Doc. No.
:
DANEM ENGINEERING WORKS FZE DEW-4604-QC-FAB-01
QA/QC PROCEDURE FOR FABRICATION Rev.:00 Page: 1 of 7
Danem Job No. : 4604
Client Name : WEIL / BWE
RUCHE PHASE 1 TOPSIDE PRODUCTION
Project Name :
FACILITY
PIPE RACKS, FGC SKID, FLARE KOD, PIG
Scope :
LAUNCHER, COMPRESSOR PACKAGE
WEIL PO Ref. : 618633, 618658, 618659, 618660, 618680
Document Type : QA/QC
QA/QC PROCEDURE FOR FABRICATION
Rev. No. Date of issue Reason of revision
0 03 Nov 2021 Initial submission
Prepared By Reviewed and Approved By
Anup M Rajesh K Pillai
QA/QC Engineer QA/QC Manager
Doc. No.:
DANEM ENGINEERING WORKS FZE DEW-PRC-QC-FAB-01
QA/QC PROCEDURE FOR Rev.: 02 Page: 1 of 6
FABRICATION
QA/QC PROCEDURE FOR FABRICATION
Rev. No. Date of issue Reason of revision
0 26 Feb 2015 First Issue
1 01 Sep 2019 Comments addressed in section 3
2 15 Oct 2021 Comments addressed in sections 1, 4
Prepared By Reviewed and Approved By
Anup M Rajesh K Pillai
QA/QC Engineer QA/QC Manager
Doc. No.:
DANEM ENGINEERING WORKS FZE DEW-PRC-QC-FAB-01
QA/QC PROCEDURE FOR Rev.: 02 Page: 2 of 6
FABRICATION
1. Purpose
The purpose of this procedure is to define the methods to ensure that
fabrication and welding are carried out under the control condition in
Danem.
This is established based on the requirements of the client for the fabrication
of the required item/s according to the project specification and related code
and international standards.
2. Scope
The scope of this procedure covers the review of fabrication drawings,
procurements of raw materials, fabrication, welding of the scope of item and
assembly of required items according to the relevant drawings, standards,
client’s specification and as per the ITP.
3. Drawings
All drawings received from the client shall be reviewed and to be cross-
checked with the drawing list/transmittal.
Any discrepancies shall be intimated immediately to the client and shall be
documented.
Only approved and AFC stamped drawings shall be released for fabrication
and inspections.
If drawings are modified, the modified drawings shall have a revision
number.
The revised drawings shall also stamp AFC.
The modified drawings shall be issued to the shopfloor and withdrawn old
(superseded) drawings.
4. Raw Materials
Materials procured for the job shall conform to the specifications, relevant
drawings, ITP, and standards/codes.
Record the markings check the dimension, and quantity.
Ensure that the materials shall be free from any transit damages and any
other defects.
The defects, which can rectify while fabrication shall be considered during
the incoming materials inspections and to be communicated to the client
accordingly.
Doc. No.:
DANEM ENGINEERING WORKS FZE DEW-PRC-QC-FAB-01
QA/QC PROCEDURE FOR Rev.: 02 Page: 3 of 6
FABRICATION
The defective materials shall be identified and quarantined for the disposal
and return to the supplier /subcontractor.
Corrective and preventive action shall be carried out according to the IMS
procedure ref. IMS-PRS-05.
The markings shall be correlated with the test certificates. The test certificate
shall be verified for chemical and physical properties with respective
code/standards. Certification type (3.2 / 3.1 / 2.2) for relevant material shall
meet ITP requirements.
The acceptable materials only shall be released for manufacturing.
All free issue materials shall be received and the quantity shall be verified
according to the packing list and stored securely in the place allocated for
free issue materials.
5. Fabrication
5.1 Fabrication shall be carried out as per the approved and AFC stamped
drawings only.
5.2 Markings on materials shall be accurate and as per the drawings or
cutting list if any, and ensure that the wastage shall be minimum.
5.3 Cutting shall be accurate, smooth and true as per the marking. For
welding, the edges shall be prepared according to the drawing and
should be free from tears, shear drags, slag and scales, paint, and
reasonably smooth surface.
5.4 Dimensions and fit up shall be in line with the drawing requirements.
Proper sequence has to be followed while fabrication and assembly.
Necessary stiffeners shall be provided to minimize the welding
distortion.
5.5 Fit up shall be checked for their weld preparation, orientation in
accordance with Drawing / ITP and released for further process.
5.6 Fabricated items shall be marked and identified for field
installation/assembly. Best engineering practices shall be followed for-
precision work and product finish.
5.7 Where the temporary supports or attachments are provided, that shall
be removed carefully by flame cutting/grinding. Ensure that the base
metal shall not damage.
5.8 Any unacceptable surface defects etc. shall be build up by welding and
ground smooth.
Doc. No.:
DANEM ENGINEERING WORKS FZE DEW-PRC-QC-FAB-01
QA/QC PROCEDURE FOR Rev.: 02 Page: 4 of 6
FABRICATION
5.9 All completed items shall be cleaned for spatters, tacks, slag, burs,
scales, oil, grease etc. before releasing for painting.
6. Welding
6.1 Welding shall be carried out in accordance with the applicable codes
(AWS D1.1, AWS D1.6) and standards / specification.
6.2 Prior to proceeding with welding necessary approvals shall be obtained
from the client on the following if required as per the contract.
6.3 Welding Procedure Specifications (WPS).
6.4 Procedure Qualification Records (PQR)
6.5 Welder performance qualification (WQT)
6.6 These shall be in accordance with the requirements given in AWS.
6.7 Only welders qualified as per the code requirements shall be utilized
for welding.
6.8 For shielded metal arc welding only properly baked low hydrogen
electrodes shall be used.
6.9 All surfaces to be welded shall be free from moisture, scale, oil, grease,
paint etc.
6.10 During welding the welds shall be protected from wind, rain, sand and
other harmful weather condition, which may affect weld quality.
6.11 Each pass shall be cleaned thoroughly and visually examined for weld
defects.
6.12 All fillet weld size shall be as per the drawing / specification.
6.13 Cleanliness shall be maintained during and after completion of
welding. Fluxes, rods, slag and other foreign matters shall be removed
from the welding and its adjacent area.
7 Non-Destructive Examinations
7.1 Visual Examination.
7.2 All Welds (100% weld length) shall be visually examined for the
acceptance.
7.3 All unacceptable defects as per AWS D 1.1/ AWS D1.6 shall be marked
and rectified.
7.4 These are re-examined to ensure that the repaired welds are within
the acceptance level.
7.5 QC Engineer shall keep the record of the welding inspected and
accepted.
Doc. No.:
DANEM ENGINEERING WORKS FZE DEW-PRC-QC-FAB-01
QA/QC PROCEDURE FOR Rev.: 02 Page: 5 of 6
FABRICATION
7.6 Type of Examination:
7.7 Liquid Penetrant Examination.
7.8 Magnetic Particle Examination.
7.9 Ultrasonic Examination.
7.10 Radiographic Examination.
7.11 All NDT procedures and NDE qualification certificates of technicians
shall be submitted for review and approval from the client before
commencing any NDE.
7.12 The non-destructive examinations item (pt, mt, ut) above is entrusted
with the in-house NDT procedure & Technicians approved by the client,
Item d above is entrusted with the third part inspection agency. The
applicable examination shall be carried out in accordance with the
client’s specification / codes /ITP.
8 Surface Preparation & Painting
8.1 Items completed and cleared by QC shall be cleaned mechanically/sand
blasted as per the client’s specification.
8.2 All cleaned items shall be visually inspected for any surface defects and
surface profile.
8.3 If any defects noticed shall be repaired as per the standard practice.
8.4 All cleaned items shall be painted in accordance with the
drawings/client’s specification.
8.5 All painted items shall be checked for their finishing and DFT as per the
drawings / client’s specification.
8.6 Ensure that during surface preparation and painting the climate
condition shall be according to the paint system.
9 Inspection
9.1 Stage Inspection
9.2 Inspection activity will be carried out all along the various stages of
fabrication, in addition to the requirements of Inspection and Testing
Plan.
9.3 Final Inspection:
9.4 All completed items shall be inspected as per drawing/specification
before releasing for painting for their:
9.5 Final dimension & distortion, etc.
Doc. No.:
DANEM ENGINEERING WORKS FZE DEW-PRC-QC-FAB-01
QA/QC PROCEDURE FOR Rev.: 02 Page: 6 of 6
FABRICATION
9.6 Weld size and defects.
9.7 Surface finishing.
9.8 Reports:
9.9 Various stage inspection records / reports shall be maintained to
ensure quality of the product.
9.10 Documentation shall be as per the client’s specification.
10 Packing
10.1 All packing shall be done in a standard practice / client’s specification.
10.2 All finished products shall be handled very carefully during packing and
loading to ensure that the products shall not get damage and paint
shall not peel off.
10.3 All completed items shall be packed according to their size and shape.
10.4 Necessary wooden packing shall be provided between the items to
avoid paint damage / transit damage.
11 Documentation
11.1 The following Documents will be provided on the completion of
projects as a Quality Dossier.
11.2 Dimensional Inspection Reports.
11.3 Weld Visual Inspection Reports.
11.4 Blasting /Painting Reports
11.5 NDT reports.
11.6 Material Test Certificates
11.7 Any additional documents shall be provided as per the client’s
specification.
12 Reference Documents
12.1 Drawings
12.2 Project Specifications.
12.3 Inspection and Test Plan
12.4 AWS D 1.1 / D1.6 / ASME Sec. IX / any related code.
12.5 Project spec.
