Professional Documents
Culture Documents
Standard Procedure
ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
ERECTION PROCEDURE
OF
TANK
0
Rev
3 Mar 06
Date of
Issue
For Construction
Status
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Nico
Prepared
Mahdi
Checked
Suroso
Approved
Page 1 of 44
ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
CONTENTS
Page
SECTION I
SCOPE OF WORK
SECTION II
SECTION III
SECTION IV
EQUIPMENT
SECTION V :
SECTION VI
SECTION VII
7.1
7.2
7.3
7.4
7.5
7.6
FABRICATION
FOUNDATION INSPECTION
2
3
SECTION VIII
6
6
6
8
8
9
10
11
8.1
Preparation
11
8.2
Jigs attachment
12
8.3
12
8.4
14
8.5
Measurement of the first stage shell plate and clean out door connection
17
8.6
19
8.7
8.8
8.9
20
20
22
SECTION IX
ATTACHMENT ASSEMBLY
23
SECTION X
24
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Page 2 of 44
ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
10.1
Column erection
24
10.2
25
10.3
Welding
25
SECTION XI :
11.1
11.2
26
26
27
SECTION XII :
27
SECTION XIII
28
SECTION XIV
:
28
14.1 General
14.2
Welding detail
29
a) Surface preparation
29
b) Weld deposit
29
c) Slag removal
30
30
e) Welding teamwork
f) Welding equipment and tools
30
30
g) Welding electrodes
30
30
i) Tack Welding
31
31
31
32
32
32
14.3
Welding criteria
32
14.4
33
34
Page 3 of 44
ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
15.1
General Items
15.2
15.3
36
36
38
39
39
15.4
15.5
34
35
39
39
39
Other Inspections
40
40
40
15.6
Leakage Testing
40
15.7
41
15.8
15.9
41
41
41
43
Tables
1. Permissible undercutting
33
36
39
Figures
1. Levelness check points on the existing foundation
2. Center positioning of bottom plate arrangement
4
5
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Page 4 of 44
ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
10
11
12
13
13
14
15
16
16
17
17
18
18
19
19
21
21
23
24
25
26
27
35
37
37
38
38
42
43
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Page 5 of 44
ERECTION PROCEDURE
I.
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
SCOPE OF WORK
This manual covers the fabrication, erection, installation, sand blasting and painting, inspection
and testing of welded steel storage tank.
II.
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Page 6 of 44
ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
III.4 Painting materials will be stored in the original container / box in protected areas with
condition recommended by paint manufacturer.
III.5 Other small components such as flanges, bolts, nuts etc, will be at warehouse.
III.6 For easy handling, all materials at storage will be in standard position.
III.7 Every delivery of materials shall be accompanied by a packing list enumerating material
description, specification and quantity. Its the responsible of the receiving party to fill in
a checking list to assure that the delivery turn to be the same as the packing list says, and
that there is no unacceptable damaged condition. If material arrives at its destination in
damaged condition, the receiving party shall promptly notify, or immediately upon
discovery, the carrier and consignee prior to unloading the materials.
IV.
EQUIPMENT
4.1
All chains, hand tools and erection tools for fabricating and assembling work will be
checked and adjusted before start of work.
4.2
Electric equipment will be checked for leakage and insulation before start-up.
4.3
All equipment relating to the work will be removed and covered to original condition
after completion of work.
V.
FABRICATION
5.1
Prior to fabricating, materials to be used will be checked and complied with the
approved construction drawings.
5.2
Lay out of plates will be carried out in accordance with approved construction drawing.
Shrinkage by welding and distance between welding lines are carefully considered.
5.3
Cutting of material and edge preparation will be carried out by means of gas and / or
plasma cutting equipment, beveller and other mechanical equipment. When edge
surfaces are uneven and shapes of them not uniform, the surfaces will be ground
smoothly by means of a grinder.
5.4
Welding groove dimension will be checked by means of welding gauge. Tolerance for
groove angle as per approval construction drawing and/or related Welding Procedure
Specification.
5.5
Rolling of plates will be carried out by means of Hydraulic Rolling Machine and special
attention to be considered for curvature of edge of rolled plates. After press work, the
rolled plates will be placed at open yard storage and supported by wooden to prevent
straightening of curvature.
5.6
Bending of steel structures such as top curb angle, compression ring, railing pipes, etc.
will be carried out by means of partial bending machine.
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Page 7 of 44
ERECTION PROCEDURE
VI.
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
5.7
The press work will be carried out so as not to sharpen any shapes or to make smooth
changing of any shapes.
5.8
All welding works will be carried out in accordance with paragraph XIV of this manual.
5.9
Upon completion of fabrication and before final acceptance, false work, rubbish, any
scraps and temporary buildings, if any, will be thoroughly removed.
FOUNDATION INSPECTION
VI.1
For the purpose of ascertaining the integrated quality of the tank to be constructed,
especially for erection work, the foundation again will be inspected in the presence of
client and /or constructor of the foundation, and the erector. The inspection results shall
conform to the previous inspection report and drawings of the foundation. Any
unacceptable discrepancies shall be notified promptly to the client and/or the foundation
constructor prior to erection work.
VI.2
The following items should be taken into account while conducting the inspection.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Clean-out-door position
(9)
VI.3
For level check at completion of foundation, the points marked should be checked in
the figure on the next page, and middle points between marked points may be arbitrarily
checked.
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Page 8 of 44
ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
Establishing of azimuth
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Page 9 of 44
ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
After confirming the completion of foundation work, mark with paint on the
concrete surface the azimuth lines of 0, 90, 180 and 270. These lines and
their intersection, centre of the foundation, should be the datum of the assembly.
(2)
Mark-off the annular plate outside circle on the concrete from the
foundation center. This circle should be 10 mm large in diameter than that
of drawing dimension.
Typical example
(c)
VII.
7.1
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Page 10 of 44
ERECTION PROCEDURE
(b)
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
Mark-off the reference line, weld the backing strip on the central and peripheral bottom
plates as shown below.
Lay the annular plate matching with the line marked-off according to the paragraph 6.5.
This plate should be the datum for the annular plate arrangement. Lay the annular plate
one by one along the circle provided beforehand, then fit the final annular plate.
(b)
After arranging the annular plate, coordinate the adjoining annular plates, check the root
opening and arrange offset of them, and then execute tack welding. After the tack
welding, fix the plates with restraining jigs and execute regular welding, except for
annular plates where clean-out-doors to be installed.
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Page 11 of 44
ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
After completing the regular welding, finish approximately 100 mm welds, which will
contact with the shell plate bottom, flush with the surface of annular plate using a grinder.
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Page 12 of 44
ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
Typical example
After setting the central bottom plate, laid the peripheral bottom plates from center to
periphery.
(b)
Execute tack welding on the bottom plate before the regular welding.
(c)
The overlapping allowance between bottom plates and annular plate must conform to that
of drawing dimension.
(d)
Remove foreign matters such as sand and dust on the area to be overlapped.
(e)
When executing regular welding of bottom plates, be careful with the welding procedure
and usage of jigs in order to minimize distortion and absorb the contraction due to
welding by applying welding as designated by welding procedures on tack and regular
weldings.
Typical example
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Page 13 of 44
ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
Butt-welding with backing strips will be utilized for bottom plate welding.
(b)
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Page 14 of 44
ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
7.6
(d)
Welding will be carried out in the direction of short joint first and then followed by tack
welding of long joint, then the next regular welding will be carried out in the direction of
longitudinal joint.
(e)
All welding works will be carried out in accordance with paragraph XIV of this manual.
After welding the bottom plate, remove the attached jigs carefully so as not to give
damage to the base metal, and finish the welds with a grinder.
(b)
Where the peel-off or cut-away of base metal is produced while removing the jigs,
execute repair welding on the damaged area and finish with a grinder.
(c)
(d)
Preparation
After completing bottom plate inspection, execute the following items of work as the preparation for
the assembly.
(a)
Mark-off the orientation 0, 90, 180, and 270 lines for the reference of shell plate
erection corresponding to the foundation datum line.
(b)
(c)
Mark-off the circle for the datum of checking the assembly of shell plate, that is 100 mm
inward from the inside diameter circle of shell plates.
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ERECTION PROCEDURE
(d)
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
Typical Example
8.2
Jigs Attachment
After marking-off the shell plate inside diameter, attach jigs for fitting shell plates as shown below.
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Page 16 of 44
ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
Before erecting shell plates, attach jigs for assembly and hooks for foot boat bracket.
NOTE: The position, size, and number of jigs should be determined at site.
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ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
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ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
Note : The space between jigs should be determined regarding warp due to welding.
(a)
Lift the shell plate and bring onto the bottom plates, match the end of the shell plate with
the reference line, and fix the plate with jigs and prevent fall-down of the plate, and
maintain perpendicularity.
(b)
Arrange and adjust clean out doors and execute the same handling as in the above item a),
then apply the specified spacer between the abutting clean-out-door reinforcement plates,
and fix with fitting jigs.
(c)
Arrange the second and subsequent shell plates one by one clockwise, or
counterclockwise, and execute the same handling as in the above item a), then apply
specified spacers between the abutting plates, and fix with fitting jigs.
(d)
After arranging shell plates, check them for arrangement by adjusting with bottom piece,
wedge etc, along the shell plate inside diameter circle, at the same time, coordinate the
groove of longitudinal joint and round edge.
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ERECTION PROCEDURE
(e)
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
After assembling the first stage shell plates and clean out-door, check them for
perpendicularity, levelness, roundness, etc in accordance with the inspection manual and
the error, if any, must be within the tolerance.
Notes :
1. Root opening should be adjusted with spacer.
2. Plate to-plate fitting should be adjusted with strong back, spacer, etc.
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Page 20 of 44
ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
As the figure below shows, measure the shell plate for levelness, perpendicularity, and roundness in
circumferential direction. Correct the error, if any, and must be within the range tolerance stipulated in
the inspection criteria.
(a)
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ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
Page 22 of 44
ERECTION PROCEDURE
(c)
8.6
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
Attaching of jigs for shell plate assembling with horse shoe and inside surface of shell plate in the
same manner as in the 1-st stage shell plate.
Extend and assemble the second and subsequent shell plates with straight strong back,
curved strong back, bull pin, etc. being careful with the root opening and offset of
circumferential and longitudinal joints.
(b)
Execute the assembly stage by stage until the uppermost stage is achieved.
(c)
When proceeding to the next stages, execute checking for levelness perpendicularity, and
roundness in accordance with the inspection manual, the error, if any, must be within the
tolerance.
Note :
8.7
The space between spacers should be determined regarding the plate size warp due
to welding, etc.
Assembly procedure of shell plates.
1)
2)
3)
4)
5)
6)
7)
8)
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ERECTION PROCEDURE
9)
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
Shell plate welds will be performed from the bottom course shell plates.
Vertical joint on shell plates is carried out first and after completion of weld on adjacent
shell plates, upper and lower stages, fitting of circumference of shell plates, tack welding
and regular welding will then be carried out.
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ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
8.9
(b)
Vertical and circular joint of weld on shell plates will have complete penetration with no
undercutting.
(c)
After the outside of shell is welded, the inside will be welded. In order to make a
complete penetration, at each distance of 80 mm to both sides from vertical joint with
circular joint intersects, vertical joint will be back chipped by using a grinder or arc
gouging. Weld flaw on the first layer of outside weld will be completely removed. After
back chipping and extreme uneven area, slag and flaw will be finished by using a
grinder.
(d)
Proper width and depth will be made so as to make inside welding easy.
(e)
Weld on the upper and lower edges of vertical joint will be carefully performed in such a
way so as not to make weld flaw in particular. When circular and vertical joint weld is
carried out it will be visually confirmed again.
(f)
After finishing of vertical weld joint on the first stage of shell plates, fillet weld on
bottom and shell plates will be carried out. Make 8 to 10 place along circumference for
draining water during tank construction by leaving these places unwelded. These places
shall be marked clearly and shall be welded just before filling the tank with water.
(g)
The attachment of shell plates and bottom plates will be T-joint of both side continuous
fillet weld with 6 mm throat thickness.
(h)
Circular joint will be fitted one after another and welded upon completion of vertical joint
weld on upper and lower stage of adjacent plate.
(i)
All welding works will be carried out in accordance with paragraph XIV of this manual.
Lay a channel on the uppermost shell course together with a pair of horizontal strong
backs.
(b)
Install top curb angle piece by inserting it between strong backs on one end and lay the
other end on the channel.
(c)
(d)
Attach temporary supports, approximately one feet apart, welded on face end of top curb
angle and on shell plate from strong backs to channel, then shift the channel as necessary
while attaching these supports.
(e)
Recheck radius
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Page 25 of 44
Responsible Department
ERECTION PROCEDURE
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
(f)
Start welding along top curb angle length and leave about 2 meter long to compensate for
welding distortion.
(g)
Repeat step a) to f) for the next top curb angle piece adjacent to it.
(h)
Perform welding of vertical joint between the first and the second pieces of top curb
angle.
(i)
Complete the remaining horizontal welding of the first piece of top curb angle.
(j)
ATTACHMENT ASSEMBLY
9.1
Open a manhole in the attendance of companys personnel in charge after adjusting the
horizontality, perpendicularity, and roundness of 1st stage shell plates, and then install the
patch nozzle after the 3rd stage shell plates have been welded.
9.2
Other auxiliaries to be attached to shell plate and roof plate, after completion of shell plate and
roof plate welding respectively, mark-off its orientation, elevation, size, etc. to conform to the
specification such as orientation, elevation, and size on the construction drawing, and checked
by the witness of companys person in charge to open the manhole.
9.3
Strengthen shell plate with reinforcements to prevent the shell plates from straining due to
welding of manholes, nozzles, etc.
9.4
All weldings will be carried out in accordance with paragraph XIV of this manual.
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ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
10.1
Column erection
Take in and erect columns by using a crane after assembly of third to fourth stage shell plates.
In this case, for the prevention of falling of the columns, strain wire ropes and adjust
perpendicularity with lever blocks.
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ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
10.3
After erection of center and intermediate columns, if any, install girders between
columns.
(b)
After the assembly of all the plates, weld traps on the plates, and install rafters from the
centre.
Welding
All weldings will be carried out in accordance with paragraph XIV of this manual.
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ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
11.1
Put roof plates in order after the assembly of the roof truss, check the inside and outside
of each roof plate on ground before lifting.
(b)
Mark-off the reference line, the overlapping allowance, etc, on the central and
peripherical roof plates as shown below.
(c)
Put roof plates in order commencing from the outer circumference to the centre, in case
of double lap joint and vise verse for single lap joint, in accordance with the assembly
drawings.
11.2
(d)
(e)
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ERECTION PROCEDURE
XII.
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
(a)
(b)
Weld will be carried out toward the outside from the center in principle
(c)
(d)
Outside fillet weld will be carried out for roof plates and top angle. Size of weld zone will
be less than 4.8 mm.
(e)
All weldings will be carried out in accordance with paragraph XIV of this manual.
(f)
Prior to welding, make sure that all rafters are in close contact with the associated roof
plate inside.
After the assembly and welding of all shell plates, fill water into the tank. Prior to water-filling, the
following items should be checked.
(a)
(b)
Remove all unnecessary jigs both in the inside and outside tank and each installed
section.
(c)
Check to see that all permanent attachments have been installed correctly and that related
prime valves and blind plates are installed correctly.
(d)
(e)
When filling tank with water, keep watching the tank for any possible leakage of water
and stop filling promptly after leakage is discovered. During water filling, draw up
inspection records of water level at each section.
(f)
(g)
(h)
While filling water and draining, open roof manhole with much care without giving
excessive pressure on the inside of the tank or destroying because of vacuumity.
(i)
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ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
14.1
14.2
General
(a)
Welding will be carried out by manual SMAW with covered electrode and shall be in
accordance with the qualified Welding Procedure Specification ( WPS ) and performed by
qualified welder.
(b)
Welder and Welding Procedure Specification will be qualified in accordance with the
Section IX of ASME Boiler and Pressure Vessel Code referring to the latest edition and
addendum.
(c)
The welder identifying mark or code, could be a number, letter, symbol or any
combination, shall be marked, either by hard stamp or by paint marker, adjacent to the
welded joint and at intervals of not more than 3 feet along the welds made by the each
welder. These marks shall be available to the inspector. The marks shall also include the
date and results of tests.
Welding detail
Tanks and their structural attachment shall be welded by manually or semi automatically according to
procedures described in Section IX of the ASME Code.
(a)
Surface Preparation
1.
2.
Various foreign substance such as moisture, oil, dust, oxidized film or slag on
melted metal or back chipped area will be completely removed before starting the
next welding stage.
3.
The work and all surfaces to be welded will be protected from wind, rain and
other harmful weather condition.
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ERECTION PROCEDURE
4.
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
Offset of butted edges will be within the tolerance stipulated in inspection manual.
(b)
Welding joint will be made by completing each weld layer before the succeeding weld
layers are deposited and block welding will not be applied unless otherwise accepted
for specific application.
(c)
Each layer of weld metal shall be cleaned of slag and other foreign material by a grinder
before proceeding to the next layer, in case of multi layer welding.
(d)
The maximum individual layer thickness will be kept not exceed 9 mm.
(e)
Welding teamwork
Welding will be performed by a welding team work consisting of at least one welder,
one fitter, one helper, and under supervision of welding supervisor.
(f)
(g)
(h)
Welding Electrode
1.
For base metal having a minimum tensile strength less than 80.000 psi, manual
arc-welding electrodes shall conform to the E60 and E70 Classification Series.
2.
Electrodes of low hydrogen content shall be used for manual SMAW, including
the attachment of the first shell course to the bottom or to annular bottom plates.
3.
4.
5.
Electrodes or filler metal will be kept in their original boxes and stored in a
warehouse at room temperature not less than 20 Celcius.
Prior to start welding, alignment shall be rechecked and provide proper support
and/or jig to compensate for shrinkage and to maintain the sound shape of base
metal.
2.
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ERECTION PROCEDURE
(i)
(j)
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
Tack Welding
1.
2.
3.
When vertical joints of tank shell are welded manually by SMAW process, tack
welds used in the assembly of the joints shall be removed and shall not remain in
the finished joint. But if Submerged Arc Welding ( SAW ) process is applied tack
welds may be left in place provided that they are thoroughly cleaned of all
welding slag, sound and thoroughly fused into subsequently applied weld beads.
5.
Tack welds to be left in place shall be performed by qualified welders and shall be
visually examined for defects which shall be removed if discovered.
6.
Tack welds shall be made using a fillet weld or butt weld procedure qualified in
accordance with section IX of the ASME Code.
(k)
(l)
2.
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ERECTION PROCEDURE
(m)
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
1.
2.
3.
The necessity of preheat for thick plates or for a low atmospheric temperature
during welding shall be taken into account when selecting the procedure.
(n)
14.3
2.
Permanent and temporary attachments to shells shall be welded with lowhydrogen electrodes.
3.
Permanent attachments may be welded directly to the shell with fillet welds
having a maximum leg dimension of inch. The edge of any permanent
attachment welds shall not be closer than 3 inches from horizontal joints of shell
nor closer than 6 inches from vertical joints of shell or reinforcing plate fillet
welds.
4.
Welding criteria
(b)
(c)
Max. acceptable
Undercutting
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ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
After proving that a joint is acceptable by visual inspection, other inspections such as Radiographic,
Magnetic Particle Inspection, Liquid Penetrant Inspection or Water Filling Testing may be conducted.
Acceptance standard, removal, and repair of defects for Radiographic shall be judged by the standards
in Section VIII, Division 1, Paragraph UW 52 of the ASME code.
Acceptance standard, removal, and repair of defects for Liquid Penetrant Inspection shall be judged by
standards in Section VIII, Division 1, Appendix 8, Paragraph 8-3 and 8-4 of the ASME Code.
Acceptance standard, removal, and repair of defects for MPI inspection shall be per Section VIII,
Division 1, Appendix 6, Paragraph 6-3 and 6-4 of the ASME Code.
14.4
All repaired welds shall be rechecked by repeating the original inspection procedures and
testing to assure that there is no another new defect discovered.
If removal cause the plate thickness to be less than the calculated minimum required thickness
based on hydrostatic test condition, re-welding shall be performed.
Weld flaw discovered by visual inspection will be repaired. In case of built-up welding, repair
will be performed under the instruction of our welding supervisor and welding inspector. The
followings are kinds of weld flaw with their respective repair.
(a)
Crater, pit
Repair by hammering such flaw and other unsightly flaws which are deeper than
the specified value on the welded surface will be ground flat and smooth by using
a grinder.
(b)
(c)
Undercutting
Joint that doesnt meet paragraph 14.3c will be re-welded without removal of
previous bead.
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ERECTION PROCEDURE
XV
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
(d)
Crack
Such flaw will be removed, and then re-welded and repaired after confirmation
that there is no more crack with the aid of Magnetic Partical Inspection. For
deposited weld crack extending to base metal, quality of base metal will be
checked carefully. If there is no problem in the quality of base metal, crack will be
removed after confirmation by Magnetic Particle Inspection and Client approval.
In case of crack extending to tank attachment, the attachment will be changed and
then re-welded.
(e)
Open lamination
Any open lamination on the edge surface of the plate will be removed after
confirmation by Magnetic Particle Inspection that there is no flaw, the flaw area
will be re-welded.
INSPECTION MANUAL
15.1
General items
1)
2)
15.2
Responsible Department
Whenever doubts are arisen during the inspection, such doubts will be discussed with
personnels in charge.
(b)
The root opening dimension of plates, groove angle of plates will be checked by means of
Welding Gage.
The following should be inspected in the assembly of annular plates.
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ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
15.3
(a)
(b)
Check of numbers of weld layers and welders of each weld lines that should be made.
(c)
The allowable value for the undercut depth should be within values given in table-1.
The undercut of 0.4 mm or less shall be vanished by grinding it smoothly, and that of
more than 0.4 mm shall be repaired by welding to grind-finished.
15.3.1 Inspection of temporary assembly after the temporary assembly of the 1 st stage and the
uppermost stage of shell plates. The horizontality, the perpendicularity and roundness shall be
measured. The measuring points should be equally spaced along the circumference.
Table-2
Inspection
Horizontality
Plumb ness
Roundness
(a)
Section
Allowable value
1st stage
uppermost stage
All stages
3 mm
10 mm
Tank Height / 200mm
1st stage
uppermost stage
15 mm
30 mm
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ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
Before arranging shell plates in place, measure the level of bottom plates, at which the
shell plates to be installed. After mounting the shell plates on the bottom plates, place a
level in the centre of bottom plates and measure the distance from the top of shell plates.
Face difference at the joint section of longitudinal and horizontal joint of the shell plates
should be as follows.
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ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
aa : Longitudinal joints
Where the uppermost course shell plate thickness is 10 mm or less, the face
difference should be 1 mm. If the thickness more than 10 mm, the difference
should be 10% plate thickness or 1.5 mm, whichever the greater.
bb : Circumferential joints
Check for the steel plate numbers after arranging the shell plates in place.
(c)
(d)
Check for the groove angles and the root gap tolerance should be within the value
shown in the following figure.
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ERECTION PROCEDURE
(b)
Responsible Department
Procedure No.
Engineering
ERP.009.YMN.04
Revision No.
Visual inspection
Execute visual check for the welds and section with jigs and check to see that defects
such as undercut, overlap, etc are not found.
The height of weld exceeding the following allowable values after grinding for the repair
of undercut or excessive height, repair by welding and finish grinding.
Height of weld
2.4 mm or less
3.0 mm or less
Reinforcements :
Place to which the radiographic
examination is applied
1.5 mm or less
15.4
Other inspections
(b)
(c)
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ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
Mounting inspection
Ensure that the mounting position and pieces are as specified with the orientation drawing
and the following inspection should be carried out.
a.1 Nozzles on a shell plate should be checked for their height from the bottom plate and
nozzle centers, the length between the shell plates and flange faces, the groove
angles, and the mounting angles.
a.2 The edge of reinforcing plates employed at the shell plate opening of the nozzle
should be visually checked.
(b)
15.6
Weld inspection
All welded section should be visually checked.
The tolerance of undercut should be 0.4 mm or less.
Leakage test
For the purpose of detecting leakage through the interior welds, nozzles and manholes supported with
reinforcing plates, the welds should be checked by blowing in 1.5-2.0 Kg/cm G air from a - inch
diameter telltale hole with the application of forming liquid on the interior and exterior welded section.
This process is only for nozzles and manholes on shell plates.
15.7
Equally space the tank bottom circumference into 8 or more, and the change for the radius direction
should be measured with level meters or by leaving string twice before water filling test and after
drainage.
15.8
Equally space the tank circumference 8 or more, and then check for the presence of a change by
measuring the mounting angle before and after the water filling.
15.9
15.9.1 Method
(a)
(b)
Time taken for the water filling and retention time shall be discussed in advance.
(c)
The height of water filling should be adjacent to the top angle + 50 mm.
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ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
(b)
(c)
(d)
(e)
Revision No.
Remove thoroughly foreign matters such as slag, sand dust, and substance such as oil and
paint adhered on the weld line of bottom plates, then clean up the entire weld line with a
wire brush.
(2)
Apply soap and water solution, or forming agent, on the weld surface to be tested,
approximately 30 inches of the seam.
(3)
(4)
Run the vacuum tester by lowering pressure down to 400 mm Hg or little below, take care
not to lower to much, then close the valve and start testing after the pressure becomes
stable.
(5)
Through a glass window in the top of this metal testing box, check visually to see whether
or not any bubble or foam is found on the surface applied soap and water solution. No
pressure increase or no foam indicate that the welding is acceptable.
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ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
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ERECTION PROCEDURE
Responsible Department
Engineering
Procedure No.
ERP.009.YMN.04
Revision No.
ATTACHMENT A
JIG TOOLS FOR TANK ERECTION
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