TANK CONSTRUCTION

ANNULAR

PLATES
BOTTOM PLATES
SHELL PLATES
ROOF STRUCTURES
ROOF PLATES
MANHOLES & NOZZELS
STAIRWAYS
PLATFORMS

TYPES OF TANKS
CONE

ROOF
DOME ROOF
INTERNAL FLOATING ROOF
EXTERNAL FLOATING ROOF
FLAT ROOF

TYPES OF FOUNDATIONS
FULL

CONCERETE FOUNDATION
BOTTOM SLOPE FOUNDATION
FLAT BOTTOM FOUNDATION
RINGWALL FOUNDATION

CONSTRUCTION
SEQUENCE

1.
2.
3.
4.
5.
6.
7.

LAY OUT ANNULAR PLATES

LAY OUT BOTTOM PLATES
ERECT 1ST SHELL COURSE
FITUP AND TACK WELD BOTTOM TO
SHELL JOINT (CORNER JOINT)
FITUP AND TACK VERTICAL JOINTS
ALLIGN VERTICAL JOINTS WITH KEY
PLATES
START WELDING OF VERTICAL FROM
OUTSIDE (V1, V2, V3 AND V4)

CONTINUE.
8. BACKGOUGE VERTICALS FROM INSIDE
9. START WELDING VERTICALS FROM INSIDE
10. ERECT 2ND SHELL COURSE PLATES
11. FITUP AND TACK WELD VERTICALS
12. ALLIGN USING KEY PLATES
13. DO NOT FIT UP HORIZONTAL JOINTS TILL
YOU COMPLETE VERTICAL JOINTS
14. CONTINUE THE SAME PROCESS FOR
VERTICALS
15. FOLLOW THE SEQUENCE.

BOTTOM PLATE ERECTION AND WELDING SEQUENCE

BOTTOM PLATES

4
5

3
1

1
3

5
4

5
4

Welding
Sequence

Welders

2 or 4

2 or 4

BOTTOM PLATE LAYOUT

TANKAGE
BOTTOM PLATE ERECTION
ERECTION

WELDING BY SAW PROCESS

BOTTOM PLATE JOINT TESTING

VACUUM BOX TESTING

Testing Requirements
100% vacuum box test shall be carried our for all
bottom welds.
100% Visual Inspection shall be performed for all
bottom welds prior to vacuum box test.

TANKAGE
ANNULAR PLATE ERECTION & TESTING
Testing Requirements
100% Visual Inspection shall be performed.
100% Vacuum box test shall be performed.
Radiography test shall be carried out as per API 650
Clause 8.1.2.

CORNER WELD JOINT (ANNULAR TO

SHELL)
OIL PENETRATE TESTING (OPT)
Testing Requirements
OPT on the entire length after 1st pass of welding and
after completion of first die welding.
Inside fillet welds in a cylindrical flat-bottom tank shall be
examined by either Dye-penetrant or Wet-fluorescent
magnetic particle method before hydrotest.
100% Visual Inspection shall be performed.

SHELL PLATES ERECTION AND WELDING

SEQUENCE
Good Fit up and fairing of tier plates & Tack weld bottom
to shell joints
SHELL PLATE

BOTTOM PLATE

SHELL ERECTION

TANKAGE
TANK SHELL VERTICAL WELDING WITH EGW PROCESS

ELECTRO GAS WELDING (EGW)

Testing Requirements
100% Visual Inspection shall be performed after completion of weld.
100% MPI (magnetic particle test) shall be done for inside or outside of the joint (weld face side)
Radiography testing shall be carried out as per API 650 clause 8.1.2.

TANKAGE
TANK SHELL HORIZONTAL WELDING WITH SAW PROCESS

SUB-MERGED ARC WELDING (SAW)

Testing Requirements
100% Visual Inspection shall be performed after completion of weld.
Radiography testing shall be carried out as per API 650 clause 8.1.2.

TANKAGE
TANK SHELL BELOW 7MM THICK WELDING WITH SMAW PROCESS

SHIELDED METAL ARC WELDING (SMAW)

Testing Requirements
100% Visual Inspection shall be performed after completion of weld.
Radiography testing shall be carried out as per API 650 clause 8.1.2.

KEY PLATE INSTALLATION

ERECTION AND WELDING OF 1ST SHELL COURSE

Fit up and Tack weld the Vertical Joints
Weld the Verticals from outside by sequence
Then weld the verticals from Inside (After back gouge)

V1

V2

V3

V4

V5

ERECTION AND WELDING OF 2ND SHELL

COURSE

Fit up and Tack weld the Vertical Joints of 2nd shell

Weld the Verticals from outside by sequence
Then weld the verticals from Inside (After back gouge)
After welding the verticals start welding the 1st Horizontal
joint

V1

V2

V3

V4

V5

FACTORS AFFECTING THE CONSTRUCTION

1. IMPROPER FITUP, (MISMATCH OR MISALIGNMENT)
2. UNCONTROLLED WELDING, CAUSES (DEFORMATION, PEAKING
AND BANDING)
3. NOT UNDERSTANDING THE DRAWINGS, CAUSES IMPROPER
STRUCTURE OF THE CONSTRUCTED TANK
4. UNSKILLED WELDER, CAUSES DEFECTS IN WELDS THAT LEADS
TO REWORK
5. IMPROPER MARKINGS, CAUSES MISMATCH OF OPENINGS
COMPARED TO APPROVED DRAWINGS
6. NOT INFORMING AND CONSULTING THE QC PERSONNELS
REGARDING ANY ISSUES IN CONSTRUCTION

FACTORS TO BE CONSIDERED DURING

CONSTRUCTION

ROUNDNESS
PLUMBNESS
PEAKING
BANDING
MISALLIGNMENTS
EXCESSIVE

WELD DEPOSIT
HEAT INPUT CONTROL

TANKAGE
TANK SHELL INSPECTION REQUIREMENTS AS PER STD
ROUNDNESS CHECKING

MAGNETIC PARTICLE TESTING ON

TEMP. SUPPORT & VERTICAL JOINTS

PICKING / BANDING

TESTING OF SHELL JOINTS USING

ToFD METHOD INSTEAD OF RT

PLUMBNESS

TESTING OF SHELL JOINTS USING

RADIOGRAPHIC METHOD (RT)

OTHER MAIN FACTORS TO BE

CONSIDERED IN CONSTRUCTION
PROPER
AVOID

VENTILATION

VACCUM PRESSURE

CORNER

JOINT WELD TO BE COMPLETED

AFTER 3RD SHELL ERECTION

INSTALL

ERV (EMERGENCY RELIEF VALVE)

BEFORE BOX UP.

INSTALL

SUPPORTIVE SLINGS, IN

AGGRESSIVE WEATHER CONDITIONS.

TANK FAILURE (VACCUM)

TANK FAILURE

THANK YOU