EEI CORPORATION

CONSTRUCTION METHODOLOGY

FOR THE CONSTRUCTION OF

15 MB VCR TANK
 SAFETY EXECUTION PLAN ON THE CONSTRUCTION OF 15
MB VCR TANK
1.0 PURPOSE
1.1 The purpose of this procedure is to establish guidelines in the
CONSTRUCTION OF 15 MB VCR TANK.
1.2 To establish a correct, safely and timely constructive work for the
CONSTRUCTION OF 15 MB VCR TANK.

2.0 SCOPE
2.1 This procedure covers the construction method and sequences in the .
CONSTRUCTION OF 15 MB VCR TANK.
.
3.0 REFERENCES
3.1 API 650 12TH Edition
3.2 Approved Construction Drawing
3.3 Project Specifications

4.0 GENERAL REQUIREMENTS AND RESPONSIBILITIES

4.1 PROJECT –IN - CHARGE

Shall be responsible in the supervision and execution of the
project. Should coordinate with client’s representative if
there are any changes in the specification.

4.2 SAFETY
4.2.1 Safety shall be a primary concern in the execution of the
works. A Safety Engineer will be mobilized to ensure Safety
Programs and Policies are being implemented. He shall see
to it that all workers are properly oriented with the hazards
of the work.
SAFETY PRECAUTIONS

4.2.2 Erection group shall check, determine and complies with

the following:

a. Check capacity of the lifting tools and / or lifting device

related to erection or lift-up.

b. Check capacity of lifting devices based on the length of

boom, working radius, angles, and its present efficiency.

c. Make sure that the load does not exceed the rated load
 capacity of lifting devices.

d. Check electric chain blocks and hooks for defect. Give special
attention to chain/sling or any lifting device, which is added
to make certain it is secured.

e. Centering of gin pole hook block directly over the load to

prevent the load from swinging when it is being raised. Be
sure that the load is balanced.

f. Rigger shall always be aware and warn everyone to stay well

out of the way in case the load should swing and fall.

g. No person shall be permitted to ride on loads of any

derrick hoist.

h. A tag line shall be provided in any load which may become

unmanageable to prevent the swinging of load when
it is
being raised or lowered.

4.2.3 All personnel involved in the erection process must wear proper
personal protective equipment and must be well oriented on safety
policies and procedures.

4.2.4 Refrain from using broken chain/sling or any dilapidated or worned-

out tools or rigging device.

4.2.5 Advise all personnel working near the area that there will be an
erection approaching on site and isolate the area by installing
barricade or barrier to avoid from entering inside unless authorized
to conduct a work within a limited area.

4.3 QUALITY CONTROL

4.3.1 QA/QC Engineer will be mobilized to ensure quality of work
and conformance to client’s specification. They will be
responsible for the development/preparation of a “Quality
Control Inspection Plan” (QCIP) for client’s approval. The
“Quality Control Inspection Plan” will define specific
responsibilities in quality control and various test and
inspection points. All works shall be done in accordance with
the client’s specifications and other applicable work
standards.
4.3.2 Quality control personnel must be well oriented in conducting test or
inspection of the following:

a. Dye Penetrant test

b. Visual Inspection
c. Dimensional Inspection
d. Vacuum Test
e. Hydro Test
f. Air test
 g. Diesel Test
h. Radiographic Testing
i. Peaking and banding
j. Plumbness test

4.4 QUALIFICATION AND MOBILIZATION OF WORKERS

4.4.1 Workers to be mobilized for this project shall be qualified according to
Personnel Qualification Standards. We have Personnel Qualification
Standards for tank fitters, steelworkers, riggers, masons, rebar men,
welders, scaffolders etc. Manpower deployment to site shall be done in
accordance with the manpower loading established by the Project-in-
Charge.

4.5 MOBILIZATION OF TOOLS AND EQUIPMENT

4.5.1 Construction tools and equipment will be deployed to the job site in
accordance with the establish tools and equipment loading. Only
tools and equipment, which have passed certification test shall be
deployed to jobsite.

4.6 MATERIAL HANDLING

4.6.1 Bottom plates, shell plates and roof plates shall be supported by
wood blocks or an A-frame to maintain its profile and convexity.
4.6.2 Provide a lay - down area near the tank foundation and lay – down
all the first course plate on an A-frame wooden dunnage prior too
erection.
4.6.3 All small parts and accessories including consumable materials such
as electrode and others shall be kept on well covered stockroom.
4.6.4 All jigging materials and other fit – up devices shall be readily
available.
4.6.5 Reinforcing bars shall lay near the perimeter of tank foundation
4.6.6 Gravel and sand shall be properly segregated

5.0 CONSTRUCTION OF TANK FOUNDATION

5.1 Excavation works for the tank foundation shall be done using backhoe.
Excavated materials shall be loaded directly on a dump truck for immediate
disposal to client’s designated disposal area. During excavation safety
paraphernalia such as perimeter barricades shall be provided. Deploy
competent spotter or guide man to ensure close monitoring on the
movement of backhoe.
 5.2 After excavation works are completed and attain the depth noted on the
approved drawing. Trim or conduct manual excavation to ensure the
levelness of subgrade materials.
5.3 Conduct compaction on the subgrade using plate compactor & walk behind
roller compactor
5.8 Laid gravel bedding to facilitate installation of rebars.
5.9 Install rebars for the footing foundation including vertical bars of the tank.
5.10 Pour concrete on tank footing foundation and make sure to get test specimen
for
concrete compressive strength test
5.11 Continue the installation for rebars on vertical , horizontal and stirrups in
order
to complete as per approved construction drawing.
5.12 Install formworks to the ringwall rebars. Ensure all the formworks are
properly
supported to resist load when concrete pouring commence.
5.13 Install the leak detection pipeline
5.14 Pour concrete on the ringwall foundation and make sure proper compaction
or consolidations are being carried-out to prevent concrete defects. Concrete
vibrator shall be utilize to ensure fresh concrete settle and cured consistently.
5.15 Backfilling of fill materials for every 250mm and conduct FDT for every layer.
5.17 Install HDPE liner and conduct miscellaneous testing to ensure the integrity
of
joint weld connections.
5.16 Laid sand and bitumen mixed on tank pad. Use plate compactor to ensure
sand and bitumen mixed are properly spread to the tank pad.

6.0 CONSTRUCTION OF TANK

Note: Fabrication, erection, and installation work activities shall be executed in
accordance with the Approved Construction Drawings, specifications, and
standard engineering practices.

BOTTOM PLATE ARRANGEMENT AND FIT - UP

6.1.1 Stretch out a piano cord along y – y axis ( 0 to 180 ) and x – x axis
( 90 to 270 ) on the surface of the tank foundation to serve as
datum line

0
 Centerline

270 90

180

6.1.2 Lay–down and fit – up the sketch plates in accordance with

drawings. The annular bottom line of the section must be
provided with backing plate to allow full penetration weld
joint.
6.1.3 Start the lay – down and fit – up of the bottom plates at the center
towards the circumference.

SKETCH PLATE USUALLY CUT TO

SUITE REQUIRED LAPPING DIMENSION

TACK WELDING ROD

TO THE CENTER OF
THE PLATE

6.1.4 Welding shall start from the center and radiate towards the
circumference. Final weld line shall be welded after the
completion of the fillet weld on the shell plate to the bottom
plate.
6.2 SHELL PLATE ERECTION
6.2.1 Prior to erection, all marking such as shell plate main and
auxiliary circular line accessories orientation and other
markings which are to be projected towards the top of the
tank, shall be inscribed clearly on the bottom / annular
plates. After the installation of bottom and annular plates,
perform full welding on all annular butt joints and then
conduct radiographic testing 50% of annular radial joints
before fit-up of shell plates.

300 mm length to be full welded

CONDUCT FULL WELDING ON PORTION OF ALL

ANNULAR PLATES PRIOR INSTALLATION OF FIRST
COURSE SHELL PLATES

6.2.2 Locate each shell plate joints and accessories on the shell circular
line, at the same time; auxiliary reference line shall be mark
inside the circular line to check shell plate roundness.
6.2.3 Each plate shall be supported by straight channel temporarily
attached to shell, down diagonally to the bottom plate to
maintain the plumb ness. It will be removed as soon as the
second course has been installed and fitted – up.
 IMPORTANT BRACE TO MAINTAIN
PLUMB NESS OF FIRST COURSE

6.2.4 After erection, fit – up of all vertical joints on first course shell plates
install strong back piece to prevent buckling before
commencing for full welding.
6.2.5 First course shell roundness, level and plumb ness shall be primarily
checked and adjusted within the tolerance stated on API
standard latest edition.
6.2.6 Once the first course shell plates finish the necessary inspection
intended for the tank. Perform full welding on all vertical
butt joints.
6.2.7 Full welding shall be carried-out using back-step method to prevent
distortion and other defects that will hamper to the integrity
of the tank. Make sure to follow approved Welding Procedure
Specification (WPS).
6.2.8 Conduct radiographic testing after all the vertical joints on first
course are completed to monitor and check the soundness
of welding.
6.2.9 Install strong back on the top of horizontal joints of the first course
shell plates.
6.2.10 Start fit-up of second course shell plates until it completed. Conduct
again the needed inspection as per API standard.
6.2.11 Then begin full welding of vertical joints from second course followed
by horizontal joints from first to second ring.
6.2.12 It is important to complete the full welding of the second course
6.2.13 Conduct radiographic testing again on the completed full welded
joints before erection of third course.
 6.2.14 Same procedure shall be follow on the next succeeding shell plates
to be erected.

7.0 STEEL STAGING PROCEDURE

7.1.1 After installation of all shell plates in the first course we
need to
install steel staging to facilitate on the erection of the
second
course.
7.1.2 Install and weld staging clip on the first course shell plate
with a
distance of 2 feet above the bottom plate. The distance of
clip
shall be suitable to the length of wooden platform.
7.1.3 Mount the steel staging on the steel clip and check for
levelness.
7.1.4 Steel staging shall be perpendicular to the shell plate.
7.1.5 Lay wooden platform on the steel staging.
Platform shall be secured using nylon rope to prevent
sudden movement prior execution of works.
7.1.6 Install 1-1/2" dia. tubular pipe staging post on steel staging.
Then install 1-1/2” dia. tubular pipe serve as mid and top
railing
to make the staging structures more durable and safe to use
7.1.7 H-frame scaffold shall be installed to serve as an access of
workers
7.1.8 Same procedure shall be applied to the succeeding shell
course.
7.1.9 Full welding shall not be permitted when the surface of joints
are
wet and/or inhibited by dirt or rust.
7.1.10 All welding works shall be done in accordance with the
approved
Welding Procedure Specification (WPS) and welding
sequence.
7.1.12 Each layer of weld metal or multi-layer welding shall be
cleaned
 from slag and any other deposits before applying the next
layer.
7.1.13 Prepare the second course plates where all the erection
jigging
materials is being attached temporarily after lay – down prior
to
erection.
7.1.14 Same procedure shall be applied on the succeeding
activities.

8.0 COLUMNS AND RAFTERS

8.1.1 Column erection shall start after the complete installation of
the bottom plates.
8.1.2 Prior to erection, column shall be pre – assembled to proper
length on the ground. This maybe done outside the tank
perimeter.
8.1.3 Locate column location, then erect column using the chain
block.
Provide guy lines to maintain column verticality and allow the
erection crew of an easy installation of connecting griders
and
rafters with less alignment job.
8.1.4 Lay the rafters and connect to the crown plate provided on
top of columns.

9.0 ROOF PLATE ASSEMBLY

9.1.1 After completion of the roof structure assembly, lay down
the roof plates starting from the center radiating outwards.
9.1.2 Fit – up then weld the short seams and long seams similar
to
weld sequence of the bottom plates.
9.1.3 Apply vacuum testing / inspection for leak test on roof
plates.

10.0 ROOF ACCESSORIES

10.1.1 Layouts contour of contact points of tank appurtenances on
roof and cut it out using manual gas cutting. Provide at least
1/8” clearance to allow full – penetration welding.
 10.1.2 Grind the edge of the opening and remove all slag. Provide
bevel
on edge if necessary or when required by client.
10.1.3 Each manhole and nozzles should be provided with
reinforcing
pad. Final installation and full welding of reinforcing pad shall
be
done after the nozzles or manhole has been completely
welded.
Apply dye penetrant testing / inspection on joint portion
between
roof plate to nozzle neck.

11.0 SHELL ACCESSORIES

11.1.1 Assemble the stair on the ground if it is made of a stringer
plate with bolted step gratings.
11.1.2 Install first the platform into its precise location prior to the
installation of stairs and bracket supports.
11.1.3 All shell opening layout for manways, nozzles and other
appurtenances shall be dimensionally checked and conforms
to drawing specifications.
11.1.4 Open the shell surface by manual gas cutting and make sure
that the edge of the opening are smoothly grinded suitable
enough to install the pad plate and nozzles or any other
appurtenances.
11.1.5 Install all accessories in accordance with the drawing
specifications.

TANK NON – DESTRUCTIVE TESTING METHODS

RADIOGRAPHIC TEST
DYE PENETRANT TEST
Required for shell plate butt – welds, annular plate
butt – welds, and flush type connections with butt –
weld. However, weld joints on bottom plates and
roof plates or for welds joining roof plate to top
angle, top angle to shell, shell to bottom and
appurtenances shall not require radiography.
Liquid penetrant examination is specified for the
tanks as per API 650 standard.
 VACUUM TEST Vacuum box testing and examination is applicable
only to the joints of the following:
o Bottom plates
o Roof plates
HYDROSTATIC TEST This test is limited to water filling only.
DIESEL TEST This test shall be carried-out on the root-pass weld of
the internal portion of shell to annular joint. Diesel
fuel oil will be apply on the external portion of shell
to annular joints.
TESTING, INSPECTION AND REPAIRS
1. Prior to acceptance, all work activities shall be completed to the satisfaction
of the client’s inspectors or the client itself. The entire tank when filled with
product shall be secured and free from any leakages.
2. All rubbish and other temporary materials remained for sometime shall be
removed or dispose when the erection is completed. Erection group shall
leave the site in good condition and free from any obstructions.

INSPECTION OF WELDS
1. Butt Welds Radiographic film shall be reviewed and evaluated by
QC personnel and submitted to client’s inspector with proper and
complete document prior to weld acceptance. In addition, the
inspector may visually inspect the butt weld joint for possible cracks,
arc strike, excessive undercuts, surface porosity, and other defects.
2. Fillet Welds Dye penetrant tests, diesel fuel oil tests, leak test
and vacuum test, these are all applicable for testing of fillet weld
joint. Inspector shall perform visual inspection for possible crater
cracks. For welds applied on nozzles, manholes, cleanout opening
and any other permanent attachment, undercutting shall not exceed
1/64”.
3. The edges of all welds shall merge with the surface of the plate
without sharp angle and the maximum acceptable undercutting is
1/64”of the base metal form vertical joints shall not exceed 1/32”
depth for horizontal butt joint.
Full welding of circumferential joint between bottom to shell plates
shall be done after the erection of the third course shell plates.
All shell plate butt joint shall be accurately matches and retain in
position during welding operation. Misalignment in completed vertical
 joints shall not exceed 10% of the thickness or 1/16” whichever is
larger.
Completed horizontal butt joints shall not project beyond the face of
the lower plate by more than 20% of the upper plate thickness
except that 1/16” projection is acceptable for upper plates less than
5/16” thick.
The maximum plumb ness error of the top of the shell relative to the
bottom of the shell shall not exceed 1/200 of the total tank height.
4. Peaking – provide 2 pcs. Sweep board or any equivalent 36” long,
one with inside radius curve and one outside radius curve for peaking
check – up. Peaking shall not exceed ½” or 12mm.
5. Banding - provides one - piece sweep board or equivalent 36” long
for banding check – up. Banding shall not exceed ½” or 12mm.

REPAIR OF DEFECTS
1. All defects found in welds shall be called to the attention of the
client’s inspector for approval shall be obtained before defects are
repaired.
2. Defects in weld shall be repaired by arc gouging or melting – out the
defects from one side or both sides of the joint as required, and re -
welding. All repaired weld joints shall be checked by repeating the
original method of inspection in accordance with API Standard.s