Data Collection For Shrinkage in Nozzle Welding

Info / Stage
Responsibilities

Sr. No.

To be filled/given by QC (No separate stage in ERP-LN)

Nozzle to
Project No. Nozzle No. Shell / D'end
Seam No.

1
2
3
4
5

12283A
12283A
12283C
12283C
12283E

NW201/A
NW201/B
NW201/A
NW201/B
NW201/A

12283E

NW201/B

T1

Shell / D'end
Material

Nozzle Material

SA336M FR F22 CL3

SA336M FR F22 CL3

SA336M FR F22 CL3

SA336M FR F22 CL3

SA387 GR F22 CL3

SA336M FR F22 CL3

SA387 GR F22 CL3

SA336M FR F22 CL3

channel side
T1 & T2
8

T2
17037A

S3
shell side
S3 & S4

10

S4

shell side
S3 & S4
10

S4

11

T3

SA336M FR F22 CL3

SA336M FR F22 CL3

SA336M FR F22 CL3

SA336M FR F22 CL3

SA387 GR F22 CL3

SA336M FR F22 CL3

SA387 GR F22 CL3

SA336M FR F22 CL3

SA336M FR F22 CL3

SA336M FR F22 CL3

SA336M FR F22 CL3

SA336M FR F22 CL3

SA387 GR F22 CL3

SA336M FR F22 CL3

SA387 GR F22 CL3

SA336M FR F22 CL3

SA336M FR F22 CL3

SA336M FR F22 CL3

channel side
T4 & T3
12

T4
17037B

13

S1
shell side
S1 & S2

14

S2

15

T3
channel side
T3 & T4

16

T4
17033B

17

S1
shell side
S1 & S2

18

S2

19

T1
channel side
T1 & T2

19

T1
channel side
T1 & T2

20

T2

SA336M FR F22 CL3

SA336M FR F22 CL3

SA387 GR F22 CL3

SA336M FR F22 CL3

SA387 GR F22 CL3

SA336M FR F22 CL3

SA336M FR F22 CL3

SA336M FR F22 CL3

SA336M FR F22 CL3

SA336M FR F22 CL3

17033A
21

S3
shell side
S3 & S4

22

S4

23

T1
17038

channel side
T1 & T2

24

T2

25
17016
26

27

28

N1

NW261

28

29

30

31

32

59
60
61
62
63
64
65
66
67

68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85

86
87
88
89
90
91
92
93
94
95
96
97
98
99
100

Welding
To be filled/given by Shop
(Before Set-up
stage will be added)

LN)

Shell/D'end
Thickness
actual

81

81

Shell/D'end
actual I/d at
Nozzle Location

To be filled/given by QC
(Stage will be added )

Nozzle
Nozzle sub
Nozzle sub
Nozzle
Nozzle actual
actual I/d
assembly height assembly height
Thickness
Length
& O/d
at setup
after welding
Lip thk. actual

NA

ID-325.4

1127.5

OD-514

1127.5

ID-325.4

1127.5

OD-514

NA

ID-215.8

1077

OD-380

1077

ID-225.8

460

505

493

448

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

448

81

81

1078

OD-380

NA

ID-325.4

1129

OD-514

1129

ID-325.4

1129

OD-514

NA

ID-215.8

1083

OD-380

1087

ID-225.8

1080

OD-380

NA

ID-215.8

1258

OD-362

1257

ID-215.8

1258

OD-362

NA

ID-325.4

1207

OD-528

1208

ID-325.4

1206

OD-528

NA

ID-215.8

505

460

448

493

805

755

556.4

606.4

755

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

755
1256

OD-362

1256

ID-215.8

1256

OD-362

NA

ID-325.4

1206

OD-528

1212

ID-325.4

1206

OD-528

1123

ID-325.4

1124

OD-514

1123

ID-325.4

1124

OD-514

805

606.4

556.4

586.7

634.7

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

NOT APPLICABLE

Setup done in PC1

To be filled/given by QC at setup stage

(No separate stage in ERP-LN)

Nozzle Type
WEP Side
Seton/Setthru (I/s or O/s)

WEP Type with actual angle

Root Gap
Offset at
Projection at
(Single 'V', Double 'V',
at Setup
Setup stage
Set-Up stage
Narrow Groove, J-Type)
stage

I/S

Single V 15R Nozzle Side X 7.5

+7.5 to Shell/Channel
0-2mm

1-2mm

934/935

SET THROUGH

I/S

Single V 15R Nozzle Side X 7.5

+7.5 to Shell/Channel
3-4mm

1-2mm

980/81

SET THROUGH

I/S

Single V 15R Nozzle Side X 7.5

+7.5 to Shell/Channel
0-2mm

1-3mm

976/977

I/S

Single V 15R Nozzle Side X 7.5

+7.5 to Shell/Channel
0-2mm

0-3mm

932/935

SET THROUGH

SET THROUGH

SET THROUGH

I/S

Single V 15R Nozzle Side X 7.5

+7.5 to Shell/Channel
1-2mm

SET THROUGH

I/S

Single V 15R Nozzle Side X 7.5

+7.5 to Shell/Channel
2-3mm

1-2mm

932/934

SET THROUGH

I/S

Single V 15R Nozzle Side X 7.5

+7.5 to Shell/Channel
1-2mm

1-3mm

935

SET THROUGH

I/S

Single V 15R Nozzle Side X 7.5

+7.5 to Shell/Channel
0-2mm

1-3mm

978

SET THROUGH

I/S

Single V 15R Nozzle Side X 7.5

+7.5 to Shell/Channel
1-3mm

1-5mm

1124/25

SET THROUGH

I/S

Single V 15R Nozzle Side X 7.5

+7.5 to Shell/Channel
0-2mm

1-3mm

1073/75

SET THROUGH

I/S

Single V 15R Nozzle Side X 7.5

+7.5 to Shell/Channel
2-3mm

1-3mm

1069/71

SET THROUGH

I/S

Single V 15R Nozzle Side X 7.5

+7.5 to Shell/Channel
0-2mm

2-3mm

1126mm

I/S

Single V 15R Nozzle Side X 7.5

+7.5 to Shell/Channel
0-5mm

1-3mm

1074mm

SET THROUGH

1-2mm

975/977

SET THROUGH

I/S

Single V 15R Nozzle Side X 7.5

+7.5 to Shell/Channel
0-3mm

SET THROUGH

I/S

Single V 15R Nozzle Side X 7.5

+7.5 to Shell/Channel
2-3mm

1-2mm

1124/1125

SET THROUGH

I/S

Single V 15R Nozzle Side X 7.5

+7.5 to Shell/Channel
1-2mm

1-2mm

1076mm

SET THROUGH

I/S

Single V 15R Nozzle Side X 7.5

+7.5 to Shell/Channel
0-4mm

0-2mm

1060mm

I/S

Single V 15R Nozzle Side X 7.5

+7.5 to Shell/Channel
0-1mm

0-1mm

1108mm

SET THROUGH

0-4mm

1125mm

To be filled/given by Shop
(After welding
stage will be added)

Distortion Cotrol
Temperory
Fixture Provided at attachment used
Setup stage (Y / N)
(Y / N)

Weld Process
(GTAW / SMAW /
SAW)

Weld Deposition ISR Required for

(in kg)
Nozzle (Y / N)

To be filled/given by QC a
welding at a time of Visual I
(No separate stage in ER

Projection After
Final welding

NO

NO

SMAW

32KG + 5KG CHIPBACK

YES

1125/1124

NO

NO

SMAW

32KG + 5KG CHIPBACK

YES

1074

NO

NO

SMAW

32KG + 5KG CHIPBACK

YES

1072/1074

NO

NO

SMAW

32KG + 5KG CHIPBACK

YES

1123

NO

NO

SMAW

32KG + 5KG CHIPBACK

YES

1076

NO

NO

SMAW

32KG + 5KG CHIPBACK

YES

1120/1124

NO

NO

SMAW

32KG + 5KG CHIPBACK

YES

1122.5/1122

NO

NO

SMAW

32KG + 5KG CHIPBACK

YES

1075/1075

SMAW

SMAW

Retainer Ring

SMAW

YES

1306/07

led/given by QC at after
a time of Visual Inspection
parate stage in ERP-LN)

Projection Before
PWHT

By QC

Repair in Nozzle
weld (Y / N)

Remarks

Data Collection For Shrinkafe in Shell & D'e

Info / Stage
Responsibilities

Sr. No.

To be filled/given by QC before overlay (No separate stage in ERP

Project
No.

Shell / D'end
Overlay seam
No.

Shell / D'end
Material
LAS
LAS

D'end Type
(Hemispherical,
Ellipsoidal)/
(Single Piece, Petal type)

1
2

17037A
17033C

OW204
OW201

NA
NA

3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38

17033B
17037A
17017A
17033D
17033C
17037B
17017B
17033B
17033B

OW203
LAS
NA
OW203
LAS
NA
As only after Overlay inspection done in SFS-Data saved in CMF folder w
OW203
LAS
NA
OW202
LAS
NA
OW201
LAS
NA
As only after Overlay inspection done in SFS-Data saved in CMF folder w
OW204
LAS
NA

39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88

89
90
91
92
93
94
95
96
97
98
99
100

ell & D'end After Overlay

To be filled/given by QC before overlay

(Stage will be added at before overlay dimension

te stage in ERP-LN)

Overlay
Thickness
(Reqd.)

Overlay
Material

5 SS347
5 SS347

Shell / D'end
Thickness
actual (avg)

Shell Outside Circumference (actual)

D'end I/S
Location before overlay
Circumference
(actual) at
Trimming Line
One End
Middle
before overlay

81.5 NA
81 NA

5 SS347
82MM
NA
5 SS347
81.5 NA
d in CMF folder where before Overlay data saved.
5 SS347
80 NA
5 SS347
80 NA
5 SS347
80 NA
d in CMF folder where before Overlay data saved.
5 SS347
81.5 NA

3801

3796

BALANCE

4314
4314
3916

4316
4317
3918

efore overlay
rlay dimension stage)

ference (actual) at 3
ore overlay

NCE

Another End

To be fi
(Stage wi

Shell / D'end I/D

actual ovality
before overlay

Overlay Process
(SMAW / ESSC /
SASC / FCAW)

Weld Deposition (in kg)

Barrier Layer

Subsequent /
Final Layer

3803 2-3MM
ESSC
4MM & 1MM
6 MM
4318 2-3MM
4316 4MM
3917 3-4 MM
2-3mm

Single Layer ESSC-

ESSC

290 NA

ESSC

290 NA
NA

ESSC
ESSC
ESSC
340kg

290

To be filled/given by Shop After overlay welding

(Stage will be added before dim after overlay stage)
Direction of Weld Overlay
1) From one end to another end
2)From Center to End
3)In Two stages
4)From Opposite Ends

O/D Ring
Provided at
End of
Shell / D'end

Distortion Control Fixture

Provided
1) I/D Ring, 2) Moon Plate
3) Any Other Special
Arrangements

1) From one end to another end

No

Not Apllicable

1) From one end to another end

No

Not Apllicable

YES

Not Apllicable
Not Apllicable

1) From one end to another end

1) From one end to another end

To be filled by QC after overlay completion

(No separate stage in ERP-LN)

Shell Outside Circumference (actual)

D'end Inside
Location after overlay
Shell / D'end I/D
Overlay
Circumference
actual ovality after Thickness
(actual) at
overlay
(Actual avg.) Trimming Line after
One End
Middle
overlay

Channel Side End5mm & Shell side

End 8mm

Not Applicable

3mm both ends

Not Applicable

3918

3916

4-5mm Dnd side wep.

Not Applicable
Not Applicable

3920
4305

3918
4307

4305

4305

after overlay completion

te stage in ERP-LN)

By QC

Shell Outside Circumference (actual) at 3

Location after overlay
Another End

4308
3910

3920
4306

Repair in
weld overlay

Remarks

Data Collection For Streching / Shrinkage in Shell

Info / Stage
Responsibilities

Sr. No.

1
2
3
4
5
6
1
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

To be filled/given by Shop at s
stage only
(No separate stage in ERP-L

To be filled/given by QC (No separate stage in ERP-LN)

Project
No.

Shell Long
Seam No.

Shell
Material

Shell
Required
I/D

17045 LW201
SA387 GR22 C
1052
17045 LW203
SA387 GR22 C
1400
17045 LW202-CONE SA387 GR22 C1400/1053
17044 LW201
SA387 GR11
2153
17044 LW203
SA387 GR11
2500
17044 LW204
SA387 GR11
2500
17025 LW202
SA387 GR22
1152
17008A LW201
SA387 GR22 CL2
17019A
17018A
LW204
SA 387-22-2
1290
SA
387-22-2
1539
17019A LW205

Shell
Required
Thickness

Thick. At
Plate stage
(actual)
from PPS
record

30
30
30
50
50
54
72

84
95

Mean Circ. at Plate

Stage (actual)
One End Another End

6921
8011
8010
3845

85
96

4316
5133

6921
8011
8010
3845

4317
5134

28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65

66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100

by Shop at setup
only
age in ERP-LN)

To be filled/given by QC at setup stage

(No separate stage in ERP-LN)
Outside Circ. after Rolling at Setup Stage (actual)

Type of Rolling
(Hot / Warm /
Normal)
Normal
Normal
Normal
NORMAL
NORMAL
NORMAL
Warm

WARM
WARM

One End
Open End At 100mm
i/s-4406
i/s-3315
3314
6772
7868
7868
3634

WEP Type
Thickness
1)Single 'V'
after
2)Double 'V'
Rolling at
3)Narrow Groove
setup
Open End At 100mm
4)'J' Type
Another End

Middle

4400
3307

4399
3307

4398.5
3307

6767
7861
7861
3618

6766
7858
7858
3616

6768
7859
7859
3618

Setup Done in Hazira

4071
4058
5448
5445

4063
5445

4057
5445

4404.5
3315
4402
6771
7867
7867
3624

4070
5449

Double
Double
Double
Double
Double
Double
Double

85
96

V
V
V
V
V
V
V

Double V
Double V

WEP
Angle
(Actual)
60
65-70
65-70
45OS , 60IS
45OS , 60IS
45OS , 60IS
45OS , 60IS

45OS , 60IS
45OS , 60IS

Root Gap
at Set-Up
Stage
0-1mm
0-2mm
0-2mm
0-2
0-2
0-2
0-2

0-2
0-3

To be filled/given by Shop before offering dimension after

welding / rerolling
(Stage will be added before dimension after rerolling stage)

Offset in
WEP

ok
ok
ok
0-1
0-1
0-1
0-1

Weld Process
(GTAW/
SMAW/
SAW)
SMAW+SAW
SMAW+SAW
SMAW+SAW
SMAW+SAW
SMAW+SAW
SMAW+SAW
SMAW+SAW

0-1
0-1

SMAW+SAW
SMAW+SAW
SMAW+SAW

Type of
Re-Rolling
(Hot /
Warm /
Normal)

To be filled/given by QC at dimensio
(No separate stage in

Distortion Control Fixture

Provided
Ovality before
Ovality
1) I/D Ring,
rerolling
after
2) Moon Plate
(after
rerolling
or Balance welding
welding)
carried out

Outside Circ. after W

One End
Open End At 100mm

COLD
COLD
COLD
NOT DONE

not able to control

not able to control
not able to control
Balance welding

10-11 MM
12-14 MM
10-12 MM
4-4mm

2-3 MM
2-2 MM
2-2 MM
NA

8185
8211
4086.5

8178
8206
4082

COLD

Balance welding
Balance welding
Balance welding

4-4mm
2-4 MM
3-4 MM

3mm
NA
NA

5446
4600
5446

5439
4594
5443

No
No

To be filled/given by QC at dimension after rerolling stage

(No separate stage in ERP-LN)

By QC

Outside Circ. after Welding/Re-Rolling

Another End
Middle

Repair in
Welding

Open End At 100mm

8176
8208
4080.5

8176
8207
4081

8181
8213
4086

5440
4596
5442

5442
4593
5443

5446
4599
5447

Remarks

Data Collection For Bow in Tubesheet after

Info / Stage
Responsibilities

Sr. No.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41

To be filled/given by QC at dimensio
(No separate stage in

Project
No.
17045

Tubesheet
Part No.

Tubesheet
Overlay
Seam No.

301 OW301

Tubesheet
Material

Tubesheet Type
(Drum / Flat /
Lip)

42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91

92
93
94
95
96
97
98
99
100

t after Overlay

at dimension before overlay stage

rate stage in ERP-LN)
O/d of
Bow in
Tubesheet
Overlay
Tubesheet
Tubesheet Tubesheet
I/d (For Lip
Thickness
Thickness
before
(Before
type) act
(Reqd.)
Overlay
Overlay)
Cleared from PC1

Overlay Process
Overlay
(SMAW / ESSC /
Material
SASC / FCAW)
ESSC + SMAW

To be filled/given by Shop after overlay completion

(Stage will be added before after overlay dim stage)
Weld Deposition (in kg)
Barrier Layer
40

Subsequent /
Final Layer
80

Direction of Weld Overlay

Back to Back
Distortion Control
1)From End to Center
Tubesheet
Fixture Provided
2)From Center to End
Arrangement
FROM END TO CENTER

NO

NO

To be filled/given by QC at a time of dimension after

overlay inspection
(No separate stage in ERP-LN)

By QC

By QC
(Stage will be add
after PWHT )

Id of
Overlay
Bow of
O/d of
tubesheet
Repair in
Bow in Tubesheet
Thickness
Tubesheet
Tubesheet
after overlay weld overlay
after PWHT
(Actual Avg.) after overlay after Overlay
(Lip type)
12mm

2mm

NA

NO

2mm

Remarks

Data Collection For BaseOut in Support Bracket & Base

Info / Stage
Responsibilities

Sr. No.

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

To be filled/given by QC at setup stage of Support Bracke

(No separate stage in ERP-LN)

Project No.

Nos. of
Supports

Material of Thickness of
Base Ring / Base Plate /
Bracket
Ring

Full / Partial
penetration weld

17038 On 90

SA387M
GR22
CL2/SA387M
GR22 CL2
18mm

10X45 chamfer to
Base Plate & fillet weld
of 9CFW

17038 On 270

SA387M
GR22
CL2/SA387M
GR22 CL2
18mm

10X45 chamfer to
Base Plate & fillet weld
of 9CFW

19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51

52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84

85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100

ort Bracket & Base Ring

by QC at setup stage of Support Bracket / Base RIng
(No separate stage in ERP-LN)
WEP Type with angle
(Single 'V', Double 'V',
Narrow Groove, J-Type)

Shell/D'end O/s
circumference
At Ring/Bracket
location

To be filled
(Stage will be add
Root Gap
at Setup
stage

Elevation at
Flatness
Distortion Cotrol
Level of
Setup Stage
at setup
Fixture Provided at
Base Ring
on 4
stage
Setup stage (Y / N)
orientation

Single V

NA

1mm

within 2
mm

658.5mm

Single V

NA

1mm

within 2
mm

660mm

To be filled/given by Shop after welding completion

Stage will be added before visual of support bracket / base ring)
Temperory
attachment used
(Y / N)

Weld Process
(GTAW / SMAW /
SAW)

Weld
ISR Required for
Deposition
welding (Y / N)
(in kg)

To be filled/given by QC at visual
stage
(No separate stage in ERP-LN)
Elevation after
Final welding

Level after
welding

By QC

Repair in
Support Bracket
welding (Y / N)

Remarks