ms t4911
TRANSCRIPT
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KNM Petrosab Engineering Sdn Bhd
METHOD STATEMENT FOR ERECTION AND
INSTALLATION OF FIXED ROOF STORAGE TANK
T-49-11 DIESEL OIL STORAGE TANK
0 19/10//2013 Hairol Zoll Edy Melchor Edy Melchor
Rev. Date Prepared By Checked By Approved By
METHOD STATEMENT FOR
ERECTION AND
INSTALLATION OF FIXED
ROOF STORAGE TANK
PROJECT. NO.
: K1202107
REVISION NO.
: 0
PAGE NO. : 1 of 12
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KNM Petrosab Engineering Sdn Bhd
REVISION HISTORY
SECTION PARA DESCRIPTION PREPARED BY
METHOD STATEMENT FOR
ERECTION AND
INSTALLATION OF FIXED
ROOF STORAGE TANK
PROJECT. NO.
: K1202107
REVISION NO.
: 0
PAGE NO. : 2 of 12
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KNM Petrosab Engineering Sdn Bhd
TABLE OF CONTENTS
SECTION DESCRIPTION PAGE
1.0 SCOPE 4
2.0 APPLICABLE CODES, STANDARDS AND REFERENCES 4
3.0 DEFINITIONS 4
4.0 LIST OF EQUIPMENT 4
5.0 PREPARATORY WORKS 4
6.0 TANK ERECTION METHOD 6
6.1 ERECTION OF BOTTOM PLATES 6
6.2 ERECTION OF SHELL PLATES 7
6.3 INSTTALATION OF ROOF STRUCTURE 9
6.4 INSTALLATION OF ACCESSORIES &
TANK APPURTENANCES 10
6.5 ASSEMBLING OF STEEL STRUCTURES 10
& APPURTENANCES
7.0 WELDING SEQUENCE 11
8.0 INSPECTION 11
9.0 LEAKAGE TESTING 11
10.0 APPENDIX 12
METHOD STATEMENT FOR
ERECTION AND
INSTALLATION OF FIXED
ROOF STORAGE TANK
PROJECT. NO.
: K1202107
REVISION NO.
: 0
PAGE NO. : 3 of 12
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KNM Petrosab Engineering Sdn Bhd
1 . 0 S C O P E
1.1 This procedure describes the sequence and methods to perform site erection and
fabrication of Fixed Roof Storage Tank for – Knock Down (KD) Tank for Sabah
Ammonia Urea (SAMUR) Project-
2.0 APPLICABLE CODES, STANDARDS AND REFERENCES
2.1 API 650 Welded Steel Tank for Oil Service (revision 11, 2010)
2.2 PTS 34.51.01.31: Standard Vertical Tanks - Selection, Design & Fabrication
2.3 PTS 64.51.01.31: Standard Vertical Tanks - Field Erection & Testing
2.4 PTS 20.156A: Standard Tanks, Volume 1 - Part 1
2.5 PTS 20.156B: Standard Tanks, Volume 1 - Part 2
2.6 Approved Drawings
2.7 BS 2654 cross reference with EN1491
3.0 DEFINITIONS
3.1 KNM PETROSAB : Contractor
3.2 Consortium : AIT
3.3 PCSB : OWNER
4.0 LIST OF EQUIPMENT
4.1 FCAW/ SMAW / SAW welding machines
4.2 Hand Grinder 4.3 Hot Air Blower
4.4 Spreader Bar
4.5 Webbing Sling 6meter, 3000kg
4.6 Webbing Sling 12m, 4000kg
4.7 Robin water pump
4.8 Portable electrode rod dryer
4.9 Mobile Crane 25 & 45 ton
4.10 Diesel water pump
4.11 Welding rectifier
4.12 Electric cut-off machine
4.13 Horizontal lifting clamp
4.14 Lifting clamp
4.15 Gauging machine
4.16 Vacuum 4.17 SLR-0365 G210 Screw Pin Chain Shackle '7/8' (6.5T)
4.18 Electrode Baking & Holding Ovens
4.19 Flux Oven
4.20 Wind girder
4.21 Welder Buggy
4.22 Panel Boards
METHOD STATEMENT FOR
ERECTION AND
INSTALLATION OF FIXED
ROOF STORAGE TANK
PROJECT. NO.
: K1202107
REVISION NO.
: 0
PAGE NO. : 4 of 12
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KNM Petrosab Engineering Sdn Bhd
5.0 PREPARATORY WORKS
5.1 A 25 ton and 50 ton hydraulic Rough Terrain type crane will be positioned
around the tank foundation (100 ton and above crane only for erection of roof
structure assembly). If unfavourable soil conditions exist, pouring of gravel
materials or laying out of thick wooden planks or steel plates will used to support
the ground and crane stability.
5.2 Before using the crane for lining operations, the inspection will be carried out for
proper functioning and verify all the safety devices (e.g. overload protection) are
operating satisfactorily. Test certificate should be available for inspection.
5.3 Scaffoldings and welding buggy will be used to facilitate erection and welding
works. Proper permit will be secured prior to erection of scaffoldings and
welding buggy on site.
5.4 All the erection aids such as clamps, wedges, shims, spacer plates and other devices for aligning the welding joints will be provided on site including all lifting tackles.
5.5 AFC drawing checked and verified by KNMPESB shall be used.
5.6 Prior to erection, the centre slope shall be checked as per approved drawing. The
dimensions and elevations of the tank foundation as well as the correct
orientation for starting point shall be checked. Ensure that the foundation work
has been formally accepted by KNMPESB and AIT before proceeding with the
tank erection. A release note shall be obtained from civil discipline on the
handover of tank foundation.
5.7 Prior to erection the centreline of the tank will be marked on the foundation as well as the four points along the circumference at 0, 90, 180 and 270 degrees by AIT surveyor.
5.8 Elevation reference benchmark will be establish and set out on site. Plates and
structural materials intended for tank erection will be laid properly on the ground
with proper support and protection for not direct contact to the ground.
5.9 All the plate material shall be check for dimensional accuracy and reported in the
Applicable Inspection Report (Appendix I)
METHOD STATEMENT FOR
ERECTION AND
INSTALLATION OF FIXED
ROOF STORAGE TANK
PROJECT. NO.
: K1202107
REVISION NO.
: 0
PAGE NO. : 5 of 12
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KNM Petrosab Engineering Sdn Bhd
5.10 Before tanks erection started, foundation shall be checked by the tank
builder with foundations contractor, and CLIENT to make sure that the
foundation are according to specification requirement. If there were some
obstacles on foundation to erecting of the tank, such foundation should be
repaired by foundation contractor. The foundation shall be marked on four
position (0°, 90°, 180° and 270°) and will be done by foundation contractor
or CLIENT. The item to be inspection of foundation are Dimension,
Flatness, Levelness and sump location.
6.0 TANK ERECTION METHOD
6.1 Erection of Bottom Plate
6.1.1 The bottom plate shall be arranged in accordance with Bottom
Plate Drawing and Orientation Drawing.
6.1.2 First Lay down, the sketches plate, start from centre through to
the four direction angle (0°, 90°, 180° & 270°).
6.1.3 The bottom centre plate shall be laid on the centre point
which had been marked by stretching piano wires crosswise
above the foundation. Centre bottom plates which will be
basis for laying other plates.
6.1.4 The arrangement of bottom plates shall be laid out from centre to
outward and tack-welded in surface to be straight as shown
attached figure. Tack welds shall be 1.18 inch long or more on
1ft - 7.68 inch pitch.
6.1.5 For three laps joint, after finished first layer welding, checked
welding line using Dye Penetrate Test or Vacuum Box Test
(Section V, article 6, of the ASME Code). Bottom plates shall be
assembled and tack-welded using special jigs for anti-distortion if
necessary. Weld sketches plates which shell plate will be laid
long of weld 7.87 inch (min.) from out to inward.
6.1.6 At the proper welding, the Vertical joints of 'V' blocks shall be
welded first. Lapped plates shall be in close contact during
welding. After the Vertical joints of 'V' blocks are welded, the
Horizontal joints 'H' blocks shall be made.
METHOD STATEMENT FOR
ERECTION AND
INSTALLATION OF FIXED
ROOF STORAGE TANK
PROJECT. NO.
: K1202107
REVISION NO.
: 0
PAGE NO. : 6 of 12
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KNM Petrosab Engineering Sdn Bhd
6.1.7 Care shall be exercised during welding of bottom plates to
assure minimum distortion and uniform lapping with as
possible, plates shall be held in close construction at all lap
joint.
6.1.8 After completion of welding works of bottom, tested using
Vacuum Box and Soap suds to all welding line with a
vacuum of 5 to 7 psi.
6.2 Erection of Shell Plate
6.2.1 First Course The shell circle line for erection shall be drawn
on the bottom plates and punched equally by number of shell
plates.
6.2.2 When the assembling of the first ring have completed, the
vertical joints shall be tack-welded from inside to outside.
6.2.3 After completion of the tack-welded on the vertical joints, the
level of top edge and plumbness shall be inspected with an
instrument theodolite.
6.2.4 Check the item horizontal measuring position should be After
Temporary Assembling of 1st Course.
6.2.5 The first continuous welding shall be made from the outside
for vertical joints and back weld from inside. The Welding
from down to up .The strong back or key plates shall be
installed at right angle with the weld line to prevent plate
distortion during welding.
6.2.6 Prior to application of the first bead to the inside welding, the
strong back or key plates shall be removed and welded joints
shall be cleaned thoroughly in a manner that will leave the
exposed surface satisfactory for fusion the weld metal to be
added. This cleaning shall be made from inside by arc-air
gouging and/ or grinding to evenly and smoothly.
METHOD STATEMENT FOR
ERECTION AND
INSTALLATION OF FIXED
ROOF STORAGE TANK
PROJECT. NO.
: K1202107
REVISION NO.
: 0
PAGE NO. : 7 of 12
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KNM Petrosab Engineering Sdn Bhd
6.2.7 Second Course, the scaffolding board shall be arranged with
lugs and brackets on both side of the first course. When the
traveling scaffolding is used the scaffolding shall be installed.
6.2.9 Vertical joints of the second course shall be assembled with
the match mark, which had stamped on the first course.
Vertical joints shall be matched accurately and retained in
position with spacers and stiffeners. Horizontal joints between
first and second course shall be matched to inside of each
plates and retained in position with spacers and stiffeners.
6.2.10 After completion of second course installed, start welding of
vertical joints of second course in the same manner as the first
course.
6.2.11 The welding of horizontal joints between first course and
second course shall be made the outside first, and being the
stiffeners removed. If there were some defect at first layer
which shall be hindrance to welding from inside, after that
the reverse side of horizontal joints shall be welded.
6.2.12 The fillet weld joint between shell plate and bottom plate shall
be welded after second or third course shell plate is assembled.
6.2.13 Third and Upper Course, third and upper course shall be
assembled in the same manner as the second course. The
temporary assembling of each course shall be completed in the
day, and the maximum allowable numbers of shell course
to be assembled temporarily shall be 3 (three) courses in case
of the plate used 8 (eight) feet width and 4 (four) courses in
case of the plates used 6 (six) feet width.
6.2.14 The vertical joints of third course shall be welded before
the welding of horizontal joints between second and third
course. Owing to circumstances of erection schedule,
welding of vertical joints of 2 (two) or 3 (three) courses
may be proceeded prior to welding of horizontal joints.
6.2.15 Assembling and welding of other upper courses shall be made
as the same manner as stated before. In principle, shell plates
which is higher than 5th courses shall be assembled and
welded one by one course.If there were some undesirable
phenomenon like a settlement of foundation during the shell
assembling and welding, the level should be measured.
METHOD STATEMENT FOR
ERECTION AND
INSTALLATION OF FIXED
ROOF STORAGE TANK
PROJECT. NO.
: K1202107
REVISION NO.
: 0
PAGE NO. : 8 of 12
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KNM Petrosab Engineering Sdn Bhd
6.2.16 Provision for Wind Load, whenever the strong winds is foreknow
to blow during temporary assembling, following provisions
shall be made.
6.2.17 When the typhoon is anticipated to approaching during the
assembling of the shell plates higher than 4th course, the
plates higher than 4th course to be assembled temporarily shall
be taken down to the ground.
6.2.18 If the shell plate have been assembled up to 4th course, the
channel stiffener ring shall be installed by clamping on the top
periphery. The plate shall also be tied to supports on grounds by
wire ropes.
6.2.19 Top Angle, top angle shall be assembled and tack-welded after
the welding of vertical joints of the shell finally and grind
smoothly of vertical weld to pass through top angle. The
horizontal joints between top angle and shell shall be welded
finally.
6.3 INSTALLATION ROOF STRUCTURE
6.3.1 Installation of Cone Roof Installation of Rafter Lug: Mark the
position of rafter lug on internal surface of top course
shell plate and then welded there to.
6.3.2 Roof Plates, roof plates shall be installed in accordance with
drawing after all roof structure bolted and welded
completely.
6.3.3 Roof plates shall be laid out and tack-welded using special
jigs for anti- distortion if necessary. Tack-welds shall be
made not less than 1 inch long on 20 inch center.
6.3.4 At the continuous welding, transverse joints shall be welded
first. The welding shall be started at the center of plate
width and proceeded outwards symmetrically. When all
transverse joints are welded, welding of the longitudinal
joints shall be made from center to outward in a same
manner as the transverse joints, circumferential joints
between roof plates and top angle shall be welded finally.
METHOD STATEMENT FOR
ERECTION AND
INSTALLATION OF FIXED
ROOF STORAGE TANK
PROJECT. NO.
: K1202107
REVISION NO.
: 0
PAGE NO. : 9 of 12
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KNM Petrosab Engineering Sdn Bhd
6.4 INSTALLATION OF ACCESSORIES & TANK APPURTENANCES
Each tank accessories and appurtenances shall be assembled and
installed in accordance with the applicable construction drawings which it
have an Approval for Construction status.
6.4.1 Nozzles & Manhole
Lay out position of Nozzles/Manhole on the shell plate and
roof plate. Check orientation, elevation and radius/diameter every nozzles. After
approved by inspector, cut the marked area and set up reinforcing plate for each
nozzles Fit up Nozzles and use temporary support for neck nozzles and also
check projection flange from shell plate. Weld joint neck nozzles to shell from
inside and outside tank and weld reinforcing plate to shell plate
6.4.2 Roof Handrail
Lay out position of all post handrail at around top roof plate,
set up and weld each post handrail to roof plate, set up and weld pipe handrail
(already bended) on the top post handrail. Set up and weld pipe handrail as middle
handrail on the middle of the post handrail. Set up and weld flat bar as bottom
handrail with distance 100 mm from roof plate on the bottom post handrail.
6.5 ASSEMBLING OF STEEL STRUCTURES AND APPURTENANCES
6.5.1 All appurtenances will be assembled and installed in accordanc with
AFC drawing within tolerance specified in PTS 64.51.01.31 (Standard
Vertical Tanks — Field Erection & Testing).
6.5.2 The shell manhole opening will be made after adjustment of the level,
verticality and roundness are completed, prior to the installation of 2nd
course shell plates.
6.5.3 Cutting of holes for nozzles will be made upon completion of the welding of bottom to shell plate and upon approval by AIT representative after
inspection.
6.5.4 When welding the manhole and nozzles, the shell plate will be
reinforced with strong back to avoid possible distortion and
deformation.
METHOD STATEMENT FOR
ERECTION AND
INSTALLATION OF FIXED
ROOF STORAGE TANK
PROJECT. NO.
: K1202107
REVISION NO.
: 0
PAGE NO. : 10 of 12
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KNM Petrosab Engineering Sdn Bhd
7.0 WELDING SEQUENCE
7.1 Welding sequence of bottom plates, shell plates and roof plates shall be as per AFC
drawings.
8.0 INSPECTION
8.1 Inspection shall be carried as per Inspection and Test Plan and other applicable
Procedures.
9.0 LEAK TEST
9.1 Leak test shall be carried out as per approved Hydrotest Procedure
(KPE1011020- Q-P-006).
METHOD STATEMENT FOR
ERECTION AND
INSTALLATION OF FIXED
ROOF STORAGE TANK
PROJECT. NO.
: K1202107
REVISION NO.
: 0
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KNM Petrosab Engineering Sdn Bhd
APPENDIX I (APPLICABLE INSPECTION FORMS)
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KNM Petrosab Engineering Sdn Bhd
APPENDIX II (SKETCHES ATTACHMENT)
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KNM Petrosab Engineering Sdn Bhd
APPENDIX III (STRUCTURAL CACULATION FOR GONDOLA CAGE)