SCOPE OF WORK:

Note: This scope covers the removal and replacement of the pontoon outer rim and portion of the
pontoon top plate including foam dam wall.

PROCEDURE FOR THE REMOVAL AND REPLACEMENT OF THE PONTOON OUTER RIM
PLATE.

1.0 PURPOSE

The purpose of this procedure is to describe the sequence to be followed when removing and
replacing the pontoon outer rim plate in the most practical manner without compromising quality
and safety.

2.0 SCOPE

The procedure covers the sequence to be followed when removing and replacing the pontoon
outer rim plate and portion of the pontoon top plate including the foam dam wall. The procedure
is to be read in conjunction with the approved quality control plans. The associated reports and
this procedure are to be included in the quality control dossier.

3.0 REFERENCES

 API Standards 650 and 653

 Welding Procedure Specifications
 Procedure Qualification Records
 Quality Control Plans
 Approved For Construction Drawings

4.0 SAFETY AND PRECAUTIONS

Safety awareness is an essential constituent of a satisfactory repair of such scope and is influenced
considerably by local conditions. The immediate hazards for such activities are the effects of
collapsing roofs, fire, explosion, falling objects and physical injury. The prime consideration in
any tank modification “Big or Small” is the need for safety. The inherent hazards are described in
the RAMS and DAILY RISK documents, specific attention should be given to these aspects to
ensure that the associated risks are minimized, or eliminated. All work must be carried out in
accordance with a permit to work (PTW) system; these permits must explicitly describe the work
to be carried out together with the precautions required. The work site should be checked
regularly to ensure that the permit requirements are being followed. Gas testing is to be done on a
regular basis.
Good housekeeping is required in order to ensure that the local working areas are free of scrap
materials and other debris, which present a safety hazard.

5.0 SUPERVISION

Suitable and adequate supervision with experience shall be used to accomplish this task

6.0 PREFABRICATION

All prefabrication shall to be in accordance with the approved for construction drawings and
approved quality control plans.
7.0 PROCEDURE FOR PRE-ERECTION

Preparation work for the safe removal and replacement of the outer rim will be carried out on site.

8.0 CONSTRUCTION OVERVIEW

Rigging activities shall be carried out by a competent rigger. All welding is to be monitored and
carried out in a controlled manner. Supervisors and QC inspector to verify proper control
measures for heat input and distortion are followed.

9.0 CONSTRUCTION SEQUENCE

9.1.1 Fit and tack channel sections across pontoon top plates, behind the foam dam wall
as close to the outer rim as possible to prevent sagging.
9.1.2 Fit and tack lugs on the shell and existing outer rim sections
9.1.3 Secure existing outer rim plates using chain blocks prior to cutting
9.1.4 Flame cut outer rim plates and remove from the tank in a controlled manner
9.1.5 Prep outer rim area for fitment
9.1.6 Fit and tack temporary support brackets to pontoon underside for new outer rim plates
9.1.7 Mark cut out area (500mm) on pontoon radial top plate section
9.1.8 Flame cut foam dam wall and remove from the tank in a controlled manner
9.1.9 Lift and position new outer rim plates over the tank shell onto pontoons via the crane.
9.1.10 Flame cut pontoon radial top plates and remove from the tank in a controlled manner
9.1.11 Fit and tack temporary supports on pontoon top plate to new outer rim plates
9.1.12 Fit, tack and weld vertical seams of new outer rim plates
9.1.13 Tack weld outer rim plates to pontoon bottom plate
9.1.14 Lift and position new pontoon radial top plates over the tank shell onto pontoons via
the crane.
9.1.15 Fit, tack and weld new pontoon radial plates to outer rim and pontoon top plate
9.1.16 Seal weld outer rim plate internals (top and bottom)
9.1.17 Weld out outer rim plates to pontoon underside.
9.1.18 Fit and tack foam dam wall plates into position
9.1.19 Weld out foam dam wall plates
9.1.20 Prep areas for pontoon patch plates
9.1.21 Fit and tack patch plates in position
9.1.22 Weld out patch plates
9.1.23 Carry out cosmetics on all welds
9.1.24 Carry out pontoon testing (12.5kPa)
9.1.25 Carry out NDE’s (specify)

10 HOUSEKEEPING
10.1 All equipment on site to be removed.
10.2 All debris and construction waste to be removed and tank returned to client.

END