Detailed Project Report on fabrication unit
Detailed Project Report on fabrication unit
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FABRICATION UNIT
(PRESSURE VESSELS, HEAT EXCHANGERS, CRYOGENIC TANKS, ROAD TANKERS FOR LPG, FUEL AND INDUSTRIAL GASES I.E. CRYOGENIC TANKS HEAT TREATMENT OF VESSELS AND EQUIPMENT, COATING (INTERNAL AND EXTERNAL) AND PAINTING OF PIPES REQUIRED IN OIL AND GAS FIELD)
[CODENO.3932]
The pressure vessels such as cylinder, pipeline or tanks are used to store fluids under pressure. The fluid being stored may undergo a change of state inside the pressure vessel as in case of steam boilers or it may combine with other reagents as in a chemical plant. The pressure vessels are designed with great care because rupture of pressure vessels means an explosion which may cause loss of life and property. The material of pressure vessels may be brittle such that cast iron or ductile such as mild steel. Pressure vessels, hydraulic cylinders, gun barrels, pipes, boilers and tanks are, in fact, essential to the chemical, petroleum, petrochemical and nuclear industries. It is in this class of equipment that the reactions, separations, and storage of raw materials occur. Generally, pressurized equipment is required for a wide range of industrial plant for storage and manufacturing purposes.
COST ESTIMATION
Plant Capacity : 0.1533 Nos/day
Land & Building (6500 Sq.MT) : Rs. 4.64 Cr
Plant & Machinery : Rs. 7.42 Cr
Working Capital for 2 Month : Rs 2.85 Cr
Total Capital Investment : Rs. 18.86 Cr
Rate of Return : 47%
Break Even Point : 52%
INTRODUCTION
PRESSURE VESSEL SHAPES
PRESSURE VESSEL DEFINITION
PRESSURE VESSEL DEFINITION - SCOPE
BOUNDARIES
WHAT IS API CODE DEFINITION FROM PRESSURE VESSEL?
WHAT IS THE API STD 510 COVERAGE?
CLASSIFICATION OR TYPES OF PRESSURE VESSELS:
1. ACCORDING TO FABRICATION:
2. ACCORDING TO FUNCTIONS:
3. ACCORDING TO MATERIAL OF CONSTRUCTION:
4. ACCORDING TO PRESSURE:
5. ACCORDING TO METHOD OF HEATING:
6. ACCORDING TO GEOMETRY OF VESSELS:
7. ACCORDING TO ORIENTATION OF PRESSURE VESSELS:
8. ACCORDING TO INSTALLATION OF PRESSURE VESSELS:
9. ACCORDING TO WALL THICKNESS OF PRESSURE VESSELS:
TYPES OF PRESSURE VESSELS ACCORDING TO SHAPE
SPHERICAL PRESSURE VESSEL
CYLINDRICAL PRESSURE VESSELS
CONICAL PRESSURE VESSEL
TYPES OF PRESSURE VESSELS ACCORDING TO PURPOSE
STORAGE VESSELS
HEAT EXCHANGERS
PROCESS VESSELS
COMPONENTS OF PRESSURE VESSEL
VESSELS PARTS:
1. VESSEL BODY
2. VESSEL HEADS
3. VESSEL SUPPORTS
4. NOZZLES AND MANHOLES
5. FLANGES
6. GASKETS
7. INTERNALS
MAIN COMPONENTS OF PRESSURE VESSEL
SHELL
HEAD
NOZZLES
SUPPORT
SKIRT
LEG
SADDLE
USES AND APPLICATION OF PRESSURE VESSEL
SPHERICAL PRESSURE VESSEL (SPHERE)
CYLINDRICAL PRESSURE VESSEL
LIFTING AND HANDLING OF A PRESSURE VESSEL
HEAT EXCHANGERS 38
ADVANTAGES OF SHELL & TUBE HEAT EXCHANGERS;
TYPES OF HEAT EXCHANGER
(1) PARALLEL-FLOW AND COUNTER FLOW
PARALLEL-FLOW AND COUNTER-FLOW HEAT EXCHANGER
(2) CROSS FLOW
FINNED AND UNFINNED TUBULAR HEAT EXCHANGER
(3) SHELL-AND-TUBE
U-TUBE, SINGLE PASS STRAIGHT AND TWO PASS STRAIGHT
HEAT EXCHANGER
SHELL AND TUBE HEAT EXCHANGER
TYPES OF SHELL AND TUBE TYPE HEAT EXCHANGER
(A) STRAIGHT TUBE HEAT EXCHANGER (ONE PASS TUBE TYPE)
(B) STRAIGHT TUBE HEAT EXCHANGER (TWOPASS TUBE TYPE)
(C) U TUBE TYPE HEAT EXCHANGER
CONSTRUCTION
FIG: - CONSTRUCTION OF STHE
FIG:- COMPONENT OF STHE TUBES
SHELL
TUBE
TUBE PITCH, TUBE-LAYOUT AND TUBE-COUNT
TUBE PASSES
TUBE SHEET
BAFFLES
SEMI-CIRCULAR CUT-SEGMENTAL BAFFLE
DIFFERENT TYPE OF HEAT EXCHANGER BAFFLE FOULING
CONSIDERATIONS
TABLE: - TYPICAL VALUES OF FOULING COEFFICIENTS AND RESISTANCES
WORKING
FIGURE:– WORKING OF STHE
FOLLOWING MATERIALS ARE USED IN HEAT EXCHANGER
STAINLESS STEEL
COPPER
FABRICATION WORK
CUTTING
CUTTING THIN STEEL SHEET
ROLLING
SURFACE GRINDING
DRILLING
GAS METAL ARC WELDING
USES AND APPLICATION
APPLICATION OF SHELL AND TUBE
B.I.S. SPECIFICATION
MANUFACTURING PROCESS
(A) FOR PREESURE VESSEL
FABRICATION PROCESS
GUIDELINE FOR FABRICATION OF PRESSURE VESSEL
COMPONENTS
MANUFACTURING PROCESSES
THE MANUFACTURING PROCESSES FALL UNDER THE FOLLOWING
HEADINGS:
PRESSING
SPINNING
BENDING
FIGURE 1: SCHEMATIC DIAGRAM OF PLATE BENDING
MANUFACTURE
FLAT HEADS:
FIGURE 2: PLATE MARKING AND TRANSFER OF IDENTIFICATION
DISHED HEADS:
THE DIMENSIONS TO BE CHECKED FOR DISHED HEADS ARE AS FOLLOWS
SHELL:
FIGURE 3: DIMENSIONAL CHECK OF FLAT HEADS
FIGURE 4: DIMENSIONAL CHECK OF DISHED HEADS
THE FOLLOWING DIMENSIONS FOR SHELL ARE CHECKED:
CONES: 72
THE FOLLOWING DIMENSIONS ARE MEASURED:
FIGURE 5: DIMENSIONAL CHECK OF SHELLS
QUALITY CONTROL
QUALITY CONTROL DURING FORMING AND SHAPING OF COMPONENTS:
QUALITY CONTROL DURING ASSEMBLY OF PARTS:
INSPECTION AND TESTS
(A) INSPECTION DURING MANUFACTURE –
(B) INSPECTION DURING FABRICATION
(C) INSPECTION OF COMPLETED PRESSURE VESSELS
TESTING OF PRESSURE VESSEL
BENEFITS OF PRESSURE VESSEL TESTING
METHODS OF PRESSURE VESSEL TESTING
(A) NON DESTRUCTIVE TESTING METHOD
1. VISUAL TEST (VT)
2. LIQUID PENETRANT TEST (PT)
3. MAGNETIC PARTICLE TEST (MT)
4. RADIOGRAPHIC TEST (RT)
5. ULTRASONIC TESTING (UT)
(B) DESTRUCTIVE TESTING METHOD
HYDROSTATIC PRESSURE TESTING
HYDROSTATIC TEST
MINIMUM HYDROSTATIC TEST PRESSURE = 1.3 X MAWP X LSR
PNEUMATIC TEST
AFTER THE PRESSURE TEST
STORAGE CONDITIONS, PACKAGING & LABELING
STORAGE CONDITIONS
TEST AND INSPECTION
GENERAL REQUIREMENT
HUMIDITY CHECK
ROUGHNESS CHECK
THICKNESS CHECK
ADHERENCE CHECK
SHIPPING, HANDLING AND STORAGE OF COATED ITEMS
QUALITY CONTROL
IDENTIFICATION OF PIPES AND EQUIPMENT
GENERAL
(I). BASIC, COLOR CODES, LINE NUMBER AND ARROW FOR PIPING
(II). TAG NUMBER OF EQUIPMENT
(III). COLOR CODING OF PIPING SYSTEMS TABLE
FOR THE COLOR BANDS FOLLOWING TABLE SHALL BE APPLIED:
NOTES FOR COLOR CODING OF PIPING SYSTEMS TABLE
(III). FINISH COLOR SCHEDULE
NOTES FOR FINISH COLOR SCHEDULE
REPAIR OF DEFECTS OR DAMAGED PAINTED SURFACES
REQUIREMENTS
DOCUMENTATIONS
EQUIPMENT, DEVICES & TOOLS FOR APPLICATION, TEST & INSPECTION
(2) FOR SHELL AND TUBE HEAT EXCHANGER
STAGES OF HEAT EXCHANGER FABRICATION
THE MAIN STAGES OF HEAT EXCHANGER MANUFACTURE
ARE AS FOLLOWS:
1. IDENTIFICATION OF MATERIALS
2. EDGE PREPARATION AND ROLLING OF SHELL SECTIONS, TACK
WELDING, AND ALIGNMENT FOR WELDING OF LONGITUDINAL
SEAMS FABRICATION OF SHELL
FIGURE - ROLLING OF SHELL PLATE. (COURTESY OF EDMONTON
EXCHANGER & MANUFACTURING LTD, EDMONTON, ALBERTA, CANADA.)
3. WELDING OF SHELLS, CHECKING THE DIMENSIONS, AND SUBJECTING
PIECES TO RADIOGRAPHY
4. CHECKING THE CIRCULARITY OF THE SHELL AND THE ASSEMBLY FIT,
INCLUDING NOZZLES AND EXPANSION JOINTS
WELDING OF NOZZLES
SUPPORTS
ATTACHMENT OF EXPANSION JOINTS
5. TUBESHEET AND BAFFLE DRILLING
TUBESHEET DRILLING
TUBE HOLE FINISH
DRILLING OF BAFFLES
6. TUBE BUNDLE ASSEMBLY
ASSEMBLY OF TUBE BUNDLE OUTSIDE THE EXCHANGER SHELL
THE END RING METHOD IS EXPLAINED NEXT.
IMPINGEMENT BAFFLES
ASSEMBLY OF TUBE BUNDLE INSIDE THE SHELL
TUBE NEST ASSEMBLY OF LARGE STEAM CONDENSERS
CAUTIONS TO EXERCISE WHILE INSERTING TUBES
ASSEMBLY OF U-TUBE BUNDLE
7. TUBESHEET TO SHELL WELDING
THE END RING METHOD IS EXPLAINED NEXT.
8. TUBE-TO-TUBE SHEET JOINING BY ROLLING/WELDING
VARIOUS METHODS OF TUBE-TO-TUBESHEET JOINT WELDING
WELDING PROCESS
FIGURE: ORBITAL TIG WELDING HEAD—WELDING OF RECESSED TUBE-
TO-TUBESHEET. (COURTESY OF POLYSOUDE S.A.S, NANTES, FRANCE.)
ORBITAL WELDING
ENCLOSED ORBITAL TUBE-TO-TUBESHEET WELDING HEADS WITHOUT
FILLER WIRE
OPEN TUBE-TO-TUBESHEET WELDING HEADS WITH OR WITHOUT FILLER
WIRE
WELDING EQUIPMENTS
SPECIFIC REQUIREMENTS OF TUBES AND WELD PREPARATIONS
WELDING OF FLUSH TUBES
WELDING OF FLUSH TUBES WITH ADDITION OF FILLER WIRE
WELDING OF PROTRUDING TUBES
WELDING OF RECESSED TUBES
INTERNAL BORE WELDING
INTERNAL BORE WELDING BEHIND THE TUBESHEET
FIGURE- INTERNAL BORE WELDING BEHIND THE TUBESHEET BY
TIG WELDING. (COURTESY OF POLYSOUDE S.A.S, NANTES, FRANCE.)
WELDING OF SECTIONS OF UNEQUAL THICKNESS
WELDED MOCK-UPS
INSPECTION OF TUBE-TO-TUBESHEET JOINT WELD
LEAK TESTING OF TUBE-TO-TUBESHEET JOINT
TEMA STANDARDS ON TESTING OF TUBE-TO-TUBESHEET JOINTS
BRAZING METHOD FOR TUBE-TO-TUBESHEET JOINTS
(10) HEAT TREATMENT
1. WITH TUBES WELDED IN ONE TUBESHEET AND LEFT FREE IN
THE OTHER TUBESHEET
THE PROCEDURE ADOPTED IS AS FOLLOWS:
2. BOTH ENDS OF THE TUBES WELDED WITH TUBESHEETS
HEAT TREATMENT: GENERAL REQUIREMENTS
ASSEMBLY OF CHANNELS/END CLOSURES
BOLT TIGHTENING
11.TESTING
ASME CODE REQUIREMENT
TEMA STANDARD REQUIREMENT
(A) HYDROSTATIC TESTING
HYDROSTATIC TESTING PROCEDURE
HYDROSTATIC TEST FLUID
(B) PNEUMATIC TESTS
PNEUMATIC TESTING PROCEDURE
(12) PAINTING
(13) MAKING UP CERTIFICATES
(3) FABRICATION PROCESS OF CROGENIC TANK
FABRICATION PROCESS
MATERIAL OF CONSTRCTION
FABRICATION
1. FORMING:
2. WELDING:
3. SURFACE TREATMENT:
CLEANING OF STAINLESS STEEL SURFACES
(A) MECHANICAL CLEANING:
(B) DEGREASING:
(C) PICKLING:
(D) PASSIVATION:
CLEANING OF CARBON STEEL SURFACES
(4) PAINTING:
(5) TESTS
(A) ULTRASONIC TEST:
(B) RADIOGRAPHIC TEST:
(C) PRESSURE TEST:
(D) LEAK TEST:
(E) PERFORMANCE TEST:
(6) INSPECTION
(4) HEAT TREAT MENT
(A) HEAT TREATMENT OF PRESSURE VESSEL
THE FOLLOWING EQUIPMENT AND CONSUMABLES WILL BE USED:
PROCEDURE
TEMPERATURE RECORDING
TEMPERATURE CONTROL:
NOTIFICATION OF HEAT TREATMENT
RECORDS:
(B) HEAT TREATMENT OF SHELL AND TUBE TYPE HEAT EXCHANGER
THE PROCEDURE ADOPTED IS AS FOLLOWS:
HEAT TREATMENT: GENERAL REQUIREMENTS
POSTWELD HEAT TREATMENT
OBJECTIVES OF HEAT TREATMENT
TYPES OF HEAT TREATMENT
EFFECTS OF CHANGES IN STEEL QUALITY AND PWHT
ASME CODE REQUIREMENTS FOR PWHT
QUALITY CONTROL DURING HEAT TREATMENT
METHODS OF PWHT
EFFECTIVENESS OF HEAT TREATMENT
DEFECTS DUE TO HEAT TREATMENT
NDT AFTER PWHT
(A) PAINTING SYSTEMS FOR PRESSURE VESSEL
APPLICABLE PAINT SCHEDULE SYSTEMS (EXTERNAL)
(B). APPLICABLE PAINT SCHEDULE SYSTEM (INTERNAL)
(I) SURFACE PREPARATION
GENERAL
DESCRIPTION ON SURFACE PREPARATION METHODS
(A) DEGREASING
(B) BLAST CLEANING
BLASTING MATERIALS:
(C) POWER OR HAND TOOL CLEANING
HAND TOOL CLEANING:
(D) SURFACE PREPARATION REQUIREMENTS
(II) PAINTING APPLICATION
GENERAL REQUIREMENTS
(III) MIXING
(IV) THINNING
(V) PRIMING
(VI) PAINTING
(B) PAINTING OF SHELL AND TUBE HEAT EXCHANGER
(C) PAINTING OF CRYOGENIC TANKS
MARKET POSITION OF PRESSURE VESSEL
PRESSURE VESSEL MARKET AND TYPE OF PRESSURE VESSEL
TYPES OF PRESSURE VESSEL CONSIDERED IN THE STUDY ARE:
PRESSURE VESSEL MARKET AND END USERS
MAJOR END USERS FOR PRESSURE VESSEL MARKET ARE:
KEY DEVELOPMENTS: PRESSURE VESSEL MARKET
BY MATERIAL, THE STEEL ALLOY SEGMENT IS EXPECTED TO MAKE THE
MOST SIGNIFICANT CONTRIBUTION TO THE PRESSURE VESSEL MARKET
DURING THE FORECAST PERIOD.
KEY MARKET PLAYERS
MATERIAL INSIGHTS
PRODUCT INSIGHTS
END-USE INSIGHTS
REGIONAL INSIGHTS
SHELL & TUBE HEAT EXCHANGERS MARKET POSITION
END-USE INSIGHTS
REGIONAL INSIGHTS
KEY COMPANIES & MARKET SHARE INSIGHTS
CRYOGENIC TANKS MARKET POSITION
CRYOGENIC LIQUID INSIGHTS
APPLICATION INSIGHTS
END-USER INSIGHTS
KEY COMPANIES & MARKET SHARE INSIGHTS
PLANT LAYOUT
SUPPLIERS OF PRESSURE VESSEL
SUPPLIERS OF HEAT EXCHANGER
SUPPLIERS OF CRYOGENIC TANKS
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF M.S PLATE
SUPPLIERS OF M.S. PIPE
SUPPLIERS OF MILD STEEL ROD (M.S ROD)
SUPPLIERS OF SS SHEET
SUPPLIERS OF SS BAR
SUPPLIERS OF SS PIPE AND TUBE
SUPPLIERS OF HYDROCLORIC ACID
SUPPLIERS OF MIG WELDING WIRE ELECTRODE
SUPPLIERS OF COATING AND PAINTING MATERIAL
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF POWER PRESS
SUPPLIERS OF SHEARING MACHINE
SUPPLIERS OF ROLLING MACHINE
SUPPLIERS OF BENDING MACHINE
SUPPLIERS OF UNCOILING MACHINE
SUPPLIERS OF SHEET LAVELING MACHINE
SUPPLIERS OF PUNCHING PRESS
SUPPLIERS OF CNC PLASMA CUTTING MACHINE
SUPPLIERS OF MILLING MACHINE
SUPPLIERS OF CNC LATHE MACHINE
SUPPLIERS OF BOARING MACHINE
SUPPLIERS OF GRINDING MACHINE
SUPPLIERS OF SEAM WELDING MACHINE
SUPPLIERS OF SPOT WELDING MACHINE
SUPPLIERS OF MIG WELDING MACHINE
SUPPLIERS OF BUTT WELDING MACHINE
SUPPLIERS OF POWDER COATING MACHINE
SUPPLIERS OF PAINTING EQUIPMENTS
SUPPLIERS OF PAINTING BOOTH
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF DG SETS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
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