"Shell forming and tube bending for process plant equipment" encompass critical techniques in the fabrication of various components, ensuring the structural integrity and functionality of equipment used in industrial processes. Metal forming processes play a pivotal role in shaping raw materials into intricate components required for process plant equipment. Sheet metal forming techniques involve the manipulation of flat metal sheets through processes such as bending, stretching, and rolling. Surface development techniques aid in transforming flat sheets into complex shapes required for components like cylindrical and conical shells. Plate bending is a key aspect of shell forming, where flat plates are bent to form cylindrical or conical shells, essential for vessels and tanks used in process plants. Dished end forming techniques are employed to shape the ends of cylindrical shells, ensuring a secure and leak-tight closure. Tube bending and pipe bending are crucial processes for creating complex piping systems required in process plant equipment. By bending tubes and pipes to specific angles and radii, Engineers can design efficient and space-saving layouts for conveying fluids or gases within the plant. The plate bending process involves the precise manipulation of metal plates to achieve desired shapes and dimensions. Through a short video demonstration, learners will gain insights into the various steps involved in plate bending, from initial setup to the final forming of the plate into the desired shape. By mastering shell forming and tube bending techniques, Engineers and fabricators can effectively produce components essential for process plant equipment, ensuring durability, efficiency, and safety in Industrial operations. Through hands-on practice and theoretical understanding, learners will develop the skills necessary to excel in the fabrication of process plant equipment components.

The manufacturing cycle for pressure vessels, crucial components in process plant equipment, involves a series of meticulous steps to ensure safety, quality, and reliability in various industrial applications. Pressure vessels come in diverse types based on construction and service requirements, including cylindrical, spherical, and non-cylindrical vessels designed for specific functions and operating conditions. Components of a pressure vessel typically include the shell, heads or dished ends, nozzles, manways, supports, and internals, each serving a vital role in containing and regulating fluid or gas pressure. The typical manufacturing lifecycle of a pressure vessel begins with meticulous planning, sequencing, and scheduling to optimize production efficiency and meet project deadlines. Plate cutting and rolling processes are employed to fabricate the cylindrical shell, while forming techniques such as petal forming are used for head fabrication. Welding plays a crucial role in assembling pressure vessel components, with long seam and circular seam setups ensuring leak-tight joints and structural integrity. Refractory application techniques are employed to line vessels operating at high temperatures, protecting them from heat-induced damage. Machining operations are used to obtain precise dimensions and surface finishes on pressure vessel components, while coating and surface preparation techniques improve corrosion resistance and life expectancy. Post-weld heat treatment, including stress relief, is used to reduce residual stresses and improve material characteristics, hence maintaining the integrity of welded seams. Through a comprehensive case study, learners will explore the importance of fixtures, supporting structures, and furnace settings in post-weld heat treatment processes, ensuring uniform heating and cooling for optimal results. By mastering the manufacturing cycle for Pressure vessels, Engineers and technicians can ensure the safe and efficient operation of process plant equipment, meeting stringent quality standards and regulatory requirements in various industrial sectors.