VD-LINE-WP57-SUB-ATM-0001-017 - ERECTION AND INSTALLATION PROCEDURE ATM TANK - Rev.1
VD-LINE-WP57-SUB-ATM-0001-017 - ERECTION AND INSTALLATION PROCEDURE ATM TANK - Rev.1
VD-LINE-WP57-SUB-ATM-0001-017 - ERECTION AND INSTALLATION PROCEDURE ATM TANK - Rev.1
Document Title :
Review Date: . . .
Engineer Lead Engineer
S.H. OH C.S. BANG
1 8-Mar-23 ISSUED FOR CONSTRUCTION M.M. SON H.G. LEE I.R. JUNG
0 26-Dec-22 ISSUED FOR CONSTRUCTION M.M. SON H.G. LEE I.R. JUNG
A 20-Dec-22 ISSUED FOR APPROVAL M.M. SON H.G. LEE I.R. JUNG
REVISION HISTORY
Rev. Date Description Page
CONTENTS
1. GENERAL .................................................................................. 4
5. BOTTOM .................................................................................. 6
6. SHELL ....................................................................................... 11
8. ROOF........................................................................................ 14
9. TEMPORARY ATTACHMENTS................................................... 16
1. GENERAL
1.1. This procedure is applied to the field erection requirements for the Cone Roof Tank (CRT) and
Internal Floating Cone Roof Tank (IFRT) for the following articles.
1.2. Project: LINE (Lotte Chemical Indonesia New Ethylene Complex) Project.
2. RELATED DOCUMENTS
2.1 Standard and Codes
1) API Standard 650 12th Ed., 2021 Welded Tanks for Oil Storage
2) ASME Section V, 2021 Ed. Nondestructive Examination
3) ASME Section IX, 2021 Ed. Welding and Brazing Qualifications
4) ASME Section II, 2021 Ed. Material
2.2 Procedure
1) WPS/PQR (ATM TANK) (VD-LINE-WP57-SUB-ATM-0001-008)
2) SURFACE PREPARATION & PAINTING PROCEDURE (VD-LINE-WP57-SUB-ATM-0001-011)
3) INSPECTION AND TEST PLAN FOR ATM TANK (LINE-000-QB-4-0017)
4) ATM TANK INSPECTION AND TEST PROCEDURE (LINE-000-QA-4-0018)
5) HYDROSTATIC TEST PROCEDURE (VD-LINE-WP57-SUB-ATM-0001-007)
6) PWHT (KINE SCOPE)
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4. FOUNDATION WORK
Prior to erection of bottom plates, the following items shall be confirmed by civil contractor.
4.1 Check the center of the foundation.
Stretched out piano chords on the axis (0°-180°) and (90°-270°) and the tank foundation shall
be obtained at the crossing points of the chords.
Marking of the final tank foundation center shall be done after lay down of the bottom center
plate.
4.2 Check the (0°- 180°) axis and the (90°-270°) axis.
Verify (0°-180°) axis and (90°-270°) axis, using transit or measuring chord between axis with
same radius from foundation center.
4.3 Check horizontality and the slope of the foundation surface.
Using automatic level, verify that the foundation has the slope as per construction drawing.
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5. BOTTOM
After foundation has been found to be acceptable as per applicable standards (API 650 para 7.5.5),
annular plate and bottom plate laydown shall be started.
5.1 Shop Cutting
1) Mark dimensional of plate for bottom and annular as per approved drawing and cutting
using cutting machine.
2) After cutting bevel the edge of plate as per approved drawing.
3) Do dimensional inspection of finish cutting bottom and annular plates as per approved
drawing and mark bottom tagging for installation.
4) For annular plates dimension tolerance + 3 mm or follow approved ATM TANK
INSPECTION AND TEST PROCEDURE (LINE-000-QA-4-0018).
5.2 Annular Plates Arrangement
1) From the established marks on the foundation, stretch piano wire along 0°-180°and 90°-
270°axes.
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2) Mark off the position of annular plates on the foundation, e.g. annular joints and outside
radius of annular.
The last joint of annular plate may be cut in field depend on another joints condition.
Note that the laydown radius of annular plate is larger than the theoretical radius
required due to anticipating for the shrinkage.
The designed diameter plus shrinkage all allowance shall be considered in the laydown.
8) In dealing with three (3) lap joints of bottom plates and cut off top plate in accordance
with bottom plate drawing. Cutting pattern and fit up of three plates lap joint are shown
below;
Figure 5.4 Cutting Pattern and Fit up of Three Plate Lap Joints
9) When plate corners are cut using flame, pay attention not to damage the plate
underneath.
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7 1 5
6
2
Note; The annular butt joint shall be welded in two (2) stages to minimized distortion of
annular plate itself.
2) The welding must principally start from the center of the tank toward the circumference.
Refer to the figure below for the welding sequence.
① Weld rectangular adjacent bottom plates together. (lengthwise) Before welding the
joint, plates shall be free from tacks.
② Weld the rectangular adjacent bottom plates together. (widthwise)
③ Weld the sketch plates together. (i.e. the adjacent plate side of one sketch plate to
another sketch plate.)
④ Weld sketch plates to bottom plates. This is the final seam.
3) After completing the welding of all outer 250 mm of annular plate joints, erect the first
shell ring course and weld the vertical joints.
4) Fit-up the corner weld joint.
5) Weld the corner weld joint of the shell plate to annual plate.
Use channels as knee braces between shell and annular plates to control the rise of
inside annular plate due to shrinkage. Leave a few places without welding to provide
drainage for rainwater temporarily.
Figure 5.7 Corner Weld Joint of The Shell Plate to Annular Plate
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6) Finish welding the annular plates together. Examine the first pass as per Project
Inspection & Testing.
7) Fit-up & weld the bottom sketch plates to the annular plates.
8) Prior to start of all welding, the welding joint shall be cleaned using grinding and wire
brush to remove moisture, oil dust, waste and other foreign materials.
9) The bottom plate welding can be performed by either manual welding or machine
welding (FCAW) in accordance with WPS.
10) In case of the tanks for which coating have applied to the inside, weld bead and plate
edges shall be smoothed.
11) After completing all the welding of the bottom plates, inspection shall be carried out as
per approved ITP (LINE-000-QB-4-0017) and procedures (VD-LINE-WP57-SUB-ATM-
0001-017).
6. SHELL
6.1 General Shell Erection Sequence
1) Erect the Shell Course No. 1.
2) Fit-up & Weld the Course No.1 vertical joints.
3) Fit-up & Weld the Corner (Shell to annular) welds joint.
(Can be done after erecting of shell course from No.1 up to top at any time, according
to the site conditions)
4) Erect at least (3) three plates at the same time (Fit-up only) in Course No.2.
5) Fit-up and weld these three plates together (Vertical).
6) Continue erecting, fitting and welding of Course No. 2
7) Fit-up & Weld the horizontal seam.
8) Erect the remaining Courses and weld the same sequence as explained above.
4) Tack pair of nuts to the bottom at the minimum spacing of 2500mm on a radius of 20mm
inside and outside shell.
5) Weld all the nuts and temporarily attach the key plate on the shell before erection.
6) Hang the Course using proper lifting equipment with clamp.
7) Set the end of the plate on the previously made punch marks.
8) Plumb plate using long level (at least 2 meters long) and tack channels between the plate
and the bottom to hold it in place.
9) Hang and hook the next plate to the first plate erected. Move the plate in or out as
required to put the other end on the punch mark.
10) Plumb the plate and tack a channel on the leading end and one at the middle sheet to
hold it plumb.
11) As the plates are hung, drive wedge to the nuts at the bottom to round the plate to
proper position.
12) Continue hanging the remaining plates using the same procedure. Hang the plates so
that both ends are on the third points of the next lower plate.
13) Do not fit the horizontal seam past any vertical seam that has not been completely
welded.
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14) Tolerance
After erection but before welding, first course shell plates roundness, level and
plumbness shall be checked and adjusted to within tolerance shown below;
· Plumbness
- 1/200 of the total tank height, Max. 6mm in any shell
· Levelness
- ±3 mm in any 9 m
- Max. ±6 mm in total circumference
· Shell inside Radius (Difference from the reference marking in radius.)
- Diameter < 12 m : ±13 mm
- 12 m ≤ Diameter < 45 m : ±19 mm
- 45 m ≤ Diameter < 75 m : ±25 mm
- Diameter ≥ 75 m : ±32 mm
2) Horizontal Joints
a) Do not fit the horizontal seam until all the vertical joints of above and below the seams
have been welded completely.
b) Before starting welding, it is important that the plate be straight and plumb after it is
fit, which means if the gap varies, the edge must be built up before welding.
c) Misalignment shall not exceed 20% of the upper plate thickness or 3mm whichever is
the smaller.
d) Due to fabrication error, uneven gap may result. In this case, built up with weld metal
to produce even gap.
e) Fit and tack in the bevel on all beveled round seam.
f) Weld the joint following the Project Welding Procedure.
g) All before/after PWHT, NDE shall be conducted in accordance with approved ITP and
procedures only for nozzle part tank no. 80-TK-121.
8. ROOF
8.1 Roof Column Assembly, if any
1) The roof column shall be pre-assembled on the temporary stand, prior to erection in the
tank.
2) The top plate, base plate and required parts shall be installed, also. And the guy wires for
erection shall be provided at the top of columns.
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9. TEMPORARY ATTACHMENTS
9.1 Holes in plate work, to assist in erection, are not permitted. Lugs, nuts, clamps and other
devices to assist in erection may be attached to the tank plants by welding, nut all such
attachments required only for the purpose of erection shall ultimately be removed and any
noticeable projections of welded metal remaining shall be carefully ground or chipped away.
9.2 Great care shall be exercised to avoid gouging or tearing of plates in the process of removing
attachments. However, when such instances occur, remedial welding shall be restricted to
areas where the depth exceeds 1.5 mm. Shallower area shall be carefully “blended” by grinding
only.
9.3 If, necessary, repair welds shall, on completion be ground smooth (but not necessarily flush
with the plate)
9.4. NDE (PT/MT) after removing temporary attachment.
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10. INSPECTION
· All Inspections shall be followed in accordance with the approved ATM Tank Inspection
Procedure (LINE-000-QA-4-0018) and Inspection and Test Plan for ATM Tank (LINE-000-QB-4-
0017).
· The inspection records shall be reviewed and signed off by the KINE’s inspector. The records
shall be submitted to KINE as required in applicable project specification.
11. PWHT
· PWHT shall be conducted by CONTRACTOR (KINE) and followed in accordance with the related
code requirement (API 650 para 5.7.4).
· The relevant procedure will be prepared and submitted later by KINE
14. SAFETY
· Tank to be internally coated and to be installed with IFR shall be grinded smoothly on welding
seam parts.
· Risk Assessment of all activities associated with this procedure shall be done before starting
any activity.
· Permit to Work shall be obtained prior to commence any activity at site.
· Frequent participation shall be done in the tool box talk by site management (CCM & CM).
· Tank shall be secured by Guy rope against wind, if required.
· Oxy-acetylene/propane gas cylinder shall be secured properly all times at site.
· Cylinder trolley shall be used for carrying of oxy-acetylene/propane gas cylinder and always
keep in vertical position.
· Gas cylinders shall be covered by wet fire blanket to avoid from any ignition source during site
activity.
· Confined space log sheet maintained by confined space hole watcher during working in
confined space.
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· Confined space hole watcher must be reported to emergency response team, in case any
emergency in confined space.
· Full face shield shall be used for while cutting & grinding.
· All welders shall be used welding mask & dark glass while performing the welding work.
· Fire extinguisher shall be checked periodically and certified.
· All personnel must be mustered under the tent during lightening.
· Radiography source shall be stored in the approved pit constructed at site (If use RT)
· Area shall be cordoned off and warning sign to be posted prior to commence the radiography
work at site.
· Permit to Work must be obtained prior to commence the radiography work at site.
· All construction waste shall be stored in appropriate waste bin and transferred to designated
waste disposal yard.
· All scrap materials shall be stored approximately 40 meters away from the workplace to avoid
from tripping hazard.
· All personnel must be followed local rules & regulations and laws.
· Barricade shall be provided underneath of working at height to avoid falling object from height.
· Area shall be cordoned off while working at height (under the roof) by using of Mobile Scaffold
Tower.
· Daily inspection of trolley wheel break shall be done.
· Unauthorized entry restricted.
· Necessary safety Sign board shall be displayed at work site.
· Chemical using for developing of films shall be reused.
· Equipment and Personnel shall be deployed as per requirement.
· All instruments/equipment shall be maintained in good working condition as per maintenance
schedule.
· Radiography shall be done at lean time. Nobody shall be allowed to work nearby during
radiography.
· All workmen, supervisors and engineers shall use proper personnel protection equipment.
· All employees should follow the HSSE Rules. Full body harness and lifeline will be used while
working at height. Sufficient numbers of Fire Extinguishers will be placed for any fire incident.
· All power tools will be inspected by competent person P&E in-charge approved by HSE
department before use.
· Lifting will be done as per the lifting plan. All necessary precautions shall be taken during lifting
operation.
· Lifting plan shall be prepared by Tank Supervisor consultation with lifting supervisor/foreman,
reviewed by Tank Erection Engineer and approved by Construction Manager and will be
attached with lifting certificate prior to commence the lifting activity at site