STANDARD OPERATING PROCEDURE

Doc No. : QA/SOP/MOF

SOP FOR MANUFACTURING OF REACTOR REV No. : 00 DATE : 03.06.2022

I. PURPOSE
To define the Standard Operating Procedure for Manufacturing of Reactor.

II. SCOPE
This procedure is applicable for Manufacturing of all Reactor at Chemsept
Engineering Pvt. Ltd.

III. PROCEDURE

SR. Activity Details Responsible Documents Remark

NO.
1 Design Department Gives GA, Details & Layouts, Design/ GA Drawings,
Client Approved Drawings of Fermenter to Quality BOM,QAP
Production & Quality Department Gives Approved
QAP to Production Department.
2 When Required Raw material For Reactor received Store PO Copy,
at Factory. The Store Person Release GRIR with GR/IR
Reference of Our PO Copy & Actual material Bill &
Tagging that Material As per GRN No. & SO No. to
ensure that the Material Should Be Used For specific
SO No.
3 Store Person Gives That GRN to Quality Department Store GRN
to Check & Release the Material For specific SO No.
or to mark with Proper Tagging & Colour Coding
After Inspection.
4 Quality Department Checks That the Material As Per Quality MTC , Material
Physically, Visually & Dimensionally With Ref. ASME/ Identification
ASTM Documents & Testing At NABL Approved Labs Report
For Chemical, Physical, Micro, Or UT Test (All Tests
As Per Requirements) Material Is of require grade Or
Not.
5 If The Received Material Is Observed Not As Per Quality Rejection
Standard At Dimensionally, Aesthetically, Or Note
Physically Damaged Or Fail At Lab Testing Or PMI
Testing Then That Case Material Shall Be Rejected.
And That Material Is Tagging By The Rejection Mark.

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 STANDARD OPERATING PROCEDURE
Doc No. : QA/SOP/MOF
SOP FOR MANUFACTURING OF REACTOR REV No. : 00 DATE : 03.06.2022

SR. Activity Details Responsible Documents Remark

NO.
6After The Clearance Of Raw Material By QC Officer The Production Release of
Required Material As Per The Drawing, The GRN
Production Officer Take That Material To Start-Up
The Production.

7 For Dish-End Marking of Blank Dia. On Given Raw Production Layout

Material S.S. Sheet/Plate As Per Design Cutting Drawing
Layout/Drawing/Calculation.
8 The QC Person Inspect The Blank Dia. Marking As Per Quality Layout
Design Drawing Cutting Layout/Calculation. Drawing
9 After Inspection the Blank is Giving For Forming as Production Dish-end
Per Drawing. Drawing
10 After Forming Of D-End QC Officer Check it By D-End Quality Dish-end
Template. Checks OCF, Height, SF, OD, ID & Drawing
Thickness as Per Drawing at Vender Site.
11 For Shell Marking of Shell Plate On Given Raw Production Shell Layout
Material S.S. Sheet/Plate As Per Design Cutting Drawing
Layout/Drawing/Calculation.
12 The QC Person Inspect The Shell Plate Marking As Quality Shell Layout
Per Design Drawing Cutting Layout/ Calculation Drawing
13 After Inspection the Shell Plate is Giving For Rolling Production Shell Drawing
as Per Drawing

14 After Rolling Of Shell ‘L’ Seam Set-Up Prepared. Quality Shell Drawing,
Then QC Officer Check it By Edge Preparation, Angle WPS
of Edge, Root Gap & Root Face.
15 Then Welder Welding the Shell At ‘L’ Seam. Production Shell Drawing,
WPS

16 ‘L’ Seam Visual inspection. ‘L’ Seam Back chip DP Quality Shell Drawing,
Inspection. LPT Procedure
17 After DP Inspection ok , QC person give clearance for Production Shell Drawing,
backside welding WPS
Production Shell & Dish
For Shell to Shell & Dish to Shell Set-Up. ‘C’ Seam Drawing, WPS
18 Set-Up Prepared

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 STANDARD OPERATING PROCEDURE
Doc No. : QA/SOP/MOF
SOP FOR MANUFACTURING OF REACTOR REV No. : 00 DATE : 03.06.2022

SR. Activity Details Responsible Documents Remark

NO.
19 Set Up Inspection by QC Officer Quality Shell & Dish
Drawing, WPS
20 ‘C’ Seam Visual inspection. ‘C’ Seam Back chip DP Quality Shell Drawing,
Inspection. LPT Procedure
21 After DP Inspection ok , QC person give clearance for Production Shell Drawing,
backside welding WPS
22 After welding vessel should offer for Radiography Production Shell Drawing,
testing. RT Procedure
23 After RT all film should be review by Level II QC Quality RT Reports &
Engineer Film
24 Limpet fitment should be done as per drawing Production Shell Drawing,
WPS
25 QC Inspector will check Limpet Fitment as per drg. Quality Shell Drawing,
WPS
26 After Inspection clearance Limpet should proceed Production Shell Drawing,
for welding WPS
27 After completion of Limpet welding shell should Production Matt/Mirror
proceed for Internal polishing. Procedure
28 Internal coil Bending & welding should be done. Production Shell Drawing,
WPS
29
For For Nozzle Marking At Top/ Bottom D-End & Shell. Production GA Drawing
Nozzle Marking Preparation At Top/Bottom D-End Or
Shell As Per Drawing.
30 Nozzle Marking Inspection By QC Officer As Per Quality GA Drawing
Drawing/ Orientation Plan. And Giving Clearance For
Nozzle Opening.
31 Nozzle Opening. Nozzle Set-Up Preparation. Production GA Drawing
WPS
32 After Preparation Inspection By QC Officer. Quality GA Drawing
WPS
33 Nozzle Welding. Production GA Drawing
WPS
34 After Nozzle welding polishing should be done Production Matt/Mirror
Procedure
35 QC inspector check all Internal & External Visual Quality Roughness
Inspection of vessel Reports
36 QC Officer Checks the Limpet Hydro Testing (To Quality GA Drawing,
Check Leakages or Pressure Drop) Hydro testing
Procedure

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 STANDARD OPERATING PROCEDURE
Doc No. : QA/SOP/MOF
SOP FOR MANUFACTURING OF REACTOR REV No. : 00 DATE : 03.06.2022

37 QC Officer Checks the Internal Coil Hydro Testing (To Quality GA Drawing
Check Leakages or Pressure Drop) Hydro Testing
Procedure
38 Pneumatic Testing At Pad Plates & Flanges (To Quality GA Drawing,
Check Porosity, Pin Holes or Cracks) Pneumatic
testing
Procedure
39 QC Officer Checks the Vessel Pneumatic Testing (To Quality GA Drawing,
Check Leakages or Pressure Drop) Pneumatic
testing
Procedure
40 After Hydro The Equipment Giving to Finishing/Acid Production GA Drawing
Cleaning/Painting As Per Requirements Given In Passivation &
Drawings. Polishing
Procedure,
Painting
Procedure
41 Final Packaging (Taking Photos during Packing) & Quality Packing
Preparation of Packing list. Procedure
42 Dispatch. Production Invoice
Packing list