Construction Guide for Tank With Φ54.

8m REFERENCE

I. Project Description

The tank detailed specification is as below:

Item Size(m) Material Max Lifting Weight Qty Roof Type

Tank shell + Aluminium roof
TANK Project 54.8m dia Carbon Steel 1 doom roof
weight : Approx 690 ton per tank
II. Process Principle and Workflow as per our equipment

1. Fitting-up and Lifting of Shell Plates

The construction method should be by hydraulic jacking system. Hydraulic jacking system is integrated by

control cabinet, power source cabinet, pump station and cylinders. Before lifting the expansion ring needs to be

installed in the bottom edge of shell plates. The expansion ring needs to be close to the shell plates by jack and

fixed by door-shape snag-gauge and pins to prevent sliding. When lifting expansion ring the shell plates can be

lifted together.

Firstly fix the expansion rings on the second course and welding the 2nd course shell plates and then

fitting-up and welding tank roof; And then lift the 1st course and roof together by hydraulic jacking system;

after that fitting-up and welding the 2nd course, cylinders and expansion ring fall down and lift the 2nd course,

1st course and tank roof. By this sequence to construct the tank body until the end.

The Principle of Hydraulic Jacking System

Top shell plates 3rd top plates – last shell Hydraulic Jacking device
2nd top shell plates plates

nd
Install Jack lifting device and expansion ring Lift 2 course shell plates jacks falls down to ground after all
on the second course the first course cutting and remove
2. Construction Workflow

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III. Construction Process and Description

1. Flooring and Fitting-up of Bottom Annular Plates

• Fit up of annular plate joints shall be carried out using proper jigs and fixtures.

• Care shall be taken during fit-up such that annular plate and backing-strip shall be in close touch.

• Annular plate joints welding shall be carried out by welding alternative joints at to ensure minimum

buckling of annular plates.

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 2. Flooring, Fitting-up and Welding of Bottom Plates

• All plates in center row shall be laid first in overlapped condition as mentioned in the drawing; all other

plates in subsequent rows shall then be laid moving towards the tank peripheral area as per the

approved drawing. While fitting up all tank bottom plates, care shall be taken to have all fillet joints in

close contact if required using indirect hammer striking on plates.

• Lap shall be maintained during fit-up of short seam and long seam as per drawing.

• Short & Long seam welding shall be carried out alternatively to avoid distortion.

• Overlapped seam can be automatically SAW welded by butt/corner seam welding machine.

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 3. Installation of Erection Chairs

Temporary chair (around 400-500mm height) with guide plates shall be installed at regular intervals

(around 1.5 to 2mtrs) on tank annular plates for having an easy access inside the tank, only then tank shell

course erection shall start, this would also facilitate an easy inspection, good workmanship & safe working,

since, all tank shell fitments & welding works shall be carried.

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 4．Automatic Welding Machine Rail Mounting

Rail bracket and the supporting device is one unit. It is 1m between two units. The distance between the

rail and the shell plate can be adjusted according to the width of shell plate (height).

5. 1st Shell Course Erection & Welding

• The first top one or two shell courses shall be erected by conventional method. And balance shell

courses shall be erected by hydraulic jacking method.

• The rolled shell plates shall be shifted to the tank foundation area and kept along the periphery using

proper lifting equipment.

• Proper care shall be taken during handling of the rolled plates.

• If the thickness of 1st course shell plates is less than 10mm we suggest use FCAW or SMAW.

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 6. Hydraulic Jacking Device Auxiliary Equipment Installation

1) Position the expansion ring by temporary pallets

2) Install cylinders

3) Weld the hanging lugs in expansion ring

4) Adjust the fastening device of expansion ring

5) Fix the expansion ring by door-shape snag-gauge and pins

7. Installation of Bordure angle steel, Doom Roof and Hydraulic Jacking System

 Weld bordure angle steel and doom roof by SMAW;

 The cylinders should be installed averagely around upright column and the quantity is calculated

according to max. lifting weight;

 The cylinders of upright column and shell plates should be controlled by one control system so that

the synchronization can be kept.

8. Preparation for First Lifting

• Whatever tank accessories shall come in top 1 or 2 shell courses like Primary and secondary wind girder,

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 staircase, support fire and foam system and other appurtenances shall be installed before lifting

operation to avoid working in height.

• Locate the expand ring finally, weld the gantry type board of expend ring. Tighten the hydraulic jack of

the expand ring layup;

• All anchor point inspections: including gantry type board welding seam, pull rod fixed base welding

seam, inclined support fixed seat welding seam, each bolt joint of hydraulic jacking, the adjusting screw

of inclined support bar, etc.

9. First Lifting by Jacking Method

• Tank jacking time: start from working in the morning ,wind power is less than level 4,no rain and snow;

• Before lifting set up the same output of pump station to promise the same lifting speed of all cylinders.

If the speed is not the same during lifting you can adjust the oil valve to adjust the lifting speed.

• During lifting observe the height of shell plates and upright column in all directions; if the height

deviation is less than 30mm no need to adjust; if more than 30mm you can adjust the cylinder’s height

through the control box of pump station separately.

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 10. Fitting-up and Welding of Shell Plates

• Start welding after fitting-up of shell plates. If the thickness is more than 10mm and less than 24mm we

suggest use EGW which can realize single face welding-double face forming without backside gouging

and welding. And it takes 20-30mins to finish one welding vertical-up seam.

• By 2-3 vertical-up seam welding machine it takes one day to finish all the work from starting, fitting-up

to finishing vertical-up seam welding of one course.

• After finishing vertical-up seam welding dismantle related tools and then start girth seam fitting-up.

• During fitting-up of girth seam according to different gap you can adjust the cylinders separately.

• After fitting-up the girth seam can be welded by automatic SAW girth seam welding machine. By single

face welding-double face forming process there is no need carbon arc gouging for inside face, only

grinding is ok.

• After fitting-up the girth seam the telescopic will retract and the machine frame can avoid the cylinders’

interference and weld inside girth seam automatically.

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 11. Fitting-up and Welding of Upright column

• Lifting 1st course upright column together with tank body and then start the 2nd course fitting up and

manual welding.

• After finishing the welding and fixing of 2nd course remove the positioning plates and cylinders and
auxiliary Tooling 2m cylindrical shell section fall down for the preparation of next lifting.
12. Installation of Remaining Shell Plates, Upright Column and Auxiliary Tooling

• The installation method of remaining is the same as 2nd course above.

• All temporary attachments shall be removed and ground & MPT/DPT shall be performed prior to

further lifting. RT shall be carried out and cleared before the next lifting；

• Spiral stairway shall be erected & welded as per the approved drawing. Staircase erection & welding

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 shall go simultaneously along with each shell lifting.

• All erection chairs shall be removed for installing bottom shell courses

• All nozzle assemblies requiring PWHT shall be prefabricated and PWHT shall be completed prior to

erection or Local SR shall be carried out as per approved procedure / code after completion of first shell

course erection.

13. Welding of Big Angle Seam and Remaining Bottom Plates

• After finishing welding of shell plates start automatic welding of big angle seam.

• By butt/corner seam welding machine the big angle seam can be welded automatically. There is

magnetic device in the welding machine which can make machine run automatically in the rail.

14. Tank Check List and Box Up

• After completion of the erection, prior to hydro test the following points shall be checked:

• All mechanical activities & radiography requirements are complete as spelled out in drawings, relevant

Specifications and code requirements.

• Records for entire NDT tests like chalk-diesel test, DPT, MPT, Reinforcement Pad pneumatic test &

vacuum box test shall be verified for completeness.

• Finally mechanical clearance from competent authority shall be taken before commencing the hydro

test in an approved format.

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 15. Tank External Scaffolding & Painting

After successful completion of Hydro test, surface preparation & painting shall be carried out as per

approved procedure and painting specification. Strict compliance to safety aspect shall be ensured while

erecting the scaffolding around tank for surface preparation & painting works. The detailed procedure for

surface preparation & painting shall be submitted separately.

IV. Introduction and Quantity of Equipment

1. Introduction and Quantity of Hydraulic Jacking System

1.1 Brief Introduction

The hydraulic lifting system is specially developed and designed for Oil Storage Tank Construction. It is

suitable for steel tank construction with construction method “from top to bottom”. With advanced technology,

the module design is introduced in this system. During the application, the oil cylinders could be lifted

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 separately or intensively.

This series of hydraulic lifting system is designed with the mode that one set of hydraulic pump station is

connected with five sets of hydraulic cylinders, so as to form a module. (According to the lifting load to decide

the number of module) hydraulic cylinders are installed inside of oil tank averagely. The lifter for this system is

single-acting double-stage hydraulic cylinder (hydraulic lifting jack), which is used for vertical lifting work. The

cylinder is able to return by its own weight or external force.

1.2 Quantity Calculation

Calculation of Hydraulic Jacking System
 Gmax = K * (G of shell plates + G of tanks roof + G of attachments + G of tools)
Gmax - Max Jacking Weight
K – Uniformity Coefficient 1.1-1.3
Quantity of Cylinders must satisfy multi following requirements
 n= Gmax / (Q×η)
n– Qty of Cylinders
Q– Max load per Cylinder (25t)
η- Capacity factor (0.6-0.7)

The distance, calculated according tank diameter, between 2 cylinders should be ＜6m

Qty of Control systems and jacking modules is depends on the qty of Cylinders.
Formula & Quantity Calculation of Hydraulic Jacking System for Shell Plates
 1). Gmax = K * (G of shell plates + G of tanks roof + G of attachments + G of tools)=692t
 2). n= Gmax ÷ (Q×η)=37≈40
 3). n=3.14*D/(3.8-6) =40

According to the above formulas the qty of hydraulic jacking system for Shell Plates should be:
Item Qty

Control System 1

Power Cabinet 8

Cylinders 40

2. Automatic Girth Seam Welding Machine

2.1 Brief Introduction

WINCOO Automatic Single-sided Girth Seam Welding System（Top-to-bottom）is a new generation of high

efficient single-sided sub-arc welding machine for vertical tank which is independently designed by We are

based on the new welding process and technologies.

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  Strong and hard structure which can ensure the machine work in bad environment in long term.

 With flame preheating device it can do preheating and dehumidification before welding.

 By single face welding-double face forming process there is no need carbon arc gouging in the back.

2.2 Technical Requirement

If the thickness of shell plates is more than 14mm we suggest K beveling, or Single V beveling.

2.3 Quantity Calculation

(1) Formula

 The deposition rate of welding wire is 3-5kg/hour.

 According to the deposition rate the welding time of one course girth seam can be calculated out.

And then we can calculate the qty of girth seam welding machine according to required construction

period.

(2) Deposition Rate reference

Welding Time (h)

Thickness a
Seam No. Thickness B（mm） Deposition Rate (kg) For two horizontal welding
（mm）
machine
1 34 38 297 43-32
2 28 34 245 38-29
3 24 28 220 32-24
4 20 24 175 25-20
5 16 20 154 23-18
6 12 16 130 19-15

(3) Quantity of Girth Seam Welding Machine

When calculate the qty of girth seam welding machine, below points should be considered in actual construction:
 Preparation time for equipment hoisting, preparation, except for welding time;

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  Equipment traveling forward and back time when welding multi-course;
 For girth seam welding, the welding seam divided into two groups: inner side and outer side;
 According to on-site process, girth seam welding equipments main cannot use on only one tank, but distributed
on two tanks;

 Rework time because of different skill of operators；

Based on above mentioned table and other influential factors, we recommend 4 automatic girth seam
welding machines can match the requirement of construction schedule.
3. EGW/FCAW Vertical-up Seam Welding Machine

3.1 Brief Introduction

Basing on characteristics of bottom-to-top and top-to-bottom tank erection, our carriage electro-gas

vertical welding machine is designed and manufactured as automatic welding equipment, which is suitable

for both bottom-to-top and top-to-bottom tank erection. This machine combines American self-protecting

vertical welding technology and Japanese carriage type electro-gas vertical welding machine.

 It adopts servo system and closed loop control welding carriage which controls the rising speed to

guarantee the stability of welding pool.

 Its main characteristic is that water cooling copper slider forcing single path welding seam forming in

one step which greatly improves the welding quality and welding efficiency and reduce welder's work

intensity.
3.2 Technical Requirement

If the thickness is less than 10mm we suggest use FCAW; if the thickness is more than 10mm we suggest

use EGW.

For EGW, if 10mm≤thickness≤24mm we suggest V bevel and use single path welding seam forming in one

step without gouging and welding in the back; if the thickness is more than 24mm we suggest use X bevel.

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 3.3 Quantity of Vertical-up Welding Machine

(1) Formula

For FCAW, if the thickness is less than 6mm the welding speed is 4-5m/hour; if the thickness is 8-10mm the

welding speed is 3m/hour.

For tank dia. with 60.5m, welding time for one course of vertical seam is:
DIA. 52m

Vertical Total Length of seam Required time for each vertical-up welding
Thickness
Seam Process
（mm） machine（h）
No （m）
1 34 76.8 8.5-12

2 28 76.8 10-13
3 24 76.8 5-6.5
EGW
4 20 76.8 5-6.5

5 16 76.8 5-6
6 12 76.8 5-6

When calculate the qty of vertical-up seam welding machine, below points should be considered in actual construction:
 Preparation time for equipment hoisting, preparation, except for welding time;
 According to on-site process, vertical seam welding equipments main cannot use on only one tank, but
distributed on two tanks;

 Rework time because of different skill of operators；

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 Based on afore mentioned form, we recommend 2 sets of automatic vertical welder can match the
requirement of construction schedule.
4. Automatic Butt/Corner seam welding machine qty and calculation basis
Butt/Corner seam welding machine is used for welding of bottom plates and bottom plates welding can be processed
simultaneously with shells erection. For this tanks we suggest equip 1 sets of automatic Butt/Corner seam welding
machine. In the earlier stage it can be used for bottom plates welding and in the later stage it can be used for roof plates
welding.
V. Summary for Equipments

1．Equipment Summary
According to above calculation, Group C needs equipment qty as below table:

Item Model No. Equipment Unit Qty

Control System set 1

Hydraulic jacking
1 YT25-2700 Pump Station set 8
system
Cylinders set 40

2 MSHW-I-D/Z SAW girth welding machine set 4

3 MEGW-I-D/Z EGW/FCAW vertical welding machine set 2

4 MLTW-P/J Butt/Corner welding machine set 2

2. Construction Team Description

Work Type
operator Helpers
Equipment

Hydraulic Jacking Device 1 1

SAW girth welding machine 4 1

EGW/FCAW vertical welding machine 2

1
Butt/Corner welding machine 2

Total 9 3

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