Manufacturing Process Plan

Ultra Engineers, Pune. INDIA

Sr No

Stages

Customer:
PO No:

Process

Raw material cutting

Cutting

First fiuup

Fit up and welding

Second Fit up

Fit up and welding

GE- Waukesha
117624

Photo

Sr No

Stages

Process

Third Fit up

Fit up and welding

Fourth Fit up

Fit up and welding

Fifth Fit up

Fit up and welding

Photo

Sr No

Stages

Process

Sixth Fit up

Fit up and welding

FinalFitup

Fit up and welding

Photo

Sr No
9

Stages
Dimensional Inspection

Process
Inspection

10

Machining

machining

11

Cleaning

Cleaning

12

Corrosion Protection

Blasting and
painting

13

Final Inspection

Inspection

14

Shipment

Packing and dispatch

Photo

MPP No:
UE/WED/MPP/OP/07

Process Plan

Rev No: 00

Description : Sump Oil Assembly

Drawing. No. : A280014B

Date: 26.Dec 2012

Details
1)Cut all parts as per Cutting Plan/layout No.
2)Clean all parts for surface scales, burs,sharp edges,cutting slags etc..
3)Inspect the child part as per Process drawing.
1)Part No. 1, thick 5mm bend and edge preparation as per drawing.
2)Part No. 3, 5 mm thick as per drawing edge preparation done and fit up in part
no 1 as per drawing.
3)Part No. 10, 32 mm thick(with m/c tolerance) fit with part no 1 as per drawing.
4)Check subassembly as per drawing.
5)Weld Part no 1 and part no 10 - fillet 5mm
6)Weld- Part no 3 Qty 4 and part no 1 -fillet 5 mm
7)Part no 4 ,thick 5mm fit up on part no 3 as per drawing, weld fillet 4 and 68 mm
length.
8)Check all welding as per drawing & Weld Plan.
9)Finish the subassembly for defect if any.

1)Part no 9 Pipe, Dia 108x 3.6 mm thk drilling as per drawing.

2)Part no 7 Pipe Dia 38x 3.2mm thk Qty-13 bending as per drawing
3)Check bend profile as per drawing with template.
4)Part No 7 Qty-13 fit up on part no 9 as per drawing.
5)Check fit up as per drawing.
6) Part no 7 and 9 welding fillet 3 mm with complete joint penetration.
7)Check all welding as per drawing & Weld Plan.
8)Finish the subassembly for defect if any.

Details
1)Part No 6 , 5mm thk. bend as per drawing.
2)Assemle Part no 6 on sub-assembly of Part 9 and 7.
3)Part No 8, 22 mm thk Qty-13 fit up on part 7 as per drawing.
4)Check all fit up as per drawing.
5) welding with 3 mm fillet all around on both face.
6)Check all welding as per drawing & Weld Plan.
7)Finish the subassembly for defect if any.

1)Assemble Part No 13,Pipe Dia 133x 4.8 mm as per drawing.

2)Welding as per Drawing
3)Machining as per Drawing.
4)Sub-assembly check as per drawing
5)Finish the subassembly for defect if any.

1)Part 13 fit up in First fit up as per drawing.

2) Part 13 welding with part 10 with inside tack welding and outside 4 mm fillet.
3)Part no 2, 32mm (with ma/c stock) fit up in part no 1 as per drawing.
4) Inside 3.5 mm fillet and outside 5 mm groove weld as per Weld Plan.
5) Part No 11, Pipe Dia 108 x 4mm thk fit up in first fit up as per drawing.
6)Part no 11 welding with part no 2 and 10 with inside tack welding and outside 5
mm grove welding as per weld Plan.
7)Check sub assembly for dimension as well as for welding as per drawing & Weld
plan.

Details
1) Part No 5 thick 38.1 mm Qty-2 Nos fit up on fifth fit up as per drawing.
2) Part 5 and 1 welding of 5 mm fillet inside and outside grove weld (convex) as
per drawing.
3)Check welding as per drawing & Plan.

1) Fit up no third fit up on fit up no 6 as per drawing

2)Welding of part no 9 on part no 10 and 2
3)Inside tack weld and outside 5 mm fillet all around.
4)welding of Part no 6 and 5 with 10 mm grove weld
5)All welding check as per drawing & Plan
6)Finish the complete assembly for defect if any.

Details
1)Before m/cing Inspect complete assembly for dimensions as per drawing.
Machining as per drawing
1) Align the component for machining. Check m/cing stock.
2) Check the tooling as per programm.
3) Complete the m/cing as per machine plan.
4) 1 st Set up- Top rail machining , Flanges machining.
2nd Setup- Part No. 2 & 10 Machining.
3) Clean the component for burrs, shart edges etc..
4) Inspect the component for dimensions.

Clean the component throughly for burss, forign matreial,

dust, particles, chips etc..
1)Blasting and Painting as per Spect.
2)Inspection for Surface prepation & Paint adhesion.
1) Inspect the component for dimension & visual apperance.
1)Packing and dispatch as per spect.

Weld Map
Ultra Engineers, Pune
Customer
PO No.

Sr.
No
A

:HALLIBURTON
: 4512263003 Rev. 00

Description
Drawing No.

: Power end case, Q10, weldment

: D00651285 Rev E, Sheet 2, 3 of 4

Weld Map No
Rev. No

Joint Details
Joint Decription

Joint
ID

Joint Design

Position

Base Mater
Ref Sketch

Part No.

Thickness

T1 & T2 0.5 inch

1St Weld Fitup (sub-assembly):

Fitup 1 : Part No 4 to 6

W1
W2

u groove (CJP) outside

with backing run as
square groove weld
(Convex weld)

1G

4 to 6

W3

Single bevel weld on other

side

1G

1 to 7

T1- 4 inch,
T2- 1.25
inch

W4

Fillet weld 0.25 inch on

other side

2F

1 to 3

T1-4 inch,
T2- 0.5 inch

W5

Fillet weld 0.5 inch on

other side

2F

1 to 8

T1-4 inch,
T2- 1 inch

2nd Weld Fitup :

B

Fitup 2 : Part No 1 to 7

Fitup 3.1 : Part No 1 to 3

Fitup 3.2 : Part No 1 to 8

Plate To Plate

Weld Map
Ultra Engineers, Pune
Customer
PO No.

Sr.
No

:HALLIBURTON
: 4512263003 Rev. 00

Joint Decription

Joint
ID

W6,
W7,
W8

Joint Design

W6-Single bevel with

additional fillet weld of
0.25 inch,
W70.25 inch fillet weld on
arrow side,
W8- Single bevel with
additional fillet weld of
0.25 inch

W9 & W10- Single bevel

W9, with additional fillet weld
W10, 0.5 inch,
W11 W11- 0.5 inch fillet weld
on arrow side

: Power end case, Q10, weldment

: D00651285 Rev E, Sheet 2, 3 of 4

Weld Map No
Rev. No

Joint Details

Description
Drawing No.

Position

Base Mater
Ref Sketch

Part No.

Thickness

1G, 2F

1 to 3

T1- 4 inch,
T2- 0.5 inch

1G, 2F

1 to 8

T1- 4 inch,
T2- 1 inch

2F

1 ith 4 & 6

T1-4 inch
T2-0.5 inch

4th Weld Fitup :

Fitup 4.1 : Part No 1 with fitup 1

(Part No. 4 & 6)

W12
W13

0.5 inch fillet weld on

other side (Inside)

Weld Map
Ultra Engineers, Pune
Customer
PO No.

Sr.
No

:HALLIBURTON
: 4512263003 Rev. 00

Description
Drawing No.

: Power end case, Q10, weldment

: D00651285 Rev E, Sheet 2, 3 of 4

Weld Map No
Rev. No

Joint Details
Joint Decription

Fitup 4.2 : Fitup 4.1 to Part No. 5

Joint
ID

Joint Design

W14-CJP single bevel with

W14, W15- 0.5 inch fillet weld
W15, on other side (Inside),
W16 W16- U groove (CJP) on
other side (Inside)

Position

1G, 2F

Base Mater
Ref Sketch

Part No.

Thickness

1 to 5

T1- 4 inch,
T2- 1 inch

W17, W17, W18- CJP weld, W19W18, Partial penetration weld

W19 with convex profile

1G

T1-4 inch
1 to 4 & 6, T2-0.5 inch,
6 to 7
T3-1.25
inch

10

W-20 U groove (CJP),

W20, W21- CJP single bevel with
W21, flush grind,
W22 W22- additional fillet weld
on W20,

1G, 2F

W20, W22- T1-0.5 inch,

4 to 5,
T2-1 inch,
W21- 1 to 5 T3- 4 inch

1G
2F

T1-0.25
inch
1 & 4 to 2
T2-4 inch,
T3- 0.5 inch

11

5th Weld Fitup :

Fitup 5 :
Part No 2 with Fitup 4

W23- Single bevel weld

with additional fillet weld
W23,
of size 0.38 inch,
W24
W24- 0.25 inch
fillet weld

ULTRA ENGINEERS
Rev No : 00
Date: 30 Dec 2015

: UE/WM/DW/ OP/02-5
: Rev. 00 dtd 30.12.2015

No

e Material
Grade

WPS NO.

ASTM A514
to ASTM
A514

ASTM A514
to ASTM
A514

UE/WPS/AWS/GMAW/2G/24

ASTM A514
to ASTM
A514

UE/WPS/AWS/GMAW/2G/21

ASTM A514
to ASTM
A514

UE/WPS/AWS/GMAW/2G/21

ULTRA ENGINEERS
Rev No : 00
Date: 30 Dec 2015

: UE/WM/DW/ OP/02-5
: Rev. 00 dtd 30.12.2015

No

e Material
Grade

WPS NO.

ASTM A514
to ASTM
A514

UE/WPS/AWS/GMAW/2G/21

ASTM A514
to ASTM
A514

UE/WPS/AWS/GMAW/2G/24

ASTM A514
to ASTM
A514

UE/WPS/AWS/GMAW/2G/21

ULTRA ENGINEERS
Rev No : 00
Date: 30 Dec 2015

: UE/WM/DW/ OP/02-5
: Rev. 00 dtd 30.12.2015

No

e Material
Grade

WPS NO.

ASTM A514
to ASTM
A514

UE/WPS/AWS/GMAW/2G/21

ASTM A514
to ASTM
A514

UE/WPS/AWS/GMAW/2G/21

ASTM A514
to ASTM
A514

UE/WPS/AWS/GMAW/2G/21

ASTM A514
to ASTM
A514

UE/WPS/AWS/GMAW/2G/21