QA/CFP/02

COLD FORMING PROCEDURE OF SINGLE PIECE

2:1 ELLIPSOIDAL DISH END REV.0
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COLD FORMING PROCEDURE OF SINGLE PIECE 2:1 ELLIPSOIDAL DISH END

CLIENT EPCL
PO NO.
MATERIAL A-36
JOB CN 2F Exchanger
SIZE OF DISH END 500mm x 6mm
TYPE OF DISH END ELLIPSOIDAL
DRAWING NO T07B01-100FE20-0200
ITEM NO 01 (QTY.02)

Altaf Khan Nauman Suria EPCL

01 Rev-00 18/3/2021 QA/QC Eng. Director Client

Sr. No. Rev. No. Date Prepared by Approved by Accepted by

 QA/CFP/02
COLD FORMING PROCEDURE OF SINGLE PIECE
2:1 ELLIPSOIDAL DISH END REV.0
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❖ SCOPE: -
This specific procedure describes the method of pressing the seamless single piece dish
end by cold forming process
❖ REFERENCE STANDERD: -
ASME Sec VIII Div. 1 Edition 2015
ASME Sec II Part A Edition 2015
ASME Sec V Edition 2015
❖
DISH END FORMING ACTIVITIES & RESPONSIBILITIES
➢ Quality Control Engineer
1. Quality Control Engineer shall be responsible to send the Quality assurance plan i.e.
Inspection test plan, Mill test certificates, Heat treatment procedures, NDT procedures,
forming procedure send to client for approval.
2. QC Engineer shall be responsible to proceed with job only after approval of all technical
documents received
3. QC Engineer shall be responsible for to ensure that the received plates are free from scales
/rust /oil / grease. If required mechanical cleaning shall be applying to clean the plate
surface.
4. Correlate the plate’s identification with Mill Test Certificate and review/verify the mill
test certificate as per requirement of ASME Sec II-part A. Original Mill Marking shall be
recorded and included in final technical dossier.
5. Verify the Dish development marking i.e. blank diameter shall be done as per plate layout
and check that identification stamping transfer on marked blanks and on balance plate.
6. QC Engineer shall prepare the Material identification report and Identify the developed
blank.
➢ Production Supervisor
a. Production supervisor shall be responsible to check the approved drawing and to ensure
that the gas cuts / plasma cutting of Dish end blank is done as per layout.
b. Production Supervisor shall be responsible to check that cut blanks are serration free
c. Seamless blank shall be formed by the cold successive pressing method. Suitable dies and
punches of CS material shall be used for required size, shape & profile as per approved
drawing. Two dimensional templates used for checking & inter-stage inspection as per the
drawing and as per relevant code.
d. Dish End shall be cold formed by following stages
1. Crowning: - Crowning is spherical pressing from edge to center successively by
super imposing 50% of pressing as shown. Below.

Dish End Blank

Dish Blank
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COLD FORMING PROCEDURE OF SINGLE PIECE
2:1 ELLIPSOIDAL DISH END REV.0
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Crowning

2. Edge braking: - Reducing diameter by braking edges and keep diameter

approximate 100 to 150 mm more than required diameter
100 -150mm
Edge braking

3. knuckling: - Edge braked portion is pressed into knuckling die & punches. This
Die & Punch is of same knuckle radius with spring back allowance and at the
same time desired circumference is achieved so is the diameter.
Dish End Diameter
Knuckling Knuckled

4. Polishing/ Ovality Correction: - by pressing high spots on crown portion to

achieve gradual profile on crown is called polishing. Ovality correction is done by
pressing minus side diameter to the required/ desired diameter.
e. After complete forming of Dish End, Heat treatment i.e. Normalizing shall be carried out
as per cycle mentioned in approved drawing.
f. Water level shall be done along with reference line. The trimming line shall be marked on
the dish ends
g. After leveling trimming to be carried out by machining and production supervisor is
responsible to monitor this activity and check that weld edge preparation shall be as per
approved drawing and checked by bevel protractor.
h. Grinding shall be carried from entire full inside & outside full surface.
➢
SAFETY: -
a. Shop floor worker shall be aware of safety procedure.
b. During the forming of Dish end all workers/operator shall wear the protective equipment
such as helmets, safety shoes, goggles & hand gloves etc.
c. No one shall be allowed to enter in shop without helmet, safety shoe.
d. All the safety procedure shall be taken as per safety manual. Special attention/safety
precaution shall be taken while pressing the dish ends
➢
INSPECTION EXAMINATION & TESTING: -
Inspection of the formed head for the dimensional and shape requirement as per approved
drawing. The following stages are carried out & shall be witnessed by client EPCL.
a. Layout of the template profile on the floor and checking of the template with reference
dimensions of dished end.
b. Checking of template in various directions inside the formed head for the over crowning
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COLD FORMING PROCEDURE OF SINGLE PIECE
2:1 ELLIPSOIDAL DISH END REV.0
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and under crowning tolerances of the code.

c. Checking the inside circumference and inside diameter as per approved drawing.
d. Checking the minimum thickness by the calibrated thickness meter at various points to
ascertain that the minimum thickness at any point is not below the drawing requirement,
e. Checking the height, ovality (±1%) as per approved drawing.
f. 100% DP Test on Inside full surface shall be carry out after complete forming & Heat
Treatment.
g.Dimensional, visual inspection report with all other technical documents including NDT
reports will be submitted to client.

➢ HANDLING & DISPATCH: -

a.Once all inspection activities over dish end shall be ready for dispatch.
b.During the handling & Dispatch proper care shall be taken.
c. During handling the dish end always use proper protection i.e. polythene/fiber sheets to
avoid the damage on side.
d.During packing use protective films such as polythene, bubble sheets to avoid the direct
contact of surface with each other.
e. During the dispatch use the antirust oil from outside of dish end to avoid the rusting due to
atmospheric condition.
f. Do not hammer the dish ends from outside to fit in packing, always make the proper packing
to avoid the damage on dish ends