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Sample Work Activities for Process Tank Fabrication

Fabrication work steps and activities are defined depends upon on the scope of tank components,
type of materials and necessary inspection. Suppose a process tank prefabrication scope includes
the following components,

(1) Tank body


(2)External components attached to tank shell
Man-ways on shell side and roof side
Inlet and outlet pipe nozzles
bottom drain pipe
(3) Internal components
Skimming box
Stilling Wells & Level Gauge,
Internal Spiders
(4) Tank Access Steel Work
Spiral Staircase
Top Roof Platform
(5) Accessories, Transport Saddles and Lifting Beam to facilitate lifting work
Assume that material for tank body, internal parts, man-ways and nozzles are stainless steel, and
for staircase, tank roof platform and bottom drain pipe are carbon steel material.
(1) Activity and work steps for tank body fabrication
(a) Base Plate
Marking and cutting
Tacking and welding
PMI Testing
Removal of backing plate
Vacuum box test welds
Erect Scaffold for access
(b) Shell Plate Fabrication (1st Course)
Marking and cutting
Rolling of plate
Setting and tacking joint to base plate, vertical joint
Full welding
Holding down plates installation
NDT Joints (DPI, RT)
PMI Inspection
(c) Shell Plate Fabrication (2nd Course)
Marking and cutting
Rolling of plate
Scaffolding installation
Setting and tacking joint to 1st course and vertical joint
Full welding
NDT Joints (DPI, RT)
PMI Inspection
(d) Shell Plate Fabrication (3rd Course)
Marking and cutting
Rolling of plate
Scaffolding installation
Setting and tacking joint to 2nd course and vertical joint
Full welding
NDT Joints (DPI, RT)
PMI Inspection

(e) Shell Plate Fabrication (4th Course)


Marking and cutting
Rolling of plate
Scaffolding installation
Setting and tacking joint to 3rd course and vertical joint
Full welding
NDT Joints (DPI, RT)
PMI Inspection
(f) Shell Plate Fabrication (5th Course)
Marking and cutting
Rolling of plate
Scaffolding installation
Setting and tacking joint to 4th course and vertical joint
Full welding
NDT Joints (DPI, RT)
PMI Inspection
(h) Shell Plate Fabrication (6th Course)
Marking and cutting
Rolling of plate
Scaffolding installation
Setting and tacking joint to 5th course and vertical joint
Full welding
Rolling of curb angle
Setting, tacking and full welding of curb angle
Roof plate clip installation
NDT Joints (DPI, RT)
PMI Inspection
Note. Nos. of course would be different depending on size of tank and how you define.
(i) Roof Work
Marking and cutting of roof ring plate, rafter, braces and roof clips
Welding of roof ring plate, rafter and braces
Marking and cutting of roof plate
Fit up and welding of roof plate
PMI test
Vacuum box test welds
Position and bolt up Roof to tank body
Full welding of roof to curb angle
PMI Test
(2) Activity and work steps for external components fabrication
(a) Man-ways
Marking and cutting of plate and reinforcement plate
Rolling and welding of man-way plate
Fabrication of flanges, hinges, handles and cover
Assembly of cover, handles and hinges
Fabricate reducing flange
Marking and cutting of man-ways in tank shell
Marking and cutting of man-ways in roof
Fit up and welding of man-ways in tank shell
Fit up and welding of man-ways in roof
Installation of reinforcement pads in tank shell
Installation of reinforcement pads in roof
PMI test

Pressure test reinforcement pad


(b) Inlet and outlet pipe nozzles
Marking and cutting of pipe and reinforcement plate
Fabrication of nozzles
NDT Joints (DPI)
Marking and cutting of nozzle location
Fit up and welding nozzle
PMI test
Installation of reinforcement pad
PMI test
(c) Bottom Drain Pipe
Marking and cut to length
Tack and welding joints
PMI Test
NDE Testing (DPI, RT)
Modify bottom drain and piping support
NDE Testing (DPI, RT)
Hydrotest of drain line
Painting work
(3) Activity and work steps for internal components fabrication
(a) Skimming Box
Marking and cutting
Assemble skimming box
Rework Skimming Box
Fit up and welding inside tank
PMI test
(b) Stilling Wells and Level Gauge
Marking and cutting of pipe and frames
Pipe drilling holes
Fabricating of support frames
Fabricate stilling wells and level gauge
NDT Joints (DPI, RT)
Fit up and welding of support frame
Positioning of stilling wells and level gauge
PMI test
(c) Internal Spiders
Marking and Cutting
Roll end plate
Fit up & welding of support clip
PMI test
Assemble internal spider
NDE Testing
Fit up to tank
(4) Activity and work steps for Tank Access Steel Work Fabrication
(a) Spiral Staircase
Rolling of stringers
Marking & Cutting of length material, support clips
Fit up & welding of support clips
PMI test
Assembly of spiral staircase
Assembly of handrail
NDE Testing

Trail fit to tank shell


Disassembling
Galvanizing
Packing
Delivery
(b)
Top Roof Platform
Rolling of structure ( angle )
Marking & Cutting of length material, support clips
Fit up & welding of support clips
PMI test
Assembly of top platform
Assembly of handrail
NDE Testing
Trail fit to tank roof
Disassembling
Galvanizing
Packing
Delivery
(5) Lifting Accessories
(a) Transport Saddles
Marking and Cutting
Assembly of saddles
Fit up & welding of saddles
NDE Testing
PMI test
(b) Lifting Beam
Marking and Cutting
Assemble lifting beam
NDE Testing
Certification of lifting beam
Painting of beam
Note: NDE= Non Destructive Examination
PMI= Positive Material Identification
DPI= Dye Penetrant Inspection/Liquid Penetrant Inspection (LPI)
Finally, most of the activities covered in this post would help you in developing a production schedule.