1) INTRODUCTION

1.1 ) COMPANY PROFILE FACT Engineering Works (FEW), an Indian Company, which has been providing reliable engineering and fabrication services for over three decades to fertilizer, chemical and petrochemical and engineering firms. FEW is the engineering and fabrication division of The Fertilizers And Chemicals Travancore Ltd. (FACT), a leading Public Sector giant with interests in fertilizers, petrochemicals, engineering design, consultancy and fabrication. For its entire range of services, be it design and fabrication of pressure vessels, heat exchangers and storage tanks or large projects like fabrication and erection of plant and equipment or cross country pipelines, FEW has installed quality system conforming to ISO 9001. FEW being a division of a chemical conglomerate operating fertilizer and petrochemical plants has deep roots in the process industry. FEW also has the experience as well as the capability to provide adequate resources to help tackle challenging fabrication problems.

FEW's Design, Fabrication and Quality Assurance Department are manned by a group of engineers and technicians with hands-on experience in the fields of fertilizers and petrochemicals.

All this means that when there is a need to replace an equipment in a fertilizer or chemical plant or need a new one, can rely on FEW for reliable, secure and efficient fabrication solutions.

1.2 HISTORICAL BACK GROUND FACT Engineering Works (FEW), the Fabrication and Engineering Division of FACT was established in the year 1966. FEW is one of the leading contracting firms in the Country offering services through the manufacturing wing with modern fabrication and testing facilities and the project wing undertaking project construction works. To expand its shop activities, FEW acquired the assets of M/s Giovanola Binny at Palluruthy, Cochin and is operating at Palluruthy from February 1989 onwards. Present range of equipment fabricated by FEW include items like Class I Pressure Vessels, Heat Exchangers in Carbon Steel, Alloy Steel and Stainless Steel, Chemical Process Equipments, Penstock Pipes, Columns, Towers, etc. Since 2006 FEW has also been producing ship building components such as Hatch Covers, Bulk Storage Tanks, Spud Pipes, Crane Posts, Hull Blocks, etc. Project wing of FEW undertakes design engineering fabrication and erection of plant piping & off-site piping for process industries; design, fabrication and erection of large size Storage Tanks including Ammonia Storage Tanks, Vessels and other items for process industries; laying of cross country pipelines for water supply schemes/oil terminals on turnkey basis. The quality system of Manufacturing Wing as well as Project Wing has been certified to ISO 9001 since 1998.

1.3 PRODUCTS PRODUCED Products at Workshop FEW has a fully automated and finely integrated workshop equipped with state of-the-art machinery and the latest in fabrication, testing and welding. The workshop offers fabrication of almost all equipment vital to the process industry like: Heat Exchangers Pressure Vessels Columns & Towers Storage Tanks in ferrous & non-ferrous metals Reactors

Products at Site FEW also has the capability and resources to undertake fabrication projects at site. A highly skilled team of engineers and craftsmen is available for projects of any description at any given site. FEW can also undertake design, engineering, fabrication and erection of: Dry seal/wet seal industrial gas holders of vertical / spiral lifts Plant piping and offshore piping for process industries Spillway shutters, pen stock pipes large size storage tanks, vessels and other items of process industries Cross country piping Oil terminals on turnkey basis Columns, Towers Floating roof tanks Refinery shut down inspection services

Codes in Practice At FEW all fabrication is done in accordance with the following internationally recognized codes: ASME Section VIII Div.1 ASME Section VIII Div.2 TEMA R, C&B AP1650 BS5500 AP1620 IS2825-1969 IS803 Inspection Agencies All Major third party inspections at FEW are carried out by agencies like: Lloyd's Register Industrial Services (LRIS) Bureau Veritas (BV) Indian Register of Shipping (IRS) Bax Counsel Inspection Bureau Pvt. Ltd. (BCIBPL) Directorate of Factories & Boilers FACT Engineering & Design Organization (FEDO) Projects & Development India Ltd. (PDIL) Engineers India Ltd. (EIL) Technical Back up and Tie ups When you assign a project to FEW, you are assured of technology leadership, technical expertise and management skills of a multi-product, multi-division corporation. For instance, FEW has access to the vast resource pool of FACT

Engineering and Design Organization (FEDO, a leading engineering consultant and a subsidiary of FACT, the fertilizer giant). While FEDO provides project implementation programmes and engineering designs, FACT offers back up in terms of personnel, training and commissioning expertise. Complementing comprehensive technical expertise is FEW's project to project tie-up with technology leaders.

2) ORGANIZATION SET-UP FACT a Government of India Enterprise has business interests in manufacturing and marketing of fertilizers, caprolactam, engineering consultancy and fabrication of equipments. Units of FACT include the two manufacturing divisions Udyogamandal Complex-UC and Cochin Division-CD, the consultancy unit FACT Engineering and Design Organization-FEDO, the fabrication division FACT Engineering Works-FEW and the Marketing Division. The Company has also interests in petrochemicals, hydrometallurgy, chemicals and

pharmaceuticals. FACT Board of Directors Chairman and Managing Director Director - Finance Director -Technical Director - Marketing Official Part -time Director Official Part- time Director

Chief vigilance Officer

Company secretary

Head office General Manager Deputy General Managers Chief Managers

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Marketing General Manager Deputy General Managers Chief Managers

Petrochemical Plants General Manager Deputy General Managers Chief Managers

Fertilizer Plants General Manager Deputy General Managers Chief Managers

FEDO General Manager(FEDO & FEW) Deputy General Managers Chief Managers

Cochin Division General Manager Deputy General Managers Chief Managers

FEW General Manager(FEDO & FEW) Chief Managers

Address: Head Office FACT Engineering Works FEDO Building Udyogamandal 683501 Kochi, Kerala Shops FACT Engineering Works Palluruthy Industrial Estate P O Kochi- 682006 Kerala

ORGANIZATIONAL CHART OF FACT ENGINEERING WORKS GM (FEDO&FEW)

CM(Projects)

Dy.CE(Design)

CM(Commercial)

Engineer

Draftsmen

Chief Engineer (Shops)

Dy. CE (Planning & Inspection)

Manager (Administration)

Manager(stores)

Manager(shops)

QA/QC Engineers

Engineers(shops)

NDT Technicians

Foremen(shops)

Fig:1 Organizational chart

3) DEPARTMENTS 3.1 INTRODUCTION Departmentalization is the efficient and effective grouping of jobs into meaningful work units to coordinate numerous jobs for the expeditious accomplishment of the organizations objectives. This creates flexibility, adaptability and unit of action within the firm. The various departments in FEW are as follows: Design Department Production Department Commercial Department Materials Department Planning and Inspection Department

3.2 ) DESIGN DEPARTMENT The design and the drawings are done at FEW design department. FEW has access to the vast resource pool of FACT Engineering and Design Organization (FEDO, a leading engineering consultant and a subsidiary of FACT, the fertilizer giant). While FEDO provides project implementation programmes and engineering designs. There is a procedure for design control and its purpose is to control and verify the design of an equipment or system in order to ensure that the requirements as specified by the client are met. There is a design plan and development activity , before the commencement of the design a plan for the design and development

activity is to be prepared .The plan has to define the various activities which are involved in the design. The design inputs includes the product requirements and the applicable statutory requirements. The design is done using the codes such as ASME,IBR,TEMA,IS , Engineering standards, Hand books and Design manuals. Equipment hand books are used to supplement as guide for design Pressure vessels a) Design hand book: Henry H Bednar b) Pressure vessel hand book: Eugene F Megsey c) Pressure vessel manual : Dennis R Moss

Welded tanks a) Pressure vessel hand book: Eugene F Megsey

Heat Exchangers a) Mechanical design of heat exchangers and & Pressure vessel components : K P Singh & A I Soler

If the design problem cannot be matched to any of the models mentioned above, the same shall be worked using the fundamental principles a) Experimental stress analysis : James W Dally, William F Riley b) Formulas for stress & strain : Roask & Young c) Theory of plate and shells : Timoshinko & Woinowsky Kreiger

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3.3) PRODUCTION WORK SHOP FACILITY FEW's self-contained workshop at Kochi can provide with state-of-the art facilities at every stage of venture. This workshop is well equipped to fabricate equipment up to 75mm thickness. The high-end facilities at FEW workshop include: CNC Drilling Machine

Table working area: 1200mm x 1200mm Solid drilling capacity in steel: 50mm hole diameter Weight carrying capacity of table: 2000kg Table travel X axis: 1500mm Spindle head travel - Y axis : 1300 Spindle vertical travel - Z axis : 400mm

Plate Bending machines of Capacities

Up to 60mm thick x 2.5m width Up to 40mm thick x 2.5m width Up to 36mm thick x 3.0m width Up 20mm thick x 2.5m width

Submerged Arc Welding Units Automatic Welding Units TIG Welding MIG Welding Pinch Press - 400 T Section Bending Machine Radial Drilling Machines
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Guillotine Shear Lathes & Shaping Machinery Press Brake Hydraulic Tube Pulling Units Hydraulic Testing Unit Self aligning self centering rotators Hydraulic Pipe Bending Hydraulic testing units Vacuum testing facility Air plasma & Argon plasma cutting units Sand Blasting Facility

HEAT TREATING FURNACE FEW has its own stress relieving furnace of size10.7mx3.85mx 3.675m certified and calibrated. This furnace can stress relieve almost all equipment in a large process industry. The stress relieving furnace is electrically heated with provisions for six thermocouples.

3.4) COMMERCIAL DEPARTMENT The financial and legal interest of the organization related to bagging of order carried out. Based on the enquiries received from existing clients or prospective clients offers are submitted by this department. For preparing the offers data available with in the department as well as from other departments are sought and competitive offers are submitted to clients. Follow up with clients for bagging order and entering into contracts with clients are done by this department.

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3.5) MATERIALS DEPARTMENT Materials section comes under the Chief Engineer (shops) and it is functioning independently. A separate stores department is maintained. The Materials section has many important functions. They are as follows: 1. In Ward Materials a. All the stores materials coming to the stores as per the different orders made by the purchase section are received. b. The quantity and quality are checked and a receipt voucher is prepared. c. After the inspection of materials, quantity is recorded as per the code of each material. 2. Dispatch a. As per the delivery commitments and readiness shop products are through various transporters. b. The invoice declaration and gate pass is prepared. c. The materials produced daily is taken into stock and maintained in the register. 4. Issues of materials The main function of this section is to issue the materials as per the issue voucher. sent purchase

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3.6) PLANNING AND INSPECTION QUALITY CONTROL DEPARTMENT Quality policy Few is committed to 1) Customers satisfaction through quality products and services 2) Up gradation of technology and engineering skills 3) Continual improvement of the management system FEW has also set up a full-fledged QA/QC department staffed by engineers qualified in ASNT Level I, II to ensure complete compliance to engineering codes and assure quality of fabrication. FEW fabrication takes pains for such exhaustive and stringent inspection. FEW conduct Non Destructive Testing and Destructive tests such as 1) Dye penetrant tests, 2) Magnetic particle tests, 3) X-ray and Gamma ray radiography, 4) Ultrasonic tests, 5) Tensile and bend tests.

Codes in Practice ASME Section VIII , Div 1 ASME Section V ASME Section IX - Rules for construction of pressure vessels - Non Destructive Examination - Qualification standard for welding procedures , elders, Brazers ,welding and brazing operators ASME Section II , part C - Specification for welding rods, electrodes and filler materials . AWS - Welding procedure and Qualification
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Quality control system

1) Material control 2) Fabrication 3) Welding 4) NDT 5) Heat treatment 6) Calibration and measurement 7) Tests 8) Records retention and documentation

Quality System Procedure Quality records falling with in the requirements of ISO 9001 The quality control procedure in FEW includes 1) Procedure for document and data control 2) Procedure for control of quality records 3) Procedure for Internal quality record 4) Procedure for corrective and preventive action 5) Procedure for control of non conformance report 6) Procedure for contract review 7) Procedure for tackling customer complaints 8) Procedure for design control 9) Procedure for control of drawings and design calculation 10) Procedure for purchase of materials 11) Procedure for verification of customer supplied product for shop jobs 12) Procedure for handling, storage, packaging preservation and delivery
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13) Procedure for product identification and traceability for shop jobs 14) Procedure for process control in shops 15) Procedure for ensuring safety of shop 16) Procedure for product planning 17) Procedure for stress relieving of equipment 18) Procedure for hydro testing of pressure vessels 19) Procedure for pneumatic testing of pressure vessels 20) Procedure for inspection and testing of shop jobs 21) Procedure for inspection measuring and testing equipment 22) Procedure for inspection and test status of jobs 23) Procedure for statistical quality control of weld defects 24) Procedure for dye penetrant test 25) Procedure for magnetic particle test 26) Procedure for straight beam ultrasonic examination of plane steel plate for special application 27) Procedure for ultrasonic testing 28) Procedure for radiographic examination of weldments 29) Procedure for Tensile and bending test 30) Procedure for in house calibration 31) Guidelines for fabrication tolerance 32) Procedure for training

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3.6.1) DOCUMENT FLOW 1ST STAGE

Order from Client

To Client/Consultant For approval

Commercial

Technical spec.

Projects Drawing for approval Quality documents For approval

Technical spec.

Design

Production

Quality control

Fig:2- Document flow 1st Stage

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DOCUMENT FLOW 2nd STAGE

Approved documents

MDR to Client Projects

QC documents

Drawings

Drawings Quality Control QC document (relevant) Design

Drawings

Feedback

Production QC document (relevant)

Fig:3- Document flow 2nd stage

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3.6.2) NON CONFORMANCE CONTROL Procurement of raw materials

Action

Stores

Receipt of materials

Receipt of materials

Action

Projects

Procurement

Request for inspection

PO/Mill certificate Quality Control Acceptance/ Non conformance Acceptance/ Non conformance

Fig:4- Non conformance control in procurement of raw material

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NON CONFORMANCE CONTROL

Stage wise Inspection and Fabrication

To design if required Production

Request for inspection

Non conformance

Acceptance Quality control

Next stage of fabrication

Fig:5- Non conformance control in stage wise inspection and fabrication

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3.6.3) WELDING PROCEDURE SPECIFICATION (WPS) AND PROCEDURE QUALIFICATION RECORD (PQR) For every welding job whether it is fabrication or repair welding procedure must be drawn up in advance .Next the procedure must be qualified by carrying out actual procedure qualification. WPS is the document which list the parameters to be used in construction of weldments in accordance with the applicable code requirements. WPQ is the Welder performance qualification as per WPS and PQR. These records shall be accessible to authorized inspector.

3.6.4) QUALITY ASSURANCE PLAN (QAP) Before the commencement of fabrication the QAP must be accepted by the Client/Consultant/Third party Inspectors. The following are the major features that forms part of a QAP for pressure vessels.

1) Review of WPS and PQR 2) Raw material identification a) Plates for shells ,cones, pads b) Dish end, top ring ,baffle plates c) Pipe for nozzles, flanges, elbow 3) Dimensional check up prior to cutting 4) Fit ups of weld joints a) L/S of shell ,cone, dish, skirt b) C/S of shell ,cone, dish, skirt c) Nozzle pipe to flanges , elbow d) Nozzle to shell and cone ,dish e) Access hole to skirt f) Lifting lugs, name plate bracket
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5) ) Welding a) L/S of shell ,cone, dish, skirt b) C/S of shell ,cone, dish, skirt c) Nozzle pipe to flanges , elbow d) Nozzle to shell and cone ,dish e) Access hole to skirt f) Lifting lugs, name plate bracket 6) Orientation check of nozzles 7) 8) 9) 10) 11) 12) 13) NDT- DPT,UT,RT Pneumatic testing of nozzles Stress relieving Hydrotesting Painting Pickling and passivation Final inspection and issue of inspection release note.

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4) PROJECTS IN HAND 1 ) FACT UC a) Pressure vessels and heat exchangers for Ammonia Plant Feed Stock conversion of Ammonia Plant to LNG as LNG is expected to be available at Kochi by the end of 2012. Modifications in the Ammonia Plant are being done for using cheaper LNG as feed stock and fuel for Ammonia

manufacture as soon as it is available. The Project will bring an energy saving in the Ammonia Plant to the tune of 0.3 Gcal / MT Ammonia.. The pay back period of this project on account of energy savings alone is just six months. b) Conversion of fuel for the boilers to LNG It is also proposed to carry out modification in the 5 boilers at Udyogamandal Complex to use LNG as fuel in place of Furnace Oil.

2) FACT, Cochin division Fabrication of Ammonia Transportation Barge In order to produce 2000 TPD of Factamfos at Cochin Division, 500 TPD of ammonia is required. As there is no ammonia production at Cochin Division, 600 MT to 700 MT of ammonia will have to be transported daily to meet this requirement as well as to ensure sufficient buffer stock. At present, a maximum of 450 MT of ammonia is being transported by road. To ensure sustained

production of Factamfos at Cochin Division, it was decided to construct own barge to transport ammonia from Udyogamandal to Cochin Division. FACT`s fabrication division, FEW, has the infrastructure to enter into the marine vessel field. This is expected to have a vast potential especially looking at the thrust given by water transport from all sides including the Kerala Government. By manufacturing a barge to meet the in-house requirement, FEW envisages to achieve a landmark shift in its capacity thereby becoming competitive in a field of barge making and other related areas.
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3) Cochin shipyard Limited Fabrication of diesel alternate intake and uptake ducts for condenser

4) Chennai Petrochemical Limited(CPCL),Chennai Economiser header and tubes

5) Kerala Metals and Minerals Limited(KMML),Kollam Fabrication of crude quench surge tank

6) Fluid Control Research Institute (FCRI),Palakkad Fabrication ,erection and commissioning of testing facilities

MAJOR PROJECTS EXECUTED BY FEW 1)Bangalore Water Supply & Sewerage Board, Bangalore Fabrication, laying & commissioning of 1800mm dia pumping main (cross country) - 34 km.

2)Bharat Petroleum Corporation Ltd., Kochi Laying of petroleum product twin pipeline 600 NB (cross country) 19 km.

3)Madras Fertilisers Ltd., Manali, Chennai Design, fabrication, site erection and commissioning of MDEA Tank Package . 4)BPCL/Kochi Refineries Ltd., Ambalamugal Erection of equipment/machinery, fabrication and erection of piping for aromatic project.

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5)BPCL/Kochi Refineries Ltd., Ambalamugal Fabrication and erection of piping, tankages, erection of equipment etc., for relocation Asphalt Filling Plant.

6)Cochin Shipyard Ltd., Kochi Rolling welding and supply of Conductor Guides/Conductor Protectors - ONGC Project. Ship Hatch Covers.

7)Kerala State Electricity Board, Thiruvananthapuram Erection of 1650 MT of steel liners for the Lower Periyar Hydro Electric Power Project.

8)FACT (RAP), Udyogamandal Fabrication, erection, testing etc. of off-site storage tank.

9) FACT Cochin Division, Ambalamedu Design, supply, fabrication, erection and commissioning of Floating Roof Naphtha Storage Tank of 3900 m3 capacity.

10) FACT (RAP), Udyogamandal Design, engineering, manufacture/fabrication, site erection of Ammonia Storage System (5000 GMT capacity). Erection of underground piping for cooling water, fire hydrant and raw water. Fabrication, erection, testing of off-site storage tank. Fabrication, erection and testing of column and towers, drums and pressure vessels - 26 nos.

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5) CONCLUSION The Fact Engineering Works is a well reputed Indian Company which has been providing reliable engineering and fabrication services for over three decades to fertilizer, chemical and petrochemical and engineering firms. FEW's Design, Fabrication and Quality Assurance Department are manned by a group of engineers and technicians with hands-on experience in the fields of fertilizers and petrochemicals. Through this In-Plant training it was able to fulfill the objective of the study. Detailed study on the processes was made possible by giving emphasis on the practical side of the theory. All together it was a good experience to see the company and various processes carried out in the shops and the various functions of the company.

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REFERENCES

[1]. www.fact.co.in [2]. www.scribd.com [3]. www.google.com [4]. www.wikipedia.org

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