Break up of Heat Exchanger MFG Proc

ATING HEAD
2) PLATE ROLLING 1) FLOATING DISHEND 2) BACK CHIP 3) BACK CHIP 4) LIFTING LUG S/U 5) FLOATING D/E 6) PWHT 7) NDT AFTER SR & 8) MACHINING &
& FLANGE SETUP & MACHINING &NDT WELDING & NDT &WELDING FINAL DIMN & RELEASE FOR CLEARANCE FOR
WELDING CLEARANCE CLEARANCE RELEASE FOR SR MACHINING ASSEMBLY

NNEL ASSY
TING 2) PLATE ROLLING 3) CHANNEL CS 101 & 102 4) NOZZLE S/U -WELDING 5) PARTITION PLATE 6) RELEASE
SETUP WELDING & NDT & NDT CLEARANCE WELDING FOR ASSY FINAL SHELLSIDE
HYDROTEST

N SHELL ASSY TUBESIDE

HYDROTEST

TTING 2) PLATE ROLLING 3) BARREL READINESS 4) NOZZLE MARKING & 5) NOZZLE 6) EXTERNAL SADDLE 7) FINAL DIMENSION &
CUTTING SETUP,WELDING & NDT SETUP & WELDING RELEASE FOR ASSY
CLEARANCE

SHOT BLASTING &

PAINTING

E BUNDLE ASSY
ET
From 2) T/S Identification 3) T/S CNC Drilling 4) T/S Post Drilling 5) T/S Inspection
Clearance N2 FILLING &
DISPATCH

2) Baffle Levelling 3) Baffle Stacking 4) CNC Drilling 5) Post Drilling

& 2) TUBING 3) NTR TUBESHEET 4) TUBE TACKING & 5) TUBE TO TUBESHEET 6) TUBE BUNDLE 7) TUBE TO TUBESHEET 8) SHELL SIDE 9) OPEN BU
GUIDING TRIMMINGTUBE TO TUBESHEET WELDING - FINAL RUN INSERTION FOR EXPANSION HYDROTEST HYDROTES
WELDING - ROOT RUN AIRTEST FOR TUBE TO T/S JOINT

I Improvements In Manufacturing
 Cycle Time Study

Cycle Time compilation for AES type of equipment executed from 2015 - 2018

Average Mfg cycle Max Mfg cycle time Min Mfg cycle tim
Total Heat Exchanger Data of exchangers
Year time after Issue of after Issue of plate to after Issue of plate
(Qty) (Qty)
plate to MFG (Days) MFG (Days) MFG (Days)

15-16 59 51 186 336 114

16-17 40 40 181 259 102

17-18 10 10 176 225 118

90
Planned cycle time from the time of issue of plate to manufacturing to
the time of dispatch. ( Including Inspection & NDT)

I Improvements In Manufacturing
 Current Status
Actual cycle time as per Execution and Primavera plan is 185 days

Target
To reduce Cycle time to 90 days by improvements.

I Improvements In Manufacturing
 Break up of Heat Exchanger MFG Pr

OATING HEAD

1) PLATE CUTTING 2) PLATE ROLLING 1) FLOATING 2) BACK CHIP 3) BACK CHIP

DISHEND & FLANGE MACHINING & NDT WELDING & NDT
SETUP & WELDING CLEARANCE CLEARANCE

4) LIFTING LUG S/U 5) FLOATING D/E 6) PWHT 7) NDT AFTER SR & 8) MACHINING &
&WELDING FINAL DIMN & RELEASE FOR CLEARANCE FOR
RELEASE FOR SR MACHINING ASSEMBLY

I Improvements In Manufacturing
 Break up of Heat Exchanger MFG Pr

CHANNEL ASSY

LATE CUTTING 2) PLATE ROLLING 3) CHANNEL CS 101 & 102 SETUP

WELDING & NDT
o Punching & Marking Rolling Machine Long Seam Setup Fixture
chine
Rolling Machine
Automation

4) NOZZLE S/U -WELDING & 5) PARTITION PLATE WELDING 6) RELEASE

NDT CLEARANCE FOR ASSY

Moon Plates, Fixture for OD Using Jack

Setup
Nozzle Setup Fixture Setup Fixture

I Improvements In Manufacturing Cycle Time:-17 Days

 Break up of Heat Exchanger MFG Pr

MAIN SHELL ASSY

1) PLATE 2) PLATE 3) BARREL

CUTTING ROLLING READINESS

Auto Punching & Using Rolling SAW Gantry

Marking Machine machine Automation

4) NOZZLE 5) NOZZLE 6) EXTERNAL 7) FINAL

MARKING & SETUP,WELDING & SADDLE SETUP & DIMENSION &
CUTTING NDT CLEARANCE WELDING RELEASE FOR ASSY

Kuka & ABB Robots Fixture For Nozzle Design Fixture to

Setup reduce setting Time

I Improvements In Manufacturing Cycle Time:-12 Days

 Break up of Heat Exchanger MFG Pr

TUBE BUNDLE ASSLY

1) Tube Sheet Forging 2) T/S Identification By 3) T/S CNC Drilling

From vendor TPI
Using Single Spindle
Using Multi
Spindle Head

4) T/S Post Drilling 5) T/S Inspection

Clearance

Using Single Spindle

Using Multi
Spindle Head

I Improvements In Manufacturing
 Break up of Heat Exchanger MFG Pr

BUNDLE ASSLY FIXTURE

I Improvements In Manufacturing
 Break up of Heat Exchanger MFG Pr

BAFFLES

1) Baffle Plate Cutting 2) Baffle Levelling 3) Baffle Stacking

Using Rolling
Auto Punching, Conventional
Machine
Marking & Cutting Method
Levelling Machine With
Machine
Conveyor

4) CNC Drilling 5) Post Drilling

Using Single Using Single
Spindle Spindle
Using Multi Spindle Using Multi Spindle
Head Head

I Improvements In Manufacturing
 Break up of Heat Exchanger MFG Pr

TUBESHEET OPERATION
1) SKELTON ASSY & 2) TUBING 3) NTR TUBESHEET
CLEARANCE GUIDING

Temp Support Manual Insertion Temp Support

Standard Fixture SPM for Insertion Standard Fixture

4) TUBE TACKING & 5) TUBE TO TUBESHEET 6) TUBE BUNDLE

TRIMMINGTUBE TO WELDING - FINAL RUN INSERTION FOR
TUBESHEET WELDING - AIRTEST
ROOT RUN

Manual Orbital Machine Using Jack Pusher

7) TUBE TO TUBESHEET 8) SHELL SIDE 9) OPEN BUNDLE

EXPANSION HYDROTEST HYDROTEST
FOR TUBE TO T/S JOINT
Manual

Using Kuka/ABB Robot

0 I Improvements In Manufacturing
1 I Improvements In Manufacturing
2 I Improvements In Manufacturing
 Brainstorming id
Brainstorming ideas
Outsourcing
1 Components to be received in ready to use condition
Outsourcing of non critical components/Maximizing
2
scope of vendors & suppliers /Ready to use Ts & baffles
3 Scale free material / quality raw material/ defect free materials
4 Ready to use materials
5 CS items to made vendored
6 U tubes packaging as per the radius & properly labeled/ identified
7 weather proof packing of tubes & closure of open ends.

People
1 Separate group
2 Skilled manpower
3 Multiskilling

3 I Improvements In Manufacturing
4 I Improvements In Manufacturing
 Brainstorming id
Planning
1 Full kitting
2 Robust monitoring system
3 Resource planning / levelling
4 Ensure no idle time of components
5 Mfg of all components in one plant
6 Method to understand current loading
7 Retiviala of materials
8 In house s/c for sub assly
9 create permanent shop layouts for sub group assemblies
10 job closure meeting
11 Critical activities in house
12 clarity of scope with each team
13 common dashboard to understand the status of the job
14 place for FG / tubes
15 allocation of jobs at the early stage of project to
16 conduct early mfg kickoff at early stage of project execution
17 proper supply chain mgmt. to manage inventory
5 I Improvements In Manufacturing
 Brainstorming id

Resources Design
Bundle pullers or pushers / tube Standardization of components standardization
1 1
bundle insertion machine of fasteners that can be kept in stock
2 self cantering rotators 2 Optimising equipment design
3 Improved roller & their movement on rails. 3 forged pipe instead of fab pipe
4 Multiple drilling spindle heads 4 nozzles are of SRNF.
5 Machining facilities in respective lines 5 forged shells
6 In house forming of D/E 6 offset nozzles shall be of lip type circular cut-out
7 Garnet recovery system 8 Allowance for shell forming
8 positioner with clamping mechanism 9 Hot formed D/E
9 Circ seam alignment roller & welding station 10 single piece D/E
10 use mechanized welding process 11 PTC testing reduction
11 inhouse team for draining /drying /N2 filling Cladded plates instead of overlay ( both for nozzle
12
12 fast water filling pumps. & shell)
13 weld joints to be easy of MFG
14 reduce the number of circ seam
15 welding volume should be reduced
16 Nozzles with out RF pads
6 I Improvements In Manufacturing
 Brainstorming id

Process Quality
1 Line flow 1 On Line NDT /On Line inspection
Separate stations 2 Minimum TPI inspection stages
2
3 NDT resources each bay wise
3 Assembly lines to be group technology
4 Reduction of RT & use PAUT/TOFD
4 Creating norms of each activities 5 One shot NDT
5 Elimination of baffle levelling 6 STD QAP to be made
6 Barcoding of components Technology
7 Back chip to be avoided 1 Quick fixings robust fixtures
8 Maximum narrow groove joints Use of advance welding
9 Station for draining & drying 2 processes/employing
ultra high deposition process for butt welds
10 Rolling process revalidation
On line tracking system of components /Real
11 Std SOP for mfg & Qc along with the flow 3
time simulation of plant
12 avoid shortcuts Advance Tube to T/s welding machine,
4
13 Tube trimming times to be reduced Expansion machine
Minimizing distortion 5 auto feed mechanism for shell rolling
14
6 maximum use of Robot
15 Issues to be resolved at shop level
7 use of super bolts for tightening
16 quick service by the respective service functions. different method of final testing to reduce
elimination of gas cylinders. Use of manifolds 8
17 number of testing

7 I Improvements In Manufacturing
dea Generated By Brainstorming

1.Outsourcing of non-critical
critical components,

2. First time right components, ready to use components,

3. Minimizing distortion,

4.Number of TPI to reduced,

5. Components to be received in ready to use condition.

8 I Improvements In Manufacturing
New Fixturing Arrangement

1.Welding
Welding Fixturing for Long Seam & Circ Seam,

2.Gantry System of SAW,

3.RT Setting time reduction,

4.Tube
Tube Bundle Skelton arrangement station,

9 I Improvements In Manufacturing