Sequence of processes

1.Material Reception
2.Plate cutting
3.Plate Edge preparation
4.Rolling
5.Long seam Welding
6.Rerolling
7.Long seam UT
8.Cir.seam fitup& Root welding
9.Flange preparation
10.Flange fitup & Root welding
11.Cir.seam SAW welding (outside)
Sequence of processes :

12.Cir.seam BG and SAW welding (Inside)

13.Visual preparation for UT
14.Cir.seam weld UT
15.Weldable Bracket fitup & welding
16.Burr grinding for all weld brackets
17.Weld brackets Dye Penetrant Test checking
18.Flange and shell Ovality Inspection
19.Flange- Easylaser (flatness & tilt)
20.Final visual inspection
21.Final dimension Internal QC and tower
Sequence of processes :

22.Blasting (Inside and Outside)

23.Painting (Inside and Outside)
24.Internals kit item Assembly
25.Final Checklist - Internal QC & tower QC
26.Dispatch .
Detail of process :1.Material Reception

1.Receiving Raw material.

Dimension ( Length ,Width
,Thickness ,camber,Diagonal
) and Quantity to be checked
with relevant Delivery
challan .

2.Verfication of Test
certificates.

3.Preparing internal
Inspection Report.
Detail of process : 2.Plate cutting

1.As per our specification

each plate cutting to be done
in programmed CNC machine

2.After cutting the plate

Dimension to be checked and
noted in the traceability
report (R09)
Detail of process : 3.Edge preparation

1.As per tower

specification, Approved
WPS,the plate edge
preparation to be done with
Pug cutting machine .

2.After cutting ,the EP area

to be cleaned and grounded
with mop grinding wheel.

3.EP profile to be checked

with relevant inspection
tools and noted in the report
Detail of process : 4.Shell Plate Rolling, LS fit up & LS root welding

1.Each plate rolled with

required radius templates
,LS fit up and LS root
welding(MAG or GMAW) to
be done.
 Detail of process : 5.Long Seam SAW welding

Out side welding

1.Long seam Outside and
inside welding to be done
with SAW process.

Inside welding
Detail of process : 6.Rerolling

1.After completion of weld,

Shell profile rerolling process
to be done with relevant
radius templates to correct
peaking and banding.
Detail of process : 7.Long seam weld UT

1.The long seam weld quality

to be confirmed with tower
Specification and Procedures
.
Detail of process : 8.Cir.seam fit up for Shell to Shell

1.Shell to shell fit up to be

done with hydraulic fit up
station .

2.Matched shells mismatches

to be checked as per
customer instruction.

3.After completion of
inspection inside root
welding to be done with MAG
process .
Detail of process : 9.Flange preparation

1.Ensure the Flange

Identification number .

2.Flange Edge preparation

area paint and rust to be
cleaned with mop (emery)
wheel.
Detail of process : 10.Flange fit up & Root welding

1.Shell to flange fit up to be

done with hydraulic fit up
station .

2.Flange Mismatch checked

as per customer specification

3.After completion of QC
inspection inside root
welding done with MAG
process .
Detail of process : 11.Cir.seam SAW welding ( Outside )

1.Cir.seam outside SAW

welding to be done with
approved WPS ,PQR and
WPQ .

2.Ensure the job thickness,

preheating requirements
,etc..before start of welding
Detail of process : 12.Cir.seam Inside BG and SAW welding

1.Cir.seam inside SAW

welding to be done with
approved WPS ,PQR,and
WPQ .

2. Ensure the job thickness

and preheating requirements
etcbefore start of welding.
Detail of process : 13.Visual preparation before UT

1. Cir. seam weld both sides,

Surface imperfections to be
cleaned with mob wheel and
weld touch up to be done
and ground
Detail of process : 14.Cir. seam weld UT

1. All Cir. seam weld quality

to be confirmed with tower
Specification and Procedures
Detail of process : 15.Weldable cleat & Doorframe fitup & welding

1. All internal cleats and door

frame locations marked with
relevant drawings .

2.Marked locations verified

with internal QC and fitup&
welding to be done with
SMAW or MAG process .

3.Doorframe BG area DP test

to be done .

4.Door weld quality to be

confirmed with UT as per
customer specification
Detail of process : 16.Burr Grinding for all weld brackets

1. All welded brackets and

bushes burr grinding to
be done with as per
customer instructions.

2. The depth of the burr

grinding 0.5 to 1mm
(Allowable)
Detail of process : 17.Weld cleat Dye Penetrant Testing

1. After burr grinding of all

welded brackets and bushes
Dye penetrant test to be
done as per customer
Specification.
Detail of process : 18.Flange and shell Ovality inspection

1. Flange ovality with in

4mm and shell ovality
with in 1% of diameter
allowed as per tower
Specification .
Detail of process : 19.Flange Easy laser (flatness & tilt)

1. Both flanges, Flatness and tilt

readings to be confirmed with
E910 Easy laser equipment
with programmed software.
Detail of process : 20.Final visual inspection

1. Section inside and outside

weld visual to be checked
as per customer
specification and check
sheet.

2. Weld mismatch readings,

to be checked as per
customer Instruction .
Detail of process : 21.Final dimension Internal QC and tower QC

1. Internal QC must check the

section length ,ovality ,flatness
and tiltness ,weld visual and
prepare the relevant
documents.

2. Black stage inspection to be

offered for tower QC clearance.
Detail of process : 22.Blasting ( Inside and Outside )

1. Before blasting, ensure

the climatic condition and
girt cleaning .

2. Blasting to be done with

covered shed.

3. After blasting the profile

must meet the customer
requirement of 50-
70microns ( To be
checked with profile
gauge. )
Detail of process : 23.Painting ( Inside and Outside )

1. Before Painting, Ensure

the climatic condition.
Detail of process : 23.Painting ( Inside and Outside )

1. Before painting, Ensure

the climatic condition.

2. As per customer painting

specification outside 3
coat system and inside
single coat system must
be done in covered shed.

3. Each coat DFT checked

with coat meter and final
coat glossiness checked
with gloss meter.
Detail of process : 24.Internals kit item Assembly

1. All internal items to be

fixed and assembled as
per customer drawing and
Specifications.
Detail of process : 25.Final Checklist - Internal QC & tower QC

1. Internal QC must check

the position, location,
dimensions of fixed items
and verify with relevant
drawings and check list.

2. White stage inspection to

be offered for tower
QC Clearance.
Detail of process : 26.Dispatch

1. Ensure the flange both side

Polyurethane dummy with
plug pin.
2. Ensure the Spider fixing for
Customer suggested flanges
only .
3. During the loading, Ensure
the saddle position .
4. After loading, Ensure the
section cleanliness.
5. Final dispatch clearance to
be received from tower
logistics before dispatch