer.
 Don’t carry out Radiography testing in absence of authorisation from
concerned authorities to perform RT.
 Don’t carry out NDT, in absence of approved procedure.
 Don’t carry out NDT by unqualified / unauthorised personnel.
 Don’t use unapproved make & Type of testing Equipment & Material.
 Don’t use the testing equipment without valid calibration.
 Don’t carry out Magnetic particle inspection without ensuring the lifting
power of Yoke.
 Don’t mix different make / brands of PT Kit.
 Don’t allow for Ultrasonic testing without having required Calibration
blocks, equipment and material.
 Don’t carry out the test, if light is less than 1000 Lux.
DON’T INTERMIX DPT KIT OF DIFFERENT MAKES

5.0 Post Weld Heat Treatment (PWHT)
Do’s: -
 Ensure approval of procedure prior to start of PWHT.

 Ensure the availability of approved Procedure with the technician during
PWHT.
 Determine the location, size and number of weld joints to be heat-treated.
 Ensure that the temperature monitoring equipment & recorders; type &
number of thermocouples and their location, are as per procedure.
 Record the type, number, and location of temperature measuring and
recording devices.
 Ensure Valid calibration for all PWHT equipment.
 Ensure required surface preparation for the joints to be heat-treated.
 Verify that the heating band width is covered with insulation as per PWHT
procedure.
 Type of heating i.e., Induction / Resistance / Flame Heating shall be
ensured, as per procedure.
 Ensure heating, cooling rates and Holding temperatures as per approved
procedure.
 Verify temperature of weld joint and adjacent base material is below 300°C
before protective insulation is removed.
 Check that thermocouples and other temporary attachments are
removed and heat affected areas examined visually / PT / MT as required.
 Verify that cleanliness is restored for weld and base metal surface.
 Verify hardness of the weld joint heat affected zone as required by the
specification.

WRAPPING OF HEATING COIL / PAD & FIXING OF THERMOCOUPLE FOR PWHT.
Don’ts: -
 Don’t allow PWHT in absence of approved procedure / specification.

 Don’t allow PWHT, If Calibration of temperature monitoring equipment,
recorders and thermocouples is not valid.
 Don’t allow PWHT, If cable connections are not insulated properly.
 Don’t allow PWHT in absence of proper earthing of item being heat treated
& electric panel.
 Don’t allow PWHT, if heating element beads are in broken condition.

6.0 Pressure Testing
Do’s: -
 Ensure the system identification & test boundaries are defined clearly
and test packs are signed off for pressure testing.
 Ensure the system w.r.t accessibility, tightness of flanged joints and
completeness as per P&ID / GA Drawing at pre-inspection stage.
 Establish the test medium, test pressure for each test, including blind
flange thickness requirement.
 Ensure that the pressure gauges are having identification and valid
calibration.
 Ensure the availability of Chart Recorders - Dual Pens (Pressure &
Temperature), if required, as per project specification.
 Ensure the pressure gauge range as per Construction Code.
 Ensure minimum 2 gauges are used for pressure testing and keep spare
pressure gauges as stand by.
 Identify components, which are not capable with the required system
test pressure and ensure those components like control valves, orifice
plates etc., are removed or isolated from the system.
 Ensure that all the required test vents, drains and filling points are
provided.
 Ensure that the required testing equipment, relief valves, pressure
regulators, isolation valves, strainers, temporary fittings are available prior
to commencement of hydrostatic testing.
 Check that all system valves are positioned as required.
 All system valves are typically placed in the open position.
 Ensure the system relief valves are removed, as required.
 Check that the system is adequately supported for expected loading
during pressure testing.

 Check that the equipment and temporary piping have been flushed
prior to connect with the system.
 Check that the system to be tested is flushed prior to testing, if required.
 Ensure vents are open to enable removal of air during filling of test
medium.
 Verify that required test witness such as the client representative is
notified in advance.
 Pressurising rate & holding time shall be as per approved procedure.
 Pressure test holding time will be 30 minutes (unless otherwise specified
in approved procedure / applicable Code). After holding period, the
related item & joints shall be checked thoroughly for leak tightness.
 If pressure drop is observed, check for leaks in the system.
 Ensure to open the vents first to release the pressure soon after the test
and are kept open during the complete draining of the test medium.
 Ensure that testing documentation is prepared and signatures of
Customer are obtained.
CALIBRATED PRESSURE GAUGE IS PRESSURE TESTING
Don’t s: -
 Don’t allow for Pressure Testing, if Pressure gauges are not calibrated.
 Don’t allow for Pressure Testing, if two pressure gauges are not available.
 Don’t allow for Pressure Testing, if range of pressure gauges not within
range as per specified standard.
7.0 Pneumatic Testing
Do’s: -
 Ensure that calibrated safety valves are installed as per the pneumatic test
pressure.
 Ensure the surrounding area of testing is cordoned off to prevent
movement of personnel during pneumatic test.
 Ensure that testing is performed by qualified personnel as per approved
procedures / specifications.
 Ensure that the test medium is at specified temperature & system is
pressurized stage wise.
 Ensure the calibration of pressure gauges is valid.
 Ensure the number & range of pressure gauges. as per Construction Code.
 Ensure to maintain the test pressure for the specified period.
 If pressure drop is observed, check for air leaks in the system.
 Verify the system by applying soap solution to ensure the all joints are leak
free.
 Ensure that testing documentation is prepared and signatures of
Customer are obtained.
PNEUMATIC TESTING
Don’ts: -
 Don’t allow for Pneumatic Testing, if Pressure gauges are not calibrated.
 Don’t allow for Pneumatic Test, if two pressure gauges are not available.
 Don’t allow for Pneumatic Test, if range of pressure gauges not within
range as per specified standard.
8.0 Inspection - Structures
8.1 Fabrication: -
Dos: -
 Verify the availability of raw material inspection reports, MTC as per QAP
 Ensure the availability of Approved Drawings, QAP, WPS, PQR and WPQR
Method Statements/Procedure before start of Fabrication.
 For welding related guide lines, please refer section 3 of this Handbook.
 Ensure that the drawing control system is in place to receive / issue the
latest revision of drawings and disposal of obsolete drawings.
 Check for Material specification & grade and dimensions as per
approved drawing.
 Verify Marking and cutting plan / scheme of structural steel as per
approved drawing before cutting.
 Ensure transfer of identification markings on balance material.
 Ensure for correct CNC programming prior to drilling of holes in the
structures.
 Check calibration status of IMTE proposed to be used for fabrication
works.
 Ensure Fit-ups as per approved drawings / layouts.
 Ensure proper supports and sequence of welding to avoid distortion.
 Check for embossing/engraving of erection mark numbers on the
fabricated structures.

USE OF CNC
MACHINES FOR
CUTTING & DRILLING
USE OF FIXTURES FOR MAINTAINING ALIGNMENT FOR WEB & FLANGE
USE OF SAW MACHINE FOR WELDING
Don’ts: -
 Don’t allow fabrication, if approved documents are not available.

 Don’t permit any work on Base Materials, which leads to altering the
appearance or metallurgical properties of the components.
 Don’t permit dimensional deviation to achieve final requirements, get

clarification from concerned authority in case of doubt
 Don’t allow for welding by unqualified welder / welding operator.
8.2 Trial Assembly at Shop: -

Do’s: -
 Ensure that all structures are inspected and cleared as per QAP.
 Ensure availability of firm & levelled platform for trial assembly.
 Ensure availability of all components as per B.O.M. of drawings
 Check adequate supports are available at camber locations.
 Ensure correct sequence and orientation of girders, as per drawing.
 Check that drilled holes are free from any geometric deviations.
 Ensure sufficient number of bolts and nuts are used.
 Ensure assembly of bracings in the girder to restrict displacement.
 Check dimensions such as overall span length, width, camber, bearing
distances, level and verticality etc.,
 Ensure that the match markings are punched at the required location /
parts for easy erection.
TRIAL ASSEMBLY ON FIRM / LEVELLED

VERIFICATION OF DIMENSIONS, WIDTH & CAMBER AT ASSEMBLY STAGE BASE
CHECK WELD VISUAL, LEVELS & ALIGNMENT FOR OPEN WEB GIRDER (OWG) BRIDGE
Don’ts: -
 Don’t allow Trial assembly, if platform is not levelled.

 Don’t apply force on bolts to match the holes, to prevent elongation of
hole.
 Don’t place auto level at points other than camber joints location for
long length segments.
 Don’t dismantle the assembly prior to punching of match markings.

8.3 Erection Works: -

Dos: -
 Ensure availability of Approved Drawings, FQP, WPS, PQR and WPQR

Method Statements/Procedure before commencing Erection.
 Ensure that the drawing control system is in place to receive / issue the
latest revision of drawings and disposal of obsolete drawings.
 Ensure availability of all components at site as per B.O.M. of drawings for
erection.
 Check welding details & any left out welding from shop (Supplier).
 Ensure that all bolts, washers and nuts are having the Material Test
Certificates as per specification.
 Check the sequence of structural members to be assembled to avoid
mismatches, during assembly.
 Ensure availability of firm & levelled platform for assembly.
 Check adequate supports are provided at camber locations.
 Ensure correct sequence and orientation of structural members.
 Check that drilled holes are free from any geometric deviations.
 Ensure correct placement & location of the structural members.
 Check torque requirement for Bolts and ensure sufficient torque is being
applied.
 Ensure to engage only qualified personnel for torque tightening, obtain
qualification certificate of the personnel from concerned authority prior
to engagement in the job.
 Check major dimensions such as overall span length, width, camber,
bearing distances etc. thoroughly
 Check for design camber intermittently to ensure the progress is in line
with the requirements.
 Check and ensure the verticality for each level and top elevation with
in tolerance as per applicable code.

 Ensure the minimum number of tie beams /cross beams are erected prior
to the vertical alignment.
SPECIFIC TO OPEN WEB GIRDERS

 Ensure to check the level of bearing pedestal (i.e. height, centre
distance between pedestal to pedestal) & orientation as per bearing
lay out drawing, in case of Bridges.
 Check & correlate the respective bearing detail with the shoe plate of
main steel girders.
 Insert HSFG bolts after matching of holes by replacing drifts.
 Follow the steps given as guidelines in IRS-B1 for erection of girders.
 Check residual camber after final torque is applied on all sizes of HSFG
Bolts
Don’ts: -
 Don’t start assembly, if B.O.M as indicated in the approved drawings are

not received.
 Don’t permit any extra welding without prior approval of the concerned
authority.
 Don’t change the sequence of structures assembly without prior
approval from the concerned authority.
 Don’t permit assembly if platform is not firm & levelled.
 Don’t apply force on bolts to match the holes, to prevent elongation of
hole and damage to Bolt threads.
 Don’t place auto level at points other than camber joints location for
long length segments.

8.4 Bolting and Tightening: -

Do’s: -
 Check for correct size & grade of Bolts, Nuts & Washers.
 Ensure fixing of bolts only after alignment / matching of splice member
holes.
 Ensure free rotation of nuts on the bolt threads by cleaning & lubricating
the threads of bolt & nuts.
 Ensure tightening of the bolts are being started from middle of the joint
to towards the free edges.
SPECIFIC TO OPEN WEB GIRDERS
 Ensure the layout of bolts during bolting i.e., outside & inside of the Head
& thread of the Bolt on girder assembly.
 Ensure that Direct Tension Indicators (DTIs) are provided below the head
of the bolt (with projections towards bolt head) in case the nut is
tightened.
 Ensure that DTIs are provided under nut (with projections towards nut), In
case the bolt is tightened.
HIGH STRENGTH FRICTION

DIRECT TENSION INDICATOR
GRIP BOLTS
Don’ts: -
 Don’t use rusted, uncleaned and defective Bolts & Nuts.

 Don't apply force on bolts to match the holes.

8.5 Torqueing and Camber of Steel Girders: -

Do’s: -
 Check the snug tightening of Bolts & Camber of the Girder with supports.
 Ensure to use calibrated Torque Wrench with an accuracy as per
specification.
 In the 1st stage, torque wrench is to be set at 75% of computed torque
for tightening of the bolt / nut.
 Ensure permanent marking to indicate the relative position with suitable
marker on the bolts and nuts after 1st stage.
 Ensure proper contact of the steel members that make up the plies of
the joint with HSFG bolts.
 Ensure the camber is as per drawing with required supports.
 In the 2nd stage, apply 100% torque & ensure the Residual camber
without supports (Jacking support at bearing location only) as per
drawing.
 Ensure tack welding of nuts after final torque tightening and inspection
clearance.
TORQUE WRENCH
Don’ts: -
 Don’t use Direct Tension Indicators without valid calibration.

 Don’t reuse the bolts / nuts which are already used once and
discarded.
8.6 Launching of Steel Girders: -

Do’s: -
 Ensure availability of approved launching scheme / method statement.

 Ensure the availability of Crane capacity as per launching scheme /
method statement.
 Ensure competent authority certificates of Cranes including all
accessories (i.e. D-shackle & Sling), before launching activity.
 Ensure that required temporary supports are provided to place the
Girder on pedestal.
 Verify marking on the girder for the lifting action.
 Place the required bearing in position (in case launching is with bearing).
 Ensure requisite safety measures have been taken as indicated in
launching scheme / method statement.
ILLUSTRATION: USE OF CRANE FOR ERECTING GIRDERS
LAUNCHING OF OPEN
WEB GIRDERS

LAUNCHING OF OPEN WEB GIRDERS
Don’ts: -
 Don’t allow the launching of girder without approved launching scheme

/ method statement.
 Don’t allow launching of girder without obtaining approved traffic block
from concerned authorities.
 Don’t allow the movement of crane without proper levelled ground.
 Don’t leave the girder for long period without connecting the lateral
bracings / Cross frames.
 Don’t leave the threads of bolts without tack welding at final stage as
per specification / guidelines.

9.0 Inspection - Piping
Do’s: -
 Ensure the availability of approved Field Quality plan, WPS/PQR and

procedure prior to Piping Fabrication.
 Ensure the availability of Approved Drawings and Piping Material
Specification (PMS).
 Ensure availability of approved NDT procedures and Codes of
Acceptance criteria.
 For welding related guide lines, please refer section 3 of this Handbook.
 Ensure that the drawing control system is established for receipt &
issuance of latest revisions and discard obsolete drawings.
 Ensure availability of all the required resources like Baking / Holding
ovens, thermos chalk, IR Thermometer, tongue tester etc.
 Ensure availability of required welding consumables.
9.1 Fabrication: -
 Verify Physical condition, quantity, identification, dimensions, chemical
& mechanical properties of Pipes, Pipe fittings, Flanges, Fasteners,
Gaskets, Valves, Traps & other bought outs.
 Ensure Dimensions, edge preparation, alignment during Fit up of Pipe /
with RF pads as applicable / fittings/ Valves etc.,
 Ensure all the exposed threads are covered by seal welding, in case of
seal welding is done on the threaded joints.
 Ensure Air test on RF pad attachment welds.
 Ensure Proper match marking and identification of spools.
 Ensure surface preparation and painting of Spools as per Painting
specification.

PIPING SPOOLS FABRICATION
9.2 Erection: -
 Check the Dimensions (width & depth) of Trench making for
underground piping.
 Check for Visual, Colour shade, uniformity, DFT of Painting of outside
surface for above ground piping.
 Check for Visual and Coating thickness of Coating and Wrapping (of
outside) for underground piping, as applicable.
 Ensure Proper positioning during of Laying of spools of underground
piping in the trenches.
 Check for Physical condition, Dimensions during Erection and alignment
of spools / valves / etc. for in-situ joints of above ground / underground
piping.

 Ensure Dimensions, edge preparation, alignment during Fit up of Field

Joints
 Ensure Completion of Drains, Vents, Instrument connections.
 Ensure Supports location, Elevation, Orientation, Completion, weld size
etc.. as per approved drawings
 Ensure Quality of water is used Hydro test is as per requirements.
 Ensure proper Flushing of Piping segments.
 Ensure completion of all punch points (including NDT) related to hot work
before water filling.
 Ensure all stage wise inspection protocols are prepared and signed by
all the concerned persons.
 Ensure completion of Pneumatic test (as applicable) and Ensue
provision of Safety relief valve for pneumatic testing.
 Ensure one of the pressure gauge is placed at top most location of the
system
 Ensure completion of Mechanical clearance & Hydro static test.
 Ensure completion of Flushing of all Lines.
 Ensure Mechanical cleaning, painting / coating & wrapping /
mechanical cleaning (as applicable) of in-situ joints, flushing & purging.
 Ensure the record of Orifice flange internal grinding.
PIPING ERECTION

SS BOLTS USED ON SS FLANGES UNDERGROUND PIPING
Don’ts: -
 Don’t allow Fabrication, if there is mismatch in GA drawings and

Fabrication drawings.
 Don’t allow Fabrication, if Material is not as per approved drawings /
approved makes.
 Don’t allow Radiographic testing, if work permit is not obtained.
 Don’t allow pressure test, if testing medium quality is not as per the
specification / procedure.
 Don’t Proceed for Inspection in absence of Approved FQP/Approved
Drawing/Acceptance Criteria/Relevant Code/Standard.
MS BOLTS ON SS FLANGE CONNECTIONS

10.0 Storage Tanks
Do’s: -
 Ensure Handing & taking over protocol between CIVIL & MECHINCAL
teams for Tank foundation.
 Ensure the sump direction and slope as per approved drawings.
 Ensure availability of approved Field Quality plan, WPS/PQR and Method
statement prior to tank fabrication.
 Ensure that the drawing control system is established for receipt & issuance
of latest revisions and discard obsolete drawings.
 Ensure approval of Shell Courses, annular & bottom plate cutting plan.
 Ensure application of painting or corrosive resistance coating on annular
/ bottom plate as per the requirement.
 Ensure bottom plate slope towards the sump.
 Ensure to carryout required NDT on annular / bottom plate weld joint.
 Ensure to carryout vacuum box testing for annular / bottom plate.
 Ensure rolling of shell courses to the required profile.
 Ensure flush grinding of weld joint at location where the shell plate is to be
placed.
 Ensure verticality, roundness and dimensions during installation of shell
course.
 Ensure peaking and banding of the Shell joints within specified limits.
 Ensure supports and welding sequence to avoid distortion.
 Ensure orientation, elevation and projection of Nozzles as per drawing.
 Ensure required NDT on Vertical, Horizontal, T- Joints of Shell and nozzle
weld Joints.
 Ensure the roof plate installation and welding sequence as per
specification.
 Ensure Height, verticality, ovality, Circumference and completeness of
attachments as per drawing.
 Ensure pneumatic test for nozzle Reinforcement pads.

 Ensure mechanical clearance and settlement location marking prior to
water filling.
 Ensure water filling for leak test as per approved Method statement.
 Ensure that there is no leakage, no seepage from civil foundation.
 Record settlement reading after filling up to 25% Tank height. Repeat
recording of settlement readings for filling at 50%, 75% and 100% height.
 Verify the leakage, seepage and settlement reading after 24 hrs.
 Ensure to keep the vents open while draining the water completely, after
leak test.
 Ensure required surface preparation and painting as per painting scheme.
 Ensure installation of instruments as per approved drawing.
STORAGE TANKS
Don’ts: -
 Don’t allow, if Handing & taking over protocol between Civil &
Mechanical teams is not available.
 Don’t allow shell erection, without application of required coating (paint
/ rust preventive) on Annular plate / bottom plate placed on foundation.
 Don’t allow shell installation, if the annular / bottom plate NDT and joints
flush grinding not completed as per the requirement.
 Don’t allow Water filling unless assembly & welding of all shell courses and
attachments including NDT are cleared from inspection.
 Don’t allow water filling, if marking for settlement of foundation is not
completed.
11.0 Static Equipment
Do’s: -
 Ensure availability of approved Field Quality plan, WPS/PQR and

procedure prior to installation.
 Ensure that the drawing control system is established for receipt & issuance
of latest revisions and discard obsolete drawings.
 Ensure all measurement tools shall have valid calibration certificates.
 Ensure Centreline, Orientation and coordinates marking on equipment
and foundation.
 Ensure Level of foundation (shims / packing).
 Cross check Mechanical equipment drawing with civil drawing
teams for equipment foundation.
 Ensure orientation marking & cleaning of foundation bolt pockets.
 Ensure No. & size of foundation bolts.
 Ensure that the No. & diameter of holes of base frame / equipment match
with actual foundation bolts.
 Verify complete availability of all items like shims, Torque wrench,
Foundation bolts etc.
 Review Load test certificates of Crane / Lifting beam / Slings / Shackles,
Wire ropes etc., from Competent Authority.
 Check the condition of Equipment for any damages, before erection.
 Ensure proper alignment between piping and Equipment, before bolting
to prevent stress on Equipment / Piping.
 During placement of Equipment on foundation, check for orientation,
elevation and not fouling with other structure.
 After erection, check for verticality, Water level, fixing of foundation bolts
and grouting of pockets.
 Ensure proper curing of Grouting.
STATIC EQUIPMENT
ERECTION
Don’ts: -
 Don’t allow, if IMTE are not having valid calibration certificates

 Don’t allow grouting, without MTC /approved make.
 Don’t allow, if certification from competent Authority for Lifting tools &
tackles is not available.
 Don’t allow, if Handing and taking over protocol between Civil &
 Don’t allow for grouting without ensuring alignment of Equipment with
piping.

12.0 Rotary Equipment

Do’s: -
 Ensure availability of approved Field Quality plan, WPS/PQR and

procedure prior to installation.
 Ensure that the drawing control system is established for receipt &
issuance of latest revisions and discard obsolete drawings.
 Ensure that all IMTE are having valid calibration certificates.
 Ensure Centreline, Orientation and coordinates marking on
equipment and foundation.
 Ensure equipment elevation, level & placement of shims / packing
as per drawings.
 Cross check Mechanical equipment drawing with civil drawing for
correctness of foundation.
teams for equipment foundation.
 Ensure alignment, Level and Orientation of Base Frame(s), as per
approved drawing.
 Check orientation of Suction and Discharge, as applicable.
 Ensure distance between couplings, as per approved drawing.
 Check the Axial & Radial alignment for Coupling of Pumps & Motors
with dial Gauges.
 Check for Tightening of bolts / nuts and grouting.
 Ensure proper curing of Grouting.
 Ensure No Load Run Test, as per approved procedure.
 Ensure alignment of Equipment without piping, as applicable.
 Ensure Final alignment of Equipment with piping (after tightening
flange bolts) / Boxing of Equipment and connected piping, as
applicable.
 Ensure Recoupling of motor & reconfirmation of alignment.

 Ensure completeness & Pre-Performance checks.

 Ensure Performance test for Temperature, Power, Noise level,
Vibration level etc., as per approved procedure.
ROTARY EQUIPMENT
ERECTION
Don’ts: -
 Don’t allow, if IMTE are not having valid calibration certificates

 Don’t allow grouting, without MTC /approved make.
 Don’t allow, if certification from competent Authority for Lifting tools &
tackles is not available.
 Don’t allow, if Handing and taking over protocol between Civil &
MIS-ALIGNMENT OF ROTARY EQUIPMENT

13.0 Inspection - Surface Preparation & Painting
Do’s: -
 Check availability of approved painting Specification, Procedure and

FQP.
 Check availability of the DFT (Dry Film Thickness) and WFT (Wet Film
Thickness) gauge.
 Ensure availability manufacturer’s Batch test certificates for Primers &
Paints.
 Verify the storage condition on FIFO basis and valid shelf life of Primers &
Paints.
 Ensure Humidity requirements, proper covering, PPE before proceeding
for Shot Blasting / painting.
 Ensure the surface roughness & profile, as per requirement / specification.
 Ensure that Surfaces to be painted are free form oxide, rust, oil, grease
and other foreign material, before painting.
 Primer paint shall be applied within specified time after surface
preparation.
 Ensure colour shade of paints as per the painting scheme.
 Ensure mixing proportions of Primer / Intermediate / Final paint, as per
Manufacturer’s recommendations.
 Ensure the paints are applied as per the recommendation of
manufacturer and the painter is measuring the WFT as per the established
procedure.
 Ensure to maintain the required drying /curing time between two coats.
 Ensure to take readings of DFT for the primer, intermediate and the final
coats, as per specification.
 Ensure the bonding as per applicable test. i.e. adhesion / peel off test,
scratch test as required by the FQP / Procedure.
 Ensure touch-ups and repairs are carried out for the damaged portions.
SURFACE PREPARATION PAINTING DFT CHECKING
COATING THICKNESS GAUGE SURFACE ROUGHNESS / PROFILE GAUGE
PROPER SURFACE CLEANING AND VERIFY SHELF LIFE AND BATCH

UNIFORM APPLICATION OF PAINT NUMBER OF PAINT

Don’ts: -
 Don’t allow painting, if materials are not from approved make.

 Don’t allow painting, if the Shelf life of painting materials has expired.
 Don’t allow Surface preparation & painting in humid environment or
wet/damp atmosphere.
 Don’t allow to proceed for next coat unless earlier coat is completely dry.
 Don’t DFT measurement readings unless paint is dry.
 Don’t measure DFT / WFT readings with un calibrated gauges.
 Don’t allow change in sequence of painting.
 Don’t allow change in mixing proportions of Primer / Intermediate / Final
paint.
DEFECTIVE PAINTING

14.0 Inspection - Insulation
Do’s: -
 Ensure the storage of Insulation Material in Fully Closed sheds on raised &
Paved platform in dry, dust free & ventilated environment.
 Ensure that the insulation material issued by stores for application is dry
and undamaged.
 Ensure appropriate insulation material & thickness for hot or cold
insulation.
 Verify that all required testing i.e., hydrostatic and non-destructive etc.,
are performed prior to application of insulation.
 Ensure that all punch list points are closed before insulation.
 Ensure availability of Manufacturer TC for insulation materials as per
specification.
 Ensure Pipe / Equipment surface is free from moisture, prior to application
of insulation.
 Verify the thickness of Aluminium metal cladding.
 Ensure staggering of Long Seam joints is carried out for lagging.
 Ensure insulation is properly secured as per specification.
 Ensure adequate overlap is maintained for the cladding joints.
 Ensure screws are provided as per specification.
INSULATION MATERIAL INSULATION ON PIPING

Don’ts: -
 Don’t allow Insulation, if required hydrostatic and non-destructive testing

has been not completed.
 Don’t allow Insulation, if insulation materials are not having Manufacturer’s
test certificates.
 Don’t allow Insulation, if insulation materials are damaged/wet.
 Don’t allow Insulation, if surface of pipe / equipment is wet.
xxx END xxx

TΛTΛ PROJECTS LIMITED
Registered Office: “Mithona Towers-1, # 1-7-80 to 87, Prenderghast Road, Secunderabad-500003, Telangana, India
EPABX: # 91-40-66238801, Fax: +91-40-66172535, Email: coeqii@tataprojects.com, Website: www.tataprojects.com

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1|P ag e ISSUE: MARCH- 2020

Table of Contents - Mechanical Works

14. Inspection - Insulation ------------------------------------------------------ 49

2|P ag e ISSUE: MARCH- 2020

1.0 Receipt and Storage

3|P ag e ISSUE: MARCH- 2020

4|P ag e ISSUE: MARCH- 2020

 For storage of heavy equipment, the roof/walls may be suitably

PIPES STACKED WITH END CAPS PIPES STACKED ABOVE GROUND

PLATES STACKED ABOVE GROUND

5|P ag e ISSUE: MARCH- 2020

 Don’t receive the material without proper supporting documents.

PIPES STACKED ON PIPES STACKED WITHOUT

6|P ag e ISSUE: MARCH- 2020

2.0 Calibration of Inspection Measuring and Test

3.0 Welding Inspection

3.1 Welding Consumables: -

STORAGE OF ELECTRODES BAKING OF ELECTRODES

8|P ag e ISSUE: MARCH- 2020

3.2 Before Welding: -

3.3 During Welding: -

 Monitor Repairs in accordance with the approved repair procedure.

WELD JOINT FIT-UP FOLLOWED BY CLEANLINESS OF BOTH SIDES OF JOINT

11 | P a g e ISSUE: MARCH- 2020

LOW HYDROGEN ELECTRODES KEPT IN PORTABLE OVEN

CALIBRATED WELDING MACHINES BAKING & HOLDING OVENS

12 | P a g e ISSUE: MARCH- 2020

CLEANED PROPERLY BEFORE FITUP STICH WELDED AT STIFFNER LOCATION

DISPLAY OF APPLICABLE WPS CLAMPS USED DURING FIT-UP

13 | P a g e ISSUE: MARCH- 2020

INTERMEDIATE STIFFENER PLATES IN GRID BEAMS AND COLUMNS KEPT IN

 Don’t allow use of wet electrodes.

14 | P a g e ISSUE: MARCH- 2020

IMPROPER CLEANING LEADS NOT PROVIDING INTERMIDIATE

TYPICAL WELD DEFECTS

EXCESS ROOT PENETRATION POROSITY

INCOMPLETE ROOT FUSION UNDERCUT

15 | P a g e ISSUE: MARCH- 2020

4.0 Non-Destructive Testing

 Ensure availability of approved procedures and personnel qualification

4.1 Radiography Test: -

16 | P a g e ISSUE: MARCH- 2020

 Ensure the availability of Film Viewer for review of RT Films

RT EQUIPMENT DENSITY METER RT FILM VIEWER

4.2 Magnetic Particle Test: -

17 | P a g e ISSUE: MARCH- 2020

 Review indications, evaluate whether it is a relevant / non-relevant

MAGNETIC PARTICLE TESTING

4.3 Liquid Penetrant Test: -

18 | P a g e ISSUE: MARCH- 2020

LIQUID PENETRANT TESTING

4.4 Ultrasonic Test: -

19 | P a g e ISSUE: MARCH- 2020

DON’T INTERMIX DPT KIT OF DIFFERENT MAKES

20 | P a g e ISSUE: MARCH- 2020

5.0 Post Weld Heat Treatment (PWHT)

 Ensure approval of procedure prior to start of PWHT.

21 | P a g e ISSUE: MARCH- 2020

WRAPPING OF HEATING COIL / PAD & FIXING OF THERMOCOUPLE FOR PWHT.

 Don’t allow PWHT in absence of approved procedure / specification.

22 | P a g e ISSUE: MARCH- 2020

6.0 Pressure Testing