GENERAL WORK FLOW

FABRICATION PROCESS OF PRESSURE VESSEL & HEAT

EXCHANGER

Rolling,
Marking Bending,
Receiving
and Drilling,
Material
Cutting Forming, etc

Inspection Welding Fit Up,

and Testing Assembling

Sand Blasting, Packing, FINISH

Painting Delivery

By : Sukiyatno_2014
 The material test certificates
shall be reviewed in accordance
with the applicable job
specification and ASME/ASTM
Code.
Item to be verified :

- Chemical composition
- Mechanical properties
- Heat treatment
- Material specification (SA516-70,etc.)
- Plate heat No.
 HEAT NUMBER

A heat number is an identification number that is

stamped on a material plate after it is removed from
the ladle and rolled at a steel mill.
ASTM A105 4" X CLASS 1500 WNRF

IDENTIFICATION
MATERIAL
IDENTIFICATION
MATERIAL
MARKING PROCESS OF 
PLATE MATERIAL TO ENSURE 
THE MATERIAL WILL BE CUT 
AS PER REQUIRED SIZE IN 
SHOP DRAWING / CUTTING 
PLAN
PLASMA CUTTING FOR 
CUTTING PLATE MATERIAL
ROLLING 
MACHINE
ROLLING OF SHELL 
PLATE
HYROLIC BENDING MACHINE

USED FOR BENDING PROFILE MATERIALS i.e: H‐BEAM, 
ANGLE, etc.
 PIPE BENDING (MANUAL)

PIPE BENDING MACHINE
CNC drilling machine is numerically 
controlled to insure the accuracy require for 
baffles and tube sheet heat exchanger
 RADIAL DRILLING 
MACHINE

TUBE SHEET FOR SHELL & 
TUBEHEAT EXCHANGER
COLD FORMING HEAD

COLD FORMING HEAD 
MACHINE
SPINNING MACHINE 
 FIT UP & ASSEMBLY

SHELL & HEAD ASSEMBLY

 FIT UP & ASSEMBLY

SADDLE ASSEMBLY
Saddle assembly to be done after shell & head
completely assembled and welded
FIT UP & ASSEMBLY

NOZZLE ASSEMBLY
Nozzle assembly to be done
after shell & head completely
assembled and welded
 WELDING

Common Welding Method to be used for

Pressure Vessel / STHE

 SMAW (Shielded Metal Arc Welding)

 SAW (Submerged Arc Welding)
 GTAW (Gas Tungsten Arc Welding) / TIG
(Tungsten Inert Gas)
 FCAW (Flux Core Arc Welding)
(Not recommended by some Owner i.e:
SHELL, etc.)
 WELDING
SMAW (Shielded Metal Arc Welding)
SAW (Submerged Arc Welding)
WELDING
 WELDING
SAW (Submerged Arc Welding)
 WELDING
GTAW (Gas Tungsten Arc Welding) /
Tungsten Inert Gas (TIG)
 WELDING
GTAW (Gas Tungsten Arc Welding) /
Tungsten Inert Gas (TIG)
FCAW (Flux Core Arc Welding) Process WELDING

FCAW Machine
 WELDING
SMAW SMAW

/GTAW /GTAW

SMAW WELDING PROCESS

(GTAW)
APPLICATION FOR
PRESSURE VESSEL
SMAW
(SAMPLE)

SAW

SAW

SAW
(GTAW)
 WELDING

Some items to be conformed before Welding Process :

Check of preheats and interpass temperature (if required)

Check of qualified welder, welding equipment and welding
material.
Check welding rod and welder qualification according to
applicable WPS.
Check dimensional, misalignment, beveling, welding gaps,
surface weld cleaning condition, etc.
Etc.
 WELDING

SHOW MOVIE

COMPLETED VESSEL ASSEMBLY AND READY

FOR HYDRO TEST
INSPECTION & TESTING ACTIVITIES: INSPECTION
 MATERIAL INSPECTION & TESTING
 NON-DESTRUCTIVE EXAMINATION (NDE)
 RT (Radiography Test)
 UT (Ultrasonic Test)
 PT (Penetrant Test)
 MT (Magnetic Test)
 PMI (Positive Material Identification)
 DESTRUCTIVE EXAMINATION
 Impact Test
 Hardness Test
 Tension Test
 Bending Test
 VISUAL/DIMENSION INSPECTION
 ROLLING/FIT UP INSPECTION
 SURVEILLANCE WELDING INSPECTION
 HYDROSTATIC TEST/PNEUMATIC TEST
 INSPECTION
TEST REPORT / MATERIAL CERTIFICATES
REVIEW & TESTING
 INSPECTION
& TESTING
NON DESTRUCTIVE EXAMINATION

RADIOGRAPHY
TEST (RT)

Radiographic testing is a non-destructive testing of

components and assemblies that is based on differential
absorption of penetrating radiation- either electromagnetic
radiation of very short wave-lengths or particulate radiation
by the part or test piece being tested
 INSPECTION
& TESTING
NON DESTRUCTIVE EXAMINATION

Ultrasonic Test (UT) :

High frequency sound waves that are introduced
into the material being tested are used to detect
surface and sub-surface flaws
 INSPECTION
& TESTING
NON DESTRUCTIVE EXAMINATION

DYE PENETRANT TEST (PT)

Liquid or dye penetrant testing is a non –destructive
method for finding discontinuities that are open to the
surface of solid and essentially non-porous materials.
 INSPECTION
& TESTING
NON DESTRUCTIVE EXAMINATION
MAGNETIC PARTICLE TEST
(MT)
Magnetic particle testing or MPT is a
nondestructive testing method for locating
surface and near surface discontinuities in
ferromagnetic materials

Magnetic particle inspection methods will

work only on ferromagnetic materials.
 INSPECTION
& TESTING
NON DESTRUCTIVE EXAMINATION

POSITIVE MATERIAL
IDENTIFICATION (PMI)

Use to determine the elements in Carbon Steel, Alloy Steel

and Stainless Steel. Ferrous and Non Ferrous materials
 INSPECTION
& TESTING
DESTRUCTIVE EXAMINATION

IMPACT TEST
The Charpy impact test, also known as the Charpy V-notch test, is a
standardized high strain-rate test which determines the amount of energy
absorbed by a material during fracture.
The test was developed around 1900 by S. B. Russell (1898, American) and G.
Charpy (1901, French).
 INSPECTION
& TESTING
HARDNESS TEST
DESTRUCTIVE EXAMINATION

Hardness is a measure of how resistant solid matter is to

various kinds of permanent shape change when a force is
applied. Hardness is dependent on ductility, elastic,
stiffness, plasticity, strain, strength, toughness,
viscoelasticity and viscosity.

There are a large number of harness testing methods

available (e.g. Vicker, Brinell, Rockwell, Meyer and Leeb).
 TENSILE TEST INSPECTION
& TESTING
DESTRUCTIVE EXAMINATION

Tensile test is most frequently performed to determine mechanical properties.

Information on various tensile properties like proportional limit, elastic limit, yield
point, yield strength, ultimate strength, breaking strength, proof stress, percent
elongation, percent reduction in area and modulus of elasticity is given in this article.
 INSPECTION
BENDING TEST & TESTING
DESTRUCTIVE EXAMINATION

Bending test provides values for the

modulus of elasticity in bending, flexural
stress, flexural strain and the flexural
stress-strain response of the material.
INSPECTION
& TESTING
 INSPECTION
HYDROSTATIC TEST & TESTING

To Qualify Newly Manufactured of Pressure vessel

 Proof Pressure test
 Leak Detection
 INSPECTION
HYDROSTATIC TEST
& TESTING
 Sand Blasting, 
Painting

Abrasive blasting Purposes :
 Smooth a rough surface
 Roughen a smooth surface
 Shape a surface
 Or remove surface contaminants. 
 Sand Blasting, 
Painting
Main purpose of painting is done to protect 
surfaces from the harmful effects of corrosion 
that can lead to drastic reduction in the metal life.
 Sand Blasting, 
Painting
PULLING TEST

THICKNESS 
CHECK
The following JGC’s Procedure shall be followed prior delivery :
 Specification for Instruction of Rust Prevention
 Surface Preparation
 Rust Prevention Treatment
 Etc.
 Project Shipping and Packing Instruction to Vendor
 Packing Requirement
 Marking Requirement
 Documentation, etc.
RUST PREVENTION :
To protect metal and prevent from corrosion

Interior Rust Prevention :

(1) Vapor Phase Inhibitor (VPI) / Volatile Corrosion Inhibitor (VCI)
(2) Dry Inert Gas (Nitrogen)
(3) Desiccant (approx. 500g/m3 or Manufacturer’s recommended)