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    Process Flow Chart - Heat Exchanger

    Uploaded by

    Anand Kesarkar
    This document provides a process flow chart for a heat exchanger (duplex) with the following key steps: 1. Verify customer purchase order and acknowledge. 2. Create bill of materials and procure materials. 3. Fabricate parts like shell plates, channel shells, and flanges through cutting, rolling, welding, and machining. 4. Assemble components like shell to shell fitting, nozzle installation, and tube bundle insertion. 5. Perform quality checks and tests such as hydrotesting, helium leak testing, and final inspection.

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    © All Rights Reserved
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    Process Flow Chart - Heat Exchanger

    Uploaded by

    Anand Kesarkar
    956 views7 pages
    This document provides a process flow chart for a heat exchanger (duplex) with the following key steps: 1. Verify customer purchase order and acknowledge. 2. Create bill of materials and procure materials. 3. Fabricate parts like shell plates, channel shells, and flanges through cutting, rolling, welding, and machining. 4. Assemble components like shell to shell fitting, nozzle installation, and tube bundle insertion. 5. Perform quality checks and tests such as hydrotesting, helium leak testing, and final inspection.

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    Process Flow Chart - Heat Exchanger

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    This document provides a process flow chart for a heat exchanger (duplex) with the following key steps: 1. Verify customer purchase order and acknowledge. 2. Create bill of materials and procure materials. 3. Fabricate parts like shell plates, channel shells, and flanges through cutting, rolling, welding, and machining. 4. Assemble components like shell to shell fitting, nozzle installation, and tube bundle insertion. 5. Perform quality checks and tests such as hydrotesting, helium leak testing, and final inspection.

    Copyright:

    © All Rights Reserved
    Download as XLSX, PDF, TXT or read online from Scribd
    Download as xlsx, pdf, or txt
    956 views7 pages

    Process Flow Chart - Heat Exchanger

    Uploaded by

    Anand Kesarkar
    This document provides a process flow chart for a heat exchanger (duplex) with the following key steps: 1. Verify customer purchase order and acknowledge. 2. Create bill of materials and procure materials. 3. Fabricate parts like shell plates, channel shells, and flanges through cutting, rolling, welding, and machining. 4. Assemble components like shell to shell fitting, nozzle installation, and tube bundle insertion. 5. Perform quality checks and tests such as hydrotesting, helium leak testing, and final inspection.

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    © All Rights Reserved
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    Process Flow Chart

    Heat Exchanger (Duplex) Drg No CR108

    Custumer PO

    Verify PO & Acknowledge to Custome

    Create BOM & Matrial Procurement

    Shell Plate Channel Shell


    Part No.- 2,3 & 4 Plate
    Part No.-1 & 6

    RM Chemical, RM Chemical,
    Physical Physical
    & Hardness

    Development Layout
    Marking & Plate
    Cutting with Edge Cutting
    Flange
    prepartion

    Rolling as per Rolling


    Templet Top & Bottom Channel Dish End Blank
    Shell Plate Cutting Cutting
    End Welding
    Welding of L-seam

    Rolling Machining
    Pressing
    Weld Joint Grind Flush from
    Inside
    Drilling
    Welding of L-seam Visual,
    Dimensional
    Inspection of Dish
    Weld Cleaning
    End
    Weld Joint Grind
    Flush from Inside
    Re-rolling after Welding

    Weld Cleaning
    Weld Cleaning

    NDT Testing - RT

    Re-rolling after Welding

    Shell to Shell
    Fit-up C-Seam Welding
    NDT Testing RT

    Weld Finishing &


    Top/ Bottom Channel Shell to Dish End
    Cleaning
    Fit Up/Welding

    Flange and Partition Plate


    NDT Testing Fitting & Welding with Bottom
    RT Channel Plate & Dish End

    Nozzle Marking on Shell and Channel

    Inspection
    (Opening Size, Edge & Surface Condition)

    RM Chemical,
    Nozzel Pipes & Flanges Physical
    & Hardness

    Reinforcement Pad Welding


    with Shell 2,3 & 4
    Cutting

    Impingment Plate Fitup &


    Welding with Shell 2 Proof Machining

    Flang Fitup & Welding

    Tubesheet to Main Shell Welding (Bottom)

    Tube Bunddle To Be Inserted into Main Shell

    Tubesheet to Main Shell Welding (Top)


    Tube Expansion

    Excess Tube Flushing

    Saddle & Support lug Welding

    Shell Side Hydro Testing

    Both side Channel & Main Shell


    Flange Bolting

    Tube Side Hydro Testing

    Helium Leak test

    Pickling & Passivation

    Final Inspection

    * Hold/Witness points are highlighted by soft Green colour


    art
    CR10830005 Alt 3

    o Customer

    curement

    Tube Sheet and Tube Sheet


    Channel Flange Bunddle
    Part No.-15 Part No.-26

    RM Chemical, Tubes
    Plate-Cutting
    Chemical,
    Physical Physical
    & Hardness

    Tube Pl
    Hydro-
    Inspection Testing
    Visual, Dimensional & UT

    Tube Laser Cutting


    Flange Plasma Cutting

    olling Machining Tie Rod Setup

    d Welding Drilling of Tube Sheet (CNC)


    & Baffle Plate (Laser) Baffle Plate Positioning &
    Alignment
    achining
    Rimming & Grooving
    Spacer Positioning &
    Drilling Alignment

    GO/ NO GO Gauge
    Fitment
    Tube Bundle
    Formation

    Inspection
    (Dimensional, Visual
    Check, Vapour
    Degreasing etc.)
    Packing Dispatch

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