FACT ENGINEERING WORKS (FEW)

FEW is an Indian Company, which has been providing reliable engineering and fabrication services to fertilizer, chemical , petrochemical and engineering firms. FEW is the division of the Fertilizers And Chemicals Travancore Ltd. (FACT), a leading Public Sector giant with interests in fertilizers, petrochemicals, engineering design, consultancy and fabrication.

PRODUCTS PRODUCED
Products at Workshop
Heat Exchangers Pressure Vessels Columns & Towers Storage Tanks in ferrous & non-ferrous metals Reactors

Products at Site
Dry seal/wet seal industrial gas holders of vertical / spiral lifts Plant piping and offshore piping for process industries Spillway shutters, pen stock pipes large size storage tanks, vessels and other items of process industries Cross country piping Oil terminals on turnkey basis Columns, Towers Floating roof tanks Refinery shut down inspection services

Codes in Practice At FEW all fabrication is done in accordance with the following internationally recognized codes:
ASME Section VIII Div.1 ASME Section VIII Div.2 TEMA R, C&B AP1650 BS5500 AP1620 IS2825-1969 IS803

Inspection Agencies All Major third party inspections at FEW are carried out by agencies like: Lloyd's Register Industrial Services(LRIS) Bureau Veritas (BV) Indian Register of Shipping (IRS) Bax Counsel Inspection Bureau Pvt. Ltd. (BCIBPL) Directorate of Factories & Boilers FACT Engineering & Design Organization (FEDO) Projects & Development India Ltd. (PDIL) Engineers India Ltd. (EIL)

ORGANIZATIONAL CHART

Departmentalization is the efficient and effective grouping of jobs into meaningful work units to coordinate numerous jobs for the expeditious accomplishment of the organizations objectives. This creates flexibility, adaptability and unit of action within the firm. The various departments in FEW are as follows: Design Department Production Department
Commercial Department

Materials Department
Planning and Inspection Department

Plate Bending machines of Capacities

Up to 60mm thick x 2.5m width Up to 40mm thick x 2.5m width Up to 36mm thick x 3.0m width Up 20mm thick x 2.5m width

 CNC Drilling Machine

Table working area: 1200mm x 1200mm Solid drilling capacity in steel: 50mm hole diameter Weight carrying capacity of table: 2000kg Table travel X axis: 1500mm Spindle head travel - Y axis : 1300 Spindle vertical travel - Z axis : 400mm

Radial Drilling Machines

Submerged Arc Welding Units Automatic Welding Units TIG Welding MIG Welding

 Pinch Press - 400 T Section Bending Machine

 Guillotine Shear Lathes & Shaping

Machinery

Press Brake

Self aligning self centering rotators

Sand Blasting Facility

Hydraulic Tube Pulling Units Hydraulic Testing Unit Hydraulic Pipe Bending Hydraulic testing units Vacuum testing facility Air plasma & Argon plasma cutting units

 Heat treating furnace

FEW has its own stress relieving furnace of size 10.7m x 3.85m x 3.675m certified and calibrated. This furnace can stress relieve almost all equipment in a large process industry. The stress relieving furnace is electrically heated with provisions for six thermocouples.

QUALITY CONTROL DEPARTMENT

Quality policy Few is committed to 1) Customers satisfaction through quality products and services 2) Up gradation of technology and engineering skills 3) Continual improvement of the management system

 FEW conduct Non Destructive Testing and Destructive tests such as 1) Dye penetrant tests, 2) Magnetic particle tests, 3) X-ray and Gamma ray radiography, 4) Ultrasonic tests, 5) Tensile and bend tests.

 Codes in Practice ASME Section VIII , Div 1 - Rules for construction of pressure vessels ASME Section V - Non Destructive Examination ASME Section IX - Qualification standard for welding procedures , elders, Brazers ,welding and brazing operators ASME Section II , part C - Specification for welding rods, electrodes and filler materials . AWS - Welding procedure and Qualification

WELDING PROCEDURE SPECIFICATION(WPS) & PROCEDURE QUALIFICATION RECORD(PQR)

 For every welding job whether it is fabrication or repair welding procedure must be drawn up in advance .Next the procedure must be qualified by carrying out actual procedure qualification. WPS is the document which list the parameters to be used in construction of weldments in accordance with the applicable code requirements. WPQ is the Welder performance qualification as per WPS and PQR. These records shall be accessible to authorized inspector.

QUALITY ASSURANCE PLAN (QAP)

Before the commencement of fabrication the QAP must be accepted by the Client/Consultant/Third party Inspectors. The following are the major features that forms part of a QAP for pressure vessels. 1) Review of WPS and PQR 2) Raw material identification a) Plates for shells ,cones, pads b) Dish end, top ring ,baffle plates c) Pipe for nozzles, flanges, elbow

3) Dimensional check up prior to cutting 4) Fit ups of weld joints a) L/S of shell ,cone, dish, skirt b) C/S of shell ,cone, dish, skirt c) Nozzle pipe to flanges , elbow d) Nozzle to shell and cone ,dish e) Access hole to skirt f) Lifting lugs, name plate bracket 5) ) Welding a) L/S of shell ,cone, dish, skirt b) C/S of shell ,cone, dish, skirt c) Nozzle pipe to flanges , elbow d) Nozzle to shell and cone ,dish e) Access hole to skirt f) Lifting lugs, name plate bracket

6) Orientation check of nozzles 7) NDT- DPT,UT,RT 8) Pneumatic testing of nozzles 9) Stress relieving 10) Hydrotesting 11) Painting 12) Pickling and passivation 13) Final inspection and issue of inspection release note.

CONCLUSION
The Fact Engineering Works is a well reputed Indian Company which has been providing reliable engineering and fabrication services for over three decades to fertilizer, chemical and petrochemical and engineering firms. FEW's Design, Fabrication and Quality Assurance Department are manned by a group of engineers and technicians with hands-on experience in the fields of fertilizers and petrochemicals. Through this In-Plant training it was able to fulfill the objective of the study. Detailed study on the processes was made possible by giving emphasis on the practical side of the theory. All together it was a good experience to see the company and various processes carried out in the shops and the various functions of the company.

REFERENCE
1]. www.fact.co.in [2]. www.scribd.com [3]. www.google.com [4]. www.wikipedia.org