Doc.

No

METHOD STATEMENT FOR BOTTOM

PLATE REPLACEMENT

600-500Z-1827

Revision No

Revision Date

May. 31. 2011

Page

1 of 9

METHOD FOR REPLACEMENT

THE BOTTOM PLATE WITH NEW ONE.
Project Title: Saudi Kayan Amine Project
Project Number: SC-2157
Requisition Description: FIELD FABRICATED TANK
Requisition Number: MFB120
Item Description: Item Number: ALL ITEM
APPROVED WITH COMMENTS
REVIEWED
RESUBMIT

THIS APPROVAL OR REVIEW DOES NOT RELIEVE THE

VENDOR/SUBCONTRACTOR OF HIS RESPONSIBILITIES
TO MEET ALL OF THE SPECIFIED REQUIREMENTS OF
THE PURCHASE ORDER

SIGN
DATE

ORIGINATOR
CHECKED

CTCI Overseas Corp. Ltd

APPD(PR)

31-05-10

ISSUED FOR APPROVAL

AM.S

AMM

Y.S.LEE

REV.

DATE

DESCRIPTION

MADE BY

CHECKED BY

APPROVED BY

WINTECO CORPORATION
SEOUL, KOREA

CTCI Overseas Corp. Ltd

TAIPAI, TAIWAN
SAUDI KAYAN PETROCHEMICAL COMPANY
AL-JUBAIL, SAUDI ARABIA

Doc. No

METHOD STATEMENT FOR BOTTOM

PLATE REPLACEMENT

600-500Z-1827

Revision No

Revision Date

May. 31. 2011

Page

2 of 9

TABLE OF CONTENTS
1. SCOPE

..3
2. REFERENCE CODES AND
STANDARDS.3
3. Work PROCEDURE
SEQUENCE...3
4. WORK SEQUENCE DETAIL...
6
5. Figure for Welding Sequence...
7

6. Figure for Jacking detail...

8

Doc. No

METHOD STATEMENT FOR BOTTOM

PLATE REPLACEMENT

600-500Z-1827

Revision No

Revision Date

May. 31. 2011

Page

3 of 9

1. SCOPE
1.1This Method is intended to Replace the bottom plate of the tank, for those
tanks in which pitting have been observed after the hydrostatic test conducted
in the site.

1.2

This Method is for the following tanks :

Tag No.

Service

TK-68007

DIETHANOLAMIN
E TANK

Size (m)
DxH
13900X1390
0

Operating Temp. Operating Pressure

(C)
(mbarg)
50
10

2. REFERENCE CODES & STANDARDS

2.1API 650 Welded Tanks for Oil Storage
2.2API 653 Tank Inspection, Repair, Alteration and Reconstruction
2.3API 575 API Recommended Practice.
2.4Q03-T01 Engineering Standard
2.5Tank Mechanical Specification Drawings
3. Work Sequence (Replacement of Bottom Plate).
1.
Mark the centre point and degree of orientation on shell plate as per approved
drawing.
2.
At first course install the Stopper outside the shell plate for the jacking system
which provides the easy access way to remove and install the Bottom plate.
3.
Installing the jacking Supports on the external shell all around the tank at
equal interval which maintains equal distribution of Tank load.

Doc. No

METHOD STATEMENT FOR BOTTOM

PLATE REPLACEMENT

600-500Z-1827

Revision No

Revision Date

May. 31. 2011

Page

4 of 9

4.
At the same location of Jacking support inside of tank fixing curvature
channel to maintain the roundness of Tank.
5.

After shifting of dimension start the cutting of old bottom one by one.

6.
First cutting the Close seam and then cutting Shell to bottom by means of
Plasma Cutter.
7.
Make sure that Shell to annular plates is completely free from weld joint
before replacement.
8.
Jack up the Shell plate at the same time with the help of same number of
operator.
9.

Localized Jacking (Maximum height between 50 to 60mm)

10. During jack up make sure that annular plate properly put down from shell
plate
11. After Jack up cut the bottom part of the anchor Chair as per sketch for the
welding of shell to Annular Plate.
12. Replace the Annular plate piece by piece until to complete the arrangement
and shall be arrange according to the radius that exceed the dimension of the
construction drawings to compensate for the welding shrinkage.
13. After cutting the first course annular plate side Edge to be smooth grinds and
should be clear from any crack.
14.

QC Personal is responsible to inspect after cutting and grinding.

15. Install the Temporary platform on the suitable opening location for shifting the
bottom plate inside the tank.
16. Before shifting the Material, Cutting one Anchor Bolt for the access of
material movement. (Due to Plate Width)
17. Lay down the bottom plate from outside toward the centre in principal as per
approved drawing
18. Plate to plate overlap in long seam and short seam shall be maintained as per
Drawing.
19.

After shifting plate to inside start the fit up Shell to annular Plate.

Doc. No

METHOD STATEMENT FOR BOTTOM

PLATE REPLACEMENT

600-500Z-1827

Revision No

Revision Date

May. 31. 2011

Page

5 of 9

20. During fitup shell to annular plate maintain the radius and avoid from any
sagging.
21. After fitup annular to annular weld the joint and perform the RT as per API
650.
22.

After accepting of RT result Start the Fitup of Shell to Annular Plate.

23. Before Jacking down, make sure that proper guider plate tacking inside and
outside on the annular plate which control the radius of Annular Plate.
24. Level, Roundness and Verticality of the shell plate to be checked prior to
Welding.
25.

Proper Care shell be taken to avoid distortion during welding.

26.
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
27.

After completing all the welding, the dimensions to be checked.

28. Inspection sequence will be followed according to joint completed and will be
recorded as per ITP
29.

Perform shell to bottom Liquid Penetrant test as per API 650 S.4.10.1.

30.

Conduct the vacuum Box as per approved Method statement 600-500Z-4432.

31.

Chemical cleaning to be carried out prior to Hydro TESTING.

32.

Hydro-test to be performed.

33.

On acceptance of hydro-test the procedure is complete.

34.

For detail follow the sequence of work.

Doc. No

METHOD STATEMENT FOR BOTTOM

PLATE REPLACEMENT

4. Work Sequence

Cutting the Old Bottom

Arrange Curvature channel
and Install jacking System

Cutting Shell to Annular

Plate

JACK UP the Tank

Remove and Transfer the
New Bottom Plate
Laying New bottom as per
Drawing

Fitup and Welding of

Annular Plate

RT OF Annular Plate

Jack down and Fitup

shell to Annular Plate
Follow below welding Sequence

Vacuum Box

Acid Cleaning

Hydro Testing

600-500Z-1827

Revision No

Revision Date

May. 31. 2011

Page

6 of 9

Doc. No

METHOD STATEMENT FOR BOTTOM

PLATE REPLACEMENT

4.1 General welding sequence is as follows :

1. ANNULAR BUTT JOINT

2. ANNULAR TO SHELL

6. ANNULAR TO BOTTOM

4. BOTTOM LONG

SEAM

3. BOTTOM SHORT SEAM

CLOSING SEAM

600-500Z-1827

Revision No

Revision Date

May. 31. 2011

Page

7 of 9

Doc. No

METHOD STATEMENT FOR BOTTOM

PLATE REPLACEMENT

FIG. 1

4.2 Jacking System Detail.

600-500Z-1827

Revision No

Revision Date

May. 31. 2011

Page

8 of 9

Doc. No

METHOD STATEMENT FOR BOTTOM

PLATE REPLACEMENT

FIG. 2

4.3 Anchor chair Rib Plate Modification

FIG-03

600-500Z-1827

Revision No

Revision Date

May. 31. 2011

Page

9 of 9