flanging 21

The last several posts have been about the workers.  It’s time to post about the work.  Here is a work order.

work order2

The top half isn’t very informative.  Note the little Brighton Man in the upper left.  The rest of the info on top is merely some tracking numbers, the customer name, some dates, the name of the salesman who placed the order.  The only item of interest in the top half is Order Quantity.  This tells me how many pieces are on the order.  In this case it’s 1.

The next section contains all the important stuff.  Starting in the left column, Job Type: Labor and Matl.  That means we are charging the customer for labor and material.  Which means we are selling them the metal the head is to be formed with.  Next is Mateiral Type: SA240-304.  This tells me what kind of metal is being formed.  In this case 304 is a grade of stainless steel.  Next is Thickness: 0.25″ Nom.  The metal is a quarter-inch thick.  Nom stands for nominal, which means the exact thickness isn’t very important; if it were, the customer would order a minimum thickness.  If the head was a quarter-inch thick with a three-sixteenths minimum, the thickness of the finished head could not be less than three-sixteenths.  Next is Blank: 97.75″.  This tells me the size of the circle of steel when it was flat.  Next is Center Hole: None.  This tells me the head is to be run without a center hole.  Most heads have a center hole, which is usually one & nine-sixteenths inches.  Next is Weld: Yes.  This means the head is not being formed from a single piece of metal, that it is a welded construction.  Which means two or more segments have been welded on a seamer, an automatic welder, to form the circle.  Next is Bevel: Outside Bevel 37&1/2 degrees with a 1/16 inch land.  This gives the machining detail for the edge.  In this instance it is an outside 37&1/2 degree bevel with a 1/16 inch land.  It could be anything, such as a square cut (which means a flat surface on the edge), or any combination of bevels and tapers and bore-ups inside and/or outside.  Next is Finish Inside and then Finish Outside:  Mill Finish in both cases.  This tells me it is not going to be polished.  Next is Weight Each: 571.  This tells me the head weighs 571 pounds.  Next is Form Code: Cold Formed and Pickled.  This tells me the head won’t be annealed (heat treated) and it will get acid cleaned.

Moving over to the right column, Tag: This is blank; in any case it is just another tracking number.  Next is Style: Standard F&D.  This tells me what shape the head will be.  A standard head is the same as an ASME head, only not held to as rigorous standards.  The F&D merely means flanged and dished.  Next is Diameter: 90″OD.  This tells me the diameter of the finished head and that it is to be measured on the outside (the OD stands for outside diameter).  Next is RD: 90″.  This tells me the radius of the dished part of the head is 90.  Next is ICR: 1″.  This tells me the inside corner radius is 1″, so I know which icr roll to form the head around.   Next is X-Ray: No.  The weld seams will not be x-ray’d for internal cracks. Next is Volume: 223.  I have no idea what that number means.  Next is SF:1.5″.  This tells me the straight flange is an inch and a half long.  Next is OAH: 14.2456″.  This tells me the overall height (which includes the thickness of the material) is approximately 14&1/4″.  Next is Circumference: 23′ 6-3/4″ OC.  This tells me the circumference, which is measured on the outside (OC) at the top of the straight flange will be 23 foot, six and three-quarters inches.

Below the two columns are the Special Notes.  The only note here is that the head will be formed from two welded segments instead of four, as the customer must have originally ordered.

Also, the machining details can be drawn out on a separate print.  Where this order says Bevel, another order might say Machine per print.  This can be a pain for several reasons.  One, the salesperson might not include the print with the order.  Two, the print might not make any sense; I’ve seen some physically impossible stuff on machining prints.  Three, the print quality can be shitty and you just can’t read the thing.

So this is what I work off of.  I’ve seen thousands, tens of thousands, maybe hundreds of thousands, of work orders like the one at the top of the page.  Once I retire I hope to never see another one of these damn things again.

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