FABRICATION

SET-UP
1

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 Dend
Long Seam S/u of Web & Flange (P1402)

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.

Offset limits for butt welds

THICKNESSLONG 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 1/8T

OR 9.53

OR 19.05
WHERE T=Nominal Thickness Or Design Thickness

Method of Offset Removal in Long Seam S/U

by Screw Wedge

Method of Offset Removal In Long

Seam S/U by Taper Wedge

L-CLEAT

TAPER WEDGE

Method of Skew Removal in Long

Seam S/U by screw wedge
Screw Wedge

Long Seam

Types of circ-seam set-up

Shell to Shell
Shell to Dend
Shell to Cone
Pipe to Flange
Reducer to Elbow

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
9

CHECKLIST
Check NDT of long Seam
Check Square ness With Respect to Reference Line
Check WEP
T

Check Ovality and Correct it

Check Orientation With Respect to Shell
Weld seam
Long Seam

Ref. line

Check Circumference Of Both Shell & calculate Offset.

10

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

11

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

12

Pair Nozzles
0

0
TSR
Weld seam
Ref. line

90

180
Root
gap

Total Length

13

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

C
B

180

Z2

Z1

270

A
X
PLAN

PLUMB BOBS
FRONT VIEW

15

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
Rotating The Shell Assembly.
Locations
At 270
ABCDE& F

Twine To Plumb Dist.

Orientations By

Half Diff ( Z1-Z2 / 2 ) MM

Enter Dim.
Z1 At 90

Z2

Of Reading

16

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
Alignment Of The Assembly.

+3

+3

+2

+2

+1

+1

00

00
A

-1
-2
-3

(
Out Of

-1
0 - 180 DEG.

-2
-3

90 - 270 DEG.

17

Checking Surface Alignment Of Shells

Y0
Y1

A(END)
B

Y2
Y3

X0
X1

X2
C

Y4

X3

X4

Y5

X5
D

Y6
Y0

X6
E
(END)

X0

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.

18

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
Reading.

Maximum Reading - Minimum

SEAM NO

ORIENTATION
0

90

180

A ( END )

X0

Y0

X1
X2

Y1
Y2

X3
X4
X5
X6

Y3
Y4
Y5
Y6

X0

Y0

D
E ( END )

270

19

Checking Surface Alignment Of Shells

Section with different thickness of shells
Y1

THK T1
Y2

A(END)

X2
B

Y3
Y4

X1

X3

X4

In Cases Of X2,X3,X4,
Alignment Is Difference Of
That W.R.T X1
In Cases Of X5,X6,X7,
Alignment Is Difference Of
That W.R.T X8
PLUMB BOBS

Y5

X5

Y6

X6

Y7

THK T2

X7

X1 = X8 + ( T2-T1 )

E(END)
Y8

X8

SKETCH - 2

20

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.

21

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
**TOLERANCE ON

UP TO 3500
<,= 3

>3

3500-4500

>4500

>3

<, = 3

>, <, = 3

TSR LEVEL WITHIN

THICKNESS <, = 25

THICKNESS > 25

- 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

22

Procedure For Reference Line Marking

By Pin Method
4

SPIDER
3

SPIDER

REF.LINE
1

POINTS (e.g 1,2,3,4) 250 mm APART

CONST.DIST
APPROX.1000 MM

TANK ROTATERS
OIL BATH

23

Procedure For Reference Line

Marking By
PinonMethod
Keep the shell horizontal
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.

24

( 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.

25

NOZZLE
Assembly of Pipe/ Forging to Flange is called Nozzle

Flange

Pipe

26

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.

27

Types of Nozzle
Radial Nozzle

Offset Nozzle
X

28

Types of Nozzle
Tangential Nozzle

Angular Nozzle

29

NOZZLE SETUP
Types of Pipe

Types of Flange

30

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

31

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 )

32

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

33

SORF Flange

SOFF Flange

WNRF Flange

LWNRF Flange

34

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

35

Set Through Nozzle

Set on Nozzle

36

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

37

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

38

Development For Radial Nozzle

12

12

11

Pipe Plan

10
5
8

11 12
10 9
8

1
7

2
6

11
4

10

4
5

9
8

3
5 4

Shell Side View

39

Nozzle Marking on Shell

12

Nozzle Centre Line

Bottom Tan / Ref Line

40

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

41

Straddling
A

VIEW A

42

Orientation Matching
2mm at hole dia

2mm

Shell
Rotation of bolt hole Orientation +/-2mm 43

HEIGHT MEASUREMENT
Nozzle

Height /
Projection

Shell

44

LEVEL CHECKING
Spirit Level
Nozzle

Shell

45

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

46

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

47

48