Tanks Production

After approval of KMD drawings their packaging arrangement is made and passed to the shops and departments of the plant.
The incoming quality inspection of metal-roll is performed to manufacture high-quality steel structures of tanks. It includes:
• verification of documents (certificates), confirming the quality of metal-roll and registration in the register of incoming control;
• visual inspection of metal-roll. The surface should be free of rolling defects - delaminations, laps, shells, etc.;
• control of thickness of metal-roll;
• control of flatness;
• control of width;
• control of length;
• ultrasonic testing of metal-roll on continuity;
• marking of delivered metal-roll according to the plant markings.

Sheet metal-roll, used for manufacturing walls and bottoms, is subject to leveling. Shaping of metal-roll is produced by means, which eliminate the formation of dents, nicks, and other damage. PJSC "MZMK" provides leveling of sheets on 7 or 11-roller sheet-straighteners.
After leveling 100% of metal-roll is inspected for visible defects.
Before the production of rolling panels, as well as before rolling of the sheets of a vessel wall, assembled with a layer method, the treatment of sheet metal-roll edges is performed. Longitudinal and transverse edges are processed.
Edge treatment provides elimination of unevenness, burrs and debris; firm adherence of parts to each other, which is the key condition of the quality of welded joints, stipulated by the design; compliance with the linear dimensions and shapes of parts, stipulated by the design.
The technology of fabrication of vertical tanks includes use of the following methods:
• rolling method;
• layer installation method;
• combined method.

Rolling Method
Rolling is an industrial method of coiling of welded panels, assembled from separate sheets, processed on the perimeter. With this method of production, a wall, a bottom and a roof of a tank are delivered to the construction site in the form of rolled welded panels.
The main advantage of this method of manufacturing tanks, compared with layer installation, is a significant reduction of welding operations on the site of tank installation, as the works on assembly and welding of walls, bottoms, pontoon bottoms and bottoms of floating roofs are held at the plant with the use of automatic welding. On average, a reduction of welding works at site makes up 80%.
Steel sheets of unitized dimensions of 1500x6000 mm are used for the manufacture of panels. Welded panels are produced on a special rolling bench by automatic welding.
The length of a roll is 12 m, and the weight is coordinated with the carrying capacity of the rolling stock.

Stages of production of panels by the rolling method:
• production of technological framework. Before welding of panels, a special frame which will roll the panels is prepared. For rolling of tanks, a shaft ladder is usually applied as a technological frame, in order to minimize metal consumption;
• assembly of sheets in accordance with KMD. Assembly of a wall, a bottom or a roof decking is made on the highest assembly-welding site of the rolling bench. In the process of assembly, the prepared steel sheets are laid out on the site in accordance with KMD and fixed by mounting hardware;
• welding and rolling. Welding is performed by automatic equipment;
• preparation of rolls for transportation. The finished products are shipped to the customer both by rail and road transport.
Along with the already mentioned advantages of the rolling method in the fabrication of steel structures of tanks - reducing welding operations on the installation site and high quality of welds due to the use of bidirectional automatic welding at the plant-manufacturer - we can mark another important advantage of this method: reducing installation time in three-four times compared with the installation of tanks by layer method.

Layer Installation Method
The method of layer installation lies in preparation of wall sheets (maximum size: 2500x10000 mm), rolled to the radius stipulated in KM, and bottom sheet parts in the plant environment. Then the sheet elements are packaged in a special manner and prepared for shipment. Assembly of a wall and a bottom is fully performed at the installation site.
Stages of production of a vertical steel tank wall and bottom by layer installation method:
• preparation of walls and bottom sheets. At this stage, specified dimensions of sheets and their geometric parameters are set, and edge machining is performed for welding;
• rolling of tank wall sheets to the radius, stipulated in design. Rolling provides cylindrical shape of a tank wall during assembly;
• packaging. Sheet structures of walls are packed and transported in specially made locating blocks (containers). Bottom parts are packed and transported in containers, the design of which corresponds to their dimension types.

Combined Method
There is also a combined method of manufacturing components of a vertical vessel. In this case, sheet structures of a vessel are produced both by the method of rolling of panels and of layer installation.

Production of Steel Structures of a Tank Roof
The technology of manufacture of roof steel structures of a vertical vessel varies according to its type, specified by the KM design. Depending on dimension types of a tank and other specific features, fixed roofs are used, which are divided into frameless (self-supporting) and frame roofs of conical and spherical shapes, as well as floating ones.

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As of today 1,200 tons of steel structures for the construction of new safe confinement of the Chernobyl nuclear power plant have been shipped. All terms on the contract are met, no reclamations.

The modernization of the gas-plasma facility, released in 2011, has been carried out for the purpose of expansion of production capacity.

Shipment of tanks to Kazakhstan has been completed. The contract has been executed on time and without reclamations from the customer.

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2000-2012 results

Rolled Tanks – 87,000 tons
Layer Installed Tanks – 82,000 tons
Steel Structures – 77,700 tons

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