Dismantle Tank Procedure (Rev. a)

1 17

PROJECT : TANK FACILITY UPGRADE, BANGKO GS

DOCUMENT TITLE : DISMANTLE TANK PROCEDURE

DOCUMENT NO. : ME - GSBGKO - TFU - QC - 001

A Issued For Information18-Feb-13 DK DS

NAME

APPROVED

CPI

NAME DATE

REV DATE PURPOSE

PREPARED BY : CHECKED BY :

TIMAS SUPLINDO PT.

NAME

PAGE

of

PT.TIMAS

Discipline : Rev. : Status : Date : Page :

QC A A 2 of 17

A B C D E F G A B C D E F G

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

49

50

47

48

45

46

43

44

41

42

39

40

37

38

35

36

33

34

31

32

29

30

27

28

25

26

23

24

21

22

19

20

17

18

15

16

13

14

11

12

9

10

7

8

5

6

3

4

1

2

TANK FACILITY UPGRADE, BANGKO GS

DISMANTLE TANK PROCEDURE

Doc. No :

ME - GSBGKO - TFU - QC - 001 18-Feb-13

TOTAL OR PARTIAL REPRODUCTION AND/OR UTLIZATION OF THIS DOCUMENT ARE FORBIDDEN

WITHOUT PRIOR WRITTEN AUTHORIZATION OF THE OWNER

TABULATION OF REVISED PAGES

PAGEREVISIONS

REMARKSATTACHMENTS

REMARKSATT PAGE

Skid TITLE : Skid CON. 107 Skid TITLE : CON. 107

TIMAS

Discipline : Rev. : Status : Date : Page :

QC A A 3 of 17

Cover

Tabulation of revision page

Table of content

1. General

Scope

Aplicable References

Equipment & Material

Man Power

Safety

2.1 Dismantle Tank Procedure

Sequence for Execution Work

2.2 Cleaning The Tank

3.1 Dismantle Roof

4.1 Dismantle of Shell Plate

5.1 Dismantle of Bottom Plate

6.1 Attachment

6.2 Load Chart 13

TOTAL OR PARTIAL REPRODUCTION AND/OR UTLIZATION OF THIS DOCUMENT ARE FORBIDDEN

WITHOUT PRIOR WRITTEN AUTHORIZATION OF THE OWNER

TABLE OF CONTENT

1

2

3

4

1.1

1.2

1.3

1.4

TANK FACILITY UPGRADE, BANGKO GS

DISMANTLE TANK PROCEDURE

Doc. No :

ME - GSBGKO - TFU - QC - 001 18-Feb-13

5

1.5

6

2.1.1

6

7

9

10

11

TIMAS

TANK FACILITY UPGRADE – BANGKO GS

DISMNATLE TANK PROCEDURE

Doc No : ME – GSBGKO – TFU – QC - 001

d

Discipline : QC

Rev : A

Status : A

Date : 18-02-2013

TOTAL OR PARTIAL REPRODUCTION AND/OR UTILIZATION OF THIS DOCUMENT ARE FORBIDDEN WITHOUT PRIOR WRITTEN AUTHORIZATION OF THE OWNER

1.1. Scope

This procedure covers the requirement for replacement of storage tanks. It also

includes dismantlement of existing roofs, rafters, columns, shells, and bottom.

1.2. Applicable References

API standard 650, 10th

Edition, Welded Steel Storage Tank for Oil Storage

API standard 653, Tank Inspection, Repair, Alteration, and Re-

Construction

Specification TR-06. Replacement of Welded Steel Cone Roof

Specification EMS-A-100, Engineering Document and Requirements

1.3. Equipment and Material

Equipment for roof removal or dismantling of roof plate that necessary

1. Cutting Torch and appurtenances

2. Flashback Arrestor

3. Drilling Machine

4. Oxygen Bottle

5. LPG Bottle

6. Grinding Machine & Grinding/Cutting Disk

7. Mobile Crane 100 tons

8. Wire Sling, Shackles, Swivel, Clamp, Wrench

Page : 4 of 17




d

Discipline : QC

Rev : A

Status : A

Date : 18-02-2013


9. Rigid Scaffold if necessary

10. Gas Detector if necessary

11. Wood Plank, Plywood

12. Platform Temporary

1.4. Man Power

Man Power for Roof Removal or Dismantling of Roof Plate shall be qualified

and experience, such as :

1. Tank Supervisor

2. Tank Foreman

3. Rigging Foreman

4. Rigger

5. Scaffolder

6. Fitter

1.5. Safety

1.5.1 Contractor shall verify that roof is safe to work on at all times.

Contractor shall provide and use planking to support the weight of personnel

working on top the roof. Contractor’s personnel shall not stand and walk on

existing steel roof at any time.

1.5.2 In area of work, the contractor shall use a minimum of one 4’x8’x3/4”

sheet of plywood or three 2”x12”x10” long planks side by side for every

two men in the area. It shall be the contractor’s responsibility to see that

Page : 5 of 17




d

Discipline : QC

Rev : A

Status : A

Date : 18-02-2013


each of piece of planking is laid to bear on at least two adjacent roof rafters.

1.5.3 Contractor shall provide at all times a planked walkway from work areas

to stairway access. The walkway shall be 4’x8’x3/4” plywood or three

2”x12” planks laid side by side. Plywood or planks are to be lapped 4 inches

and nailed together at ends.

2.1. Dismantle Procedure Tank T-03

2.1.1. Sequence for execution work Tank

Site preparation work :

The electric / Instrumentation system disconnected

Checking all existing pipe was dismantling and blinded

Open all Man hole /Nozle ( Roof , shell )

Gas freeing

Tank cleaning and flushing

Entrance permit ,Hot permit

Setting equipment , Generator , rectifier panel distribution

Safety orientation , Confined space ,etc .

2.2. Cleaning the Tank

Site preparation work and process :

2.2.1. Arrange for disposal of sludge.

2.2.2. Select appropriate personal protective equipment . If fress air respiratory

equipment is used , ensure that worker do not remove masks while in the tank because of

discomfort .

2.2.3. Execute entry permit if tests results and tank conditions are acceptable and

condition are safe for entry , ignition sources have been controlled , no lightning storms are

threatening ,and the intergrity of the tank is satisfactory .

Page : 6 of 17




d

Discipline : QC

Rev : A

Status : A

Date : 18-02-2013


2.2.4. Atmospheric testing should continue periodically ,such as at the start of each work

day , at shift change ,and during the shift as conditions change due to temperature increase ,

agitation of sludge, leaking tank bottom exposed ,piping leaks , hydrocarbon absorbed in

roof, etc .

2.2.5. If the tank has side manholes , consider the use of a water hose stream to start

cleaning from out Side the tank . The employer shall determine the personal protective

equipment and vavor concentration at wiworkers may safely begin cleaning the tank

from outside the man way without entering the tank .Ensure that hose nozzles are

electrical bonded to the tank .Such cleaning may require and entry permit if personnel

must break the plan of the manway .

Remove loose sludge , scrape or hydro blast those internal to be required

When necessary ,enter the tank and wash and remove waste materials .A vacuum

truck may assist in this .

Tank nozzles , coulomn ,are cafable of trapping hydrocarbons and should be

cleaned .

Be alert to leaking tank bottom with entrapped product .

Clean areas above the inside tank and waste materials should be removed.

Ensure contiuous ventilation throughout the cleaning process.

Maintain control over potential ignition sources.

In warm climates , monitor workers for heat stress.

3.1. Dismantle of Roof Plate

Dismantling of roof plate shall include dismantling roof rafter and top angle .

Generally dismantle work shall follow the opposite quarter system means when roof

dismantling of quarter completely executed next dismantling must be the opposite quarter or

two team work at the same time on both opposite quarter .

The following initial step shall be fulfilled prior to execution of the dismantling work :

Page : 7 of 17




d

Discipline : QC

Rev : A

Status : A

Date : 18-02-2013


Hot permit must be issued because several hot cutting work shall be conducted

Working highly shall be executor training course before execution started and permit

must be issued by client owner ( HSE dept.).

Lifting Temporary Platform on roof plate as per drawing. Temporary Platform will be

use for standing place when cutting a roof plate.

Inspect the roof condition to verify that the roof is safe to work on at all times and

above / below roof by cold cut a window on roof plate to check the availability of

flammable crude oil in storage tank and freeing gas.

This dismantling work shall be equipped the following equipment and tools

- Crane 100 Tons capacity

- All lifting tools and handling appurtenances (Swl sling , shackle ,clamp ,spreader

bar,etc )

- Safety cables are reeve to blank nuts attached around circumference

- Riggid scaffold ( Bracket standard ) around top shell circumferential of tank

- Cutting devices (oxy-acetylene )

- Two plies of three Planks 3/4’’ thick or plywood sheets 3/4’’ thick for support the

workers on existing roof plate .

Coordinate the sequence of work with other work team

When the preparation completely finished and safe for working on ,dismantling of

roof shall be executed and sequenced as follow :

Remove all tank appurtenances attached on the roof plate.This step shall be directed

and supervised by COMPANY Representative officer. Dismantling proses shall be started

from centre of roof to the peripheral of roof .

1. Remove the weld deposits or cut the roof plate nearby the weld joint .

2. Fit the lifting or handling device ( Clamp , shackle , Sling , Etc ) and prepare the sling

and sprider bar for lifting plate .

3. Drawn the plate location of the boom of crane coverage area .

Page : 8 of 17

Intall riggid scaffold around the out side of top to down bottom shell circumferenc

approx. 4’-0”( 1.2 m) below top angle .Install riggid scaffold conducted by scaffolder.




d

Discipline : QC

Rev : A

Status : A

Date : 18-02-2013


4. Take the plate down and transport to cutting area where the plates shall be cut to

standard size

5. When quadrant completely , the team must move from the opposite quadrant.

6. When all roof plates have completely removed , install 3 position of guy lines which

shall connect the centre coulomn to intermediste coulomn away from rafter shal be

removed. Following the center coulomn after all inner rafter completely removed .

7. Inner intermediate roof rafter shall be removed in second step .Left one rafter at each

corner of inner girder.Install guy lines that connect two innercoulomns to next two

coulomn at intermediate coulomns circle of coulomn –girder where the inner shall be

dismantled .Repeated this step until all inner coulomns and girders and attached rafter

completely removed .

8. Same step shall be used when excecute outer intermediate rafter , intermediate

coulomn-girder and finally outer rafters and coulomns-girders .

9. Dismantled rafters , girders and coulomns are taken down to the bottom inside tank

and step by step transported out side the tank to the storage area through the door

sheet or upper shell before shell be dismantled .

4.1. Dismantling of Shell plate Tank

Shell plate dismantle after Roof plate ,rafter ,coulomn ,girder , have completely

removed ,It must be on the upper Shell to lower Shell as dismantling sequences . Before Shell

activities are started . All Tank appurtenances attached on the shell plate shall be removed

carefully and stored include tools Instruments and accessories .

The following step dismantling of Shell plate shall be execute and sequenced as

follow :

1. Dismantling proses shall be started from upper shell plate to lower of shell plate .

2. Install riggid scaffold ( bracket standard ) around shell plate circumference approx

every range 1,8 metres and weld bracket clip for hanger of riggid scaffold beginning

Page : 9 of 17




d

Discipline : QC

Rev : A

Status : A

Date : 18-02-2013


from upper Shell to lower shell course with layer by layer every segment of shell

circumference .

3. Fit lifting or handling device ( Vertical clamp ,Spreader bar Shackle , Sling belt or

wire sling , wire rope , ).

4. Set up position lifting Crane for lift shell and hanging boom of Crane while prosess

cutting start .

5. Remove the weld deposit or cut at position welding seam joint as partial segment per

segment by cutting flame .

6. Remove shell by lifting Crane after prosess cutting finished for segment by segment

on circumference of shell plate to storage yard and the same event .

7. Continue prosess cutting and lifting at regular position step by step until to lower shell

finished .

5.1. Dismantling of Bottom plate Tank

Bottom plate may be dismantled at same time with dismantling work of roof plate .

But have to be finish after roof rafters and coulomn removal shall be sarted.As described

above the removal of bottom plate shall be coordinate with roof plate dismantling sequence .

It must be done on the opposite quadrant against the roof plate dismantling activities .Before

bottom activities are started all attached of apputunances on the bottom plate shallbe removed

carefully and storage .

Remove filled weld deposit or cut nearby the filled weld joint segment by segment as

arranged Bottom existing and finally transport bottom plate in the sequence as described

above to storage Area and cut as per requirement .

Page : 10 of 17




d

Discipline : QC

Rev : A

Status : A

Date : 18-02-2013


6.1. Attachment

Page : 11 of 17

Figure 1. Assesment Site




d

Discipline : QC

Rev : A

Status : A

Date : 18-02-2013


6.1.2. Assessment

Do assessment for make sure the metodh, equipments,and tools can be aplied on Site.

Page : 12 of 17

Figure 2. Lay Out




d

Discipline : QC

Rev : A

Status : A

Date : 18-02-2013


6.2 Load Chart

Page : 13 of 17




d

Discipline : QC

Rev : A

Status : A

Date : 18-02-2013


Page : 14 of 17




d

Discipline : QC

Rev : A

Status : A

Date : 18-02-2013


Page : 15 of 17




d

Discipline : QC

Rev : A

Status : A

Date : 18-02-2013


Page : 16 of 17




d

Discipline : QC

Rev : A

Status : A

Date : 18-02-2013


Page : 17 of 17

Documents

Dismantle Tank Procedure (Rev. a)