CONTRACT NO.

:
Document No.:

Tank Erection Procedure

Contract No.

Title Tank Erection Procedure

Document
MWP-C-CS-PC-0009 In Replacement of: No. of Sheet: 15
No.

Issued for Oct 30,

B
Approval 2014
Revision Prepared Checked Reviewed Approved
Revision Date
Details By By By By
 Rev. Rev.
A B A B
Pages Pages
COVER1 X X
PAGE
X X
SHEET
Table of
X X
Contents
4-15 X X

Issued for Oct 30,

B Xu Tianchen Xu Dong Li Lei Xing Qianli
Approval 2014

Revision Prepared Checked Reviewed Approved

Revision Date
Details By By By By

Rev. B Page 1 of 15
Contract No.:
Document No.: MWP-C-CS-PC-0009 Title: Tank Erection Procedure
 Table of Contents

1.0 Scope............................................................................................................4

2.0 Definitions...................................................................................................4

3.0 Reference Codes and Standards...............................................................4

4.0 Main Materials...........................................................................................5

5.0 Construction Preparation..........................................................................5

6.0 Foundation Acceptance.............................................................................5

7.0 Welding.......................................................................................................6

8.0 Main Parts...................................................................................................6

9.0 Tank Prefabrication and Erection Procedure.........................................7

10.0 Methods and specific demands of tank prefabrication

and erection.................................................................................................8

11.0 Geometric shape of tank body..................................................................12

12.0 Hydrostatic testing.....................................................................................12

13.0 Safety and technical measures..................................................................12

14.0 Coating Work.............................................................................................13

15.0 Completion..................................................................................................13

Rev. B Page 2 of 15
Contract No.:
Document No.: MWP-C-CS-PC-0009 Title: Tank Erection Procedure
 16.0 Quality Records and Inspection Reports.................................................14

1.0 Scope

This procedure provides a detailed method for all the tanks to be erected in
Matola.

2.0 Definitions

In this document, the following definitions shall be used in PROJECT:

3.0 Reference Codes and Standards

API Std. 650 Welded Steel Tanks for Oil Storage

ASME IX Qualification Standard for Welding and Brazing Procedures, Welders,

Brazers, and Welding and Brazing Operators

AWWA D100 Welded Carbon Steel Tanks for Water Storage

AWS D1.1 Structural welding code-steel

API1104 Welding of Pipelines and Related Facilities

Rev. B Page 3 of 15
Contract No.:
Document No.: MWP-C-CS-PC-0009 Title: Tank Erection Procedure
 4.0 Main Materials

Main materials shall conform to approved detail drawings& Datasheet of plates

and be inspected by Owner before using.

MWP-E-MA-DS-0001 Data Sheet for Steel Plates of All Tanks

5.0 Construction Preparation

The prefabricated plant is set up near the tank foundation and it doesn’t affect
the tank body erection according to the overall station construction
arrangement.

Such work will be finished in the prefabricated plant as plates sizing, bevel
cutting and wall plates shaping.

All plates should be coated at least one layer of primer prior to erection and
installation, back surface of bottom plate should be finished all coating works
prior to installation.

The technical procedure is inquired by all the construction personnel so as that

they can well understand the erection size and technical requirement.

6.0 Foundation Acceptance

The level of ring beam of tank foundation shall be inspected and the asphalt
surface level shall be checked in accordance with approved tank foundation
drawings before erection of storage tank.

Concrete ring beam is provided under the shell, the top of the ring beam shall
be level within ±3mm in any 9m of the circumference and within ±6mm in the
total circumference measured from the average elevation.

Rev. B Page 4 of 15
Contract No.:
Document No.: MWP-C-CS-PC-0009 Title: Tank Erection Procedure
 The thickness of asphalt layer of all tanks are 100mm, the asphalt layer of
foundation surface shall be compacted and free of impenetrate and
delamination default.

7.0 Welding

No welding work shall be performed when the surfaces to be welded are wet
from rain and when humidity level is too high.

Each layer of weld or multilayer welding shall be cleaned of slag and other
deposits before the next layer is applied.

The edges of all welds shall merge smoothly with the surface of the plate
without a sharp angle.

All completed welds shall be visually inspected to ensure absence of under

cutting, cavities, trapped slag and etc,

The welder qualification testing for all welders should be performed under the
witness of Owner on site, and the welder qualification testing should be in
accordance with ASME IX-Qualification Standard for Welding and Brazing
Procedures, Welders, Brazers, and Welding and Brazing Operators, all the weld
seams and joints only can be welded by the welders which are accepted by
Owner.

8.0 Main Parts

The main parts of tank are as follows:

Tank roof;

Roof structures;

Rev. B Page 5 of 15
Contract No.:
Document No.: MWP-C-CS-PC-0009 Title: Tank Erection Procedure
 Tank shell (Top angle);

Tank bottom;

Internal floating roof;

Tank nozzles;

Spiral stair way, platform, handrail, walkway;

Anchorage, manholes, vents;

Other Tank accessories.

9.0 Tank Prefabrication and Erection Procedure

Tank prefabrication and erection shall be done step by step as follows:

1. Foundation acceptance;

2. Prefabrication of tank bottom plates;

3. Laying out and welding of tank bottom plates;

4. NDT for outside welding seams of annular plate;

5. Erection of top course shell plate and top angle;

6. Prefabrication and erection of roof structures and etc;

7. Prefabrication and erection of roof plates;

8. Erection of remaining shell plate ;

9. Welding shell-to-bottom seams and remaining bottom plate seams;

Rev. B Page 6 of 15
Contract No.:
Document No.: MWP-C-CS-PC-0009 Title: Tank Erection Procedure
 10. Prefabrication and installation of internal floating roof;

11. Installation of last channel plate of first course shell;

12. Installation of spiral stairway, handrail & shell nozzles and platforms;

13. Installation of fire fighting ring pipes (water and foam);

14. Installation of other tank accessories;

15. Hydrostatic testing for tank;

16. Coating work of tank body.

17. Completion acceptance;

10.0 Methods and specific demands of tank prefabrication and erection

10.1 All prefabrication work is based on approved detail drawings. When material
requires straightening, the work shall be done by pressing or another non-
injurious method prior to any layout or shaping according to API 650.

Materials used to aid in the fabrication of tanks shall not have a detrimental effect
on the structural.

10.2 The edges of plates shall be plasma arc cut. Circumferential edges of roof and
bottom plates may be manually gas cut.

10.3 After preparation all edges shall be examined and all plates showing
laminations, slag inclusions, edge cracks or any other faults shall be rejected.

10.4 Effective measures shall be taken to avoid distortion, damage and rust of
materials during prefabrication and erection course. All surface defects due to
transport, prefabrication and erection shall be mended.

10.5 Prefabrication and erection of tank bottom plates

Rev. B Page 7 of 15
Contract No.:
Document No.: MWP-C-CS-PC-0009 Title: Tank Erection Procedure
 All plates shall be approved by Supervision. Shall be verified the heat number
and the respective certificates. The heat code shall not be erased from the
plates before approval by Supervision.

All prefabricated work shall be performed after each steel plate is visual-
examined. The plate thickness and size are checked to be acceptable.

For consideration the shrinkable weld, the diameter of plates arrangement for
the bottom plates shall be more than 0.1%~0.2% of designed diameter.

Remain two annular plates with symmetrical arrangement as adjustable plate

and blanking according to actual dimension on site.

Measure and determine a center of the tank foundation with theodolite, and
make a mark.

The cut bottom plate is marked its location as per the arrangement diagram.
The under surface is painted with anti-corrosion coating within 50mm away
from the edge.

Take the center of locating plate as a reference; carry out installation of tank
bottom plates to all directions according to the overlapping requirement on
detail drawing. The installing method is to lift and install mechanically, to
modulate by manual work and to validate by measure instrument in turn.

After completing installation of base plates, it shall be inspected to meet the

design drawings, and then start welding process. The tank bottom welding will
adopt the welding procedure and sequence with minimum shrinkage and
deformation.

Firstly perform welding seams at outer 300mm edge of annular plate, uniformly
distribute welders, implement welding symmetrically. Secondly weld middle
plates, the welding procedure shall start from center to all directions, first for
short weld, then for long weld, and the lowest-layer welding pass will use a
back step welding or skip welding method. The welding of the shell to bottom
shall be practically completed before the welding of bottom joints that may have

Rev. B Page 8 of 15
Contract No.:
Document No.: MWP-C-CS-PC-0009 Title: Tank Erection Procedure
 been left open to compensate for shrinkage of any welds previously made is
completed.

Upon completion of welding of the tank bottom, shall be followed NDT

procedure. Particular attention shall apply to areas such as dents, three-plate
laps, and etc. In addition, all welds shall be tested by vacuum-box test
according to API650.

10.6 Prefabrication and erection of tank shell plates

Control the following procedure quality before erection. For example blanking
length, width tolerance, diagonal tolerance, groove angle, and etc. Control
misalignment value, butt welding space strictly to decrease error accumulation
so as to ensure quality of fitting up for steel plate.

Weld the locating blocks of shell plates at inner side of the circle of assembling
datum line.

Lift the first piece of shell plate with crane and special lifting tools to install shell
plates one by one according to the requirement of shop drawing. After boarding
operation, adjust clearance of vertical seam and inspect roundness and
levelness of shell plates again. After totally qualified, fix them with clipping tools
and perform welding.

Plates to be joined by butt welding shall be matched accurately and retained in

position during the welding operation.

Misalignment for plates less than or equal to 18mm thick shall not exceed
1.5mm. In completed horizontal butt joints, the upper plate shall not project
beyond the face of the lower plate at any point by more than 20% of the
thickness of the upper plate.

Local departures from the design for the shell horizontally and vertically should
not exceed 18mm for plates less than or equal to 12.5mm thick, 13mm for
plates 12.5mm to 25mm thick when measured over a length of 2.5m remote
from weld joints.

Rev. B Page 9 of 15
Contract No.:
Document No.: MWP-C-CS-PC-0009 Title: Tank Erection Procedure
 At horizontal and vertical shell seams, shell profile should not deviate from
design by more than 10mm for plates less than or equal to 12.5mm, 8mm for
plates 12.5mm to 25mm thick when measured over a length 1m.

The maximum out-of-plumbness of the firstly installed shell course is 3mm.

Out-of-plumbness of other shell course shall be less than 3/1000 of plate width.

Prior to butt-welding, mud and sand, oily filth and rust shall be cleaned out from
bevel and within 30mm scope at both sides of bevel. Each welding seam shall
be performed by one welder.

After visual inspection is qualified, the nondestructive detection shall be done

for welding seams according to approved NDT procedure. NDT should be tried
to put in the night, so as not to conflict with installation work normally. The
defective welding seam shall be repaired timely, after qualified through re-
inspection, shift to next working procedure.

10.7 The installation procedure of tank roof is as follows:

Preparation→ installation of roof structures→ tacking for tank roof plates→

welding overhead seams of the tank roof→ welding flat seams of the tank roof
→installation of the platform and handrail→ cut hole for still pipes of
instruments installation→ welding for relevant positions→ derusting of welding
seams

etc, →painting for the roof plate→ visual inspection.

10.8 Tapping on tank body and installation of accessories

Tap inlet nozzle, outlet nozzle, drain nozzle, manhole, etc. on tank body
according to the drawing requirement.

When installing accessories on tank body, firstly measure its altitude and
levelness with a level, implement uniform tacking, then take symmetrical
welding process and reinforced.

Rev. B Page 10 of 15
Contract No.:
Document No.: MWP-C-CS-PC-0009 Title: Tank Erection Procedure
 11.0Geometric shape of tank body

Acceptance of tank geometric shape of tank body should be inspected as

per section 7.5 of code API650.
The maximum out-of-plumbness of the top of the shell relative to the bottom of
the shell shall not exceed 1/200 of the total tank height. The maximum out-of-
plumbness of roof columns, guide poles, or other vertical internal components
shall not exceed 1/200 of the total height. The 1/200 criteria shall also apply to
fixed roof columns.

Radii measured at 0.3 m (1 ft) above the bottom corner weld shall not exceed
±19mm.

12.0Hydrostatic testing

Hydro-test for tank should be performed as per section 7.3.

13.0Safety and technical measures

The site construction personnel are inculcated with safety knowledge to

strengthen their safety consciousness and avoid accident occurrence.

All construction personnel must wear personal protection equipment, special

for safety helmets.

Secondary wire used for welding in tank must be a new electrical welding cable
with good insulation.

The lighting facilities in tank must be installed on the insulated material and all
power supply lines shall be with good insulation and avoid be failing and
impacting.

The lifting equipment must be commanded by a qualified person.

The nondestructive detection shall stagger normal construction to avoid

radiation.

Rev. B Page 11 of 15
Contract No.:
Document No.: MWP-C-CS-PC-0009 Title: Tank Erection Procedure
 At normal boarding operation, it’s better not to weld at the same time to avoid
intercross operation resulting in collision.

At filling water test, observe the tank at any time, stop filling water immediately
and discharge timely in case of discovering tank sloping.

If finding leak, discharge water to 300mm below leaked weld seam, then repair
the leaked weld seam.

The measures of reducing temperature and preventing heatstroke shall be

taken during construction in tank due to higher temperature in summer.

Connection of process piping and tank body couldn’t be performed until the
hydro-test is qualified.

14.0Coating Work

Coating work shall conform to following documents:

MWP-C-CS-PC-0015 Construction procedure of painting

MWP-E-MA-SP-0002 Specification for Coating Materials of Tank
15.0Completion

Clean all dust and temporary support inside and outside the tank. Check
whether all the installation work has been finished. After all the work has been
finished, the Owner will carry out overall inspection and acceptance for oil tank
quality according to the design drawings and related specifications after
qualified completely.

16.0Quality Records and Inspection Reports

The quality record shall be done timely during the installation course by
appointed person and inspected by QC engineer and technical engineer.

Inspection report shall be done by QC engineer. Key points of quality control

are as table 1.

Rev. B Page 12 of 15
Contract No.:
Document No.: MWP-C-CS-PC-0009 Title: Tank Erection Procedure
 Table 1 Key Points of Quality Control
Serial Inspection
Inspection subitem Survey contents Remarks
No departments
Inspection for
Certificate for kinds of materials, APPE &
1 construction materials
Sign for kinds of materials Owner
and accessories of tank
According to requirements of design APPE &
2 Foundation hand over
drawings Owner

Inspection for conceal Painting inspection for bottom plate APPE &
3
item of tank Owner

Witness the test on site, welds visual APPE &

4 Welder qualification test
inspection and NDT Owner
5 Non-destructive test for According to MWP-C-CS-PC- APPE &

Rev. B Page 13 of 15
Contract No.:
Document No.: MWP-C-CS-PC-0009 Title: Tank Erection Procedure
 welding seam 0012NDT procedure Owner
Installation of tank Position and dimension of manholes APPE &
6
accessories and nozzles Owner
Geometric dimension of Lever radius, plumbness, APPE &
7
tank Local deviations Owner
Penetration test of
APPE &
8 internal floating roof Kerosene
Owner
weld seams
Hydro-test & up and
down test of internal Foundation settlement condition APPE &
9
floating roof and Weld seams Owner
Settlement Observation
APPE &
10 Coating Surface and thickness
Owner
Conceal project
APPE &
11 inspection （manhole Cleanness inside the tank
Owner
closed ）
APPE &
12 Capacity checkout Height and radius of tank
Owner

Rev. B Page 14 of 15
Contract No.:
Document No.: MWP-C-CS-PC-0009 Title: Tank Erection Procedure