SOURCING ENERGY TO OUR LIVES

MAINTENANCE –
HOT WORK AT A LIVE TERMINAL
PRESENTATION HIGHLIGHTS

• Introduction of Cylingas

• Tank Maintenance

• Hot work at live terminal - Annular Replacement

2
INTRODUCTION - History

• Established in 1974

• Late H.H. Sheikh Rashid Bin Saeed Al Maktoum, the Ruler of Dubai

• Cylingas Started Production in 1976

• First LPG Cylinder Manufacturing Company in GCC.

• Location: Al Quoz Industrial Area 3, Dubai – UAE

INTRODUCTION – Key Business

SITE EHS & QUALITY

CONSTRUCTION/EPC
PROJECTS

SHOP FABRICATION OHSAS ISO ISO

PROJECTS 18001:2007 14001:2004 9001:2008

MANUFACTURING STANDARD

LPG PROJECTS

“U” “U2” “R”

“NB”
INTRODUCTION – Major Activities

• EPC / Site Construction Projects

– Tank Farm, Plant Piping, Storage Tanks for Crude Oil & Finished Products etc.
• Pressure Vessels & Tanks Manufacturing
– Knock out Drums, Filters, Vent Drums, Separators etc.
• Gas Projects
– Storage Tanks & System Installation for LP, Propane
– Aerosol/Odorless & Synthetic Natural Gases
– Piping Networks Industrial, Building etc.
• Maintenance Projects
– Storage Tank Repair, Tank Bottom Plates Replacement, Loading Arm Maintenance
etc
TANKS & PIPING PROJECTS - Executed By Cylingas

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EFDTT Project - ENOC Fujairah Distribution & Trading Terminal
EPC Contract
Engineering, Procurement &
Construction Of 12nos. Vertical
Storage tanks + Floating suction
& Floating suction level
indicator for tank 8 Nos.,
29Mts. Dia. x 24 Mts. High (mix:
internal aluminium floating
deck + internal carbon steel
pontoon type floating deck) 4
Nos., 41Mts. Dia. x 24Mts. High
(mix: internal aluminum
floating deck + internal carbon
steel pontoon type floating
deck)
ELOMP Project - Lubricants and Grease Manufacturing Plant - Fujairah
EPC Contract
Design, Engineering, Procurement,
Construction, Fabrication & Commissioning
of Base Oil Storage Tanks and Vessel,
additive vessels, compartmental tanks, 9
Nos. Vertical Storage Tanks (various sizes),
16 Nos. Vessels (various capacities), 6nos.
Additive vessels with 7 Vertical Storage
tanks, ranging from 5Mts Dia. X 14Mts High
to 15Mts. Dia. X 18Mts High 14
Homogeneous vessels ranging from 2.7Mts
Dia. X 7.5Mts High. to 4250Mts Dia. X 9Mts
High, total plant and utility piping,
structural works for pipe racks and walk
ways, equipment erection and fire fighting
system, loading Bay with associated
facilities at inside Port of Fujairah. 9
Falcon Project – Horizon Terminal at Jebel Ali For Dubai Airport

Engineering,
procurement,
construction, & civil
works of 7nos.
Vertical Storage
tanks (3 tanks CS
Roof and remaining
with Aluminum
dome roof). Ranging
from 14Mts Dia. X
13Mts High to 40Mts
Dia. X 25Mts High
VHFL Project – Vopak Horizon Fujairah Limited

Design, Engineering,
Supply, Fabrication,
Painting,
Erection/Installation,
Testing and Pre-
commissioning of 8
Nos. Product Storage
Tanks of sizes: 55m
Dia x 25m Ht. 4 Nos.
& 39m Dia x 25m Ht.
and its associated civil
works.
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DEWA Project-Phase II & Phase III
Engineering, Supply, Fabrication, Painting,
Erection/Installation, Testing and Commissioning
of 3 Nos. Fixed Cone Roof Diesel Storage Tanks of
sizes: 35M Dia x 14.5 M Ht. & 3 Nos. 35Mtrs. Dia.X
5.1Mtrs. high for Diesel & 1 No. 21 Mtrs.
Dia.X15.7 Mtrs. high for Demineralised Water
Tank
FUEL FARM-Airports
Design, Engineering, Supply, Fabrication, Painting,
Erection/Installation of
DUBAI Airport: 5 Nos. Truss Supported Fixed Cone
Roof Storage Tank for Aviation Jet Fuel & 1 No. Refuel
Storage Tank. Sizes: 33M Ø x 14.6M Ht. (4 Nos.),
17Mtrs. Ø x 11.6Mtrs. Ht. (1 No.) & 7Mtrs. Ø x
5.2Mtrs. Ht. including Floating Suctions
FUJAIRAH Airport: 1 No. Aviation Jet Fuel Tank API-
650 Size 10Mtrs. Ø x 10Mtrs. Ht. 12
ADCO BUHASA Project - Fuel Storage Tanks, Abu Dhabi

Erection, Testing and

calibration of 2 Floating Suction
Tanks of size 30.5 m Dia x 12.5m
ht., 2 Fresh Water Tanks of size
9.14m Dia x 7m ht. & 2 Disposal
Water Tanks of size 16m Dia
x 11.5m ht. – Total 6 Tanks.

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 TANK
MAINTENANCE
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CYLINGAS EXPERIENCE IN MAINTENANCE PROJECTS
Major Maintenance Projects handled include:

• EPCL tank repair works

• MELUBCO Tank Repair work

• HJATL Tank Repair and Calibration works

• VHFL Tank Repair works

• EIL tank Repair works

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CYLINGAS EXPERIENCE IN MAINTENANCE PROJECTS
Middle East Lubricants LLC
• Tank repair including bottom plate replacement
(MELUBCO)
VOPAK Horizon Fujairah Ltd
• Annular Plate replacement works for 9 Tanks
(VHFL)

United Eastern Petroleum Services, • Supply, fabrication, testing, painting & delivery of 10 Nos. Mooring Sinker of size 2 Mtrs. Width x 4 Mtrs.
Abu Dhabi Long and 660mm High

• Repair works on the annular tanks for 10nos. of Product Tanks. Remove pitted tank bottom annular plates
VOPAK Horizon Fujairah Ltd.,
and re-welding new annular plates as per API 653 tank inspection, repair, alternation and Reconstruction
Fujairah
code

• Refurbishment of Tank
• Repairing & Reconditioning of 45M Dia. x 18.75M high Storage Tank
• Mechanical, piping and associated civil and electrical works for Tank Bottom Repairing Work for 5 Tanks
EPPCO International, Dubai
and piping work
• Piping modifications at Berth 1 Valve Station & Terminal 2 which includes pipes, valves etc.
• Bottom plate repair/replacement of 1 No. 18 Mtrs. Dia x 17.3 Ht. Storage Tank

ENOC Processing Co. LLC., Jebel • Annular plate replacement and repair works including new shell nozzles, calibration, painting etc. for 3
Ali Tanks

• Annular plate replacement and repair works including calibration, painting etc. for 1 Tank
EPPCO, Dubai
• Tank Modification and Jetty Pipeline

ENOC TERMINALS • Tank repairs including replacement of floor plates

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STORAGE TANKS - Repair & Re-Construction Code API
653
API 653 Tank Inspection, Repair, Alteration and Re construction
Repairs of tank constructed to API 650 and API12C. Scope
limited to tank foundation, bottom, shell, structure, attached roof
appurtenances and nozzles up to first flange or threaded joint.

API 579 shall be used in conjunction to evaluate the fitness of

service.

This standard suited to tanks intended to

(a) hold/store liquids with gases/vapours above their surface
(b) hold/store gases/vapours alone.
This standard not applicable to lift-type gas holders. 17
INSPECTION TO ASSESS THE REPAIR REQUIRED
• Assess the tank condition using various inspection techniques

• Define the scope (Extent of repair)and methodology based on

international code(API 653) and client requirements

• Isolate the tank

• Minimize the down time with Automation/improved methodology

• Test and calibrate the tank

• Test pack, certification and guarantee.

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INSPECTION TO ASSESS THE REPAIR REQUIRED
• Complete inspection of the tank with specific attention to the tank
bottom, floating roof, seals, pontoons, painting, tank internals
including, heating coils, floating suction, etc.

• Blasting and Scanning of tank bottom and measuring the

corrosion and the available plate thickness.

• Checking the leak detection system to identify the product

leakage, etc.

• Checking for damaged seal and wear & tear to the seal system for
Floating roof

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METHODOLOGY

• The tank is to be emptied and gas freed in preparation for hot

works.

• The method statement to be prepared and reviewed along with

risk assessment.

• While working inside the tank, the tank will be vented using
electric blowers, venturies, exhaust fans etc.

• Once all preparations are in place and the risks identified and
mitigated… Job is ready to start

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RISK MANAGEMENT INPUTS
Among the main concerns would be:
• Positive isolation of the tank from the rest

• Products stored and operated in the nearby tanks

• Operations in the vicinity such as pump house, manifold, etc

• MSDS of the last product kept in the tank

• Crane access (sizing the crane correctly)

• Access for manual handling

• Condition of the tanks and product leak assessment. 21

SAFETY PRECAUTIONS

• Proper Work permit system to be implemented

• Ensure that Isolation of the tank is positive

• Ensure that the risk assessment is validated

• Ensure that all the potential fire risk (drains, valves, valve pits,
etc) are covered with fire blanket to be protected from welding
and grinding spatter

• Gas testing both continuously and periodically as prescribed in

the risk assessment.

• Emergency Response Plan to be in place and communicated

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PERSONNEL

• Experienced staffs, these include, experienced in working in live

operational classified locations, experienced with tank repair
works, familiar with codes and standards, familiar with EHS
requirements

• Equally important to have competent and experienced workmen

and the various technicians including qualified and certified
welders, riggers, grinders, fitters, etc.

• It is also important for the works to be quantified and the right

number of persons required of various categories to perform the
job safely
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HOTWORK AT A LIVE TERMINAL
Annular Replacement

24
Annular Replacement Procedure

25
ANNULAR PLATE DAMAGES
EDGE CORROSION
ANNULAR
PITTING
1. TANK ISOLATION
ISOLATING
TANK
OUTLET
CONNECTIONS

(1/4)
ISOLATING
TANK
OUTLET
CONNECTIONS

(2/4)
ISOLATING
TANK
OUTLET
CONNECTIONS

(3/4)
 ISOLATING
INTERCONNEC
TING
WALKWAY

(4/4)
2. MATERIAL
UNLOADING & STACKING
MATERIAL
UNLOADING
&
STACKING

(1/2)
MATERIAL
UNLOADING
&
STACKING

(2/2)
3. SHELL TO BOTTOM PLATE WELD GOUGING
SHELL TO
BOTTOM
PLATE
WELD
GOUGING
4. TANK LIFTING WITH
HYDRAULIC JACKS
 TANK
LIFTING
WITH
HYDRAULIC
BOTTLE
JACKS
5. EXISTING ANNULAR
PLATE CUTTING AND REMOVAL
EXISTING
ANNULAR
PLATE
CUTTING

(1/4)
EXISTING
ANNULAR
PLATE
CUTTING

(2/4)
EXISTING
ANNULAR
PLATE
REMOVAL

(3/4)
EXISTING
ANNULAR
PLATE
REMOVAL

(4/4)
6. REMOVAL OF
CONTAMINATED SAND
AND LAYING OF NEW SAND
REMOVAL OF
CONTAMINATED
SAND
(1/4)
REMOVAL OF
CONTAMINATED
SAND
(2/4)
LAYING OF
NEW SAND
(3/4)
LAYING OF
NEW SAND
(4/4)
7. SHELL EDGE
PREPARATION
SHELL EDGE
PREPARATION

(1/2)
SHELL EDGE
PREPARATION

(2/2)
8. LAYING OF THE
NEW ANNULAR
PLATE
LAYING OF
THE NEW
ANNULAR
PLATE

(1/3)
LAYING OF
THE NEW
ANNULAR
PLATE

(2/3)
LAYING OF
THE NEW
ANNULAR
PLATE

(3/3)
9. ANNULAR TO ANNULAR
PLATE FIT UP / WELDING / MPI
ANNULAR
PLATE FIT
UP

(1/4)
 ANNULAR
TO
ANNULAR
PLATE JOINT
WELDING

(2/4)
 ANNULAR
TO
ANNULAR
PLATE JOINT
WELDING

(3/4)
 ANNULAR
TO
ANNULAR
PLATE JOINT
WELDING

(4/4)
ANNULAR
TO
ANNULAR
ROOT
WELD MPI
(1/1)
10. UT OF ANNULAR
BUTT WELDS
 UT
OF
ANNULAR
PLATE
11. SHELL TO BOTTOM
FITUP & ROOT WELDING
SHELL TO
BOTTOM
FITUP

(1/2)
SHELL TO
BOTTOM
ROOT
WELDING

(2/2)
12. OIL PENETRATION TEST
 OIL
PENETRATION
TEST
13. SHELL TO BOTTOM
WELDING / MPI
SHELL TO
BOTTOM
INSIDE
WELDING

(1/4)
SHELL TO
BOTTOM
OUTSIDE
WELDING

(2/4)
SHELL TO
BOTTOM
WELDING
MPI

(3/4)
SHELL TO
BOTTOM
WELDING
MPI

(4/4)
14. SKETCH TO ANNULAR
FIT UP / WELDING /
VACUUM BOX TEST
SKETCH TO
ANNULAR
PLATE
FIT UP

(1/4)
SKETCH TO
ANNULAR
PLATE
FIT UP

(2/4)
VACUUM
BOX
TESTING

(3/4)
VACUUM
BOX
TESTING

(4/4)
15. NEW SUMP
WELDING / ERECTION /
UT TESTING
NEW SUMP
WELDED
&
READY FOR
ERECTION

(1/4)
NEW SUMP
WELDED
&
READY FOR
ERECTION

(2/4)
NEW SUMP
ERECTED

(3/4)
UT TESTING
OF SUMP
JOINT

(4/4)
16. HYDROTEST
HYDROTEST

(1/3)
HYDROTEST

(2/3)
HYDROTEST

(3/3)
17. INITIAL BLASTING /
DEGREASING
(HYDRO JETTING)
 INITIAL
BLASTING /
DEGREASING
(HYDROJETTING)

(1/3)
 INITIAL
BLASTING /
DEGREASING
(HYDROJETTING)

(2/3)
 INITIAL
BLASTING /
DEGREASING
(HYDROJETTING)

(3/3)
18. FINAL
BLASTING & PAINTING
 FINAL
BLASTING
& PAINTING

(1/6)
BLAST PROFILE
MEASUREMENT

(2/6)
SALINITY
TEST

(3/6)
REPAIRED
&
PAINTED

(4/6)
REPAIRED
&
PAINTED

(5/6)
 DFT-PAINT
THICKNESS
MEASUREME
NT

(6/6)
 For further enquiries and feed back please contact
Email : enquiries.cylingas@enoc.com
Website : www.cylingas.ae
Tel : +971 4 347 2648
Fax : +971 4 313 1471

THANK YOU
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