APPLICATION OF ERROR ON CALIBRATED TAPES

TYPES OF ERROR
+VE ERROR TAPE 25005
WITH USER
STD TAPE 25000 WITH QA
24995
- VE ERROR TAPE WITH USER

ERROR CORRECTION

TYPE OF OPERATION
ERROR MARKING MEASURING
(ADD ERROR) (SUBTRACT ERROR)

+ VE X + (+Y) X -- (+Y)
-- VE X + (--Y) X -- (--Y)

NOTE :1. USE CALIBRATED TAPES ONLY

2. DO NOT USE TAPE HAVING ERROR MORE THEN +1 mm FOR
CRITICAL JOBS.
PROCEDURE FOR MARKING, CUTTING AND CHECKING OF
SHELL PLATES

SHELL
PLATE
K1

5U
SA 516 GR

9262 /

4 UNITS
70 24357

NI
K2

TS
3

ROLLING DIR.

3 UNITS
L
TOLERANCE
L - + 1 mm / M, Max. 3 mm., & W - + 1 mm / M, Max. 3 mm
K1 - K2 = + 1 mm / M, Max. + 5 mm
IDENTIFICATION MARKING TO ROLLING DIRECTION.
L - NOMINAL CIRCUMFERENCE = MEAN DIA. X
= 3.1415926535897932384626433832792...
 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

270
A
PLUMB BOBS
X
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
 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.
 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.
 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
 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
B
OF 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

SKETCH - 2
 CHECKING SURFACE ALIGNMENT OF SHELLS
SECTION WITH DIFFERENT THICKNESS OF SHELLS

1. THE DIMENSION SETTING AT ENDS ( X0 ) ARE DECIDED

TAKING IN TO CONSIDERATION OF SHELL COURSE
THICKNESSES ( 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.
 TOLERANCES ON CIRC. OF SHELLS, DENDS , CONES &
BELLOWS

THE REQUIRED CIRCUMFERENCE SHALL BE COMPUTED

BY THE FOLLOWING METHOD.

REQUIRED CIRCUMFERENCE = ( ID + 2T ) * PIE

WHERE,I.D = INSIDE DIA. AS SPECIFIED IN DRAWINGS
T = ACTUAL THICKNESS MEASURED AT ENDS
PIE = VALUE OBTAINED FROM CALCULATOR

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 REMARKS

UP TO 8 9 TO 18 19 TO 50 ABOVE 50

ROLLED SHELLS AT (+) 5 (+) 7 (+) 10 (+) 12 CIRCUM. TO BE CHECKED AT

L/S SET-UP STAGE (-) 2 (-) 4 (-) 7 (-) 9 3 LOCATIONS, 2 ENDS AND AT
CENTRE

PRESSED / FORMED (+ / - ) 5 (+ / - ) 8 (+ / - ) 10 (+ / - )15 IF COMPONENT IS IN SET-UP

DEND, CONE & STAGE WITHOUT WELDING
EXPANSION BELLOW (-0 / +10)** (-0 / +15)** (-0 / + 18)** (-0 / + 25)** PER JOINT 3MM SHRINKAGE
AFTER COMPLETING SHALL BE ADDED TO BASIC
WELD JOINT IF ANY CIRCUMFERENCE.

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.
 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
REFERENCE LINE MARKING / CHECKING WITH OPTICAL
INSTRUMENTS.

PLACE THE SHELL WITH THE AXIS VERTICAL.

THE BOTTOM EDGE OF THE SHELL SHALL BE AT LEAST 1 MT ABOVE
THE GROUND LEVEL.
SHELL OVALITY TO BE CORRECTED WITHIN 0.25 % OF I/D AT BOTH THE
ENDS USING SPIDERS.
THE ALIGNMENT OF THE SHELL SHALL BE WITHIN 2 MM. THIS IS TO BE
ASCERTAINED BY DROPPING PLUMBS AT FOUR ORIENTATIONS 90 DEG.
APART.
THE MARKING / CHECKING SHALL BE DONE ON SHELL O/D AS WELL AS
I/D BY KEEPING THE PARAGON LEVEL OUTSIDE THE SHELL AS SHOWN
BELOW

LINE OF PARAGON
REF.LINE SIGHT LEVEL

GROUND LEVEL
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
PROCEDURE FOR REFERENCE LINE
MARKING BY PIN METHOD

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.
 P-1402 GENERAL REQUIREMENTS

CIRCULARITY (0.20 % OF RADIUS )

+/- 8 FOR 8 M DIA SECTION
+/-10 FOR 10 M DIA SECTION

CIRCULARITY IS DEVIATION FROM IDEAL CIRCLE

METHODS OF MEASURING CIRCULARITY

1. SWING ARM METHOD

2. MESUREMENT BY TAPE OR TELESCOPIC GAUGE

 1. SWING ARM METHOD

PENCIL
SECTION

SPIDER GRAPH
PAPER

SWING ARM
ROLLER
 METHOD OF FINDING OOC

1. MEASURE THE AREA OF CURVE

2. CALCULATE MEAN RADIUS R= A/

3. MARK THREE CIRCLE ON A PAPER

(I) MEAN R
(II) MEAN R+ TOLERANCE
(III) MEAN R- TOLERANCE

4. ADJUST THE CURVE ON THE CIRCLES & DEMONSTRATE

THAT THE CURVE IS WITHIN THE OUTER & INNER CIRCLES.
 MESUREMENT BY TAPE OR TELESCOPIC GAUGE

1. FIND THE GEOMETRIC CENTRE OF THE SHELL-COURSE BY

CROSSING 4 TWINES, MARK THE CENTRE OF POLYGONE

POLYGONE

TWINES

SHELL

2. MEASURE THE RADIUS AT 48 LOCATIONS (R1 TO R48)

3. CALCULATE AVERAGE RADIUS = R1+R2++R48 / 48

MESUREMENT BY TAPE OR TELESCOPIC GAUGE

4. PLOT THE DEVIATIONS R(av.) - Rn ON A CIRCLE

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
 PROCEDURE FOR MAINTAINING 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 1, S/U, WELD & CLEAR NDT OF

CLOSING SEAM

4. TACK FRAMES # SHELL

 FRAME MANUFACTURE

APPLICABLE TOLERANCES 3

1. FRAME HEIGHT = + 4MM

- 3
4 4
2. ID/OD ( MACHINED ) = D +/- 0.3 1

3. FLANGE WIDTH. +/- 2 MM

4. UNBALANCE +/- 1 MM
5
5. FLANGE TILT 3 MM
 T FRAME MANUFACTURE

CURRENT METHOD
1. MAKE COMPLETE FLANGE WITH REQUIRED
CIRCUMFERENCE **

2. MAKE WEB SEGMENTS COMPLETE WITH ID/OD

MACHINED & WEP COMPLETED AS APPLICABLE

3. 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. JOIN ALL WEB SEGMENT AND FROM A CIRCLE

2. WELD & CLEAR NDT OF WEB L/S.

3. MARK OD/ID ( AS APPLICABLE ) FOR MACHINING & MACHINE

4. S/U FLANGE # WEB & WELD

5. 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
A = 2/3 t Tan(X- )
X
B = 1/3 t Tan(X + )

X

 GENERAL WEP

WHEN JOINING PLATES OF DIFFERENT THICKNESS

T1 T2
PROCEDURE FOR WELD EDGE PREPARATION ON
CUTOUT OF PENETRATION

01. MARK THE CENTRE POINT OF PENETRATION ON SHELL.

02. MAKE THE CUT OUT USING THE DEVELOPMENT.

03. C LEAR MARKING FROM INSPECTION.

04. MAKE CUT OUT TO THE ABOVE SIZE.

05. MARK THE ROOT FACE BY JOINING TWO POINTS

USING SCALE ( -90 ).
 PROCEDURE FOR WELD EDGE PREPARATION ON
CUTOUT OF PENETRATION

OFF SET DIST.

SINE-1
O/S RADIUS

OFFSET = 1400/4027.5
DISTANC 0-
90 =20.3410
E

= 900-

= 900 - 20.3410
DI IDE
RA T S
US

=69.6590
OU
 PROCEDURE FOR WELD EDGE PREPARATION ON
CUTOUT OF PENETRATION

SHELL

50 - ( 90 - ) 500
900
X2
X1 500

X1 = H tan(90 - )

X2 = H tan [ 50 - ( 90 - )]
 PROCEDURE FOR WELD EDGE PREPARATION ON
CUTOUT OF PENETRATION
90

90 + Y + 2Y
+Y

Y= 90-
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 TO 90
DEG & THEN FROM 90 DEG TO 180 - .
PROCEDURE FOR WELD EDGE PREPARATION ON
CUTOUT OF PENETRATION

06. CALCULATE ANGLE AS INDICATED IN THE SKETCH.

USING OUT SIDE RADIUS & OFFSET.

OFF SET DISTANCE FROM CENTRE OF PEN.

OUT SIDE RADIUS

07. CALCULATE ANGLE A OF PENETRATION WITH THE

SHELL = 90 -
 PROCEDURE FOR WELD EDGE PREPARATION ON
CUTOUT OF PENETRATION

09. DIST. OF MARK FROM

CUTOUT = X1 + X2
X1 =H * TAN ( 90- ),
X2 = H * TAN ( 50 - ( 90 - ))

10. JOIN ALL THE POINTS FREE HAND AND PUNCH

THE LINE
 PROCEDURE FOR WELD EDGE PREPARATION ON
CUTOUT OF PENETRATION
900
14.76 mm 14 mm 18.5 mm
970 83.50
20 mm
8.77 mm Thk 17.5 76.50
1040 Thk -Q

Thk -5 Thk 20.5

v = 24.91 mm
= 69.6590
Thk-1 Thk 26.5

X1 = V Dist = H ( thk ) tan ( 90 - )

X2 = H ( thk ) tan [ 50 - ( 90- ) ]

 PROCEDURE FOR WELD EDGE PREPARATION ON
CUTOUT OF PENETRATION

EXP :- X1 = H tan ( 900 - ) X2 = H tan [ 50 - ( 900 - )]

= 26.5 tan ( 900 - 69.6590 ) = 26.5 tan [ 500 - ( 900 - 69.6590 )]

= 26.5 tan ( 20.3410 ) = 26.5 tan [ 500 - ( 20.3410 ) ]

= 26.5 0.37072 = 26.5 tan ( 29.6590 )

X1 = 9.82 mm X2 = 26.5 9.82 mm 0.56944

X2 = 15.090 mm

V Dist = X1 + X2
9.82 + 15.090
24.91 mm
PROCEDURE FOR TRIMMING LINE MAKING ON
SUB-SECTION
Y2 FWD end

Y1

FWD end

X1

X2 AFT end
 PROCEDURE FOR TRIMMING LINE MAKING ON
SUB-SECTION

1. LEVEL SECTION FWD SIDE REF. LINE WITHIN +/- 1 MM.

2. CORRECT THE SAME TO +/- 1 MM IF REQUIRED.
3. ENSURE THAT FOLLOWING DIMENSIONS ARE ACHIEVED
WITHIN TOLERANCE.
ACTUAL POSITION OF FRAME
FRAME REF. LINE
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.
 PROCEDURE FOR TRIMMING LINE MAKING ON
SUB-SECTION

7. RECORD ALL DIMENSIONS IN GIVEN FORMAT.

8. CHECK ALL 72 VALUES OF TOTAL ( S )AFTER ADDING 2 MM

ROOT GAP.

9. IN CASE, IT IS NOT WITHIN +/- 6 MM, X2 & Y2 SHOULD BE

ADJUSTED TO GET THE DESIRED SPACING.

10. INVOLVE SUPERVISOR & IN CHARGE IN ABOVE TRIMMING LINE

MARKING.

11. MARK TRIMMING LINE & COMPLETE TRIMMING / SQUARENESS.

12. COMPLETE WEP MARKING IN FULL CIRC. USING.

13. CLEAR INSPECTION.