5 Chapter 5Figure 5.1 Angle grindersFigure 5.2 Nibbler Figure 5.3 Laser alignment verification on rotary table of horizontal boring...Figure 5.4 (a) Lathe and (b) Lathe machining weld prep on pipeFigure 5.5 Router and detail of router bit for 45° bevelFigure 5.6 Split frame pipe beveler producing J‐groove weld prep Figure 5.7 Edges of longitudinal seam being aligned using lugs and wedges (l...Figure 5.8 Cylinder end being rounded up using a pipe plus hydraulic cylinde...Figure 5.9 Adjustable spider assembly Figure 5.10 Flange nozzle neck fit up Figure 5.11 Head to shell and nozzle fit up on positioner and turning rolls ...Figure 5.12 Bolt holes straddling centerline Figure 5.13 Welding axial residual stress, inside weld first, followed by in...Figure 5.14 Welding axial residual stress, outside weld first, followed by o...Figure 5.15 Column and beam manipulator being prepared to weld vessel segmen...Figure 5.16 Vertical boring mill facing large vessel flange Figure 5.17 Large spheroidal segment on tilt table Figure 5.18 Special fixturing for field welding of large fabrication
6 Chapter 6Figure 6.1 Plate shearFigure 6.2 Edge of sheared plateFigure 6.3 Typical 3/4 in. (19 mm) flame cut componentsFigure 6.4 Plasma torchFigure 6.5 Plasma cut edgeFigure 6.6 Laser‐cut parts ready for processingFigure 6.7 Laser‐cut nozzle contoursFigure 6.8 Vertical boring mill (VTL)Figure 6.9 Machining a typical tubesheetFigure 6.10 Typical tee‐slots for clamping partsFigure 6.11 Clamping lugs using tee‐slots to hold part for machiningFigure 6.12 Simple flange drill jig with hardened bushingsFigure 6.13 Feeds and speeds of lathes. (a) Axial cut on lathe. (b) Face cut...Figure 6.14 Boring mills. (a) Bridgeport‐type vertical mill. (b) Large gantr...Figure 6.15 24 in. (60 cm)‐diameter latheFigure 6.16 Hand cutting threads in aluminum using a taper tap
7 Chapter 7Figure 7.1 Some types of fillet welds: (a) single fillet weld, (b) double fi...Figure 7.2 Bevel joints: (a) single bevel joint and (b) double bevel jointFigure 7.3 Typical J bevel jointFigure 7.4 Typical U bevel jointFigure 7.5 Reference LineFigure 7.6 Weld symbols inserted on Reference Line: (a) arrow side and other...Figure 7.7 Various weld configurationsFigure 7.8 Two methods of showing weld details: (a) weld detail, (b) weld sy...Figure 7.9 Nozzle‐to‐shell attachmentFigure 7.10 Basic components of electron beam weldingFigure 7.11 Electroslag weldingFigure 7.12 Gas metal‐arc weldingFigure 7.13 Gas tungsten‐arc weldingFigure 7.14 Oxy‐fuel gas weldingFigure 7.15 Plasma‐arc weldingFigure 7.16 One type of submerged‐arc welding
8 Chapter 8Figure 8.1 Inserting a pressure vessel into a furnaceFigure 8.2 Pressure vessel subsequent to PWHTFigure 8.3 Welding of clad platesFigure 8.4 Weld overlayFigure 8.5 Nozzle with loose liner in overlaid vesselFigure 8.6 Nozzle with loose liner in a clad vessel
9 Chapter 9Figure 9.1 Various types of heat exchangersFigure 9.2 Typical components of heat exchangersFigure 9.3 Typical tube‐to‐tubesheet junctions in water tube boilersFigure 9.4 Some typical tube‐to‐tubesheet junctions in pressure vessel appli...Figure 9.5 Plastic alignment bullet at the end of a tubeFigure 9.6 An example of a floating tubesheetFigure 9.7 Examples of tube rollersFigure 9.8 Expansion of the tube diameterFigure 9.9 Typical grooved tubesheet configurationFigure 9.10 Hydraulic expanderFigure 9.11 Typical arrangement of explosive expansion prior to detonationFigure 9.12 Some types of expansion jointsFigure 9.13 Bellows expansion jointsFigure 9.14 Some tubesheet‐to‐shell and ‐channel attachments.Figure 9.15 Tube bundle sliding railsFigure 9.16 Dimpled plate welded to plain plateFigure 9.17 Dimpled plate jacket welded to a pressure vesselFigure 9.18 Some fabrication methods for layered shellsFigure 9.19 Spiral‐wrapped shell with tapered plate [5]Figure 9.20 Wrapping of thin layer concentric and spiral layered vesselsFigure 9.21 Components of shrink‐fit layered vesselFigure 9.22 Layered shell‐to‐thinner head attachmentsFigure 9.23 Layered shell‐to‐thicker head attachmentsFigure 9.24 Layered pressure vessel shell‐to‐shell weldFigure 9.25 Layered shell supportsFigure 9.26 Rectangular vessel fabricated of two formed C sectionsFigure 9.27 Some typical rectangular vesselsFigure 9.28 Vessel supportsFigure 9.29 Pipe leg supportFigure 9.30 Unusual pressure vessel configuration and view of portion of int...
10 Chapter 10Figure 10.1 Surface finish comparator gaugeFigure 10.2 Abrasive blasting roomFigure 10.3. Large equipment paint room
11 Chapter 11Figure 11.1 Lifting a pressure vessel using a spreader beamFigure 11.2 Lifting a U‐tube heat exchangerFigure 11.3 Attachment of cables to spreader beam. (a) Applied loads are equ...Figure 11.4 Typical spreader beamFigure 11.5 Light load on an exclusive truckFigure 11.6 A 300 ton (270 tonne) stationary craneFigure 11.7 Heavy‐lift crane in the fieldFigure 11.8 Specialized transportFigure 11.9 Sophisticated dolly for transporting large cylindrical shells...Figure 11.10 Heavy load trailersFigure 11.11 Idler flat railroad car behind a vesselFigure 11.12 A long load requiring three railroad carsFigure 11.13 Position of railroad cars and vessel along a curveFigure 11.14 Swivel angle and saddle motionFigure 11.15 Strap and rod tie‐downsFigure 11.16 Cradle supportFigure 11.17 Shipping partial components by railFigure 11.18 Drive on barge loadFigure 11.19 Multiple loads on a bargeFigure 11.20 Plimsoll marksFigure 11.21 Heavy vessel being loaded onto an Antonov An‐124 aircraft
12 Chapter 12Figure 12.1 Sample name plateFigure 12.2 Actual name plate
13 Chapter 13Figure 13.1 Temper bead manual weldingFigure 13.2 Temper bead automatic or machine weldingFigure 13.3 Outside weld buildup to repair inside thinningFigure 13.4 Sleeve with longitudinal weld onlyFigure 13.5 Sleeve with circumferential and longitudinal weldsFigure 13.6 Hot tapping sleeveFigure 13.7 (a) Hot tap valve and drill attached to pipe, (b) hot tap drill ...Figure 13.8 Typical hydraulic nut‐cutterFigure 13.9 A crack in a deep structural steel vessel support girder
14 Appendix EFigure E.1 Ellipsoidal headFigure E.2
15 Appendix GFigure G.1 U‐tube bendFigure G.2 U‐Tube bendFigure G.3 Reduction of tube wall
16 Appendix IFigure I.1 Types of shacklesFigure I.2 Types of pinsFigure I.3 Dimensions of chain shackleFigure I.4 Dimensions of anchor shackleFigure I.5 Maximum pickup angleFigure I.6 Side‐loaded shackle
Guide
6 Preface
10 Appendix A Units and Conversion Factors