COLD FORMING PROCEDURE

INDEX

1. General

2. Reference Documents.

3. Responsibilities

4. Bending & Fabrication Flow

5. Bending & Fabrication method

6. Fit up

7. Longitudinal Seam Welding

8. Final inspection and Quality Record

Attachment
1. General.
This procedure is applied to cold forming for Tubulars and Cones used during Fabrication
Phase Fire Heaters Unit 30 & Unit 70 of AMURSKY GAS PROCESSING PLANT PROJECT.
Cold Forming and Pressing may be carried out for a DT: t ratio of 20;1 or greater, (where D is
the outside diameter of tubular and t is the plate thickness.
All Fabricated Tubular or Conical Members shall be formed from steel plate types, as states in
the Specifications, approved for the Project.

2. Reference Documents.

0055-4.0.0.00.CPC-KM.TT-0001 General structural specification

0055-4.0.0.00.CPC-THM.TT-0004 Specification for fired heaters
0055-4.0.0.00.CPC-THM.TT-0016 Specification for welding, nde and pwht of
pressurised equipment
AWS D1.1 Structural steel welding code

3. Responsibilities
The Constriction Manager is responsible for implementation of details mentioned in the
procedure.
The QC Inspector is responsible for Inspection and monitoring of the work product by measuring
methods, Visual Assessment and or comparison to Project Specified Requirements.

4. Bending & Fabrication Flow

MARKING EDGE
M.I BENDING
& CUTTING BENDING

RE-
NDE WELDING FIT UP
FORMING

CHECK ASS’Y GIRTH WELDING

GIRTH NDE
DIMENSION JOINT
JOINT

DIMENSIONAL
INSPECTION

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5. Bending & Fabrication method
5.1 Marking & Cutting
Confirmation of Steel Plate: Steel material shall be compared with the cutting plan for
dimension, plate thickness, steel grade and work order number of steel materials;
Marking the steel plate depend of the fabrication size of bending margin in order to
bend of both edge as follow below

Take care of diagonal & whole length and bending margins in accordance with piece
drawing.
Marking the information which are direction and a radius of curvature on the plate
surface.
5.2 Roll Bending
Bending Method:

 Confirm the information which are bending direction and radius of curvature on
the plate surface;
 Select the gauge that is the radius of curvature equal to member (gauge size:
over 20 % degrees of the circumference 360 degree)
 Marking the reference line for bending on the plate additionally;
 Cleaning surface on the die in order to protect from damage prior to bending;
 Setting the bending plate at the center of the machine;
 Edge bending for both end of the plate;
 Bending;
 Checking roundness, diameter, arc length as follow the dimensional control
specifications;


6. Fit up
The following provision shall be observed:

 Adjust the Joint Line on the roll bending machine and tack welding with Approved WPS
at the inside of tubular and cone;
 Take out from roll bending machines;
 Checking fit up condition;
 Inspection dimension as per following:
Tack welding pitch(P) = minimum 300mm

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 Welding leg = max 6mm
Welding length (wl) : min 50mm

7. Longitudinal Seam Welding.

 Setting on the welding table;
 Confirmation a part number, material, WPS;
 Fit up end tabs for welding;
 Welding inside of tubular or cones as following WPS;
 Gouging, Visual Inspection, Welding and NDE outside of tubulars or cones as follow
WPS;
 Inspection the roundness, straightness dimension, and squareness of the ends as follow
dimensional control procedure after welding;


8. Final inspection and Quality Record

Final Inspection will executed as per following steps:

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 a) After Longitudinal Seam Welding;
b) After Girth Weld completion.
Following the inspection, records will be generated as mentioned in the ITP:
- Tubular Check Sheet (PR-200)
- Cone Check Sheet (PR-201)
- Dimensional report Final Stage. (PR-202)