PT.

PAKARTI TIRTOAGUNG
JL. RAYA TENGAH NO. 4 PASAR REBO
JAKARTA TIMUR

STORAGE TANK REPAIR AND MODIFICATION

RU V PERTAMINA – BALIK PAPAN
 Content of Presentation

 Code and Reference

 Common SOW Repair and Modification of storage
tank
 Excluding SOW
 Doc / Data Required
 Project Management
 Project Execution
 Quality Control / Method of inspection
 Documentation
 Certification
 Q and A
 Code and Reference

 API 653 , Tank inspection, Repair, Alteration and

reconstruction
 API 650, Welded Steel Tank for Oil Storage
 ASME Section V , Non Destructive Examination
 ASME Section IX , Welding, Brazing Qualification
 ASME Section II , Material and Specification
 Undang Undang keselamatan kerja No. 1 Tahun 1970
 Peraturan menteri tenaga kerja dan trsnsmigrasi Per. 01/Men/
1982.
 Permenaker No 37 Tahun 2016 Tentang K3 Bejana Tekanan
dan Tangki Timbun
 Job Requirement Specification
 As agreed ITP ( Inspection and Test Plan ) for Certification
Common SOW Repair and Modification of storage tank
 Tank Cleaning ( Other Contractor ).
 Tank Bottom Replacement
 Shell Patches or replacements
 Roof plate repair and replacement
 Shell Nozzles, Man Hole, & Appurtenances
 Stairways, Handrails, & Platforms
 Out-of Round or buckled Tank Shell Repairs
 Cone Roof & Structure Repair & Replacements
 Piping Work
 Blasting and Painting / Coating
 Tank Foundations and Other Civil Work
 Primary & Secondary Seals for Floating Roof Tanks
 Cathodic Protection
 Electrical Work
 Instrumentation work
Excluding SOW Repair and Modification of storage tank

 Tank Jacking ( karena tanki di anggap miring ).

 Tank Leveling
 Tank Relocation
 Tank Table / Metrologi issue ?
 Tank Deformation and settlement analysis
 Material, Except Consumable
Doc / Data Required

 As built drawing
 Last inspection report
 Last certification document
 Job Requirement Specification
 Detail BOQ
 Repair Drawing if any
 ITP repair if any
Project Management

 Man Power / Personnel

 Engineering
 Material Procurement & Supply
 Construction
 Material & Logistic Transportation
 Fabrication
 Installation
 Mobilization & Demobilization
 Hook Up, Installation & Integration
 Pre-Commisssioning, Commisssioning and Start-up
 Documentation and As Built Document
Project Execution

 AFC Detail Engineering drawing

 Approved Construction procedure
 Running WPS and PQR
 Material procurement
 Fabrication
 Erection
 Civil Work.
 Electrical Work
 Instrumentation Work
 Commissioning and Start UP
 Certification
PROJECT EXECUTION

SEQUENCE FOR REPAIR / MODIFICATION A STORAGE TANK

ENGINEERING

ERECTION
DETAIL ENGINEERING
/CONSTRUCTION
ENGINEERING
QC

PROCUREMENT
FINAL TESTING

FABRICATION &
WELDING
QUALIFICATION COMMISIONING/
START UP
 RUNING WPS & PQR - 1

Qualification
WPS Welding Procedure
Qualification Record.

Welder ( PQR )
Qualification

WELDING MAP, FABRICATION & ERECTION SEQUENCE

DIAGRAM AND SHOP DRAWING.

FABRICATION : In accordance with shop drawing

Cutting, Forming/Rolling, Welding on components, such as :
Shell Plates, Bottom Plates, Roof Plates
Nozzles and Manhole
Rafter Winf Girder, Annular Plate, Compression Ring, Bracing, etc
 RUNING WPS & PQR -2

CODE : ASME Sect. IX.

Material : A joint with A or B

Joint design : - Joint type : Single Vee, Double Vee, Fillet.
- Thickness range.
Welding Electrode/Filler : Spec , Manufacturer, Size.
Welding Parameter : Current, Voltage, Travelling Speed and Progression

Condition : Preheat, Interpass Temperature, Post Heat Treatment, etc.

WPS Identification : No., Prepared by …, Approved by…

Remarks ………….
Quality Control

Dimensional Inspection
 Foundation Inspection
 Location Mark Check
 Fit-up Inspection
 Roundness
 Plumbness
 Local Deviation
Quality Control

Nondestructive Examination
 Visual Inspection
 NDE Procedure
 Radiographic Examination (RT)
 Liquid Penetrant Examination (PT)
 Vacuum Box Test (VBT)
 Pneumatic Leak Test (LT)
 Repair and Re-examination
Quality Control

Hydrostatic Test
Pre-test Check
Water Filling
Settlement Monitoring
Hydrostatic Test
QUALITY CONTROL – ITP

INSP & PERFORMED

NO PARTS/COMPONENTS/JOINT TEST ITP NO RESPONSIBILITY
METHOD
Cont’ 3rd Com
r pan
y
1 Incoming material Mils Cert  
2 Nozzle neck RT
3 All fabricated component joint Pt
4 All component DC
5 Foundation DC
7 Annular Bottom Plate Joint RT
8 Annular to Bottom Joint DC&PT
9 Bottom Plate joint MT/VT
10 Shell Plate Mils Cert

11 Shell Plate joint RT,MT &

Vacum
12 Itermediate Wind Gorder PT/MT
 QUALITY CONTROL - ITP

INSP & PERFORMED

NO PARTS/COMPONENTS/JOINT TEST ITP NO RESPONSIBILITY
METHOD
F I O
13 Top Wind Girder PT
14 Rafter/Bracing/Gusset/Shoe PT
Angle/Crown/Inner Girder
15 Nozzle to Shell/Roof PT
16 Roof Plate to Comp Ring Joint PT/SST
17 Roof Plate SST
18 Whole Tank HT
19 Bottom Plate after Hydro Test VT
 HYDROSTATIC/PNEUMATIC TEST

If no Sufficient water is available for testing.

PSV
Apply Vacuum or internal pressure.
P = 1.25 Pd. or
Pv = Pdv – 5 gr/cm2

Roundness and Plumbness

Check.

Apply all welding joint with

penetrating oil or soap.
Visual check on leakage.

When deformation occurred,

pressure shall be released or
vent.
 HYDROSTATIC/PNEUMATIC TEST
If Sufficient water is available for testing.
Open one Nozzle on Top.
PSV
Fill Tank with water up to 2” over
the top angle
Every 2 m or 2 course, : Check Pb,Rd
and deformation and leaks on plate.
Should there is any of out of talerance
or leaks or deformation, water filling
shall be stopped immediately.
Install Air Line. Close all Nozzle
& Valve exept air line.
Apply air pressure, P = Pd , then
SST roof pale joint & deformation
check. Then P = Psv

Vent

Vent down when deformation occur

 HYDROSTATIC/PNEUMATIC TEST
Apply air pressure, P = 1.25 Pd , then
SST roof pale joint & deformation
check.
Vent down when deformation occur

Close air line valve

Drain water to create vacuum
condition until P = Psv vacuum.

Open top nozzle/Manhole and Vent

Drain down the water untill tank empty

Vacuum Box Test all Bottom Plate joint

Vent
Project Documentation

 Engineering Document
AFC drawing , Repair Procedure
 Procurement Document
Material Certificate , COO , COC, test certificate, others
 Fabrication Document
Fit up, Welding Traceability, Dimensional report
 Erection Document
Plumpness, Roundness , Verticality, and other report.
 QC Document
NDE as UT, RT, MT, PT, Fill up water, Foam test
 Certification Document
commissioning and start up report
compilation all report as agreed in ITP
Project Certification

 Approved ITP between client, contractor, certifier, PI

 Residence inspector from PI or Client
 Agreed Master Deliverable Register
 Compilation of report all project activity during
Procurement, Engineering, Construction, Inspection
and Commissioning
 MARKING
PS
V

API STANDARD 650/620

APPENDEIX YEAR COMPLETED

EDITION REVISION NUMBER
NOMINAL DIAMETER NOMIKNAL HEIGHT
NOMINAL CAPACITY DESIGN LIQUID LEVEL
DESIGN SPECIFIC GRAVITY MAX OPERATING TEMP
DESIGN PRESSURE PARTIAL STRESS RELIEF
MANUFACTURER SERIAL NO PURCHASING TANK NO
FABRICATED BY
ERECTED BY

SHELL COURSE MATERIAL

 Tahun 2019

NO. URAIAN SATUAN Bulan ke TOTAL

1 2 3 4 5 6 7 8 9 10 11 12 E/M

1 Yard and Workshop Facility unit 1 1 1 1 1 1 1 1 1 1 1 1 12

2 Heavy Equipment

Telescopic Mobile Crane, 15 ton Cap unit 0 5 5 5 5 5 5 5 5 2 2 2 46

Crawler Crane, 50 ton Cap unit 0 0 2 2 2 2 2 2 2 2 2 2 20

Crawler Crane, 150 / 100 ton Cap unit 1 1 1 1 1 1 6

Forklift 5 ton unit 1 1 1 1 1 1 1 1 1 1 1 1 12

Hiyab Crane Tadano, 3 ton unit 1 1 1 1 1 1 1 1 1 1 1 1 12

3 Fabrication and Erection Equipment

Generator set 250 KVA unit 5 5 5 5 5 5 5 5 5 5 5 5 60

Welding Transformer 500 Amp unit 25 25 25 25 25 25 25 25 25 25 25 25 300

Automatic Cut & Bevel Machine unit 5 5 5 5 5 5 5 5 5 5 5 5 60

Automatic welding unit 1 1 1 1 1 1 1 1 1 1 1 1 12

CNC Cutting machine / Plasma unit 1 1 1 1 1 1 1 1 1 1 1 1 12

Handtools unit 20 20 20 20 20 20 20 20 20 20 20 20 240

Rolling Plate Machine unit 1 1 1 1 1 1 1 1 1 1 1 1 12

Bending Machine unit 1 1 1 1 1 1 1 1 1 1 1 1 12

Bending Hydraulic Manual unit 5 5 5 5 5 5 5 5 5 5 5 5 60

Tank Jack, Cap 25 Ton, 3 Meter Stroke unit 40 40 40 40 40 40 240

4 Blasing and Painting Equipment 0

Air Compressor 375 CFM portable unit 5 5 5 0 0 0 0 0 0 5 5 5 30

Blasting pot and accessories unit 5 5 5 0 0 0 0 0 0 5 5 5 30

5 Testing Equipment 0

Air test equipment unit 2 2 2 2 2 2 2 2 2 2 2 2 24

Hydrotest equipment unit 2 2 2 2 2 2 2 2 2 2 2 2 24

Dimensional equipment unit 5 5 5 5 5 5 5 5 5 5 5 5 60

NDT equipment unit 1 1 1 1 1 1 1 1 1 1 1 1 12

6 Other

Electrical Equipment Lot 0 0 0 0 0 0 1 1 1 1 1 1 6

Instumentation Equipment Lot 0 0 0 0 0 0 1 1 1 1 1 1 6

 Tahun 2019

NO. KLASIFIKASI SATUAN Bulan ke TOTAL

1 2 3 4 5 6 7 8 9 10 11 12 M/M

A Project Management Team

1 Project Manager Person 1 1 1 1 1 1 1 1 1 1 1 1 12

2 Site Manger Person 1 1 1 1 1 1 1 1 1 1 1 1 12

3 Engineering Manager Person 1 1 1 1 1 1 1 1 1 1 1 1 12

4 Mechanical Engineer Person 1 1 1 1 1 1 1 1 1 1 1 1 12

5 Piping Engineer Person 1 1 1 1 1 1 1 1 1 1 1 1 12

6 Electrical Engineer Person 1 1 1 1 1 1 1 1 1 1 1 1 12

7 Instrument Engineer Person 1 1 1 1 1 1 1 1 1 1 1 1 12

8 Civil Engineer Person 1 1 1 1 1 1 1 1 1 1 1 1 12

10 Procurement Engineer Person 1 1 1 1 1 1 1 1 1 1 1 1 12

11 Construction Manager Person 1 1 1 1 1 1 1 1 1 1 1 1 12

12 QA / QC Manager Person 1 1 1 1 1 1 1 1 1 1 1 1 12

13 HSE Manager Person 1 1 1 1 1 1 1 1 1 1 1 1 12

14 Project Planer Person 1 1 1 1 1 1 1 1 1 1 1 1 12

15 Cost Control Person 1 1 1 1 1 1 1 1 1 1 1 1 12

16 Document Control Person 5 5 5 5 5 5 5 5 5 5 5 5 60

17 HRD & Legal Officer Person 1 1 1 1 1 1 1 1 1 1 1 1 12

18 Project Secretary Person 5 5 5 5 5 5 5 5 5 5 5 5 60

19 Office Boy Person 5 5 5 5 5 5 5 5 5 5 5 5 60

20 Driver Person 5 5 5 5 5 5 5 5 5 5 5 5 60
 Tahun 2019
NO. KLASIFIKASI SATUAN Bulan ke TOTAL
1 2 3 4 5 6 7 8 9 10 11 12 M/M
0
B Skill Personal 0
1 Designer Person 5 5 5 5 5 5 5 5 5 5 5 5 60
2 Drafter Person 5 5 5 5 5 5 5 5 5 5 5 5 60
3 HSE Officer Person 5 5 5 5 5 5 5 5 5 5 5 5 60
4 QA QC Inspector M Person 5 5 5 5 5 5 5 5 5 5 5 5 60
5 QA QC Inspector P Person 5 5 5 5 5 5 5 5 5 5 5 5 60
6 QA QC Inspector E Person 5 5 5 5 5 5 5 5 5 5 5 5 60
7 QA QC Inspector I Person 5 5 5 5 5 5 5 5 5 5 5 5 60
8 QA QC Inspector C Person 5 5 5 5 5 5 5 5 5 5 5 5 60
9 Spv Mechanical Person 5 5 5 5 5 5 5 5 5 5 5 5 60
10 Spv Piping Person 5 5 5 5 5 5 5 5 5 5 5 5 60
11 Spv Electrical Person 5 5 5 5 5 5 5 5 5 5 5 5 60
12 Spv Instrument Person 5 5 5 5 5 5 5 5 5 5 5 5 60
13 NDT Team 1 1 1 1 1 1 1 1 1 1 1 1 12
 Tahun 2019
NO. KLASIFIKASI SATUAN Bulan ke TOTAL
1 2 3 4 5 6 7 8 9 10 11 12 M/M
0
0
C Direc Worker 0
1 Welder Person 30 30 30 30 30 30 30 30 30 30 30 30 360
2 Fitter Person 25 25 25 25 25 25 25 25 25 25 25 25 300
3 Helper Person 12 12 12 12 12 12 12 12 12 12 12 12 144
4 Electrician Person 0 0 0 0 0 4 4 4 4 4 4 4 28
5 Instrumen tech Person 0 0 0 0 0 4 4 4 4 4 4 4 28
7 Mechanic Person 4 4 4 4 4 4 4 4 4 4 4 4 48
8 Civil Work Craftman Person 20 20 20 20 20 20 20 20 20 20 20 20 240
9 Material control Person 5 5 5 5 5 5 5 5 5 5 5 5 60
10 Tools keeper Person 5 5 5 5 5 5 5 5 5 5 5 5 60
Question
1. Project permit
2. Crane provided by ?
3. Feed Doc or Engieering doc ?
4. WPS and PQR by ?
5. PQT for painting is required ?
6. Paint Material specification ?
7. Impact test is for PQR or for material ?
8. Scaffolding specification ?
9. After repair valve ? Certification ?
10. Is custody tank ?
11. Re Engineering issue regarding change the media ?
12. Quantity lot ? Little bit difficult to estimate the qty ?
13. COI or PLO ?
14. PI ?
END OF PRESENTATION
THANK YOU