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