TANK ERECTION METHOD STATEMENT FOR MOT OIL STORAGE TANKS

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TANK ERECTION METHOD STATEMENT FOR MOT OIL STORAGETANKS 1.0 SCOPE:This
document is created by M/s Exterran - Belleli S.p.A to provide detailed method
statementand 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-42.2 Tanks General Layout2.3 Tanks General Arrangement and
Related Drawings1) C003-24-84-33-3600-001: GA for Tank 1501/1502/1506/15072)
C003-24-84-33-3600-002: GA for Tank 1503/1504/15082.4 Project Scope of work 2.5
Specification Tank Specification Doc. No. 30-50-32-06062.6 Data Sheet For Crude
Oil Storage Tanks MOT Fujairah Doc. No. 24-84-34-16032.7 Inspection Test
Plan,C003-30-99-93-3601 Rev.0 & C003-30-99-93-3602 Rev.03.0 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 Basket4.0 PREFABRICATIONAll plates when
received will be color coded and staked in storage yard. Plates will beinspected
and recorded in a form ³Material 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 byBELLELI rolling machine. Shell plates for Habshan site
tanks will be rolled in Fujairah andtransported to Habshan.4.4 Surface
preparation and Primer paint application of the prefabricated componentsas
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
PROCEDUREErection 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 anunderground 4´
pipe, coming out in the center of the foundation, to be used as a sleeve for
thepower cable inside the tank (ref. Fig. 11). The protruding portion of pipe
will be approx. 2.5 m highand 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 plates5.2.1 Before handing-over foundation shall be jointly checked
by Belleli and Civilcontractor as per civil drawing provided by CPECC and
elevation differences shall be within thetolerances 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 foundationarea 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 providedby CPECC for all tanks.5.2.4. Bench mark with X, Y, Z
coordinates shall be provided by CPECC5.2.5. 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 linein 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 overlapshall 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 thelong seams
shall be welded from center going outwards to the periphery5.2.13. After fit-up,
approx 350 mm of two segment joint from the outside to inner shall bewelded
first. Joints will be back stripped as per drawing.5.2.14. For method to control
/ prevent distortion in joints while welding5.2.14.1For method to control /
prevent distortion in joints while welding5.2.14.1.1 Fit up of joint using
Chicago plate as shown in fig no. 3 checking the alignmentusing
temp-plates.5.2.14.1.2 After joint fit up, every vertical joints welding will be
done one ³Yes´ and one ³No´alternatively.5.2.14.1.3 Root pass welding will be
done by back step method. Vertical joints will bedivided into 4 parts as shown
in fig no.12. Welding will start in the first section (75cm) from downto
top.5.2.14.1.4 At completion of first section, the second section will be
started with same uphillmethod.
5.2.14.1.5 Similar method will be used for 3rd and 4th section. The above root
pass sequencewill 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 doneon the other side.5.2.14.2.4 This joint welding process
will be done from inside and outsidetank 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 above20 mm and for thickness less than 20 mm, filling can be
done completed in one side and then theother side.5.2.14.3. Horizontal joint - (
Figure No.14)The sequence of welding will be same like vertical joint and will
be as below5.2.14.3.1 After the joint fit up, the root pas will be done always
by Back step method withenough 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 thetank.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 outsideuntil 25% of
the welding surface.5.2.14.3.5 This joint welding process will be done from
inside and outside tank alternativelyuntil full welding of the joint.5.2.14.3.6.
The above sequence of filling will be adopted only for shell plate thickness
above20 mm and for thickness less than 20 mm, filling can be done completed in
one side and then theother side.5.2.14.15. Alternate welding sequence shall be
followed in welding annular plate segments toavoid 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 torest after acceptance of radiographic test.5.2.14.18.
Balance welding of the annular joints shall be done before connecting the
weldedbottom 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
berecorded as per ITP.5.3 Erection of Shell course5.3.1Mark 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 beremoved 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 verticality5.3.11 Fit-up 1st course with annular
5.3.12 Internal welding5.3.13 Leak test5.3.14 Permanent fabricated wind girders
will be used as temporary working platform to erectthe 2nd to 8th shell
course.5.3.15 Install temporary working platform on upper side of the 1st shell
course usingtemporary 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 bewelded, as they will be removed for entering inside the tank,
until completion of the internalfloating 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 joints5.3.20
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 8thcourse5.3.25 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
thetop wind-girder on the final position of the shell 8th course. Proper care
shall be taken to avoiddistortion during welding.5.3.27 Install and fit-up the
top curb angle5. 3.28 Weld curb-angle5.4 Erection method of shell course5.4.1.
Shell courses are erected one upon the other using temporary
stiffenersconnecting 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 bewelded on the top side portion of the base course, both sides
from course 2 ÷ 7 andonly 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 inFig. 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 annulareplate and
fixed with stoppers. It will be supported from inside by steel members welded to
bottomplate.
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 verticalfixture 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-4891-00-0015.4.11 After welding and QC check is completed,
bracket for bearing temporary wind girdersshall 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 shellcourse.
Temporary platform holding brackets shall be welded in Shell plates as shown in
Fig. 45.4.13 A ladder shall be attached to Winder girder with support welded to
Shell as shown inFig. 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 inhorizontal joint as shown in Fig.
4.5.4.15 Second course plate shall be lifted and kept in position upon the base
course. Secondcourse plates are anchored by driving the carrot pin in anchor
after locking with fixture as shown inFig. 2.5.4.16 Movable cage will be placed
upon the first plate of 2nd shell course for assistingerection 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 firstplate and locked with both horizontal and vertical
fixtures. Similar way all plates shall be erected in2nd ÷ 8th course.5.4.18 All
the temporary attachments like Eye Nuts, clamps etc will be removed bygrinding.
Excess weld metal will be flushed by grinding. If required build up will be done
and willbe ensured by Magnetic particle test (as per procedure
C003-30-9990-3603).5.5 Sequence of welding for shell course to annular
plateSequence 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 oilpenetrant 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 outside5.5.5 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 sketchplate5.5.8 MPI of internal / external shell to annular corner
joint.5.6 Erection of stair case5.6.1Pad location for the stair case support
shall be marked on the shell plates5.6.2 Pad shall be welded and appropriate QC
check to be done. Weep hole shall be providedon all pads.5.6.3 All stair-treads,
handrails must be bolted to stringer in segments up to the intermediatelanding
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 plusthe internal welding between 1st shell course and annular
plates, vacuum box test shall beconducted and cleared for internal float roof
assembly.5.7.2. Internal floating Roof lower deck plates shall be laid and
welded in samesequence 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 andrafter.5.7.5 Complete welding of
vertical and all joints to the lower deck plates5.7.6 Welding of the compartment
of the floating deck shall be done starting from the oppositeside of the entry
ramp.5. 7.7 When total assembly and welding of the floating roof without roof
plates iscompleted, including sleeves supporting legs, all manholes and nozzles
of 1st shell course shall beclosed.5.7.8 Temporary ladder positioned in two
locations of the 2nd or 3rd shell course shall beprovided 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 tocomplete 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 willbe lifted up. Water shall be pumped
until the Float reaches the height allowing the insertion of thepins into the
legs.5.7.11 Check of the orientation of the Floating Roof. As per floating roof
lay-outdrawing.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 dam5.7.16 Installation of manholes, drainage, internal
piping, etc5.7.17 Installation of roller ladder 5.7.18 Primary shoe and seal
shall be installed after final hydrotest and internalpainting, as per supplier
instruction.6.0 FIGURESSK-4891-00-001 rev. 01: Shell and bottom welding
detailsFigure 01: Anchor welded to the shell platesFigure 02: Erection and
fit-up of shell courseFigure 03: Fixture for erection and fit-up of vertical
joint of shell courseFigure 04: Fixture of temporary bracket for wind girder
Figure 05: Bracing of the opening of the 2nd or 3rd shell course during floating
roof assemblyFigure 06: Transportation / Handling of rolled shell course
platesFigure 07: Handling / Installation of bottom platesFigure 08: Handling /
Installation of the shell course platesFigure 09: Installation of ladder to
access the wind girder Figure 10: Access with double ladder during floating roof
assembly completion / floatingFigure 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.

TANK ERECTION METHOD STATEMENT FOR MOT OIL STORAGE TANKS

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