PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :- Cambered flange end piece(Dished-end)

Article No
:- 259523 22
Drawing No :- 259523
Rev No:- --

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

Raw Material Details :Description

4 mm Thk. Plate

Material
AL 111 2349 -02 (SS-316)

Requirement
CR/HR Plate.

Inspection
Chemical C,Cr,Ni,Mo

Process :Sr.
NO
1

Process

Reference Schematic Dig.

Remarks

Plate Cutting as per

Drawing.(Oxygen
Laser Cutting will
also be alternative
method for cutting)

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.
4) Remove sharp edges.

02

Dished end pressing

on Die-Punch.
(DE/DD/CY/01)

Sketch

1) Check Dimensions after pressings.

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

03

Machining.(I.D and
Face )

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.
6) Store material carefully.

04

Finishing/Polishing.

1)Do the Inside & outside finishing and

Polishingof Dished End before Din-Male
part fitting toIt .because after fitting/welding
of Din Male Part to dished end, finishing
and polishing cannot be done properly
near it.
2) Use Flexible Grinder and 80 Grit Polish
paper for finishing.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :- Din male Part
Article No :- 574203- 09
Drawing No :- 574203

Rev 0

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

Raw Material Details :Description

Bought out (LKM make)

Material
AL 111 2349-02 (SS-316)

Requirement
LKM make, As per Drg.

Inspection
Test Certificate , Dimensional ,Visual.

Process :Sr.
NO
01

Process

Reference Schematic Dig.

Dimensional and
Visual Inspection of
Din Male Part.

Use Drg No 574203 R0

(Article No. 574203-09)

Remarks
1) As soon as you get the material from
LKM,Check wheather ther are received
as per drawing.
2) Check Test Certificates of said item.
3) Check Dimennsional aspects as per
drawing.
4) Check finishing of the items.
5) Check wheather any dent and scratch
marks are not their on the items.
6) Store and handle material carefully.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name
Drg No
Ref Article No
Ref Drawing No

:
:::-

Cambered Flange End Piece and Din male Part Assly.

573329 R2 (Art No 573329 01)
259523 22 , 574203- 09
259523 Rev N0 - -, 574203 Rev 0

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

Raw Material Details :Description

01) 04 mm Thk. Dished-end
02) Din Male Part (LKM
make)

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

Requirement
Press part
Bought Out (LKM make)

Inspection
Dimensional ,Visual
Test Certificate , Dimensional ,Visual

Process :Sr.
NO
01

Process

Reference Schematic Dig.

Fitting of Din Male

part to Dished-end.

Sketch

02

Finishing and
Polishing of dished
end.

Remarks
1) Insert the Din Male Part in the ID of
Dished-End and tack Weld at 2 spots.
2) Check Squareness and dimensions.
3) Increase Tack weld spots.
4) Apply wire brush or sander dish 60 Grit
on weld spots.
5) Do the welding from inside.
a. Use Dia 1.6 mm, 316L filler wire.
b. Current 80-90 amps.
1)Do the Inside & outside finishing of
Dished End
2) Use Flexible Grinder and 80 Grit Polish
paper for finishing.
3) Store material carefully.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :- Jacket
Article No :- 573327 -01
Drawing No :- 573327

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

Rev No:- 2

Raw Material Details :Description

04 mm Thk. Plate.

Material
AL 111 2349 -02 (SS-316)

Requirement
CR/HR Plate.

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

Process :Sr.
NO
01

Process

Reference Schematic Dig.

Remarks

Plate Cutting .
(Require Size
372 x 930 +/- 0.5
mm)

Sketch

1) Cut the plate as per drawing.

2) Taper should be within 01 mm.
3) Apply chamfer 2.0 mm x 30 deg.
4) Remove Burr after cutting.
5) Store material properly .

02

Rolling

03

Welding

1) Roll the job on rolling machine as per drawing.

2) Ensure that Pre Pinching is done before rolling.
3) Ensure Gap between joint is 1.5 to 2.0 mm.
4) Ensure there is no Ovality in the shell.
1) Check the dimensions after rolling if the
diameter is varying then do the fitting as per
required diameter.
2) Increase the tack weld spots.
a) Use Dia2.0 mm, SS 316L filler wire.
b) Apply Backing Gas (Argon or Nitrogen )

3) Apply wire brush or sander dish 60 Grit on

weld joint.
4) Do the welding of L-Seam.
a) Use Dia2.0 mm, SS 316L filler wire.
b) Apply Backing Gas (Argon or Nitrogen ).
c) Current 90 amps.
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.
04

Joint Finishing

1) Apply Sander dish 36 Grit on weld joint.

2) Check the ovality in diameter if required
apply hammering of correctness.
3) Use correct type of tool and hammer.
4) If required send the shell for Re-Rolling.
5) Apply 2 x 30Deg Chamfer on one end of the
shell.
6) Do the inside finishing of shell.
a) Do the Inside finishing of shell(Jacket)
b) Use Flexible Grinder and 80 Grit Polish
paper for finishing.
7) Carry out D.P Test for weld joint from
both sides.
a) If find any point then back chip and
reweld.
b) Finish the joint once again and carry
out D.P Test once again.
c) Repeat the procedure till you get D.P
Okay.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :- Taper (Cone)
Article No :- 573324 -01
Drawing No :- 573324

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

Rev No:- 3

Raw Material Details :Description

04 mm Thk. Plate.

Material
AL 111 2349 -02 (SS-316)

Requirement
CR/HR Plate.

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

Process :Sr.
NO
01

Process

Reference Schematic Dig.

Remarks

Plate Cutting .
as per drawing .
a) Manually by Angle
Grinder.

Sketch

1) Cut the plate as per drawing.

2) Taper should be within 01 mm.
3) Use 7 Angle grinder and correct type of
cutting wheel.
4) Apply chamfer 2.0 mm x 30 deg.
5) Remove Burr after cutting.
6) Store material properly .

b)By Laser
Cutting.(Oxygen
Laser Cutting)

1) Check Laser Programme before cutting.

2) Apply sander dish 60 Grit on cutting edges for
blackness removal.
3) Apply chamfer 2.0 mm x 30 deg. As per
drawing.
4) Remove Burr after cutting.
5) Store material properly .

02

Pressing/ Rolling

1) Press/Roll the profile plate on hydraulic press

machine as per drawing.
2) Ensure that rolling/pressing is done as per
drawing. And theie is no dent and press/tool
mark on the surface of the plate.
3) Ensure Gap between joint is 1.5 to 2.0 mm.
4) Ensure there is no Ovality in the cone.

03

Welding

1) Check the dimensions after Pressing if the

diameter is varying then do the fitting as per
required diameter.
2) Increase the tack weld spots.
a) Use Dia2.0 mm, SS 316L filler wire.
b) Apply Backing Gas (Argon or Nitrogen )
3) Apply wire brush or sander dish 60 Grit on
weld joint.
4) Do the welding of L-Seam.
a) Use Dia2.0 mm, SS 316L filler wire.
b) Apply Backing Gas (Argon or Nitrogen ).
c) Current 90 amps.
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.

04

Joint Finishing

1) Apply Sander dish 36 Grit on weld joint.

2) Check the ovality in diameter if required
apply hammering of correctness.
3) Use correct type of tool and hammer.
4) If required send the shell for Re-Pressing.
5) Carry out D.P Test of weld joint after
finisning.

05

Re pressing on
Hydraulic press
machine using DiePunch Press Tool
(DE/DC/01)

1)
2)
3)
4)

06

Machining

1) Tack weld M.S. ring from back side of cone

for machining purpose.
2) Hold the Cone in M.S.ring and do the facing
and chamfering as per drawing.
3) Check the dimensions like height,SF and
other parameters.

Press the formed part on press m/c

Use Press Tool Die-Punch(DE/DC/01)
Check dimensions after pressings.
Check taper,degree ,SF and other
parameters.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :- Tube
Article No :- 545411 -01
Drawing No :- 545411

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

Rev No:- --

Raw Material Details :Description

Dia 101.6 mm x 2 Thk.
Pipe.

Material
AL 111 2349 -02 (SS-316)

Requirement
ERW

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

Process :Sr.
NO
01

Process

Reference Schematic Dig.

Remarks

PipeCutting .
(Require Size
105 +/- 01 mm)

Sketch

1) Cut the pipe as per drawing (Use 7 Angle

Grinder and correct type of cutting wheel)
2) Taper should be within 01 mm.
3) Remove Burr after cutting.

02

Machining (Facing
from both ends)

03

Hose Bidding as per

drawing

04

Machining (Facing
from both ends and
chamferring)

1) Turn the job as per drawing from both ends.

(Face cut only)
2) Maintain Length
3) Remove sharp edges
4) Check squareness.
1) Use designed tool for this and carry out
bidding operations.
2) Check the dimensions after bidding.
1) Turn the job as per drawing from both ends.
(Face cut only)
2) Maintain Length and chamfer as per
drawing.
3) Remove sharp edges

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name
Drg No
Article No
Drawing No

:- 01)Taper(Cone) and Tube Assly.

:- 573329 R2 (Art No 573329 01)
:- 573324 01 , 545411- 01
:- 573324 Rev N0 03, 545411 Rev --

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

Raw Material Details :Description

01) 04 mm Thk. Cone

Material
AL 111 2349-02 (SS-316)

02) Dia 101.6 x 2 thk pipe.

AL 111 2349-02 (SS-316)

Requirement
Inspection
Press part Dually welded Dimensional ,Visual
and finished.
Hose beaded pipe.
Dimensional ,Visual

Process :Sr.
NO
01

Process

Reference Schematic Dig.

Fitting of Tube to
taper (Cone)

Sketch

02

Finishing and
Polishing

Remarks
1) Do the fitting as per drawing and tack
Weld at 4 spots.
2) Check Squareness and dimensions.
3) Increase Tack weld spots.
4) Apply wire brush or sander dish 60 Grit on
weld spots.
5) Do the welding from outside.
a. Use Dia 1.6 mm, 316L filler wire.
b. Current 80-90 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.
1)Do the Inside & outside finishing of
Cone.
2) Use Flexible Grinder ,pencil cutter and 80
Grit Polish paper for finishing.
3) Carry out D.P.Test.
4) Store material carefully.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name
Drg. No
Article No
Drawing No

:- Jacket and Taper (with tube welded) assly.

:- 573329 R2 (Art No 573329 01)
:- 573327 01 , 573324 01 & 545411- 01
:- 573327 Rev N0 02, 573324 R03 & 545411 Rev --

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

Raw Material Details :Description

01) 04 mm Thk. Shell
02) Cone with tube welded.
Process :-

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

Requirement
Rolled part.
Welded part.

Inspection
Dimensional ,Visual
Dimensional ,Visual

Sr.
NO
01

Process

Reference Schematic Dig.

Remarks

Fitting of cone to
jacket.

Sketch

02

Joint Finishing and

Polishing

1 ) Do the fitting as per drawing and tack

Weld at 4 spots.
2) Check Squareness and dimensions.
3) Increase Tack weld spots.
4) Apply wire brush or sander dish 60 Grit on
weld spots.
5) Do the welding from outside.
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.
g. If Penetration is not proper then
back chip where ever required and
do as per point a,b,c,d.
1) Apply 36 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 and polishing.
3) Carry out D.P.Test.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :- Flange
Article No
:- 573333 01
Drawing No :- 573333

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

Rev No:- 0

Raw Material Details :Description

25 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) Do the pocket milling as per drawing on
milling machine.
4) Check all the dimensions.
5) Ensure that there is no tool and scratch
marks on the surface and O.D of the
flange.
6) Store material carefully.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :- Inlet pipe
Article No :- 573279 -01
Drawing No :- 573279

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

Rev No:- 01

Raw Material Details :Description

1)Sq. Pipe 89 x89 x 4 Thk.
0R
2) 4 mm thk Plate
Process :-

Material
AL 111 2349 -02 (SS-316)

Requirement
Draw Tubes/pipe.

AL 111 2349 -02 (SS-316)

CR/HR Plate.

Sr.
NO
A

Process

Reference Schematic Dig.

Remarks

Pipe Cutting .
As per Drawing.

Sketch

Fabrication of
Sq.Pipe/Tube

Sketch

1) Make a Template as per drawing.

2) Cut the pipe as per drawing/Template
(Use 7 Angle Grinder and correct type of
cutting wheel)
3) Taper should be within 01 mm.
4) Remove Burr after cutting.
5) Store material carefully.
1) Cut the 4 thk Plate as per development/Drg.
(Use 7 Angle Grinder and correct type of
cutting wheel)
2) Do the marking for bending.

a) Plate Cutting.

b) Bending.

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

1) Do the bending as per marking / Drawing on

bending machine.
2) Check all the dimensions.

c) Welding.
1) Do the fitting of two C-Channels/bent
pipe(as per drg.) so that it will take the
shape of sq.pipe.
2) Tack weld at 4 spots take all the dimensions
feel the joint level.
a)Use Dia 2.0 mm, 316L filler wire.
b)Current 80-90 amps.
c)Apply backing gas (Argon or N2)
d)Apply Wire Brush on weld joint
3) Increase the weld spots.(Repeat the
procedure a,b,c,d)
4) Give the supports to both bent plates(To
avoid distortion during welding.)
5) Do the full welding.
(Repeat the procedure a,b,c,d)

d) Joint finishing

1) Apply 36 Grit sander dish on weld joint .

2) Use pencil cutter/round tool where ever
necessary.
3) Do the finishing using Flexible grinder
Use 80 Grit polish paper
3) Repeat the procedure of process A.(Points
01 to 05)

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name :- 1) Rib
Article No
:- 573347 01
Drawing No :- 573347
Rev No:- 0

2) Rib
573501 01
573501
Rev 0

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

Raw Material Details :Description

8mm Thk. Plate

Material
AL 111 2349 -02 (SS-316)

Requirement
HR Plate.

Inspection
Chemical C,Cr,Ni,Mo

Process :Sr.
NO
1

Process

Reference Schematic Dig.

Plate Cutting as per

Drawing.(Oxygen
Laser Cutting will
also be alternative
method for cutting)

Sketch

Remarks
1) Make template as per drawings.
2) Place the template on 8mm thk plate and
mark the boundries by pointed tungsten
tip(0.5 mm)
3) Check cutting marking before plate
cutting.
4) Use Angle Grinder 7 and correct type of
cutting wheel.(Oxygen Laser Cutting will
also be alternative method for cutting.)
5) Check dimension after cutting.
6) Remove sharp edges.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name
:Drg No
:Ref Article No :Ref Dwg No :-

Jacket/Cone with tube, Inlet Pipe, Flange and Rib Assly.

573329 R2 (Art No 573329 01)
573327 01 ,573324 01 ,545411 01, 573279- 01 , 573333 01, 573347 01,573501 01
573327 R02, 573324 R02, 545411, 573279 R01, 573333 R0,573347 R0,573501 R0

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

Raw Material Details :Description

01) Cone and tube assly.
02) Inlet pipe 4 mm Thk
03) Flange 22.5 thk.
04) Rib 8 thk.
Process :Sr.
NO
01

Process

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

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

Reference Schematic Dig.

Fitting of Inlet pipe to Sketch

jacket, Ribs to jacket
and flange to inlet
pipe.

Requirement
Dually assembled (Fabricated)
Cut as per template(Drg.)
Dually Turned.
Cut as per template or Laser cut.

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

Remarks
1 ) Do the marking for fitting inlet pipe to
jacket & Rib on the jacket.
a sper drawing .
2) Cut The marked portion of jacket where inlet
pipe will fit in..
3) Take the inlet pipe and place it on the cut
portion ,tack Weld at 4 spots.
4) Check Squareness and other dimensions.
5) Take the turned flange and fit it on the inlet
pipe as per drawing.Tack weld at 02
spots.Take other dimensions.
6) Take the both ribs and fit it on the jacket as
per marking and drawing
7) Check required all dimensions.
8) Increase Tack weld spots.
9) Apply wire brush or sander dish 60 Grit on
weld spots.

10) Do the welding where ever required.

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

Finishing and
Polishing

1) Apply 36 grit sander dish on weld joint

and do the weld joint finishing from
Inside & outside
2) Use 12000 RPM Flexible grinder and HSS
pointed and round tool for cuttering near
ribs & inlet pipe and where ever required..
3) Use Flexible Grinder and 80 Grit Polish
paper for finishing and polishing.
4) Carry out D.P.Test.
5) Measured all the dimensions.

PROCESS SHEET FOR COMPONENE MANUFACTURING

Part Name

:- 01)Cambered Flange End

Piece with Din male Part

02)Bottom body(Includes
Jacket,Taper with tube,inlet
pipe, ribs and flange.)

Drg No
:- 573329 R2 (Art No 573329 01)
Ref Article No :- 259523 22 , 574203- 09,573327 01,573324 01,545411 01,573279 01,573347 01,573333 01,573501 01
Ref Drawing No :- 259523 Rev N0 - , 574203 Rev 0

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

Raw Material Details :Description

01) Cambered Flange End
Piece with Din male Part
02) Bottom body(Includes
Jacket,Taper with tube,inlet
pipe, ribs and flange.)
Process :Sr.
NO
01

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

Process

Reference Schematic Dig.

Fitting of Cambered
Flange End Piece
(with Din male
Part)
To bottom body.

Sketch

Requirement
Fabricated Part Dually
Finish /polish.
Fabricated Part Dually
Finish /polish.

Inspection
Dimensional ,Visual
Test Certificate , Dimensional ,Visual

Remarks
1) Take M.S Ring Of I.D 300.4 and tack weld it
on the bottom body i.e on the jacket near top
end 10 mm away from end.It will act like
stiffner which will be using for preventing
distortion during welding of Bottom body and
cambered flange end piece.
2) Take the Cambered Flange End Piece with
Din male Part and place it on the bottom
body.Keep the gap of 2.0 mm for welding
purpose in between cambered flange and
bottom body.
3) Tack Weld at 4 spots.
4) Check Squareness and dimensions.
5) Increase Tack weld spots.
6) Apply wire brush or sander dish 60 Grit on
weld spots.

7) Do the welding from outside(C-Seam)

a.
b.
c.
d.

Use Dia 2.0 mm, 316L filler wire.

Current 80-90 amps.
Use Backing gas (Argon or N2)
Ensure that required amount of
penetration is coming from the back
side.
e)Slack and oxidation should not allowed
inside.

02

Finishing and
Polishing .

1)Do the outside finishing, Apply wire brush

and then sander dish 36 Grit on weld joint.
2) Remove M.S.Ring from jacket and grind
weld spots.
2) Use Flexible Grinder and 80 Grit Polish
paper for finishing.
3)Do the finishing/polishing all-over.Do not
leave any scratch mark,dent mark on the
total surface of the component.
4) Carry out D.P test.
5) Apply K2 Paste from inside on weld joint
And then rinse with water.Yellow and
black spots are not allowed.
6) Check all the the dimensions.
7) Store material carefully.

03

Finish Machining

04

Final Polishing .

1) Check for any scratch mark , dent marks

and other visuals& if required do the final
finishing /polishing using flexible grinder
and 80/120 grit polish paper.

04

Cleaning and
Stainless steel shot

1) Clean the component with soap and

normal water.

Use Drawing No. 573329 R2

1) Do the finish machining as per drg no

mentioned above.
2) Check all the dimensions , squareness, and
remaining parameters.
3) Store material carefully.

blasting

2) Clean the component with dry clothes.

3) Do the remaining assly as per drg. Like
fitting gaskets, blanks and nut to din male
part.
4) Do the stainless steel blasting as per
required standard .
5) Store the material carefully.

05

Final inspection

Use Drawing No. 573329 R2

06

Packing and
forwarding as per
instructions.

Refer Instruction Documents.

1) Carry out the inspection as per drawing

no 573329 R2.
2) Make Final inspection report.

Pack the job carefully as per instructions.