ACE AL FARIS FZC P.O.

Box 42768, Plot:2D-11/22,

Hamriyah free Zone, Sharjah - U.A.E. Tel:
Hamriyah Free Zone +971(6)5269080 Fax:+971(6)5269096
Email: a f @a c e -m e .com

MANUFACTURING PROCEDURE OF A CUSTOM BUILT

SOUND PROOF ENCLOSURE USING PANEL SHEETS

Building structural engineering & fabrication, generator sound proof enclosure, crane
structural, pressure vessels, storage tanks, process plant fabrication and installations,
machining, crane maintenances and engineering services, blast cleaning & painting.
 ACE AL FARIS FZC

Index
1. Purpose
2. Scope
3. International codes and standards
4. Vendor Documents
5. Responsibilities
6. Quality
7. Equipment List
8. Safety Hazards & Control Measures
9. Documentation
10. Projects Schedule
11. Material procurement
12. Main skid and Engine Skid fabrication
13. Side structure and roof fabrication
14. Ladder Fabrication
15. Panel Fabrication
16. Splitter Fabrication
17. Louver fabrication
18. Engine and alternator coupling
19. Muffler support fabrication
20. Assembly
21. Final painting
22. Mono rail installation
23. Instrumentation and Electrical work
24. Dispatch
 ACE AL FARIS FZC

1. PURPOSE :

To ensure the Quality and Safety in Fabrication shop of Structural & Steel for the
Construction of Custom built Sound proof enclosure is assured by designing a
procedure for monitoring all activities related to structural & steel fabrications.
2. SCOPE:
This procedure is applicable for shop floor / site fabrication, inspection & testing of
structural & steel fabrication done Ace Al Faris for the Construction of Custom built
Sound proof enclosure.
3. INTERNATIONAL CODES AND STANDARDS REQUIREMENTS
AWS D1.1: Structural Welding Code-Steel.
ASME Sec V- Non-Destructive Examination.
ASME Sec IX Welding and Brazing Qualifications.
4. VENDOR DOCUMENTS :
Procedure for Magnetic Particle Testing
Procedure for Liquid Penetrate Testing
Procedure for Ultrasonic Testing
Procedure for Radiography Testing
Procedure for Positive Material Identification Procedure (PMI)
AAF-WPS-012, AAF-WPS-016, AAF-WPS-017, AAF-WPS-019, Welding
Procedure Specifications (WPS)
ACE-PP-02 Painting Procedure

5. RESPONSIBILITIES :
 ACE AL FARIS FZC
Production manager & his team are responsible for implementing & effectively
improving this procedure. All Production teams are aware of the project
specifications and requirements.
Project Manager / Project Engineer are responsible for any approval /
submission to Client. He will forward the approved documents to production
department & Quality department.
Quality Engineer is responsible for the stage inspections, Welding Procedure
Specification (WPS), Procedure Qualification Records (PQR), Welder Qualification
Test (WQT), Internal Non conformance Record (NCR) and implementation of the
procedure.
HSE Advisor / Officers are Responsible for safety awareness and necessary
requirements as per HSE plan.
Store in charge / Store Keeper is responsible for Material Loading, Unloading,
Material storage, Handling and Issue material to the production team as per the
request.

6. QUALITY:
WELDER QUALIFICATION :

Each welder to be qualified without back welds.

Qualified welder should have welder ID for identification purpose.
Welder PRQ, test records and identification card to be witnessed and
reviewed by approved TPI.
Quality induction to be given to all qualified welders on those particular
project quality requirements. And these records to be recorded and
maintained properly.
Welder past experience records to be submitted for Client approval.

WELDING PROCESS :
Vendor proposes SMAW process for structural steel welding.

WORKMAN SHIP:
Spatters, arc strikes and other indication are not allowed, these shall be
removed carefully by grinding. MT to be applied after grinding and to be
reported.
After completion of welding works slag and debris need to be removed and
visual inspection has to be done and results to be recorded.
 ACE AL FARIS FZC
As per the Approved ITP, NDT has to be performed. For NDT inspection
approved TPI shall witness.
All production welds to be mentioned by weld joints and welder has to be
mentioned by marker.

INSPECTION :
All inspection shall be carried out as per the project requirements and
approved ITP.
Each stages visual and dimensional inspection to be done and to be
recorded.
As per Project ITP, NDT to be done, Approved TPI shall be witnessed as per
the client requirements.
All NDT activities to be performed by approved NDT services only.
All NDT procedure to be approved by client. Before preceding any activity.

WELD REPAIR:
All welding repairs to be rectified as per approved welding procedures and
approved welders only.
After rectification applicable NDT to be carried out and test records to be
kept as record.

INSTRUMENTS & EQUIPMENT CALIBRATION:

All measuring & inspection instruments to be calibrated at least once a
year.
Additionally welding machines, Packing & holding ovens to be calibrated
once a year.
All lifting equipments and accessories to be certified by TPI.

7. EQUIPMENT LIST
GTAW Welding Machines
High Frequency machines.
SMAW Welding Machines
Packing Ovens
Holding ovens
Fork Lift
Certified Cranes
Blasting Machine
Air less Spray Painting Machine
Air Compressor
Fitter hand tools & Power tools
Calibrated Inspection instruments
Chain Block
Structural Consumables
Drilling machine
 ACE AL FARIS FZC
Shearing & Bending Machine
CNC Cutting Machine
Lifting Accessories
Scaffoldings

8. SAFETY HAZARDS & CONTROL MEASURES :

WELDING EQUIPMENT :
All welding equipments should be in good condition, preventive maintenance
records have to be maintained properly. This is applicable for all welding
activities of the project.
Before welding process, cables, earth cables and other accessories,
connection has to be checked.
Electrical cables connection should be connected properly, loose connection
not permitted

WEATHER PROTECTION:
Sufficient precautions and protection to be taken prior to start of welding.
Applicable areas fire blankets, welding tents, etc. to be used.

WELDING CONSUMABLES & CONTROL METHOD:

As per the manufacture, electrode has to be stored properly. Store in-charge
is responsible for consumable storage and issue.
As per the manufacturer, packing and holding temperature has to be
maintained, and oven temperature has to be recorded. QC department has to
check these records on daily basis.
QC department to verify the Welding consumables from supplier. The
following details need to be checked as minimum.
1. Size and length.
2. PO requirements.
3. Batch certificates.
4. Electrode conditions.
Welding engineer/supervisor need to check the welding consumable storage
and oven working conditions. If any oven is not working properly, out of order
tag to be displayed.
After packing the electrodes, it shall be shifted to holding oven.
As per the supervisors instruction, welders need to collect the welding
consumables from store. And collected electrodes to put inside electrode
quiver and to be kept under temperature from 110C 150C during the tack
welding & production welding activities.
Only low hydrogen electrodes shall be used for structural welding, tack
welding & temporary welding.
 ACE AL FARIS FZC
Vacuum pack electrodes can be used directly to structural welding without
Packing.

The following Risk Hazards are involved in these fabrication activities, the Risk
ranking will be assessed as per the EHS Risk assessment template.
General safety hazards and control measures as mentioned below.
Welding: Check the welding machine condition & power cables prior to the start
of work.
Painting: MSDS (Material Safety Data Sheets) should be available for all paints
and thinner materials.
Machineries: All Machineries should have the schedule check list and before
start of work to be checked as per the check list.
Lifting Accessories: All lifting accessories like Lifting belts, D-Shackles, Slings,
Hooks and Wire Ropes should have third party certification and before start of
work needs to be check.
Cutting & Grinding: All consumables to be used with suitable machines as per
the manufacture instruction like speed, size and purpose. Proper shield to be
fixed and before operation operator should have safety glasses and hand gloves.
Fork Lift / Cranes: While doing loading, Unloading and handling activities it
should be ensured that the minimum height requirements and Speed should not
exceeds 30 Km/h.
All operators should know the emergency evacuation plan at time of emergency
and shop floor should have First aid box, trained fire warden and first aider.

9. DOCUMENTATION:
Project dept will get all the documents like drawing approval, ITP, welding
procedure, painting procedure, grade and quality of materials used required for
smooth production by the client. They will clear any clarifications from client or
production dept. They should track all the activity going on in the yard and match it
with the project schedule. If any work is lagging behind, then it is the duty of
projects dept to find the reason for the delay and try to accelerate the production.

The following documents must be readily available for ready references.

Approved GA drawings for construction.
Approved ITP.
Approved WPS, PQR & WQT.
Approved NDT Procedures & Technician qualification certificates.
Calibration certificates.
Stage inspection reports.
 ACE AL FARIS FZC
NDT reports.
Blasting, Painting and Galvanizing (if applicable) reports.

10. PROJECT SCHEDULE:

Project schedule must be prepared at the prior of the work. The project engineer must
prepare the schedule and make sure that the scheduled activities are going according
to the planed schedule.

11. MATERIAL PROCURMENT:

Material procurement will be started as soon as the GA drawing is approved by
the client. Project engineer will prepare the bill of materials by the help of GA
drawing and submit the BOM to procurement Dept for the materials to be
procured.
All Structural steel material before unloading, QA/QC team should inspect as per
the Project requirements / Specifications. After the QA/QC inspection, Client
approved TPI to inspect all items as per the project requirements.
After giving clearance from QA/QC department, material to be unloaded with
proper lifting accessories as per HSE Advisor /Office instructions.
Each material should have material GRN number.
Material to be stored properly to prevent from any damages.
Free issued material will be inspected as per the client packing list/ Project
requirements/Fabrication drawings. Clients approved TPI to verify.

12. MAIN SKID FABRICATION / ENGINE SKID FABRICATION:

CUTTING
Fabrication drawing to be prepared as per approved drawing and structural
material specifications.
Production drawings are done by draftsman and should be approved by the
client.
These approved drawings must be handed over to production dept by projects
dept with proper seal and date.
Soon after the materials have been arrived, the materials are blasted using auto
blast or manual blast then a coat of primer is applied.
Production engineer will instruct the foreman about how to cut the material for
fabrication according to fabrication drawing.
As per fabrication drawing structural material will be cut and each material
should have the traceability.
Material identification to be done after cutting material as per fabrication
drawings.
Before cutting process, nozzle size, gas pressure and cutting speed to be
confirmed.
 ACE AL FARIS FZC
When oxy-fuel cutting is used, edges to be ground after cutting process.
After cutting all exposed edges shall be tapered to 1.5mm.

JOINT PREPARATION :
Joint preparation shall be done as per approved WPS. Each joint to have a table
with joint no. WPS no, welder ID, fit-up date and visual date.
As per approved WPS required root gap, root face and bevel angle to be
maintained.
Packing strips or consumable inserts can be used for structural welding.

FABRICATION FIT-UP :
After the materials are ready, the production in charge will guide the fabricators
and welders to fit up the engine skid or Main skid.
Tack welds & temporary welds will be done by qualified welders on the skid.
Tack weld shall be of a minimum length of four times the plate thickness.
Tack welds or temporary weld shall be carried out with same care, preheat,
electrodes, materials and procedure as permanent welds.

FABRICATION TOLERANCE :
Joint preparation tolerance will be maintained as per approved WPS.

FULL WELDING
Once the QA/QC has checked the skid for any flaws or corrections, the skid is
further preceded for full welding.

CHEQUERED PLATE FIT UP:

The plate is blasted and painted with primer.
The plate cutting is done according to the Production drawing and it is fitted
upon the skid by stitch weld or continuous weld which depends on client.

INTERNAL FUEL TANKS:

The fuel tank can be in the maun skid or in engine skid.
If the skid has an inbuilt fuel tank in the GA drawing, the material is blasted and
painted with primer and intermediate.
The sheet will be fitted according to the drawing and will be checked by QA/QC
dept.
After the approval of QA/QC, the fuel tank is continuously welded with a suitable
method of welding.
Leak test is performed by the QA/QC and checked for any leaks. If any leakage is
found then it is cleared at this stage itself.

MOUNTING PLATE FIT UP:

The material is cut according to the fabrication drawing.
 ACE AL FARIS FZC
The plates which are cut are ground and drilled.
If the thread is required internally, then the tapping is done.
The plates are now placed on the floor of the enclosure as per the dimensions.
Full welding is done around the plates.
Primer and intermediate coats are applied.

13. SIDE AND ROOF STRUCTURE FABRICATION:

Once the production drawing of side and roof structure is ready, the production
engineers will proceed with the fabrication of side and roof structure.
The structure materials will be cut as per the production drawing. The structural
material will be blasted and painted with a coat of primer before the actual fit up.
The materials which are cut have a tracing identity on them which is easier for fit
up.
The fit up is done using only the temporary welds.
After the structural fit up, the QA/QC team will check the dimensions and
tolerance of the structure.
If any defects are found, then it is reported to production dept and the corrective
action is implemented and the full weld of the structure is done.

14. LADDER FABRICATION:

The production drawing will have the location of the ladder.
The ladder can be of 2 types
a) Integrated ladder
b) Externally bolted ladder
The material required for the ladder is cut and sent for blasting and primer.
The integrated ladder is welded directly in between the two support frames of
enclosure as per the drawing. Suitable gap is maintained in between the
supports of ladder.
If the ladder has any safety measures like caging or support for hands, these
materials are fabricated.
The ladder pipes are fabricated according to drawing.
The external ladders are built separately with all safety caging and hand
supports.
The ladder is then fitted to the enclosure by bolt and nuts.
15. PANEL FABRICATION:
CUTTING AND BENDING
The panel sheet is cut and bent according to the drawing as per the supervision
of the production engineer.
The extra bits required for the fabrication like angles and channels are also cut
and bent
The angles and channels required for rock wool or glass wool filling are cut and
bent.
BLASTING AND PRIMER
 ACE AL FARIS FZC
After cutting and bending of panel sheets, it is blasted and painted with primer
as per the client requirement.
If the blasting is not recommended, the primer is applied as a standard
procedure.

FIT UP AND FABRICATION

The cut and bent sheets are placed together according to the drawing and
fabricated by temporary welds.
After the entire sheet fit up is complete, the full welding is done.
The provisions for rock wool filling are made.
The angles and channels are fabricated on the inner side wall of the panel
sheets.

ROCK WOOL / GLASS WOOL FILLING

As recommended by client, the rock wool or the glass wool is provided as
insulation for sound attenuation.
The suitable insulator is cut and shaped which has to be matched to the
fabricated sheets.
The insulator is filled to the panels without leaving any crevasse or gaps
Once all the panel sheets are filled, the fiber cloth is covered on the insulation.
Perforated sheets (blasted and painted) are now fitted by channels and angles
and are riveted together.

16. SPLITTER FABRICATION:

There are 2 types of splitters used, they are
A) Flat head splitter
B) Curved head

CUTTING AND BENDING

Procured materials are cut according to the drawing with the supervision of the
production engineer.
If the client recommends the blasting of the splitter sheets, it will be blasted. The
coat of primer and intermediate is painted as a standard procedure for all sheets.
After the material is cut, the sheets are bent according to the appropriate profile
as per the drawing.
The required angles and channels are also cut and bent accordingly.

FABRICATION
All the bent sheets, angle, and channels are fabricated together with perforated
sheets.
Fiber cloth is laid on top of the perforated sheet and then the rock or glass wool
is filled.
It is then covered by fiber cloth and then the perforated sheet.
 ACE AL FARIS FZC
This assembly is riveted together to form the individual splitter.
The outer solid frame is fabricated using strong ms materials. The individual
splitters are lined together vertically inside the frame to form the Sound
attenuating splitters. Equal gap is maintained between each splitter horizontally.
Final coat of paint is painted and allowed to dry.

ASSEMBLY
The entire assembly is inserted into the enclosure using fork lift.
The splitters are now bolted to the floor and side walls of the enclosure. If there
are 2 set of attenuators, they are bolted on both sides of the enclosure
depending on the requirement of that particular project.

17. LOUVER FABRICATION

There are different types of louvers that are produced according to the project
requirement.
They are:
Weather proof louver
Chevron Type louver.
Motorized louver
Sand Trap Louver
Motorized and Sand trap louvers are outsourced.

WEATHER PROOF LOUVERS:

The material used is sent for cutting and bending according to the Drawing.
If the client recommends for the blasting, then all the sheets are blasted
The bent louver is then fabricated and set up vertically by outer frame. Rivets
are used to hold the louver and frame together.
Primer and intermediate coat is applied.
The entire louver set up is then installed to the ends of the enclosure as per the
drawing.
A steel mesh is attached before the louvers so that the large foreign materials
cannot enter the enclosure.

CHEVRON TYPE LOUVER:

The material used is sent for cutting and bending according to the Drawing.
If the client recommends for the blasting, then all the sheets are blasted
The rock or glass wool is sandwiched in between the layer of fiber cloth,
perforated sheet and galvanized sheet.
Rivets are used to fasten these together. A strong frame is built to hold the
chevron louvers.
Louvers are stacked one upon another with a uniform gap between consecutive
chevron louvers.
Primer and intermediate coat is applied.
 ACE AL FARIS FZC
The entire louver set up is then installed to the ends of the enclosure as per the
drawing by the help of fork lift.
Louver is bolted to the enclosure in all the sides.

18. ENGINE AND ALTERNATOR COUPLING:

The free issued materials include the engine and alternator. Both these units are
coupled together before mounting them to the base skid or engine skid.
The rubber gland is fitted to the alternator is aligned with the engine.
Slowly the engine shaft and alternator shaft are brought together and is fastened
by rubber coupling.

19. MUFFLER SUPPORT FABRICATATION:

The muffler saddle material is sent for cutting and blasting.
As per the fabrication drawing, the saddle supports are fabricated.
The muffler support frame is checked by QA/QC dept and after their approval, full
welding of the support frame is carried out.
The muffler is fitted to the support and bolted. If there is any insulation work as
per the client recommendations, the insulation is done by outsourcing the work.

20. ASSEMBLY
The coupled engine and alternator are mounted on the engine skid or on the
base skid as per the drawing.
The engine and alternator are always mounted by the vibration isolators or
rubber bushes according to the size of the engine or project requirement.
Radiator is installed in front of the engine and the piping work is done in between
engine and radiator.
The muffler along with its saddle is fitted on top of the enclosure by bolts and
nuts. Its fitted as per the drawing and the exhaust of engine should match with
the inlet of muffler.
SS flexible is bolted in between the muffler and engine outlet manifold.
Flexible pipes are installed in between engine and muffler and the covering work
around the roof where muffler rest is covered by cowling cloth
If there is any engine cowling work, then the production dept must carry out with
this work.
Diverters are fabricated and installed in suction and exhaust side if
recommended by client or if needed.
21. PAINTING:
The final coat of paint is painted on both sides of the enclosure.
The paint color and system is pre determined by the client.
During the time of delivery, the final paint touchup works will be done.

22. MONO RAIL INSTALLATION

 ACE AL FARIS FZC
Mono rail is installed within the container for the lifting and moving heavy parts
of engine or alternator.
The beams will be installed inside the container with cross rail.
The hoist of suitable loading carrying capacity is installed on top of the cross rail

23. INSTRUMENTATION AND ELECTRICAL WORK

The fuel lines and manhole work will be initiated. The nozzles are fixed according
to the fabrication drawing.
The recommended pipes are used to connect the fuel line, over flow line, filling
lines and oil drain lines.
Pressure indicators and manometers are installed as per the drawing.
All control panel work will be carried out. Smoke detectors and fire detectors will
be installed.
Emergency switches will be installed as per the drawing.
Bulk head lights will be installed at the outer surface of the enclosure and
florescent lights will be fitted in the inside if the enclosure.
Fire extinguishers will be installed where ever required.
All the gauges related to CO2 cylinder are installed.
All the oil filters, fuel filters and air filters are installed.

24. DISPATCH
The enclosure is packed with suitable packing system.
The loading of the enclosure is done according to the lift plan.
Appropriate crane and slings are used depending on the mass.
All the locks are locked and packing list is delivered along with the enclosure.
A proper document for shipment is provided.