FABRICATION DEPARTMENT

1) Fabrication plan The inputs of our departments are as follows Raw material-the fabrication of various kinds which involves various kinds of raw materials. The raw material can be broadly classified in to following types 1. Mild steel (grade IS 226, IS 2062 etc) 2. Stainless steel SS 304 , SS 316 , SS 304L, SS 316 , etc Company is following as per program given by PPC department which is called Monthly Fabrication Program (MFP). In this programmed the work Order Number ,Type of Pump , Name Of Client , Description Of job along with Drawing ,Quantity & MOC is given . They scheduled our activities as per this plan. They collect all drawings & prepared raw materials Ident for the fabrication & handed over to purchase department for procuring the same . they also get Planning cards and MRC /BMR from PPC to withdraw material from stores. Also consumables are planned which are required for scheduled fabrication work , & the General Indent is given to purchase Dept for procurement . They are maintaining Production Report daily basis on register as well as soft copy for the same . The daily completed jobs & tonnage record are maintained . In case of emergency order we chalked Bar chart for our activities . They are doing internal planning based on total tonnage or otherwise on availibility of hours. The capacity of the shop is app. 40tons per month or 85 hours daily .

2) Various Processes In fabrication various steps are involved 2.1) Marking In this operation marking all the ref. is involved . Marking all the refs on plates, centre line marking & drilled holes marking etc . are the basic steps in marking operation . 2.2) Preparation - After making all these references preparation can be done by following operations, Gas cutting In this cutting is done by gas cutting withhelp of Oxygen Acetylene gas. Shearing The cutting below 10 mm for M.S & Stainless steel plates are done on shearing machine. The advantage over gas cutting is better edge and clean cut , but the thichness is limitation. Folding Sometimes we needed folded section then we can do it on folding machine. Different dies and blades are available for folding depending upon sec required. Rolling Sometimes they needed folded section, and then they can do it on the folding machine. Different dies & blades are available for folding depending upon sections required. Beveling V preparation for welding of pipes is done upon beveling machine. Plasma cutting - For SS plates can be cut on this machine. Fitting When all refs are ready as per manufacturing drawing, can be fitted & kept ready for welding. In this operation various dimensions are maintained as per drawings, while doing this critical dimension is taken care. This operation is important as the basic profile of the job is depending upon this. Welding- After Fitting of the job, welding operation is involved. Before welding all necessary dimensions is checked thoroughly sufficient machining allowance by two major processes:

2.2.1) SMAW PROCESS (Shielded Metal Arc Welding) :-This conventional type of welding which is also known as Electric Arc Welding, in this process types of electrodes that will give weld metal having a chemical composition similar to that of parent material. The electrode is classified according to AWS classification. Different names are given to rod as per manufacturers specification. Various parameters are involved while doing welding such as electric current, voltages & speed. The sizes of electrodes are also playing important role while doing welding. More commonly 2.5, 3.115,4,5 mm are available in the market . In the electrode we find flux coating over electrode which prevents oxidation process.

2.2.2) GMAW Process :- It is known as Gas Metal Arc Welding. In this process gas is used as a shielding purpose . the Following gases or gases mixture shall be used while doing welding: Argon this is inert gas ,mostly it is used in stainless steel Welding in TIG welding process . CO2-this is active gas, mostly it is used in mild steel Welding in MAG welding process . Sometimes CO2 &Argon Mixture with various proportion (75 Argon : 25 Co2 /80Argon :20 CO2etc ) Are used. The advantage in this is better weld bead & higher deposition rate is achieved. However shielded gas also acts similar to the flux in electrode. In this process continuous welding wires has been specifically designed to make feeding smooth & to minimize spatter . The advantage over SMAW is Higher deposition rate (rate is 8 to 9 kg /hr as in SMAW it is 3to 4 kg /hr ) # Deeper penetration power Sress Relieving :- It is a post weld operation ,in which the sress that are formed during welding were removed by heating method & this method is widely accepted

in this whole job is heated & cooled as mentioned as per ASME section. The cycle is as follows : Components are heated up to 600-650 deg . C. rate of heating should not exceeds 120 deg.c.per hour . socking period 1 hours components are cooled in furnace up to 300 deg.c . rate of cooling should not cross 100 deg.c. per hour . Components are then air cooled. Passivation ; This operation is for Stainless steel fabrication . Pickling and Passivating In years gone by, the the process specified was to pickle and passivate a two step method in order to create a surface on stainless steel that would be resistant to corrosion . Today , we differentiate between the two . It is two separate processes. Pickling ( or Chemical Descaling ) is done to remove scale . Passivation is done to make the surface more passive and corrosion resistant . The following description of each process applies primarily to applies primarily to 300 series stainless steels. Other stainless steels containing low levels of chromium and nickel may require alternative pickling and passivation processes to the ones described herein. Pickling (chemical descaling ) Pickling or chemical de scaling is but one of several pretreatement steps available for preparing an article for further processing such as passivation or electropolishing , or to perform a superior cleaning operation of welded structures . Prior to pickling , the heavy surface soils such as oil , grease , buffing compounds ,drawing compounds , some scale , heavy rust , dye and paint markings , tape , adhesive , residue and other foreign substances must be removed . This step may be accomplished by the use of alkanes cleaners , solvent cleaning , vapor degreasing , ultrasonic cleaning , steam cleaning , water jetting , or other mechanical cleaning. Pre-cleaning is not required if oxide or scale is the only soil on the surface . Picklng is typically performed to remove tightly adherent oxide films resulting from hot forming, heat-treating , welding and other high temperature operations.

Welding or heat treatement often produces complex oxides that can vary in color . All these oxides are generally reffered to as scale and must be removed . Where applicable , alternative mechanical mechanical methods such as blasting , shot penning , tumbling , and wheel abrading may also be performed . Abrasives containing iron should not be used . In many cases , pickling of stainless steels is performed in two steps , one for softening the scaleand onefor final scale removal. Over Pickling , under-pickling , and pitting usually are the direct results of lack of control over process variables including acid considerations , solution temperature and contact time . Passivation Passivation is a process performed to make a surface passive , i.e.,a surface film is created that causes the surface to lose its chemical reactivity . Passivation unipotentialises the stainless steel with the oxygen absorbed by the metal surface , creating a monomolecular oxide film . This passivity can result in the very much desired low corrosion rate of the metal. Passivation is performed when free iron , oxide scale , rust , iron particles , metal chips or other nonvolatile deposits might adversely affect the metallurgical or sanitary condition or stability of the surface the mechanical operation of a part , component or system ,or contaminate the process fluid . Passivation is performed on clean stainless steel , providing the surface has been thoroughly cleaned or de scaled . Since the term passivation is used to describe distinctly different operations or processes relating to stainless steels , it is necessary to define precisely what is meant by passivation . 1. Passivation is the process by which stainless steel will spontaneously form chemically inactive surface when exposed to air or other oxygen-containing environments .

Steels containing more than 11% Chromium are capable of forming an invisible , inert or passive , self-repairing oxide film on their surface . It is this passive layer that gives stainless steels their corrosion resistance. Itf a

stainless steel surface is scratched then more Chromium is exposed which reacts with oxygen allowing the passive layer to reform . However if a particle of carbon steel is embedded in the scratch then the passive layer cannot reform and corrosion will occur when the metal is wettled or exposed to a corrosive environment . 2. Passivation is the chemical treatement of a stainless steel surface with a mild oxidant such as nitric acid solution . This process is to accelerate the process is to accelerate the process noted above in no.1 3. Passivation is the removal of exogenous iron or iron compounds from the surface of stainless steel by means of a chemical dissolution , most typically by a treatment with an acid solution that will remove the surface contamination but will not significantly affect the stainless steel itself . This is necessary because during handling and processing such as rolling , forming , machining , pressing , tumbling , and lapping , particles may be embedded in or smeared on or in to the surfaces of stainless steel components. If allowed to remain , these particles may corrode and produce rust spots on the stainless steel this is due to the formation of galvanic couple between two dissimilar metals that can promote a corrosive reaction . To dissolve the embedded Or smeared iron and prevent this condition , as well as restore the original corrosion resistanse surface , semi finished or finished parts are given passivation treatement .

4. Passivation also is accomplished by electro polishing . Electro polishing is an electrochemical process that is a super passivator of stainless steel and results in a more passive surface than the other methods mentioned above.

3) CONSUMABLES:Consumables we are required various types of consumables like wedding rods , gases , Plasma electrode , nozzles , etc . (further details refer C ) - WELDING RODS : We are using following types of consumables like welding rods For Mild Steel welding -1. Super bond S 2. Unvers W 3. CO2 spools Automating wire & Falxofill 31 wire . For Stainless Steel -1. Superinox 2C (SS 316 L) 2. Staintorde D 3. Bentox D 2 MO (SS to MS ) - Gases _ 1> Oxygen & Acetylene (for gas cuttinan g & brazing) 2> CO 2 (for MAG Welding) - Plasma nozzle and electrode-for stainless steel cutting.

4) PRODUCTIVITY MEASUREMENT: Productivity can be measured in terms of tonnage or hours wise in case of small and medium type of fabrication. Shop capacity of Mild Steel heavy type of fabrication is 40 tonns per month or in case of Stainless Steel it is 16 tonns per month. In case of small or medium fabrication we measure in terms of hours given in planning card Vs hours taken(considering efficiency factor)

5) FABRICATION COSTING: The fabrication costing is calculated in following way- Total tonnage per month is calculated - Total expenses of the month on consumables and contactors payment is also noted - Cost per kg can be calculated Y rupees Y/X Rs per kg X tons

6) NON-DESTRUCTIVE TEST: The following tests are carried out while fabricationa) Dye penetration test: This test is commonly known as DP test. The procedure for this is as follows: - The surface under this test shall be made free from dust. Scale, spatters, grease or oil etc and the irregularities are smoothly ground. - The surface examined shall be cleaned by lint free, cloth saturated with cleaner. - After natural drying of surface it is coated with red colored penetrate by brush for 10 to 15 min. - After this time any excess penetrate shall be removed completely by wiping with lint free cloth with penetrate remover and wipe the surface till all the traces of penetrate are removed.

- After drying in ambient air, wet developer shall be uniformly applied on the surface by spray method. - After this we will be able to detect the defects on the surface and respective decision can be taken. b) X-Ray test: By this method we can find out various internal welding defects like Lac of penetration, porosity, cracks or slag interruption in welding beam. It can be taken as per clients requirement like 10% or 100% welding length.