1)JOB PROCEDURE for Tank( How to Fabricate or Eriction) Important

7/23/2019 1)JOB PROCEDURE for Tank( How to Fabricate or Eriction) Important

http://slidepdf.com/reader/full/1job-procedure-for-tank-how-to-fabricate-or-eriction-important 1/15

DOC NO

DATE

PAGE NO

03 OF 16

PROJECT TITLE

PROCEDURE FOR FABRICATION & ERECTION OF

TANKAGES BY JACKING UP M ETH OD

J O B P R O C E DU R E F O R F A BR IC A T IO N & E R E CTI O N O F T A NK AG E BY J A C K I NG ME T HO D

1. SCOPE:

This procedure covers detailed activities for fabrication, erection and testing of thestorage tanks, and also equipment & manpower required for the same. All the tasks /activities need to be carried out with atmost care with good workmanship and in

accordance with the specifications to achieve satisfactory completion of the wholeactivities.

2. PURPOSE:

The purpose of this document is to follow proper methodology to carry out theactivities in a proper sequence for fabrication, Erection and Testing of the storagetanks.

3. REFERENCE:

A! "#$ A%E %ec !' A%E %ec (Tender %pecification.i.e. )*+)**+--+$+(+$+$$)+A0 (%%$$0 )*+)**+$$/1+$$+

$$)0 )*+)**+--+$$+(.$+$$#+A etc Approved 2rawing / %pecification.

4. RESPONSIBILITY:

The responsibility of implementation of this procedure rests with 3onstructionanager of /% (ishal %tructurals vt. 4td.

5. METHOD OF CONSTRUCTION:

5.1 IDENTIFICATION OF MATERIALSEach iece of lates, fittings or any other component of tankage system shall beclearly identified by marking heat no. on the part 5e.g.6 !% $" 7r.8, 9.:o.+''';using hard punching.Each weld <oint shall be marked with <oint :umber with =elder :umber.

5.2 FABRICATION WORK

All fabrication work involving material identification, marking, cutting, rolling andwelding shall be done in accordance with this <ob procedure, A! "#$ 54atestedition;, >E %pec and tender documents. The workmanship shall be good in everyrespect meeting all safety, ?3 & :2T requirements, with the coordination of Engineer+!n+3harge.

Prepared by

CONTRACTOR

Concurred by

Name :Design:

Hindustan Petroleum Crop. Ltd.

Approved by

Name :Design:

Hindustan Petroleum Crop. Ltd



DOC NO

DATE

PAGE NO

04 OF 16

PROJECT TITLE

PROCEDURE FOR FABRICATION & ERECT ION

OF TANKAGES BY JACKING UP M ETH OD

4ay all the plates, %tructural & pipes in such a way prior to fabrication tofacilitate proper checking of dimensions & heat no.

ark the components as per the drawings.

5.2.1 ANNULAR & BOTTOM PLATE FABRICATION:

ark the plates as per drawing 3arry out the cutting operation after proper inspection. All the cutting operation shall be carried out by 7as 3utting. 7rind the cut edges smooth to remove burrs and slag. %tack the plates at designated place in the fabrication yard in proper

sequence. 8acking @ strip shall be fitted and tacked with annular plate as per drg. After completion of the fabrication under side of annular and bottom plates shall

be blast cleaned and painted as per the specification to the satisfaction of theengineer+in+charge.

3heck the >oint osition, oot gap for welding after welding !nspection by weldvisual & :2T as per A! "#$ / Tender document.

5.2.2 SHELL PLATE FABRICATION

4ay all the plates in the open area such a way easy for marking and cutting. ark the plates as per drawing and to the satisfaction of Engineer+in+charge. The cutting operation includes beveling shall be carried out by gas cutting

method on all the four sides. 7rind the cut edges smooth to remove slag and burr. The edge prepared plates shall be shifted by hydra crane to the rolling area. The plates shall be fed to rolling m/c. by means of hydra crane & proper lifting

tools and tackles.

Prepared by

CONTRACTOR .

Concurred by

Name :

Design:


Approved by

Name :

Design:




DOC NO

DATE

PAGE NO

05 OF 16

PROJECT TITLE



The plate shall be rolled as per drawing details and the radius shall be checkedusing Template.

roper care shall be taken for the smooth curvature. "BB 4ong 5# to "mm thk.; Template shall be used to check rolling curvature

accurately.

The Template shall be checked and cleared by inspection authority. The rolled plates shall be inspected and shall be within $mm. of tolerance

limit. The rolled plates shall be shift to shot blasting yard to carryout the shot blast

as per >E specification. Cinal profile and dimensions check shall be carried out before sent for rection.

5.2.3 ROOF PLATE FABRICATION

ark the roof plate as per drawing

All the cutting operation as per requirement shall be carried out after gettingthe clearance from the inspection authority.

All the cutting operation shall be carried out by gas cutting method on all thefour side.

7rind the cut edges smooth to remove burrs &slag. %tructural item of the roof shall be fabricated as per drawing. These roof plates shall be shifted to blasting yard to carryout the blasting and

painting.

Prepared by

CONTRACTOR .

Concurred by

Name :Design:


Approved by

Name :Design:




DOC NO

DATE

PAGE NO

06 OF 16

PROJECT TITLE



5.2.4 APPURTENANCES

ark the required items of the Appurtenances as per the drawing. All the

cutting operation as per requirement shall be carried out after getting the

clearance from inspection authority.

All the cutting operation shall be carried out by gas cutting method.

7rind the cut edges smooth to remove burrs & slag.

Clanges face to be covered with a suitable cover to protect from damage

during handling, fabrication and transportation.

The entire shell noDDle, roof appurtenance, i.e. flanges, flanges to pipe

<oint and other requirements etc. %hall be fabricated as per approved

drawings. All the fabrication and welding activities shall be carried out after the stage

wise inspection wherever required.

The :.2.T requirements as per code specification.

5.2.5 SPIRAL STAIRWAY HAND RAILING

All the structural items shall be straightened before marking and cutting.

ark the components as per drawing.

All the cutting operation, as per requirement shall be carried out after getting

the clearance from inspection authority.

All the cutting operation shall be carried out by gas cutting method.

7rind the cut edges smooth to remove burrs & slag.

Cabrication such as fitting, welding, drilling, etc. %hall be carried out as per

drawing and after the clearance from inspection authority.

After fabrication all these structural items shall be blasted and painted as per

requirement.

5.3 ERECTION:

5.3.1. ANNULAR PLATE LAYING

3heck the level of foundation as per specification A! "#$ clause *... 4atest

edition. After getting clearance for annular plate laying, mark the $

o, -$

o, )*$

o, $

oco+

ordinates on the foundation from the reference point.

4ay the annular plate as per approved drawing.

Prepared by

CONTRACTOR .

Concurred by

Name :

Design:Hindustan Petroleum Crop. Ltd.

Approved by

Name :

Design:Hindustan Petroleum Crop. Ltd



DOC NO

DATE

PAGE NO

07 OF 16

PROJECT TITLE



Fut radius of the annular plate shall be in positive side 5# to )$ mm.; in order to

achieve the final required radius after weld shrinkage.

Frientation of the annular plate <oint shall be as per approved +drawing.

Cit up of annular plateGs <oints shall be carried out using proper <igs and fiHtures as

shown in drawing.

3are shall be taken while fit+up, such that there should not any gap betweenannular plate and backing+strip.

Annular plates <oints welding shall be carried out by welding alternative <oint at four

quadrants.

?ualified welders shall be engaged for the welding work according to =%.

!f any defect found the defect weld shall be removed by grinding and re+weld and

conduct the 4T check test. epeat the sequence until the defect cleared.

3omplete the welding, clean the final weld surface by wire brushing and grinding.

emove the <igs and fiHtures which were used for fit+up of the annular <oint and

grind the tack. adiography shall be taken as per A!+"#$ %ec+".

5.3.2 BOTTOM PLATE LAYING:

4ay the center plate on the foundation top as per drawing.

=ith co+ordination of 3entre plate lay the bottom plates sequentially as per drg.

4aps shall be maintained while the fit+up of short seam and long seam as per drg.

Temporary tack weld to be carry out on the 4ong+seam to avoid uneven

movements, while the fit+up and welding of short+seam.

%hort seam welding will be carried out alternatively to avoid distortion.

After the completion of short+seam welding, remove the temporary tacks on the

4ong+ seam by grinding to facilitate the long+seam fit+up.

%hort seam welding will be carried out alternatively to avoid distortion.

After the completion of short+seam welding, remove the temporary tacks on the

4ong+ seam by grinding to facilitate the long+seam fit+up.

Prepared by

CONTRACTOR .

Concurred by

Name :


Approved by

Name :




DOC NO

DATE

PAGE NO

08 OF 16

PROJECT TITLE



inimum laps shall be maintained while the fit+up of long+seam as per approved

drg. >oggling shall be carried out by hammering wherever it necessary. 5Three plate

>oining <unction.;

8efore starting the welding, channels shall be tacked along the long+seam to avoid

the distortion.

After completion of shot seam welding long seam welding will be carried out

alternatively to avoid distortion.

?ualified welder shall be engaged and welding shall be carry out as per approved

=%.

After 3ompletion of welding thoroughly clean the weld I<oint by wire brushing and

grinding. %ketch to annular plate <oint shall be welded only after shell to bottom <oint welding.

All the bottom plateGs <oints vacuum boH test shall be carried out as per approved

procedure and code specification.

!f any defect found the defect weld shall be removed by grinding and re+weld and

conduct the vacuum boH test. epeat the sequence until the defect cleared.

5.3.3. SHELL COURSE ERECTION

After the completion of welding of Annular plates and bottom plates, mark the tankinner radius on the annular plates.

CiH # :os. of erection stools at the equal interval on the annular plates & transfer the inside tank diameter on the stools.

The top one shell courses shall be erected by conventional method. 8alance shell courses shall be erected by hydraulic <ack method. The rolled shell plates shall be shifted to the tank foundation area stacked around

the periphery by using hydra crane.

roper care shall be taken while handling the rolled plates.

3are shall be taken that the shell plate erected to the diameter marked on theannular plate.

>igs and fiHtures shall be use to align the shell plates. 3omplete the fit up eHcept the final <oint which shall be fitted and weld after

completion of the welding of the other <oints. 5To avoid the shrinkage;

Prepared by

CONTRACTOR .

Concurred by

Name :

Design:


Approved by

Name :

Design:




DOC NO

DATE

PAGE NO

09 OF 16

PROJECT TITLE



eaking to be checked after the fit+up of the vertical <oints. eaking shall be withinthe tolerance as per A! + "#$. 5Tolerance )/J;

eaking shall be checked at top, middle and bottom of the vertical <oints using a

%weep board of "K long.

lumbness shall be checked for the verticality of the shell course at every "$L

and shall be within the tolerance 5tolerance )/$$ of the total shell height;

Cor perfect verticality, channels shall be provided at the regular interval inside of

the shell course 5 to # meters; roviding the channels shall be facilitates the

alignment last shall course. Tack welds of the fitted vertical <oints shall be ground smooth. Fffer for inspection and get clearance from Engineer+in+charge for the vertical

fit+up 3omplete the first side welding by using qualified welders. 3are shall be taken while the welding to avoid the peaking and the roundness

distortion After completion of first side welding, back+chip shall be carried out for sound metal

from other side of the weld by grinding.

8ack+chipped grooves shall be offered for inspection before starting the welding.

3omplete the nd side welding using qualified welders.

>oint :os. & welder :o. shall be marked on both side of the weld .<oint.

3are shall be taken to avoid the peaking and roundness distortion. 3lean weld <oints from both sides by wire brushing and grinding. After completion of welding from both sides remove all the temporary <igs and

fiHtures and flush grind the tacks. 52o the weld fill up wherever required; and the

portion checked by 2..test.

3heck the peaking, plumb ness, circumference and the radius, offer for inspectionto the satisfaction of the Engineer+in+3harge.

Erect last shell course plate on top of the erected shell plate, mm thick spacersshall be kept between first and last but one shell course plates to maintainhoriDontal seam gap.

Erection channels shall be fiHed between last but one shell course plates andlast shell course plates at regular intervals to align and hold the last shell in

vertical position.

Prepared by

CONTRACTOR .

Concurred by

Name :


Approved by

Name :




DOC NO

DATE

PAGE NO

10 OF 16

PROJECT TITLE



After all the shell plates for last shell course is erected, fit+up the vertical <oint using

<ig plates which has been fiHed during erection and tack weld the <oints. 3heck peaking at vertical <oints of shell using a sweep board of "J wide,

acceptable tolerance shall the as per A!+"#$ clause #.#. 5local deviation shallnot eHceed )/J;

3omplete welding of last course vertical seam inside after getting clearance fromthe Engineer+in+charge.

8ack chip & welding shall be carried out following as same as for other shellcourse to the satisfaction of Engineer + in + 3harge. After completion of welding, weld visual, peaking & circumference shall be

checked out and recorded to the satisfaction of Engineer + in+3harge. Cit up the 9oriDontal seam between top shell courses and tack welded, remove the

spacers provided during erection, tack weld shall be ground smooth and ensurethat the tacks are sound and there are no defects like cracks and porosity etc.

3heck peaking at vertical <oints of shell using a sweep board of "J wide,acceptable clearance shall be as per A! "#$ clause #.#. 5local deviation shallnot eHceed )/J; Msing a vertical sweep board "J long, check banding athoriDontal <oints. 2eviation shall not eHceed )/J.

3heck (erticality of the last shell course, (erticality 5plumb ness; tolerance shall

be as per A! + "#$ clause #.#. 5maH. out of plumbness at the top of the shellrelative to the bottom of the shell not to eHceed )/$$ of total shell height from top

of last shell to 8ottom; =hile welding care shall be taken for banding and the roundness.

8ack+chip shall be carried out by grinding for the sound metal and to the

satisfaction of Engineer+in+3harge. 3omplete the nd side welding and clean the <oint thoroughly from both sides by

grinding and wire brushing. 3heck banding, plumb ness and recorded in the approved format to the

satisfaction of Engineer + !n+3harge. Fffer weld visual to the satisfaction of Engineer+!n+3harge. .

ark the T spots as per the instruction of the Engineer +!n+3harge, and completethe T as per A! + "#$ %ec+" requirements.

Prepared by

CONTRACTOR .

Concurred by

Name :


Approved by

Name :




DOC NO

DATE

PAGE NO

11 OF 16

PROJECT TITLE



Fffer the T film for reviewing to the Engineer+!n+3harge, and if any repair occursthe repair spot shall be repaired by grinding for the sound metal, e+ weld therepair spot as per code A! +"#$ sec+" requirements.

Take the repair spot T and re offer for the inspection to the satisfaction of Engineer+!n+ 3harge

%piral staircase Erection shall be carried out as per drawing including brackets.

emove all the temporary cleats and tacks by grinding. !nstall <acks as per requirement and the distance between the <acks shall not be

more than .# meter. 3onnect the power pack and check the total system is readyfor erection of the shell.

!nstall the <acking cleats on the bottom shell course 5inside; and weld soundly thecleats to the shell. oof structure & oof shall be erected then start <acking.

%tart <acking of the assembly of top two shell course along with the wind girder.4ift till the required space for the lower shell course plate width N Erection chair height. 5$$O#$ mm;

Erect the lower shell course by using the 9ydra crane for shifting and position theplates.

Alignment and fit up shall be carried out by using <igs and fiHture and as per drawing offer the fit up for inspection.

Collowed by welding, weld visual, peaking and plumb ness before and after as

mentioned above for the top two shell courses.

After completion of the welding lower down the <acked up assembly on top of rdshell from top.$ mm thick spacer shall be kept between rd and nd shell from topto maintain the 9oriDontal <oint gap.

Cit up the 9oriDontal <oint between rd and nd shell courses from top using <igsand fiHtures and tack weld, remove the spacers provided during erection. Tackshall be ground smooth, check the banding and record. Fffer fit up and banding tothe satisfaction of Engineer+!n+3harge.

Collowed by welding, banding & plumb ness before and after welding shall becarried out as mentioned for the above 9oriDontal <oint.

T shall be carried out and cleared before the neHt lifting ortion of the spiral stairway shall be erected as per drawing

Prepared by

CONTRACTOR .

Concurred by

Name :


Approved by

Name :




DOC NO

DATE

PAGE NO

12 OF 16

PROJECT TITLE



After clearance from inspection, the <acking cleats shall be fitted to rd shell fromtop course plates and the total assembly shall be <acked up by required height for erection of the all the shell courses.

!n the same manner erect all the shell courses and spiral stairway. The )

stshell course plates shall be erected, provide min. " mm thick packing plates

at required location in each shell plate to facilitate proper welding of the bottommost portion of the vertical <oint. This packing plate shall not be removed untilcommencement of shell to annular fit up. 4eave the final shell plate open byproviding angular frame in order for deck plate shifting and working.

After completion of welding of vertical seams of the )st shell course by followingabovementioned process and the 9oriDontal <oint between the shell courses ) and shall be aligned by lowering the <acks and the fit up shall be carried out.

Collow the above+mentioned process for the horiDontal <oint welding andclearance.

T shall be carried out as per A!+"#$ %ec." %hell to annular plate <oint shall be carried out using <igs and fiHture. After getting fit up clearance for welding, root weld shall be carried out from

inside.

After completion of inside welding clean the weld thoroughly by wire brushing,grinding and buffing.

The shell to bottom <oint area from both sides shall be cleaned thoroughly to carryout the chalk+diesel test.

Apply chalk solution from inside. Apply diesel by a hand spray pump from out side. 9old it as per instruction of the Engineer+!n+3harge and check the root weld for

any defect. !f any defect found the defect shall be repaired by grinding the defect area for the

sound metal plus )#$mm from both end of the defect. 3onduct the chalk + diesel test on the repair spot. 3arry out the whole process until

the repair cleared to the satisfaction of Engineer + !n @ 3harge.

Prepared by

CONTRACTOR .

Concurred by

Name :

Design:


Approved by

Name :

Design:




DOC NO

DATE

PAGE NO

13 OF 16

PROJECT TITLE



After completion of shell to bottom out side welding visual inspection will becarried out to the satisfaction of the Engineer+!n+3harge.

Fn completion of shell to bottom welding / :2T and having completed all erectionand welding work on the tank inside related to the roof and roof structure, allunwanted materials and scrap shall be removed from inside of the tank.

T of vertical and horiDontal <oint shall be completed. %ketch to annular plate <oint fit up shall be carried out and complete the welding. (acuum boH test the shall be carried out for the bottom plate short seam, long

seam and sketch to annular plate <oint.

!f any repair occurs the same shall be repaired and re+tested as per the approvedprocedure and A!+"#$.

5.3.4 ERECTION OF CONE ROOF PLATES AND STRUCTURES

After completion of the Top two shell courses erection, fit up, welding and curb ringfit up & welding shall be done.

Erect the fabricated 3entre 2rum, oof Truss, and cross girders as per drawing. 3omplete the welding of oof structure by approved welders and as per approved

=%. Erect and 4ay the oof plates on the structure as per the 2rg. =hile fit up of the short seams and long seams 4ap to be maintained as per 2rg

=eld the short seams by welding alternative <oint or sequence mentioned in the2rg.to prevents the distortion.

rovided proper support lengthwise of the long seam and weld the <oints as per 2rg. sequence.

oof :oDDles and top shell noDDles fit+up and welding shall be carryout as per theapproved drawing and subsequently it has to be correlated with the concern pipingdrawing.

Prepared by

CONTRACTOR .

Concurred by

Name :

Design:


Approved by

Name :

Design:




DOC NO

DATE

PAGE NO

14 OF 16

PROJECT TITLE



5.3.5 APPURTENANCES INSTALLATION

Clanges to pipe <oint shall be prefabricated and required :2T shall be completedbefore erection.

ark the noDDle location as per drawings. 3ut the openings by gas cutting after proper !nspection+by+inspection authority.

Erect the noDDles as per the orientation & the elevation shown in the drawing. !nstall C. pads wherever required before noDDle erection %uitable <igs & fiHtures shall be provided to prevent the distortion during the

welding.

After completion of bottom shell course welding shell noDDles shall be marked asper drawing and offer for inspection.

3ut open the noDDle opening, install the C. ads and erect the noDDles

5prefabricated; as per drawing. Frientation, elevation & pro<ection shall be maintained as per drawing and offer for

the inspection clearance. roper care shall be taken for the welding by providing <igs & CiHtures to prevent

distortion. =elding shall be as per =% and to be welded by the qualified welder. an+9ole neck shall be fabricated and the longitudinal <oint shall be radio

graphed.

All the C ad weld shall be pneumatically tested at an pressure of ).$# Pg/3m C. ad pneumatic test shall be carried out to the satisfaction of the engineer+in+

charge. All the shell noDDles final weld from both sides and C. ads welds shall be

inspected by visually and by 4T, to the satisfaction of the engineer+in+charge.

Prepared by

CONTRACTOR .

Concurred by

Name :

Design:

Hindustan Petroleum Crop.

Ltd.

Approved by

Name :

Design:

Hindustan Petroleum Crop.

Ltd



DOC NO

DATE

PAGE NO

15 OF 16

PROJECT TITLE



!. PROPOSED PLANT AND MAJOR E"UIPMENT

PLANT #E"UIPMENT #TOOLS # TACKLES

9ydra )$T / )T capacity. =elding transformers /ectifiers $$ a & "$$ a =elding generators. adiography source !r )-. Test ump. =ater pump Transporting Equipment. late bending achine.

ipe 8ending achine

9ydraulic >ack ) T Qwith power pack & accessoriesR and other required equipment.

7rinding machine QA7 + , A7 + , 7? @ & CCR 7as cutting equipment Qug cutting m/c & hand cutting m/cR (acuum pump and vacuum boH with 7auge. (ernier 3aliper 4ifting Tools & Tackles and 2errick other & ortable Fven All easuring Tape 5$ , )# , #, .; iano =ire, lumbob 59eavy weight;

(iewer

Aluminum 4adder + :os. )v 9and lamp set for all four tanks. EHhaust fan for all four tanks. 27 set with panel board separately for welding ectifiers and 7rinding. Elcometer r.7auge, Air+3ompressor etc.

$. MAN POWER

A% E E?M!EE:T

Prepared by

CONTRACTOR

Concurred by


Approved by




DOC NO

DATE

PAGE NO

16 OF 16

PROJECT TITLE



%. "UALITY ASSURANCE & "UALITY CONTROL

This shall be followed and maintained with the compliance / adherence to the drawings,procedure and code specification. ecords shall be kept in the relevant check sheet andformats duly signed by all the concerned departments.

. SAFETY

Tested & certified 4ifting equipments should be used for lifting and shiftingpurpose.

%afety recautions should be followed during fabrication and erection as per >Especification.

=elding cables and power cables to be laid properly as per !E rules and local stategovt. rules.

roper house keeping and clean condition shall be maintained in the fabricationshop and site as per requirement.

1'. RECORDS

Coundation hand over report

aterial !nspection ecords

Electrode, 3onsumables etc. verification record =elding !nspection report :2T reports Test reports

Prepared by

CONTRACTOR .

Concurred by

Name :

Design:


Approved by

Name :

Design:




1)JOB PROCEDURE for Tank( How to Fabricate or Eriction) Important

Documents