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LARSEN & TOUBRO LIMITED

HED HAZIRA WORKS Quality Control & Inspection

Procedure for Establishing Surface Alignment of Shell

Assemblies

0 REV. NO.

First Issue REVISION DETAILS

24-10-03 DATE

PDL / SCM PREP. BY

PDL APPR. BY

This document is the property of Larsen & Toubro Limited and must not be copied or lent without their permission in writing.

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Surface Alignment of Shell Sections 1. Scope: Cylindrical sections of Columns, Towers, Pressure Vessels and heat exchangers are manufactured by rolling and welding plates. Two or more shell courses are welded together to form sections. This procedure covers method of establishing surface alignment of shell sections with two or more shell courses welded together. For the purpose of this procedure, shell course includes rolled cylindrical sections, forged shells, pipes, cones and expansion bellows. The procedure is applicable to all products manufactured in Shop & LEMF where the assembly is possible / not possible to rotate on its axis. 2. Surface alignment: When two or more shell courses are welded together, the surface of each individual shell shall align with the adjacent shells within the tolerance specified by the equipment drawing or tolerance chart. The procedure stated below elaborates method of finding out the extent of deviation from the true surface at a particular orientation of a welded shell assembly. The procedure takes in to consideration of four orientations at equidistance (0, 90, 180 & 270) for deriving the surface alignment. 3. Tools and accessories: The following tools and accessories shall be made available. Plumb bobs Measuring tape Twines Scale Manometer (Water level with accessories) Magnets

4. Prescribed Methods: Surface alignment of an assembly can be established by one or more of the following methods explained below. 4.1 4.2 4.3 Method1: - With twine and plumbs at two orientations. (By rotating the job) Method2: - With twine and magnets at four orientations. (Without rotating the job) Method3: - With plumb & twine and Manometer. (Without rotating the job)

5. Method1: -With Twine and plumbs at two orientations. (By rotating the job): This method is applicable to small assemblies, which can be rotated on the tank rotator. The following arrangements and preparations shall be made 5.1 Keep the shell section on a pair of tank rotators with its axis horizontally.
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Surface Alignment of Shell Sections 5.2 Rotate the assembly and keep the shell orientations 0 -180 on horizontal plane and 90 - 270 in vertical plan 5.3 Provide plumb lines as shown in Annexure I by hanging single twine over the cylindrical sections. Stretch two twines on both sides of the section as shown in the Annexure I. The twine shall be at equidistance from shell surface at two extreme ends as shown in the sketch. They shall be approximately horizontal. 5.4 Measure the horizontal distance from the plumb line to horizontal twines as shown in the sketch in Annexure I at all points in between the first and last. 5.5 Record the readings as detailed in Table1. 5.6 Rotate the assembly by 90 so that 90 - 270 orientation remains in horizontal plane. 5.7 Repeat the para 5.1.3. through 5.1.5 6. Method 2: With twine and magnets at four orientations: This method is applicable to assemblies with maximum length / height of 10m (maximum three shell courses) and all shell courses are of equal out side diameters. The assembly is kept either its axis horizontally on a saddle / tank rotator or axis vertically on three supports. The following arrangements and preparations shall be made. 6.1 Keep the shell section vertically or horizontally. 6.2 Note and record the orientation of the assembly in horizontal and vertical plane if it is kept its axis horizontally. 6.3 Keep a pair of magnets of equal height at two extreme ends of each of four orientations as shown in the sketch in Annexure II. 6.4 Stretch twines from one end to the other on the magnets as shown in the sketch. 6.5 Measure readings from the twine to the line of orientation on the shell surface at every weld joint as shown in the sketch in Annexure II at all four orientations. 6.6 Record the readings at all four orientations as detailed in Table 2. 7. Method 3: With plumb & twine and manometer (without rotating the job): This method is applicable to too long assemblies that are not possible to rotate on its axis due to its weight and size. The following arrangements and preparations shall be made. 7.1 Keep the shell section on a pair of tank rotators / saddles with its axis horizontally 7.2 Note and record the orientation of the assembly in horizontal and vertical plane 7.3 Provide plumb lines as shown in the sketch in Annexure I by hanging single twine over the cylindrical sections. Stretch two twines on both sides of the section as shown in the sketch in Annexure I. The twine shall be at equidistance from shell surface at the extreme ends. They shall be approximately horizontal.
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Surface Alignment of Shell Sections 7.4 Measure the horizontal distance from the plumb line to horizontal twines at all points (Cir. Seam locations) in between the first and last as shown in the sketch in Annexure I. 7.5 Record the readings as detailed in Table3 7.6 Arrange a manometer at an appropriate height on bottom side of the shell section a shown in the Annexure III. Measure the vertical distance between the water level and the shell surface in contact with manometer tip at the extreme two ends. A fixture mounted with scale and manometer shall be used for measuring the distance directly between the water level and point of contact. Find the difference in readings at the two extreme ends. 7.7 Measure the distance between the two extreme end points and calculate the inclination of the shell surface from horizontal plane. 7.8 Measure the vertical distance between the water level and the shell surface at all points near the sirc. Seams as shown in the sketch in Annexure III. 7.9 Apply the correction factor on account of the angle of inclination and thickness difference / diameter difference if any to all readings 7.10 Record the corrected readings as detailed in Table 3. 7.11 Arrange a manometer at an appropriate height on the top of the assembly as shown in the Aneexure III. Measure the height of water column at the two extreme ends of the assembly. Find the difference in readings of water columns. Difference in thickness or diameter shall be taken in to consideration to derive the effective difference in manometer reading. 7.12 Measure the distance between the two extreme end points and calculate the inclination of the shell surface from horizontal plane. 7.13 Measure the height of the water columns near all Cir. Seams as shown in the sketch in annexure III. 7.14 Apply the correction factor on account of the angle of inclination and difference in thickness / diameter, if any to all readings 7.15 Record the corrected readings as detailed in Table 3 8. Measurements And Tabulation Of Readings: Readings recorded as per para 5.5; 6.6; 75; 7.10 & 7.15 above shall be incorporated in the respective columns of the applicable tables below. The readings taken at different orientations (in horizontal plane/vertical plane - 0 , 180, 90, 270) shall be recorded separately. The readings taken in vertical plane with manometers shall be recorded duly corrected with the correction factor on account of inclination, thickness difference and diameter difference.

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Surface Alignment of Shell Sections

Table 1 (Readings from Method 1) Location of reading A0 B1 B2 C0 D0 E1 E2 F1 F2 G1 G2 H0 0 (H1) X

X1 X2 X3 X4 X5 X6 X7 X8 X9 X10

Twine to plumb distance in mm 180 (H2) 90 (H1) Y X

Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10 X1 X2 X3 X4 X5 X6 X7 X8 X9 X10

270 (H2) Y
Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10

Table 2 (Readings from Method 2) Location of reading A0 B1 B2 C1 C2 D0 0 50 0-B1 0-B2 0-C1 0-C2 50 Twine to shell surface reading 180 90 50 50 180-B1 90-B1 180-B2 90-B2 180-C1 90-C1 180-C2 90-C2 50 50 270 50 270-B1 270-B2 270-C1 270-C2 50

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Surface Alignment of Shell Sections

Table 3 (Readings from Method 3) Location of reading A0 B1 B2 C0 D0 E1 E2 F1 F2 G1 G2 H0 Twine to plumb distance in horizontal plane in mm Left X
X1 X2 X3 X4 X5 X6 X7 X8 X9 X10

Right Y
Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10

Manometer readings in mm Readings after correction due to difference in dia. and tilt Top Bottom A0-T A0-B B1-T B1-B B2-T B2-B C0-T C0-B D0-T D0-B E1-T E1-B E2-T E2-B F1-T F1-B F2-T F2-B G1-T G1-B G2-T G2-B H0-T H0-B

9. Plotting The Points To Derive The Alignment: Plot the readings taken from all the points on each orientation separately on a graph paper. The recorded readings shall be on Y axis and the distance between the two measuring points on the shell surface shall be on X axis. Connect all the points on the graph by straight lines as shown in the sketch1 below. The lines represent the surface alignment of the section at that particular orientation. The maximum deviation from the true surface shall be obtained by joining the first and the last points by straight line as shown in the sketch below. . Sketch 1

Y
-

Maximum surface misalignment

A0-T B1-T B2-T

C0-T

D0-T

E1-T E2-T

F1-T F2-T

G1-T G2-T

H0-T

X A0T = H0T
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Surface Alignment of Shell Sections ANNEXURE I Arrangement for Readings in Horizontal Plane with Twine and Plumb
(Repeat readings X1 to X10 & Y1 to Y10 after rotating by 90 )

H0-H1

Y H0-H2

X10

G2-H1 G1-H1

Y10 0 Y9

Y3

X9

G2-H2 G1-H1

F2-H1 F1-H1 E2-H1 E1-H1 D0-H1 C0-H1

X8 X7 X6

Y8

Y7 Y6

F2-H2 F1-H2 E2-H2 E1-H2 D0-H2 C0-H2

X5%

Y5

%
X4 Y4 Y3

Y2

B2-H1 B1-H1

Y1

B2-H2 B1-H2

A0-H1

Y Vertical Plane (90-270)

A0-H2

H1 Plumb

Shell Section Staff Horizontal Plane 0 - 180 H2 Plumb

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Surface Alignment of Shell Sections AnnexureII Arrangement for Readings with Twine and Magnets at four orientations.

0
0-A0
(50 mm Magnet)

90 - 270

180
180-A0
(50 mm Magnet)

0-B1 0-B2 Twine

180- B1 180- B2 Twine

0-C1 0-C2

180-C1 180-C2

0-D0
(50 mm Magnet)

180-D0 (50 mm Magnet)

Support Block

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Surface Alignment of Shell Sections ANNEXURE III Arrangements for Readings with Manometer

Water Level H0-T G1-T G2-T F1-T F2-T E1-T E2-T D0-T C0-T B1-T B2-T

Manometer A0-T

H0-B

G1-B G2-B Saddle

F1-B F2-B

E1-B E2-B

D0-B C0-B

B1-B B2-B

A0-B

Water Level Water Level

Manometer

Manometer T

B Water Level Manometer

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Surface Alignment of Shell Sections A0-T, B1-T, B2-T, C0-T = Manometer reading (Dia. difference + height difference due to tilt of the job) D0-T, E1-T, E2-T, F1-T, F2-T, G1-T, G2-T, H0-T = Manometer reading height difference due to tilt of the job A0-B, B1-B, B2-B, C0-B = Manometer reading (Dia. difference - height difference due to tilt of the job). D0-B, E1-B, E2-B, F1-B, F2-B, G1-B, G2-B, H0-B = Manometer reading + height difference due to tilt of the job

This document is the property of Larsen & Toubro Limited and must not be copied or lent without their permission in writing.