Presentation on

ECTION SEQUENCE OF TAN

RAPID 22

04 December 2013

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Pile Driving

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Pile Head cut & Grading

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Grading

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Lean Concrete Layer

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Drain out pipe laying

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Pile Cap Casting

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Sand -Bitumen Layer Laying

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 FOUNDATION LEVEL CHECK

On completion of sand bitumen layer, the levels will be taken as per stipulation of API 650 &
recorded in proper format. Correction of levels will be done as necessary

One day will be allowed for natural curing of the bitumen layer

On the next day, orientation of the tank axis and erection radius of the Annular plates shall
be marked on the bitumen layer

Normally the erection radius of annular plate is approx. 20 to 30mm extra than the actual
radius of annular plate of particular tank to take care of weld shrinkage

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 ERECTION OF ANNULAR PLATE
Fabricated annular plate shall be kept ready along the periphery of the tank foundation in
advance

Annular plates will be erected as per approved drawing maintaining proper orientation and
gap

Annular plate joints shall be properly fitted using required Jigs & Fixtures

Dummy annular plate of required size and shape shall be placed in the location of Clean
Out Door

Once all the joints are fitted, the same will be offered for inspection

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 ERECTION OF ANNULAR PLATE
Welding will start from opposite end of the clean out door

Welding will be carried out by SMAW method

Welding will be carried out on alternate joints

Two welders shall start welding and move in opposite directions circumferentially

On completion of the root run, the welds shall be ground & visually inspected followed by
completion of joint

Radiography of annular plate joints shall be carried out as per stipulation of API 650 &
Specification

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 ERECTION OF BOTTOM PLATE
Fabricated sketch plates and full size bottom plates shall be kept ready along the periphery
of the tank foundation in advance

Bottom plates will be erected as per approved drawing maintaining proper location,
orientation and lap

Plates will be erected on the foundation by crane up to its reach. After plates will be taken to
individual locations by rolling over pipes

Bottom plate joints shall be properly fitted using required Jigs & Fixtures

Once all the joints are fitted, the same will be offered for inspection

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 ERECTION OF BOTTOM PLATE
First, stitch welding shall be done along the long & short seams and also along the sketch
to annular plate joint, so that erection of Jack posts can be started for shell erection.

Full welding of bottom plate will start from tank center towards periphery following proper
sequences to reduce welding distortions

LT7 machine shall be used for welding of long seams by SAW method. The short seams, T-
joints and sketch to annular joint shall be done by SMAW method

Sketch plate to annular plate joint shall be carried out after erection and welding of the 1st
shell course to annular plate

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 ERECTION OF BOTTOM PLATE
Once the bottom plate welding is complete for some area, the same will be offered for
inspection & NDT as per stipulation of API 650 & Specification.

Central sump shall be erected, welded & tested after the welding of central portion of tank
bottom is complete.

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Erection of Annular & Bottom Plate

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 ERECTION OF SHELL PLATE BY
There are 8 shell courses of 2.50m each for all the tanks

For the tanks which will be erected by jacking method, the rolled & beveled plates for 7th
shell course shall be distributed along the circumference considering the orientation of each
plate

Orientation of the tank axis and erection radius of the shell plate shall be marked on the
annular plate

7th shell course plates shall be erected on the annular plate using crane, lifting beam and
other tools & tackles.

The plates will be hold vertically by means of temporary channel frames

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 ERECTION OF SHELL PLATE BY
The vertical seams shall be fitted using proper jigs & fixtures

The vertical welding shall be carried out by SMAW method following proper welding
sequence to keep distortion as well as the peaking & banding within acceptable limits

Shell joints shall be inspected as per stipulation of API 650 & Specification.

The 8th shell course plates shall be erected over the 7th shell course by conventional
method when sufficient no. vertical joints of 7th shell course are complete.

The vertical seams of the 8th course shall be fitted, welded & tested by similar method.

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 ERECTION OF SHELL PLATE BY
The Top wind girder shall be temporarily erected on shell outside, 600mm below the
horizontal joint between 7th & 8th courses, using clamps & bull pins, to act as the outer
working platform

On inside, metal board platform shall be erected, 600mm below the horizontal joint between
7th & 8th courses, on temporarily installed brackets. Proper temporary hand railing shall
also be installed

The horizontal joint shall be carried out by SMAW method after proper fitting of the joint
using required jigs & fixtures

12MT capacity hydraulic jacks shall be used for the jacking system erection.

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 ERECTION OF SHELL PLATE BY
Required no. of Jack posts including jack stays shall be erected at equal spacing

The power pack shall be located near the tank center

The top wind girder shall be erected at its final position by crane

Bracket for fire protection system piping shall be erected and welded at required locations
as per approved drawings

Installation of erection jacks shall be continued while the shell horizontal joint & wind girder
welding are in progress

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 ERECTION OF SHELL PLATE BY
Jacking cleats shall be welded on shell at required locations as per drawing

Spiral stairway erection shall start from the wind girder opening location and move
downward as per drawing

On completion of shell horizontal joint, the assembly of 7th & 8th Shell course, wind girder
and part of spiral stairway shall be jacked up to a level of 2.70m above the annular plate
and the jacks will be locked

The 6th shell course shall be erected by crane from outside and placed in position

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 ERECTION OF SHELL PLATE BY
Once the 6th course shell plates vertical ends are locked, the jacked assembly shall be
lowered down on to the 6th shell course plates and horizontal joint locking between 7th &
6th course shall be done

Welding of 6th course vertical seams and the horizontal joint between 6th & 7th shell
course shall be carried out in similar way as detailed earlier

The jack cleats shall be transferred to the 6th shell course from 7th shell course plates

On NDT clearance, the assembly of 6th, 7th & 8th Shell course, wind girder and part of
spiral stairway shall be jacked up to 2.70m level

Same method will be followed till the 1st shell course is erected

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 ERECTION OF SHELL PLATE BY
The dummy annular plate at the clean out door location shall be replaced by the
prefabricated & stress relieved clean out door assembly

On completion of 1st course vertical joints and the horizontal welding between 2nd & 1st
shell course, the welding of 1st course to annular plate shall be carried out followed by
welding of sketch plates to annular plates

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Erection of 7 th Shell Course

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Erection of temporary Platform

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Erection of 8 th Shell Course

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Erection of Top Plat form

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Jack Assembling

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Erection of Shell by Jack Method

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Erection of 6 th Shell Course

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Erection of Spiral Stairway

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Resembling the Jack

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Erection of Shell By Jack

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Erection of 5 th Shell Course

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Erection of Shell Courses

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Erected Shell Courses with Stairway

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 ERECTION OF SHELL PLATE BY
For the tanks which will be erected by conventional method, the rolled & beveled plates for
1st shell course fitted with nozzles shall be distributed along the circumference considering
the orientation of each plate

Orientation of the tank axis and erection radius of the shell plate shall be marked on the
annular plate

1st shell course plates shall be erected on the annular plate using crane, lifting beam and
other tools & tackles.

The plates will be hold vertically by means of temporary channel frames

The vertical seams shall be fitted using proper jigs & fixtures

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 ERECTION OF SHELL PLATE BY
The vertical welding shall be carried out by SMAW method following proper welding
sequence to keep distortion as well as the peaking & banding within acceptable limits

Shell joints shall be inspected as per stipulation of API 650 & Specification

The Top wind girder shall be temporarily erected on shell outside, 800mm below the
horizontal joint between 1st & 2nd courses, using clamps & bull pins, to act as the outer
working platform

On inside, metal board platform shall be erected, 800mm below the horizontal joint between
1st & 2nd courses, on temporarily installed brackets. Proper temporary handrailing shall
also be installed

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 ERECTION OF SHELL PLATE BY
The 2nd shell course plates shall be erected over the 1st shell course when sufficient no.
vertical joints of 1st shell course are complete

The vertical seams of the 2nd course shall be fitted, welded & tested by similar method

After proper fitting of the joint using required jigs & fixtures, the root run of the horizontal
joint shall be carried out by SMAW method followed by complete welding by SAW method
using Automatic Girth welding machine

In some tanks, SMAW method may only be used for the total horizontal joint

2 nos. single side AGW machine shall be deployed for one tank to take care of welding from
inside & outside

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 ERECTION OF SHELL PLATE BY
On completion of shell horizontal joint, the 3rd shell course plates shall be erected on 2nd
shell course.

Once the 2nd course shell plates vertical ends and horizontal joint locking between 2nd &
3rd course is done, the outside wind girder and inside metal board platform shall be shifted
to 800mm below the 2nd to 3rd shell course horizontal joint.

Welding of 2nd course vertical seams shall be carried out by SMAW method followed by
the horizontal joint between 2nd & 3rd shell course by SAW method.

Same method will be followed till the 8th shell course is erected

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 ERECTION OF SHELL PLATE BY
On completion of 4th course vertical joints and the horizontal welding between 3rd & 4th
shell course, the welding of 1st course to annular plate shall be carried out followed by
welding of sketch plates to annular plates

On completion of 8th course vertical & the horizontal welding between 7th & 8th course, the
top wind girder will be erected to its final position and welded to shell as per drawing.

Spiral stairway erection shall start from the bottom of the tank and move upward as per
drawing.

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 ERECTION OF ALUMINIUM DOME

The procedure of erection of Aluminium dome roof is under preparation by the dome roof
manufacturer

On receipt of the same, PLL will prepare the detailed methodology of erection of Dome roof
since this requires detailed study of the manufacturers recommendation

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Assembling of Dome Roof

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Assembling of Dome Roof

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Erection of Dome Roof

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Erected Dome Roof

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Erection of Top Walkway

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 ERECTION OF TANK INTERNALS
Tank internals e.g heating coils, nitrogen coils, inlet diffuser, outlet vortex breaker, jet mixer,
drain & stripping lines, stilling wells etc shall be prefabricated in spools which will be taken
inside the tank through the temporary access opening in the 1st shell course.

The items shall be erected in proper locations maintaining required levels & orientations as
per approved drawings

The stilling wells shall be assembled inside the tank on the tank bottom and after the NDT
clearance, it will be erected to position using crane from outside. The crane sling will hang
through the opening on the dome

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Erection of Tank
Internals

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The methodology of tank Hydro test is under preparation and will be
discussed later. The methodology of IFR erection is under
preparation by the IFR manufacturer and will be further detailed by
PLL before actual installation.

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Hydro-test

HYDRO TEST

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Painting

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Assembling of IFR

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Erected IFR

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Floatation Test

FLOATATION TEST

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Erected Tank ready For Pre-Commissioning

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