Roadmap for Fabrication shop

 

Roadmap for Fabrication shop

 

To set up a fabrication shop for manufacturing Boiler supporting structure and TG Building structure for Power plants, the following roadmap is proposed.

 

1.         Bharat Heavy Electricals Ltd (BHEL)’s Tiruchhirapalli and Ranipet units undertake this work. Thermax Pune is another player. L&T has set up a JV for supercritical boilers and have recently won many orders. It is necessary to identify the key executives in these companies dealing with outsourcing and contact them. BHEL being a PSU has to follow the guidelines set by CVC and it is important to get registered as a vendor with them. All the three companies have their vendor appraisal systems. Registration forms need to be obtained as a first step.

 

2.         Appointment of a CEO to take care of this business. He should be Engineering graduate in Mechanical with extensive exposure to welding technology. A CEO needs to be aware of costing, quality requirements, statutory requirements related to the product and manufacturing.

 

3.         Establishment of manufacturing facility. The fabrication consists of plates/ structures of thickness up to 63 mm, length of columns which can be accommodated in 20 T trailer and the base plates of 2 M x 2 M. Weight of individual piece is maximum 20 T. Columns are fabricated in 5/6 pieces depending on the height of structure. Trial assembly of 3 pieces is carried out for checking alignment and straightness. Assembly bed to be of sufficient length to accommodate this. Crane capacity adequate to handle these structures.

 

4.         As some of the weld joints may require to be radiographed, identify agency for doing this work. The agency should be approved by BARC (Bhabha Atomic Research Centre) and have radioactive source.

 

5.         Engage persons with qualifications for undertaking Ultrasonic testing (UT) and Magnetic Particle inspection (MPI). For evaluating radiographs, a qualified person is required. These persons should have ASNT level II certification. Same person can be QA/ QC chief or coordinator. Alternatively, the work of UT/ MPI/ RT can be out sourced to a reputed agency.

 

6.         The layout should be such that raw material comes from one side and finished product goes out from other side. Separate areas for plates, angle, channels and beams should be planned. All raw material needs to be tested for defects as laminations are not permitted. It is better to procure UT grade steel from mill. This is costly and delivery time is more.

 

7.         Normally 2 coats of primer and 1 finish coat of paint are applied before shipping the components. Final paint is either synthetic enamel or Epoxy/ Rubberized chlorinated paint depending on the site location. For this shot blasting needs to be done and separate area for shot blasting needs to be planned with enclosure. Ensuring thickness of each coat is important and gauges for this need to be procured.

 

8.         The following infrastructure needs to be planned-

 

a.      Covered shed with EOT crane – 30 M x 50 M

b.      Open area preferably concrete floor with Gantry crane

c.       PUG cutting machines for plates with attachment for cutting circle

d.      Cutting machines

e.      Horizontal milling machine for edge preparation

f.         Drilling machines – max dia 63 mm

g.      Portable drilling machine – 32 mm

h.      Pre-heating arrangement for welding

i.         Post- weld heating arrangement for stress relieving with recorder

j.         Welding machines and rectiformers

k.       Submerged arc welding machine for automatic welding of plates

l.         Electrode baking ovens with temperature controller

m.    Electrode holding ovens

n.      Heating torches

o.      Press and hydraulic jacks for bend removal

p.      Portable cutting/ grinding machines

q.      Straight edge, steel tapes, bevel protractors, spirit level gauges, fillet weld gauges, facility for blue matching

 

 

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