FABRICATION
SET-UP
1
Module : Fabrication Set-up
Faculty : Course co-ordinators (KMM, NBD, JSM )
Demonstrator : Workmen from Shops
Duration : Maximum 16 Hours
Participants : Max. 05 / Module (Workmen from shops)
No. Topics Time
1 Introduction to SRMs. 30 Min.
2 Pre test 30 Min.
3 Classroom training 5.0 Hrs
4 Demonstration 3.0 Hrs
5 Practical training 4.0 Hrs
6 Skill test 2.0 Hrs
7 Post test and feed back 1.0 Hr
2
Unit : 1 Long. Seam Setup
DESCRIPTION TIME
• Introduction and Pre Test 1 Hr
• Long Seam Setup Theory 1 Hr
• Long Seam Setup demonstration 1 Hr
• Long Seam setup practice 1 Hr
3
Types of Long Seam Set-ups
• Long Seam Set- Up of Plate # Plate
• Long Seam Set- Up of Rolled Shell
• Long Seam S/u of Petal # Petal D’end
• Long Seam S/u of Web & Flange (P1402)
4
Procedure For Long Seam Set-up
• Check weld edge preparation as per drg.
• Wire wheel 50 mm area around seam.
• Check the skew.
• Measure the outside circumference at both the
ends and at centre.
• Ensure proper root gap & root face.
• Ensure offset within tolerance.
• Put run In - run out plates & PTC as per job
requirement.
• Recheck the circumference at both the ends & at
centre.
• Offer the set-up for inspection. 5
Offset limits for butt welds
THICKNESS LONG CIRC.
SEAM SEAM
• UPTO 12.7 INCLUSIVE 1/4T 1/4T
• OVER 12.7 TO 19.05 INCL 3.18 1/4T
• OVER 19.05 TO 38.10 INCL. 3.18 4.76
• OVER 38.10 TO 50.80 INCL. 3.18 1/8T
• OVER 50.8 LESS OF 1/16T LESS OF /6T
OR 9.53 OR 19.05
• WHERE T=Nominal Thickness Or Design Thickness
6
Method of Offset Removal in Long Seam S/U
by Screw Wedge 7
Method of Offset Removal In Long
Seam S/U by Taper Wedge
‘L’-CLEAT
TAPER WEDGE
8
Method of Skew Removal in Long
Seam S/U by screw wedge
Screw Wedge
Long Seam
9
Unit 2: Circ. Seam setup
Topic Time
• Circ. Seam Setup Theory 2 Hours
• Demonstration By Senior W/m 1 Hour
• Hands On Practice 1 Hour
10
Types of circ-seam set-up
• Shell to Shell
• Shell to D’end
• Shell to Cone
• Pipe to Flange
• Reducer to Elbow
11
Parameters for Circ-seam
Set-up of Shell
• Circumference of both Shells
• Squareness of both Shells
• WEP ( Degree, Root Face )
• Ovality of both Shells
• Orientation ( With Respect to Long Seam )
• Off-set & Root Gap
• Total Length & Alignment
12
CHECKLIST
• Check NDT of long Seam
• Check Square ness With Respect to Reference Line
• Check WEP
T T
Ref. line
• Check Ovality and Correct it
• Check Orientation With Respect to Shell
Long Seam Weld seam
• Check Circumference Of Both Shell & calculate
Offset. 13
PROCEDURE
• Align shell positioners (Tank Rotators)
• Keep both the Shells on the shell positioners
• Keep Root Gap as per Requirement
• Lock Four Orientation ( 0 , 90, 180, 270 )
(Keep Offset as per the Circumference Difference.)
• Check Total Length
• If Pair Nozzles, check external Dimension
14
Procedure ….
• Check TSR / internal Dimensions
• Check Surface Alignment
• Remove Spider ( If It Is Used )
• Complete the balance Set-up (Maintain Equal Offset)
• Again Check all The Dimensions Like,
- Offset
- Root Gap
- Pair Nozzle / External
- TSR / Internal
- Total Length
- Take Surface / Axial Alignment
• Clean The Seam.
• Fill Up The Dimension Protocol Page-3
15
Pair Nozzles
0 0
TSR
Weld seam
Ref. line
90 90
Root
gap
Total Length
16
Checking Axial Alignment Of Shells
Procedure
• Level the
Shell Orientations Vertically / Horizontally
• Arrange Shell Assembly As Shown In Sketch Below
X
F
90
E
D
180 0
C Z2 Z1
B
27
A 0
PLUMB BOBS
X 18
PLAN FRONT VIEW
Checking Axial Alignment Of Shells
Measure Perpendicular Distance Between Plumb Line And
Horizontal Twine & Tabulate Readings As Shown Below.
Locations Twine To Plumb Dist. Half Diff ( Z1- Z2 / 2 ) MM
Z1 At 0 Z2 At 180 Of Reading
A
B
C
D
E
F
• Similarly Repeat This Exercise For 90 / 270 Orientations By
Rotating The Shell Assembly.
Locations Twine To Plumb Dist. Half Diff ( Z1-Z2 / 2 ) MM
Enter Dim. Z1 At 90 Z2 At 270 Of Reading
ABCDE& F
19
Checking Axial Alignment of Shells
• Plot the Points on a Graph Paper With Suitable Scale and Find out the
Best Possible Centre. The Radial Distance from this line is “Out Of
Alignment”
• Find out Max. out of Alignment in both the Planes & Note As
( A ) 0 - 180 Deg. = _________ ( B ) 90 - 270 Deg. = ____________
• Superimpose both the Graphs in Order to Find out the Total “Out Of
Alignment” Of The Assembly.
+3 +3
+2 +2
+1 +1
00 00
-1 A B C D E F -1 A B C D E F
-2 -2
-3 0 - 180 DEG. 90 - 270
-3 DEG. 20
Checking Surface Alignment Of Shells
Y0 A(END) X0
Y1 X1
B
Y2 X2
Y3 X3
C
Y4 X4
Y5 X5
D
Y6 X6
Y0 E X0
(END)
1. Level The Shell Orientations ( 0 - 180 , 90-270 ) Vertically / Horizontally
2. Drop The Plumbs Near Each Circ.Seam And Put Twines
Horizontally On Both Side Of Shells.
21
Checking Surface Alignment Of Shells
3. Maintain Same Dimensions At Both Ends Of The Sections
Between Horizontal Twines & Plumb.
4. Measure Perpendicular Distance Between Other Plumbs
And Horizontal Twines And Record The Readings In The
Table Below.
5. Similarly Rotate the Job 90 Degrees and take Dimensions
For other two Orientations and record them.
6. Surface Alignment is = Maximum Reading - Minimum
Reading.
SEAM NO ORIENTATION
0 90 180 270
A ( END ) X0 Y0
B X1 Y1
X2 Y2
C X3 Y3
X4 Y4
D X5 Y5
X6 Y6
E ( END ) X0 Y0 22
Checking Surface Alignment Of Shells
Section with different thickness of shells
Y1 X1
A(END) In Cases Of X2,X3,X4,
THK T1
Y2 X2 Alignment Is Difference Of
B
That W.R.T X1
Y3 X3 In Cases Of X5,X6,X7,
Alignment Is Difference Of
That W.R.T X8
Y4 C X4
PLUMB BOBS
Y5 X5
THK T2
Y6 X6
D
Y7 X7
E(END) X1 = X8 + ( T2-T1 )
Y8 X8
23
SKETCH - 2
Checking Surface Alignment Of Shells
Section With Different Thickness Of Shells
1. The dimension setting At ends ( X0 ) are decided
taking into consideration Of shell course
thickness. ( Refer sketch 2 )
For rest same procedure is to be adopted.
Note:
The shell ovality / shape shall be controlled within The limit
In order To get better alignment.
24
Reference Line Marking Procedure
1 Optical Method 2 Pin Method
DECIDING FACTORS
1 DIAMETER OF SHELL
2. THICKNESS OF SHELL
3. TOLERANCE ON TSR.
The chart below recommends the method (pin or optics ) to be followed for marking the
reference line on towers with internals as tsr
SHELL DIA UP TO 3500 3500-4500 >4500
**TOLERANCE ON <,= 3 >3 >3 <, = 3 >, <, = 3
TSR LEVEL WITHIN
THICKNESS <, = 25 O P O O O O
THICKNESS > 25 O P P O O O
- P DENOTES PIN METHOD OF MARKING
- O DENOTE S OPTICAL METHOD OF MARKING / MARKING ON MACHINE BED WITH SHELL
AXIS VERTICAL.
- ** TOLERANCE ON TSR WITHIN 3 mm MEANS THAT THE SPECIFIED TOLERANCE IS + 1.5 mm
- ALL DIMENSIONS ARE IN mm
25
Procedure For Reference Line Marking
By Pin Method
4 4
SPIDER
SPIDER
3 3
2 2
REF.LINE
1 1
POINTS (e.g 1,2,3,4) 250 mm APART
CONST.DIST
TANK ROTATERS
APPROX.1000 MM
OIL BATH
26
Procedure For Reference Line
Marking By Pin Method
• Keep the shell horizontal on a pair of tank rotators.
• Correct the ovality To 0. 25 % both ends.
• Spiders shall be rigid enough to prevent buckling.
• Tack weld a pin Of 10 dia at the centre of the spider.
( The pin shall be parallel to shell axis)
• The pin shall have a machined ‘V’ groove for the plumb.
• Drop a plumb along the groove of the pin.
• The plumb is to be suspended in an oil bath.
27
( PROC. CONTD…..)
• Divide the circumference of shall appro x. 250 mm apart on
i/d and o/d as shown in sketch.
• Check square ness of The shell
• Punch mark A constant distance from the plumb on I/D and
on O/D
• Join The punch marks by a flexible steel rule.
• Minimum 3 points are to be covered In one setting of scale
• Rotate the shell In both directions and confirm the reference
line marked on I/d and O/D.
• Write The reference line elevation from I/S & O/S with paint.
28
UNIT : 3
NOZZLE SETUP AND DEVELOPMENTS
TOPIC TIME
• Nozzle Setup Theory 1 Hr
• Development of Radial Nozzle 1 Hr
Pipe and Shell
• Demonstration on nozzle s/u 1 Hr
by senior workman
• Practice for Development 1 Hr
• Practice for Nozzle Setup 1 Hr
29
NOZZLE
• Assembly of Pipe/ Forging to Flange is called
Nozzle
Flange
Pipe
30
Application
• Used for Inlet or Outlet connections
• Used for Man way.
• Hand hole
• Used as Pressure, Temp, & Level Indicator.
• Fitting Safety Valve and Devices
• For Vent connection.
31
Types of Nozzle
• Radial Nozzle • Offset Nozzle
32
Types of Nozzle
• Tangential Nozzle • Angular Nozzle
33
NOZZLE SETUP
• Types of Pipe
• Types of Flange
34
Types of Pipe
• Fabricated Pipe
Fabricated from Plate by doing rolling & welding.
• Seamless Pipe
Standard Pipes available as per NB and Schedule.
Normally we us standard pipes. Applicable
Standard is B 36.10
35
Standard Pipe Schedule
• Applicable Std is B 36.10
• Outside Diameter depends on Nominal Bore size
and it is fixed for a given Nominal Bore size
• Schedule determines wall thickness of pipe for a
given nominal pipe size .
• Ex. 5” NB, Sch. 80 From Schedule table one can
find out OD and Thickness of pipe.
Where 5” NB = mm. ( From table )
Sch. 80 = mm ( From table )
36
Types of Flange
• WN : Weld Neck
• SO : Slip On Lapped
• THD : Threaded Socket
Types of Face on Flange
1. RF : Raised Face
2. FF : Flat Face
3. GF : Groove Face
4. RTJ : Ring Type Joint
5. Male- Female
37
SORF Flange SOFF Flange WNRF Flange
LWNRF Flange
38
Types of Nozzle to Shell Set Up
Nozzles can be fitted with shell by two ways.
Set On : Cut Out On Shell to be Made as per the
Pipe ID and WEP is made on pipe.
Set Through : Cut Out On Shell to be Made as per the
Pipe OD and WEP on Shell
39
Set Through Nozzle Set on Nozzle
40
Procedure of Nozzle to Shell Setup
• Study of Drawings & Tolerance Sheet
• Development of Cutout
• Marking on Shell
• Make Cutout
• Do Nozzle Set Up
• Dimensional Checkup
41
Drawing Study
• Nozzle Mark
• Nozzle Size, pipe Schedule, Pipe Thickness
• Elevation From Bottom Tan / Ref Line
• Height from Centre Line
• Orientation of Nozzle
• Tolerance Sheet
• Details of Pair Nozzle if any
• Released or under Hold
42
Development For Radial Nozzle
12 1 2 1
12 2
11 3 11 3
Pipe Plan 10 4 10 4
5 9 5
9
6 8 6
8 7 7
1
11 12 2
3
10 9 8 7 6 5 4
Shell Side View
43
Nozzle Marking on Shell
12 Nozzle Centre Line
Bottom Tan / Ref Line
44
Procedure : Nozzle to Shell Set Up
1. Straddle the nozzle
2. Match the Orientation
3. Adjust the Height
4. Level the Nozzle
5. Provide small tacks to Supports
6. Ensure Dimension as per drawing
7. Strengthen the tacks
8. Re-check the dimensions
45
Straddling
A A
VIEW A A A 46
Orientation Matching
3mm
3mm
Shell
Deviation of Orientation +/-3mm 47
HEIGHT MEASUREMENT
Height /
Nozzle Projection
Shell
48
LEVEL CHECKING
Spirit Level
Nozzle
Shell
49
Nozzle Tolerance
A. For any pair Nozzles
Distance between Nozzles +/- 1mm
Orientation +/- 1mm
Nozzle face inclination 1/4 Degree
B. Elevation from R.F Line
Man Hole +/- 6 mm
Nozzles +/- 3 mm
50
Nozzle Tolerance
C. Projection of Flange Face From Shell
Surface
Manhole +/- 6mm
Nozzles +/- 3mm
D. Circumferential Deviation From True
Orientation +-3mm
E. Tilting of Nozzle +- 1/2 Degree
51
Fabrication setups
POST TEST
Description Time
• Questions on Long. seam Setup 15 Min
• Questions on Circ. Seam Setup 15 Min
• Questions on Nozzle Setups 15 Min
and Developments
52
SKILL TEST = 2 hrs
Description Time
• Dimensional Check up for 15 Min
Long. seam Setup
• Circ. Seam S/u Inspection 60 Min.
with alignment graph
• Nozzle Development for
Pipe and Shell 45 Min.
53
