http://cpfccadcop.blog.163.

com/blog/static/12009980020098231289348/

GACHA
LOFTER-
-

CPFCC-Abu Dhabi Project

LOFTER

TANK ERECTION METHOD STATEMENT

FOR MOT OIL STORAGE TANKS
2009-09-23 13:28:09| ||

LOFTER |

1.0 SCOPE:

This document is created by M/s Exterran - Belleli S.p.A to provide detailed

method statement and sequence for erection of Main Oil Storage - 08 Nos in
Fujairah and 02 Nos. in Habshan.

2.0 REFERENCE CODES, DRAWINGS AND DOCUMENTS:

2.1 API 650 10TH Edition Addendum-4

2.2 Tanks General Layout

2.3 Tanks General Arrangement and Related Drawings

1) C003-24-84-33-3600-001: GA for Tank 1501/1502/1506/1507

2) C003-24-84-33-3600-002: GA for Tank 1503/1504/1508

2.4 Project Scope of work

2.5 Specification Tank Specification Doc. No. 30-50-32-0606

2.6 Data Sheet For Crude Oil Storage Tanks MOT Fujairah Doc. No. 24-84-34-
1603
 2.7 Inspection Test Plan,C003-30-99-93-3601 Rev.0 & C003-30-99-93-3602
Rev.0

3.0 LIST OF EQUIPMENT

Mobile Crane 16 t, 35 t, 45 t, 60 t, 70 t.

Diesel Driven Generators 200 kVA, 365 kVA, 400 kVA

Circomatic Welding Machines

Fork Lift

Pick up

Diesel Driven Air Compressors

Trailers

Electrode Baking & Holding Ovens

Flux Oven

FCAW / SMAW / SAW welding machines

Boogie (Self Propelled)

Transformer

Panel Boards

Man Basket

4.0 PREFABRICATION

All plates when received will be color coded and staked in storage yard. Plates
will be inspected and recorded in a form Material Entry Note, see procedure PR-
MAT-007 Rev.0. When required for erection, material will be transferred to the
required location of the tanks.

Following are the main activities for prefabrication:

4.1 Plates etc., necessary for assembly and erection of Tanks are to be
fabricated at Belleli Site. Any sub-contract for fabrication deemed necessary will be
awarded only to qualified fabricator.
 4.2 Clean out door shall be done in our Jebel Ali Workshop.

4.3 Rolling of Shell Plate and Nozzle Reinforcing Pads will be done at BELLELI
site by BELLELI rolling machine. Shell plates for Habshan site tanks will be rolled in
Fujairah and transported to Habshan.

4.4 Surface preparation and Primer paint application of the prefabricated

components

as required will be done at Site before or after the erection.

4.5 Activities to be done by our Subcontractor

Painting

Radiography

Post weld Heat Treatment

Fabrication of Spiral Stairs and Handrails and other minor appurtenance

Tank internals - Still wells, Foam pourer etc.

5.0 ERECTION PROCEDURE

Erection sequences of Tanks will be as follows:

Laying of Annular plates

Laying of Bottom plates

Erection of Shell Plates, Wind Girder and Top Curb-angle.

Assembly and Installation of Internal Floating roof

Erection of Structural and Appurtenances.

Installation of Tank Internal Piping

Tank Hydrotest

Painting

Installation of seal

Box-up
 Handing-over

5.1 Tank foundation (Contractor Scope : M/s CPECC)

Before the completion of the last 2 - 3 layers of foundation backfilling, Belleli will
install an underground 4 pipe, coming out in the center of the foundation, to be
used as a sleeve for the power cable inside the tank (ref. Fig. 11). The protruding
portion of pipe will be approx. 2.5 m high and will be removed before hydrotest. The
remaining holes in the tank bottom and floating deck shall be blind with doubler plate
by welding and shall be carried out applicable NDT tested.

5.2 Erection of annular and bottom plates

5.2.1 Before handing-over foundation shall be jointly checked by Belleli

and Civil contractor as per civil drawing provided by CPECC and elevation
differences shall be within the tolerances specified. Reading shall be recorded. All
inspection will be done as per ITP, C003-03-99-93-3601 for MOT Fujairah and C003-
03-9993-3602 for MPS Habshan.

5.2.1 A ramp will be prepared to allow a crane 15 - 45 t capacity to enter inside

the foundation area for handling and installation of bottom plates, floating roof plates
and other materials.
 5.2.3.Tank centre and 04 marking on outer diam. at 0, 90, 180 & 270 degree
shall be provided by CPECC for all tanks.

5.2.4. Bench mark with X, Y, Z coordinates shall be provided by CPECC

5.2.5. Underneath of both Bottom and Annular plates shall be painted as per
procedure C003-30-99-90-3625.

5.2.6.All plates required for the tank bottom shall be loaded and brought inside
the tank foundation through the ramp by boogie/trailer (ref. Fig. 5 and 6)

5.2.7. Bottom plates shall be removed from the boogie and laid on the
foundation by crane (ref Fig no. 15)

5.2.8. Bottom plate on the centre of the tanks shall be marked after installation
with centre line in both axes, after annular plates can be installed.

5.2.9. Further bottom plates shall be laid with slope down towards the tank
periphery.

5.2.10. Bottom plate lap joints (shall be shingled to shell towards the drain,
minimum overlap shall be 25mm) are fitted together by placing the stoppers at
appropriate spacing. Removal of stoppers shall be carried out using cutting disk /
grinders.

5.2.11. Plate to plate overlap in long seam and short seam shall be maintained
as per

drawing.

5.2.12. Joint shall be welded in proper sequence: first shall be welded the short
seams, after the long seams shall be welded from center going outwards to the
periphery

5.2.13. After fit-up, approx 350 mm of two segment joint from the outside to
inner shall be welded first. Joints will be back stripped as per drawing.

5.2.14. For method to control / prevent distortion in joints while welding

5.2.14.1For method to control / prevent distortion in joints while welding

 5.2.14.1.1 Fit up of joint using Chicago plate as shown in fig no. 3 checking the
alignment using temp-plates.

5.2.14.1.2 After joint fit up, every vertical joints welding will be done one Yes
and one No alternatively.

5.2.14.1.3 Root pass welding will be done by back step method. Vertical
joints will be divided into 4 parts as shown in fig no.12. Welding will start in the first
section (75cm) from down to top.

5.2.14.1.4 At completion of first section, the second section will be started with
same uphill method.

5.2.14.1.5 Similar method will be used for 3rd and 4th section. The above root
pass sequence will be adopted for all vertical shell plate joints. ( Figure No.13)

5.2.14.2.1 This will be done by uphill method starting from bottom of joint to the
top.

5.2.14.2.2Filling pass will start from the same side of the root pass.

5.2.14.2.3 Filling will be done for 25% of weld surface from one side. Then 25%
will be done on the other side.

5.2.14.2.4 This joint welding process will be done from inside and outside

tank alternatively until full welding of the joint.

5.2.14. 2.5 The above sequence of filling will be adopted only for shell plate
thickness above 20 mm and for thickness less than 20 mm, filling can be done
completed in one side and then the other side.

5.2.14.3. Horizontal joint - ( Figure No.14)

The sequence of welding will be same like vertical joint and will be as below

5.2.14.3.1 After the joint fit up, the root pas will be done always by Back step
method with enough welders allotted all along, equally divided circumferential
joint.

5.2.14.3.2 After the root pass, SAW welding can be started for filling joints from
inside the tank.
 5.2.14.3.3 After the first SAW pass, grinding will be done in the joint from outside
the tank.

5.2.14.3.4 The filling inside can proceed up to 25%, then SAW welding can be
done outside until 25% of the welding surface.

5.2.14.3.5 This joint welding process will be done from inside and outside tank
alternatively until full welding of the joint.

5.2.14.3.6. The above sequence of filling will be adopted only for shell plate
thickness above 20 mm and for thickness less than 20 mm, filling can be done
completed in one side and then the other side.

5.2.14.15. Alternate welding sequence shall be followed in welding annular plate

segments to avoid distortion.

5.2.14.16. Joints will be checked by radiography as per applicable standards

from API 650.

5.2.14.17. Reinforcement weld on the annular plate shall be ground flush where
the shell is to rest after acceptance of radiographic test.

5.2.14.18. Balance welding of the annular joints shall be done before connecting
the welded

bottom plates and after the internal welding between annular and 1st
course.

5.2.14.19. Vacuum box testing for all the joints shall be done.

5.2.14.20. Inspection sequence will be followed according to joint completed and

will be

recorded as per ITP.

5.3 Erection of Shell course

5.3.1Mark the base course position on the annular plates.

5.3.2Mark the centre line of foundation on the Bottom Plates.

5.3.3 Mark the axes on the annular plates.

 5.3.4 Install temporary stoppers.

5.3.5 Erect Base course plates in position and tack weld the vertical joint.

5.3.6 Backing support shall be given by welding steel members from inside the
tank

5.3.7Check verticality of internal surface of shell course using plumb-bobs with

proper

dampening.

5.3.8 After installation of all the 1st course shell plates, one plate matching with
ramp will be removed for easy access to tank and position shall be marked in the
annular with punching.

5.3.9 Weld vertical joints of 1st course. Check verticality / plumb-ness again.

5.3.10 Check internal diameter and course verticality

5.3.11 Fit-up 1st course with annular

5.3.12 Internal welding

5.3.13 Leak test

5.3.14 Permanent fabricated wind girders will be used as temporary working

platform to erect the 2nd to 8th shell course.

5.3.15 Install temporary working platform on upper side of the 1st shell course
using

temporary brackets (ref. Fig. 4).

5.3.16 Check elevation of 1st shell course.

5.3.17 Install second shell course plates and fit-up. No. 2 plates in 2nd course
shall not be welded, as they will be removed for entering inside the tank, until
completion of the internal floating roof works.

5.3.18 The 1st and the last plate of the 2nd shell course will be braced against
wind with

two1.6 t tirforts (ref. Fig. 5)

 5.3.19 Weld second course vertical joints

5.3.20 Weld horizontal (circumferential) joint between 1st course and 2nd
course.

5.3.21 Check verticality.

5.3.22 Complete Radiography, removal of temporary attachments from vertical

joints, dressing, NDT etc.

5.3.23 Transfer temporary working platform on upper side of the shell course - 2.

5.3.24 Continue with shell course erection in the same sequence as above, till
top course 8th course

5.3.25 After completion of circumferential welding between 6th & 7th shell
courses, install, fit-up and weld the intermediate wind-girder on 7th shell course.

5.3.26 After welding intermediate wind-girder and the last shell course, install
and fit-up the top wind-girder on the final position of the shell 8th course. Proper care
shall be taken to avoid distortion during welding.

5.3.27 Install and fit-up the top curb angle

5. 3.28 Weld curb-angle

5.4 Erection method of shell course

5.4.1. Shell courses are erected one upon the other using temporary
stiffeners connecting the courses and welded to the shell plates (ref. Fig. 2)

5.4.2. For horizontal fit-up, no. 6 anchors (refer Fig. 1 and 2) at equal distance
shall be

welded on the top side portion of the base course, both sides from course 2 7
and

only on the bottom for shell course 8.

5.4.3 For vertical fit-up, no. 4 anchors will be welded on both side of the plate
as shown in Fig. 1 and 3.

5.4.4 Anchors are welded horizontally only in one side and vertically both sides.
 5.4.5. Temporary windgirder bracket holding clamps shall be welded to the shell
plate.

Welding shall be in three sides only.

5.4.6 First plate in the Base course will be lifted and kept in position as marked
in the annulare plate and fixed with stoppers. It will be supported from inside by steel
members welded to bottom plate.

5.4.7 Second plate in the base course shall be lifted and positioned on the
marking of annular plates. This plate will be locked with the first plate by driving
carrot pin after locking with vertical fixture as given in Fig. 3.

5.4.8In similar way, all plates of base course shall be erected.

5.4.9 Alternate Vertical joints shall be welded.

5.4.10 For welding Horizontal and vertical joint, refer details in sketch SK-4891-
00-001

5.4.11 After welding and QC check is completed, bracket for bearing temporary
wind girders shall be hooked in the fixture which was previously welded to the shell
plate (ref. fig. 4)

5.4.12 Temporary winds Girder are erected upon the bracket and Tack welded to
the shell course. Temporary platform holding brackets shall be welded in Shell plates
as shown in Fig. 4

5.4.13 A ladder shall be attached to Winder girder with support welded to Shell
as shown in Fig. 5 and 9.

5.4.14 4 - 5 mm flat bar shall be tack welded to the top of base course plate to
maintain gap in horizontal joint as shown in Fig. 4.

5.4.15 Second course plate shall be lifted and kept in position upon the base
course. Second course plates are anchored by driving the carrot pin in anchor after
locking with fixture as shown in Fig. 2.
 5.4.16 Movable cage will be placed upon the first plate of 2nd shell course for
assisting erection works like removal of vertical lifting clamp and to drive carrot pins
in vertical fixtures etc.

5.4.17 Second plate of the second course shall be lifted, kept upon the base
course near the first plate and locked with both horizontal and vertical fixtures.
Similar way all plates shall be erected in 2nd 8th course.

5.4.18 All the temporary attachments like Eye Nuts, clamps etc will be
removed by grinding. Excess weld metal will be flushed by grinding. If required build
up will be done and will be ensured by Magnetic particle test (as per procedure
C003-30-9990-3603).

5.5 Sequence of welding for shell course to annular plate

Sequence of welding will be as follows:

5.5.1Welding of 1st shell course to annular plates from inside shall be done first.

5.5.2 The First pass of internal side of shell to annular weld shall be inspected
100% by oil penetrant test method .(except clean out door assembly)

5.5.3 Completion of Internal side welding of shell to annular.

5.5.4 Leak test of internal welding with diesel/gasoline from outside

5.5.5 External side welding of shell to annular.

5.5.6 Visual inspection of internal and external welding of shell to annular.

5.5.7 Fit-up and weld balance of the annular joints and weld annular to bottom
sketch plate

5.5.8 MPI of internal / external shell to annular corner joint.

5.6 Erection of stair case

5.6.1Pad location for the stair case support shall be marked on the shell plates

5.6.2 Pad shall be welded and appropriate QC check to be done. Weep hole
shall be provided on all pads.
 5.6.3 All stair-treads, handrails must be bolted to stringer in segments up to the
intermediate landing platforms.

5.6.4 Assembled lower segment of spiral stairway shall be lifted and installed.

Following the lower segment, first intermediate platform shall be erected.

5.6.5 After welding of the lower segment, further portion shall be erected in
similar way.

5.6.6 MPI shall be carried out on all temporary attachment removal areas.

5.7 Assembly of Internal Floating Roof (Double Deck)

5.7.1When half portion of the bottom plates are welded, including annular plates
segment plus the internal welding between 1st shell course and annular plates,
vacuum box test shall be conducted and cleared for internal float roof assembly.

5.7.2. Internal floating Roof lower deck plates shall be laid and welded in
same sequence of Bottom plates.

5.7.3 Mark up on the lower deck plates, the location of outer rim, Intermediate
rim, compartment plates, structures, leg supports and accessories.

5.7.4 Positioning, fit up and welding of outer rim, intermediate rim plate, center
rim plate and rafter.

5.7.5 Complete welding of vertical and all joints to the lower deck plates

5.7.6 Welding of the compartment of the floating deck shall be done starting
from the opposite side of the entry ramp.

5. 7.7 When total assembly and welding of the floating roof without roof
plates is completed, including sleeves supporting legs, all manholes and nozzles of
1st shell course shall be closed.

5.7.8 Temporary ladder positioned in two locations of the 2nd or 3rd shell course
shall be provided to enter in the tank (ref. Fig. 10).

5.7.9 Closing of the 1st, 2nd and, in case, 3rd shell course will be done in steps,
in order to complete at the same time the assembly of the floating roof (still without
roof plates).
 5.7.10 Sea Water shall be pumped inside the tank trough one nozzle and slowly
float roof will be lifted up. Water shall be pumped until the Float reaches the height
allowing the insertion of the pins into the legs.

5.7.11 Check of the orientation of the Floating Roof. As per floating roof
lay-out drawing.

5.7.12 Draining of the water

5.7.13 Tank shall be cleaned with high pressure water jet.

5.7.14 Installation of floating deck roof plates.

5.7.15 Installation of foam dam

5.7.16 Installation of manholes, drainage, internal piping, etc

5.7.17 Installation of roller ladder

5.7.18 Primary shoe and seal shall be installed after final hydrotest and
internal painting, as per supplier instruction.

6.0 FIGURES

SK-4891-00-001 rev. 01: Shell and bottom welding details

Figure 01: Anchor welded to the shell plates

Figure 02: Erection and fit-up of shell course

Figure 03: Fixture for erection and fit-up of vertical joint of shell course

Figure 04: Fixture of temporary bracket for wind girder

Figure 05: Bracing of the opening of the 2nd or 3rd shell course during floating
roof assembly

Figure 06: Transportation / Handling of rolled shell course plates

Figure 07: Handling / Installation of bottom plates

Figure 08: Handling / Installation of the shell course plates

Figure 09: Installation of ladder to access the wind girder

 Figure 10: Access with double ladder during floating roof assembly completion /
floating

Figure 11: 4" Pipe underground the foundation.

Figure 12: Vertical joint root pass sequence.

Figure 13: Vertical joint filling sequence.

Figure 14: Horizontal joint root pass sequence.

Figure 15: Bottom lay-out.



(8180)| (1)


2011-09-23 17:20:35

2010-09-23 18:15:47


>>

2011-05-26 17:42
gdasgb

retyhsgvbs c

- - - LOFTER APP -

1997-2017