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LARSEN & TOUBRO LIMITED

HED HAZIRA WORKS Quality Control & Inspection

Procedure for Establishing Axis Alignment Of Shell Sections without rotation

0 REV. NO.

First Issue REVISION DETAILS

01-10-03 DATE

PDL / SBB PREP. BY

PDL APPR. BY

This document is the property of Larsen & Toubro Limited and must not be copied or lent without their permission in writing.

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Axis Alignment of Shell Sections Without Rotation 1. Scope: Cylindrical and conical sections of Columns, Towers, Pressure Vessels and heat exchangers are manufactured by rolling and welding the plates to individual shell courses. Two or more shell courses are welded together to form sections. This procedure covers method of establishing axis alignment of shell sections with more than one shell course welded together. For the purpose this procedure, shell course includes rolled cylindrical shells, forged shells, pipes, cones and expansion bellows The procedure is applicable to all products manufactured in Shop & LEMF where the assembly is not possible to rotate on its axis. The assemblies that are possible to rotate on tank rotators shall be checked for its axis alignment in accordance with HED-HZW-INS-P-032. 2. Axis of Sections: When two or more shell courses are welded together, central axis of each individual shell shall align with the adjacent shells within the tolerance specified by the equipment drawing or tolerance chart. The procedure stated below elaborates method to establish the extent of deviation from the best-fit axis. The procedure takes two orientations perpendicular to each other (Horizontal & Vertical) in to consideration for deriving the best fit axis of the section in consideration. 3. Tools and accessories: The following tools and accessories shall be made available. Plumb bobs Measuring tape Twines Scale Manometer ( Water level with accessories )

4. Arrangements /Preparations & Measurements: The following arrangements and preparations shall be made 4.1 Keep the shell section on a Saddle as shown in the sketch in Annexure I and II. Note the shell orientations on vertical and horizontal plane and record. Alignment checks in Horizontal plane. 4.3.1 Provide plumb lines as shown in the sketch (Annexure I) by hanging single twine over the cylindrical sections. 4.3.2 Stretch two twines on both sides of the section as shown in the sketch ( Annexure I). They shall be approximately horizontal and precisely parallel to each other. 4.3.3 Measure the horizontal distance from the plumb line to horizontal twines as shown in the sketch (AnnexureI).
This document is the property of Larsen & Toubro Limited and must not be copied or lent without their permission in writing.

4.2 4.3

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Axis Alignment of Shell Sections Without Rotation 4.3.4 4.4 Record the readings as detailed in para 5.

Alignment checks in vertical plane. 4.4.1 Keep a manometer at an appropriate height on bottom side of the shell section a shown in the sketch (AnnexureII). Measure the vertical distance between the water level and the shell surface in contact with manometer tip. A fixture mounted with scale and manometer shall be used for measuring the distance directly between the water level and point of contact. 4.4.2 Keep the manometer on the top of the assembly at the locations shown in the Sketch (AnnexureII). Measure the height of water column from the point of contact as shown in the sketch. 4.4.3 Record all readings as per para 5.

5. Measurements And Tabulation Of Readings: Readings measured at all locations as per para 4.3.3, 4.4.1 & 4.4.2 above, shall be recorded at the specified columns in the Tables below. The readings taken in horizontal plane with plumps shall be recorded appropriately in the columns of Left side and Right side in Table1. The readings taken in vertical plane with manometer shall be recorded appropriately in columns of Bottom side and Top side in Table2. Half the difference of two readings in a particular location (elevation) shall be recorded in the last column of both the Tables. The difference shall be recorded with the positive or negation sign. Table 1 (Readings in horizontal plane) Twine to plumb distance in mm Location of reading H1 (Left side) H2 (Right side) A0 B1 B2 C0 D0 E1 E2 F1 F2 G1 G2 H0

Half the difference of reading (H1-H2 /2); + or - in mm

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Axis Alignment of Shell Sections Without Rotation Table 2 (Readings in vertical plane) Readings of distance in mm
B (Bottom side) T (Top side)

Location of reading A0 B1 B2 C0 D0 E1 E2 F1 F2 G1 G2 H0

Half the difference of reading (B-T /2); + or in mm

6. Plotting The Points To Derive The Alignment: Plot all the points of half the difference of reading recorded in the last column in a graph paper with a suitable scale as shown in the sketch in Annexure III. The positive or negative sign of the number shall be taken in to consideration while plotting the points on Y-axis of the graph paper. The distance between two points of readings shall be on X-axis. 7. Alignment Check: Connect all the points plotted on the graph paper with straight lines ( doted line ). This will be the graphical representation of the axis in that particular plane/orientation. Place a best-fit straight line in the cluster of points as shown in the Annexure III. Find the point with maximum distance from the line. The figure is the maximum out of alignment to be considered in that particular plane/orientation. Repeat the same for the other plane/orientation and derive the maximum out of alignment.

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Axis Alignment of Shell Sections Without Rotation ANNEXURE I Arrangement for Readings in Horizontal Plane

H0-H1

H0-H2

G2-H1 G1-H1

G2-H2 G1-H2

F2-H1 F1-H1 E2-H1 E1-H1 D0-H1 C0-H1

F2-H2 F1-H2 E2-H2 E1-H2 D0-H2 C0-H2

B2-H1 B1-H1

B2-H2 B1-H2

A0-H1 2 Twines - Parallel

A0-H2

Vertical Plane Shell Section Staff H1 Plumb Horizontal Plane H2 Plumb

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Axis Alignment of Shell Sections Without Rotation

ANNEXURE II Arrangements for Readings in Vertical Plane

Water Level H0-T G1-T G2-T F1-T F2-T E1-T E2-T D0-T C0-T B1-T B2-T

Manometer A0-T

H0-B

G1-B G2-B Saddle

F1-B F2-B

E1-B E2-B

D0-B C0-B

B1-B B2-B

A0-B

Water Level

Manometer

Water Level

Manometer T (TOP)

B (BOTTOM) Water Level Manometer

This document is the property of Larsen & Toubro Limited and must not be copied or lent without their permission in writing.

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Axis Alignment of Shell Sections Without Rotation

Y ANNEXURE 3 Positive Best Fit axis

A0

0 . B1& B2 Negetive C0 D0 .

E1&E2

F1&F2 .

X H0

G1&G2 MAX. MISALIGNMENT IN HORIZONTAL PLANE

Y Positive MAX.MISALIGNMENT IN VERTICAL PLANE E1&E2 F1&F2 H0 X A0 Negetive Best Fit Axis B1&B2 C0 D0 G1&G2

This document is the property of Larsen & Toubro Limited and must not be copied or lent without their permission in writing.