Are We Qualified?
Actual Answers to Actual Customer Questions
(Excerpted from completed questionnaires)
1. Summarize Your Operating Experience?
- We have custom fabricated over 7,000 shell & tube heat exchangers, ASME pressure vessels and a variety of tanks in over 5,500 unique jobs.
- Each year, 67% of our production is dedicated to the fabrication of custom shell & tube heat exchangers. The remaining production is primarily in ASME Pressure Vessels with tanks filling out the remainder of our capacity.
- Common fabrication materials include 316, 304, 2205, C276, 904, 200 Nickel, and Carbon Steel.
2. Fabrication Area?
- 50,000 sq. ft. in two fabrication buildings
3. Office Area?
- 3,200 sq. ft. office building
4. Open Storage?
- 5 acres fenced and secure
5. Bridge Crane Total Capacity?
6. Overhead Cranes?
- (1) 25 ton, (1) 20 ton, (3) 10 ton, (5) 5 ton, (2) 2 ton
7. Maximum Bay Height?
8. Maximum Door Access?
9. Production Vessel Dimensional Limitations?
- Maximum length – 120 ft.
Maximum diameter – 24 ft. 4 in.
Maximum weight – 160 tons
10. Tank Turning Rolls?
- (30) Sets (10 ton to 150 ton)
11. Transportation Alternatives?
- Road – Limitation 120’, Diameter 15’-6”, Weight 135 Tons
- Rail – Adjacent to rail yard, within 5 miles of Midwest Inland Port Railway Hub)
12. Major Facility Production Equipment?
- Plate Roll – 1.25” x 10’ Bertsch; 3/8” x 5’ Webb; Subcontract to 3” thick
- Press Brake – 600 ton 14’ bed
- Burn Table – CNC BurnTable 10’ x 50’ MG
- Shear – ½” x 12’ Niagra
- Flame cutters (9) to 6” CS
- Plasma cutters (6) to 2” SS
13. How do you segregate alloy and iron steels during fabrication.
- Alloys are received, stored and segregated from iron steels through fabrication process
- Fabrication work stations are segregated and partitioned with segregation screens
- Tools, especially grinding wheels, are coded and dedicated to specific type of steel
- Shared equipment, like plate rolls, are brushed and cleaned with zylene between each material change over
- Completed stainless vessels are passivated
14. Do you provide ASME SA materials?
- Yes. We provide SA, SB & SFA materials with MTR’s
15. Do you fabricate to ASME Section VIII.
- Yes. Conformance to ASME Sec. VIII, Division 1
16. Do you possess a “U” Stamp for pressure vessel fabrication?
17. Do you possess other Stamps?
18. Do you have an in-house engineering department or appropriate engineering support within organization?
- Yes. Engineering is staffed with degreed mechanical and chemical engineers
19. Describe your engineering capabilities and software used.
- Mechanical Engineering – PV Elite; API 620/650; TEMA, ASME SEC VIII, Div. 1
- Thermal Sizing – Aspen Tech.,
20. Do you do process engineering?
21. Do you have formal quality control system?
- Yes. Per ASME Code, our formal Quality Control System is documented in our Quality Control Manual and is independently audited every three years.
22. Does your organization have a separate quality manager?
- Yes. Our Quality Control Manager reports directly to the Company President.
23. Do you have a quality manual available for review?
- Yes. Copies are available under controlled distribution.
24. Do you provide project tracking and communication?
- Projects are tracked from inception with receipt of an RFQ through receipt of purchase order, design & drawing approval, long lead materials ordering, machining, bundle insertion, hydro-test, inspection points, complete fabrication, paint if required, shipping.
- Delivery dates are quoted in “weeks after receipt of approved drawings” – (ARAD).
- Customers and/or their quality inspector agents are notified in advance of dates for requested hold points.
- Logistics coordinates shipping and delivery with customer needs and timing.
- Communication is ongoing throughout entire process through our Inside Sales single point of contact or directly with specific company staff.
- Customers and their agents are welcome to visit our facility to inspect or discuss their projects.
25. Do you have systems in place to receive material and track it through the shop fabrication process?
- Yes. Material is tracked and recorded through entire process. Information is filed in permanent job files.
26. Do you have procurement support within the organization?
- Yes. Procurement is managed by an experienced Purchasing Manager utilizing purchasing management tools within an integrated software system.
- Our material receiving manager confirms and documents receipt of purchased materials including receipt of supporting MTR documentation for formal tracking of all materials used in a project.
27. Do you have on-site accommodation for third party inspection.
- Yes. Designated parking, desk, phone, computer with access to Wi-Fi and conference room available.
28. Do you do machining?
- Due to the almost limitless machining capabilities available locally, we subcontract most our machining resulting in accelerated deliveries and very competitive pricing for our final products.
29. Sand blasting on site?
30. Do you have inside painting capability?
- Painting is done in a partitioned area in our shop normally during our 2nd shift.
31. Describe your ability to handle size & weight of fabrication between manufacturing steps.
- We have demonstrated ability to handle 320,000 lbs, although this is beyond our cranes.
- We use up to 500 ton auxiliary lift capability when needed.
32. Please provide typical lead-time from purchase order issue to shipment.
- As a custom fabricator, this time will vary based on each individual job quoted and customer needs. Typical lead times range from 8-16 weeks after receipt of approved drawings.
33. What is your typical delivery time for receipt of materials?
- Heads, 5 weeks
- Plate, 1 week
- Pipe, 1 week
- Flanges, 1 week
- Tubes, 5 weeks
- Tube Sheet Material, 1 week
34. Maximum production capacity?
- 14,000 to 16,000 hours per quarter with ability to increase second shift by an incremental 5,200 hours.
35. Do you do field work?
36. Do you do repair work?,/h3>
- Yes. Mason does repair heat exchangers and pressure vessels in house. Mason requires that customers ship units that are clean and dry with Safety Data Sheets (formerly MSDS sheets).