Typical Panel Fabrication Flowchart:

Text Box: Frame Fabrication Personnel pre-certified to cut and weld parts. Use jigs & fixtures to maintain dimensional conformity. Non-destructive test all welds to spec. Conduct in-process inspections and final visual tolerance, weld & dimensional check. Text Box: Receive from Procurement

Text Box: Inspection & Identification Inspect to insure proper tolerances are maintained. Tag & cross-reference each component & fitting for each panel. Produce tape & voice video to note any difficulties, modifications, assembly procedures, etc. for use during re-assembly. Text Box: Tubing Build-Up Personnel trained and certified to perform tube forming and flaring. Attach brackets, holders and subcontractor components. Incorporate mock-up fittings if long lead items have not been received. Determine tube routing and measure to decide precise tube requirements. Form tubing using Mandrel Parker hydraulic bender and flare tubing using PhI (Conrac) 3CP tubing end preparation equipment. If required, weld tubing using ARC 200 amp computerized orbital welding system for 1/8 " to 2" tubes. Conduct final weld inspection to specifications. Conduct in-process inspections, insure concentricity, ovality, and size using calibrated tolerance gauges. Text Box: Piping Build-Up Attach brackets, holders and subcontractor components. Incorporate mock-up fittings if long lead items have not been received. Determine pipe routing, starting with largest diameter pipe, and measure to decide precise pipe requirements. Use simulated piping joint configurations for close tolerance areas or to check shrinkage and distortion. Tack weld, full penetration weld, etc. piping as required. Check internal purge gas pressure and maintain interpass temperature during welding. Create weld map. Conduct in-process inspections, insure concentricity, ovality, and size using calibrated tolerance gauges, visually check in-process welds, radiograph inspect welds as specified. Conduct final weld inspection to specifications. Text Box: Paint & Blast Blast all carbon steel hardware to remove oxidation. Apply primer within 6 hours. Paint in accordance with specifications. Inspect blasted surface and all coatings. Reassemble frame & faceplate with dissimilar metals. insulated. Text Box: Deliver to Cleaning

Text Box: Handling Pre-Cleaned Components Stored in original packaging. If needed for fitting, RTV is used as sealant of port fittings which are cleaned to level of component and inserted. After fitting, component is returned, sealant removed and component is re-packed in certified clean film. Text Box: Pre-Cleaning Valves and components are disassembled, fittings are removed. Disassembled panels are maintained as a unit. Metal parts are put through controlled degreasing solution followed by a chemical process to remove oxidation and then acid-passivated. Parts are rinsed with pH 6-8 demineralized water and visually dried with clean gaseous nitrogen. Parts with threads or blind passages and software are ultrasonically cleaned. Text Box: Clean Room Procedures All parts are flushed, flowed, or immersed in ultra high purity solvents. Samples are collected to determine particulate level and NVR content. Cleaning procedure and NVR analysis is repeated until samples fall within specified tolerances. Parts are purged with clean, dry, gaseous N2 for drying. Components and valves are reassembled using manufacturer drawings and torque recommendations. All soft goods are reused.

Text Box: Receive from Fabrication Text Box: Functional Test Custom written test procedure sent to customer for review and approval 30 days prior to test start. Customer may witness tests as desired. Tests will be witnessed and signed-off by Quality Assurance. Panel undergoes full operation simulation actuating all elements of the panel. All valves and regulators are cycled and tested to assure functional integrity and zero external and internal leakage. Text Box: Final Assembly Controlled by specifications, supplemented by cross-reference tags and video tape. Assures proper torque values and mating & leak tight connections on all fittings. Only certified LOX/GOX compatible lubricants are used. Assembly tools are cleaned and maintained to Clean Room specifications. All connections are tamper proofed w/QA seal. Ports are packed or plugged to render airtight seal. Text Box: Deliver to Shipping

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