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OFF-SHORE TRAINING Page 1 of 4

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Module 4

Introduction to Construction, safety, defects, challenges in construction of

storage tanks and Questions and Answers (session)

Introduction to construction:

Introduction to storage tanks, fundamentals, accessories & type of tanks/vessels,

designing code is all explained previously.
Once the design, type of storage tank, capacity of tanks/vessels etc. are finalized
w.r.t the client requirements, the next step is to start construction/ fabrication of
tanks at onshore yard for transportation to offshore. Construction comprises of
three steps mainly as;

(i) Fabrication (ii) Transportation (iii) Installation/Erection

Fabrication:

For fabrication following are prerequisite as minimum;

(i) Approved Detail and Shop drawings for commencement of Fabrication.

(ii) Availability of Material of Construction.
(iii) Availability of code of fabrication/ project specifications (latest revision).
(iv) Equipment required facilitating fabrication.
(v) Project schedule.

Fabrication is to be started immediately after finalization of design and based on the

availability of MOC. Storage tanks/vessels are constructed in fabrication yard at
onshore. Tanks and vessels of bigger sizes are installed on platform at fabrication
yard itself. However in revamping jobs old storage tanks, already installed on
platforms, are to be replaced with new one at offshore sites only.

Fabrication includes Cutting, grinding, assembly, welding & NDT. All the activities
are documented as a part of project final documents.

Type of Welding procedures & welders and Type of NDT to be performed shall be
qualified & approved at site as per the project requirement for the job.

Types of Tanks/Vessels:

As construction point of view we categorized vessels / tanks as;

a) Horizontal Vessels/Tanks
b) Vertical Vessels/Tanks
c) Skid Mounted Vessels/Tanks

The above categorization is for easy understand the shape by construction

engineers and to design the erection/Installation Plan accordingly.

The Fabricator shall be capable of design and manufacture pressure vessel in

accordance with ASME Sec VIII, BS 5500 and also certified to manufacture Vessels
with ASME 'U' Stamp Certification and is also authorized to use 'R' Symbol for the
repair of vessel in accordance with the provision of National Board.

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Transportation:

After fabrication is over, tanks/vessels need to be transported to the location of

installation and erection to be done as per the equipment layout drawings.
Transportation and erections is a critical activity hence needs meticulous planning
and skilled manpower and coordinated action & the most important is Team Work.

(Onshore)

Tanks are to be transported from location of fabrication to the location of erection

via road route with a multi-axel flat bed carrier trailers.

i- Road route being chosen is to be surveyed for checking/confirming, clear

of route.
ii- Reputed contractor for transportation.
iii- Alternate road route as a contingency plan.

(Offshore)

Items are to be transported to the nearest port via road route for further
transportation to offshore locations via sea route with the help of Marine spread.

Erection/Installation:

Once the consignment reached to the location of installation, erection plans need to
be worked out. Rigging arrangements & contingency plan shall be prepared and
demonstrated to the team and concerned personals. Necessary Permit to Work
(PTW) shall be obtained from the concerned authorities for work in
premises/site/location.

Equipment required:
i- Crane of suitable capacity
ii- Chain pulley blocks
iii- Scaffolding with a team of scaffolders
iv- Lifting gears.
v- Marine spread (Cargo barge & Hookup barge) with Crane of suitable
capacity.
vi- Barge positioning and Anchor pattern/ Mooring arrangements.

Challenges During construction: Despite construction seems easy & simple, but
many challenges are being faced by the construction team, few are listed as below;

i) Improper sea fastening: Sea fastening is done to secure the

module/equipment/vessels for transportation through Marine spread. Sea
fastening shall be done with the approved plan (welding & NDT) and shall
be inspected & reviewed by the Marine Warranty Surveyor (MWS).
Improper sea fastening may cause serious loss of man, machine and
material.

ii) Space constraint: Means limited space for erection and placement of the
Equipments/Vessels. Main reason behind this kind of problem is drawing is
not updated and in absence of As-Built drawing. This type problem comes
in revamping jobs and modification in erection plan or in equipment, if not
break the integrity of equipment, needs to be worked out as per the site
conditions.
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iii) Difficulty in mooring/ barge positioning: sometimes difficulty in

anchor pattern for mooring is faced due to available existing facilities in
the near vicinity of installation/erection. Anchor pattern is very important
for barge positioning to commence erection. Anchor pattern shall be
carefully prepared and reviewed by the concerned.

iv) Approach constraint: The consignment is reached at site, but for

erection to the location sometime you may get restricted approach. This
kind of problem may come due to many types of equipment already
present on the platforms or limited reach of deck crane. To cope up with
this type of situations, one should have visited the site in advance and
lifting plan shall be prepared meticulously considering the facts.

v) Fouling with associated structures and facilities: Prior to erection at

site, we come to know that the equipment at this location is fouling with
the existing facilities, this happened again in absence of As-built
drawings/data during engineering.

vi) Temporary Deck extension: As explained in Approach constraint, to

cope with the situation and facilitate erection/installation temporary deck
may be installed, so that the crane reach can be achieved and aid to
installation of heavy equipments/vessels by skidding beam or roller
arrangement.

Safety: Heavy equipments are being lifted during erection/installation at onshore

and offshore, hence safety of personals & facilities in the vicinity of erection cannot
be ignored. Safety plays an important role in successfully completion of any project.

Safety measures;
1- Lifting plan to be checked and feasibility to be established.
2- Lifting gears shall be inspected prior to use and calibration to be verified.
3- Erection plan to be explained to the concerned
4- Drop object study shall be prepared
5- SIMOP
6- Skilled manpower to be engaged.
7- Certified and factory made tools & tackles.
8- HAZOP

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