8/20/2019 Brazil CSP-Ball Tank Erection Manual

CONTENTS

1. GENERAL

2. RELATED DOCUMENTS

3. OVERALL SEQUENCE

4. FOUNDATION

5. ASSEMBLING OF TANK

6. WELDING SEQUENCE

7. INSPECTION

8. POST WELD HEAT TREATMENT, IF APPLIED

9. ASSEMBLING OF ACCESSORIES

10. HYDROSTATIC TEST

11. CLEANING AND PAINTING

12. FIRE PROOFING ON COLUMNS

13. WATER SPRAY PIPING TEST

 
http://slidepdf.com/reader/full/brazil-csp-ball-tank-erection-manual 1/18
8/20/2019 Brazil CSP-Ball Tank Erection Manual

1. GENERAL 

1.1 This procedure is applied to the field erection of the spherical tank for the following
articles.
1.2 Supplied for: RCC Off Gas to Propylene Project UP-VI Balonqan of PT. PERTAMINA
(PERSERO)
1.3 Items to be supplied

Item No. Q'ty Description

42-T-404 E/F/G/H 4 Propylene Storage Tanks

2. RELATED DOCUMENTS 

2.1 Applicable Code and Standards

 ASME Sec. VIII, Division 1, 2004 Ed. & including 2006 Add.
 ASME Sec. IX, 2004 Ed. & including 2006 Add.
 ASME Sec. V, 2004 Ed. & including 2006 Add.

2.2 Project Specifications

ROP-S-00-1351-001T-E-0
ROP-S-00-1351-002T-E-0
ROP-S-00-1351-003T-E-0
ROP-S-00-1354-301T-E-0
ROP-S-00-13A1 -001 T-E-0
ROP-S-00-13B4-001R-E-0
ROP-S-00-145-002R-E-1
General Specification for Pressure Vessels
Vessel Standards
General Specification for Equipment Welding
General Specification for Spherical Tank
General Specification for Painting
General Specification for Fireproofing for Static Equipment
Packing and Marking Instruction to Vendor

2.3 Related Procedures

VP-42-T-404-E-010 Latest Painting Procedure Specification
VP-42-T-404-E-011 Latest WPS with PQR (Shop)
VP-42-T-404-E-012 Latest WPS with PQR (Field)
VP-42-T-404-E-013 Latest Inspection & Test Procedure with Plan at (Shop)
VP-42-T-404-E-014 Latest Inspection & Test Procedure with Plan at (Field)
VP-42-T-404-E-015 Latest Non-Destructive Examination Procedure (Shop)
VP-42-T-404-E-016 Latest Non-Destructive Examination Procedure (Field)
VP-42-T-404-E-017 Latest PWHT Procedure (Field)
VP-42-T-404-E-018 Latest Hydrostatic Test Procedure (Field)
VP-42-T-404-E-019 Latest Packing & Marking Procedure
VP-42-T-404-E-020 Latest Fabrication Procedure

 
http://slidepdf.com/reader/full/brazil-csp-ball-tank-erection-manual 2/18
8/20/2019 Brazil CSP-Ball Tank Erection Manual

3. OVERALL SEQUENCE  

The plannedwith
accordance sequence of construction
the construction and and
schedule completion involves
approved the erection of spheres in
drawings.

Deliveries of materials are scheduled to satisfy the erection sequence, mobilization of facilities &
equipment and mobilization of manpower.

 
http://slidepdf.com/reader/full/brazil-csp-ball-tank-erection-manual 3/18
8/20/2019 Brazil CSP-Ball Tank Erection Manual

 
http://slidepdf.com/reader/full/brazil-csp-ball-tank-erection-manual 4/18
8/20/2019 Brazil CSP-Ball Tank Erection Manual

4. FOUNDATION 

The foundation shall be checked using an accurate instrument set on center of grade.
4.1 The following dimension typically marked A, B, C, D, E, F1 ~ Fn, and H as shown in Fig-1
shall be checked and adjusted as necessary prior to commencement of field erection.

4.2 Tank center point s hall be established on the ta nk foundation. The orientation of tank
foundation shall be subjected to the approved construction drawing.

0 

F1
F2
F3

F4
270 
D E 90 
F5
C H

 A B
G.L

180

 Anchor bolt Concrete base

Fig-1 Anchor Bolt & Orientation of Tank Foundation

4.3 Inspection

Before acceptance of foundation, inspection shall be made for the following items with
presence of Vendor/Subcontractor, Contractor's inspector. All dimensions shall be
checked against approved drawings and ensure that the standard tolerances are met. All
records shall be reported and reviewed by Contractor.

(1) Intervals between anchor bolts

(2) Measurement of the distances between individual column foundation centers
(between adjacent column, column diagonal distances)
(3) Measurement of foundation level
(4) Measurement of bolt projection length
(5) Check the mark of tank center line

4.4 Leveling of foundation surfaces

(1) On the foundation for supports, pipelines, and stairs, padding shall be made after

measuring
acceptance.the
Thelevel of foundation
foundation surfacessurface
shall bewith the presence
roughened, before of QC inspector
padding for
installation.
(2) Padding for support foundation shall be formed in such a way as shown in Fig-2 so as to
meet the tolerances.
(3) Grouting using non-shrinkage mortar between the foundation surface and base plate
 
http://slidepdf.com/reader/full/brazil-csp-ball-tank-erection-manual 5/18
8/20/2019 Brazil CSP-Ball Tank Erection Manual

shall be completed after PWHT and before the pressure test of tank.
(4) The difference in pad levels shall be within 2.0 mm.

SCALE
LEVEL

SCALE

 ANCHOR BOLT

LINER PLATE
TANK
CENTER
LINE

PAD

Fig. 2 Padding on Foundation Surface

4.5 Allowable tolerance of each dimension shall be in accordance with the specific Inspection
and Test Procedure with Plan at Field.

 
http://slidepdf.com/reader/full/brazil-csp-ball-tank-erection-manual 6/18
8/20/2019 Brazil CSP-Ball Tank Erection Manual

5. ASSEMBLING OF TANK

5.1 Typical erection sequence

& 
% 
' 

( 

! 

) 

# 
$ 

 

*  " 

* 

  Lower column
!  Equator plate with upper column and equator without column
"  Bracing (Note 2)
#  Lower ring plate
$  Bottom crown plate and pole plate
%  Upper ring plate
&  Top crown plate and pole plate (Note 1)
'  Stairway & platforms
(  Internal pipes & ladder
)  Water spray system
*   Accessories (nameplate, earth lugs, etc.)
+  Others
Note:
(1) For ventilation of inside welding fume and heat, one of crown plate may
open until completion of production welding of all shell joints, and then the
plate will be installed and welded to the final weld joint.
(2) When PWHT is required for assembled tank, the column-bracing pipe
shall be welded after PWHT.

5.2 Assembling of column

 
http://slidepdf.com/reader/full/brazil-csp-ball-tank-erection-manual 7/18
8/20/2019 Brazil CSP-Ball Tank Erection Manual

(1) Lower columns shall be assembled first.

The plumb of each column shall be checked as shown in Fig-4 and adjusted after
assembling of equator plates in the presence of QC inspector for acceptance

Plumb
Check Points

 
   0
   0  A
   2

Reference Mark
String with For Levelness Check
Plumb-Bob

B  
   0
 
   0    0
   0    5
   4
G.L

Fig-4 Plumb Check of Tank Column

(2) Allowable tolerances of plumb and levelness of each column shall be in accordance with
the Inspection & Test Procedure with Plan at Field.

1) After erection of each lower column, the top of lower column shall be level
within ! 3 mm in any one.

2) After erection of lower column and stress relieving the tank, the verticality of
each lower column shall not exceed 1/500 of the total length.

3) Sequence and installation notice, when applicable PWHT;

Before and during the Post Weld Heat Treatment (PWHT), following shall
be kept carefully.

- To provide sliding between base plates and sliding plate during PWHT,
grease shall be applied on the sliding plate before erection of lower column.

- Before PWHT, the bracing shall be released on thread parts or bracing

pipes.

- To adjusting within tolerance between low columns, temporary hydraulic

 jack or jigs shall be installed before PWHT performed.

- During PWHT, a distance between lower columns shall be adjusted with

tolerance according to the Inspection and Test Procedure at Field.

- Tack welding shall be done sliding plate to base plate.

- After checked by QC Inspector for a distance between lower columns after

 
http://slidepdf.com/reader/full/brazil-csp-ball-tank-erection-manual 8/18
8/20/2019 Brazil CSP-Ball Tank Erection Manual

PWHT, welding shall be done and removed temporary hydraulic jacks

and/or jigs.

5.3 Assembling of equator plate

(1) Typical assembling sequence

0  

16
14 3

15 2

12 5

90  
270   13 4

10 7

1 6
8 9

180  

Fig-5 Typical Assembling Sequence of Equator Plates

(2) Erection of equator plates

Wire Rope

Turn Buckle

Equator Plate

 Angle Stake or Concrete Block

Fig-6 Typical Guy-Wire for Equator Erection

 
http://slidepdf.com/reader/full/brazil-csp-ball-tank-erection-manual 9/18
8/20/2019 Brazil CSP-Ball Tank Erection Manual

1)  As shown in Fig-7, assemble each equator plate successively, and make surface aligned
tack welding shall be performed by qualified welder.

Wire Rope

G.L

Fig-7 Erection Schematic of Equator Plates

Note
(1) To adjust verticality of lower column and root gap between equator plates, the
bracing pipe should be installed after erection and fit-up of equator plates. (See Note 2
of 5.1)
(2) When rigging the shell plate to assembling each other, pulling rope should be used
to prevent rotation, and it shall be tied in with both sides of erection key-nuts on the
inside and outside surface of shell as shown in the above Fig-7.
(3) When available, equators may assemble and/or weld two plates between column shell
and non-column shell on the ground before erection.

2) The difference between maximum and minimum diameter "D" given as Fig-8 shall not
exceed 0.3% specified diameter in the approved construction drawing

D D" 

  G.L

http://slidepdf.com/reader/full/brazil-csp-ball-tank-erection-manual 10/18
8/20/2019 Brazil CSP-Ball Tank Erection Manual

Fig-8 Diameter Check

(3) Procedure for alignment

TAPER PIN

BALL PIN

KEY PLATE

KEY NUT

Fig-9 Temporary Assembly of Jigs Alignment

1) As shown in Fig-9, surface alignment of shell plates shall be

adjus ted using temporary jigs such as key-plates, key-nuts, wedge, etc.
2) Perform alignment from the plate center marks with each other, and
perform tack weld on the central portions only, in this way, assemble
tempora ry, assemble temporarily all of the plates.
3) After temporarily assembled plates, make surface alignment and tack
welding upward and downward starting from the plate center. (The
tolerances for the measurement of level in the surface alignment shall
comply with Inspection & Test Procedure with Plan at Field.
4) For tack welding of equator plates, as shown in Fig-10, about 500 mm in
length at top and bottom portions adjacent to the upper and lower ring
plates should be made surface alignment and tack welding after
temporary assembly of each crown plate.
5) Arc strike on the surface of the base metals shall not be permitted. The
proper non-destructive examination shall be applied on the area above
after rectification.

UPPER RING PLATE

500mm

EQUATOR PLATE

500mm

LOWER RING PLATE

 
http://slidepdf.com/reader/full/brazil-csp-ball-tank-erection-manual 11/18
8/20/2019 Brazil CSP-Ball Tank Erection Manual

Fig-10 Tack Welding on Equator Plates

(4) In fitting the plate, put the scaffold blanks, key-plates, etc., on the ground as shown in
Fig-11, when possible, and lift them together with plates.

Hand Rail

Scaffold Plate

Bracket

Fig-11 Typical Scaffolding

5.4 The lower ring or bottom crowns as shown in Fig-12 are supported by temporary jigs (key-
plate, key-nut, etc as per Fig-9) with tack welding during erection and the inclination in
adjusted with them.

Lower Ring

Pipe Support Level Block

For Ad ustment

Fig-12 Erection Schematic of Lower Ring or Bottom Crown Plates

 
http://slidepdf.com/reader/full/brazil-csp-ball-tank-erection-manual 12/18
8/20/2019 Brazil CSP-Ball Tank Erection Manual

5.5 Assembling of bottom crown plates

(1) As in the case of equator plates, attach each jig and make temporary assembly.
(2) Each bottom crown plate is installed and tack welded respectively in order  / !   and
then (3) as shown in Fig-13. The curvature of joint is checked with a curvature gauge as
per Inspection and Test Procedure with Plan at Field.
(3) Before the erection of the bottom crown, the roundness of the lower ring should be
checked by QC inspector and adjusted if it is necessary, refer to Inspection and Test
Procedure with Plan at Field.

CURVATURE GAUGE

  "  ! 

JACK

Fiq-13 Assembling of Bottom Crown Plates

5.6 Assembling of upper ring plate

The upper ring or top crown as shown in Fig-14 are supported by temporary jigs (key-plate,
key-nut, etc as per Fig-9) with tack welding during erection and the inclination in adjusted
with them.

Upper Ring

Fiq-14 Assembling of Upper Ring or Top Crown Plates

 
http://slidepdf.com/reader/full/brazil-csp-ball-tank-erection-manual 13/18
8/20/2019 Brazil CSP-Ball Tank Erection Manual

5.7 Assembling of top crown plates

(1) The top crown is erected after the roundness adjustment of the upper ring opening.
(2) The erection procedure is similar to the bottom crown.
(3) Mount the members after assembling the internal scaffold.
INSPECTION SCAFFOLD

INSIDE SCAFFOLD
BRACKETS

INSIDE OUTSIDE

Fig-15 Inspection Scaffolding

5.8 Erection jigs for shell plate

(1) Key plate and key nut
Shell plates are installed with key plates, key nuts and drift in. Key is set 4 pieces for a
vertical joint and 2 pieces for a horizontal joint.

a) Detail of key plate b) Detail of key nut

Fig-16 Detail of Key-plate and Key-nut

 
http://slidepdf.com/reader/full/brazil-csp-ball-tank-erection-manual 14/18
8/20/2019 Brazil CSP-Ball Tank Erection Manual

(2) A plate joint is adjusted plainly with suitable device (plain-dog) if it is uneven.
The
(withplain-dog
regardlessshall be Numbers).
Group the same P-Number material as the base metal of the tank
Qualified welder shall perform the attachment of plain-dog to base metal,
which is to adjusted alignment.
Not allowed to remove the plain-dog with hammering and the reminder on the
plates shall be applied non-destructive examination.

Wedge
Plain dog
Wedge Plain dog

Welding

Fiq-17 Detail of Plain-dog

(3) Strong back

Strong backs with the same P-Number material with regardless Group Number as the
base metal shall be used to reinforce the shell plate and to prevent the welding
distortion; two pieces of them are set for a plate on the horizontal joint.

For each shell-to-shell joint, key-plates will substitute for strong-backs if those shall not
be taken off until completion of one side of the production welding.

Strong back
Strong back Top crown
To be set
400 Upper ring on outside

Center ring
C=150mm 120
To be set
Lower ring
on inside
Welding
Bottom crown
40R

Fiq-18 Strong Back

(4) Typical Direction of Bracket Shoe

 
http://slidepdf.com/reader/full/brazil-csp-ball-tank-erection-manual 15/18
8/20/2019 Brazil CSP-Ball Tank Erection Manual

The bracket shoe for scaffolding should be set on ground prior to starting erection
for eachshoe
Bracket plate.are set as given in below;

Fiq-19 Typical Direction of Shoe

6. WELDING

Full welding shall be done with the approved welding procedure specification (WPS) and
qualified welder. Welding sequence shall be minimizes distortion and shrinkage. Welding repairs
shall be made using the same WPS that used for original production welding with approved
WPS.

 
http://slidepdf.com/reader/full/brazil-csp-ball-tank-erection-manual 16/18
8/20/2019 Brazil CSP-Ball Tank Erection Manual

6.1 Typical welding sequence

Fiq-20 Typical Welding Sequence

   Weld equator course radial joints

!  Weld column splices any time after equator course radial joints and before test.
"  Weld lower ring course radial joints
#  Weld upper ring course radial joints (It may weld with joint no. (3) at same time.
$  Weld lower and upper course radial joints
%  Weld girth joint joining equator to lower and upper courses
&  Weld girth joint joining ring courses to lower and upper course
'  Weld bottom head plates together
(  Weld girth joint joining bottom head plates to adjoining course
)  Weld top head plates together
*  Weld girth joint joining top head plates to adjoining course
+  Weld column-to-bracing pipe (See Note 2 of 5.1)

NOTE:
1) Perform welding on equator course vertical joint as soon as they are fitted. The
columns splices may be welded after a minimum of one side of all equator
course plates are welded.
2) Welding of girth joint may be performed simultaneously with running of welding radial
 joints which the welding of girth joints does not cross the unwelded or partially
welded radial joint.
3) Perform fit-up for the vertical or girth joint with key-plates and tack welding.
Finger bars should be used at all times on the fit-up side of welding courses
either distortion of the plate of the joint could be close. If the key-plate is
insufficient, the amount of finger bar shall be increased in alternate to the
amount
(6 mm), of key-plates.
weld Finger
the groove bar minimum
at 1500 thickness
mm interval shall
distances andnota be less than
minimum of 61/4 inch
inches
(150 mm) in length and the weld deposited shall be at least 6 mm thickness.

6.2 Dimensional Tolerance

 
http://slidepdf.com/reader/full/brazil-csp-ball-tank-erection-manual 17/18
8/20/2019 Brazil CSP-Ball Tank Erection Manual

 After the completion of the shell plate welding, the maximum permissible deviation
between
drawing. maximum and minimum diameter shall not exceed 0.5 % of specified diameter in

7. INSPECTION

 All inspection shall be done in accordance with the specified Inspection and Test
Procedure with Plan at Field for the spherical tank.

 All NDE inspection shall be carried out in accordance with the Inspection and Test
Procedure with Plan at Field, the approved NDE Procedures and approved
construction drawings.

8. POST WELD HEAT TREATMENT 

When applicable at field, PWHT shall be done in accordance with the approved
PWHT Procedure.

9. ASSEMBLING OF ACCESSORIES 

When specified in the contract, the items shall be done according to the following articles.

9.1 Accessories such as top stages instrument nozzle (stand pipe) and water spray
system
shall be installed successively after the non-destructive examination of the body.
9.2 Valves and instruments
9.3 The thermometers should be set before the hydrostatic test.
9.4 The pressure gauge should be set after completion of hydrostatic test.
9.5 Valves should be set with special care of the adequate tightening center ring gasket.

10. HYDROSTACTIC TEST  

Refer to the approved Hydrostatic Test Procedure at Field.

11. CLEANING AND PAINTING 

Refer to the approved Painting Procedure Specification.

12. FIRE PROOFING ON COLUMN  

Fire proofing on the column, it shall be constructed according to the drawing

after completion of hydrostatic test and all inspection of tank.

13. WATER SPRAY PIPING TEST  

Water spray piping test shall be performed according to the drawing or the specified
specification.

http://slidepdf.com/reader/full/brazil-csp-ball-tank-erection-manual 18/18