Indian Welding Journal

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Challenges & Development in Manufacturing Technology for Fabrication of Super Heavy Tubular Reactors


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1 Larsen & Toubro Limited, Hazira Works; Surat; Gujarat - 394510, India
     

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Super Heavy Tubular Reactors have grown to the size of up to 10m dia and 1500MT weight. These reactors pose huge challenges for the equipment manufacturers since they involve fabrication of heavy thickness Tube sheets (up to 450mm thick), huge diameter shells (10m OD), large number of nozzles and enormous amount of Tube # Tube sheet welds (30000 per equipment). The present paper describes development of various manufacturing technologies to counter such challenges - namely Narrow Gap SAW of Longitudinal & Circumferential seams. Fabrication & Distortion control of super heavy tube sheet including weld overlay on it, Narrow gap orbital Nozzle welding by SAW, Strip cladding on channel shells and Automatic Tube # Tube sheet welding.


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  • Challenges & Development in Manufacturing Technology for Fabrication of Super Heavy Tubular Reactors

Abstract Views: 310  |  PDF Views: 5

Authors

Pallav Chattopadhyay
Larsen & Toubro Limited, Hazira Works; Surat; Gujarat - 394510, India
B. K. Rai
Larsen & Toubro Limited, Hazira Works; Surat; Gujarat - 394510, India
H. K. Patel
Larsen & Toubro Limited, Hazira Works; Surat; Gujarat - 394510, India
K. B. Desai
Larsen & Toubro Limited, Hazira Works; Surat; Gujarat - 394510, India
Sanjay Chaudhary
Larsen & Toubro Limited, Hazira Works; Surat; Gujarat - 394510, India

Abstract


Super Heavy Tubular Reactors have grown to the size of up to 10m dia and 1500MT weight. These reactors pose huge challenges for the equipment manufacturers since they involve fabrication of heavy thickness Tube sheets (up to 450mm thick), huge diameter shells (10m OD), large number of nozzles and enormous amount of Tube # Tube sheet welds (30000 per equipment). The present paper describes development of various manufacturing technologies to counter such challenges - namely Narrow Gap SAW of Longitudinal & Circumferential seams. Fabrication & Distortion control of super heavy tube sheet including weld overlay on it, Narrow gap orbital Nozzle welding by SAW, Strip cladding on channel shells and Automatic Tube # Tube sheet welding.