Spec Storage Tanks- EPC

SUMED – ARAB PETROLEUM PIPELINES COMPANY

Expansion of SUMED Ain Sukhna Storage Capacity Phase 5

Specification for storage tanks

0 08-Jul-10 First Issue

Rev Date Revision Prepared By Approved By

document.doc

Document Number: M-AS-SPC-11602-10Document Type: SpecificationPages: 14

TABLE OF CONTENTS

1 SCOPE......................................................................................................................3

2 ENGINEERING.........................................................................................................3

3 TANK SPECIFICATION............................................................................................4

4 TANK SITE WELDING SPECIFICATIONS...............................................................6

5 PROTECTIVE COATING AND PAINTING OF TANKS............................................9

6 TESTING AND INSPECTION OF TANK................................................................10

7 TANK CALIBRATION......................................................................................121112

Arab Petroleum Pipelines Co. (SUMED) M-AS-SPC-11602Expansion of SUMED Ain Sukhna Storage Capacity Phase 5 Rev. 01

Specification for Storage Tanks Page 3 of 14

1 SCOPE

1.1 This specification covers Contractor’s scope of work regarding the design, engineering, supply and shipping of materials, transport from Alexandria port to site, erection, testing and painting of floating roof storage tanks on turn key basis.

1.2 Design, fabrication, erection and testing shall be in accordance with API 650 11 th edition, its Appendices, the philosophy of the existing tanks on site and this specification unless otherwise specified.

1.3 Contractor accepts full responsibility for compliance with all the provisions of the following SUMED Conditions:

a) API 650 11th edition and its supplement, addenda and appendices specially Appendix B, C, E, L, I, O,P .

b) N.F.P.A code.c) API 2000, venting atmospheric and low pressure storage tank.d) API 2003, Recommended Practice for protection against ignition out of static lighting

and stray currente) API 2350 Overfill Protection.f) API 651 Cathodic Protections.g) Since all soil investigation and tank foundations design and construction are included in

Contractor scope of work the adequacy of the foundation is Contractor responsibility.h) The adequacy of all materials supplied by contractor or others (sub suppliers, Sumed,

steel supplier, etc…) are contractor responsibility.

2 ENGINEERING

2.1 Contractor shall prepare detail and assembly drawings for each tank to include all data and details necessary for fabrication and erection. Drawings shall be in the English language and metric (SI) system. Show a complete nozzle and appurtenance schedule on the assembly drawing. Show all weights of all components of material take off on each drawing. Maintain the drawing list current showing revision and issue status of each drawing. Reissue this list with each issue of drawings

2.2 Contractor shall certify to SUMED according to API 650 11 th edition section 8 figure 8.2 that the tank has been designed, fabricated and constructed according to the requirements of the Contract. An as built data sheet shall be attached to the certification letter.

2.3 Contractor to define in detailed engineering Thermal stress relieving for fabrication shop and field relieving specially for first course and indicate method applied and equipment used.

2.4 Contractor shall furnish the API monogram name plates on each tank according to API 650 11th edition.



3 TANK SPECIFICATION

Stored crude design Sp.Gr. ranging from 0.7 to 0.95Design wind velocity 100 miles per hourDesign metal temperature 4 degrees celciousCelsiusCorrosion allowance NOService condition sulfur content in the crude oil max 5%

3.1 The height of the floating roof in operating position shall be as minimum as possible with provisions for housing for mixers and vortex beaker and rain drain system.

3.2 Datum plate shall be Stainless steel with Teflon washers.

3.3 Suitable internal spreader on the filling line coming off the bottom plate to eliminate vortex action during suction and to prevent impingement on the bottom side of the roof or overflowing of crude from roof rim seal or around roof supports when filling. Maximum filling / pump out rate is 15000 MT/hr.

3.4 Foundation loading to be submitted to SUMED for approval.

3.5 Allowable external load on tank shell openings shall be conducted by Contractor and taken into consideration in tank and piping design according to API 650 11 th Appendix P and upon piping stress analysis conducted by him

3.6 Variable-design-point method article 3.6.4 of API 650 11 th edition shall be used.

3.7 Sea water shall be used for hydrostatic test S.G of 1.03. 5

3.8 Rain fall to be defined by Contractor in the offer.

3.9 Earthquake and seismic loading as per API 650 11 th edition appendix E Zone 3.

3.10 Annular plates shall have a minimum radial width that provides 1100 mm between the inside of the shell and any lap welded joint, and 100 mm projection outside the tank shell.

3.11 Materials used for tank fittings shall be fully compatible with the materials used for tank construction. This shall not preclude the use of otherwise suitable material when so agreed by SUMED.

3.12 Each tank shall be fitted with the following minimum shell openings / attachments:

a) 2 X 36 inch manway doors in accordance with API 650.b) 6 X 30 inch manway doors in accordance with API 650 reinforced for Mixer installation.

Orientation to be suitable for blending and sludge/water removal.c) Roof drain nozzle (Qty to be calculated by contractor).d) 1 X 12” (minimum) nozzle flanged nozzle ANSI 150 for oily sewer system.e) 2 X (36” x 48”) flush type clean out doors designed per API 650 11 th edition.f) Earthing pads on the bottom course of plates.g) A spiral stairway shall be provided, the stairway to be fitted with flame shields to sides

and below treads.h) Each tank shall be surrounded by a cooling ring consisting of four sections each fed

riser attached to tank shell and connected to fire fighting network.



N.B1: Shell manholes to be provided with hinges and clean out doors to be provided with hinges or monorail for easy maintenance.

N.B 2: A walk way to be added from the spiral stairway to the bund wall for roof access.

3.13 Minimum weld requirements and spacing of welds around connections shall be revised according to API 650 11th edition and Contractor shall issue relevant drawing in detailed engineering phase after award for SUMED approval before fabrication.

3.14 Each tank shall have the following bottom connections:

a) 1 X 42 inch (filling / discharge) line is to come off the bottom plate fitted with a dam to prevent water from getting in suction 250 mm height.

b) 1 X 12 inch bottom draw off sump.

3.15 Contractor shall submit his proposed design for suitable internal suction spreaders to eliminate any vortex action when pulling the tank down and also to prevent impingement on the bottom side of the roof when filling.

3.16 Bottom plates shall be fitted with pads for roof supports as in API 650.

3.17 The roof design is to be of the contact, fully wetted type, generally in accordance with API standard 650 11th edition Appendix “C”. Provision shall be made in the roof for the installation of:

a) Temperature measuring / transmitting devices.b) Automatic level gauge (RTG).

3.18 The following equipment shall be fitted, generally in accordance with API 650.

a) Electric bonding to be achieved by approved suitable insulated cupper flexible cable.b) Gaugers platform and rolling ladders to provide access to the floating roof, the platform

shall have self-levelling treads and flame shields.c) Rolling ladder wheels shall rotate independently of the axle and be fitted with grease

nipples wheels shall be of Teflon type.d) Manual and automatic gauging to be performed from platform.e) Anti-rotating devices, to prevent the floating roof from rotating and damaging such

accessories as rolling ladders, drainage system, etc.f) Rain drains pipes complete with swing check valve.g) Automatic bleeder vents, which are to be sized for not less than the maximum filling

and suction rates of 15,000 metric tons per hour.h) Rim vents to prevent excess of pressure build-up within the rim space. Number per

tanks shall be calculated.i) Gauge hatch with self-closing, non-sparking cover.j) Metallic sealing ring with pantograph hangers and a continuous fabric seal weather

proof and fire-resistant secondary seal.k) Foam dam according to NFPA



4 TANK SITE WELDING SPECIFICATIONS

4.1 Tanks are toshall be all welded construction with floating roof.

4.2 Shell plates are to be butt-welded, the radial seams connecting the seams of the annular plates shall be butt welded to the option of the manufacturer.

4.3 All welding shall be carried out in compliance with the requirements of the following Standards and Codes of Practice:

- API 650 standard 11th edition.- ASME Boiler and Pressure Vessel Code, Section IX, latest edition and as further

specified herein, and generally speaking with guided by SUMED previous tank welding procedures.

4.4 Tanks and their structural attachments shall be welded by, manual shielded metal arc weld, automatic shielded gas and/or submerged arc welding processes, using qualified operators and suitable equipment.

4.5 Welding Procedures

4.5.1 Welding shall be carried out in accordance with specified welding procedures prepared by Contractor in accordance with ASME code and API 650 11 th edition and approved by SUMED / SUMED representative.

4.5.2 Welding procedures shall be qualified in accordance with the requirements of ASME boiler and Pressure Vessel Code, Section IX, latest edition and as further specified in Clauses 3.2.3 to 3.2.6 inclusive.

4.5.3 Charpy V-notch impact test coupons shall be taken from each procedure test weld specimen. the notches shall be located in the weld metal of the welded zone and in the plate at a distance of 15 mm from the transition zone.

The tests shall show a mean impact value for three tests not less than 3.5 kg-m with no single value less than 2.6 kg-m at 0oc.

4.5.4 Hardness surveys shall be carried out on procedure tests. At no point in the weld or HAZ shall hardness exceed a value of 280 Brinell or 300 HV 30.

4.5.5 Macro and micro specimens shall be prepared from each procedure test to enable examination of weld geometry and micro structure.

4.5.6 All welding procedure and test butt welds shall be radiographed. Interpretation of radiographs shall be in accordance with clause 4.10.5 of this specification.

4.5.7 Welding procedures qualification test shall be recorded in detail.

4.6 Operator qualification

4.6.1 All welders employed on the works shall be suitable qualified. A qualified welder shall be a welder who has successfully passed the welder qualification test. Test requirements shall conform to the relevant section of the ASME boiler and Pressure Vessel Code, Section IX, latest edition.



In addition to the mechanical tests prescribed above, all qualification butt welds shall be radiographed

4.6.2 The tests will be in accordance with the responsibilities of each individual welder differentiation being made between the automatic, semi-automatic, manual downhand and manual all positional operators.

4.6.3 Welder qualification tests shall be witnessed and approved by Sumed representative.

4.6.4 SUMED representative on site has the right to retest the qualified welders and also retest any welder on site at any time if his welds were found to be unacceptable according to the code standards.

4.7 Electrodes

4.7.1 Horizontal joints with full penetration will be made by the submerged arc process using electrode wires and fluxes of good quality.

Contractor shall supply with the electrode wire a certificate indicating the chemical analysis of this wire.

4.7.2 Hydrogen controlled electrodes shall be used for all manual arc welds if plate wall thickness is greater than ½” (12mm).

4.7.3 Where the automatic MAG process is in use, adequate shelter shall be provided over each joint, to protect the work from adverse weather conditions. The gas used shall be a welding qualifies gas (CO 2).

4.7.4 Welding electrodes shall conform to one of the following specifications:

ASTM A 233 AWS 5.1ASTM A 316 AWS 5.5ASTM A 558 AWS 5.17ASTM A 559 AWS 5.18

4.7.5 Welding consumables shall stored and handled so as to avoid damage to them and to the container in which they are shipped. Those in opened containers shall be protected from deterioration and excessive moisture changes. Welding consumable which show signs of damages or deterioration shall not be used.

4.7.6 Shielding gases shall be kept in the container in which they are supplied and these shall be stored away from extremes of temperature.

4.8 Site welding

4.8.1 Welding employed on the site shall be of a size and type suitable for the work, and shall be maintained in such condition as to ensure acceptable welds, continuity of operators and safety of personnel. Welding equipment shall be such as to supply the amperage, voltage and gas flow within the ranges given in the qualified welding procedure. Any equipment which does not meet the requirements shall be repaired or replaced.

4.8.2 When Contractor shall deem it necessary, welding work shall be done with sufficient weather protection against rain or wind.



4.8.3 The qualified welding procedure shall specify the preheating and stress relieving practices, which are to be followed according to the type of material used.

4.8.4 The preparation of edges to be welded shall be in accordance with Contractor’s standards and will be indicated on his drawings. The edges to be welded will be prepared by oxygen flame cutting, machine cutting or arcair gouging in the case of repairs.

4.8.5 Immediately prior to any welding operation the surfaces to be welded shall be cleaned so as to allow welding under good conditions.

4.8.6 Plates shall be accurately aligned and retained in position during the welding operation. Pins and key-plates shall be used to hold shell plate edges in line. In the case of submerged arc welds, pins shall not be used. The plates shall be kept in position by tack-welds in the bevel. All pins, erection squares and other temporary accessories used for erection and adjustment of the joints shall be removed after use and tested by Magnetic Particle Inspection (M.P.I)

4.8.7 The joint welding sequence throughout construction shall be such that distortion is kept to a minimum.

4.8.8 On multipass welding, each pass shall be cleaned of slag and other deposits before applying the next pass, in particular, all apparent defects on the surface of the weld bead shall be removed by grinding, gouging or arcair gouging before depositing the next bead.

4.8.9 The welding techniques shall be in accordance with the procedure qualification tests. The edge of all weld beads shall merge gradually with the plate surface so as to avoid undercutting of the base metal. All butt weld reinforcements shall be in accordance with API 650 11th edition.

4.8.10 The qualified welding procedure shall specify the method by which the reverse side of double welded full penetration butt joints shall be prepared. When the welding process requires it, the back of the initial bead shall be removed by arcair gouging until clean metal appears.

In this case, the width of the gouged area shall allow a sufficient foundation for the next welding pass.

4.9 Repairs

4.9.1 The approval of SUMED Representative on site is required without delaying the progress of the work, before the repair of any defect undertaken by Contractor.

4.9.2 Injurious defects or damage in the plate shall be ground out, leaving a smooth, uniform appearance.

Where the resulting plate thickness is greater than the minimum permissible wall thickness, no further repair work is required.

4.9.3 Plates containing defects or damage greater than 30% of specified wall thickness in depth shall be rejected.

4.10 Inspection of welding seams:

4.10.1 All welds may be subject to visual inspection. This inspection may be carried out at any stage in the operating zone and shall bring no impediment to the normal course of the work.



4.10.2 Upon completion of the welding of the tank bottom, a vacuum test shall be carried out on the joints. Defects located shall be suitable repaired.

4.10.3 Radiographs of weld intersections shall show a minimum 3” of each weld length. Radiograph of seam welds shall show a minimum 15” of weld length.

4.10.4 Radiographic procedure and quality of resulting radiographs shall be in accordance with the requirements of API Standard 650 11th, section 6 and ASME section VIII paragraph UW-51(b) latest edition using (D4) films.

4.10.5 Radiographic standards of acceptance of welds the qualify of welds controlled by radiography shall be judged in accordance with API 650 11 th section 6 and ASME section VIII paragraph UW-51(b) latest edition.

5 PROTECTIVE COATING AND PAINTING OF TANKS

5.1 After erection and testing both surfaces of all tank plates mentioned below will be cleaned by shot grit or sand blasted in accordance with Svensk Standard SIS03-5900 1967-SA 2 ½.

5.2 For the purpose of this specification the following areas shall be defined with the corresponding paint system:

Area Code

Definition Paint System Minimum Requirements

AREA A

Interior tank bottom. Interior shell up to be 1.5m

in height. Lower ends of floating roof

supports.

Solvent free epoxy 25 micron.

Two or more coats of solvent free epoxy reinforced with one layer of glass mat 450 g/m2 for a total dry film thickness of 1.5 – 1.8 mm.

AREA B

Upper side of floating roof deck including all manholes.

Rolling ladder track, leg supports, all other apparatuses.

Upper 1.5 m of shell interior and top angle & external shell first course.Exterior shell, stair ways,

gauges platform wind girders stiffeners etc…

One prime coat of zinc rich epoxy primer solid contents not less than 50% by volume to dry film thickness of 60 microns.Total Zinc in D.F.T 80% by weight.

towo coats two packs two component of high solids epoxy polyamide grey, solid contents not less than 82% by volume to a nominal dry film thickness 150 microns

Two coat two packs of white polyurethane gloss, solid contents not less than 50% by volume for a dry film thickness of 80 microns (2 x 40 micron) and black for rolling ladder & first course.



AREA C

Under side of floating roof deck and interior tank apparatuses up to 1 meter in height.

One coat two pack of high build epoxy coal tar coating solids contents not less than 70% by volume to nominal dry film thickness of 200 microns.



Area Code

Definition Paint System

AREA D

Exterior shell, stair ways, gauges platform wind girders stiffeners etc…

One prime coat of zinc rich epoxy primer solid contents not less than 50% by volume to dry film thickness of 60 microns.Total Zinc in D.F.T 80% by weight.

Two coats two packs of high solids two component grey epoxy polyamide, solid contents not less than 82% by volume to a nominal dry film thickness 150 microns.

Two coat two packs of white polyurethane gloss, solid contents not less than 50% by volume for a dry film thickness of 80 microns (2 x 40 microns).

AREA ED

Internal side of roof compartments and first roof compartment.

Roof compartment (body Pontoon) and first compartment (Ring Pontoon) from insidePontoon’s area should be sandblasted and painted as follow:First coat: Zink Reach epoxy primer DFT 60 micron.Second coat: High Solid content polyamide epoxy DFT 100 micron.

AREA FE

Underneath of tank bottom plates One prime coat of zinc rich epoxy primer solid contents not less than 50% by volume to dry film thickness of 60 microns.Total Zinc in D.F.T 80% by weight.

Two-pack epoxy coal tar or equivalent contents not less than 70% by volume with dry film thickness 200 microns.

AREA FTack weld, gaps All tack weld gaps shall be interfiled with

towo pack solvent free epoxy filler.

6 TESTING AND INSPECTION OF TANK

6.1 Inspection by SUMED or its authorized third party inspectors does not negate Contractor obligations and responsibilities including but not limited to provision of quality control and inspection necessary to ensure such compliance.

6.2 All inspection procedure, instrumentation, consumables, materials and qualified personnel required for performing inspection shall be contractor responsibility.

6.3 All tank inspection required by API 650 11 th edition shall be conducted by contractor, The following are the minimum requirement for tank inspection, contractor shall prepare a full inspection and test plan (ITP) for the tank containing these min requirements and /or other inspection method for tank inspection and testing.

6.4 Tank bottom:



6.4.1 Testing of tank bottoms shall be made using a vacuum box in conjunction with a solution of soap and water, which shall be brushed on to the seam.

6.4.2 The gauge of the vacuum box shall register a partial vacuum of at least two hundred and eighty (280) grams/square centimeters (41b/sq.in) for each section tested. The vacuum test shell be carried out as soon as possible after welding of the tank bottom and shall be supplemented by a rigorous visual inspection.

6.5 Tank shells:

6.5.1 Tank radiographic inspection level shall be as per API 650 11 th edition.

6.5.2 Magnetic Particle Inspection (M.P.I) shall be used to test areas of the removed temporary accessories used for erection.

6.5.3 Tank shell shall be tested by filling the tank with clean sea water until primary seal reach curb angle. The initial filling shall be done at a rate not exceeding one point eight (1.8) meters (6’) in 24 hours.

6.5.4 Contractor shall take level reading around the entire periphery of the tank radially over the entire floor area before water is introduced into the tank for the hydrostatic test. Readings shall then be continued at reasonable intervals around the periphery during the entire filling operation and be plotted promptly in suitable form to indicate whether any undue or uneven settlement is occurring.

6.5.5 If at any time any questionable amount or rate of settlement occurs, filling of the tank shall be stopped until a decision is reached as to what, if any, corrective measures are necessary.

6.5.6 Reference points shall be selected so that they are accurately reflect of the subgrade and are and are not affected by possible changes in the shape of the tank walls.

6.5.7 If a minor amount settlement is observed during the course of the filling operation and still continues after a tank is filled to the highest level required in the hydrostatic test, the water level in the tank shall not be lowered until further settlement has substantially ceased.

6.5.8 After the tank has been emptied, further reading shall be taken of all reference points both around the tank periphery and over the floor area, these readings shall be plotted in suitable form.

6.5.9 In no event shall the hydrostatic test be used as a planned means of soil compaction. Eventual leaks shall be detected by visual inspection.

6.5.10 The tank shall remain full for a period of seven (7) days during which no leakage shall take place. Daily checks on the level of the foundation shall be made during this period. During filling and emptying operations roof manholes shall be left open so that no excessive pressure or vacuum conditions may occur.

6.6 Tank roof:

6.6.1 The roof compartment (pontoon) shall be tested by penetrating oil.

6.6.2 Testing of tank roof plates shall be made using a vacuum box in conjunction with a solution of soap and water, which shall be brushed on to the seam.



6.6.3 During filing and emptying of floating roof tank, the roof shall be closely observed by Contractor for free movement.



7 TANK CALIBRATION

7.1 The calibration of tanks shall be carried out by contractor according to API 2550 latest

edition for critical transfer.

Calibration tables shall include following data:

Date of calibration.

Standard used.

Units shall be metric.

Tank nominal diameter and height (overall).

Difference heights.

Floating roof weight.

Liquid, shell and ambient temperature used for shell corrections.

Hydrostatic head correction applied and volume (total accumulative up to working

height).

API gravity 60o F.

Critical zone.

Millimetric bottom table with bottom as the ref.

Bottom cone volume.

Detailed deadwood volume.

Tank ring circumference, diameter and thickness.

Empty tank volume up to working height without any other corrections.

Total temperature correction volume (shell) up to the working height.

Documents

Spec Storage Tanks- EPC