Document No:- 9560/NBEL/SITE/QAC/022, REV.

PROJECT : 500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations

LOCATION: 10th of Ramadan City, Industrial Area A1, Egypt

CLIENT EPC CONTRACTOR

SPREA FOR CHEMICALS NUBERG ENGINEERING LIMITED

DOCUMENT TITLE

JOB PROCEDURE FOR TANKS WORK

DOCUMENT NUMBER

9560/NBEL/SITE/QAC/022, REV.0

Document Category Document Review Status (by Owner/PMC)

(Submission Purpose)
Approval ☐ 1. Approved / Reviewed
☐ Review ☐ 2. Approved / Reviewed with comments as marked
☐ Information ☐ 3. Not Approved / Resubmit
FOR REVIEW AND ANAND ASHWANI
☐
00 Implementation ☐ R. Retained for Information TYAGI
/ Records RAJEEV SHARMA
APPROVAL SHARMA
Rev Date: ___/____/____ Name: ____________________
Checked By
Date Document Status Prepared By Approved By
. This approval does not absolve the Contractor from meeting their contractual obligations of delivering a
complete, safe and efficiently operating units/facilities meeting all requirements of the contract
 Document No:- 9560/NBEL/SITE/QAC/022, REV.0

JOB PROCEDURE FOR TANKS WORK

TABLE OF CONTENTS
Sl. No. Description
1 Scope
2 Purpose
3 Reference
4 Responsibility
5 Method of Construction
5.1 Sand pad foundation
5.2 Identification of Materials
5.3 Fabrication Work
5.3.1 Annular & Bottom Plate Fabrication
5.3.2 Shell Plate Fabrication
5.3.3 Roof Structure Fabrication
5.3.4 Roof Plate Fabrication
5.3.5 Appurtenances Erection
5.3.6 Spiral Stairway and Hand railing
6 Sand Blasting and Painting
7 Welder Performance Qualification
8 Erection and Welding
8.1 Annular plates laying and welding
8.2 Bottom plates laying and welding
8.3 Shell plates erection and welding
8.4 Roof structure and roof plates erection & welding
8.5 Appurtenances Installation
9 Water Fill test
10 Equipment’s
11 Man power
12 QA & QC
13 Safety
14 Documentation
15 General

1. SCOPE:

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 Document No:- 9560/NBEL/SITE/QAC/022, REV.0

JOB PROCEDURE FOR TANKS WORK

This procedure covers detailed activities for fabrication, erection, welding and testing of the storage
tanks including the requirement of equipment’s & manpower for 500 TPD Sulphuric Acid Plant
with 5.0 MW Power Generation Egypt . All the tasks/ activities need to be carried out with most
care & good workmanship in accordance with the specifications to achieve satisfactory completion of
the whole activities.

2. PURPOSE:
The purpose of this document is to follow proper methodology to carry out the activities in a proper
sequence for fabrication, erection, welding and testing of the cone roof tanks inspection testing to be
done during construction to ensure that a standard construction and workmen ship can be achieved
to the satisfaction of NBEL.

3. REFERENCE:
 API 650 Latest Edition
 ASME Sec IX
 ASME Sec II
 ASME Sec V
 ASME Sec VIII
 IS 803
 Approved NDT Map for tanks
 Approved Drawings
 9560/SITE/QAC/022/ITP-13

4. RESPONSIBILITY:
The responsibility of implementation of the job procedure during construction of tanks rests with Site
Manager & Engineers of Sub Contractor.

5. METHOD OF CONSTRUCTION:
5.1 TANK PAD FOUNDATION:
Check the level foundation as per specifications, approved drawings and API 650 clause latest
edition. After getting clearance for annular plate laying, mark the 0, 90,180 & 270 degrees co-
ordinates on the foundation from the reference points.

5.2 IDENTIFICATION OF MATERIALS:

The materials received at site shall be properly unloaded and stocked at store/yard. Each Piece of
Plates, pipes, fittings and any other component of tank work shall be clearly identified by marking
heat no. on the part (e.g.: IS 2062 Gr. B, H.No.-XXX) using painting or hard punching. All materials
shall be inspected visually and MIR shall be recorded as per approved ITP.

5.3 FABRICATION WORK:

All fabrication work involving material identification, marking, cutting, rolling and welding shall be
done in accordance with this job procedure, API 650 (Latest edition) and Technical specification of
Client. The workmanship shall be good in every respect to meeting all specification, safety, QC & NDT
requirements, with the co-ordination of Engineer-In-Charge.
All welding consumables shall be procured from approved manufactures and also batch certificates
shall be submitted prior to fabrication. All consumables shall be stored properly in the closed
container.

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 Document No:- 9560/NBEL/SITE/QAC/022, REV.0

JOB PROCEDURE FOR TANKS WORK

5.3.1 ANNULAR & BOTTOM PLATE FABRICATION:

 Lay all the plates in the fabrication yard such a way easy for marking and cutting.
 Mark the plates as per approved drawing.
 Carry out the cutting operation after inspection of client’s representative.
 All the cutting operation shall be carried out by Gas Cutting only.
 Grind the cut edges smooth to remove burrs and slag.
 Stack the plates at designated place in the fabrication yard in proper sequence.
 Backing – strip shall be fitted and tacked with annular plate as per approved drawing.
 After completion of the fabrication, under side of annular and bottom plates shall be blast
cleaned and painted as per painting specification to the satisfaction of the Engineer-in-charge
before bottom laying on tank foundation.

5.3.2 SHELL PLATE FABRICATION:

 Lay all the plates in the open area such a way easy for marking and cutting.
 Mark the plates as per approved drawing and offer inspection to the Engineer-in-charge.
 The cutting operation includes beveling shall be carried out by using PUG cutting machine only
on all the four sides.
 Grind the cut edges smoothly to remove slag and burr.
 The plates shall be fed to rolling machine with proper guide ways.
 The plate shall be rolled as per drawing and the radius shall be checked by using Gauge plate
(Template).
 Proper care shall be taken for the smooth curvature.
 36’’ Long and 6mm thk. template shall be used to check rolling curvature accurately.

5.3.3 ROOF STRUCTURE FABRICATION:

 All the structural items shall be straightened before marking and cutting.
 Roof structure shall be fabricated as per approved drawings.
 Before fabrication of structure, physical layout shall be drawn to get exact dimensions of all
structural members and gusset plates.
 Structure Layout shall be inspected by Engineer-in-charge.
 All the cutting operation, as per requirement shall be carried out after getting the clearance
from inspection authority.
 All the cutting operation shall be carried out by gas cutting method.
 Grind the cut edges smooth to remove burrs & slag.
 Fabrication such as fitting, welding, drilling etc., shall be carried out as per drawing and after
the clearance from inspection authority.
 After fabrication all the structural members, it shall be blasted and painted as per Technical
specification.

5.3.4 ROOF PLATE FABRICATION:

 Mark the roof plate as per approved drawing.
 All the cutting operation shall be carried out after getting the clearance from the inspection
authority.
 All the cutting operation shall be carried out by gas cutting method only.
 Grind the cut edges smoothly to remove burr & slag.
 Structural item of the roof shall be fabricated as per drawing.

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5.3.5 APPURTENANCES:
 Mark the required items of the Appurtenances as per the approved drawing.
 Cutting operation shall be carried out after getting the clearance from inspection authority.
 All the cutting operation shall be carried out by gas cutting method only.
 Grind the cut edges smoothly to remove burr & slag.
 Flanges face to be covered with a suitable cover to protect from damage during handling and
fabrication.
 The entire shell appurtenances, roof appurtenances, i.e. necks, flanges to pipe/neck joints and
other requirements etc., shall be fabricated as per approved drawings or Technical
specification.
 All the fabrication and welding activities shall be carried out after the stage wise inspection
wherever required.
 NDT requirements shall be applicable as per code/NDT Procedure/ specification.

5.3.6 SPIRAL STAIRWAY, HAND RAILING:

 Mark the components as per approved drawing.
 All the cutting operation, as per requirement shall be carried out after getting the clearance
from inspection authority.
 All the cutting operation shall be carried out by gas cutting method.
 Grind the cut edges smooth to remove burr & slag.
 Fabrication such as fitting, welding, drilling etc., shall be carried out as per drawing and after
the clearance from inspection authority.

6. BLASTING & PAINTNG:

Painting work shall be carried out as per painting specification. Manufactures test certificates paint
shall be submitted along with the painting materials.

7. WELDER PERFORMANCE QUALIFICATION:

All welders before employed on the job, they shall be qualified as per the approved WPS prior to
welding in tank. WPQ records shall be maintained for the qualified welders.

8. ERECTION & WELDING:

8.1. ANNULAR PLATE LAYING & WELDING:
 Check the level of sand pad foundation as per code/ specification.
 After getting clearance for annular plate lying, mark the 0 o, 90o, 180o, 270o co-ordinates on
the foundation from the reference point.
 Lay the annular plate as per approved drawing.
 Out radius of the annular plate shall be in positive side (>10mm) in order to achieve the final
required radius after weld shrinkage.
 Orientation of the annular plate joint shall be as per approved -drawing.
 Fit up of annular plate's joints shall be carried out using proper jigs and fixtures and also
care shall be taken while fit-up, such that there should not any gap between annular plate
and backing-strip.
 Check the joint position, root gap for welding as per drawing.
 Annular plate’s joints welding shall be carried out by welding alternative joints at four
quadrants.
 For welding of annular joints, qualified welders shall be engaged as per approved WPS.
 DP Test shall be conducted for root, if any defect found the defect shall be removed by
grinding and re-welding to be done. Repeat the sequence until the defect cleared.
 After completion of welding, clean the weld surface by wire brushing and grinding.
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 Remove the jigs and fixtures where ever used for fit-up of the annular joint and grind the tack
welds properly to avoid surface damages in annular plate.
 Radiography shall be taken as per API-650/NDT Procedure/Technical specification.

8.2 BOTTOM PLATE LAYING & WELDING:

 Lay the center plate on the sand pad foundation as per marking after clearance from
NBEL/client.
 With co-ordination of Centre plate laid the bottom plates sequentially as per approved drawing.
 Laps shall be maintained while the fit-up of short seam and long seam as per approved
drawing.
 Temporary tack weld to be carry out on the Long-seam to avoid uneven movements, while the
fit-up and welding of short-seam.
 Short seam welding will be carried out 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 lap shall be maintained while the fit-up of long-seam as per approved drawing.
 Joggling shall be carried out by hammering wherever it is necessary (Three plate Joining
junction).
 Before starting the welding, channels shall be tacked along the long-seam to avoid the
distortion.
 After completion of short seam welding, long seam welding will be carried out alternatively to
avoid distortion.
 Qualified welder shall be engaged for job and welding shall be carried out as per approved WPS.
 After completion of welding, thoroughly clean the weld joint by wire brushing and grinding.
 Bottom sketch plate to annular plate joint shall be welded only after completing the shell to
bottom joint welding.
 All the bottom plate's joints shall be tested with vacuum box as per approved procedure, code/
specification.
 If any defect found in the bottom plate welding, the defect shall be removed by grinding and re-
weld to be done and conduct the vacuum box test. Repeat the sequence until the defect
cleared.

8.3. SHELL COURSE ERECTION & WELDING:

 After the completion of annular plates and bottom plates welding, mark the tank inner radius
on the annular plates and make hard punch on the marking.
 Fix the required erection stools at the equal interval on the annular plates & transfer the inside
tank diameter on the stools.
 The top shell course shall be erected by conventional method on its beneath shell.
 Balance shell courses can be erected by hydraulic jack method.
 The rolled shell plates shall be shifted to the tank foundation area and stacked around the
periphery by using hydra crane with necessary precautions.
 Proper care shall be taken to check the diameter marked on the annular plate and orientation
during the shell plate erection.
 Jigs and fixtures shall be used to align the shell plates.
 Complete the fit up except the final joint which shall be fitted and weld after completion of the
welding of the other joints to avoid the shrinkage in shell plates (especially lower thick plates).
 Peaking shall be checked after the fit-up of the vertical joints at top, middle and bottom of the
shell plate by using a Sweep board (Template) of minimum 36” long. Peaking shall be within
the tolerance as per API - 650.

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 Plumbness shall be checked for the verticality of the shell course at every 60° and shall be
within the tolerance (1/200 of the shell height).
 For perfect verticality, channels shall be provided at the regular interval inside of the shell
course (3 to 5 mtrs) shall facilitate the alignment of last shell course.
 Offer for inspection and get clearance from Engineer-in-charge for the vertical fit-up and
complete the first side welding by using qualified welders.
 Care shall be taken while the welding to avoid the peaking and the roundness distortion.
 Tack welds on the shell plates near vertical joints shall be ground smooth.
 After completion of first side welding, back-chip shall be carried out for sound metal from other
side of the weld by grinding.
 Back-chipped grooves shall be tested with DP and offered for inspection before starting the
welding.
 Complete the back-side welding using qualified welders and Joint no. & Welder no. shall be
marked on both side of the weld joint.
 Proper arrangements shall be done to avoid the peaking and roundness distortion.
 Clean weld joints from both sides by wire brushing and grinding.
 After completion of welding, remove all the temporary jigs and fixtures and flush the tack welds
on both sides (Do fill up wherever required) to offer weld visual inspection.
 Check the peaking, plumb ness, circumference and the radius, offer for inspection to the
satisfaction of the Engineer-in-Charge.
 Erection and welding of Curb Angle after inspecting the plumb of 1 st shell course.
 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 Sec-6 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-6 requirements.
 Take the repair spot RT and re offer for the inspection to the satisfaction of Engineer-In- Charge.
 After getting the inspection clearance Roof structure and Roof plate erection will be started as
per no. 8.4.
 Spiral staircase Erection shall be carried out as per drawing including brackets.
 Remove all the temporary cleats and tacks by grinding.
 Install jacks as per requirement and the distance between the jacks shall not be more than 3
meter. Connect the power pack and check the total system is ready for erection of the shell.
 Install the jacking cleats on the top shell course (inside) and weld soundly the cleats to the
shell. Roof structure &partial of roof plate shall be erected then start jacking.
 Start jacking of the assembly of top shell course along with the roof structure. Lift till the
required space for the next shell course plate width + Erection chair height. (400~450 mm).
 Erect the next shell course by using the Hydra crane for shifting and position the plates.
 Alignment and fit up shall be carried out by using jigs and fixture and as per drawing offer the
fit up for inspection.
 Followed by welding, weld visual, peaking and plumb ness before and after as mentioned above
for the top shell courses.
 After completion of the welding lower down the jacked-up assembly on top of 2nd shell from top
3 mm thick spacer shall be kept between 1st and 2nd shell from top to maintain the
Horizontal joint gap.
 Fit up the Horizontal joint between 1st and 2nd shell courses from top using jigs and fixtures
and tack weld; remove the spacers provided during erection. Tack shall be ground smooth,
check the banding and record after completion of shell fit-up. Offer fit-up for peaking/banding
to the satisfaction of Engineer-In-Charge.
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 Followed by welding, banding & plumbness before and after welding shall be carried out as
mentioned for the above Horizontal joint.
 RT shall be carried out and cleared before the next lifting.
 Portion of the spiral stairway shall be erected as per drawing.
 If Jack trushel box get merged below the curb angle then balance 15% roof plate has to be erect
and periphery welding/nozzle fit up & welding / hand railing fit-up welding to be completed
(It depend upon width of the plate as jack trushel height is 3.5 mtrs).
 After clearance from inspection, then jacking cleats shall be fitted to 2nd shell from top course
plates and the total assembly shall be jacked up by required height for erection of the all the
shell courses.
 In the same manner erect all the shell courses and spiral stairway.
 The 1st shell course plates shall be erected, provide min. 6 mm thick packing plates at required
location in each shell plate to facilitate proper welding of the bottom most portion of the
vertical joint. This packing plate shall not be removed until commencement of shell to annular
fit up. Leave the makeup shell plate open by providing angular frame in order to insert the
floating roof deck plate and working inside the tank.
 After completing the welding of vertical seams of the 1st shell course by abovementioned
process and then Horizontal joint between the shell courses shall be aligned by lowering the
jacks and the fit up shall be carried out.
 Follow the above-mentioned process for the horizontal joint welding and clearance.
 RT shall be carried out as per API-650 Sec-6/ Tech. specification.
 Shell to annular plate joint fit-up shall be carried out using jigs and fixture.
 After getting fit up clearance for welding, root weld shall be carried out from inside.
 After completion of inside welding clean the weld thoroughly by wire brushing, grinding and
buffing.
 The shell to bottom joint area from both sides shall be cleaned thoroughly to carry out the
chalk-diesel test.
 Apply chalk solution from inside. Apply diesel by a hand spray pump from outside.
 Hold it as per instruction of the Engineer-In-Charge and check the root weld for any defect.
 If any defect found, the defect shall be repaired by grinding the defect area for the sound metal
plus 150mm from both end of the defect.
 Conduct the chalk - diesel test on the repair spot. Carry out the whole process until the repair
cleared to the satisfaction of Engineer - In – Charge.
 After completion of shell to bottom out side welding, visual inspection shall be carried out to the
satisfaction of the Engineer-In-Charge.
 On completion of shell to bottom welding / NDT and having completed all erection and welding
work on the tank inside related to the roof and roof structure, all unwanted materials and
scrap shall be removed from inside of the tank.
 RT of vertical and horizontal joint shall be completed.
 Sketch to annular plate joint fit up shall be carried out and complete the welding.
 Vacuum box test shall be carried out for the bottom plate lap joints, sketch to annular and
annular plate butt joints.
 If any repair found the same shall be repaired and re-tested as per the approved procedure and
API-650.

8.4 ERECTION & WELDING OF ROOF STRUCTURE AND ROOF PLATES:

 After completion of the Top one shell courses erection, fit up, welding and curb ring fit up &
welding shall be done.
 Erect the fabricated Centre Drum, Roof Truss, cross girders and wind bracings as per approved
drawings in sequential order.
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 Complete the welding of Roof structure by approved welders and as per approved WPS.
 Erect all the roof plates on the structure after completing of welding and visual inspection as
per the approved drawing.
 Align and fit up of the roof plates shall be done at available space where jack posts does not
fails, lap to be maintained as per approved drawing/ specification.
 Weld the short seams by welding alternative joint or sequence mentioned in the approved
drawing to prevent the distortion.
 Provide proper lengthwise support to the long seams and weld the joints as per approved
drawing sequence to avoid distortion.
 Balance roof plates will be aligned and weld after erection of next shell or until the jack
Thrushel support merged below the curb angle.

8.5 APPURTENANCES INSTALLATION:

 After completion of bottom shell course welding, mark the nozzle location on the shell and cut
the openings by gas cutting after proper inspection by Engineer-In-charge.
 Flanges to pipe/ neck joint and plate fabricated necks shall be prefabricated and also required
NDT shall be completed before erection as per code/ specification.
 Install RF pads wherever required and erect the nozzles as per the approved drawings/
specification.
 Suitable jigs & fixtures shall be provided to prevent the distortion during the welding.
 Orientation, elevation & projection shall be ensured as per drawing and offer for the inspection
to do welding.
 Proper care shall be taken for the welding by providing jigs & fixtures to prevent distortion.
 Welding shall be done as per approved WPS and by the qualified welder.
 All the shell nozzles final weld from both sides and RF. pads welds shall be inspected by
visually to the satisfaction of the engineer-in-charge.
 RF Pad weld shall be pneumatically tested at the pressure of 1.05 Kg/Cm2 and to the
satisfaction of the engineer-in-charge.
 Roof nozzles and top shell nozzles fit-up and welding shall be carryout as per the approved
drawing and subsequently it has to be correlated with the concern piping drawing.

9. WATER FILL TEST:

 After completion of the welding and NDT work in all respects of tank. The tank can be
released for Water Fill test as per approved test procedure.
 After successfully completion of the hydro test, tank calibration shall be done as per code/
specification.
 After taking shell plate measurement, the water shall be completely drained by using water
pump/ proper de-watering method.

10. EQUIPMENTS:
 Telescopic crane 15MT / 20MT capacity or as per requirement.
 Welding Machines.
 Water Fill test Pump.
 Water pump.
 Transporting Equipment.
 Plate rolling Machine.
 Hydraulic Jack 12 MT [with power pack & accessories] and other required equipment.
 Grinding machine. [AG-7, AG-5, AG-4]
 Gas cutting equipment. [Pug cutting m/c & Hand cutting set]

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 Vacuum box with Pump & Gauge.
 Vernier Caliper.
 Lifting Tools & Tackles and Derrick.
 Mother Oven & Portable Oven.
 All Measuring Tape (50M, 30M, 15M, 5M, and 3M).
 Piano Wire, Plumb bob (Heavy weight).
 Radiography Film Viewer.
 Aluminum Ladder.
 DG set with panel board separately for welding Rectifiers and Grinding m/c’s.
 Surface Gauge, Elcometer, Pressure Gauges, Air-Compressor etc.
 Leveling instrument.
 Sieve analysis equipment.
 Core cutting test equipment.
 Earth rammer.

11. MAN POWER:

 As per Project requirement.

12. QUALITY ASSURANCE & QUALITY CONTROL:

This shall be followed and maintained with the compliance / adherence to the approved draw ings, as
per approved ITP, codes & specification. Records shall be maintained in the relevant formats duly
signed by the concerned inspection authority.

13. SAFETY:
 Tested & certified Lifting equipment’s should be used for lifting and shifting materials.
 Safety precautions should be followed during all works at site as per NBEL-HSE requirements
of the project.
 Welding cables and power cables shall be laid properly as per NBEL-HSE engineer instruction/
HSE rules.
 The radiography duration shall be informed to all other contractors working in tanks area will
be advance.
14. DOCUMENTATION:
All documents shall be prepared and maintained as per approved ITP in the designated formats.

15. GENERAL:
 All stag wise inspection shall be carried out as per approved ITP.
 Required access/scaffolding shall be made available wherever required.
 The house keeping shall be done at regular intervals to maintain good and neat working
condition.

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