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Job Procedure For Tanks Work: 10 of Ramadan City, Industrial Area A1, Egypt
Job Procedure For Tanks Work: 10 of Ramadan City, Industrial Area A1, Egypt
Job Procedure For Tanks Work: 10 of Ramadan City, Industrial Area A1, Egypt
PROJECT : 500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations
DOCUMENT TITLE
9560/NBEL/SITE/QAC/022, REV.0
1. SCOPE:
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Document No:- 9560/NBEL/SITE/QAC/022, REV.0
2. PURPOSE:
The purpose of this document is to follow proper methodology to carry out the activities in a proper
sequence for fabrication, erection, welding and testing of the cone roof tanks inspection testing to be
done during construction to ensure that a standard construction and workmen ship can be achieved
to the satisfaction of NBEL.
3. REFERENCE:
API 650 Latest Edition
ASME Sec IX
ASME Sec II
ASME Sec V
ASME Sec VIII
IS 803
Approved NDT Map for tanks
Approved Drawings
9560/SITE/QAC/022/ITP-13
4. RESPONSIBILITY:
The responsibility of implementation of the job procedure during construction of tanks rests with Site
Manager & Engineers of Sub Contractor.
5. METHOD OF CONSTRUCTION:
5.1 TANK PAD FOUNDATION:
Check the level foundation as per specifications, approved drawings and API 650 clause latest
edition. After getting clearance for annular plate laying, mark the 0, 90,180 & 270 degrees co-
ordinates on the foundation from the reference points.
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Document No:- 9560/NBEL/SITE/QAC/022, REV.0
Lay all the plates in the fabrication yard such a way easy for marking and cutting.
Mark the plates as per approved drawing.
Carry out the cutting operation after inspection of client’s representative.
All the cutting operation shall be carried out by Gas Cutting only.
Grind the cut edges smooth to remove burrs and slag.
Stack the plates at designated place in the fabrication yard in proper sequence.
Backing – strip shall be fitted and tacked with annular plate as per approved drawing.
After completion of the fabrication, under side of annular and bottom plates shall be blast
cleaned and painted as per painting specification to the satisfaction of the Engineer-in-charge
before bottom laying on tank foundation.
Lay all the plates in the open area such a way easy for marking and cutting.
Mark the plates as per approved drawing and offer inspection to the Engineer-in-charge.
The cutting operation includes beveling shall be carried out by using PUG cutting machine only
on all the four sides.
Grind the cut edges smoothly to remove slag and burr.
The plates shall be fed to rolling machine with proper guide ways.
The plate shall be rolled as per drawing and the radius shall be checked by using Gauge plate
(Template).
Proper care shall be taken for the smooth curvature.
36’’ Long and 6mm thk. template shall be used to check rolling curvature accurately.
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Document No:- 9560/NBEL/SITE/QAC/022, REV.0
After completion of bottom shell course welding, mark the nozzle location on the shell and cut
the openings by gas cutting after proper inspection by Engineer-In-charge.
Flanges to pipe/ neck joint and plate fabricated necks shall be prefabricated and also required
NDT shall be completed before erection as per code/ specification.
Install RF pads wherever required and erect the nozzles as per the approved drawings/
specification.
Suitable jigs & fixtures shall be provided to prevent the distortion during the welding.
Orientation, elevation & projection shall be ensured as per drawing and offer for the inspection
to do welding.
Proper care shall be taken for the welding by providing jigs & fixtures to prevent distortion.
Welding shall be done as per approved WPS and by the qualified welder.
All the shell nozzles final weld from both sides and RF. pads welds shall be inspected by
visually to the satisfaction of the engineer-in-charge.
RF Pad weld shall be pneumatically tested at the pressure of 1.05 Kg/Cm2 and to the
satisfaction of the engineer-in-charge.
Roof nozzles and top shell nozzles fit-up and welding shall be carryout as per the approved
drawing and subsequently it has to be correlated with the concern piping drawing.
10. EQUIPMENTS:
Telescopic crane 15MT / 20MT capacity or as per requirement.
Welding Machines.
Water Fill test Pump.
Water pump.
Transporting Equipment.
Plate rolling Machine.
Hydraulic Jack 12 MT [with power pack & accessories] and other required equipment.
Grinding machine. [AG-7, AG-5, AG-4]
Gas cutting equipment. [Pug cutting m/c & Hand cutting set]
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Document No:- 9560/NBEL/SITE/QAC/022, REV.0
13. SAFETY:
Tested & certified Lifting equipment’s should be used for lifting and shifting materials.
Safety precautions should be followed during all works at site as per NBEL-HSE requirements
of the project.
Welding cables and power cables shall be laid properly as per NBEL-HSE engineer instruction/
HSE rules.
The radiography duration shall be informed to all other contractors working in tanks area will
be advance.
14. DOCUMENTATION:
All documents shall be prepared and maintained as per approved ITP in the designated formats.
15. GENERAL:
All stag wise inspection shall be carried out as per approved ITP.
Required access/scaffolding shall be made available wherever required.
The house keeping shall be done at regular intervals to maintain good and neat working
condition.
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