Dos & Don'ts

Shop Floor Practices

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Dos & Don'ts Shop Floor Practices

Dos Don'ts
Check fabrication Do not proceed for
drawing requirements. fabrication without
Read / study drawings. availability of approved
Check for fabrication drawings.
tolerances (Project- Do not fabricate without
specific). correct information on
tolerances but arrange to
get the same before start-of
fabrication.
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Dos & Don'ts Shop Floor Practices

Dos Don'ts
Check the base material Do not proceed for
thoroughly before fabrication without
commencing fabrication. checking on base
For Boilers - Check for materials for size &
PTC (Production Test classification.
Coupons) requirements Do not fabricate
for production, if any without checking for
PTCs.
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 Dos & Don'ts Shop Floor Practices

Dos Don'ts
Check for general surface Do not proceed for
conditions before fabrication without
welding ask for wire visual check on parent
brushing for doubtful metal surface.
cases, blasting for pitting Do not proceed
check, etc. without visual check
Check the base material on weld bevel edges &
edges for obvious cleanliness, which
laminations & otherwise will show as
cleanliness before tack- defects in RT.
welding. 4
Dos & Don'ts Shop Floor Practices

Dos Don'ts
Check quality of weld Do not clear for tack-
bevel preparations & welding for improper
groove geometry prior bevel angle, root-face,
to tack-up. root-gap.
Do not carry out fit-ups
Check for ovality &
without adequate checks
shape with templates.
for ovality.
Check for alignment
Do not forget to check for
of large structures. alignment within the
tolerances. 5
Dos & Don'ts Shop Floor Practices

Dos
Check welding m/cs. & calibration before start of shift.
Check for Welders approval & qualification expiry.
Check for welding electrodes.

Don'ts
Do not weld with defective machines, which may cause weld
repairs due to wrong welding parameters output.
Do not use unapproved welder.
Do not use wrong electrodes & diameter outside WPS limits.
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 Dos & Don'ts Shop Floor Practices
Dos
Check welding preheat & parameters reqd. before welding.

Monitor all critical joints during welding activity.

Don'ts
Do not weld with wrong preheating / parameters which may
cause weld cracks.

Do not leave the welders unattended for critical joints, e.g.

Heavy-wall applications, WB 36, Casting repairs,..

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Dos & Don'ts Shop Floor Practices

Dos Don'ts
Check for release by Do not proceed for
Q.C. before taking up fabrication without
fabrication activities. prior Inspection.
For Stainless steel & Do not use carbon
non-ferrous materials steel tools for
check for availability fabrication of SS,
of SS tools. Duplex SS,

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 Dos & Don'ts Shop Floor Practices

Dos Don'ts
Check all tools for related Do not fabricate with
calibration before start of shift. defective tools.
Check with Welding Engineer Do not use unapproved
for Welders approval. welder for tack-
Check for proper welding welding.
electrodes with the Welding Do not use wrong
Engineer. electrode quality.

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 Dos & Don'ts Shop Floor Practices

For tack- welding :

Preheating check on higher thickness component.
Ensure tacks are free from defects such as undercuts,
cracks, porosities, improper fusion.
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Dos & Don'ts Shop Floor Practices

Stray arc Hardened zone

Cracks

For tack- welding :

Arcing shall be avoided on the base material,
otherwise will lead to cracks.

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Dos & Don'ts Shop Floor Practices

1-2
mm

For tack- welding :

Ensure a gap of 1-2 mm before welding a temporary
stiffener to the work-piece - to avoid a parent-material rip-
off.

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Dos & Don'ts Shop Floor Practices

Dos Don'ts
Check welding preheat Do not weld with
reqmts. before tack- wrong preheating /
welding. parameters which may
Check for wind cause weld cracks.
protection before tack- Do not weld with the
welding. wind as weld
porosities may result.

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 Dos & Don'ts Shop Floor Practices
Dos
Ensure that the run-in / run-
out tabs & temporary supports
are carefully removed.
Gouging / Touch-ups shall be
minimized. The touch-ups shall
be carried out progressively on
daily-basis to avoid
substantial negative appearance.
Don'ts
Do not permit damage to
the base material when
removing the temporary
attachments.
Hidden Factory :
Do not allow wastage of
man-hours due to excess
gouging & grinding.
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Dos & Don'ts Shop Floor Practices
Dos Don'ts
Ensure that the Do not permit the wastage
fabricators & fitters of costly fit-up tools.
are returning back the Do not weld in high winds
reqd. tools at the end- without wind-screens
of-shift. /tarpaulin protection.
Ensure that tarpaulins
for wind protection.

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Dos & Don'ts Shop Floor Practices
Dos Don'ts
Do not deviate from the
Use correct torque
wrenches for tightening specified parameters for
as per the specified bolt-tightening.
tables. Do not assume the

In case of doubt, check drawings are correct to

rating & bore of flanges. fine details.

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Dos & Don'ts Shop Floor Practices

Dos Don'ts
Ensure that piping Do not keep the ends of
ends are closed when pipes open as dirt &
not being fabricated. contamination chances
Ensure that the gasket- are likely.
face of flanges are Do not expose the
well protected to avoid gasket-face of flange as
damage /leakages. leakages would occur
during hydro test in case
of damage. 17
Dos & Don'ts Shop Floor Practices

Dos
Offer similar types of joints for RT in small batches.

Use correct distortion control procedure / sequence for welding.

Don'ts
Do not accumulate a large no. of joints for RT as corrective
action cannot be taken up.

Do not use unbalanced welding sequence which will cause

distortion.
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Thanks!!

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