MOLEETA FPF

AND
OBC PROJECT
Contract No: PDOC/23/07-482

REV NO.: A

DOCUMENT NO.: PDOC-236207-MS-MEC-101

PAGE 1 of 23

Moleeta FPF
And
OBC Project

METHOD STATEMENT FOR

TANK ERECTION
DOCUMENT No. PDOC-236207-MS-MEC-101

Rev
No.

Date

Description

Prepared
by HPSIC

Reviewed
by HPSIC

Mott MacDonald Ltd

Higleig Petroleum Services & Inv.Co.Ltd.

St. Anne House, 20-26, Welle Sley Road

Hai Elsafa, Abeid Khatim Street,

Croydon, Surrey, CR9 2UL,

P.O.Box 13224

United Kingdom

Khartoum, Republic of the Sudan

Approved
by PDOC

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

REV NO.: A

PAGE 2 of 23

INDEX
Page
1.0

INTRODUCTION

2.0

SCOPE

3.0

REFERENCES

4.0

SAFETY

5.0

MATERIALS OF CONSTRUCTION

6.0

CONTROL PROCEDURE

4 - 17

7.0

SEQUENCE OF ERECTION WITH

HYDRAULIC JACKING EQUIPMENT

17 19

8.0

DESCRIPTION OF PRINCIPLE OF
ERECTION SYSTEM

19

9.0

WORKING PROCEDURE

19

10.0

ASSEMBLY OF JACKING EQUIPMENT

& LIFTING

21 - 22

11.0

HYDROSTATIC TESTING

22 - 23

12.0

ROOF PRESSURE TEST

23

13.0

FIELD PAINTING

23

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

REV NO.: A

PAGE 3 of 23

TANK ERECTION PROCEDURE

1.0

INTRODUCTION:
This procedure covers the erection of Fixed Cone Roof Storage Tank including all
appurtenances of Moleeta FPF & Operation Base Camp Project.

2.0

SCOPE:
This document covers the procedure of field erection of crude storage tanks, Produce water
tank, skim oil tank, fuel oil (crude) tank, diesel storage tank, fire water storage tank, treated
water tank, pilot water injection tank, heat medium storage tank & water level control box.

3.0

REFERENCES:
3.1

AP1 650 Welded Steel Tanks for Oil Storage.

3.2

ASME Section V -Non Destructive Examination.

3.3

ASME Section IX Qualification Standard for welding & brazing procedure, welders,
brazers and welding and brazing operators.

3.4

ASTM-E94 Radiographic Testing.

3.5

ASTM-E709 Practice for MPI.

3.6

AP1 STD.2000 - Venting Atmospheric & Low Pressure Tanks.

3.7

SIS 05-5900 Pictorial Surface Preparation Standard for Painting Steel

Surfaces.

3.8

SSPC Manual Steel Structures Painting Council

Surface Preparation Standards

3.9

PDOC Specifications:
3.9.1

PDOC-SP-MEC-004 - Atmosphere Storage Tanks.

3.9.2

PDOC-SP-CIV-016-Platforms, stairs, ladders and hand railings.

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

4.0

REV NO.: A

3.9.3

PDOC-SP-CIV-019 External Painting and Protective Coating.

3.9.4

PDOC-SP-MEC-011 Equipment welding

3.9.5

PDOC-SP-PIP-011 Piping Materials

PAGE 4 of 23

SAFETY:
4.1

4.2

Personnel Protection Equipment:

-

Persons entering at job site must wear safety shoes and helmets.

In addition to the above the persons involving directly or indirectly on works,

such as welding, cutting, grinding or handling of rough, sharp edged, abrasive
materials should wear gloves, goggles, and face shields as required.

While persons involving directly or indirectly on works such as welding,

cutting, grinding or handling of rough, sharp edged, abrasive materials, shall
wear gloves, goggles, face shields as required.

While persons working on elevated areas will use the safety belt and secured
it properly.

Storage & Handling of Materials:

-

All the gas cylinders such as oxygen, acetylene etc. shall be handled with
care, protected against excessive heat and kept away from oil and grease.

All cylinders shall be at all time be kept to the vertical position and secured
with suitable steadying device (e.g. A chain to prevent their being knocked
over while in use)

All the paint materials shall be protected against excessive heat.

All the steel materials such as plates, pipes, structural steel etc. shall be
stacked in order, limit of height and secured properly.

All scrap, waste materials, rubbish and etc. shall be gathered at collecting area
for daily removal and the overall clean up shall be periodically organized by
safety committee.

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

4.3

4.4

4.5

REV NO.: A

Waste material and rubbish shall not be thrown from upper

lower levels or to the ground.

PAGE 5 of 23

levels to

Lighting:
-

Offices, workrooms, stairways, passageways, construction roads and working

areas shall be adequately lighted while work is in progress.

Where the use of artificial light is required, it shall be maintained until

workmen have left the area.

Electrical Wire & Apparatus:

-

All live part of wiring or equipment shall be effectively guarded to project all
persons or objects from harmful contact.

All work on electric wiring and equipment shall be performed by competent

and qualified personnel for class of work involved.

When temporary wiring is used, an approved type switch properly identified

and plainly marked shall be provided at or near the entrance to such space for
cutting off the current in emergencies.

Earth leakage protection system shall be provided on all temporary electrical

systems.

All the electrical generator shall be arranged with fences / screens / partitions
or interference by them with equipment inside.

Welding Apparatus / Equipment:

-

All welding apparatus and equipment shall be inspected frequently, defective

apparatus and equipments shall be removed from service, replaced or repaired
and re-inspected before again being placed in service.

Switching equipment for shutting down the welding machine shall be

provided on or near the welding machine.

When the operator has occasion to leave his work or stop for any appreciable
time, the power supply switch in the equipment should be opened and the unit
shut down.

All welding machines equipped with sockets for the purpose of power tools
etc. shall at all time are around.

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

4.6

4.7

4.8

REV NO.: A

PAGE 6 of 23

Hand Tools:
-

All hand tools shall be of recognized industrial manufacture and be kept in

good and used only for the purpose for which designed. They will be
subjected to regular inspection.

Tools having mushroomed heads, split or defective handles, worn parts or

other defects that will impair their strength or render them unsafe for use,
shall be removed from service and shall not be reissued until the necessary
repairs have been made.

Tools shall not left on scaffolds, ladders or overhead working spaces when not
in use.

The practice of throwing tools from one location to another, from one
employee to another, or dropping them to lower levels, shall not be permitted.

Wooden tool handles shall be sound, and shall be kept smooth, in good
condition and securely fastened to the tool.

Sharp edged or painted tools shall not be carried in workmens pockets.

Only non-sparking tools shall be used in locations where sources of ignition

may cause a fire or explosion.

Grinding Tools:
-

Grinding wheels shall be guarded for at least three fourth of the

circumference.

Work or tool rests shall not be adjusted while grinding wheel is in motion.
Tool rests on power grinders should not be allowed to be more than 3 mm
distance from the wheel.

Cracked or damaged grinding wheels shall not be used.

Grinding wheels shall not be operated in excess of their rated safe speed.

Pneumatic Tools:

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

4.9

REV NO.: A

PAGE 7 of 23

Pneumatic tools shall be used only by employees familiar with and properly
instructed in their use.

Pneumatic tools shall be kept in good operating condition, thoroughly

inspected at regular intervals and particular attention given to control and
exhaust valves, hose connections, die dies and tools from being accidentally
expelled from the barrel.

Safety clips or retainers shall be installed on pneumatic impact tools to

prevent dies and tools from being accidentally expelled from the barrel.

Pressure shall be shut off and exhaust from the line before disconnection the
line from any tool or connection.

Safety lasting shall be provided at connection between tools and hose.

Air hose shall be suitable to safety withstand the pressure for which is
intended. Leaking or defective hoses shall be removed from service.

Hose shall not laid over ladders, steps, scaffolds or walkways in such a
manner as to create a tripping hazard.

The use of compressed air for blowing dirt from hands, face or clothing is
prohibited.

Lifting Works:
Rigging : Ropes, cables & Chains:
-

The use of ropes, cables and chains shall be in accordance with the safe usage
recommended by the manufacturer or within the safe limits.

Slings, their fittings and fastenings, when in use, shall be inspected before
using by a authorized person for evidence of overloading, excessive wear or
damage. Slings found to be defective shall be removed from the service.

Proper storage shall be provided for slings while not in use.

The maintenance and testing of slings shall be done only by authorized

persons.

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

4.10

REV NO.: A

PAGE 8 of 23

Suitable protection shall be provided between the sling and sharp unyielding
surfaces of the load to be lifted.

Signals:
A uniform signal system shall be used on all operations of similar nature only one
person shall be designated to give signals to the operator. The signal shall be located
as to be clearly visible to the operator at all times. The signalman shall also carry a
whistle to sound warning signals.

4.11

4.12

Erection:
-

The erection work plan and procedure shall be checked thoroughly by

construction supervisors.

Warning signals of No Entry and safe ropes shall be provided as required.

The strength of the road and any obstacles on the route of the crane shall be
checked.

Cranes shall be locked or braked when not in operation.

All cranes shall be subjected to the statutory inspections in accordance with

local regulation.

Radiography:
-

Posters showing the rated power output, that radiation is taking place, no entry
allowed, and danger shall be displayed where radiation work is being carried
out. Before starting the radiological work, the restricted area shall be checked
to confirm by blowing a whistle or other audio device that no unauthorized
persons are in the area and reconfirmed during the radiation work.

Radiation apparatus shall be operated by a technician authorized by the local

authority.

During radiation work, doses of radiation at the boundary of the restricted area
shall bed measured and recorded by Geiger Counter.

When radiation work is scheduled at night above ground level, a watchman

shall be stationed on the ground.

Storage of Radioactive Material:

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

REV NO.: A

DOCUMENT NO.: PDOC-236207-MS-MEC-101

PAGE 9 of 23

Radioactive materials shall be packed in a container, which shall be placed in

a storage pit. Both container & storage pit shall be
5.0

MATERIALS OF CONSTRUCTION:
Bottom Plates

ASTM A 36

Shell Plates

ASTM A 36

Roof Plates

ASTM A 36

Roof Frame

ASTM A 36

Steel Works

ASTM A 36

Pipes

ASTM A 106 Gr. - B

Flanges

Stud / Nuts (For internal)

316L - SS

Stud / Nuts (For external)

A 193B7 / A 194 2H

Steelwork Bolting

ASTM A 307

Gaskets
6.0

ASTM A 105

Non Asbestos 3 mm thk.

CONTROL PROCEDURE:
6.1

Drawing and Document Control:

a)

Drawings, calculation sheets, fabrication & inspection procedures etc. shall be

submitted to PDOC / PMC prior to commencement of work.

b)

Drawings, calculation sheets and procedures shall be controlled by documents

and drawing control sheet.

c)

Any revision on drawings or documents shall be updated by re-submitting for

review or record.

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

d)

6.2

6.3

REV NO.: A

PAGE 10 of 23

All the inspection and testing shall be kept in a safe manner and handed over
to PDOC / PMC after completion of the project work.

Material Control:
-

All the delivered materials shall be carefully verified for the quality, size and
specification with mill certificate and drawings and shall stored properly.

All fittings, plates etc. shall be properly laid out on wooden supports clear of
the soil. Special care shall be taken that damage does not occur to joint faces
of flanges or beveled ends of fittings.

Fabricated parts and cutting materials shall be controlled by materials

description number and the drawing number.

Handling of materials shall be performed carefully so as not to damage or lose

them.

All materials shall be examined and repaired as necessary at the site before
being erected, to ensure that any damage incurred in transit is made good to
the satisfaction of PMC / PDOC representative. Particular attention shall be
paid to the removal of buckles and distortions in the shell and bottom plates.

Temporary Welding Control:

Holes in plate work to assist erection are not permitted. Lugs, nuts, clamps and other
devices required only for the erection purposes may be attached to the tank plates by
welding. All these attachments must be removed, and any noticeable projection of
weld metal remaining should be carefully ground or chipped away. Plates must not be
gauged or thorn in the process of removing attachments, and any indentation caused
thereby must be filled with weld metal and grand flush with the plate surface.

6.4

Welding Procedure Qualification Control:

Manual Welding:
Before beginning of erection, the proposed WPS shall be qualified by test
plates using these procedures to demonstrate to PDOC / PMC representative
that these procedures are suitable for making welds which conform to the
specified requirements. Each welding procedure shall be qualified in
accordance with the latest practice as given in the applicable rules of Section
IX of the ASME Boiler and Pressure Vessel Code.

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

6.5

REV NO.: A

PAGE 11 of 23

Weather Control:
Welding shall not be carried out when the surfaces to be welded are wet, nor when
rain or high winds are blowing, unless the welder or welding operator and the work
are properly shielded.
For carbon steel, the metal shall be a temperature warm to the hand for a distance of
not less than four times the thickness, or 75 mm whichever is the greater, in any
direction from the joint to be welded.

6.6

Preheating Control:
All seams of plates over 19 mm in thickness shall be preheated throughout to a
temperature between 50% and 100%.
For temporary welds, tank welds and manual repairs on plates over 19 mm in
thickness, these plates shall be preheated to a temperature of approx. 100 o C.

6.7

6.8

Tack Welds Control:

a)

All the tack welding directly involving the permanent components of tanks
shall be done only by the qualified welder in accordance with the approved
WPS / PQR.

b)

The tack welds used in the vertical joints between shell plates and in the
horizontal joint between the bottom course of shell plates and the bottom
plates, during the assembly of the tank, shall be removed and shall not remain
in the finished joints.

c)

Tack welds in the horizontal joints between shell plates and in the joints
between roof plates and shell plates, need not be removed provided that they
are sand and free from cracks, that the covering beads are thoroughly fused
into them, and that the quality of the welding is to the satisfaction of PDOC /
PMC representative.

Erection Control:

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

REV NO.: A

DOCUMENT NO.: PDOC-236207-MS-MEC-101

6.8.1

PAGE 12 of 23

Annular Plate:
6.8.1.1 Erection & Fit-up:
a)

Backing strip shall be fitted and tack welded to the

underside of each annular plate on the same side as
per the approved respective drawings with qualified
welder.

b)

Annular plates shall be laid in clock-wise and fit up

as per the approved drawings with specified root gap
etc.

c)

Check shall be carried out to ensure the laid bottom

diameter is as specified in the respective tank
approved drawings.

6.8.1.2 Welding:

6.8.2

a)

Welding shall be in sequence.

b)

Necessary jigs and fixtures shall be provided to

minimize the distortion due to weld shrinkage.

c)

After completion of welding the shell resting portion

of all butt weld annular joints shall be ground
smooth. The outer edge shall be radiographed and the
remaining portion of these joints shall be vacuum
tested.

Bottom Plates:
6.8.2.1 Erection & Fit Up:
a)

Before commencing erection the foundation shall be

checked for dimension level etc. The foundation
surface immediately under the shell plate shall not
exceed + 6 mm with a distance of 10 m and + 12 mm
between any two points around periphery.

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

REV NO.: A

PAGE 13 of 23

b)

Prior to installation of bottom plates to ensure that

underside of bottom plates are painted as per painting
procedure.

c)

Centre plate shall be laid first and shall transfer the

tank center on top of this plate.

d)

Prior to install the center (bottom) plate the center

pump shall be installed, welded and D.P. tested.

e)

All other plates shall be laid and lightly tack welded

with specified laps outward from center.

f)

Contact surfaces of plate shall be free from paint, oil

and water.

g)

Bottom plates shall be laid out carefully in

accordance with drawing.

h)

Three plates laps in tanks bottom shall not be closer

than 300 mm from each other and also the annular
plate joint shall not be closer than 300 mm from the
tank shell vertical joint.

6.8.2.2 Welding:

6.8.3

a)

Prior to application of each layer of welding the metal

surface shall be cleaned and dried thoroughly.

b)

All welding shall be done in principle from center to

outside.

c)

Jigs and fixtures shall be fitted as required to

minimize the distortion during welding.

d)

After completion of bottom plates welding and

vacuum test shall be carried out to all the weld joints
including butt weld joints using soap suds.

Shell:
6.8.3.1 Erection:

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

6.8.4

REV NO.: A

PAGE 14 of 23

a)

All the shell plates of the tanks shall be erected and

welded in accordance with the relevant approved
drawings, codes and specification.

b)

Tanks in this project shall be erected by Hydraulic

Jacks and Lifting Trestles (Big Tanks).

Shell Appurtenances:
6.8.4.1 Erection:
a)

The orientation, elevation, diameter of the shell

appurtenances such as shell manways, inlet / outlet
nozzles etc. shall be marked as specified in the
approved nozzle orientation drawings.

b)

Before making holes in the shell, a check shall be

carried out to ensure that the markings are correct.

c)

Cutting, grinding and bevel preparation shall be done

in accordance to the approved drawings.

6.8.4.2 Welding:

6.8.5

a)

Before beginning welding, necessary stiffener shall

be provided both tanks inside and outside the tank to
minimize the deformation of the shell plates. Special
care shall be taken for the large size appurtenances.

b)

Prior to welding all the weld joints shall be cleaned

and dried as required.

Roof Appurtenances:
6.8.5.1 Erection:
a)

The orientation, radial distance from the tank center,

diameter of the roof appurtenances such as roof
manways, vent, gauge hatch nozzles and etc. shall be
marked as per the approved drawings and shall be
checked prior to cutting a hole.

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

REV NO.: A

DOCUMENT NO.: PDOC-236207-MS-MEC-101

PAGE 15 of 23

b)

Cutting of hole on the roof grinding and installation

of appurtenances shall be done in accordance with the
approved drawings.

c)

Prior to cutting, special care shall be taken to ensure

that these nozzles have with sufficient clearance from
the roof framing members by the way of doing layout
of roof framing on top of roof plates.

6.8.5.2 Welding:

6.8.6

a)

Prior to welding all the weld joints shall be cleaned.

b)

Required jigs and fixtures shall be provided to

minimize deformation during welding.

c)

Welding shall be done in accordance with approved

drawings and specifications.

Welding Control (General):

a)

Welder qualification test shall be performed as per approved WPS.

b)

Any welding or repair of welding in connection with construction of

these tanks is performed by qualified welders and with qualified
welding procedures.

c)

The surfaces to be welded shall be cleaned and free from oil, dust,
water and other foreign material. When edges of plates are flame
cutting, the resulting surface shall be uniformed and smooth and shall
be free from scale and slag accumulation before welding.

d)

Single pass butt weld shall not acceptable.

e)

Each layer of weld metal in multi layer welding shall be from slag and
other deposits before applying the next layer.

f)

All completed welds shall be free from slag, brushed and thoroughly
cleaned before final inspection and subsequent painting.

g)

The reverse side of double welded vertical and horizontal butt joints
shall be back chipped, ground or flame gauged before the application
of the first run of welding to this side in a manner which will leave the

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

REV NO.: A

PAGE 16 of 23

exposed surface accessible and satisfactory for the fusion of the weld
metal to be added.
h)

The above requirements of back chipping may be released, when the

back of the metal run smooth and free from services which might
entrap slag and the PDOC / PMC representative is satisfied with the
standard of quality.
If back chipping is done by arc gauging, grinding shall be done to
bright the metal.

6.8.7

6.9

i)

Undercut on the base metal shall not be allowed, any undercut shall
be rectified.

j)

All the butt-welded joints shall have complete penetration through the
full thickness of the parent plate.

k)

The weld metal on both sides of all butt joint, except offset faces of
horizontal joints of unequal plate thickness, shall be built up in the
form of an overlay so that all the finished face in the area of fusion
shall extend above the surface of the adjoining plates to a height of
preferably not more than 1.5 mm.

l)

The edges of all welds shall merge with the surface of the adjoining
plates without a sharp angle.

m)

Peeving of butt welds shall not be allowed.

Weld Repair Control:

6.8.7.1

All defects found in weld shall be repaired. All completed

repairs shall be subjected to the same examination and the
approval of PDOC / PMC representative.

6.8.7.2

Any defect and cracks shall be repaired by gauging out and or

grinding such defect from the side of the joints as required
and re-welding.

6.8.7.3

Repairs of defects discovered during or after the tank has

been filled with water for testing shall be made with the water
level at least 300 mm below the point being repair, or with the
tank empty if repairs are on or near tank bottom.

Inspection and Testing Control:

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

6.9.1

5.9.2

6.10

REV NO.: A

PAGE 17 of 23

Inspection:
a)

All NDT and testing shall be done in accordance with tank quality
control plan for storage tanks.

b)

Quality Control Inspection shall be done progressively throughout the

construction work.

Testing:
a)

The vacuum testing of bottom plates shall be done after completion of

welding.

b)

Upon completion of welding of the entire tank, the tank shall be tested
by filling water.

c)

The roof test and reinforcement plate pneumatic testing shall be done
in accordance with pneumatic test procedure.

Painting Control:
All the surface preparation and painting works shall be done in accordance with the
surface preparation and painting procedure.

7.0

SEQUENCE OF ERECTION WITH HYDRAULIC JACKING EQUIPMENT:

7.1

Tank foundation is completed.

7.2

After checking, center point and co-ordinates are marked.

7.3

Fabricated annular plates and bottom plates are erected, welded and tested as per code.

7.4

Tank shell ring location is marked.

7.5

Temporary structural members 200 mm width preferably fabricated from 350 or 400
mm beam are erected at every 3000 mm. The shell ring plates are erected on these
structural members. These structural members provide passage for the manpower,
equipments inside the tank. This also helps in air circulation.

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

8.0

REV NO.: A

PAGE 18 of 23

7.6

Top most shells to a height of 4000 mm are placed or erected first on the support
members.

7.7

Curb angle or angle ring is welded. The gives a proper share to the tank.

7.8

Roof structurals are erected.

7.9

Erection of roof plates is completed.

7.10

The vertical trestles with stay pipes are positioned and aligned inside the tank.

7.11

The jacking units are assembled.

7.12

The hydraulic circuit is completed with the hydraulic pump.

7.13

The lifting lugs and fend off lungs are welded to the shell at the required locations.

7.14

By operating the pump, the tank shell ring is lifted to the required height suitable for
placing or erecting the next shell ring plates on the structural support members.

7.15

On completing the shell ring, the top shell ring (being held in position by jacking
units) is lowered, aligned and welded with the new shell ring.

7.16

The jacking units are disengaged and lowered to the base level.

7.17

The lifting lugs fend off lugs are removed from the top shell ring and fixed to the
lower new shell ring.

7.18

Operation under Sl. No. 6.14 to 6.17 is repeated till the last shell or first shell erection.

7.19

Before erecting the first shell, remove the temporary structural support in members.

7.20

The last shell ring plates are placed in position on the Base Plants and welded.

7.21

The top shells are lowered and aligned with the new shell ring.

7.22

The jacking units are dismantled and removed.

7.23

Wind girders, hand railing, spiral staircase, any other fittings, radiography of joints,
cleaning of the shell etc. are completed simultaneously.

DESCRIPTION OF PRINCIPLE OF ERECTION SYSTEM:

8.1

The tank bottom plates are placed on the prepared foundation and welded together.

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

9.0

REV NO.: A

PAGE 19 of 23

8.2

The beams or lattice work of the roof are assembled and finally joined to the upper
rim of the shell ring. Possibly the inner sheets of the roof are placed and welded
together and a special run around crane for transporting and positioning of the
following shell rings is installed.

8.3

The lifting equipment is assembled according to section 9. The plates of the second
shell ring (next to top ring) are positioned outside the first one.

8.4

The completed part of the tank (the roof and top shell ring) in lifted hydraulically to a
height, at which the plates of the second shell ring can be moved into place and the
roof sheeting can be completed.

8.5

The plates of the second shell ring are located exactly and welded together to the
lower edge of the first shell ring.

8.6

The plates of the third shell ring are placed outside the second shell ring.

8.7

The completed part of the tank (the roof and two uppermost shell rings) is lifted.

8.8

The above cycle of operations is repeated until the last (bottom) shell ring is finished.

8.9

The entire tank is lowered down to the bottom plate and welded to this.
The lifting equipment is dismantled.

WORKING PROCEDURE:
9.1

The tank periphery is marked out on the bottom plates.

9.2

Shoring trestles for guiding the sheets are placed at approx 2 m centers in between and
are tack-welded to the bottom plates.

9.3

The first (uppermost) shell ring is positioned on the sharing trestles. The shell ring is
checked to be exactly level. The shell plates are wedged in the shoring trestles to fit up
against the fixed trestle leg, bringing them into vertical position at the correct radius.

9.4

Roof beams are assembled and finally fastened to the uppermost shell ring. Possibly,
some of the roof sheets are placed and welded.

9.5

The location of the lifting trestles is masked out inside the erected shell ring. The
division should be symmetrical with equal spacing between all tank trestles.

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

REV NO.: A

PAGE 20 of 23

9.6

The lifting equipment is installed according to Section 9.

9.7

The first shell ring is lifted to a height at which the top edges of the tank trestles are
below the roof sheets. If the height of the two uppermost shell rings added together is
less than the height of the tank trestle, these two shells rings should be welded
together before this height is reached.

9.8

The roof sheets are placed and finally welded.

9.9

The run-around crane, for positioning shell plates is mounted on the roof. The crane
hoisting point shall run as close to the tank as possible.

9.10

Raise the completed part of the tank so that the next shell ring can be inserted below
the first one.
Do not lift unnecessarily high. The lifting can be stopped any moment by putting the
operating lever into the neutral position. The lift may not exactly the same at all
points. As soon as the required height is reached at one point, the lifting is stopped and
the stop valve of that lifting point is close. Then the lifting starts again until another
point has reached the same height. This procedure is repeated until the correct height
is reached at all lifting points. All valves are thus now closed and the elevated part of
the tank is now loading the lower grip-jaws of the climbing jacks.

9.11

Adjustment of the tank level can, if necessary, be made by lifting or lowering with one
or more jacks at a time, in doing which the valves on the other jacks should be closed.

9.12

The next shell ring is lifted and horizontally welded. For making the entrance to the
tank easier, the placing of the final sheet is left as long as possible.

9.13

The shell is finish-welded on both sides.

9.14

During the assembly of the next uppermost shell ring the previously finished part of
the tank has loaded the tank trestles. This part is now lowered until it rests on the
shoring trestles.

9.15

The climbing jacks and sliding chairs are lowered one at a time using the rope with
chain and holder. During this operation both the grip jaw sets of the jack must be in
disengaged position.

9.16

The lifting and fend-off lugs are now welded to the next uppermost shell ring.

9.17

The same procedure as above now repeated for following shell rings. As the load on
the lifting trestles now has increased, the oil pressure must be increased, but not mot
than necessary for liftings.

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

9.18

REV NO.: A

PAGE 21 of 23

Before the assembly of the last (bottom) shell ring, all shoring trestles are removed. If
necessary, the pump can be placed outside the tank. When the last shell ring is welded
to the tank wall, the whole tank is lowered and welded to the bottom plates.
Alternatively, the last shell ring too, is assembled on the shoring trestles and welded,
after which the finished tank is lifted slightly in order to remove the shoring trestles.

10.0

9.19

The assembly and lifting equipment is dismantled.

9.20

Never make a lift in strong winds without checking the tank stability.

ASSEMBLY OF JACKING EQUIPMENT & LIFTING :

10.1

The trestle column with climbing jack and graphite greased ball and socket joint,
sliding chair, stays and base-plate are placed radially along the tank periphery. The
base plate is tack-welded to the tank bottom having a space measure of 95 mm
between the inside of shell sheet and the outside of the base plate.

10.2

The vertical column of the lifting trestles is raised into vertical position. The two stay
lugs are welded to the tank bottom. The screws for vertical adjustment of the lifting
trestle shall be screwed out about 70 mm in order to have adjustment. The vertical
position is checked and adjusted in both directions, if required by rearranging the two
stays.

10.3

All tank trestles are set up as described above.

10.4

The lifting and fend off lugs are welded to the inside of the shell sheet. Note that there
must be a space of about 10 mm between the upper edge of the spacing clamp of the
sliding chair and the fend-off lug. Then the wedges between the shell sheet and the
shoring trestles, described in operation 9.3, are removed.

10.5

The stop cocks are fitted to all jacks.

10.6

The pump is placed in the center of the tank. Connect the pump with hoses to the
jacks. See that the hoses are not twisted and hang them up for prevention of damage.

10.7

Test the oil pump. Check before starting that the motor is set for the existing voltage.
Check the direction of rotation. Check the oil level.

10.8

Close all stop cocks of the climbing jacks and run the pump with 110 kp/cm 2 oil
pressure to check the tightness of the hose joints.

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

REV NO.: A

PAGE 22 of 23

10.9

Regulate the pump pressure to 20 30 kp / cm2 and stop the motor open all stop
cocks. The equipment is now ready for lifting.

10.10

Lifting: Start the pump. Put the operating lever into lift position and watch the
pressure gauge and the jacks. If no lifting takes place at the set oil pressure, increase
the pressure until lifting starts. This operation must always be made with the
lowermost pump pressure required as in that way even and uniform lifting occurs.
When all the jacks have made their full spoke, the operating lever is slowly brought
back into return position. Keep it in this position until all jacks have made their return
stroke, that is, the piston rods are completely retracted in the cylinders.
The above operations are repeated until the required lifting height is reached.

10.11

LIFTING SPEED:
It is desirable that lifting is made as quickly as possible. The time for the oil to return
back to the pump after each lifting stroke should thus be the shortest possible. This
return time depends on the oil viscosity and the oil must be fluid at the existing
temperature conditions. In cold weather a circulation run with preheated oil before
starting the lifting operation can considerably shorten the return speed. Normal return
capacity is about 15 lit / min. The return time is calculated from stopping the pump
until starting it again. The pumping time is calculated from starting the pump until
stopping it. This pumping time is directly dependant on the pump capacity and the
number of jacks connected, provided that the oil system is completely filled with oil
and free of air. For a lift of 95 mm (+ one theoretical lifting step of 100 mm) the lifting
time will be = pumping time + return time.

11.0

HYDROSTATIC TESTING:
This work will start after completion of all hot works on the bottom / shell plates as well as
after completion of roof structural erection. The hydrotesting shall be as per approved
hydrotesting process.

12.0

ROOF PRESSURE TEST:

This test shall be carried out while tank is full of water in accordance with the pneumatic test
procedure.

MOLEETA FPF
AND
OBC PROJECT
Contract No: PDOC/23/07-482

DOCUMENT NO.: PDOC-236207-MS-MEC-101

13.0

REV NO.: A

PAGE 23 of 23

FIELD PAINTING:

The external painting may start and carried out after filling water up to the top level and
prior to start dewatering where up to the top level and prior to start dewatering where as the
internal painting will be carried out after completion of dewatering. Both the painting will
be done as specified the surface preparation and painting.

14.0

QUALITY CONTROL:
14.1 The quality records and inspection reports shall be performed simultaneously with
construction. These records shall correctly and timely reflect the status of the
construction. Q.C engineers & technicians hall often review these records. The
specified personnel shall be
responsible for record making.
14.2 The inspection report made by the Q.C inspectors shall reflect the inspection items
and quality status