SUPERVISED INDUSTRIAL TRAINING REPORT

IKAN Engineering (Pvt.) Ltd

BSc MECHANICAL ENGINEERING TECHNOLOGY

SUBMITTED BY
Ghulam Muhammad
2016-GCUF-03505
59068

Training Period
06-02-20 to 06-05-20

DEPARTMENT OF MECHANICAL ENGIEERING

TECHNOLOGY GOVERNMENT COLLEGE
UNIVERISITY FAISALABAD

2020
SUPERVISED INDUSTRIAL TRAINING REPORT
IKAN Engineering (Pvt.) Ltd

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD

OF THE DEGREE OF

BSc MECHANICAL ENGINEERING TECHNOLOGY

SUBMITTED TO

THE FACULTY OF THE MECHANICAL ENGINEERING DEPARTMENT

GOVERNMENT COLLEGE UNIVERISITY FAISALABAD

SUBMITTED BY
NameofStudent RollNo.
GhulamMuhammad 59068

Training Period
06 02-2020 to 06-05-2020

GOVERNMENT COLLEGE UNIVERISITYFAISALABAD

 CERTIFICATE

I hereby certify that I have completed the Tweleve weeks Training in partial fulfillment of the
requirements for the award of BSc MECHANICAL ENGINEERING TECHNOLOGY .I did my
training in IKAN Engineering (Pvt.) Ltd from06-02-2020 to 06-05-2020
.

Signature of Student
Ghulam Muhammad 59068

Examined by:

Engr. TahirAbbas

INCHARGE/HOD
Department of MechanicalEngineering
Technology
 Acknowledgments

Simply put, I could not have done this work without the lots of help I received cheerfully from
whole IKAN Engineering Services Private Ltd. The work culture in IKAN really motivates.
Everybody is such a friendly and cheerful companion here that work stress is never comes in
way. I would specially like to thank Dy. Manager Mr. Afzal for providing the nice ideas to
work upon. Not only did they advise me, but listening to their discussions in Specific
departments meeting have evoked a good interest in Image analysis.
Table of Contents
1 Introduction of IKAN Engineering(Pvt.)Ltd ............................................................................. 9
1.1 IKANEngineering ............................................................................................................... 9
1.2 Authorized StampbyASME ................................................................................................ 9
1.3 Address ................................................................................................................................ 9
1.4 Industry ............................................................................................................................... 9
1.5 OperatingSince .................................................................................................................... 9
2 TrainingWork........................................................................................................................... 10
2.1 Departments ...................................................................................................................... 10
2.1.1 MarketingDepartment ................................................................................................ 10
2.1.2 Planning &ManagementDepartment ......................................................................... 10
2.1.3 Design Department: ................................................................................................... 10
2.1.4 Production Department .............................................................................................. 10
2.2 QualityAssurance/QualityControl ..................................................................................... 10
2.3 AccountSection ................................................................................................................. 10
2.4 Clients ............................................................................................................................... 10
2.5 Clients ............................................................................................................................... 11
2.6 MachiningWorkshop ......................................................................................................... 12
2.6.1 MaterialsUsed ............................................................................................................ 12
2.6.2 MachineShop ............................................................................................................. 12
2.7 DrillingShop ...................................................................................................................... 12
2.7.1 Machines&Equipments .............................................................................................. 12
2.8 AluminumWorkshop ......................................................................................................... 12
2.9 Products ............................................................................................................................. 12
2.10 MechanicalEngineering ................................................................................................. 13
2.11 Civil Engineering........................................................................................................... 13
2.12 Telecommunication ....................................................................................................... 13
2.13 Valves ............................................................................................................................ 13
2.13.1 ValvesParts ................................................................................................................ 13
2.13.2 ValveOperators .......................................................................................................... 13
 2.13.3 GateValve .................................................................................................................. 14
2.13.4 Plugvalve ................................................................................................................... 15
2.13.5 Ball Valve .................................................................................................................. 16
2.13.6 Globevalve ................................................................................................................. 18
2.13.7 ButterflyValve ........................................................................................................... 18
2.13.8 Check Valve (Swing or Uni-Flow direction orNon-ReturnValve) ............................ 18
2.13.9 PressureSafetyValve .................................................................................................. 20
2.14 Flanges ........................................................................................................................... 21
2.14.1 Types .......................................................................................................................... 21
2.14.2 Types accordingto face .............................................................................................. 21
2.14.3 Slip on Flanges........................................................................................................... 21
2.14.4 Weld NeckFlanges ..................................................................................................... 22
2.14.5 RaisedFacedFlange .................................................................................................... 22
2.14.6 FlatFaceFlange ........................................................................................................... 22
2.15 Support .......................................................................................................................... 23
2.15.1 SADDLESUPPORT: ................................................................................................. 23
2.15.2 LEGSUPPORT: ......................................................................................................... 23
2.15.3 LUG SUPPORT ......................................................................................................... 23
2.16 Types ofPressureVessels ............................................................................................... 24
2.16.1 Spherical PressureVessel ........................................................................................... 24
2.16.2 Cylindrical PressureVessel ........................................................................................ 24
2.16.3 Uses ofPressureVessels.............................................................................................. 24
2.16.4 PressureVessel Parts .................................................................................................. 25
2.17 Quality Assurance/QualityControl ................................................................................ 25
2.17.1 Responsibilities ofQA/QC Department: .................................................................... 25
2.17.2 Main Function ofQA/QC Department ....................................................................... 25
2.18 Inspection techniques .................................................................................................... 25
2.19 RadiographyTest............................................................................................................ 25
2.19.1 MagneticParticleTesting ............................................................................................ 26
2.19.2 UltrasonicTesting ....................................................................................................... 26
2.19.3 VisualTesting ............................................................................................................. 26
2.20 Welding ......................................................................................................................... 26
 2.20.1 Weld Bead.................................................................................................................. 26
2.20.2 Electric ArcWeldingProcesses ................................................................................... 26
2.20.3 Non-consumable Electrode ArcWeldingProcesses ................................................... 26
2.20.4 Consumable Electrode ArcWeldingProcesses ........................................................... 26
2.21 Types ofWeld Joints ...................................................................................................... 26
2.21.1 ButtJoint ..................................................................................................................... 26
2.21.2 CornerJoint................................................................................................................. 26
2.21.3 EdgeJoint ................................................................................................................... 27
2.21.4 LapJoint ..................................................................................................................... 27
2.21.5 Teejoints..................................................................................................................... 27
2.22 Sand Blasting ................................................................................................................. 27
2.23 AbrasiveGrit Blasting .................................................................................................... 27
2.23.1 Type ........................................................................................................................... 27
2.23.2 Units of Measure ........................................................................................................ 28
2.24 Inspection OfPressureVessels ....................................................................................... 28
2.25 Inspection of MildSteelPlates. ....................................................................................... 28
2.26 MillTest Certificate. ...................................................................................................... 28
2.27 Reviewing the MillTestCertificate ................................................................................ 28
2.28 Services.......................................................................................................................... 29
2.28.1 Dish endformingmachine ........................................................................................... 29
2.29 Galvanizing.................................................................................................................... 29
2.30 Design Department: ....................................................................................................... 29
2.30.1 Responsibilities and Coordination withDesign Engineer .......................................... 29
2.30.2 DesigningSoftware..................................................................................................... 30
2.30.3 Longitudinal and CircumferentialStress Calculation. ................................................ 30
2.30.4 Hoop orCircumferentialStress ................................................................................... 30
2.31 StandardPlate ................................................................................................................. 33
2.31.1 GivenData .................................................................................................................. 33
2.31.2 Calculation for TotalPlateLength............................................................................... 34
2.31.3 RemainingPlateDimension ........................................................................................ 35
2.32 General Arrangement Drawing ..................................................................................... 35
2.32.1 DetailedDrawing ........................................................................................................ 36
 2.32.2 Design Data................................................................................................................ 36
2.32.3 Maximum AllowableWorkingPressure ..................................................................... 37
2.32.4 Design Pressure.......................................................................................................... 37
2.32.5 Minimum Design Metal Temperature ....................................................................... 37
2.32.6 Post Weld Heat Treatment ......................................................................................... 37
2.32.7 Annealing ................................................................................................................... 37
2.32.8 Normalizing ............................................................................................................... 37
2.33 ElectrodeCode ............................................................................................................... 37
2.33.1 Blank Flat Length ofaCylinder .................................................................................... 1
2.34 MarkingTypes.................................................................................................................. 1
2.34.1 Non-DestructiveExamination ...................................................................................... 1
2.34.2 Inspection Techniques ................................................................................................. 2
2.34.3 RadiographyTest .......................................................................................................... 2
2.34.4 MagneticParticleTesting .............................................................................................. 2
2.34.5 UltrasonicTesting ......................................................................................................... 2
2.34.6 VisualTesting ............................................................................................................... 2
1 Introduction of IKAN Engineering (Pvt.)Ltd
1.1 IKANEngineering
Starting from 1991 from a very small construction job has over the past decade progressed
with giant strides to be a world class organization and amongst the top most Engineering firms
of Pakistan, all achieved within a short span of just 16 years.
IKAN Engineering Services Private Limited is an ISO 9001:2008, ISO 14001:2004 ISO
18001:2007 certified organization.
Today we have expanded our services from fabrication to erection, from construction to
turnkey solutions, from buildings to roads and airports, from electrical to telecom and from
trading of Engineering materials to office furnishing.
1.2 Authorized Stamp byASME
S Stamp: Fabrication of Boilers
R Stamp: Repairing of Pressure Vessels
1.3 Address
34-KM Multan Road, Lahore, Pakistan Industrial area in Shamkay Bhattian,
Pakistan. Email:hr@ikan.com.pk
PH: +92 423 5380462-5
Email: ikan@ikan.com.pk
1.4 Industry
Importers/ Distributors/Exporters
1.5 Operating Since
1992
2 Training Work
2.1 Departments
2.1.1 Marketing Department
The Marketing Department plays a vital role in promoting the business and mission of an
organization. It is the Marketing Department's job to reach out to prospects, customers,
investors and/or the community, and create an overarching image that represents your company
in a positive light that is, your brand.
2.1.2 Planning & ManagementDepartment
In organizations, planning is a management process, concerned with defining goals for
company's future direction and determining on the missions and resources to achieve
those targets. To meet the goals, managers may develop plans such as a business plan
or a marketingplan.
2.1.3 Design Department:
Design management is a business discipline that uses project management, design, strategy, and
supply chain techniques to control a creative process, support a culture of creativity, and build a
structure and organization for design.
2.1.4 Production Department
Aims and functions of production department. Production is the functional area
responsible for turning inputs into finished outputs through a series of production processes.

The Production Manager is responsible for making sure that raw materials are provided and
made into finished goods effectively.
2.2 Quality Assurance/Quality Control
QA/QC is the combination of quality assurance, the process or set of processes used to measure
and assure the quality of a product, and quality control, the process of ensuring products and
services meet consumer expectations.
2.3 AccountSection
Part of a company's administration that is responsible for preparing the financial statements,
maintaining the general ledger, paying bills, billing customers, payroll, cost accounting,
financial analysis, and more. The head of the accounting department often has the title of
controller
2.4 Clients
2.5 Clients
• NHA
• EMAARUSAID
• UNICEF
• HMC
• Frontier Work Organization
• NLC
• PSO
• NESTLE
• PEL
• ICI
• Unilever
• Schlumberger
• Pakistan Tobacco Company
• Parco
• Zong
• Siemens
• Ufone
• Mobilink
• Motorola
• BahriaTown
• EngroCorp
• Descon
• SprintGas
• Ericsson
• PowerTech
• Oil & Gas Development CompanyLtd
• MoL
• DGCement
• MadniGas
• HabibConstruction
• SNGPL

2.6 MachiningWorkshop
2.6.1 Materials Used
1. CarbonSteel
2. StainlessSteel
3. High AlloySteel
2.6.2 MachineShop
1. LatheMachine(Vertical/Horizontal)
2. Bending
3. Shaper
4. HydraulicPress
2.7 DrillingShop
1. Radial drillingMachines
2. CNCMachine
2.7.1 Machines &Equipments
1. 1500 Ton Hydraulic PressMachine
2. Overhead Crane 6 Ton Capacity
3. Sand Blasting
2.8 AluminumWorkshop
1. Milling
2. Hydraulic powerpress
3. Lathemachine
4. Shapermachine
5. Powercutter
6. Hydrauliccutter
7. Tabledrill
8. Radial drill
2.9 Products
1. LPG Bowser storagetanks
2. Reactorvessels
3. Pressure vessels of allkinds
4. Bridges,
5. Flyovers
6. Underpass
7. Telecommunication Towers
8. Sign Boards
2.10 Mechanical Engineering
1. Design, fabrication and Supply of 03 Nos. Vertical filterseparators.
2. LPG Transportation Boozers 30 Tons Capacity
3. Installation & Erection of CoalBoilers
4. Relocation of Complete BoilerRoom
5. Civil & Mechanical Works for Fuel Storage Tanks Manufacturing&Installation
6. Installation and Erection of 30 MW Coal Fired PowerPlant
7. Supply, Fabrication & Installation of Steel Structural Bridges (South, Baradam &North)at
LowariTunnel
2.11 CivilEngineering
1. Construction of Flyover Across Railway Crossing, Raiwind City DistrictLahore.
2. Construction of Bridge Over River Ravi for Metro Bus System atLahore
3. Supply, Fabrication & Installation of Steel Structural Bridges (South, Baradam& North)at
Lowari Tunnel including Civil Works Civil Construction Works of BSPL Biomass Boiler
Island Project & Construction of Temporary Building atKasur
2.12 Telecommunication
1. Telenor project on Turnkey Basis, Dir/Chitral
2. Telenor project on Turnkey Basis,Zhob
3. Telenor project, Construction of Cell Sites 1200 Nos including Civil, Mechanicaland
Electricalworks.
2.13 Valves
Valves are used to control and regulate flow of fluid in piping. Many types of valves are used in
the industry.
2.13.1 ValvesParts
1. Disc
2. Seat
3. Body
4. Bonnet
5. Stem
2.13.2 ValveOperators
1. HandLevers
2. Handwheels
3. Chainoperated
4. Pneumatic and hydraulic operated
5. Gearsoperated
6. ElectricMotors
2.13.3 GateValve
Gate valve is mostly used, flat, vertical wedge, or gate, that slides up on down as the valves
hand wheel is turned, designed to be either fully opened or closed, the gate valve should not be
operated in a partially opened/closed position.
2.13.4 Plug valve
Plug valve is used in low pressure application usually in gas service, quarter of the turn
make valve full open/ full close, sealing is done to avoid leakage.
2.13.5 BallValve
Ball valve can be seem in household applications, quarter of the turn make valve full
open/full close, disc is made in the type of ball, it is inexpensive valve used in low flow
application.
Fig (3.7)
2.13.6 Globevalve
Used for throttling process, the design of the globe valve body forces the commodity to change
direction with in the valve itself. This change in the direction creates substantial pressure drop
and turbulence. The globe valve is therefore not recommended when flow resistance and
pressure drop area voided.

2.13.7 ButterflyValve
Quarter of the turn make valve full open/ full close, used mostly for water
service.
The butterfly uses a circular plate or wafer operated by a wrench to control
flow.
They are good for the n-off and throttling service and perform well when
controlling large flow amounts of liquids and gases.

2.13.8 Check Valve (Swing or Uni-Flow direction or Non-Return Valve)

1. Check valve are designed to prevent backflow.
2. Check valves do not use hand wheels to control the flow of a
commodity but instead use gravity and the pressure for the commodity
to operate thevalve.
3. Check valve are often used in safety or precautionaryequipment.
2.13.9 Pressure SafetyValve
They are designed to release excessive pressure that builds up in the
equipment and piping system.
Relief valves are use a steel spring as a means to automatically
open when the pressure reaches an un safe level.
2.14 Flanges
Flanges are used to connect where extensive maintenance is required.

2.14.1 Types
Weld Neck
Slip On
Threaded
Socket welded Flange
Lap Joint Flange
Ring TypeFlange

2.14.2 Types according toface

Raised Face
Flat Face

2.14.3 Slip onFlanges

Slip on flanges are probably the most common type of flanges used in the industry and
used for the low pressure applications.
Cheaper as compared to the weld neck race.
Lighter as compared to weld neck.
2.14.4 Weld NeckFlanges
Weld Neck Flanges have a long tapered hub are often used for high
pressure applications.
Preferred in an environment with extreme temperature conditions.

2.14.5 Raised Faced Flange

High machining cost.
80% utilization in industry.

2.14.6 FlatFaceFlange
Operate at low pressure rating.
More Surface area, less pressure on gasket.
2.15 Support
1. Support is used to bear all the load of pressure vessel, earthquake and windloads.
2. It is considered to be the non-pressurized part of thevessel.
3. There are different types of supports which are used depending upon the size and
orientation of the pressurevessel.

1. Saddlesupport
2. Skirt support
3. Legsupport
4. Lugsupport

2.15.1 SADDLE SUPPORT:

1. Horizontal drums are typically supported at two locations by saddlesupport.
2. It spreads over a large area of the shell to prevent an excessive local stress in the
shellac supportpoint.
3. One saddle support is anchored whereas the other is free to permit unstrained
longitudinal thermal expansion of thedrum.

2.15.2 LEGSUPPORT:
1. Small vertical drums are typically supported on legs that are welded to the lower
portion of theshell.
2. The max. ratio of support leg length to drum diameter is typically 2:1
3. Reinforcing pads are welded to the shell first to provide additional local reinforcement
and loaddistribution.
4. The number of legs depends on the drum size and loads to becarried.
5. Support legs are also used for Spherical pressurized storagevessels.
6. Cross bracing between the legs is used to absorb wind or earth quakeloads.
2.15.3 LUGSUPPORT
1. Vertical pressure vessels may also be supported bylugs.
2. The use of lugs is typically limited to pressure vessels of small and medium diameter (1
to 10 ft)
3. Also moderate height to diameter ratios in the range of 2:1to5:1
4. The lugs are typically bolted to horizontal structural members in order to provide
stability against overturningloads.
2.16 Types of PressureVessels
2.16.1 Spherical PressureVessel

2.16.2 Cylindrical PressureVessel

Fig (1.4)
2.16.3 Uses of PressureVessels:
Pressure vessels are used in a variety of applications in both industry and the private sector.
They appear in these sectors as industrial compressed air receivers and domestic hot water
storage tanks. Other examples of pressure vessels are diving cylinders, recompression
chambers, distillation towers, autoclaves, and many other vessels in mining operations, oil
refineries and petrochemical plants, nuclear reactor vessels, submarine and space ship
habitats, pneumatic reservoirs, hydraulic reservoirs under pressure, rail vehicle airbrake
 reservoirs, road vehicle airbrake reservoirs, and storage vessels for liquefied gases such as
ammonia, chlorine, propane, butane and LPG.
2.16.4 Pressure VesselParts
✓ Shell
✓ Heads
1. Ellipsoidal Head
2. Hemispherical Head
3. Tori-spherical Head
4. Standard Flange Dished Heads
5. Flanges OnlyHeads
6. ConicalHeads
7. Deep DishedHeads
8. NozzleSupport
2.17 Quality Assurance/ Quality Control
2.17.1 Responsibilities of QA/QC Department:
1. Perform all daily inspection and test of the scope and character necessary to achieve the
quality of construction required in the drawings and specifications for all works under the
contract performed ON or OFFsite.
2. Cary out inspection and checking for all quality related procedures in the site and ensures
activity at the site are as per approved method statement and inspection testplan.
3. Coordinate with the consultant’s representative and Site En-charge for inspection and
meeting about quality problems including the closure of Non-ComplianceReport.
4. Taking care of QA/QC documents of the entire project including certificates, calibration,
test results, inspection requests, non-compliance reports and site instruction/observations,
permanent materials delivered and other QA/QC documents. Responsible for the closure
of Non-conformance, NCR and Site Instruction,SI.
2.17.2 Main Function of QA/QCDepartment
1. Client Satisfaction, so that they are satisfy their product is manufactured according to
theirexpectations.
2. Third partyInspection.
3. Authorized InspectionAgency.
4. Some companies required U-Stamp for (Pressure Vessels) and S-Stampfor(Boilers).
2.18 Inspection techniques
It can be defined as the process of inspecting, testing, or evaluating materials, components
or assemblies for discontinuities in characteristics without destroying the serviceability of
the part or system part can be reused after inspection.
2.19 RadiographyTest
Industrial radiography is a method of non-destructive testingwhere many types of
manufactured components can be examined to verify the internal structure and integrity of
the specimen. Industrial Radiography can be performed utilizing either X-raysor gammarays.
Both are forms of electromagneticradiation.
This method of weld testing makes use of X-rays, produced by an X-ray tube, or
gamma rays, produced by a radioactive isotope. The basic principle of radiographic
inspection of welds is the same as that for medical radiography. When the X-rays pass
through the welded portion form the material then a bright spots generated on the film, so it
is easy to detect the defected portion in thematerial.
2.19.1 Magnetic ParticleTesting
Magnetic particle Inspection (MPI) is a non-destructive testing (NDT) process for detecting
surface and slightly subsurface discontinuities in ferromagnetic materials such as iron, nickel,
cobalt, and some of their alloys. The process puts a magnetic field into the part.
The piece can be magnetized by direct or indirect magnetization. Direct magnetization occurs
when the electric current is passed through the test object and a magnetic field is formed in
the material. Indirect magnetization occurs when no electric current is passed through the test
object, but a magnetic field is applied from an outside source. The magnetic lines of
force are perpendicular to the direction of the electric current, which may be eitheralternating
current (AC) or some form of direct current (DC) (rectifiedAC).
2.19.2 UltrasonicTesting
Ultrasonic testing (UT) is a family of non-destructive testingtechniques based on the
propagation of ultrasonicwaves in the object or material tested. In most common UT
applications, very short ultrasonic pulse-waves with center frequencies ranging from 0.1-15
MHz, and occasionally up to 50 MHz, are transmitted into materials to detect internal flaws
or to characterize materials. A common example is ultrasonic thickness measurement, which
tests the thickness of the test object, for example, to monitor pipe workcorrosion.
2.19.3 Visual Testing
Visual Inspection, used in maintenance of facilities, mean inspection of equipment and
structures using either or all of raw human senses such as vision, hearing, touch and smell
and/or any non-specialized inspection equipment.
2.20 Welding
Welding is a process in which the metals parts are join together by heating the surfaces
to the point of melting with an electric arc basically it is a way to make high strength joints
between two or more parts, requires a high degree of skills.
2.20.1 Weld Bead
A deposit of filler metal from a single welding pass is known as welding bead.
2.20.2 Electric Arc WeldingProcesses
2.20.3 Non-consumable Electrode Arc WeldingProcesses
1. Gas-Tungsten ArcWelding
2. Plasma ArcWelding
2.20.4 Consumable Electrode Arc Welding Processes
1. Gas-Metal ArcWelding
2. Shielded-Metal ArcWelding
3. Flux-Cored ArcWelding
4. Submerged ArcWelding
2.21 Types of WeldJoints
2.21.1 ButtJoint
A butt weld or a square groove, Is the most common and easiest to use. Consisting of
two flat pieces that are parallel to one another, it also is an economical option. It is the
universally used method of joining a pipe to itself, as well as flanges, valves, fittings, or other
equipment.
2.21.2 CornerJoint
A corner weld is a type that is between two metals parts and is located at right angle
to each other in the form of L. As the name indicates, it is used to connect two pieces
together, forming acorner.
2.21.3 Edge Joint
Edge welding joints, a groove type of weld, are placed side by side and welded on the
same edge. They are the most commonly replaced type of joints due to build up accumulating
on the edges. They are often applied to parts of sheet metal that have edges flanging up or
formed at a place where a weld must be made to join two adjacent pieces together.
2.21.4 Lap Joint
This is formed when two pieces are placed atop each other while also over lapping
each other for a certain distance along the edge. Considered a fillet type of a welding joint,
the weld can be made on one or both sides, depending upon the welding symbol or drawing
requirements. It is most often used to join two pieces together with differing levels of
thickness.
2.21.5 Teejoints
Tee joints, considered a fillet type of weld, form when two members intersect at 90°
resulting in the edges coming together in the middle of a component or plate. It may also be
formed when a tube or pipe is placed on a base-plate.

2.22 Sand Blasting.

Sandblasting is basically a process to achieve surface cleaning and roughness
Sandblasting is a general term used to describe the act of propelling very fine bits of material
at high-velocity to clean or etch a surface. Sand used to be the most commonly used
material, but since the lung disease silicosis is caused by extended inhalation of the dust
created by sand, other materials are now used in its place. A sandblasting setup usually
consists of three different parts: the abrasive itself, an air compressor, and a blasternozzle.
Sand particle speed: 450mph Pressure: 100mpa
2.23 AbrasiveGritBlasting
It is a method used to achieve a clean and a rough surface, basically the abrasive media is
accelerated through high pressure blasting nozzle by means of compressed air or a
centrifugal wheel is used to propel the abrasive material at a high speed, this process is also
used to prepare surfaces forrepainting.
2.23.1 Type
1. SteelBlasting
2. BristleBlasting
3. Glass BeadBlasting
2.23.2 UnitsofMeasure

SFT Square Feet

CFT Cubic Feet
NOS Numbers
LTR Liters
KG Kilogram
TON Ton
BAG Bag
RF Running Feet
FT Feet

2.24 Inspection Of PressureVessels

It should be known that ASME Code Section 8 has three divisions. Division 1 covers
pressure up to 3,000 psi, Division 2 has an alternative rule and covers up to 10,000 psi, and
Division 3 can be used for pressure higher than 10,000 psi.
1. Inspection of material according to ASME section and DesignData.
2. Thickness ofMaterial.
3. Maximum Allowable WorkingPressure(MAWP).
4. Minimum Design Metal Temperature(MDMT).
5. HydrostaticPressure.
6. Dye Penetrating Test of Weld joints and VesselSurface.
7. Internal Design Pressure..
8. Circumference ofVessel.
9. ImpactTest
10. Ultrasonic FlowDetection
11. VisualTesting
12. Radio graphicTest
13. Nozzles and AttachmentsProjection.
14. WeldReinforcement.
15. IKAN QA/QCStamp.
2.25 Inspection of Mild SteelPlates.
1. Inspection ofLength.
2. Inspection ofthickness.
3. Checking thediagonals.
4. Inspection ofMaterial.
5. Checking the HeatNumber.
6. Marking according to plate thickness (Paint, Engraved, TransferredMarking).
7. ProductNumber.
2.26 Mill TestCertificate.
2.27 Reviewing the Mill Test Certificate
✓ Manufacturer name andLogo.
✓ Code edition either it is ASTM or ASME/APIstandard.
✓ Matching the heat number on MIR with the heat number on the MTCreports
2.27.1.1 Heat Number
A heat number is an identification coupon number that is stamped on a material plate
after it is removed from the ladle and rolled at a steel mill. A heat number is similar to a lot
number, which is used to identify production runs of any other product for quality control
purposes.
Heat No: S1344002

2.28 Services
The following services are provided by IKAN Engineering.
2.28.1 Dishend formingmachine
IKAN is engaged in offering Dished-Ends of following Types:
Standard Flange Dished Heads (SD-TYPE)
Deep Dished Heads (DD-TYPE)
Ellipsoidal Dished Heads (ED-TYPE)
Flanges Only Heads (FH-TYPE)
Conical Heads (CH-TYPE)
Hemispherical Heads Crown & Petal type
2.29 Galvanizing
We are processing high quality checked Galvanizing at our work's Galvanizing Plant using
Super High Grade (SHG) imported Zinc & imported Chemicals to make high standard results.
2.30 Design Department:
Design management is a business discipline that uses project management,
design, strategy, and supply chain techniques to control a creative process,
support a culture of creativity, and build a structure and organization for
design.
2.30.1 Responsibilities and Coordination with DesignEngineer
✓ Studied the Cutting plan of a MetalPlate.
✓ Calculation of circumferential and longitudinal Stresses in a pressurevessel.
✓ Reviewing pressure vessels design, piping design and fabricationdrawings.
✓ Basics things related toAuto-CAD.
✓ Design of the Pressure Vessels on the CompressedSoftware.
✓ Stresses in PressureVessels.
✓ Description of Types & Maincomponents.
✓ Design Stages of a processEquipment.
2.30.2 Designing Software
✓ Auto CAD/CAM
✓ Compressed Software for designing pressure vessels
✓ CADWorks
✓ Auto Plant
✓ TEKLAStructures
2.30.3 Longitudinal and Circumferential StressCalculation.

2.30.4 Hoopor CircumferentialStress

This is the stress which is set up in resisting the bursting effect of the applied
pressure and can be most conveniently treated by considering the equilibrium of the
cylinder.

In the figure it is shown a one half of the cylinder. This cylinder is

subjected to an internal pressure p.

p = internal pressure
d = inside diameter
L = Length of the cylinder
t = thickness of the wall
Total force on one half of the cylinder owing to the internal pressure 'p'

= p x Projected Area

=pxdxL

= p.d.L ------------------------- (1)

The total resisting force owing to hoop stresses sH set up in the cylinder walls

= 2 .sH.L.t -----------------------------(2)

Because s H.L.t. is the force in the one wall

of the half cylinder. By equalizing the

equations (1) & (2) ,

2 . sH . L . t = p . d . L

sH = (p . d) / 2t Circumferential or hoop Stress (sH) = (p .d)/ 2t

Longitudinal Stress
Consider now again the same figure and the vessel could be considered to have closed ends
and contains a fluid under a gage pressure p. Then the walls of the cylinder will have a
longitudinal stress as well as a Circumferentialstress.

Total force on the end of the cylinder owing to internal pressure

= pressure x area

2 /4

Area of metal resisting this force = d.t.

Because
d is the circumference and this is multiplied by the wall thickness

Hence the longitudinal stress

Stress = Force/Area
=p x d2 /4/ dt
Longitudinal Stress = (p .d)/ 4t

Cutting Plan

2.31 StandardPlate
Length = 12000mm Width = 2500mm Thickness = 36mm

2.31.1 Given Data

Outer
Diameter
= 914mm
Thickness
= 36mm

Required Length of the Cylinder = L = 3600mm

To develop the blank flat length for a cylinder rolled from sheet or plate is quite
simple:
 (Outside Diameter – Thickness) x 3.1416 = Length of Plate Required (Inside Diameter +
Thickness) x 3.1416 = Length of Plate Required
2.31.2 Calculation for Total PlateLength
(OD – Thickness) .(3.14)

(914mm – 36mm) .(3.13)

Thus, the total length of the plate

Total Length of plate required = 2756.92mm

2.31.2.1 Remaining Plate Dimensions

Fig
(1.6)
2.31.3 Remaining PlateDimension

2.32 General Arrangement Drawing

A drawing that illustrates structural cross-sections, main dimensions, elevation
plans, sub- structural borings, and other basic details of a construction project.
2.32.1 Detailed Drawing
A "detail drawing" is a drawing of a single component, assembly of multiple parts, or an entire
system of assemblies. A detail drawing provides complete and precise descriptions of a part's
dimensions, shape and how it is manufactured. A detail drawing should be concise, in that it
conveys only the information needed to create the part. Information such as the exact size, type
of material, finish, tolerance and any special shop instructions that are necessary to create the
part are included its detail drawing

2.32.2 Design Data

• The design data includes the

following information. Design Code
ASME Section VIII.
• ASME Certification Mark Required Yes
With U Designator. Design Internal Pressure
(9928.45) kpag(1440)psig

• Design Temperature (Internnal) (54.44oC) @(130oF).

• Maximum Allowable Working Pressure (MAWP)
(9928.45) kpag Minimum Design Material
Temperature(MDMT).
• Corrosion Allowance
• Hydrostatic Pressure (14892.68) kpa 1.5 times ofDesign
 Internal Pressure. Painting: See Drawing #2571-02-M-02

2.32.3 Maximum Allowable WorkingPressure

Maximum allowable working pressure (MAWP) is the maximum pressure that the
weakest component of the system can handle. This is based on design codes and back
calculation from the fabrication of the vessel, piping, etc. The MAWP should be
clearly stated for vessels or piping to figure out what pressures the system can
withstand. Note that the MAWP does not remain constant throughout the life of the
system and will reduce due to corrosion (carbon steel), wear and fatigue.

2.32.4 Design Pressure

Design Pressure is the maximum pressure that the system that can be exposed to and
sets the system relief valve at the same pressure. This should be below MAWP and
based on company standards can vary from 10% to 25% above the maximum
operating pressure of the system.

2.32.5 Minimum Design Metal Temperature

Minimum Design Metal Temperature, is the lowest temperature that the vessel can
withstand with the chosen material and thickness. It is a critical factor in designing a
pressure vessel that depends on the environment where the pressure vessel has to be
installed.

2.32.6 PostWeld HeatTreatment

In order to ensure the material strength of a part is retained after welding, a process
known as Post Weld Heat Treatment (PWHT) is regularly performed. PWHT can
be used to reduce residual stresses, as a method of hardness control, or even to
enhance material strength.
2.32.7 Annealing
Annealing heat treatment process is heating a material above the critical temperature,
holding long enough for transformation to occur and slow cooling, full annealing heat
treatment is different form normalizing heat treatment in that the annealing
temperature is typically 150-200F lower than the normalizing temperature and the
cooling rate is slower.
2.32.8 Normalizing
Annealing heat treatment process is heating a material above the critical
temperature, holding long enough for transformation to occur and air cooling it
establishes a more uniform carbide size.
2.33 ElectrodeCode
The prefix "E" designates an arc welding electrode. The first two digits of a 4-digit number
and the first three digits of 5-digit number indicate minimum tensile strength. For example,
E6010 is a 60,000 psi tensile strength electrode while E10018 designates a 100,000 psi
tensile strength electrode, (E6013), (E7018).
2.33.1 Blank Flat Length of aCylinder

To develop the blank flat length for a cylinder rolled from sheet or plate is quite
simple: (Outside Diameter – Thickness) x 3.1416 = Length of Plate Required
(Inside Diameter + Thickness) x 3.1416 = Length of Plate Required

2.34 MarkingTypes

✓ Paint Marking (use when thickness of the material is less than6mm).

✓ Engraved Marking (use when thickness of material is greater than6mm).
✓ Transferred Marking (when a metal is cut into section then transferred marking isused).

2.34.1 Non-DestructiveExamination
2.34.2 Inspection Techniques

It can be defined as the process of inspecting, testing, or evaluating materials, components

or assemblies for discontinuities in characteristics without destroying the serviceability of
the part or system part can be reused after inspection.

2.34.3 RadiographyTest

Industrial radiography is a method of non-destructive testingwhere many types of

manufactured components can be examined to verify the internal structure and integrity of
the specimen. Industrial Radiography can be performed utilizing either X-raysor gammarays.
Both are forms of electromagneticradiation.
This method of weld testing makes use of X-rays, produced by an X-ray tube, or gamma rays,
produced by a radioactive isotope. The basic principle of radiographic inspection of welds is
the same as that for medical radiography.
When the X-rays pass through the welded portion form the material then a bright spots
generated on the film, so it is easy to detect the defected portion in the material.

2.34.4 Magnetic ParticleTesting

Magnetic particle Inspection (MPI) is a non-destructive testing (NDT) process for detecting
surface and slightly subsurface discontinuities in ferromagnetic materials such as iron, nickel,
cobalt, and some of their alloys. The process puts a magnetic field into the part.

The piece can be magnetized by direct or indirect magnetization. Direct magnetization occurs
when the electric current is passed through the test object and a magnetic field is formed in the
material. Indirect magnetization occurs when no electric current is passed through the test
object, but a magnetic field is applied from an outside source. The magnetic lines of force are
perpendicular to the direction of the electric current, which may be either alternating
current(AC) or some form of direct current (DC) (rectified AC).
2.34.5 UltrasonicTesting

Ultrasonic testing (UT) is a family of non-destructive testingtechniques based on the

propagation of ultrasonicwaves in the object or material tested. In most common UT
applications, very short ultrasonic pulse-waves with center frequencies ranging from 0.1-15
MHz, and occasionally up to 50 MHz, are transmitted into materials to detect internal flaws
or to characterize materials. A common example is ultrasonic thickness measurement, which
tests the thickness of the test object, for example, to monitor pipeworkcorrosion.

2.34.6 Visual Testing

Visual Inspection, used in maintenance of facilities, mean inspection of equipment and

structures using either or all of raw human senses such as vision, hearing, touch and smell
and/or any non-specialized inspection equipment.

Dye Penetrating Test

 Dye penetrant inspection (DPI), also called liquid penetrant inspection (LPI) or penetrant
testing (PT), is a widely applied and low-cost inspection method used to locate surface-
breaking defects in all non-porousmaterials (metals, plastics, or ceramics). The penetrant may
be applied to all non-ferrous materials and ferrous materials, although for ferrous components
magnetic- particle inspectionis often used instead for its subsurface detection capability. LPI is
used to detect casting, forging and welding surface defects such as hairline cracks, surface
porosity, leaks in new products, and fatigue crackson in-service components

✓ Section of the material with a surface-breaking crack that is not visible to the nakedeye.
✓ Penetrant is applied to thesurface.
✓ Excess penetrant isremoved.
Developer is applied, rendering the crack visible.