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Fabrication and Erection Procedure

The document provides procedures for the fabrication and erection of storage tanks according to API 650 standards. It outlines the methodology, including identifying materials, fabricating plates and attachments, erecting the tank using jacking methods, and ensuring quality control and safety throughout the process. Fabrication involves cutting, rolling, welding and non-destructive testing of annular, bottom, shell and roof plates. Erection uses jacks to lift sections into place.

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100% found this document useful (2 votes)
312 views13 pages

Fabrication and Erection Procedure

The document provides procedures for the fabrication and erection of storage tanks according to API 650 standards. It outlines the methodology, including identifying materials, fabricating plates and attachments, erecting the tank using jacking methods, and ensuring quality control and safety throughout the process. Fabrication involves cutting, rolling, welding and non-destructive testing of annular, bottom, shell and roof plates. Erection uses jacks to lift sections into place.

Uploaded by

shivanshsov
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 13

TECHNO FAB ENGINEERS Procedure No : FT/23-24/PE/TK-001

FABRICATION AND
Rev.:00
ERECTION PROCEDURE
Date:10-02-2024

CERTIFICATE:-
WE HEREBY CERTIFY THAT THIS
PROCEDURE FOR TANK FABRICATION AND
ERECTION IS BASED ON API 650 (13
EDITIONS)

PREPARED BY APPROVED BY REVIEWED BY


SHIVANSH SINGH
YADAV (QA/QA)

1
TECHNO FAB ENGINEERS Procedure No : FT/23-24/PE/TK-001
FABRICATION AND
Rev.:00
ERECTION PROCEDURE
Date:10-02-2024

Scope:-
The Method Statement for storage tank construction provides detailed
information on the procedure and rules for conducting all fabrication,
erection, and testing of the storage tanks and similar static equipment. All
the tasks / Activities should be completed with utmost care with good
workmanship and in accordance with the specifications to realize
satisfactory completion of the entire activities. This document will provide a
reference for a proper methodology to realize the activities during a proper
sequence for fabrication, Erection, and Testing of the storage tank.

Reference Documents
 API 650
 IS 803
 ASME Sec IX
 Approved Drawing / Specification
 ASME Sec V

Storage Tank Construction Methodology


:

1. Identification of Tank Materials


2. Tank Construction and Fabrication
 Annular and Bottom Plate Fabrication
 Shell Plate Fabrication
 Roof Plate Fabrication
 Spiral Stairway and hand railing.
2
TECHNO FAB ENGINEERS Procedure No : FT/23-24/PE/TK-001
FABRICATION AND
Rev.:00
ERECTION PROCEDURE
Date:10-02-2024

 Annular Plate laying


 Bottom Plate laying
 Erection of Cone Roof plates and Structures
 Shell Course Erection
 Appurtenances installation

Identification of Tank Materials


All items required for tank fabrication like Plates, fittings, and
other components of the tank system must be clearly identified by marking
heat numbers by hard-punching on each part. Each weld joint shall be
marked with a joint Number with Welder Number.

Storage Tank Construction and fabrication

All fabrication works like tank material identification, marking, cutting, rolling
and welding must be performed as mentioned in the latest API 650. It must
be meeting all safety, Quality Control & Non-Destructive Testing
requirements, with the coordination of the Engineer-In-Charge.

 Lay all the plates, Structural & pipes in such a fashion that facilitates
proper checking of dimensions & heat no.
 Mark the components as per the drawings.

Tank Annular and Bottom Plate Fabrication


 Marking of plates as per the drawing
 Perform the cutting operation after proper inspection.
 All the cutting operations shall be administered by Gas Cutting.
 Grind the cut edges smoothly to get rid of burrs and slag.
3
TECHNO FAB ENGINEERS Procedure No : FT/23-24/PE/TK-001
FABRICATION AND
Rev.:00
ERECTION PROCEDURE
Date:10-02-2024

 Stack the plates at designated places within the fabrication yard in


proper Sequence.
 The backing strip shall be fitted and tacked with an annular plate as per
the drawing.
 After completion of the fabrication underside of the annular and bottom
plates shall be blast cleaned and painted as per the specification to the
satisfaction of the Engineer-in-charge.
 Check the Joint Position, Root gap for welding after welding Inspection
by weld visual & NDT as per API 650.

Tank Shell Plate Fabrication


 Lay all the plates within the open area such as how easy it is for marking
and cutting.
 Mark the plates as per the drawing and to the satisfaction of the
Engineer-in-charge.
 The cutting operation including beveling shall be administered by the
gas-cutting method on all four sides.
 Grind the cut edges smoothly to get rid of slag and burr.
 The stings-prepared plates shall be shifted by crane to the rolling area.
 The plates shall be fed to the rolling machine. By means of a crane &
proper lifting tools and tackles.
 The plate shall be rolled as per drawing details and therefore the radius
shall be checked using a Template.
 Proper care shall be taken for the graceful curvature. 36’’ Long (5 to 6
mm thick). The template shall be wont to check rolling curvature
accurately.
 The Template shall be checked and cleared by the inspection authority.
 The rolled plates shall be inspected and shall be within 3 mm of the
tolerance limit.
4
TECHNO FAB ENGINEERS Procedure No : FT/23-24/PE/TK-001
FABRICATION AND
Rev.:00
ERECTION PROCEDURE
Date:10-02-2024

 The rolled plates shall be shifted to the shot blasting yard to hold out the
shot blast as per specification.
 Final profile and dimensions check shall be administered before sending
for erection.

Tank Roof plate fabrication


 Mark the roof plate as per the drawing.
 All the cutting operations as per requirement shall be administered after
getting clearance from the inspection authority.
 All the cutting operations shall be administered by the gas-cutting
method on all four sides. Grind the cut edges smoothly to get rid of burrs
& slag.
 Structural items of the roof shall be fabricated as per the drawing.
 These roof plates shall be shifted to the blasting yard to hold out the
blasting and painting

Tank Attachments
 Mark the specified items of the attacments as per the drawing. All the
cutting operations as per requirement shall be administered after getting
clearance from the inspection authority.
 All the cutting operations shall be administered by the gas-cutting
method.
 Grind the cut edges smoothly to get rid of burrs & slag.
 The Flange face is covered with an appropriate cover to guard against
damage during handling, fabrication, and transportation.
 The whole shell nozzle, roof appurtenance, i.e. flanges, flanges to pipe
joint, and other requirements, etc. Shall be fabricated as per approved
drawings.
5
TECHNO FAB ENGINEERS Procedure No : FT/23-24/PE/TK-001
FABRICATION AND
Rev.:00
ERECTION PROCEDURE
Date:10-02-2024

 All the fabrication and welding activities shall be administered after the
stage-wise inspection wherever required.
 The NDT requirements are as per code specification.

Spiral Stairway, Hand Railing of Storage


Tanks
 All the structural items shall be straightened before marking and cutting.
 Mark the components as per the drawing.
 All the cutting operations, as per requirement shall be administered after
getting the clearance from the inspection authority.
 All the cutting operations shall be administered by the gas-cutting
method.
 Grind the cut edges smoothly to get rid of burrs & slag.
 Fabrication like fitting, welding, drilling, etc. shall be administered as per
drawing and after the clearance from the inspection authority.
 After fabrication of these structural items shall be blasted and painted as
per requirement.

Storage Tank Erection


There are two methods for storage tank erection:

 The Jacking method &


 The conventional method.
The conventional method is tough & unsafe as compared to the jacking
method that’s why the jacking method for Tank erection is used everywhere.

6
TECHNO FAB ENGINEERS Procedure No : FT/23-24/PE/TK-001
FABRICATION AND
Rev.:00
ERECTION PROCEDURE
Date:10-02-2024

In the jacking method, we calculate the overall weight of tank ages except
for the bottom & deck, and accordingly, jacks are used. The number of
jacks to be used is directly subjected to the weight of the tank to be lifted.

Laying of Storage tank Annular Plate


 Check the extent of the foundation as per specification Latest API 650.
After getting clearance for annular plate lying, mark the 0 degrees, 90
degrees, 180 degrees, and 270 degrees coordinates on the
inspiration from the point of reference.
 Lay the annular plate as per the approved drawing. Out radius of the
annular plate shall be on the positive side so as to realize the
ultimately required radius after weld shrinkage.
 The orientation of the annular plate joint shall be as per the approved
drawing.
 Fit from the annular plate’s joints shall be administered using proper jigs
and fixtures as shown in the drawing.
 Care shall be taken while fit-up, such that there shouldn’t any gap
between the annular plate and backing strip.
 Annular plate joints welding shall be administered by welding alternative
joints at four quadrants.
 Qualified welders shall be engaged for the welding work consistent
with WPS. If any defect is found the defect weld shall be removed by
grinding and re-weld and conducting the Diesel chalk test.
 Repeat the sequence until the defect is cleared.
 Complete the welding, and clean the ultimate weld surface by wire
brushing and grinding.
 Remove the jigs and fixtures which were used for the fit-up of the annular
joint and grind the tack.
 Radiography shall be taken as per API-650 Sec-8.

7
TECHNO FAB ENGINEERS Procedure No : FT/23-24/PE/TK-001
FABRICATION AND
Rev.:00
ERECTION PROCEDURE
Date:10-02-2024

Laying of Storage Tank Bottom Plate


 Lay the middle plate on the inspiration top as per the drawing.
 With the coordination of the Centre, plates lay rock bottom plates
consecutively as per the drawing.
 Laps shall be maintained while the fit-up of a short seam and long seam
as per drawing.
 Temporary tack weld is to be performed on the Long-seam to avoid
uneven movements, while the fit-up and welding of the short seam are.
 Short seam welding is going to be administered alternatively to avoid
distortion.
 After the completion of short-seam welding, remove the temporary tacks
on the Long- seam by grinding to facilitate the long-seam fit-up. Short
seam welding is going to be administered alternatively to avoid distortion.
 After the completion of short-seam welding, remove the temporary tacks
on the Long- seam by grinding to facilitate the long-seam fit-up.
 Minimum laps shall be maintained while the fit-up of the long seam is as
per the approved drawing.
 Joggling shall be administered by hammering wherever necessary.
(Three plates Joining junction.)
 Before starting the welding, channels shall be tacked along the long
seam to avoid distortion. After completion of shot seam welding long
seam welding is going to be administered alternatively to avoid
distortion. a professional welder shall be engaged and welding shall be
performed as per the approved WPS.
 After Completion of welding thoroughly cleans the weld joint by wire
brushing and grinding.
 Sketch to annular plate joint shall be welded only after shell-to-bottom
joint welding.
 All rock bottom plate joints vacuum box tests shall be administered as
per the approved Process and code specifications.
8
TECHNO FAB ENGINEERS Procedure No : FT/23-24/PE/TK-001
FABRICATION AND
Rev.:00
ERECTION PROCEDURE
Date:10-02-2024

 If any defect is found the defect weld shall be removed by


grinding and re-weld and conducting the vacuum box test.
Repeat the sequence until the defect is cleared.

Erection of Cone Roof Plates and


Structures
 After completion of the highest two shell courses erection, fit-up, welding,
and curb ring fit & welding shall be done.
 Erect the fabricated Centre Drum, Roof Truss, and cross girders as per
drawing.
 Complete the welding of the Roof structure by approved welders and as
per approved WPS. Erect and Lay the Roof plates on the structure as
per the Drawing. While fit from the short seams and long seams Lap to
be maintained as per the Drawing.
 Weld the short seams by welding the alternative joint or sequence
mentioned within the drawing to stop the distortion.
 Provide proper support lengthwise of the long seam and weld the joints
as per the drawing sequence.
 Roof Nozzles and top shell nozzles fit-up and welding shall be carried
out as per the approved drawing and subsequently, it’s to be correlated
with the priority piping drawing.

Erection of Storage Tank Shell


 After the completion of the welding of the Annular plates and bottom
plates, mark the tank’s inner radius on the annular plates.
 Nos. of erection tools at equal intervals on the annular Plates &
transfer the within tank diameter on the stools.
 The last 2 shell courses shall be erected by the conventional method.
 Balance shell courses shall be erected
9 by the Jacking method.
TECHNO FAB ENGINEERS Procedure No : FT/23-24/PE/TK-001
FABRICATION AND
Rev.:00
ERECTION PROCEDURE
Date:10-02-2024

 The rolled shell plates shall be shifted to the tank foundation area
stacked around the periphery by using a crane.
 Proper care shall be taken while handling the rolled plates.
 Care shall be taken that the shell plate is erected to the diameter marked
on the annular plate. Jigs and fixtures shall be used to align the shell
plates.
 Complete the fit-up except for the ultimate joint which shall be fitted and
welded after completion of the welding of the opposite joints. (To avoid
shrinkage).
 Peaking shall be checked at the top, middle, and bottom of the vertical
joints employing a Sweep board. Plumpness shall be checked for the
verticality of the shell course and shall be within the tolerance. For
perfect verticality, channels shall be provided at the regular
interval inside the shell course providing the channels shall facilitate the
alignment shell course.
 Tack welds of the fitted vertical joints shall be ground smooth. Offer for
inspection and obtain clearance from Engineer-in-charge for the vertical
fit-up Complete the primary side welding by using qualified welders.
 Care shall be taken while welding to avoid peaking and therefore
the roundness distortion.
 After completion of first side welding, the back-chip shall be administered
for sound metal from the other side of the weld by grinding.
 Back-chipped grooves shall be offered for inspection before starting the
welding.
 Complete the 2nd side welding using qualified welders.
 Joint Nos. & welder No. shall be marked on both sides of the weld joint.
Care shall be taken to avoid peaking and roundness distortion. Clean
weld joints from each side by wire brushing and grinding. After
completion of welding from each side remove all the temporary jigs and
fixtures and flush grind the tacks. (Do the weld refill wherever
required) and therefore the portion checked by M.P.T.

10
TECHNO FAB ENGINEERS Procedure No : FT/23-24/PE/TK-001
FABRICATION AND
Rev.:00
ERECTION PROCEDURE
Date:10-02-2024

 Check the plumpness, circumference and therefore the radius, offer for
inspection to the satisfaction of the Engineer-in-Charge. While
erecting subsequent coarse spacers shall be kept between the shell
courses.
 Erection channels shall be fixed between the jacked shell and to be
erected shell course plates at regular intervals to align and hold the last
shell in a vertical position.
 Check to peak at vertical joints of shell employing a sweep board,
acceptable tolerance shall the as per API-650.
 Complete welding of last course vertical seam inside after getting
clearance from the Engineer-in-charge. Back chip & welding shall
be administered following as same as for other shell courses to the
satisfaction of Engineer – in – Charge.
 After completion of welding, weld visual, verticality & circumference shall
be verified and recorded to the satisfaction of Engineer-in-Charge. Fit up
the Horizontal seam between 2nd shell courses & 1st shell courses.
 Check Verticality of the last shell course, Verticality (plumpness)
tolerance shall be as per API – 650.
 While welding care shall be taken for banding and therefore
the roundness. Back-chip shall be administered by grinding for the sound
metal and to the satisfaction of Engineer-in-Charge. Complete the 2nd
side welding and clean the joint thoroughly from each side by grinding
and wire brushing. Check banding, plumpness, and record within
the approved format to the satisfaction of Engineer – In-Charge.
 Offer welds visual to the satisfaction of Engineer-In-Charge. Mark the RT
spots as per the instruction of the Engineer -In Charge, and complete the
RT as per API – 650 requirements. Offer the RT film for reviewing to the
Engineer-In-Charge and if any repair occurs the repair spot shall be
repaired by grinding for the sound metal, Re- weld the repair spot as per
code API -650 sec-8 requirements.
 Take the repair spot RT and re-offer for the inspection to the satisfaction
of Engineer-In- Charge. Spiral staircase Erection shall

11
TECHNO FAB ENGINEERS Procedure No : FT/23-24/PE/TK-001
FABRICATION AND
Rev.:00
ERECTION PROCEDURE
Date:10-02-2024

be administered as per drawing including brackets & avoiding fouling


with welds.
 Remove all the temporary cleats and tacks by grinding. If any defect is
found the defect shall be repaired by grinding the defect area for the
sound metal plus 150mm from both ends of the defect.
 Conduct the DP test on the repair spot. perform the entire
 Process until the repair is cleared to the satisfaction of Engineer – In –
Charge.
 After completion of the shell to the bottom outside welding visual
inspection is going to be administered to the satisfaction of the Engineer-
In Charge.
 On completion of the shell to bottom welding / NDT and having
completed all erection and welding work on the tank inside associated
with the roof and roof structure, all unwanted materials, and scrap shall
be far away from inside the tank.
 RT of the vertical and horizontal joints shall be completed.
 Sketch to Annular plate joint fit up shall be administered after completing
the shell to bottom welds.
 Vacuum box test shall be administered for rock bottom plate short seam,
long seam, and sketch to annular plate joint. If any repair occurs an
equivalent shall be repaired and re-tested as per the approved procedure
and API-650.

Installation of Tank Attachments


 Flanges to pipe joint shall be prefabricated and required NDT shall be
completed before erection.
 Mark the nozzle location as per the drawings. Cut the openings by gas
cutting after proper Inspection-by-inspection authority.
 Erect the nozzles as per the orientation & the elevation shown within
the drawing. Install RF. pads wherever required before nozzle erection.

12
TECHNO FAB ENGINEERS Procedure No : FT/23-24/PE/TK-001
FABRICATION AND
Rev.:00
ERECTION PROCEDURE
Date:10-02-2024

 Suitable jigs & fixtures shall be provided to stop the distortion during the
welding.
 Orientation, elevation & projection shall be maintained as per drawing
and offer for the inspection clearance. Proper care shall be taken for
welding by providing jigs & Fixtures to stop distortion.
 Welding shall be as per WPS and to be welded by the qualified welder.
 The man-Hole neck shall be fabricated and therefore the longitudinal
joint shall be radio graphed. The entire RF Pad weld shall be
pneumatically tested at a pressure. The pneumatic test shall
be administered to the satisfaction of the engineer in charge.
 All the shell nozzles finally weld from each side and RF Pads welds shall
be inspected visually and by LPT, to the satisfaction of the engineer-in-
charge.

13

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