STANDARD OPERATION PROCEDURE

SOP NO:
CUSTOMER: Danieli PROCESS DESCRIPTION: FLANGE TO SHELL WELDING DATE: 22.07.2018
PREPARED BY: ANAND KESARKAR
AIM ENGINEERS REVIEWED BY:
SUPPLIER: INDIA PVT LTD. PART NUMBER: FLANGE THICKNESS 20MM, 25MM, 28MM & 36MM CYCLE TIME: NA
APPROVED BY: NAVED SHAIKH

SEQ. NO. ACTIVITY MACHINES/ TOOLS PIC. NO PROCEDURE CHECK POINT PROCESS STEPS / SKETCH / PHOTOGRAPH

1 2
Ultrasonoc Examination to be Discontinuty in Plate,
done on plates as per ASME Sec V, Physical, Chemical and
1
Raw Material UT Machine with TR 1 by the competant personnel by
Inspection Probe, Coolant Mechanical properties
ASNT NDT Level II. Lab Test to be
of material.
carried out if necessary.

Make GRN on inward inspection.

Mentioned details in GRN report
of inward matl. like supplier, matl.
2 GRN _ _ details, qty., size, grade, remark
( Accepted / not accepted ).
The material fail to corelate should
be tested in NABL approved lab.
Check Report are ok or
not. ( supplier name,
matl. details, qty., size,
grade, remark
( Accepted / Rejected
qty.)

3 Plasma Cutting Overhead crane, _ Plate to be cut in three segments Profile Size (ID, OD etc.)
Plasma Cutting M/c as per drawing requirment.

3
4 Edge Preparation Grinder _ All sharp edges & burr to be Edges of profile.
after cutting removed.

"V" preparation to be done as per

Measurement Tape, approved drawing and WPS/PQR.
5 Weld Set-up of Joints Vernier calipe, 2 Weld set up to be checked as per
Weld set up,
Dimensions
Template drg. Flange dimensions to be
checked.

joints are to be welded as per

6 Welding of Joints Welding Machine 3 procedure mentioned in WPS/PQR
Welding Parameters

Do's A) Always wear the personal protective equipments and follow quality stds. SAFETY POINT= WHEN YOU HAVE ANY ABNORMALITY CALL YOUR SAFETY: QUALITY: EASE:
Don'ts A) Don't leave your work station before completing the operation cycle. SUPERVISOR AND WAIT.
 STANDARD OPERATION PROCEDURE
SOP NO:
CUSTOMER: Danieli PROCESS DESCRIPTION: FLANGE TO SHELL WELDING DATE: 22.07.2018
PREPARED BY: ANAND KESARKAR
AIM ENGINEERS INDIA REVIEWED BY: CYCLE
SUPPLIER: PVT LTD. PART NUMBER: FLANGE THICKNESS 20MM, 25MM, 28MM & 36MM TIME: NA
APPROVED BY: NAVED SHAIKH

SEQ. NO. ACTIVITY MACHINES/ TOOLS PIC. NO PROCEDURE CHECK POINT PROCESS STEPS / SKETCH / PHOTOGRAPH

4 5
Weld Joint Backchip Backchip DP test after root run Discontinuty in
7
DP
_ 4 to be carried out. Plate.

8 Weld Finish Buffing M/c - Welded joint to be flushed Surface Finish

from both side after welding.

All joints to be 100% UT/RT Discontinuty in

9 Welded Joint UT/RT _ 5 checked. Weld.

Couple the flanges that 6

10 Tack Welding of Welding Machine - connect two different Flange allignmemt,
matting flange. Mismatch
segments with spot welding.

Marking for Drilling hole to be

11 Marking for Drilling Measurement Tape,
Vernier calipe.
6 done on flanges for PCD, Hole PCD
center.

Drill the flanges for spring pin

12 Drilling Drilling Machine - Hole Size
and bolts.

Do's A) Always wear the personal protective equipments and follow quality stds. SAFETY POINT= WHEN YOU HAVE ANY ABNORMALITY CALL YOUR SAFETY: QUALITY: EASE:
Don'ts A) Don't leave your work station before completing the operation cycle. SUPERVISOR AND WAIT.
 STANDARD OPERATION PROCEDURE
PREPARED BY: ANAND KESARKAR
CUSTOMER: Danieli PROCESS DESCRIPTION: FLANGE TO SHELL WELDING DATE: 22.07.2018
REVIEWED BY:
AIM ENGINEERS INDIA PART NUMBER: FLANGE THICKNESS 20MM, 25MM, 28MM & 36MM APPROVED BY: NAVED SHAIKH CYCLE
SUPPLIER: PVT LTD. TIME: NA

SEQ. NO. ACTIVITY MACHINES/ TOOLS PIC. NO PROCEDURE CHECK POINT PROCESS STEPS / SKETCH / PHOTOGRAPH

13
Insert the pins and all bolts
into the drilled holes. Follow
Tightening
the tightening sequence (ref. sequence, Torque,
13 Bolting Torque Wrench _ 6.331145.X ) to tight the bolts.
Bolts must be remained Gap between
flanges.
tightened during assembly and
further welding phases.

Flatness

14 Inspection _ _ Check the gap between

flanges.

Support adequately every

single shell in order to reach
15 Weld Set up - Flange _ _ the perfect alignment between Alignment, Root
to Shell gap, Root Face etc.
them. Take atleast 3 shells
together.

16
13
Weld the flanges to shells Flange in bolted
16 Welding of above. Welding Machine _ maintaining the flanges bolted condition, Full
together. penetration weld

Inspection after Weld to be visually checked for

17 _ _ full penetration, weld finish Weld Penetration
welding etc.

Do's A) Always wear the personal protective equipments and follow quality stds. SAFETY POINT= WHEN YOU HAVE ANY ABNORMALITY CALL YOUR SAFETY: QUALITY: EASE:
Don'ts A) Don't leave your work station before completing the operation cycle. SUPERVISOR AND WAIT.