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Petal to petal long seam

welding by SAW
Eliminating need of heavy duty
Turn Table

Description

Task in hand

Project No.s
Customer
Dish end diameter
Total kg deposition
Planned process
Planned resources

- Welding of 6 Dishends
(Petal to Petal long seam) of
the following jobs in MFS1
- 23199 A, B & C
- KJV
- 4000mm, Weight - 12 Tons
- 550 kgs.
- SAW
- Column & Boom,
Aranson positioners
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Constraints
Bottleneck - One Aranson Positioneer available for
welding 6 DEnd long seams.
Frequent breakdowns of the turn table during the first
DEnd welding adversely affected manufacturing
schedule .
PTC qualified for SAW welding.
MMA welding would have been a costlier option.

Conceptual stage
Requirement:- Eliminate need of Turn table
Fixture

Hemispherical D/E

DEnds will be connected together and positioned inside


the fixture. Long seams to be welded by placing the DEnd
along with fixture on Tank Rotators.
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Initial Preparation:

Two Dished Ends are positioned on top of each other and


joined together to get a perfect Sphere while maintaining the
trimming lines parallel to each other.
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Design Features

Two half Rings bolted


together.(Rings were
available)
Segments cut to suit
the Dend outer profile.

Clamping bolts to
hold the D/E firmly
in position.
Pipes connecting
the two rings.

Long seam welding in progress.

One long seam is welded at a time , 4 seams of Dends can be welded in


one set up.To weld 6+ 6=12 L/S , set up needs to be changed three times. 7

Long seam welding in progress.

Long seams
welded

Long seams
positioned
for welding.

After welding 4 long seams the bolts on the upper half of the fixture
are loosened to make the Dend free inside fixture and the Dend is
rotated to set the next set of 4 seams for welding.
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Further Development.
Gap between two
DEnds.

SAW Boom

Welding Head
Back Chip welding of Petal to Petal long seam by SAW
using the same fixture which otherwise would have
been welded by SMAW.
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Contribution:
Conceptualization , design & manufacturing.
(Production Engineering HEW)
- R.V. Mahajan
- K. A. Khochare

Execution:
(MFS 1 - Service and Assembly shop)
- R. N. Parikh
- A. G. Surve

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Future Plan
Similar design will be adapted for the following
DEnds with improvised fixture design to reduce
the set up time.
1. 23200

- Dia. 5140 x 53 thick - 20 T

2. 23222

- Dia. 3864 x 50 thick - 9.5T

3. 23211

- Dia. 3330 x 40 thick - 4.9T


Total 6 hemispherical D/Es

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