STANDARD OPERATING PROCEDURES

Form No.: TGS/F/F&W-05 Form Rev. No.: 0 Effective date: 01/09/2021

SOP No. TGS/SOP/4.4.2/F&W-01 Effective Date 01/09/2021 REVISION No 00.00
SOP DESC Fitting in Fabrication Section Fabrication and Welding
DEPARTMENT Manufacturing Control Page Page 1 of 11

1) PURPOSE : This work instruction gives instructions which are followed to be followed for Fitting activity in
fabrication.

SCOPE
2) : This document is followed by all persons working in the Fabrication & Welding shop.

3) Procedure
REFERENCE
:

O P
4) DEFINITIONS None

d S
:

a l i
5) ANNEXURE
V
:

DISTRIBUTION
6)
:

O P
PREPARED BY APPROVED BY

d S
Name and Designation: - Mr. K.V.R Patro (Sr.Manager F&W)

Signature with Date

Fabrication)
Signature with Date
a i
Name and Designation:- Mr. B.K Chhabra (Head Equipment

l
Printed By -V S Raviteja Bhamidi(162840) Print valid till - 25-Dec-2023
V
Printed on - 15-Dec-2023 SOP Valid Till - 13-Sep-2024
STANDARD OPERATING PROCEDURES
Form No.: TGS/F/F&W-05 Form Rev. No.: 0 Effective date: 01/09/2021
SOP No. TGS/SOP/4.4.2/F&W-01 Effective Date 01/09/2021 REVISION No 00.00
SOP DESC Fitting in Fabrication Section Fabrication and Welding
DEPARTMENT Manufacturing Control Page Page 2 of 11

Step Activity Associated Responsibilit Process / tools / PPEs (HOW) Remarks

No. (WHAT) Requirements/Hazards/Impacts y (WHO) /
Referen
ce
1. Receiving of Safety : Fall of material, tripping Supervisor  Use PPEs and avoid loose clothing.
material hazards, wounds, poor  Plates to be handled by plate clamps.
from housekeeping , forklift operation  While handling items with sharp edge packing
Preparation to be provided to avoid sling damage
Section  Care should be taken while forklifts are moving
in the working area.
Environment : Air pollution, noise Supervisor  Ventilation
pollution.  Use of ear plug

Quality :
 Housing keeping
O P
Supervisor  Marked place for prepared items.
 P.O number , item number on all items to be
 Proper stacking

d S marked.
 Item straightness , flatness and free of notches

a l i to be received. Material of the P.O allotted in the

area to be only received ( monthly plan
fabrication)

V  Received material must be kept in proper

sequence of use, with proper stacking.
 Materials of P.O to be kept at a location and to
be entered in a register (material receiving
register)
 Material receiving logbook should mention
receiving date , person, and time.

O P
PREPARED BY APPROVED BY

d S
Name and Designation: - Mr. K.V.R Patro (Sr.Manager F&W)

Signature with Date

Fabrication)
Signature with Date
a i
Name and Designation:- Mr. B.K Chhabra (Head Equipment

l
Printed By -V S Raviteja Bhamidi(162840) Print valid till - 25-Dec-2023
V
Printed on - 15-Dec-2023 SOP Valid Till - 13-Sep-2024
STANDARD OPERATING PROCEDURES
Form No.: TGS/F/F&W-05 Form Rev. No.: 0 Effective date: 01/09/2021
SOP No. TGS/SOP/4.4.2/F&W-01 Effective Date 01/09/2021 REVISION No 00.00
SOP DESC Fitting in Fabrication Section Fabrication and Welding
DEPARTMENT Manufacturing Control Page Page 3 of 11

Step Activity Associated Responsibility Process / tools / PPEs (HOW) Remarks /

No. (WHAT) Requirements/Hazards/Impacts (WHO) Reference

2. Receiving the Safety : Fall of material, tripping Supervisor  Use PPEs and avoid loose clothing.
following items hazards, wounds, poor  Dedicate place for storing items of
1.Brought out housekeeping. machined surface and proper packing to
2.Pre-Machine avoid surface damage.

Environment : Air pollution, noise Supervisor  Ventilation

pollution  Use of ear plug

Quality :
 Housing keeping
O P
Supervisor  Marked place for items from store and
machine shop.
 Proper stacking

d S  Check the item code , P.O number prior to

receiving the job.

a l i  Inspection report of the P/M and B/O to be

checked.
 Received material must be kept in proper

V sequence of use, with proper stacking.

 Materials of P.O to be kept at a location and
to be entered in a register (material receiving
register)
 Pre- machining receiving logbook should
mention receiving date , person, and time.

O P
PREPARED BY APPROVED BY

d S
Name and Designation: - Mr. K.V.R Patro (Sr.Manager F&W)

Signature with Date

Fabrication)
Signature with Date
a i
Name and Designation:- Mr. B.K Chhabra (Head Equipment

l
Printed By -V S Raviteja Bhamidi(162840) Print valid till - 25-Dec-2023
V
Printed on - 15-Dec-2023 SOP Valid Till - 13-Sep-2024
STANDARD OPERATING PROCEDURES
Form No.: TGS/F/F&W-05 Form Rev. No.: 0 Effective date: 01/09/2021
SOP No. TGS/SOP/4.4.2/F&W-01 Effective Date 01/09/2021 REVISION No 00.00
SOP DESC Fitting in Fabrication Section Fabrication and Welding
DEPARTMENT Manufacturing Control Page Page 4 of 11

Step Activity Associated Responsibilit Process / tools / PPEs (HOW) Remarks /

No. (WHAT) Requirements/Hazards/Impacts y (WHO) Reference

3. Preparation Safety : Tripping hazard falling, Cuts, Fitter  Use PPEs and avoid loose clothing.
of working Wounds.  Cleaning of bed
bed  Removal of unwanted material form bed
 Dressing  Dressing of high points
 Levelling  Beds to be free from any holes , damage or
else they can create STF hazard.
 Grinding of the high points and spatter
guards to be provided
 Follow Grinding SOP.
Environment : Air pollution, noise
pollution, use of natural resource,
energy consumption.
O P
Supervisor 


Ventilation
Use of ear plug
Ensure optimum use of natural resources.

d S  Miss use of energy to be avoided

i
Quality : Quality of water level pipe,

l
& calibration of measuring tape /
scale
a
Fitter 


Clean water
Visible / transparent water level pipe
Calibrated measuring tape / scale

V  Water level of bed with the help of water level

& calibrated measuring tape / scale.
 Ensuring the level of bed is within ±1 mm to
ensure verticality and flatness of the job that
is to be fabricated.

O P
PREPARED BY APPROVED BY

d S
Name and Designation: - Mr. K.V.R Patro (Sr.Manager F&W)

Signature with Date

Fabrication)
Signature with Date
a i
Name and Designation:- Mr. B.K Chhabra (Head Equipment

l
Printed By -V S Raviteja Bhamidi(162840) Print valid till - 25-Dec-2023
V
Printed on - 15-Dec-2023 SOP Valid Till - 13-Sep-2024
STANDARD OPERATING PROCEDURES
Form No.: TGS/F/F&W-05 Form Rev. No.: 0 Effective date: 01/09/2021
SOP No. TGS/SOP/4.4.2/F&W-01 Effective Date 01/09/2021 REVISION No 00.00
SOP DESC Fitting in Fabrication Section Fabrication and Welding
DEPARTMENT Manufacturing Control Page Page 5 of 11

Step Activity Associated Responsibilit Process / tools / PPEs (HOW) Remarks /

No. (WHAT) Requirements/Hazards/Impacts y (WHO) Reference

4. Safety : Cut , wound , Slip Trip and Fitter &  Use PPEs and avoid loose clothing.
Dimensional Fall hazard, Electric shock Grinder  Use of screen to protect others from grinding
checking & splash / iron particles.
dressing of  Grinding M/C with guard & Cable with proper
prepared insulation.
Items  Extension board with HRC fuse.
 Check tools and tackles.
 Check Expiry date of Grinding wheel.
 Follow Grinding SOP

Environment : Air pollution, noise

O P
Supervisor  Ventilation
pollution, use of natural resource,
energy consumption.

d S  Use of ear plug

 Use of screen to protect others from grinding

a l i splash / iron particles.

 Use of face mask

bevel angle.
V
Quality : Straightness , flatness , Fitter  Check the flatness and straightness of the
items received.
 Check the length , width , thickness and
necessary dimensions of the items prior to
fitting using tape (calibrated) w.r.t the
drawing of the P.O allotted in the area

O P
PREPARED BY APPROVED BY

d S
Name and Designation: - Mr. K.V.R Patro (Sr.Manager F&W)

Signature with Date

Fabrication)
Signature with Date
a i
Name and Designation:- Mr. B.K Chhabra (Head Equipment

l
Printed By -V S Raviteja Bhamidi(162840) Print valid till - 25-Dec-2023
V
Printed on - 15-Dec-2023 SOP Valid Till - 13-Sep-2024
STANDARD OPERATING PROCEDURES
Form No.: TGS/F/F&W-05 Form Rev. No.: 0 Effective date: 01/09/2021
SOP No. TGS/SOP/4.4.2/F&W-01 Effective Date 01/09/2021 REVISION No 00.00
SOP DESC Fitting in Fabrication Section Fabrication and Welding
DEPARTMENT Manufacturing Control Page Page 6 of 11

Step Activity Associated Responsibilit Process / tools / PPEs (HOW) Remarks /

No. (WHAT) Requirements/Hazards/Impacts y (WHO) Reference

5. Marking Safety : Slippage of punch , Fitter  Use PPEs and avoid loose clothing.
Hummer, Cut , Wound.  Hammer with wooden handle.
 Proper illumination.
 No use of mushroom head hammer and
punch.
 Use of hand gloves to avoid injury during
working.
Environnent : Air pollution, noise Supervisor  Ventilation
pollution.  Use of ear plug

Quality : Condition of drawing &

O P
Fitter
 Proper illumination

 Drawing must be readable and A1 for

measuring tape,.

d S drawing with a greater number of items and

intricate assemblies.

a l i  In case of jobs whether dimensions are not

clear these to be clarified either by
consultation with PED or to be mailed to

V designer.
 Only controlled copies to be used and
drawing to be taken only from PED and not
from any unauthorised location.
 All drill holes to be marked and punched on
the items , diameter of the hole to be marked
to ensure the lap of the hole is maintained.

O P
PREPARED BY APPROVED BY

d S
Name and Designation: - Mr. K.V.R Patro (Sr.Manager F&W)

Signature with Date

Fabrication)
Signature with Date
a i
Name and Designation:- Mr. B.K Chhabra (Head Equipment

l
Printed By -V S Raviteja Bhamidi(162840) Print valid till - 25-Dec-2023
V
Printed on - 15-Dec-2023 SOP Valid Till - 13-Sep-2024
STANDARD OPERATING PROCEDURES
Form No.: TGS/F/F&W-05 Form Rev. No.: 0 Effective date: 01/09/2021
SOP No. TGS/SOP/4.4.2/F&W-01 Effective Date 01/09/2021 REVISION No 00.00
SOP DESC Fitting in Fabrication Section Fabrication and Welding
DEPARTMENT Manufacturing Control Page Page 7 of 11

Step Activity Associated Responsibilit Process / tools / PPEs (HOW) Remarks /

No. (WHAT) Requirements/Hazards/Impacts y (WHO) Reference

6. Handling Safety : Cuts, wound, strain, Rigger  Use PPEs and avoid loose clothing.
of item with dressing of body parts, sharp edges  Use pipe guards to prevent damages to the
crane of plates, long plates , structural slings / rope
item , Proper space for movement of  Insure proper hook in the job to be lifted,
material.  Use proper sling / D-shackle.
 Use proper sling / chain for lifting the plates,
considering centre of gravity to prevent
falling.
 Use of guy rope to maintain distance from

O P the job to be lifted.

Note(dt 04-06-09) :- while inverting the ring

d S more then 5 Mtr. Dia put support stiffener on joint

without scallop. Also do the full welding. Use 50

l i
Environment : Air pollution, noise
pollution.
a
Supervisor
mm X 200 mm x 800 mm size stiffener on joint.
 Ventilation
 Proper illumination

V
Quality : Standard quality of slings, Rigger
 Use of fluorescent jackets
 Disposal of damaged slings in scrap bins

 Quality of sling, rope, chain & D-shukle to be

rope, chain & D-shukle. checked prior to use.
 Only calibrated tools to be used.

O P
PREPARED BY APPROVED BY

d S
Name and Designation: - Mr. K.V.R Patro (Sr.Manager F&W)

Signature with Date

Fabrication)
Signature with Date
a i
Name and Designation:- Mr. B.K Chhabra (Head Equipment

l
Printed By -V S Raviteja Bhamidi(162840) Print valid till - 25-Dec-2023
V
Printed on - 15-Dec-2023 SOP Valid Till - 13-Sep-2024
STANDARD OPERATING PROCEDURES
Form No.: TGS/F/F&W-05 Form Rev. No.: 0 Effective date: 01/09/2021
SOP No. TGS/SOP/4.4.2/F&W-01 Effective Date 01/09/2021 REVISION No 00.00
SOP DESC Fitting in Fabrication Section Fabrication and Welding
DEPARTMENT Manufacturing Control Page Page 8 of 11

7. Clamping Safety : Slippage of wedge, hammer, Fitter  Use PPEs and avoid loose clothing.
& wedging Wound, Cuts, Tripping hazard  Taper of wedge must be proper.
 Face of wedge must be smooth.
 Wooden hammer handle to be used.
 Welding of C-clamps & L-champs must be
sound.
 No use of mushroom head hammer / wedge.

Environnent : Air pollution, noise Supervisor  Ventilation

pollution.  Proper illumination

Quality : Condition of hammer,

condition of wedge, welding of
O P
Fitter  Checking of condition of hammer & wedge.
 Sound welding of clamps to be ensured.
clamps.

d S
a l i
V

O P
PREPARED BY APPROVED BY

d S
Name and Designation: - Mr. K.V.R Patro (Sr.Manager F&W)

Signature with Date

Fabrication)
Signature with Date
a i
Name and Designation:- Mr. B.K Chhabra (Head Equipment

l
Printed By -V S Raviteja Bhamidi(162840) Print valid till - 25-Dec-2023
V
Printed on - 15-Dec-2023 SOP Valid Till - 13-Sep-2024
STANDARD OPERATING PROCEDURES
Form No.: TGS/F/F&W-05 Form Rev. No.: 0 Effective date: 01/09/2021
SOP No. TGS/SOP/4.4.2/F&W-01 Effective Date 01/09/2021 REVISION No 00.00
SOP DESC Fitting in Fabrication Section Fabrication and Welding
DEPARTMENT Manufacturing Control Page Page 9 of 11

Step Activity Associated Responsibility Process / tools / PPEs (HOW) Remarks /

No. (WHAT) Requirements/Hazards/Impacts (WHO) Reference
8. Fit and Safety : Electric shock, cut, wound, Fitter  Use PPEs and avoid loose clothing.
Tacking of smoke, burn, spatters, , tripping  Portable screen guards to be used
the items. hazard, falling of job, falling of  Cable should be insulated.
workman. Electrode stubs on the  Cable must be free from any joint up to at
floor. Defective or damage cable & least 3 meter from electrode holder.
electrode holder, Proper earthing,  Proper tightening of earthing of job.
Welding machine with ELCB.  Proper support to be given to job if required.
 Use welding machine with ELCB.

Environment: Air pollution, noise

O P
Superviser
 Use welding screen while tacking.(rev.-
01/dt.07/06/2010).
 Ventilation
pollutionon.

d S  Proper illumination

holes , centre line marking

a l i
Quality : CTQ dimensions , marking
of machining items , marking of drill
Fitter  Fit and tack all items to the maximum possible
extent as per drawing.
 Provide adequate supports using angle ,

V channel , beam.
 When the job involves multiple machining
centre line marking , hole C.L marking to be
done prior to welding
 After tacking the job to be offered to
inspection depending upon the category of job
and checklist to be filled prior to offer.

O P
PREPARED BY APPROVED BY

d S
Name and Designation: - Mr. K.V.R Patro (Sr.Manager F&W)

Signature with Date

Fabrication)
Signature with Date
a i
Name and Designation:- Mr. B.K Chhabra (Head Equipment

l
Printed By -V S Raviteja Bhamidi(162840) Print valid till - 25-Dec-2023
V
Printed on - 15-Dec-2023 SOP Valid Till - 13-Sep-2024
STANDARD OPERATING PROCEDURES
Form No.: TGS/F/F&W-05 Form Rev. No.: 0 Effective date: 01/09/2021
SOP No. TGS/SOP/4.4.2/F&W-01 Effective Date 01/09/2021 REVISION No 00.00
SOP DESC Fitting in Fabrication Section Fabrication and Welding
DEPARTMENT Manufacturing Control Page Page 10 of 11

Step Activity Associated Responsibility Process / tools / PPEs (HOW) Remarks /

No. (WHAT) Requirements/Hazards/Impacts (WHO) Reference

9. Heating & Safety : Burns, wounds, slippage of Fitter & Gas  Use PPEs and avoid loose clothing.
straighteni wedge, hammer, pressing of body Cutter  Check the condition of hoses, regulators prior
ng parts, leakage of LPG / DA / to use.
Oxygen. Condition of hoses &  Use back fire arrestor with torch.
regulators & heating torch.  Keep the cylinders in vertical and chained
condition.
 Don’t touch the hot surface.

O P
Environnent : Air pollution, noise
pollution, Consomption of natural

d S Supervisor  Ventilation
 Proper illumination
resources.

a l i  Prevent leakage of gases.

V
Quality : Condition of regulator ,
hoses, torch.
Fitter & Gas
Cutter
 Ensure the good & safe condition of regulator,
hoses & torch.

O P
PREPARED BY APPROVED BY

d S
Name and Designation: - Mr. K.V.R Patro (Sr.Manager F&W)

Signature with Date

Fabrication)
Signature with Date
a i
Name and Designation:- Mr. B.K Chhabra (Head Equipment

l
Printed By -V S Raviteja Bhamidi(162840) Print valid till - 25-Dec-2023
V
Printed on - 15-Dec-2023 SOP Valid Till - 13-Sep-2024
STANDARD OPERATING PROCEDURES
Form No.: TGS/F/F&W-05 Form Rev. No.: 0 Effective date: 01/09/2021
SOP No. TGS/SOP/4.4.2/F&W-01 Effective Date 01/09/2021 REVISION No 00.00
SOP DESC Fitting in Fabrication Section Fabrication and Welding
DEPARTMENT Manufacturing Control Page Page 11 of 11

Step Activity Associated Responsibility Process / tools / PPEs (HOW) Remarks /

No. (WHAT) Requirements/Hazards/Impacts (WHO) Reference

10. Assembly at Safety : Falling from height, fear of Supervisor &  Use PPEs and avoid loose clothing.
height height, unwanted materials, Working Fitter  Use standard stand with railing & toe guard.
on platform / stand / ladder,  The length of full body harness is max. 1.8m
Inflammable material like wood, oil , and dia 19mm (max.)
cotton lying near or under the fitting  Use proper ladder like rubber pad at bottom.
& welding area. Hot spatters.  Remove unwanted material from working
space.
 Remove the inflammable material lying near

O P welding area. For e.g. wood, oil etc..

Provision to arrest. Hot spatters & barricade
underneath.

d S
l i
Environnent : Air pollution, noise
pollution, Consomption of natural
resources.
a
Supervisor  Ventilation
 Proper illumination

V
Quality : Condition of stand &
arrangement of working at height.
Supervisor &
Fitter
 Check the condition of stand & arrangement
of working at height prior to use.

O P
PREPARED BY APPROVED BY

d S
Name and Designation: - Mr. K.V.R Patro (Sr.Manager F&W)

Signature with Date

Fabrication)
Signature with Date
a i
Name and Designation:- Mr. B.K Chhabra (Head Equipment

l
Printed By -V S Raviteja Bhamidi(162840) Print valid till - 25-Dec-2023
V
Printed on - 15-Dec-2023 SOP Valid Till - 13-Sep-2024