DRUM MANUFACTURING

D.Vijayasarhathy Abhijeet infra Ltd.

Drum Manufacturing
The plates for manufacturing drum have been imported mostly from European countries due to quality needs. The plate material for shell and dish end is SA299 (carbon steel). The thickness of the plates varies drum to drum according to the requirement of holes to be drilled. 1. First the drum plate from the stores is being made to undergo chemical composition test (PMI positive material identification), Mechanical test, UT (ultrasonic testing). 2. After clearance of the above tests the plate has been marked according to the dimensions in reference with the manufacturing drawing. 3. After marking the plate has to be preheated for gas cutting and cutting is to be made according to the requirements. An extra 10mm - 15 mm to be left in all side of the plates. 4. For thickness above 150 mm hot forming is to be made. 5. For hot forming the material shall be heated all around uniformly for the temperature of around 870 - 900 c. 6. After soaking inside the furnace, the plate has to be loaded in the 8000 tonne capacity press for pressing the first half of the drum shell. 7. The pressing has been made gradually by starting from the end of the plate. 8. A person holding a die of the prescribed shape of the shell will look after the shape forming, and another person will be looking after the table movement, press cylinder movement in the control unit. 9. Press has a plate guider on both sides of the table which guides the shell plate in to and fro motion. The table moves in horizontal direction and the tool (die) moves in vertical direction. 10. The press will be completed before temperature reaches 621 deg c. 11. After it has been loaded for SR (stress relieving). Then another plate of different thickness which has been loaded in the furnace for hot pressing is taken and loaded in the press table. 12. Same process is repeated for forming and SR of the second half of the shell. 13. For dished ends preparation, a circular disc has been formed from raw material after finishing all chemical, mechanical and ultrasonic tests according to the engineering information. 14. A hole has been made in the centre of the dish after which the dish has to undergo pressing in the 1000 tonne press which has to be fitted up with the specific die for pressing. 15. After pressing SR is to be made for both the dishes. 16. After SR, marking is done for the holes to be drilled in the dish surface for fitting of stubs, nipples, safety valve nozzles etc., 17. After drilling EP (edge preparation) is made for dish ends. Fitting of stubs, nipples, safety valve nozzles etc., are made by SMAW (submerged metal arc welding) and inspection is performed and kept ready for welding with the shell.

DRUM MANUFACTURING
D.Vijayasarhathy Abhijeet infra Ltd. 18. The above operations for dish manufacturing have been prepared simultaneously during the shell manufacturing. 19. The extra area which has been left in the long seam (LS) side of the shells has been marked and then removed by gas cutting. 20. After gas cutting EP has been made in planning machine on both the shell plates. 21. After EP the two shell half are joined by CO2 welding (inside). Inspection has to be made by MPI/MT (magnetic particle inspection / magnetic test) for inside of the LS side. 22. A single coat of SAW (submerged arc welding) welding is made outside. 23. After SAW, back grinding is done on the outside till the edge of the other side (around 2 mm of the other side weld) i.e. CO2 weld, because while CO2 welding is done some areas at the end will not be filled properly. 24. After grinding, the gap is filled fully with SAW in the LS side. SAW weld is preferred to make the joint strong and also mainly for higher thickness this type of welding is preferred. 25. Surface grinding is performed to remove burs, unwanted materials etc., on the surface of the shell. 26. RT (radiographic test) is taken for where the defect is located and in which location, what type of defect; UT (ultrasonic test) is Tested for defect how much depth and length of defect. 27. After inspection clearance, EP to be made on CS (circumferential seam) side of the shell for joining a dish ends with it. After that LPI (liquid penetration test) is performed on the EP. 28. Drilling is to be performed on the shell for stubs, down comers, nozzles etc., according to the manufacturing drawing for the fit ups. 29. Component identification (Melt. no., material, size) is made for stubs, nozzles etc., which were manufactured by forging process. 30. Stubs, nozzles, down comer pipes, etc., are welded in their respective holes in the shell by manual SMAW. 31. Then surface grinding has been performed for removing the extra materials and burs etc on the surface of the welded joints. 32. Shell, dish end fit ups are made by SAW on inside and MPI is performed on all welded joints and inside of the shell dish fit ups. Then a layer of weld is made on outside. 33. Back grinding is performed on outside of shell-dish joint then SAW is performed fully on outside. 34. Machining (grinding) process is performed to remove the burs etc., and MPI is made. 35. RT and UT are witnessed. 36. Component identification (Melt. no., material, size) is made for stubs, nozzles etc., which were manufactured by forging process. 37. Safety valve, nipples etc., are welded in their respective holes in the dish by manual SMAW. 38. Other fittings like steam separator, turbo separator, headers etc., are being fitted inside the shell.

DRUM MANUFACTURING
D.Vijayasarhathy Abhijeet infra Ltd. 39. Kerosene test is performed on internal part of drum (passage of steam + water particles). 40. After that another dish end is welded on the other side of the shell. And all other fittings are made in the drum and inspection is made. 41. Then the drum has to undergo heat treatment (SR) thro heating the drum in the furnace till 610 10c. 42. The temperature rise must be 50 c /hr. till 610 10c 43. Then maintain the temperature at 61010c for 8hrs (soaking time) 44. After soaking time, reduce the temperature till 400c at the rate of 1c for every 2 minutes. 45. After reaching 400c take out the drum and make it to cool in still air. 46. After Heat treatment the drum has to undergo hydro test. Hydraulic medium is water. 47. There should not be any welding or heating process be carried after hydro test. 48. Internal attachments of drum are fitted. 49. Painting work is made and DFT (dry film thickness) test is carried out. 50. Packing with suitable structural before dispatch is made. 51. Final stage of inspection is made and drum is sent to shipping for dispatch.

The normal duration of transforming the raw materials to finished drum is 4 to 5 months.