TANK ERECTION METHOD STATEMENT FOR MOT OIL STORAGE TANKS

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)

necessary for assembly and erection of Tanks are to be fabricated at Belleli Site.3 Rolling of Shell Plate and Nozzle Reinforcing Pads will be done at BELLELI site by BELLELI rolling machine.2 Clean out door shall be done in our Jebel Ali Workshop.0 ERECTION PROCEDURE Erection sequences of Tanks will be as follows: ·Laying of Annular plates ·Laying of Bottom plates · Erection of Shell Plates.. When required for erection. material will be transferred to the required location of the tanks. Foam pourer etc. Wind Girder and Top Curb-angle.1 Plates etc. Following are the main activities for prefabrication: 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 . 5.·Transformer ·Panel Boards ·Man Basket 4. 4.0 PREFABRICATION All plates when received will be color coded and staked in storage yard.0. see procedure PR-MAT-007 Rev. 4. 4. 4. Any sub-contract for fabrication deemed necessary will be awarded only to qualified fabricator. Plates will be inspected and recorded in a form ³Material Entry Note´.Still wells.4 Surface preparation and Primer paint application of the prefabricated components as required will be done at Site before or after the erection. ·Assembly and Installation of Internal Floating roof . Shell plates for Habshan site tanks will be rolled in Fujairah and transported to Habshan.

5. 5.·Erection of Structural and Appurtenances.2 Erection of annular and bottom plates 5. The protruding portion of pipe will be approx. All inspection will be done as per ITP. to be used as a sleeve for the power cable inside the tank (ref. coming out in the center of the foundation. 2. 11). Belleli will install an underground 4´ pipe.45 t capacity to enter inside the foundation area for handling and installation of bottom plates.2. · 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 .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. .2. Fig. C003-0399-93-3601 for MOT Fujairah and C003-03-9993-3602 for MPS Habshan.5 m high and will be removed before hydrotest.1 A ramp will be prepared to allow a crane 15 . 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.3 layers of foundation backfilling. floating roof plates and other materials.

2.All plates required for the tank bottom shall be loaded and brought inside the tank foundation through the ramp by boogie/trailer (ref. 5. 5.2. Joint shall be welded in proper sequence: first shall be welded the short seams.3 Root pass welding will be done by back step method. Y. Joints will be back stripped as per drawing.2.2. 15) 5. 5 and 6) 5.5. Removal of stoppers shall be carried out using cutting disk / grinders. 5.2. 5. 90.4 At completion of first section.9. the second section will be started with same uphill method. Bottom plate lap joints (shall be shingled to shell towards the drain.2.14.2. Plate to plate overlap in long seam and short seam shall be maintained as per drawing.2.2.2. 5. Welding will start in the first section (75cm) from down to top. 5. Vertical joints will be divided into 4 parts as shown in fig no. 5.4. after the long seams shall be welded from center going outwards to the periphery 5. Bench mark with X. Fig. Z coordinates shall be provided by CPECC 5.2 After joint fit up.13.1 Fit up of joint using Chicago plate as shown in fig no.1.11. minimum overlap shall be 25mm) are fitted together by placing the stoppers at appropriate spacing.2.Tank centre and 04 marking on outer diam.2. 3 checking the alignment using temp-plates. Underneath of both Bottom and Annular plates shall be painted as per procedure C00330-99-90-3625.7.1For method to control / prevent distortion in joints while welding 5. Further bottom plates shall be laid with slope down towards the tank periphery. 5.5.14. every vertical joints welding will be done one ³Yes´ and one ³No´ alternatively.12.14. after annular plates can be installed.1.2.14.8.14.14. 5.1.2.12. Bottom plate on the centre of the tanks shall be marked after installation with centre line in both axes. 5.3.2. approx 350 mm of two segment joint from the outside to inner shall be welded first.2.1. .2. 180 & 270 degree shall be provided by CPECC for all tanks. Bottom plates shall be removed from the boogie and laid on the foundation by crane (ref Fig no. After fit-up. For method to control / prevent distortion in joints while welding 5.10. at 0.6.

2. 5.18.13) 5. filling can be done completed in one side and then the other side.14. The above root pass sequence will be adopted for all vertical shell plate joints.3.3.17.14.( Figure No.3. then SAW welding can be done outside until 25% of the welding surface.14. 5.2.2.2. 5.2.15.4 This joint welding process will be done from inside and outside tank alternatively until full welding of the joint.2.14. SAW welding can be started for filling joints from inside the tank. 5.3 Filling will be done for 25% of weld surface from one side. Reinforcement weld on the annular plate shall be ground flush where the shell is to rest after acceptance of radiographic test. 5.14.16.2.6.5 Similar method will be used for 3rd and 4th section.2. Joints will be checked by radiography as per applicable standards from API 650.14. the root pas will be done always by Back step method with enough welders allotted all along.1.14.1 After the joint fit up.2.14) The sequence of welding will be same like vertical joint and will be as below 5. . 5.3.5.14.2.2.14. filling can be done completed in one side and then the other side. 5. 5. 5. ( Figure No.3.2. 5.3.14.14.14. 5.4 The filling inside can proceed up to 25%.2.3.2. 5. Horizontal joint .2. 5.5 The above sequence of filling will be adopted only for shell plate thickness above 20 mm and for thickness less than 20 mm.2Filling pass will start from the same side of the root pass. 2.14.14.14.2.14. Then 25% will be done on the other side.2 After the root pass. Alternate welding sequence shall be followed in welding annular plate segments to avoid distortion.5 This joint welding process will be done from inside and outside tank alternatively until full welding of the joint. equally divided circumferential joint.2.1 This will be done by uphill method starting from bottom of joint to the top.2.2. The above sequence of filling will be adopted only for shell plate thickness above 20 mm and for thickness less than 20 mm.2. 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.2. 5.14. grinding will be done in the joint from outside the tank.3 After the first SAW pass.

5. until completion of the internal floating roof works.3.3.7Check verticality of internal surface of shell course using plumb-bobs with proper dampening.17 Install second shell course plates and fit-up.3. 5.3. Inspection sequence will be followed according to joint completed and will be recorded as per ITP.3.14 Permanent fabricated wind girders will be used as temporary working platform to erect the 2nd to 8th shell course. 5.10 Check internal diameter and course verticality 5.2.16 Check elevation of 1st shell course.3.18 The 1st and the last plate of the 2nd shell course will be braced against wind with .14.3.3.3.9 Weld vertical joints of 1st course. 5.3.14.5. as they will be removed for entering inside the tank. 5.6 Backing support shall be given by welding steel members from inside the tank 5. No. 5.5 Erect Base course plates in position and tack weld the vertical joint.3.20.3 Erection of Shell course 5.3 Mark the axes on the annular plates. one plate matching with ramp will be removed for easy access to tank and position shall be marked in the annular with punching. 4). Fig.2.3. 5. 5. 5. 5.1Mark the base course position on the annular plates.3.2Mark the centre line of foundation on the Bottom Plates.19.3. 5. 5.3. 5. Vacuum box testing for all the joints shall be done.4 Install temporary stoppers.3.13 Leak test 5.3.11 Fit-up 1st course with annular 5. Check verticality / plumb-ness again.8 After installation of all the 1st course shell plates.12 Internal welding 5. 5. 2 plates in 2nd course shall not be welded.15 Install temporary working platform on upper side of the 1st shell course using temporary brackets (ref.3.

Fig. Fig.21 Check verticality.3 For vertical fit-up. 2) 5.3.25 After completion of circumferential welding between 6th & 7th shell courses. 5.22 Complete Radiography. 5) 5. both sides from course 2 ÷ 7 and only on the bottom for shell course 8. till top course 8th course 5.24 Continue with shell course erection in the same sequence as above.2.3.3. 1 and 3. 1 and 2) at equal distance shall be welded on the top side portion of the base course.27 Install and fit-up the top curb angle 5. install. Proper care shall be taken to avoid distortion during welding. It will be supported from inside by steel members welded to bottom plate. NDT etc.4. Temporary windgirder bracket holding clamps shall be welded to the shell plate. 4 anchors will be welded on both side of the plate as shown in Fig.5. 5.2. install and fit-up the top wind-girder on the final position of the shell 8th course.26 After welding intermediate wind-girder and the last shell course.3. Welding shall be in three sides only. 5. fit-up and weld the intermediate wind-girder on 7th shell course. Shell courses are erected one upon the other using temporary stiffeners connecting the courses and welded to the shell plates (ref.two1.3. 5.4. For horizontal fit-up. 5.23 Transfer temporary working platform on upper side of the shell course .4 Erection method of shell course 5.1. 5.3. .4.4. 5.3.4 Anchors are welded horizontally only in one side and vertically both sides.28 Weld curb-angle 5. 5.6 t tirforts (ref.6 First plate in the Base course will be lifted and kept in position as marked in the annulare plate and fixed with stoppers. 6 anchors (refer Fig. 5. no. no. removal of temporary attachments from vertical joints.4.3. dressing.3.20 Weld horizontal (circumferential) joint between 1st course and 2nd course.4. 3.19 Weld second course vertical joints 5. 5.

5.5.15 Second course plate shall be lifted and kept in position upon the base course. 4 5. 5. Similar way all plates shall be erected in 2nd ÷ 8th course.4.13 A ladder shall be attached to Winder girder with support welded to Shell as shown in Fig.4.10 For welding Horizontal and vertical joint. This plate will be locked with the first plate by driving carrot pin after locking with vertical fixture as given in Fig. 5. 5. 5.4.18 All the temporary attachments like Eye Nuts.7 Second plate in the base course shall be lifted and positioned on the marking of annular plates. 5 and 9.5 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 Leak test of internal welding with diesel/gasoline from outside 5.4.5.9 Alternate Vertical joints shall be welded.8In similar way.5 External side welding of shell to annular. 5. 5.1Welding of 1st shell course to annular plates from inside shall be done first.5. 5.4.12 Temporary winds Girder are erected upon the bracket and Tack welded to the shell course. Second course plates are anchored by driving the carrot pin in anchor after locking with fixture as shown in Fig.17 Second plate of the second course shall be lifted. bracket for bearing temporary wind girders shall be hooked in the fixture which was previously welded to the shell plate (ref. 3.4.5.(except clean out door assembly) 5. 5. 5. 5.5 Sequence of welding for shell course to annular plate Sequence of welding will be as follows: 5.4. 4.5.5.3 Completion of Internal side welding of shell to annular. 4) 5.4.2 The First pass of internal side of shell to annular weld shall be inspected 100% by oil penetrant test method . If required build up will be done and will be ensured by Magnetic particle test (as per procedure C003-30-9990-3603).4.4. kept upon the base course near the first plate and locked with both horizontal and vertical fixtures.14 4 . Excess weld metal will be flushed by grinding. . refer details in sketch SK-4891-00-001 5.4.4. all plates of base course shall be erected.11 After welding and QC check is completed. 2. clamps etc will be removed by grinding. fig.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. Temporary platform holding brackets shall be welded in Shell plates as shown in Fig.

7. leg supports and accessories. .3 Mark up on the lower deck plates. 5. the location of outer rim. 5. 7. 5.7 When total assembly and welding of the floating roof without roof plates is completed. Weep hole shall be provided on all pads.6 Erection of stair case 5.2 Pad shall be welded and appropriate QC check to be done.5 After welding of the lower segment. 5.1When half portion of the bottom plates are welded. Fig.6. intermediate rim plate.7. 5. 5.7. 5.6.4 Assembled lower segment of spiral stairway shall be lifted and installed.6.5.5 Complete welding of vertical and all joints to the lower deck plates 5. vacuum box test shall be conducted and cleared for internal float roof assembly. 5. handrails must be bolted to stringer in segments up to the intermediate landing platforms. 5.5. 5.8 MPI of internal / external shell to annular corner joint.4 Positioning.7 Assembly of Internal Floating Roof (Double Deck) 5. including sleeves supporting legs.6. center rim plate and rafter. all manholes and nozzles of 1st shell course shall be closed.6 Visual inspection of internal and external welding of shell to annular.5.6 Welding of the compartment of the floating deck shall be done starting from the opposite side of the entry ramp.6 MPI shall be carried out on all temporary attachment removal areas. 5. compartment plates. structures.6. 5.7. fit up and welding of outer rim. Internal floating Roof lower deck plates shall be laid and welded in same sequence of Bottom plates.7.2.3 All stair-treads.7.5.7. Intermediate rim.8 Temporary ladder positioned in two locations of the 2nd or 3rd shell course shall be provided to enter in the tank (ref. 10). Following the lower segment. first intermediate platform shall be erected. 5.6.1Pad location for the stair case support shall be marked on the shell plates 5.7 Fit-up and weld balance of the annular joints and weld annular to bottom sketch plate 5. including annular plates segment plus the internal welding between 1st shell course and annular plates. further portion shall be erected in similar way.

7. etc 5.7. drainage.7. .15 Installation of foam dam 5. 5.14 Installation of floating deck roof plates.7.11 Check of the orientation of the Floating Roof.12 Draining of the water 5.5.0 FIGURES SK-4891-00-001 rev.7.7. 5. 2nd and. 6.7.10 Sea Water shall be pumped inside the tank trough one nozzle and slowly float roof will be lifted up. internal piping. 3rd shell course will be done in steps.17 Installation of roller ladder 5. 5.7. 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. in order to complete at the same time the assembly of the floating roof (still without roof plates). 5.13 Tank shall be cleaned with high pressure water jet. in case.18 Primary shoe and seal shall be installed after final hydrotest and internal painting.16 Installation of manholes.7. 5.7. Water shall be pumped until the Float reaches the height allowing the insertion of the pins into the legs.9 Closing of the 1st. as per supplier instruction. As per floating roof lay-out drawing.

Figure 13: Vertical joint filling sequence. Figure 15: Bottom lay-out. Figure 14: Horizontal joint root pass sequence.Figure 12: Vertical joint root pass sequence. .

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