Contact
Phone :
00971 55 1096988
00971 55 1096981
00971 55 1096985
Fax :
00971 4 3331415
Manufacturing cargo bodies
We Propose to manufaturing different kinds of commercial bodies other than fuel tanklers , in a glance proposed product range are
  • Fuel Tankers
  • Bitumen Tankers
  • Stainless Steel Tankers
  • Chemical Tankers
  • Water Tankers
  • Vacum Tankers
  • Storage Tanks
  • Refuse Compactors
  • Tippers
  • Tipper Semi Trailers
  • Cement Bulkers
  • Flat Bed Trailers
  • Low Bed Trailer
  • Hoopers
  • Skip Loaders
  • Cargo Bodies
  • Water Bottle Carriers
  • Curten Side Trailers
  • Skeleton Trailers
  • Special Units
  • Silos
DESCRIPTION
After receiving the job card & engineering drawings, the supervisor shall arrange various resources for production. He will receive materials from the storekeeper using ‘Material Issue Note.

The Production Engineer shall co-ordinate with supervisors and plans the daily work programme possibly in the evening hours itself and the same will be informed to the crew members at the earliest to avoid the time waste in the next day.

After receiving the raw materials from store, the items to be cut shall be marked on the raw materials as per the cutting plan (if provided) / drawing. The materials identification marks like heat no. job no. etc shall be transferred to each part before cutting of all parts, and shall be offered to QC Engineer, who will verify the markings and record the identification nos. of parts.

Upon releasing the materials for cutting, the supervisor shall allot technicians skilled in the operation of gas cutter for cutting. During cutting all necessary safety measures shall be taken as per the Safety Procedure.

When edges of plates are gas cut, the resulting surfaces shall be uniform and smooth and Shall be freed from scale and slag accumulation before welding. Shell plates shall be cut by machine operated gas torch. Stainless steel plate required special type of cutting like Plasma cutting.

When materials require straightening, the work shall be done by pressing or another non-injurious method prior to any layout or shaping. Heating or hammering is not permissible.

Plates for rolling shall be properly squared and edge preparation done as per drawing prior to rolling. Before rolling starts, a template shall be made from steel sheet. The radius of curvature shall be written on it by metal marker, and shall be inspected by the QC Engineer.

While rolling stainless steel plates, the rollers must be rapped with cloth tapes to avoid contact with the M.S rollers.

During rolling the operator shall control the curvature by monitoring the same with the template. While rolling plates to small radius e.g. manhole neck, extra length has to be kept on either end so that the straight ends can be trimmed off.

After finishing rolling of each plate the QC Engineer will examine it for dimensional correctness and markings. The heat no., job no /item no will be recorded.

Fit-up for welding shall be done after edge preparation as per drawing. Suitable stiffeners and retainers shall be provided to minimise distortion during welding. Temporary stiffeners welded to the job for fit-up purpose shall be of the same type as the parent material.

Tack welds shall be carried out using the same welding procedure indented for the production welding of the joint. If unqualified welders make tack welds, the same have to be removed by grinding during production welding by qualified welders.

After finishing fit up the joint has to be cleaned from rust, slag, oil, grease etc., and prior to welding.

All main fit-ups, longitudinal and circumferential joints on shell, dished ends, fit-up of nozzles, fit-up of bottom plates, roof plates shall be inspected by QC personnel prior to welding.

The QC Engineer shall issue a list of qualified welders to the supervisors. The supervisor shall allot welding works to welders from this list and welding will be carried out as per approved welding procedures issued by the QC Engineer for the job.

If different welding processes are to be used on the same job, the QC Engineer shall issue a weld plan indicating the welding procedure to be used for each joint.

No welding of any kind shall be performed when the surfaces of the parts to be welded are wet from rain, snow.

Each layer of weld metal of multi layer welding shall be cleaned of slag and other deposits before the next layer is applied. The finished welds after removal of slag shall be left unground unless otherwise specified.

Reinforcement shall not exceed the maximum values allowed by the construction code.

Under cuts if any shall be ground to merge with the base metal are strikes if any shall be ground off. Whenever possible, the second side of full penetration butt welds shall be background to sound metal and re-welded.

INSPECTION
Upon receipt of Job Card and relevant specifications, QC Engineer shall prepare a Quality plan and issue to the supervisors. The inspections requirements of the job from raw materials to delivery shall be mentioned in the QP.

For jobs with third party inspection, the QC Engineer shall also prepare an ‘Inspection & Test Plan’ (ITP) which describes all inspection stages by QC department and the third party. The QC Engineer and third party inspector shall carry out all inspection activities as per the ITP at every stage as the fabrication progresses.

After inspecting at each stage, if found satisfactory, the QC Engineer and third party inspector shall sign on the ITP against that particular inspection point. This signature indicates that the person performing that inspection has verified all requirements as per the acceptance criteria and found satisfactory.

Whenever detailed reports of inspection are to be maintained, the details of inspection and results shall be recorded on separate inspection reports. The QC Engineer maintains various forms for this purpose.

The QC Engineer shall inspect all the raw materials used for jobs. Upon receipt of material the Storekeeper after his preliminary inspection for any transit damage, broken crates, leak etc, shall fill the Goods Receipt cum Inspection Report (GRIR) and offer to the QC department.

The QC Engineer shall inspect the material and ensure that the material meets all P.O and specification requirements.

Mill test certificates shall accompany all plate, pipe, flanges & fittings materials.

The QC Engineer shall verify the dimensions of materials and ensure that they meet the requirements of the specification. Dimensional tolerances shall be as per the relevant material specification.

The QC Engineer shall mark the number of pieces accepted/rejected on the GRIR and copies will be issued to the storekeeper and the purchaser.

Any non-conformance observed shall be handled as per QSP-04 (Control of Non-conformances)

The QC Engineer is responsible for maintaining traceability of materials used in fabrication work. All pressure parts shall be marked with proper identification marks and the material heat/ job number before they are cut.

The above identification nos. shall be maintained throughout the fabrication process, and the QC Engineer shall record the details of each part on ‘Material Traceability Record’.

The QC Engineer shall be monitoring the fabrication process throughout. Visual/Dimensional inspections shall be carried out at appropriate stages and feedbacks shall be given to production.

This includes inspection of fit up, welding, dimensional inspection of dished ends, shells, radius check, plumbness check, inspection of nozzle cut outs, final dimensional check, etc for pressure vessel/ shell fabrications.

Special care will be taken during fabrication of stainless steel pressure parts as per the customer/ code& standards requirements.

Non-destructive tests (e.g. RT, MT, PT, UT etc.) if specified, shall be subcontracted to reputed and approved inspection agencies.

The QC Engineer shall review and approve the NDT procedure and personnel qualification records of NDT technicians prior to carrying out NDT work.

The QC Engineer shall mark the locations to be tested with the consent of the third party inspector/client representative if required.

The QC Engineer shall review all NDT reports. Defects if any shall be repaired using a repair procedure approved GM/ QC Engineer.

After finishing all fabrication and welding works on pressure vessels the QC Engineer prior to final testing shall carry out a dimensional and visual inspection.

After getting clearance for final testing, the vessel/ pressure parts shall be hydro tested as required the specification/code.

The hydro test shall be carried out as per procedure approved by the QC Engineer or customer requirements. Arrange TPI witness& permanent pressure recorder for hydro test if customer insists.

All welders performing welding on coded constructions shall be qualified by the QC Engineer to the requirements of the construction code. Generally welders are qualified to ASME Sec. IX of the Boiler & Pressure vessels code.

Welder qualification tests shall be witnessed by a reputed third party inspection agency or customer authorised representative.

The QC Engineer shall approve welding procedures used for coded constructions. The QC Engineer shall arrange procedure qualification test as and when required.

The scope of Painting activity is limited at present. The surface will be cleaned manually or mechanically well without having grease, oil and other impurities. Apply the primer as per the customer & paint manufacture recommendations.

Atmospheric temperature, Humidity and Dew point temperature all should be taken into consideration for before applying of primer, mid coat and final coat. Always check the Pot life of the paint. Allow the Induction period for the mixing of paints as per the Data sheet.

Check the Wet film thickness during painting and Dry film thickness after curing. All the inspection stages should be recorded. Permit only the Qualified personal for this process.