Procedure

Procedure
For
Fit-up and Assembly
Job Number
Document No
2
FABRICATION DIVISION
RELIANCE INDUSTRIES LIMITED, JAMNAGAR
Revision Number
E
00
01
02
Date
06/09/0
3
20/0
7/06
03/01/0
7
Prepared By
GR/SE
RR
RR
Department:
Structural Fabrication Shop
Checked By
CLJ
CLJ/
CPB
GR/CP
B
Location:
Jamnagar
Approved By
KR
VKS
VKS
Hard copy of this document shall be treated as uncontrolled if not signed by approver
For latest revision please check with soft copy.
Total No. of Pages :08
CONTENTS
1.
INTRODUCTION
2.
PURPOSE
3.
SCOPE
4.
ABBREVIATIONS & DEFINITIONS
5.
RESPONSIBILITY AND AUTHORITY
6.
REFERENCE
7.
FLOW CHART
8.
PROCEDURE
9.
RECORDS
10.
ATTACHMENTS
Procedure for fit-up and assembly

Doc. No.: 2 SFQSP GE 006 Rev. 02 Dt:03-01-2007
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Structural fabrication shop

Jamnagar
1.
INTRODUCTION
Fabrication division fabricates structures for various clients. Fit up and assembly is an
important activity for fabrication of structure. In order to ensure that effective functioning of
a quality system requirements are fulfilled, there is a need to establish a quality system
involving the functions of fit up and assembly and to ensure the activities are in controlled
condition.
2.
PURPOSE
The purpose of this procedure is to establish a documented procedure for fit-up and
assembly of structural steel to ensure that the specified quality requirements are fulfilled
with international quality system and to ensure continuos process stability and to achieve
the customer need in time.
3.
SCOPE
This procedure is applicable to all the activities related to fit-up and assembly of structural
steel at structural fabrication shop
4.
5.
ABBREVIATIONS & DEFINITIONS

AM
Area Manager
CM
Construction Manager
HOD
Head of Department
SFS
Structural Fabrication Shop
PE
Production Engineer
DCC
Document Control Cell
NCR
Non-conformance Report
NDT
Non-destructive Testing
QMD
Quality management department
RESPONSIBILITY & AUTHORITY

Activity
Responsibility and Authority

Manage
Construction Manager
Structural fabrication division
Establishing
Fit-Up
&
Perform
Assembly Procedure and its
implementation
Production Engineer as per

departmental QP
Verify
6.
Lead engineer Production as

per departmental QP
REFERENCE

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Quality Manual (100MAN GE 001)

Procedure for Traceability of structural steel works (2SF QSP GE007)
7.
FLOW CHART
Receiving
priority schedule
from planning
Receiving
drawings from
DCC
Preparing material cutting requisition

and cutting plan for splicing of material
if required.
Preparing additional requirement of
material if required
Issuing material cutting

requisition & cutting plan of prefabrication in machine shop
Pre fabricated material or steel from

machine shop
Fit-up
Fit up inspection with

respect to drawings
(accepted/ rejected )
NOT OK
Rework as per drawing

specification .If accepted sent
for welding .
NOT OK
Not accepted
sent to scrap
area
OK
Welding & assembling
(assembling carried out
if applicable)
Accepted fabricated material sent
to Lay down Area

NOT OK
Rework carried
out as per
welding
Specification
(accepted)
NOT OK Not accepted

sent to scrap
area
OK
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Jamnagar
8.
PROCEDURE
8.1
8.2
8.3
On receipt of the drawings, priority schedules from planning ( through e-mail/

transmittal ) through DCC .
Contractor to withdraw material from stores as per MIN received.
a) Physical verification of raw material shall be carried out before issuing the raw
material to Engineer (CNC). If any discrepancy was found PE shall raise MDR (Material
Discrepancy Report) / FOR (Field Observation Report ) / SER (Site Engineering Request)
b) Preparing material cutting requisition format No. 2SF FMT ME041 and same shall be
hand over to Engineer (CNC) for pre-fabrication i.e., cutting and drilling operations to be
performed by Lead Engineer (CNC).
8.4
Preparing additional requirement of material if any required and same shall be

forwarded to Material Controller through e-mail.
8.5
PE (Fit & Assembly) shall co-ordinate with Engineer (CNC) for availability of semifinished material after cutting and drilling.
8.6
Normally PE (Fit & Assembly) shall receive pre fabricated material / steel from
machine shop and verify the mark number and material specification (Identification of
material specification for plates other than IS 2062 and ASTM A36 shall be done ) with
drawing number and ensure the compliance before proceeding for further work. But in
some cases & extra ordinary circumstances the under mentioned procedure shall be
followed.
a) Raw steel / painted steel shall be used directly according to machine load availability.
b) Raw steel / painted steel shall be used directly in order to minimize the scrap percentage
and utilization of material.
c) Raw steel / painted steel shall be used directly if the available material is less than 2.5
meters ( less than 2.5 meters length can not be processed in cnc machines for drilling.
d) For identification and Traceability refer Departmental Procedure no. 2SF QSP GE 007.
8.7
PE (Fit & Assembly) shall responsible for allocating the pre fabricated material for
FIT-UP to sub-contractors and inspect the fit-up material for dimensions with respect to
drawings/tolerances. If found acceptable shall transfer the item part no/ mark number,
drawing number on the item by hard punching for identification.
8.8
In case the dimensions are not acceptable, PE (Fit & Assembly) shall make decision
for rework and identified as Rejected by permanent marker.
8.9
Acceptable material shall be processed for weld preparation and fit-up of the parts as
per the drawing requirements. Fit-up of the parts shall be done sequentially so as to ensure
welding accessibility
8.10
PE (Fit & Assembly) shall check the fit-up dimensions and orientation with
drawing. Full penetration joints shall be provided with notch cutting as required by
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Jamnagar
drawings or applicable project specifications to ensure full penetration. If fit-up is found

acceptable, PE (Fit & Assembly) shall release the fit-up for welding by signing the
inspection report format no. 2 QA FMT ME 003.One copy inspection report is handed over
to QMD engineer , one copy inspection report with sub-contractor and one copy sent to
planning for updating. After updating the copy shall be retained back from planning.
8.11
In case the fit-up is not found to be acceptable, it shall be rectified and re-inspected
8.12
PE (Fit & Assembly) shall co-ordinate with contractor for getting welding
equipment/machine and welding consumable
if it is not under the scope of sub
contractor. Arranging Qualified welder as per the applicable qualified WPS is under sub
contractors scope.
8.13
Control of welding process activities shall be taken by Welding engineer as per
procedure No. 2 SF QSP GE011. Weld visual inspection, NDT examination shall be
conducted by QMD Engineer as per the requirements of Inspection and test plan and shall
release the structural members, if there is no final assembly of the members involved.
8.14
In case of final assembly of the parts is required to be done as per the production
plan/drawings, PE (Fit-up & Assembly) shall review the Assembly drawing and list out all
member required for assembly and check-up the Inspection and test status of the members
with QMD. Only accepted structural steel members shall be taken-up for assembly.
8.15
PE (Fit-up & Assembly) shall ensure that the parts are properly leveled and aligned
as per the drawing requirements and shall then verify the assembly dimensions using
standard measuring instrument. Assembly dimensions shall be recorded in a dimensional
protocol of assembly.
8.16
In case there welding involvement in final assembly, fit-up shall be inspected by PE
(Fit-up & Assembly) and Points 8.10 to 8.13 shall be followed. Assembly dimensions shall
be rechecked after welding and it shall be recorded in the protocol duly.
8.17
In case of final assembly, PE (Fit-up & Assembly) shall verify if holes are matching
and are within the acceptable limit. In case it is found that holes are not matching rework
shall be carried out and same shall be registered in rework / Rejection log note.
8.18
Rectification shall verified as per the Inspection and test plan by QMD. Final
assembly dimension shall be recorded in protocol format by PE ( Fit-up and assembly )
8.19
Delivery of fabricated structure / material shall be taken care by production
engineer, for external job in co-ordination with stores. If packing is specified by client
the following Procedure for Packing 2SF QSP GE 008 shall be followed by production
engineer.

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9.
RECORDS
Inspection report (2 QA FMT ME 03)
10. ATTACHMENTS
NOT-APPLICABLE

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FORM NO.: 2 QA FMT ME 003

Rev. No.: 00
CONTRACTOR:
Structural Steel Fabrication Inspection

Report
SHEET: 1 OF 1
UNIT / JOB NO.:
REPORT NO:
DATE:
Sl.
No.
Drawing No.
Rev
.No Mark No.
.
Mat.
grade
WPS No Qty
Material /Fit up /
Preheat Weld Visual inspection
Dimensional verification
temp
Contractor
RPL
Contractor
RPL
NDT Report
No
Date
Touch up
painting
Section Deviation if any :
Splice Detail if any:
Remarks :
Note: Welding Inspection shall be certified after completion of all the weld joints against particular mark no.
Contractor
SIGNATURE
NAME
DATE
RIL Execution Engineer
RIL QMD
Client / Third Party
Weight
( Kgs)

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Structural Fabrication Shop

Total No. of Pages :08

ABBREVIATIONS & DEFINITIONS

RESPONSIBILITY AND AUTHORITY

Procedure for fit-up and assembly

Structural fabrication shop

ABBREVIATIONS & DEFINITIONS

Structural Fabrication Shop

Document Control Cell

Quality management department

RESPONSIBILITY & AUTHORITY

Responsibility and Authority

Production Engineer as per

Lead engineer Production as

Procedure for fit-up and assembly

Structural fabrication shop

Quality Manual (100MAN GE 001)

Preparing material cutting requisition

Issuing material cutting

Pre fabricated material or steel from

Fit up inspection with

Rework as per drawing

Accepted fabricated material sent

to Lay down Area

Procedure for fit-up and assembly

NOT OK Not accepted

Structural fabrication shop

On receipt of the drawings, priority schedules from planning ( through e-mail/

Preparing additional requirement of material if any required and same shall be

Structural fabrication shop

drawings or applicable project specifications to ensure full penetration. If fit-up is found

Procedure for fit-up and assembly

Structural fabrication shop

Inspection report (2 QA FMT ME 03)

Procedure for fit-up and assembly

Structural fabrication shop

FORM NO.: 2 QA FMT ME 003

Structural Steel Fabrication Inspection

UNIT / JOB NO.:

Section Deviation if any :

Splice Detail if any:

RIL Execution Engineer

Client / Third Party

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