GONTRACT NO.

RH PetroGas TANK D101-1

REPAIR AND CLEANING SERVICES PBL-2017 -056

DOGUMENT NO.

clGArRe 003/P RO D/P roced ure IGKP I 2017

17 Sheets

FABRICATION & ERECTION PROCEDURE

c
A

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C 13t11t2017 lssued for Approval &/ttt @,
B 02t11t2017 lssued for Review \

A 22t0812017 lssued for Review

SGO YS DAB Approved Approved

Rev. Date Description
PT. GATRA KILANG PERSADA PETROGAS PETROGAS
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RH P+ r rc:C.r., I TANK D101-1 REPAIR AND cLEANING

-oT I SERVTcES AGATRA
PBL-2017-0s6

TABULATION OF REVISED SHEETS

REVISIONS REVISIONS
SHEET SHEET ?
A B C 0 1 2 3 4 A B C 0 1 2 4
I x 41
2 X 42
3 X x 43
4 X 44
5 X X 45
b X 46
7 X X 47
8 X X 48
I X X X 49
10 X 50
11 X X X 51
12 X 52
'13 X 53
14 X 54
15 X X 55
tn X 56
17 X X x 57
18 58
19 5g
20 60
21 61
22 62
23 63
24 64
25 65
26 66
27 67
28 68
29 69
30 70
31 71
32 72
33 73
34 74
35 75
36 76
37 77
38 78
39 79
40 80
 FABRICATION & ERECTION
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I rlux D101-1 REPAIR

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HH PetroGas AND cLEANING

SERVICES AGATRA
PBL-2017-056

1, OBJECTIVE

This working procedure is working procedures to carry out "Repair Work of Tank
D101 - 1 PETROGAS SOROiTG, dia. 60.960mm x H 17.069mm, Single floating
roof. and this procedures as a guidelines for the involved in carrying out this work.

2. SPESIFIKASI TEKNIK
l Tank lnside Diameter 60.960 mm
l Tank Height 17.069 mm
l Type Single Floating Roof
f Capacity 313,000 BBL
l Seruice Crude Oil

3. WORK METHODOLOGY
Work implementation began with the demolition of the old seal that the roof will be
replaced with a new seal
Followed by replacement work for annular plate, and replacing some of the old
bottom plate with the new plate with cut menthod / on Gouging. Furthermore the
bottom plate of the old and new ones can be removed and inserted through the tank
dheel plate . to avoid buckling, then added a stiffener to the sheel plate surronding the
hole to maintain tank roughness and tank plumbness.
Repair pontoon and deck plate with overlay plate that experienced thinning /
corrosion evenly on the implementation carried out in accordance with marking by
petrogas engineering stationery, as well as replacement of some of its accesories
includes two main phases, namely the process of dismantling the parts that were
damaged deck plate support parts in accordance with inspection and repair healing
pontoon positions.
Fixing shell plate course 1 until course 5 and wind girder that having pitting
corrosion by filling with weld on the plate and shell and at time of its implementation in
accordance with the marking made by the PETROGAS Stationery Engineering
inspector.
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M7 RH Peirof:;tl TANK D101.1 REPAIR AND CLEANING
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SERVICES AGATRA
PBL-2017-056

Accessories Replacement that damage and nozzle repair along with other tank
accessories.
Responsibility of this work implementation start from the procurement of all the
equpment and material meedes, technical administration preparation and engineering,
and jack lifts up work for thanks, other parts that broken. And also including the inside
of labor supply, supervision, equipment supply and contruction equipment supply..

4. WORKING PREPARATION
f Making Meet Direction
o Preparing when enter the refinery for all vehicles and employees, hot work permits
and cold work permits
Water supply for work, lighting, security Fencing and Securi$ Officier, as well as
other things that needed to smooth the work
Make The Material Storage either open or closed in such a way so as to protect
the materials from damage and loss
Provide Waterpass and theodolites for the purpose of setting out, checking and
other purposes measurements
tr Open Bundwall for temporary roads access to the tank area
tr Work began after the tank cleaning process completed
D Preparing and check in the condition of the tank
D Make notes as necessary based on the founded conditions
D Ensure that the tank had been declared gas free and feasible to implement hot
work (working fire)
Remove appurtunance tanks and other equipment, and create reference points for
placed the jack-up position outside the tank shell plate for mounting the jack up
and support the lifting.
Planning working drawings (shop drawings) and schedules (work schedule), lTP,
JSA, other data conformed to API 650/653, submitted to PETROGAS for approval
before work begins.
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5. STANDARD CODE USED IS UPON :

tr API STD.650 American Petroleum lnstitute Standard 650

tr API STD.653 American Petroleum lnstitute Standard 653
tr ASME ll Part A American society of Mechanical Engineering ll Part A
tr ASME lX American society of Mechanical Engineering lX
D AWS D1.1 American Welding Society D1.1
0 ACI American Concrete lnstitution
D PBI-71 Peraturan Beton lndonesia
tr ANSI American National Standard lnstitute
tr NFPA National Fire Protection Association
tr Other Standardlcode approved by Petrogas.
o Above Standard are mutually complementary, and if there is a conflict then
the standard taken is determined by Petrogas.

6. WORKING PROCEDURE
tr FABRIGATION METHOD
Checkin / inspection of the materials with which it used to work for cleaning, repair and
painting of tank D101-1, whether the material is in accordance with predetermined
snecifications by Petrogas, and also check the material certificate of each material.
!
After examination and verification of completed material and the minutes of the
examination has been made and has been signed by both parties inspector, the fabrication
work is to begin.
Fabrication work begins by first making measurements or making on materials that will
cut on the material plate, pipe and other materials in accordance with pictures by
PETROGAS or shop drawings which have been approved by Petrogas and transporting
the material that has been fabricated into the tank area D101 - 1 .

a
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o BOTTOM / ANNULAR PLATE FABRICATION

Annular Plate
Preparations were carried out is to prepare two pieces of plate 5/13'x 6'x 20' laid on a
plat area to be measured dimensions, as well as in marking to set the dimensions to
suit the working drawings.
Annular side that categorized straight and do not need to be cut but will be made as a
side overlap to the bottom plate connection.
After marking the second, the plate overlap drafted to ensure that the dimensions
have really fit including the overlapping material, marking the line using iron chalk for
each angle to be coded V or X, and if necessary implemented peniting stamp.

o
= r_rtier
trt F,;.J! ]_

Drawing. 1

Perform cutting using a cutting machine. Note that the cuts must be precise
to follow the line marking set.

fIlr !i -

Drawing.2
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RH Pi:iroG;,:.
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The annular thickness was 5113" the followed with forcing implementation
using the bevel machine or with a grinding machines to from a weld seam, which the
shape and angle follow the work drawings.
Former side cuts cleaned with a wire brush or knife plate and if the surface is very
hard, use a grinding machine.
The first annular dimensions were measured again to ensure that the
measures are in accordance with the working drawings, because the first annular plate

o use as a guide or a mall to the other annular.

To ensure that the entire annular has a correct assembling implementation,
then the annular is setting quarter part minimum of the entire annular.
The competed annular is marked or stamped following the working drawing code.
Backing strip is marking accordingly with the dimensions on working
drawings, and ensured that the length t '10 mm wider than the annular plate. Backing
strip is cut using a cutting machine following the line marking that has been made.
Sharp edges from the cutting cleaned with grinding machine.
On one side of each annular plate in fit-up with the backing strip and
continued with the spot welding. Distance spot t 150 mm and spot length t 50 mm.

Drawing.3

Make a visual statement annular dimension is implemented and compiled

intoaQA/QC.
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RH PC-:iTOG;I: I TANK D101.1 REPAIR AND CLEANING

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g6ArRA
PBL-2017-056

. Bottom Plate
Bottom plate 5/16" x 6'x20'can be prepared in a wide area in the workshop.
Ptates were connected to a lap joint form and then done tack weld a while.
Marking the edge of the plate so that the bottom plate composition of thr tank
shape in a circle as shown in the shop drawings.
During the marking ensure that the highest overlap side completely straight,
one side of the straight plate is the early part of marking, thus formed into

rectangular and the edge made into corners.

Plate which has been completely marking will cut using a cutting machine.
Then performed a large bottom diameter fabrication and symmetrical lay-out
planning.
Bottom plate 5/16" x 6' x 20' compiled % or Yz portion of the bottom circle and
connected to form a lap joint then performed tack weld a while.
Marking the edge of the plate so that the bottom plate composition formed a
tank circle as in the shop drawings.
Whereas, plate % or Tz the remaining parts that are made symmetrical
also arranged Yo or Yz porlion with annular (if annular available on the picture) for
marking.

o Plate which has been completely marking has to be cut using a cutting
machine. Fabrication of large diameter bottom and lay-out plan not symmetrical,
bottom plate that has not been cut deliver to the site based on needs. The bottom
plate arranged above the surface of the foundation.
Marking the edge of the plate into a tank circle shaped and cut that on the
site. There is a view to be considered, length of the lap joint between bottom plate
and bottom plate is 25 mm minimum.

Drawing.4
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RH Prtr:oG;:t I rANKD101-1 REPAIRANDGLEANING

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Length of the lap joint between the bottom plate and annular plate is 60 mm minimum.

Drawing.5

Bottom edge of the finished cut, tackweld temporarily removed. After weld
permanent for plated. Shall be NDE MT/PT and Vacum test to be [Link]
sheet of the cutted bottom plate are given the erection mark to facilitate the erection
covering (No Tank and Bottom Code).

OUTER RIM, INNER RIM AND FOAM DAM PLATE FABRICATION

Make the cut pattern and measure the outer rim, and the rim foam dam plate. Plate
prepared on a flat place, marking carried out in accordance with the dimensions of
working drawings.

o During marking the straight elongated side nor the widened, if surface is really flat
then it will become the maintained side whereas the other side becomes the cutting
side to adjust the dimension and the side of forming bevel.

Drawing.6

When marking is finished, then perform cut using cutting machine and to the part
which is cut following the marking line.
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TANK D101-1 REPAIR AND cLEANING
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GATRA
PBL-2017-056

The outcome of cuts plate be checked the length, width, diagonal and angle of
its corners in order to ensure the size, whereas the tolerance which recommended
such as in the following table.

Drawing. T

Created a mal with a length of 1000 mm and rolled into a curved form that
appropriate with the circle diameter.
Making mal of wood or of other suitable material, with a minimum length of 1000
mm and a radius is according to the radius of the inner part of the tank. Mal is intended to
guide the implementation of the rolling.

Drawing.8

Plate was cut, rolled using a rolling machine. The entire plate that rolled, to be test the
curvature using the mal as shown below.
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tm:
Drawing.9

The maximum tolerance is 4 mm on tne nght edge and on the left edge also from the
bottom. Once completed, the entire plate is given the erection mark in the form of signs
,no numoers
J
o DEGK PLATE AND WIND GIRDER FABRICATION
Deck & wind Girder plate shall be inspected to visual and measurement of
thickness : if any shell identificated thickness is below minimal thickness shall be
replaced.
Makes marking and cutting plate for overlay plate and insert pontoon plate, deck
plate and wind girders with plate 6 mm x 1829 mm x 6096 mm according to the size of
pontoon and deck plate that will be improved. Creating and marking the pipe for deck
support as much as tank D101-1 needs.

(D . AccESSoRtES FABRtcArtoN
Accessories part on the tank generally are roof drain, foam line and fire water line,
Tank Heater, pipe steam supply and pipe condensate return, valve, mixer, gauge pole,
bridge crossing, counter weight, Drain pot, manhole, and tank accessories, accessories
parts fabricated as per drawing work, the main concern is the type, shape, bolt holes
and connections.
For connection that possibly adjust with actual condition then implemented on
erection, which when fabrication should be given extra tolerances.
After complete the fabrication erection mark awarded in the firm if signs and
numbers that covers (Tank Number and Accessories Code).
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TANK Dl01-1 REPAIR AND CLEANING
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o PAINTING AND SANDBLASTING

Material that has been completed in fabrication continued with the implementation
of sandblasting and primary painting. Material shall be sandblating and primary painting
prror to KMT. lmplementation of the painting can be seen in the painting procedure.

SHELL PLATE WITH ANNULAR PLATE INSTALLATION WORK

r Check roundness to position 00-1800, 45o -2250,90o-270o, 1350-3150, ensure that
the tank diameter is fixed round.
I Create a diameter size in the tank of the annular plate using the arc-term and the
wax chalk then drip it so that the size is not vanish
I Make a reference line t 100 mm from the diameter line inside the tank that has
been made firsts and will be use later on to check the shell plate position that will be
fit up to the annular plate so that won't deviate from its tank diameter size
I Perform joint inspection prior to welding between the shell plate with the annular
r Perform welding the bottom plate in the center of the tank
r Perform vacuum testing of the bottom to the bottom of the last welded bottom plate
and between the annular plate with the shell plate using a vacuum box corner.

FLOATING ROOF WORK

TEMPORARY SUPPORT MAKING
r Measuring, cutting and setting the WF iron. 200 which will be used to supporl
triangular pontoon as many as 44 pieces (Sketch-1) attached to the tank wall
supporl each mounted at a distance of 6 meters around each tank under the
pontoon.
WF 2OO

SKETCH -1 TYPICAL TEMPORARY SUPPORT PONTOON

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HH p I rnrur D1o1-1 REeAIR AND cLEANING

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PBL-2017-056

l UNP. 125 will be use for support under the deck plate which has improved.
l lnstall temporary support triangle WF.200 every 6 feet on the tank wall to hold
the pontoon, before conduct the support installation prior to lift the pontoon
which decreased by using a jack-up cap. 30 tons to achieve the desired level.

Deck plate

iiii
SKETCH - 2
TRIANGLE SUPPORT I NSTALLATION ORIENTATION

lnstall temporary pipe support to hold the deck plate that experience buckling,
before installing temporary pipe support on deck plate, first thing is to perform
lifting using a jack-up cap. 30 tons to achieve the desired height elevation.
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flH Petrqc:qs I [Link] D101-1 REPAIR AND cLEANING

SERVICES OGATRA
PBL-2017-056

Pontoon

Support Jack up H.1 50

SKETCH - 3
D After checking on the pontoon and deck plate leveling according to the desired
height, then the inspection work on the parts mentioned above is to determine
which part need to be replaced with new material can be done.
The repair
area as
directed by
Petrogas
The repair area as
directed by
Petrogas

The repair area as

directed
Petrogas

The repair area as

directed by
Petrogas

sKETcH - 4 the marking olilont"rion to be replaced

tr Perform inspection to the area that experience damaged.

tr Perform marking to the area that experience damaged and need to be replace.
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PBL-2017-056

PONTOON, FOAM DAM, ROOF DECK, TOP OUTER RIM, AUTOMATIC BLEEDER
VENT AND ROOF SUPPORT INSTALLATION WORK.
tr Perform repositioning pontoon parts to exact positions using the sliding method, by
way of raising the pontoon elevation, in a way
jack using the jack cap. 30 ton (acking up), until the elevated position of pontoon
post (free) + 2 "above the bottom, then installed temporary support is in the drawing
sketch -1.
tr Slide the pontoon position towards the shell plate, so that the distance of the outer
pontoon (outer rim) to the shell plate appropriate with the existing drawing, using
the chain block cap. 5 tons of the number as needed, previously prepared an
additional amplifier on the shell plate where the hook chain block so that the shell
does not deformation.
tr Once completed with the pontoon reposition then performed pontoon parts repair
and roof decks including roof manhole that had pitting corrosion with fill up and weld
the plate that experienced of pitting corrosion.
tr lnsert patch plate pontoon and single deck that experiencing thinning / corrosion
evenly with 6096 x1829 x 5 mm thick plate SA-283 Gr.C.
tr Overlay plate that experience thinning / corrosion evenly with 6096 x 1829 x 6 mm
thick plate SA-283 Gr.C. on the pontoon and single deck
O
f, lmproving healing pontoon until the slope recommended by Petrogas Stationary
Engineering to dismantle the inner rim plate then put back.
I Adding foam dam height to adjustment the roof seal height with 6096 x 1829 x 6
mm thick plate SA-283 [Link] foam dam height added as a vendors roof seal
direction.
tr Replacing the foam dam that seriously corroted with 6096 x 1829 x 6 mm thick plate
SA-283 Gr.C
D Cleaning foam slug that had accumulated between the dam and the roof seals.
tr Replace the Automatic Bleeder Vent (for a service matter, without the material
replacement)
tr Replacing the entire roof tank support as many as 221 tanks set in accordance with
the drawings (Ref. 477809-4-010'1/K001-(7 1 8)-0 Dwg. No. 33 Rev.0 dan 477809-
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PBL-2017-056

4-0101-(719)-0 Dwg No. 34 Rev.0) or according with the condition in site (such as:
sleever, Pin dia.1 y4" Cotter pins dia. 1yo" , sin. Nut dia. 1 T+", sttpport, pad and
base plate.

ROOF SEAL REPLACEMENT WORK

tr Lift allthe Roof Seal raw material
tr Assembly the raw Roof Seal
u lnstall Roof Seal
tr Roof Seal installing according with Vendor Roof Seal guidance or Supervisor of
PETROGAS.
tr lnstallation should be able to adjust to the conditions of the roundness of the tank at
the time of installation untuil the roof seals tightly fixed to the tank wall and no
steam (vapor) hydrocarbon that comes out from under the roof tank.
tr Secondary seal elevation that mounted is maximum 50mm below the foam dam
elevation.
o lnstall grounding shunt to each maximum distance of 1 (one) meter that connects
the shell and floating roof tanks with shunt size width 2" thick minimum 0.03.
tr lnstalling must be under the expect supervision from manufacturer / Vendor Roof
seal.

ROOF DRAIN REPLACEMENT WORK

tr Old drain roof tank demolition.
tr lnstall / weld pipe support of rigid pipe and rigid pipe roof drain that has been
fabricated in accordance with the install drawing and must be under
supervision by the roof drain agen.
o Installing 3 (three) pcs of new roof drain must be under supervision by the
roof drain agent.

TANK ACCESSORIES INSTALLATION WORK AND OTHER WORK ;

tr Foam line and fire water line repair work

tr Repair of Manhole, Gauge pole, overpass, counter weight, drain pot and other
tank accessories.
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RH PEITOGAS I TANK D101.1 REPAIR AND CLEANING

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PBL-2017-056

SHELL PLATE COURSE I to COURSE 5 AND WIND GIRDER REPAIR WOF-K

tr Shell plate shall be inspected to visual and measurement of thickness : if any shell
identificated thickness is below minimal thickness shall be replaced. Spend by
welding the parts that have a corrosion pitting on the inside shell plate on course
o/o
#1 until course #5 with estimation 0,25 from the total course area #1 ( 0.8 meter
height from the annular plate ).
tr On course #5 replace t 0.5 % on the execution based on the marking done by
inspector of Stationary Engineering PETROGAS.
Spend by welding the parts that have a corrosion pitting on the wind Girder
(including its support) with estimation as big as 1o/o from spacious area on the
execution based on the marking done by inspector of Stationary Engineering
PETROGAS.
lnsert patch plate Wind Girder experiencing thinning / corrosion evenly with 5/16 x
6' x 20' thick plates SA-283 Gr.C. taken 100o/o from total spacious wind girder
when on the execution based on the marking done by inspector of Stationary
Engineering PETROGAS.
Overlay plate Wind Girder experiencing thinning / corrosion evenly with 5/16 x 6' x
20'thick plates SA-283 Gr.C. when on the execution based on the marking done by
inspector of Stationary Engineering PETROGAS for the forecasts calculation taken
5% of the total area of plate corner radius is 2 "and refers to the API Standard 653
item 7.3.
Wind girder support modification by adding the base plate at the welds connection
support to the tank shell base plate size 150 X 150 X 5 mm or according to the
instructions of PETROGAS.
NDE shall be performed to shell plate replaced & NDE (RT, MT/PT) to dedicated as
per API 653