Title: ETP&DMRO RESID

UPGRADATION PROJECT
CPCL MANALI -68

ERECTION PROCEDURE OF SITE

FABRICATION TANKS

PROJECT : ETP & DMRO RESID UPGRADATION PROJECT

SITE AT : MANALI - CHENNAI

CONSULTANT : JACOBS

CLIENT : CPCL, MANALI, CHENNAI -68

DOC NO : CPCL/JACOBS/PL/ MECH / TANK-02- REV-01

1 15/03/2016 PARAMOUNT LIMITED JACOBS

PREPARED & CHECKED

REV- APPROVED BY
DATE BY
01
 ERECTION PROCEDURE BY JACKING METHOD
THE PROCEDURE AND ERECTION SEQUENCE USING JACKING METHOD AS UNDER THE
FOLLOWING TANKS – 7NOS.
A) PECT400-D01A/B/C (20MTR DIA X 18.5 HEIGHT) - 3 No’s
B) UECTANK (13.75MTR DIA X14 MTR HEIGHT - 2 No’s
C) FILTER WATER BACKWASH TANK (8M DIA X10.5 HT) - 1 No’s
D) DM WATER BUFFER TANK (13.9DIAX16.5) -1 No’s
.
1. Scope:
This Procedure covers the sequence and details of erection of Storage Tank, at Chennai
PETROCHEMICAL LTD, CHENNAI MANALI – India.

2. Référence Documents:

 API 650.
 ASME – SEC.1X
 ASME - SEC.V
 ASME - SEC.II, PART C
 IS : 2007,2008
 Detailed Drawings approved by JACOBS
 Approved Inspection & Test Plans.
 Approved Procedures.

3. General Notes:
 Latest Approved Revision of the documents shall be followed.

 Inspection & Testing shall be carried out as per the approved Inspection Test Plans.

 Immediately before welding, the surface to be welded shall be cleaned thoroughly of all
Scale, Grease & any Oxide. On Multi-layer Welding each Layer of the Weld Metal shall be
cleaned of Slag before the Next Layer is deposited.

 Welding will not be carried out when the Surfaces are wet due to Rain / dew condensation.
During High Wind Condition, the Work shall be properly shielded before Start of Welding.
When the Metal Temperatures is lower than Permissible by Code ( 16º C), the Joint to be
welded and the adjacent area ( at least 3” on each side) shall be heated to a Temperature
that is Warm to hand, not lower than permissible by Code before Start of Welding.

 After Welding, the Seams shall be cleaned by Chipping / grinding to remove slag
completely. Reinforcement of Welds will be in accordance with Clause 6.12 (Table 6.2) of
API 650. Fillet welds of Tank Bottoms shall be welded with at least two passes.

 All Safety Measures including Proper Area Lighting shall be strictly observed as per the
Safety Plan. Regular Housekeeping of Fabrication Area and the Tank during the Entire
Period of Construction shall be followed.

 All Welding including Temporary Attachments shall be done as per Approved Weld
Procedures & Approved Welders.
4. SAFETY OF TANK DURING CONSTRUCTION:
FOUNDATION:

The levels should be checked & recorded before tank bottom plates are laid on the foundation.

PROTECTION AGAINST WIND:

Unfinished tanks without stiffeners and before the roof structure is erected are highly prone to
collapse during high winds.

High velocity winds passing over the tank diameter cause partial vacuum inside the tank (Educator
effect) and this coupled with external force in the direction of the wind causes the shell to collapse
either partially or fully into most awkward shapes.

5. Foundation:
Before Start-up of Tank Erection, the Foundation shall be jointly inspected by PARAMOUNT LTD
JACOBS & the Civil Contractor, in accordance with Clause C8.7 of API 650.

Center of the Tank & orientations (0º, 90º, 180º & 270º) will be marked & punched on the
foundation by the Civil Contractor. This shall be checked by PARAMOUNT & JACOBS , prior to
take over of Foundations.

A Joint Inspection Report shall be prepared & signed. After satisfactory inspection, erection of the
tank will be started.

6. Prefabrication, Blasting and Painting

A: PRE-FABRICATION
PRE-FABRICATION ACTIVITY COVERS THE PREFABRICATION OF ALL
COMPONENTS OF THE TANK AS PER APPROVED DRAWINGS.

B: BLASTING & PRIMER PAINTING

ALL THE PAINTING SHALL BE CARRIED OUT AS PER SPECIFICATIONS AS
BELOW:-

1. UNDERSIDE OF BOTTOM OF THE TANK BEFORE LAYING ON THE FOUNDATION.

2. ALL SHELL PLATES OF THE TANK TO BE BLAST CLEANED AND PRIMED AFTER
PREFABRICATION AND ERECTED ON THE POSITION.

3. TOP SIDE OF ROOF PLATE TO BE BLAST CLEANED AND PRIMED AFTER PRE
FABRICATION AND ERECTED ON THE POSITION OF ALL 7 TANKS.
 4. TOP & BOTOM SIDE OF ROOF PLATES TO BE BLAST CLEANED AND PRIMED
AFTER PRE FABRICATION AND ERECTED ON THE POSITION OF ALL 7TANKS.

5. ALL STRUCTURAL MEMBERS TO BE BLAST CLEANED AND PRIMED AFTER

PREFABRICATION AND ERECTED.

7. Sequence of Construction:
The following sequence shall be followed for Construction of Tank: The same has been
schematically shown in attached sketches.

S# Description

1 Taking hand over the foundation.

2 Erection and welding of Annular plates.

3 Completing of RT for Annular plates as per code.

Erection and welding of the bottom plates. Joint between annular to sketch plates being
4
the last.

5 Erection and welding of top Shell course on elevators. Erection and welding of Curb
angles.

6 Erection of central temporary structure for the central drum.

7 Assembly and welding of central drum around the structure.

Jacking up the central drum to the desired elevation with 4 jacks or by high capacity
8
crane or chain pulley blocks with posts.

9 Erection and welding structural and Main rafters and cross girders

Removal of temporary central structure and completion of central roof beams for both of
10
Tanks.

11 Erection & welding of roof petals and roof plates.

12 Fixing and welding of roof nozzles, roof Hand railing.

Fixing and welding of Staircase and handrail in every shell course before lifting of the
13
Tanks.

Jack up the tank by providing required no of jacks internally, check the load test and
14
commence the jacking up the shell after approved erection procedure by jacking.

15 Complete the Tanks by progressive jacking up. Install the Wind Girders as the jacking
progresses. In the bottom shell course leave a one shell plate size door for access inside
the tank.
 16 Insert and install internal pipes, Nozzles, Roof Drain etc and close the makeup plate.

17
Complete the shell to bottom joint and complete the shell nozzle welding of the Tanks.

18 Complete all balance works and prepare tank for Hydro test.

19
After hydro test and stabilization of the settlement of tank, weld the tank anchor Chairs.

20
Erection, Welding and Testing of Water Storage systems

21 Empty the tank; carry out external, painting, handover the tank to clients for further
works.

8. Construction Procedure:
The sequence of construction is as listed above. Some of the critical procedures are as given
below:

Tank Bottom:

i) Annular Plates of the Tank Bottom will be erected first & Butt-welded with
backing strip (6mm). Required Non-destructive Testing (NDT) shall be carried
out as per Approved Inspection Test Plan and the Annular Plates Assembly will
be lowered on the Foundation using Hydra cranes /Chain Pulley Blocks.
Orientation of the Annular Plate will be as per Approved Drawing.

ii) As per sequence of construction above, bottom Plates shall be erected from
Center of the Tank towards the Annular Plates. The Fillet Welds of the Bottom
Plates shall be done with minimum two passes. Short Seams will be welded first.
To prevent distortion of the Plates due to welding, suitable Structural Stiffeners
shall be temporarily attached to the Bottom Plates. After welding of Short Seams
of two adjacent rows, the Long Seam between the rows shall be fit-up. Two
Adjacent Long Seams will not be welded simultaneously. Annular Plates to
Bottom Plates Circular Joint will be welded only before completion of Shell
Plates Welding with Annular Plates.

Shell Plate Rolling:

i) The Plate after squaring will be checked by the Inspection Department of

paramount limited /Jacobs. After Inspection Clearance, the Plate will be rolled in
the Rolling Machine (Plate Bending Machine). After each Rotation of the Plate,
the Gauge has to be checked ensuring the Radius is as per the requirement of the
both the type of Tanks respectively. After completion of Rolling, the Plate is to
be staked in the Saddle Constructed as per the Radius. Care should be taken that
the Radius of the Rolled Plate does not change after Staked in the Saddle.
 ii) The Plate after Squaring will be rolled in the Rolling Machine. A Gauge of the
required Radius is made. Before starting Rolling, the distance between the Upper
Roller & Bottom Rollers is to be adjusted for parallel. The Plate to be placed in
the Rollers and then inserted between the Rollers. Care should be taken that the
Length of the Plate inserted in the Roller should be same at both sides. After each
Rolling Movement, the Gauge has to be checked, so that the Plate is not rolled
more than required. After rolling, the Plate has to be stacked in the Saddle of
same Radius, so that the Radius of the Plate does not change or vary.

Tank Shell Course:

After each shell course erection all the vertical joints shall be fully finished. Then
only the lifted tank shall be lowered on the welded shell course ring and then
horizontal fit up and welding shall be done. For vertical welds, the step back method
of dividing the vertical joint in all segments shall be done and each segment will be
welded independently from bottom to top. This avoids undue heat input and any
distortion.

Roof Center Ring

The Central drum Center Ring shall be erected over a Permanent Structure.

Fixed Roof Assembly:

Locations of Rafters shall be marked on inside surface of the tank checked. Main
rafters @ 90º each shall be erected using a crane of Adequate capacity and fit-up with
the center Ring / Drum. Verticality of the center column will be checked once again
and the Balance Main Rafter will be erected. Laterals / cross Girders shall be fit-up
with the Main Rafters. The Laterals / cross Girders nearest to the Roof center ring
shall be fit-up first and the Laterals / cross Girders near the Tank Shell will be fit-up
last. Diagonal bracings shall then be fit-up. The entire fixed roof assembly shall then
be welded. Welding shall progress from center of the Tank towards the Shell. Roof
plates shall then be erected, fit-up & welded.

Jacking-up of Tank:

The Tank Assembly comprising of the erection, Fit-up and Welding of Top Shell
Course, Roof Structural & Roof plates and will be completed before lifting by
Jacking Method detailed below. The Welding of Roof plates can be continued parallel
or after jacking.

a) Installation of Jacks required No’s per tank (Total weight of the tank to be
decided for the requirement of jack) prior to Commencement of Jacking of Shell
Courses; the Jacking Equipment is assembled internally:

i) Base Plate to be fixed on the bottom annular plates.

ii) Vertical Post to be fit-up on the Base Plate.
iii) Jack & Loading Arm to be fixed on Vertical Post.
iv) Cross Bracings to be fit-up from Vertical Post and Bottom plate.
v) Locking of Loading Arm to Shell.
vi) Connecting Hose to Jack & Power Pack.
 The Number of the Hydraulic Jacks required is calculated as follows:

i) Maximum Weight of the Tank to be lifted (i.e. Shell Plates, Roof Structure, and
Roof Plates with Roof Handrails & Nozzles).

ii) The distance between two adjacent Jacks shall not exceed 2.5 meters.

Accordingly, the number of Jacks required is calculated as follows:

1. Empty Weight of the tank as per approved GA (Excluding the Weight of Tank Bottom,
bottom shell course)

Capacity of Each Jack =’ X ‘Tons. (Ref test certificate)

No. of Jacks Required for 1Tank = Toal weight of the Tank / one jack capacity (as
per calculated)

No. of Jacks that will be used for one Tank = and extra jack may be added for factor of
safety.
1
Final Load / per jack should not be exceeded from the 75 % of the jack
capacity.

The Hydraulic Jack comprises of the following:

 Vertical trestle Base Plate (using IS 2062 Steel Cleats for attaching with
Bottom Plates)
 Stay Lug Bottom
 Hydraulic Jack
 Sliding Chair
 Fend Off Lug (Using IS 2062 Steel Cleats for attaching with shell Plates)
 Lifting Arm Stay
 Lifting Lug
 Vertical Jack Trestle with Two Stay pipes.

Before erecting, Teeth on each Jack Post will be checked. Jacks with Worn-out Teeth
will not be used.

Verticality of each Jack Post shall be checked with a Plumb Bob and corrected. The
Side Bracings shall then be erected. Any alignment of trestle shall be done with the
turn buckle arrangement on the stay pipes. The load bearing disc shall be installed
properly to suit the spherical contour on the jack top.

b) Jacking Procedure:
 Hydraulic Pressure will be applied to the Jacks by operating the level of
the Power Pack. With each Stroke of the Lever, the Tank Assembly will
be lifted by 100 mm height. After each Stroke, Pressure will be released
and the Pistons of the Hydraulic Jacks will be allowed to come back to the
original position.

 After all lifts, gap between the Bottom Annular Plates & the Tank
Assembly will be measured at all locations of Jacks along the
 Circumference of the Tank to ensure that all the points are equally lifted.
Any shortfall shall be corrected by selective jacking.

 Jacking Operation shall not be carried-out during Heavy Winds or in

climate Weather Conditions.

 After Lifting of the Tank to the required height, the Next Shell Course
Plates shall be erected over the Erection trestles. The Vertical Joints will
be fit-up & welded first. The Verticality at every fit-up to be checked.
The horizontal joint between the Two Shell Courses shall then be fit-up
after lowering of the tank and the Outside Welding to be completed. The
Assembly will be jacked-up and the remaining Shell Courses shall be
Erected & Welded as above. The Temporary Structure used for center
Drum will be removed simultaneously. Verticality Check at every Shell
Course Fit-up shall be done.

 The 1st Shell Course will be erected directly over the Bottom Annular
Plates. During the Previous Jacking-up, Care will be taken to ensure that
the Gap between the Task Assembly & Top of the 1st Shell Course will not
be more than 20 to 40 mm. After welding the Vertical Seams of the 1st
Shell Course, the tank will be lowered on the bottom most shell and
horizontal joint will be fitted up and welded.

 After every shell course erection completed required inspection to be

carried out peaking, bending, verticality and roundness and recorded.

Completion of Tank Shell Wind Girders & Stiffeners:

The subsequent shell courses shall be erected & welded as described.

Temporary Door Provision:

The Shell Courses will be erected as above procedure. After completion of Shell
Course No.2, the 1st Shell Course will be erected. As approach for the Movement of
Manpower & Machineries inside the Tank, 1 No. of Shell Plate will not be erected,
facilitating for the Movement of Machinery & Man-power.

Staircase & Hand railing and Fire & cooling systems:

The Staircase and handrail and Fire & Cooling systems will be Fabricated & Fit-up
will be done on the Pad Plate of the Tank. The same will be erected by Segments on
the every Tank Shell Course after completion.

Nozzles:
Roof Nozzles will be installed parallel to Tank Shell Construction. Location of
Nozzles will be marked over the Roof Plates & checked before cutting. Sleeves on
Roof will be installed along with Reinforcing Pads & Sleeves prior to Installation of
the Nozzles. Elevation of the Nozzles above Roof & Nozzle to Sleeve Gap will be
maintained as per the respective drawings attachments. Shell Nozzles shall be
installed after Tank Shell Construction. To facilitate Nozzle Installation Works, Tank
Shells will have Construction Opening. Adjacent to the Construction Opening,
Stiffeners will be provided. After Installation of the Nozzles, After Welding &
required NDT, the Tank Shell Opening will be closed.
 Anchor Bolts Attachment:

All welding & NDT activities shall be completed prior to Hydro Test. Anchor Chair will
be welded to the Shell plate after hand tightness required finally check then fill the water
stage wise.

Hydro Test of the Tank:

A Separate Procedure for Hydro-test of the Tank will be submitted.

Top levels of the Foundation will be monitored at least at 8 Equidistance Points,

periodically to check for any differential settlement or uniform settlement of
substantial magnitude. Verticality of the Tank shall also be checked at regular
intervals during Water Filling by suitable method. Limits for Differential
Settlements shall be based on maximum permissible deviation of verticality of the
Tank. Limits for Uniform Settlement of Substantial Magnitude shall be as per
Paramount/Jacobs Instructions. In case of any such Undue Settlement, Water Filling
shall be stopped.

Test Water Quality shall open during filling. After filling water up to Maximum
Design Liquid Level. Tank Shell Weld Seams shall be visually inspected for any
possible leakages. In case of any leaks, Water Level shall be lowered to suitable
elevation and the Weld Seam shall be repaired and NDT (Radiography) shall be
completed for the repair. Testing shall then be continued by filling water once again
to Maximum Design Liquid Level. After Satisfactory Inspection of the Shell Weld
Seams & Foundation Settlement Check, all the Roof Nozzles will be closed.

The Tank shall then be Draining of Test Water through Shell Nozzle in a Controlled
Manner. The Tank will be held in Vacuum Condition for requisite time to check the
stability. Vacuum Test shall be conducted with a Vacuum Breaker Arrangement.
Roof Nozzles shall be opened on Completion of Vacuum Test. The Test Water shall
then be drained from the Tank. After Draining, Sediments etc. will be removed
physically and the tank will be cleaned & dried.

Water filling shall be done at 25%, 50%, 75% 100% and kept the tank with load for
24 hrs for each percentage and the settlements of base slab of the tank shall be
carefully monitored. Survey shall be carried out at every 2.5m height of filling &
emptying of the tank. Differential settlement or uniform settlement of substantial
magnitude requires an immediate stop of Water Filling. During Water Filling, the
Weld Joints of the Tank shall be visually inspected from Annular Space for any
leakage & mechanical damage when the water has been filled to the Testing Level,
the Tank Foundation shall be inspected for settlement. After Completion of the
Water Filling & Settlement of the Tank, All Shell Joints up to Test Water Level shall
be checked for leakage by Visual Inspection. If any leakage found, the Water Level
will be reduced to that suitable height below the Defect Location and the defect will
be repaired, all necessary NDT’s will be carried out and the Hydro-test shall be re-
hydro tested. And the calibration of the tank shall be done by the approved agency
and report to be submitted.

Fixing of Safety Valves with Isolation Valves & Vent Stack if any:
 Vent Stack will be carried on as per the Approved Drawings and as per the
manufacturer’s recommendations.

Final Painting of Tank outside/inside:

The Outer and inner Surfaces of the Tank shall be painted as per approved Painting
Procedure after the mechanical Completion of the tank including NDT.