PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :- Ring

Article No
:- 565285 01
Drawing No :- 565285

Document
:Doc. Rev
:Date
:- 21.12.2008
Approved By :-

Rev No:-

Raw Material Details :Description

50 x 35 mm Thk. Plate

Material
AL 111 2349 -02 (SS-316)

Requirement
HR Plate cut.

Inspection
Chemical C,Cr,Ni,Mo

Process :Sr.
NO
1

Process

Reference Schematic Dig.

Remarks

Plate Cutting and VPreparation as per

Drawing.

Sketch

1) Check cutting marking before plate cutting.

2) Use Angle Grinder 7 and correct type of
cutting wheel.
3) Check dimension after cutting.
4) Remove sharp edges.
5) Make V-Preparation as per drawing.

02

Pressing (Ring type

pressing).

Sketch

1) Mark layout as per drawing on the straight

plate for radius checking after pressing of
35 thk plate.
2) Ensure that proper Pre-Pinching is done
before pressing .
3) Press the plate on edges (i.e.ring type
Pressing) as per drawing.

3) Tack weld with SS-316 Electrode.

4) Avoid damages and heavy tool mark on
The plate .
5) After pressing the plate place it on the
layout for checking .

03

Welding and joint

finishing.

04

Straightning of ring.

05

Radiography.

06

Pre-Machining of
ring as per drawing.

1) Tack weld with SS-316 filler

2)
A)Dia 2.0 mm filler and current
110 amps.
B) Remove/Grind SS-electrodes
welding completely which took
place in pressing.
3) Do the Remaining welding.
A) Dia 2.0 mm filler and current
110 amps.
B) Use Backing Gas Argon/N2.
4) Back Chip and follow the point no 03.
5) Apply wire brush and sander dish 60 Grit
on weld spots.
6) Check all the dimensions.
1) Straighten the ring on Hydraulic press.
2) Avoid press marks on the surface.
3) Straightness should be within 1.5 mm.
1) Do the Radiography of the weld
joint 100%.
2) If the Radiography is O.K then do the
machining as per drawing And if it not
O.K then R/W as per film till the
radiography result is not positive.
1) Do the machining on Lathe M/C as per
drawing.
2) Check all the dimensions as per drawing.
3) Avoid tool mark on the surface.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :- Ring
Article No
:- 584174 01
Drawing No :- 584174
Rev No:-01

Document
:Doc. Rev
:Date
:- 21.12.2008
Approved By :-

Raw Material Details :Description

30/32 mm Thk. Plate

Material
AL 111 2349 -02 (SS-316)

Requirement
HR Plate cut.

Inspection
Chemical C,Cr,Ni,Mo

Process :Sr.
NO
1

Process

Reference Schematic Dig.

Pre Machining as per

drawing.

Sketch

Remarks
1) Do the Premaching as per drawing on
Lathe machine.
2) Avoid tool marks on the surface.
3) Check all the dimensions.
4) Store the material carefully.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :- Plate
Article No
:- 565294 01
Drawing No :- 565294
Rev No:-0

Document
:Doc. Rev
:Date
:- 21.12.2008
Approved By :-

Raw Material Details :Description

Dia 75 mm bar

Material
AL 111 2349 -02 (SS-316)

Requirement
Bright Bar.

Inspection
Chemical C,Cr,Ni,Mo

Process :Sr.
NO
01

Process

Reference Schematic Dig.

Bar cutting on Bandsaw m/c.

Sketch

02

Pre Machining as per

drawing.

Remarks
1) Cut the bar on band-saw machine as per
drawing.
2) Remove sharp edges.

1) Do the Pre maching as per drawing.

2) Check all the dimensions as per drawing.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :- Pipe Socket
Article No
:- 2521201 34
Drawing No :- 2521201 Rev No:-18

Document
:Doc. Rev
:Date
:- 21.12.2008
Approved By :-

Raw Material Details :Description

Pipe NB x Sch

Material
AL 111 2349 -02 (SS-316)

Requirement
Seamless Pipe

Inspection
Chemical C,Cr,Ni,Mo

Process :Sr.
NO
01

Process

Reference Schematic Dig.

Pipe cutting on Bandsaw m/c.

Sketch

02

Finish Machining as
per drawing.

Remarks
1) Cut the pipe on band-saw machine as per
drawing.
2) Remove sharp edges.

1) Do the finish maching as per drawing.

2) Check all the dimensions as per drawing.
3) Avoid toom marks on the components.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :- Elbow pipe
Article No
:- 584146 01
Drawing No :- 584146
Rev No:-0

Document
:Doc. Rev
:Date
:- 21.12.2008
Approved By :-

Raw Material Details :Description

Dia 21.3 mm OD elbow

Material
AL 111 2349 -02 (SS-316)

Requirement
Elbow

Inspection
Chemical C,Cr,Ni,Mo

Process :Sr.
NO
01

Process

Reference Schematic Dig.

Elbow as per
drawing.

Sketch

Remarks
1) Check all the dimensions a sper drawing.
2) Dents not allowed.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :- Elbow Pipe (Assembly)
Article No
:584146 01
Drawing No :584146 Rev No:-0
Ref drg. No :- 584146 ,2521201 R18

Document
:Doc. Rev
:Date
:- 21.12.2008
Approved By :-

Raw Material Details :Description

Pipe elbow ( As per 584146 01)
Pipe Socket (As per 2521201 34)

Material
AL 111 2349 -02 (SS-316)
AL 111 2349 -02 (SS-316)

Requirement
In seamless pipe.
Dually Machined.

Inspection
Dimensional , Visual.
Dimensional , Visual.

Process :Sr.
NO
01

Process

02

Welding

03

Finishing

Reference Schematic Dig.

Fitting as per drawing Sketch

Remarks
1) Do the chamfering 1.5x30 deg to both the
ends of elbow pipe for welding purpose.
2) Do the fitting of Elbow pipe and Pipe socket
as per drawing.
a) Tack weld at 2 spots.
b) Use Dia 1.6mm SS-316L filler
wire, current 70 amps.
1) Do the welding from outside.
a. Use Dia 1.6 mm, 316L filler wire.
b. Current 80-90 amps.
c. Use Backing gas (Argon or N2)
Ensure required amout of weld penetration is
observed from back side.
1) Do the finishing using 120 grit polish paper.
2) Use flexible grinder for polishing and
Finishing .
3) Store material carefully.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :- Jacket
Article No
:- 584137 01
Drawing No :- 584137

Document
:Doc. Rev
:Date
:- 21.12.2008
Approved By :-

Rev No:-01

Raw Material Details :Description

04 mm Thk. Plate

Material
AL 111 2349 -02 (SS-316)

Requirement
HR/CR Plate .

Inspection
Chemical C,Cr,Ni,Mo

Process :Sr.
NO
1

Process

Reference Schematic Dig.

Remarks

Plate Cutting and

V-Preparation as per
Drawing.

Sketch

1) Check cutting marking before plate

cutting.
2) Use Angle Grinder 7 and correct type of
cutting wheel.
3) Check dimension after cutting.
4) Remove sharp edges.
5) Make V-Preparation as per drawing.

02

Rolling

Sketch

1) Roll the plate on rolling machine .But

before it Ensure that proper Pre-Pinching
is done
2) Check the dimensions after rolling.Check
Ovality.
Note: Leave the roll plate on tack weld
condition only .Do not weld its weld joint.(LSeam)

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :- Cone
Article No
:- 584138 01
Drawing No :- 584138
Rev No:- 01

Document
:Doc. Rev
:Date
:- 21.12.2008
Approved By :-

Raw Material Details :Description

4 mm Thk. Plate
Process :-

Material
AL 111 2349 -02 (SS-316)

Requirement
CR/HR Plate.

Inspection
Chemical C,Cr,Ni,Mo

Sr.
NO

Process

Reference Schematic Dig.

Plate Cutting as per

Drawing.

Sketch

1) Check cutting marking before plate cutting.

2) Use Angle Grinder 7 and correct type of
cutting wheel.(Laser Cutting will also be
alternative method for cutting.)
3) Check dimension after cutting.
Remove sharp edges.

02

Dished end pressing

on Die-Punch.
(DE/DD/02)

Sketch

1) Check Dimensions after pressings.

2) Record Hydraulic pressure for Dished-End
pressings, which will be helpful for next batch.

03

Pre Machining.(I.D and

Face )

Remarks

1) Do the machining on Lathe Machine as per

drawing.
2) Maintain all the dimensions as per drawing.
3) Avoid chuck-mark, tool- mark during
machining.
4) Maintain 2x30 chamfer on lathe machine only
for welding purpose.
5) Measured the height on surface plate.
Store material carefully.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :- Tube
Article No :- 584140
Drawing No :- 584140

Document
:Doc. Rev
:Date
:- 19.12.2008
Approved By :-

Rev No:- 01

Raw Material Details :Description

Dia 114 mm x 3.2 Thk.
Pipe.

Material
AL 111 2349 -02 (SS-316)

Requirement
ERW/Seamless

Inspection
1) Chemical C,Cr,Ni,Mo
2) Visual Inspection.(Avoid Dents and heavy
scratches)

Process :Sr.
NO
01

Process

Reference Schematic Dig.

Pipe Cutting .

Use Template which is as per drawing 584140 Rev 01

02

Finishing

Remarks
1) Cut the pipe as per template as per drawing .
(Use 7 Angle Grinder and correct type of
cutting wheel)
2) Taper should be within 01 mm.
3) Match the profile of pipe as per drawing by
grinding it.
3) Remove Burr after cutting.
1) Do the finishing from inside/outside
Using 80/120 grit polish paper and Flexible
grinder machine.
2) If the pipe is ERW then grind and finish the
welding joint.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :- Flange
Article No
:- 553966 13
Drawing No :- 553966 Rev No:- 07

Document
:Doc. Rev
:Date
:- 21.12.2008
Approved By :-

Raw Material Details :Description

36/38 mm Thk. Plate

Material
AL 111 2349 -02 (SS-316)

Requirement
HR Plate cut.

Inspection
Chemical C,Cr,Ni,Mo

Process :Sr.
NO
01

Process
Pre Machining

Reference Schematic Dig.

Remarks
1) Do the Pre machining as per drawing on
lathe machine .
2) Check all the dimensions and finish of the
flange.
3) Ensure that there is no tool and scratch
marks on the surface and O.D of the
flange.
4) Store material carefully.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name
Drg. No
Ref Article No
Ref Drawing No

:- Jacket AND Cone Assly.

:- 584136 R2
:- 584137 01 , 584138- 01
:- 584137 Rev 01 , 584138
Rev -01

Document
:Doc. Rev
:Date
:- 19.12.2008
Approved By :-

Raw Material Details :Description

01) 04 mm Thk. Shell
02) 04 mm Thk Cone.
Process :Sr.
NO
01

Material
AL 111 2349-02 (SS-316)
AL 111 2349-02 (SS-316)

Requirement
Rolled part.
Press part.

Inspection
Dimensional ,Visual
Dimensional ,Visual

Process

Reference Schematic Dig.

Remarks

Fitting of cone to
jacket.

Sketch

1 ) Do the fitting (Tack weld at 08 spots)of jacket

to cone by fitting point to point (By revolving
jacket plate on the periphery of cone)so that
you will not observe any dimensional change
in the circumferential area of both the
components. Also there will not be any step in
between the two joints.
2) Check Squareness and other required
dimensions.
3) Increase Tack weld spots.
4) Apply wire brush or sander dish 60 Grit on
weld spots.
5) Do the TIG welding from outside.(CO2 MIG
welding is also possible)
a. Use Dia 2.0 mm, 316L filler wire.
b. Current 90-100 amps.
c. Apply backing gas (Argon or N2)
d. Apply Wire Brush on weld joint
e. Check required amount of weld
penetration observed on back side
of weld joint.
f. If Penetration is not proper then
back chip where ever required and
do as per point a,b,c,d.

02

Joint Finishing
1) Apply 36/60 grit sander dish on weld joint
and do the joint finishing from Inside &
outside
2) Use Flexible Grinder and 80 Grit Polish
paper for finishing on weld joint.
2) Carry out D.P.Test.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :Drg No
:Ref Article No
Ref Drawing No

Frame Top Part Welded

584136 R2 (Article No :- 584136 02)
:- 584137 01, 584138- 01, 584147 0 , 565285 01 , 584140 01, 584146 01, 565294 01, 553966 13
:- 584137 R01, 584138 R01, 584174 R01, 565285 , 584140 R01, 584146 R0 , 565294 R0, 553966 R7

Document
:Doc. Rev
:Date
:- 19.12.2008
Approved By :-

Raw Material Details :Description

01) 04 mm Thk. Jacket/Cone Assly.
03) 29.5 mm Thk. Ring
04) 30 mm Thk Ring
05) Dia 114 mmx3.2 thk Profile cut pipe
06) Elbow Pipe assly
07) 28 mm Thk plate from Dia 75 mm bar
08) 35/36 mm thk Welding Flange
Process :Sr.
NO
01

Material
AL 111 2349-02
AL 111 2349-02
AL 111 2349-02
AL 111 2349-02
AL 111 2349-02
AL 111 2349-02
AL 111 2349-02

(SS-316)
(SS-316)
(SS-316)
(SS-316)
(SS-316)
(SS-316)
(SS-316)

Requirement
Dually Fabricated.
Pre machined component
Pre machined component
Dually cut as per template.
Dually finished.
Machined component
Pre Machined component

Inspection
Dimensional ,Visual
Dimensional ,Visual
Dimensional ,Visual
Dimensional ,Visual
Dimensional ,Visual
Dimensional ,Visual
Dimensional ,Visual

Process

Reference Schematic Dig.

Remarks

Fitting of rings to
Jacket and cone resp.

Sketch

1 ) Placed the Ring( as per drg. No 565285) in

the fixture DE/FTP/01. Now placed jacket and
cone(Dually fabricated and with joint finished) in
the ring location.(See Drg of ring).Tack weld it at
8 welding spots.Now placed ring ( as per drg. No
584147 R01) on the top of the cone it will get
automatically placed in its position (see drg of
ring). Now tack weld it at 8 welding spots.
2) Check Squareness and other required
dimensions. Measure its height and Ensure
that its height should not more and less than
200mm (Within 0.5 mm allowance) after fitting.
Considering its welding distortion ,this is very
important to keep this dimension in control.
3) Increase Tack weld spots.
4) Apply wire brush or sander dish 60 Grit on
weld spots.

5) Clean the welding gap by compressed air and if

compressor is not available then clean it with
pressurized oxygen gas flow.
6) Do the TIG welding from outside.(CO2 MIG
welding is also possible)
a) First run will be fuse run only
between ring and jacket joint
(Current 70-80 amps.)Apply wire
brush on the welding joint.
b) Use Dia 2.0 mm, 316L filler wire
for second run(Current 90-100
Amps , Fillet will be 3mm). Apply
wire brush on the
welding joint.
c) Now do the welding of top ring and
cone . Use Dia 2.0 mm, 316L filler
wire (Current 90-100Amps , Fillet
will be 3mm). Apply wire brush on
the welding joint.
d) Now do not open the bolts of the
fixture till the job get cool.
d) After cooling take out the job from
fixture and weld both the joints
from back side Use Dia 2.0 mm,
316L filler wire (Current 90100Amps , Fillet will be 3mm).
Apply wire brush on the welding
joint.
7) Measure the height after cooling.
Considering final machining, It should
not be more than 205 mm and less than
203 mm.

02

Joint finishing from

inside(Ring and
jacket joint)

03

Marking of tube
connection, plate
connection and elbow
pipe connection.

04

Milling and Drilling

for plate and elbow
pipe connection.

05

Cutting

1) Do the finishing from inside only by light

grinding and then apply 36/60 grit sander
dish on it.
2) Carry out D.P.Test for the same.
1) Mark 0,45,90,180,270 (Deg.) orientation on
the Ring(Dia 826 mm ring).Take that
dimension line ahead on the jacket and cone
which will be helpful for further marking.
2) Now placed the fabricated component once
again in the fixture DE/FTP/01.Now take
the tube and place in its location provided
in the fixture. Mark the border line of tube
profile from outside with the pointed tip
lead pencil.
3) Now do the marking for plate at 45 deg on
the jacket.
4) Now do the marking for elbow pipe
connection on the cone at 270 deg as per
drawing.
1) Do the milling as per marking for plate
Connection.
2) Do the drilling of Dia 22 mm for elbow
pipe connection on the marking.
1) Cut the profile( from the inside leaving
1-2 mm area near the profile border line)
which made on the cone/jacket where tube
will fit in.Check the pipe and cutout profile.
a) Use 7 Angle Grinder and correct
type of cutting wheel.
2) Now grind the cutout so that it will exactly
match the profile marking.
a) Use 4 Angle Grinder.
3) Now apply 60 Grit sander dish on it.

06

a)Fitting of
tube/flange to
cone/jacket profile.

1) Take the pipe and place it on the cutout.Tack

weld at 4 spots.
2) Take the flange & tack weld it on the tube as
per drg..

b) Fitting of plate to
jacket profile.

3) Take the plate and place it on the

cutout.Tack weld at 4 spots.
4) Now increase the weld spots
5) Apply wire brush or sander dish 60 Grit on
weld spots.

07

Polishing and
finishing

08

Fitting of elbow pipe

connection

5) Do the TIG welding .(For points a and b)

a. Use Dia 2.0 mm, 316L filler wire.
b. Current 90-100 amps.
c. Apply backing gas (Argon or N2)
where ever is necessary.
d. Apply Wire Brush on weld joint
e. Check required amount of weld
penetration observed on back side
of weld joint.
f. If Penetration is not proper then
back chip where ever required and
do as per point a,b,c,d.
1) Do the finishing from inside/outside
Using 80/120 grit polish paper and
Flexible grinder machine.
1) Take the pipe and place it in the drill hole as
per dimensions reqd.Tack weld at 4 spots.
2) Now increase the weld spots
Do the TIG welding .
a. Use Dia 1.6 mm, 316L filler wire.
b. Current 70-80 amps.

09

Polishing and
finishing

1) Do the finishing from inside/outside

Using 80/120 grit polish paper and Flexible
grinder machine.If Required use pencil cutter.

10

Final Polishing,

11

Cleaning and
Stainless steel shot
blasting.

12

Final inspection

Use Drawing No.

1) Carry out the final inspection as per

drawing
2) Make Final inspection report.

13

Packing and
forwarding as per
instructions.

Refer Instruction Documents.

Pack the job carefully as per instructions.

Check for any scratch mark , dent marks and

other indivisuals& if required do the final
finishing /polishing using flexible grinder and
80/120 grit polish paper.
1) Clean the component with soap and
normal water.
2) Clean the component with dry clothes.
3) Do the stainless steel shot blasting as per
required standards.
4) Store the material carefully.