STANDARD OPERATING

PROCEDURE
( HEADERS )

Prepared By: Checked By Approved By:

Sandeep S. Bhandari M. K. Jadhav A. S. Kulkarni

SOP / BnHQAC / 02, Rev. 0 Page 1 of 5

 SOP:- STANDARD OPERATING PROCEDURE
HEADERS [ECO. / SH / INBED / EVAP. / SUPPORT]
For Tolerance, refer control sheet no.
Getting Drawing:-

Ensure that approved drawing is received and if any backside is there then it shall be pasted on
backside of drawing. The drawing shall be provided by planner to shop QC / Shop.

Review of QA Plan:-
Shop QC shall review the latest revision of QA Plan to ensure which stages are to be offered to TPI /
IBR / IA & if any special requirement mentioned.
Layout Marking & Inspection of stubs:-
Ensure that platform used for layout marking is in water level condition. Production to carry out layout
& shall get it check from Shop QC.

Shop QC shall ensure all parameters of layout marking such as Orientation, All dimensions [Length,
Width, diagonal, Bend Degree, Bend radius, Projection]

Sample / First Production Bend (Max. bend degree):-

After Clearance of previous stage by Shop QC, Production shall prepare the sample production bend
with max. degree and shall offered to Shop QC for inspection.
Shop QC shall ensure that proper material as mentioned in drawing is used [Size, Specification] & is
cleared by inspecting authority as applicable.
Shop QC shall inspect the sample bend for Dimensions of Bends on layout [Bend Radius, bend
Degree, Pitch], Ovality, Thinning, Flow area, Kink, Flatness as per template, wrinkles & any surface
defects, die marks.
After clearance by Shop QC, Production shall start the production of stubs & shall offer for inspection
to Shop QC.
Bending of Tubes:-
Production shall start the bending of tubes with the same parameters of machine as used for sample
bend.
Shop QC shall ensure the ovality, thinning, ball pass for on continuing production runs at least one
bend of every hundred bends along with Visual insepction of surface & shall maintain the records for
the same.
If Ovality & thinning founds unacceptable then bending shall be stop & setting of the machine to be
changed & sample bend shall be prepared again.
If pinching is resulting from die forming which is not acceptable then blend grind uniformly to
surrounding metal & thickness check to ensure that minimum wall thickness is maintained as per
drawing or torus formula.
Butt Weld Setup for Header Pipe:-
Shop QC shall ensure that proper material as mentioned in drawing is used [Size, Specification] & is
cleared by inspecting authority as applicable.
Shop QC shall ensure the setup dimensions [Root Gap, Root face, Groove angle] & Cleaning of joint
& adjacent 1" area on both sides of joint.

SOP / BnHQAC / 02, Rev. 0 Page 2 of 5

 Shop QC & production shall ensure that proper preheating of joint & its adjacent 1" area is carried out
before welding & interpass temperature is maintained, if applicable.

Shop QC shall carry out visual inspection of weld such that no discontinuity is present

After clearance, Production shall offer the same for applicable NDE.

After clearance from NDE, Production shall carry out the marking on Headers.

Drilling - Marking & its inspection:-

After carring out marking production shall offer it to Shop QC.

Shop QC shall ensure marking of stubs, nozzles on Headers as per approved drawing.

Shop QC shall ensure the Water level of Header & line marked is straight with combination set.

Shop QC shall ensure all parameters such as Pipe straightness, [Total Length, Orientation, Quadrant
division, LH / RH marking, Quadrant wise hole locations from ends / center, No. of openings for stubs,
Pitch, End edge preparation, Hole size marked on Header, Centre punch inlinement, End hole location,
Structural attachments marking].
Drilling inspection:-

After drilling, Headers shall be inspected by Shop QC.

Shop QC shall ensure all parameters such as [orientation, Quadrantwise hole locations from ends /
centre, No. of Openings for stubs, Pitch, Drilled hole dimension(with template), Inlinement of drilled
holes, hole finish (no burrs, smooth surface, free from discontinuity)
Machining & Stamp Trsnsfer:-

Shop QC shall ensure the proper identified material is used for end plate & reducers as per drawing.

Shop QC shall ensure the machining of the same material & all the idenfication such as [Heat No.,
Mat. Specification, inspecting authority's Stamp] are properly transferred after machining.

Shop QC shall ensure the dimensions of the machined parts as per drawing.

Branch Weld, Endcovers & Reducers Setup & welding:-

On clearance of previous stage, Production to go for set up of Reducers, Endcovers, stubs, Nozzles
which ever is applicable.

On completion of setup, Shop QC shall ensure its inspection as per approved drawing.

Shop QC shall ensure all the parameters such as [Orientation, Setup dimensions, Alignment,
Squareness, Projection, CTC distance between stubs / Nozzles] for stubs & nozzles

SOP / BnHQAC / 02, Rev. 0 Page 3 of 5

 Shop QC shall ensure all the parameters such as [Orientation, setup dimensions(Groove angle, Root
gap, Root face), Projection, Alignment,Squareness] for Endcovers & reducers

Shop QC shall ensure the cleaning of joint & 1" adjacent area on all sides of joint.

Shop QC & production shall ensure that proper preheating of joint & its adjacent 1" area is carried out
before welding & interpass temperature is maintained, if applicable.

Shop QC shall carry out visual inspection of weld such that no discontinuity is present

Shop QC shall ensure Welder No., Weld reinforcement, Weld profile, Appearance

Production shall offer all butt welds & fillet welds for applicable NDE.

Setup of structural Attachments & its welding:-

Production to carry out setup of the attachments & shall offer for inspection to Shop QC.

Shop QC shall ensure its orientation, dimension & material size & specification.

Shop QC & production shall ensure that proper preheating of joint & its adjacent 1" area is carried out
before welding & interpass temperature is maintained, if applicable.

Production shall offer for NDE, if applicable

Inspection before PWHT:-

After completion of all previous stages, PWHT is to be carried out.

Shop QC shall ensure overall dimensions, Orientation, NDE clearances, Code punching, Straightness
of Header
If straightness of Header is not within acceptable limit then straightning of Header is to be carried out
as per SOP no. SOP / BnHQAC / 04 to bring straightness within acceptable limit.

Shop QC shall ensure that PMI is carried out, if applicable.

Shop QC shall ensure the scope of drawing before clearing for PWHT.

Inspection after PWHT:-

Shop QC shall ensure overall dimensions, Orientation, Code punching, Straightness of Header

Shop QC shall review the Heat Chart to ensure the Heating rate, Soaking period & Cooling rate as per
thickness & shall sign off the chart.

Production shall offer the Header for NDE, if applicable. ( For Heat corrected area, Fillet welds)

Final Inspection:-

SOP / BnHQAC / 02, Rev. 0 Page 4 of 5

 Shop QC shall ensure that required NDT is completed & is cleared.

Shop QC shall ensure Orientation, Edge preparation for site welds,

Shop QC shall ensure that stamp of inspecting authority's is stamped on header along with date, if
applicable & Rub-off shall be taken & shall be submitted to defined authority.

Shop QC shall ensure the Scope of drawing & BOM so that nothing is missed.

Painting Inspection:-

QC shall ensure the proper cleaning of Headers before painting.

QC shall ensure that proper shade of paint, approved brand of paint, Batch no. of paint

QC shall ensure visually that no Rundowns, Peel - offs, cracks are present & complete coverage of
Headers.

QC shall check the DFT of paint.

QC shall ensure the cleaning of Headers from inside before capping.

QC shall ensure that all tubes ends & other opening are properly capped.

Shop QC shall ensure that color coding is carried out as per the material & idnetified chart, if
applicable.

QC shall ensure the stenciling [BLR No., Drg. No., Mark No.,Part No.]

SOP / BnHQAC / 02, Rev. 0 Page 5 of 5