Rupesh

BY SAWANT RUPESH C. B. Tech. (PRODUCTION) (D-050729) UNDER GUIDANCE OF

Prof. D. V. SHIRBHATE

  



 



Deploy right man on right job. Distribute the work to the workmen. Study the job related documents and give proper written instructions to workmen to ensure quality of products. Make an inspection entry at predetermined stage as per ICL. Issue consumable requisition. Interact with maintenance to ensure proper working of Machinery. Co-ordination with planning, prod.engg, maintenance, inspection department.

           

Estimated hours for shop scope of work. CDD/ latest promised delivery date. Target hours. Sequence of Manufacturing. Welding procedures. Stages of machining/ PWHT. Inspection check list. Weld plan. Applicable drawings, NCRS, DCRS. Test Plan. RT/UT reports. Man-hours booked.

    

 

Positions of welding. Why preheat is necessary? Why post heat is necessary? What is interpass temperature? Methods of recording temperature while welding. Type of weld defects. Why PTC (production test coupon) is required?

 

 

Various NDE techniques. What is spot radiography? Can several seams be combined for spot RT? What are the acceptable defects? Various leak detection tests?

  





Why venting is necessary during hydro test? What care is to be taken during de-pressurizing? What supporting arrangements are needed during hydro test/pwht/ transportation? What care is to be taken during high pressure pneumatic test? What is the necessity of thoroughly drying the vessel after hydro test?

 

 



  

Distribution of work. Maintaining drawing folder, weld plan and test plan on shop floor. Drawing materials from stores. Check the material received against material challan. Report material lost / spoilt / rejected on shop floor to planning through foreman. Transfer of material from shop floor. Maintaining shift change list/request. Maintain records of RT/UT reports.

 

 





Use reports for communicating with counterpart. Make proper inspection / maintenance entry giving all the details. Issue consumable slip after entering all the details Obtain priority for RT/UT/wagon movement/machining/pwht before positioning the job. Give requirement for indirect material/jigs and fixture /tools to planning in advance. Check correctness of dimensions / feedback being given to inspection, planning, welding engineering.

Do’s  Fix the earthing clamp directly to the job.  Use properly baked electrodes.  Always refer the weld plan before issuing the electrode to the welder.  Use qualified welder on the job. Dont’s x Don't use fresh electrode from the Packet x Don't tack less than 50mm long. The tack may crack due to restraint.

           

ROUTE CARDS (RC). PURCHASE REQUEST (PR). PURCHASE ORDER. MATERIAL REQUISITION (MR). PLATE CUTTING REQUISITION (PCR). JOB TICKET (JT). OPERATION CARD. NON-CONFIRMATIIVE REPORT (NCR). DESIGN CHANGE REQUEST (DCR). MANUFACTURING SCHEDULE. PRODUCTION PROGRAMME. SHOP LOADING STATEMENT.

            

RAW MATERIAL IDENTIFICATION. PLATE CUTTING & WEP PREPARATION. EDGE BREAKING. ROLLING-FORMING. LONG SEAM S/UPS. CIRC SEAM S/UPS. NOZZLE S/UPS. WELDING. HEAT TREATMENT. INSPECTION. HYDROTEST. SHOT BLASTING & PAINTING. DESPATCH.









Material Quality, Thick. & Size – Drawing. Verify HT No., Plate No. & Insp. ID -- Material & TC. Verify Properties Reported W in TC – ASME Verify NDT (UT) Requirement. Look For Pitting, Surface Damage / Defect on Both Sides.

SHELL PLATE

K1 SA 516 GR 70 24357 9262 / 3



K2 ROLLING DIR.

L











Gas Cut Edges Free From Serrations. All Corners Along the Edge Rounded Off. Plate Loaded on M/c With ID Up side. Identification Marking On Bottom Side. Rollers Across The Plate Length.

ACTUAL THK.

4 D/ MP TE

PEAK OUT

LONG SEAM S/UP

D/ TE 4 MP

I/D CHECK IN HORIZONTAL PLANE

PEAK IN

4

4

SPIDER 3

SPIDER

2

3

2

REF.LINE 1

1

POINTS (e.g 1,2,3,4) 250 mm APART CONST.DIST APPROX.1000 MM

TANK ROTATERS OIL BATH

SMAW

GTAW

STAGES :    

Die penetrating test. Ultrasonic testing. Radiography testing. Visual testing.

 





The project was successfully completed under my supervision. Although the project got delayed by 10 days from the scheduled date,due to reasons not in our scope,the job was delivered within the buffer limit. A very good exposure to the execution of projects, shop supervisor skills, and various fabrication stages for the manufacturing of equipments. Understood the scope, functions & job responsibilities of Shop Supervisor in Capacity augmentation cell.







Meeting deadlines of time seems challenging and one feels boosted because of an organized effort. Working as a team to achieve a specific preset objective, is sincerely a different experience in itself. To sum up,this project will definetly provide me a strong base to work in L&T.