2015 - Tower Kick Off Presentation

Alloy Tower Fabrication and
Construction Requirements
Project Kick-off Presentation
Presented by: MECS Alloy

May 6, 2018
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MECS, Inc. Alloy Tower Fabrication
Quality Requirements
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Maintaining the integrity of design
The MECS
The MECS quality requirements
are engineered to maintain the
integrity of our design throughout
the fabrication, erection and
installation of the MECS, Inc.
equipment.
Compliance to these
requirements are to be verified
through inspection first by the
fabricator, erector or installing
contractor. And these inspections
are verified by the MECS, Inc.
authorized inspection
representative..

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These requirements are specified in the
following MECS project documents:
MECS project documents;
 Project Specifications:
412-001 Alloy Platework
412-002 Dye Penetrant Examination
416-001 Inspection and Test Plan – Alloy Towers
The Applicable Project Drawings

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Material Traceability
All materials shall be marked with a heat number or control

number traceable back to their respective heat number and
mill test report.
Traceability of materials shall be maintained through the

fabrication and installation process. All materials shall be
permanently traceable by quality documentation such as
shell rollouts, weld maps, cut sheets etc.

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NDE Requirements

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Non Destructive Examination:
Liquid Penetrant:
100 percent of all welds on the tower and its components require
LPT. This includes all of the sites where temporary attachments
have been removed from the base metal.
Shell circumferential and vertical weld seams require LPT of the root
and final pass. For double side weld joints that includes the cover
pass of both the inside and outside surfaces.
Only certified NDE technicians shall perform LPT following a

qualified LPT procedure.
Welders are not permitted to perform LPT.

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9

Radiography:
Blue Section: (Above the gas inlet nozzle)

1. Spot Radiography of all shell seam welds.
One shot per every 50’ (15M) of weld in
accordance to API 650 including penalty
shots.
2. The fabricator shall calculate the length of

all seam welds both vertical and
circumferential in order to determine the
number of spot radiographs.
3. All rejected spot shots and penalty shots

shall be tracked to assure that every weld
has been repaired and re-examined with
satisfactory results.
4. 100 percent of all shell seam junctions or
T joints.

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10

Radiography: (continued)
Yellow Section: (below the bottom of the gas inlet

nozzle)
1. 100 Percent Radiography of all shell seam
welds including floor seam welds.
2.All rejected welds shall be tracked to assure

that every weld has been repaired and re-
examined with satisfactory results.
3.Radiographs shall be traceable back to the

physical location on the weld represented.
Other Testing:
1.Vacuum Box leak testing of the floor to shell

welds.

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After a weld subjected to LPT is accepted. The developer and penetrant
residue shall be immediately cleaned off to prevent rusting. Any rust on
the weld joints due to developer left on the weld shall be pickled and
passivated at the fabricator or erectors expense.

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Positive Material Identification
Interpass and Final towers use both ZeCor-Z and ZeCor-310M

materials which are incorporated into the same tower. These are
strategically located in order to provide the maximum corrosion
resistance on components where either weak acid or oleum tends to
form.
On these towers it is necessary to perform 100% PMI (Positive

Material Identification) on all ZeCor-310M materials in order to
assure that the correct material is used in the correct place.
It is important to note that ZeCor is a corrosion resistance family of

materials, which include ZeCor-Z, ZeCor-310M, ZeCor-C, ZeCor-29-
4C and ZeCor-HRS. To refer to any of these materials simply as
“ZeCor” has caused failures and unscheduled shutdowns due to the
wrong grade of ZeCor materials being used.

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Visual Weld Inspection
All welds require 100 percent visual weld inspection.
All seam welds on the shell, roof and bottom plates shall be full
penetration.
Welds must have a thicker cross sectional thickness equal to or

greater than the parent metal.
Weld reinforcement on internal or external surfaces shall not exceed

1/8” (3.2mm) maximum.
Welds shall be free from visible imperfections such as cracks of any

type, voids, craters, slag inclusions open to the surface or undercuts
greater than 1/32” (0.6mm) deep and 3/8” (9.6mm) long.

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Important Dimensional Tolerances

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Shell Out of Roundness
English Units Metric Units
Over Up To And Including Tolerance Over Up To And Including Tolerance
0'-0" 14'-0" ± 1 in. 0m 4.25 m ± 25 mm
14'-0" 32'-0" ± 11/2 in. 4.25 m 9.75 m ± 40 mm

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Shell Deviations

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Plate Misalignment
Vertical Joints: Misalignment shall not exceed 10% of the plate

thickness or 1/16” (1.6mm) whichever is greater.
Horizontal Joints: In any horizontal joint, the upper plate shall not
project beyond the face of the lower plate at any point by more than
20% of the upper plate thickness or 1/8” (3.2mm) whichever is
greater.

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Tubesheet Tolerances
The tubesheet plate shall be flat within ¼” (6.4mm).
Any greater deviations will require the installation of
additional tubesheet drains in the low areas.

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Mist eliminator flanges shall be flat within 1/32” (0.6mm) as
measured between two adjacent bolt holes and 1/16” (1.6mm)
between three bolt holes.

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Mist eliminator flange faces shall not vary more than 1/8” (3.2mm) from
a level horizontal plane.

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Critical Tolerances relating to the packing
support structures.

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The spacing between the outside circumference of the packing support
grid and the inside diameter of the shell shall not be less than 1”
(25mm) or not greater than 1.5” (37.5mm).

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The spacing between the ends of the packing support beams
and the inside diameter of the shell shall not be less than 1”
(25mm) or not greater than 1.5” (37.5mm).

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Alloy Separation / Segregation

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All tools used on Alloy platework shall be segregated for alloy work
only by a color code or some other suitable means to assure that
tools used on carbon steel are not used on alloy projects.
All carbon steel work surfaces, vises, lift truck forks or tank scaffold
brackets shall be clad with stainless steel or some other material to
prevent cross contamination.
All plate rolls shall be covered in heavy gauge plastic or cardboard

to prevent alloy plate from being contaminated.
All alloy material sitting on the ground or the shop floor shall be
protected by wooden palates or dunnage to avoid contamination.

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Any contamination and rusting of alloy material shall be pickled and
passivated at the fabricator or erectors expense.

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Packing Support Grid

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Our goal is quality.
We at MECS take a great deal

of pride in our products and
plant designs. Therefore, we go
to considerable expense to
enforce our specification and
quality requirements.
The following are examples of

what an MECS packing support
grid should look like.

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To avoid weld quality problems and costly rework, the packing
support grid is required to be welded using the GTA welding
process.

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Grid Welding Problems

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Typical quality problems associated with packing support
grids welded by the GMA or FCA welding process.

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Hot Cracking

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Due to the small size of the packing support grid fillet
welds, it is very difficult to control the weld wire to achieve satisfactory
results.

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Things to Remember
1. The packing support grid is not grating. It is designed to
bear very high loads of ceramic packing and it is critical to
the function of the tower.
2. Weld the grid using only the GTA welding process.
3. Secure the grid during weld out.

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In order to keep the grid from warping due to welding heat related
distortion the grid needs to be secured in a jig during welding.

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Grid Installation Issues
The packing support grid must be installed with a 1” (25mm)
spacing between the ID of the shell and the OD of the grid.
In order to do this, the grid must be fabricated within the MECS

roundness tolerances found in the MECS Alloy Platework
Specification 412-001C, Paragraph 8.2.
Therefore we require the fabricator to tack the shell sections

together, install the packing support beams and the grid to assure
that the components will all fit together with the appropriate spacing.
The 1” (25mm) minimum spacing of tower internal components is

non-negotiable.

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Why all the fuss?
It is all about the wetting of the interior surfaces of the tower….
The superior corrosion resistance of ZeCor materials depends on

the free flow of acid down in interior surfaces of the ZeCor towers.
Areas inside the tower where dry spots “shadowing” can occur
will dramatically shorten the lifespan of the tower.
As acid mist accumulates in a shadowed area of the tower, it can

super concentrate forming oleum which is a tower’s worst
enemy.

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Packing Support Beam Saddles
The packing support beam saddles bear the entire load of the
ceramic packing, the grid itself and the packing support beams as
well as the acid. Therefore it is critical that the packing support beam
saddles are welded to the shell using only full penetration welds.
Failure to do so could lead to catastrophic failure of the tower.

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This photo shows a proper fit-up of a packing support beam
in order to achieve a full penetration weld to the shell.
The MECS inspection and test

plan has assigned a MECS hold
point for the fit-up of the packing
support beam saddles to the
tower shell.
To assure a weld joint geometry

conducive to achieving a full
penetration weld, the joints
should be seal welded to
prevent stress corrosion
cracking.

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Packing Support Beams

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The packing support beams require full penetration welds and LPT
of all root and cover passes.

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The MECS inspection and test plan requires that for field erected towers,
the shell section(s) associated with the packing support structures be
pre-fit in the shop before shipment to the field to verify that all minimum
spacing is correct. This is an MECS inspection hold point.

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Mist Eliminator Tubesheet

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Remember that the mist eliminator flanges shall be flat within
1/32” (0.6mm) as measured between two adjacent bolt holes
and 1/16” (1.6mm) between three bolt holes. This is very
difficult but by managing the sequence of fabrication, it can be
easy.

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In order to meet the MME flange face flatness criteria, use the
following fabrication sequence:
1. Weld the nozzle cylinder’s longitudinal weld seam,
2. Weld the face ring to the nozzle cylinder,
3. Machine the flange face to remove any weld related heat distortion.
Note: The bolt holes can be drilled before or after welding.

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Remember the mist eliminator flange faces shall not vary more than
1/8” (3.2mm) from a level horizontal plane.
This can be very difficult, but this can be achieved by the sequence
of fabrication.

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The purpose of this sequence of fabrication is to minimize welding heat
related distortion. Without measure similar to those shown in the following
slides it will be virtually impossible to hold the tolerances critical to the
proper function of the mist elimination equipment.
In order to prevent welding heat related distortion of the tubesheet we must

first stabilize the outside edge of the tube sheet. This is done by first
fabricating the shell course directly below the tubesheet. Since the HRS
tower is often times too large of diameter to ship over the road the
tubesheet must be sent to the field in two pieces and welded together in
the field, which is even more challenging to accomplish within the
tolerances required by the MECS platework specification.

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Since the shell will eventually have to be shipped to the field in two
180°sections, the two halves of the shell should only be tacked
together to make a cylinder.

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Generally HRS tower tubesheets are welded together from several
pieces of plate. The welding of each half should be performed with the
tubesheet plate being secured in some sort of jig or secured by a
strongback system in order to keep heat related distortion to a
minimum. The use of backstep welding will also aid in avoid heat
distortion as well.

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First off, the tube sheet should be fabricated as flat as possible.
Even with stiffeners as shown below the tube sheet will have a
significant amount of weld heat related distortion.
The tube sheet drains should be located based on the location of the
low point of the tube sheet. If numerous low points outside of
tubesheet tolerances additional tubesheet drains may be required.

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Attaching strongbacks as shown below will aid in keeping the field
weld edge stabilized throughout the shop fabrication process and
avoid warpage.

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The next step would be to fit one half of the tubesheet to the tacked
together shell course and weld the tubesheet to the shell course
except for the area shown. It is important that the orientation of the
shell course be as shown on the drawing below to accommodate easy
disassembly for transport. Please note the tubesheet to shell weld joint
is required to be a full penetration weld. At this point weld the
underside T beam of the tubesheet to the shell to add additional
stability to the tubesheet.

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In the same manner, fit and weld the second half of the tubesheet to
the shell course being careful not to weld in the areas within the blue
ovals shown below. Now at the fabricators option, the mist eliminator
pedestals can be fit and welded. Do not weld the two center rows of
pedestals in place since it is likely that the heat from welding the center
tubesheet seam will cause some degree of distortion which would
likewise cause issues with the plumbness of the pedestals parallel to
the center tubesheet seam weld.

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Once the shell sections are welded completely to the tubesheet, cut
the tack welds so the unit can be disassembled into two halves to
accommodate shipping.

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Once the halves of the tube sheet assembly has been shipped
to the field, the two halves can be welded together. Be careful to
use backstep welding on the tubesheet center seam weld and
monitor interpass temperatures so not exceed 300º F or 150°C.
This will minimize the distortion due to welding heat.

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Then install the MME nozzles using a long straight edge to assure that
each nozzle tacked in place, so that it is flat in its relationship with the
adjacent flanges.

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Then the flanges are carefully welded in place using a low heat input
welding process being careful to limit the size of the fillet welds to no
more than that which is called for on the drawings.

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Install mist eliminator pedestals and weld out using the GMA
welding process to minimize weld related heat distortion.
Remember it is critical that the flange faces of the mist eliminator
pedestals be installed in a level plane. The tolerance on these is
1/8”. Anything beyond this may cause the mist eliminator elements
to rub and prematurely fail.

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All mist eliminator pedestal to tubesheet welds must be subjected to
liquid penetrant testing. Once these are all completed with acceptable
results, then take a five gallon bucket of water and pour it on the top of
the tube sheet in order to locate the tubesheets low spots. Once the
low spot is found mark the low spot and locate the tubesheet drains
accordingly.

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The finished tubesheet shall be inspected after welding to assure that
the relational flatness is within MECS specification requirements. This
can be done by simply stretching a heavy string or cord across the
entire tube sheet and the gaps in the flange faces measured and
recorded on the inspection copy of the drawing. Any deviations greater
than 1/8” will require rework of the MME nozzle as shown below;

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Shell Fabrication and Erection

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Banding / Welding Heat Distortion
Banding or heat related distortion

at horizontal weld joints shall not
exceed ½ in. (13 mm) for
equipment with an I.D. greater
than 79 in. (2.0 m).
Equipment 79 in. (2.0 m) I.D.

and less, peaking shall not
exceed ¼ in. (6mm).
Banding at horizontal weld joints

shall be determined using a
straight edge.

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Peaking / Heat Related Distortion
Peaking at vertical weld
joint(A) shall not exceed ½ A
in. (13 mm) for equipment
with an I.D. greater than 79 Vertical Weld
in. (2.0 m). Seam
Equipment 79 in. (2.0 m) I.D.

and less, peaking (A) shall
not exceed ¼”.
Peaking at vertical weld

joints shall be determined
using a horizontal sweep
board 900 mm (36 in.) long.
The sweep board shall be
made to the nominal radius
of the tank. It shall be on
site and available to the
Inspector.

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Banding can be avoided by controlling interpass temperatures and
using stiffer plates behind the weld joint. The backing plates if used,
must be made of the same material as the shell.

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All carbon steel spiders or other temporary attachments shall
be welded to poison pads made from the same material as
the shell plates they are to be welded to.
In no case is it acceptable to weld any material to ZeCor

materials in the circulation section of the tower other than
same grade of ZeCor as the shell material.
Note:
All temporary welds must be removed by grinding only.
Hammering off a temporary attachment is strictly
prohibited.
All sites where temporary attachments have been

removed must be subjected to liquid penetrant testing.

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Base Metal Damage
Base metal thickness is directly
proportional to the longevity of the
tower. Therefore the thickness of
the tower must be protected from
any thinning during fabrication.
The biggest cause of shell

thinning is from temporary welds
to the shell. Since welders know
the weld is going to be removed
less care is taken to avoid
undercuts, but when the
temporary weld is removed, the
damage to the base metal is often
“blended out”. This practice thins
the base metal even more than
the initial damage caused by the
weld undercut.

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This photo shows an
area where there was
some undercut which
the welder decided
he would blend out,
however he created
much more damage
by blending the base
metal.
The only acceptable

means of repairing
rejectable undercut
is to fill in the
thinned area by
welding.

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Shell Weld Profiles
The shell seam welds shall
have a smooth transition
between the weld crown and
the adjacent parent metal.
This is mainly to prevent dry

spots or shadows on the
underside of the welds which
can quickly corrode the shell
base material and cause
premature failure of the tower.
The weld shown on the right

shows the ideal shell weld
profile.

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HRS Pump Boot

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The pump boot flange shall be flat and level within 1/16”.

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Important
Important Considerations
Considerations
When one considers the amount of welding required on the pump boot
and the effects of welding heat on 300 series stainless steel, meeting
the 1/16” tolerance is nearly impossible. Therefore it is recommended
that the rectangular pump boot flange itself be made from one piece of
steel without weld seams.
It is also recommended that the flange be tacked to a heavy plate to

prevent the flange from warping when all of the rectangular nozzle neck
welds and associated gusset welds are made.
If minor warping does occur, then the flange assembly can be machined
flat by a turret lathe or similar equipment after all welding is completed.
Please Note: Any variation beyond 1/16” in the flatness of the

pump boot flange will cause the pump to pump boot
connection to leak.

© MECS.
reserved. The The
science™, or TM
and are trademarks
affiliates.
affiliates.
Below is a completed pump boot flange / nozzle assembly in a turret
lathe in order to machine the flange face flat.

© MECS.
reserved. The The
science™, or TM
and are trademarks
affiliates.
affiliates.
Nozzles

© MECS.
reserved. The The
science™, or TM
and are trademarks
affiliates.
affiliates.
HRS Pump boots often have a large number of nozzles and
gussets in a relatively small area. This causes a problem with an
excessive concentration of heat in a relatively small area and will
always result in the shell warping, resulting in all of the nozzles
being out of plumb.
To avoid this problem it is necessary to utilize a 310 clad strong

back on the inside and outside of the vessel shell in order to
stabilize the shell during weld out.
Failure to do this will result in re-work at the fabricator’s expense.

© MECS.
reserved. The The
science™, or TM
and are trademarks
affiliates.
affiliates.

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Alloy Tower Fabrication and

Presented by: MECS Alloy

No portion of any MECS equipment may be subcontracted

Copyright ©Copyright TM, The Miracles of ScienceTM and all

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412-001 Alloy Platework

412-002 Dye Penetrant Examination

416-001 Inspection and Test Plan – Alloy Towers

The Applicable Project Drawings

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All materials shall be marked with a heat number or control

Traceability of materials shall be maintained through the

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Only certified NDE technicians shall perform LPT following a

Welders are not permitted to perform LPT.

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Non Destructive Examination:

Blue Section: (Above the gas inlet nozzle)

2. The fabricator shall calculate the length of

3. All rejected spot shots and penalty shots

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Non Destructive Examination:

Yellow Section: (below the bottom of the gas inlet

2.All rejected welds shall be tracked to assure

3.Radiographs shall be traceable back to the

1.Vacuum Box leak testing of the floor to shell

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Interpass and Final towers use both ZeCor-Z and ZeCor-310M

On these towers it is necessary to perform 100% PMI (Positive

It is important to note that ZeCor is a corrosion resistance family of

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All welds require 100 percent visual weld inspection.

Welds must have a thicker cross sectional thickness equal to or

Weld reinforcement on internal or external surfaces shall not exceed

Welds shall be free from visible imperfections such as cracks of any

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Over Up To And Including Tolerance Over Up To And Including Tolerance

0'-0" 14'-0" ± 1 in. 0m 4.25 m ± 25 mm

14'-0" 32'-0" ± 11/2 in. 4.25 m 9.75 m ± 40 mm

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Vertical Joints: Misalignment shall not exceed 10% of the plate

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All plate rolls shall be covered in heavy gauge plastic or cardboard

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We at MECS take a great deal

The following are examples of

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