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TYPES OF ERROR
+VE ERROR TAPE 25005 25000 24995
STD TAPE
- VE ERROR TAPE
ERROR CORRECTION
TYPE OF ERROR
+ VE -- VE
OPERATION
MARKING
(ADD ERROR)
MEASURING
(SUBTRACT ERROR)
X + (+Y) X + (--Y)
X -- (+Y) X -- (--Y)
W
ROLLING DIR.
L TOLERANCE
L - + 1 mm / M, Max. 3 mm., & K1 - K2 = + 1 mm / M, IDENTIFICATION MARKING
3 UNITS
W - + 1 mm / M, Max. 3 mm
3.1415926535897932384626433832792...
ACTUAL THK.
ID < < < < < < < < < < < < 152 305 457 610 914 1219 1524 1905 2133 2438 2743 3048
Allowed gap Pick in / out 0.8 MM 1.2 MM 1.6 MM 2.4 MM 3.2 MM 4.0 MM 4.8 MM 5.6 MM 6.4 MM 6.4 MM 7.1 MM 7.9 MM 0.2% OF ID
PEAK OUT
PEAK IN
>3048
LEVEL THE
SHELL ORIENTATIONS VERTICALLY / HORIZONTALLY ARRANGE SHELL ASSEMBLY AS SHOWN IN SKETCH BELOW X
F
90
E D
180 0
Z1
C B
Z2
270
A
PLUMB BOBS X PLAN FRONT VIEW
+3 +2 +1 00 -1 -2 -3 0 - 180 DEG. A B C D E F
+3 +2 +1 00 -1 -2 -3 90 - 270 DEG. A B C D E F
Y2 Y3 C
X2 X3
Y4 Y5 D Y6 Y0 E (END)
X4 X5
X6 X0
1.
2.
DROP THE PLUMBS NEAR EACH CIRC.SEAM AND PUT TWINES HORIZONTALLY ON BOTH SIDE OF SHELLS.
5.
6.
MAXIMUM READING
ORIENTATION
90 180 Y0 Y1 Y2 Y3 Y4 Y5 Y6 Y0 270
MINIMUM
THK T1
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
Y3
X3
Y4
X4
Y5 Y6
X5 X6
THK T2
Y7 E(END) Y8
X7
X1 = X8 + ( T2-T1 )
X8
SKETCH - 2
NOTE: THE SHELL OVALITY / SHAPE SHALL BE CONTROLLED WITHIN THE LIMIT IN ORDER TO GET BETTER ALIGNMENT.
MEASURE THE ACTUAL CIRCUMFERENCE ON THE JOB. ONLY CALIBRATED TAPES SHOULD BE USED FOR MEASUREMENT. COMPARE THESE TWO VALUES OF CIRCUMFERENCE AND CHECK THE ACCEPTABILITY BASED ON BELOW GIVEN TOLERANCE CHART.
TOLERANCE ON CIRCUMFERENCE
TOLERANCE ON CIRCUMFERENCE COMPONENTS THICKNESS OF COMPONENTS IN MM UP TO 8 ROLLED SHELLS AT L/S SET-UP STAGE (+) 5 (-) 2 9 TO 18 (+) 7 (-) 4 19 TO 50 (+) 10 (-) 7 ABOVE 50 (+) 12 (-) 9 CIRCUM. TO BE CHECKED AT 3 LOCATIONS, 2 ENDS AND AT CENTRE IF COMPONENT IS IN SET-UP STAGE WITHOUT WELDING PER JOINT 3MM SHRINKAGE SHALL BE ADDED TO BASIC CIRCUMFERENCE. REMARKS
PRESSED / FORMED DEND, CONE & EXPANSION BELLOW AFTER COMPLETING WELD JOINT IF ANY
(+ / - ) 5 (-0 / +10)**
(+ / - ) 8 (-0 / +15)**
(+ / - ) 10 (-0 / + 18)**
NOTES: THE ABOVE LIMITS ARE APPLICABLE ONLY IF NO OTHERS STRINGENT TOLERANCE IS SPECIFIED. ** THIS TOLERANCE IS APPLICABLE ONLY WHEN ABUTTING SHELLS HAS HIGHER THICKNESS WITH OUTSIDE TAPER AND INSIDE FLUSH.
2 PIN METHOD
SHELL DIA **TOLERANCE ON TSR LEVEL WITHIN THICKNESS <, = 25 THICKNESS > 25 O O
P P
O P
O O
O 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
REF.LINE
LINE OF SIGHT
PARAGON LEVEL
GROUND LEVEL
4 SPIDER SPIDER 3 3
2 REF.LINE 1
POINTS (e.g 1,2,3,4) 250 mm APART CONST.DIST APPROX.1000 MM TANK ROTATERS OIL BATH
KEEP THE SHELL HORIZONTAL ON A PAIR OF TANK ROTATERS. 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.
( PROC. CONTD..)
DIVIDE THE CIRCUMFERENCE OF SHALL APPROX. 250 mm APART ON I/D AND O/D AS SHOWN IN SKETCH. CHECK SQUARENESS 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 & O/D. WRITE THE REFERENCE LINE ELEVATION FROM I/S & O/S WITH PAINT.
CHECK THE STRAIGHTNESS OF DCBB WITH 300mm LONG SCALE ( IT SHALL BE WITHIN 1mm. )
DCBB
TANK ROTATOR
180
DCBB
90
LOCATION OF DCBB NEAR TANK ROTATOR (APPROX. 45 DEGREES )
a) MINIMUM TWO READINGS PER T.S.R. SEGMENT OF LENGTH < ONE METER b) FOR T.S.R. MORE THAN ONE METER MEASURE NEAR BOTH ENDS & EVERY ONE METER FROM OPEN END. ( i.e. ONE PASS, TWO PASS, OR FOUR PASS TRAY )
CHECK THE FLATNESS OF TSR (MAX. - MIN. READING IN ELEVATION IS THE TSR FLATNESS )
CHECK THE STRAIGHTNESS WITH 300 mm LONG SCALE AND IT SHALL BE WITHIN 1mm
TSR
REF. LINE
5 KG PULL
TRISQUARE
PERPENDICULARITY TSR
90
45
180
0
90 B SKETCH 1
315
270
SKETCH 2
0 FLANGE FACE
PENCIL SECTION
SPIDER
GRAPH PAPER
3. MARK THREE CIRCLE ON A PAPER (I) (II) (III) MEAN R MEAN R+ TOLERANCE MEAN R- TOLERANCE
4. ADJUST THE CURVE ON THE CIRCLES & DEMONSTRATE THAT THE CURVE IS WITHIN THE OUTER & INNER CIRCLES.
2. MEASURE THE RADIUS AT 48 LOCATIONS (R1 TO R48) 3. CALCULATE AVERAGE RADIUS = R1+R2++R48 / 48
5.1
SUPER- IMPOSE THE CURVE DRAWN THOUGHT ALL 48 POINTS ON TWO CIRCLES MARKED SHOWING MAXIMUM & MINIMUM ALLOWABLE DEVIATIONS
5.2 ENTER THE DATA IN CIRCLE PROGRAM & OBTAIN THE CIRCULARITY
HAZIRA METHOD
1. MAKE THE FRAMES & M/C OD/ID 2. WRAP THE SHELL AROUND THE FRAMES WITHOUT TACKING FRAME & SHELL 3. ENSURE GAP e 1, S/U, WELD & CLEAR NDT OF CLOSING SEAM 4. TACK FRAMES # SHELL
FRAME MANUFACTURE
APPLICABLE TOLERANCES
1. 2. 3. 4. 5. FRAME HEIGHT = + 4MM - 3 ID/OD ( MACHINED ) = D +/- 0.3 FLANGE WIDTH. +/- 2 MM UNBALANCE +/- 1 MM 5 FLANGE TILT 3 MM 3
4 1
T FRAME MANUFACTURE
CURRENT METHOD
1. MAKE COMPLETE FLANGE WITH REQUIRED CIRCUMFERENCE ** 2. 3. MAKE WEB SEGMENTS COMPLETE WITH ID/OD MACHINED & WEP COMPLETED AS APPLICABLE USE THE FIXTURE WITH APPROPRIATE BRACKETS FOR WEB # FLANGE S/U 4. WELD ROOT RUN ON WEB SEGMENT L/S ,TACK THE WEB # FLANGE JOINTS 5. REMOVE THE FRAME FROM THE FIXTURE & COMPLETE WELDING OF WEB L/S & CLEAR RT.
T FRAME MANUFACTURE
OLD METHOD
1. 2. 3. 4. 5. JOIN ALL WEB SEGMENT AND FROM A CIRCLE WELD & CLEAR NDT OF WEB L/S. MARK OD/ID ( AS APPLICABLE ) FOR MACHINING & MACHINE S/U FLANGE # WEB & WELD FLANGE WIDTH MACHINING WAS DONE AS THE FINAL OPERATION
SHRINKAGE ALLOWANCE
FOLLOWING SHRINKAGE ALLOWANCE IS TO BE ADDED ON THE CIRC. OF FRAMES WHILE S/U. INTERNAL FRAMES = 0.6 mm/M OF CIRC. EXTERNAL FRAMES = 0.9 mm/M OF CIRC.
HENCE THE S/U STAGE DIMENSIONS OF T FRAMES ARE NOT AS PER DRAWING & THE DIMENSIONS ARE GIVEN BY PLANNING IN A DATA SHEET.
GENERAL WEP
WHEN THE JOINING COMPONENTS ARE NOT AT 900
MARKING AT...
A B X
E
GENERAL WEP
WHEN JOINING PLATES OF DIFFERENT THICKNESS
T1
T2
01. 02.
MARK THE CENTRE POINT OF PENETRATION ON SHELL. MAKE THE CUT OUT USING THE DEVELOPMENT.
03. C LEAR MARKING FROM INSPECTION. 04. 05. MAKE CUT OUT TO THE ABOVE SIZE. MARK THE ROOT FACE BY JOINING TWO POINTS USING SCALE (w -90 ).
SINE-1
U = 1400/4027.5 U =20.3410
SHELL
50 - ( 90 - w )
900
500
w
500
X1 = H tan(90 - w) X2 = H tan [ 50 - ( 90 - w )]
90 + Y
w + 2Y w+Y w Y= 90- w 3
9.
WE WILL CALCULATE THE DISTANCE OF V FROM CUT OUT BY DIVIDING EACH QUADRANT AS ABOVE. THE ANGLE OF PENETRATION WITH THE SHELL VARIES FROM w TO 90 DEG & THEN FROM 90 DEG TO 180 - w.
= INV. SIN
07.
09.
10.
JOIN ALL THE POINTS FREE HAND AND PUNCH THE LINE
v = 24.91 mm
w = 69.6590
Thk-1 Thk 26.5
EXP :- X1 = H tan ( 900 - w ) = 26.5 tan ( 900 - 69.6590 ) = 26.5 tan ( 20.3410 ) = 26.5 0.37072
X1 = 9.82 mm
FWD end
X1
X2
AFT end
4. MARK REF. LINE AT (SECTION LENGTH - 200 MM) ON AFT SIDE MEASURED FROM FWD SIDE. 5. COMPLETE ABOVE ACTIVITY FOR BOTH SECTIONS. 6. CHECK THE DIMENSIONS X1,X2,Y1,Y2 AT EVERY 5 DEGREE AS SHOWN IN SKETCH.