brazil csp-ball tank erection manual

8/20/2019 Brazil CSP-Ball Tank Erection Manual

1/18

CONTENTS

1. GENERAL

2. RELATED DOCUMENTS

3. OVERALL SEQUENCE

4. FOUNDATION

5. ASSEMBLING OF TANK

6. WELDING SEQUENCE

7. INSPECTION

8. POST WELD HEAT TREATMENT, IF APPLIED

9. ASSEMBLING OF ACCESSORIES

10. HYDROSTATIC TEST

11. CLEANING AND PAINTING

12. FIRE PROOFING ON COLUMNS

13. WATER SPRAY PIPING TEST


2/18

1. GENERAL

1.1 This procedure is applied to the field erection of the spherical tank for the following

articles.

1.2 Supplied for: RCC Off Gas to Propylene Project UP-VI Balonqan of PT. PERTAMINA

(PERSERO)

1.3 Items to be supplied

Item No. Q'ty Description

42-T-404 E/F/G/H 4 Propylene Storage Tanks

2. RELATED DOCUMENTS

2.1 Applicable Code and Standards ASME Sec. VIII, Division 1, 2004 Ed. & including 2006 Add. ASME Sec. IX, 2004 Ed. & including 2006 Add. ASME Sec. V, 2004 Ed. & including 2006 Add.

2.2 Project SpecificationsROP-S-00-1351-001T-E-0 General Specification for Pressure Vessels

ROP-S-00-1351-002T-E-0 Vessel StandardsROP-S-00-1351-003T-E-0 General Specification for Equipment WeldingROP-S-00-1354-301T-E-0 General Specification for Spherical TankROP-S-00-13A1 -001 T-E-0 General Specification for PaintingROP-S-00-13B4-001R-E-0 General Specification for Fireproofing for Static EquipmentROP-S-00-145-002R-E-1 Packing and Marking Instruction to Vendor

2.3 Related Procedures

VP-42-T-404-E-010 Latest Painting Procedure SpecificationVP-42-T-404-E-011 Latest WPS with PQR (Shop)VP-42-T-404-E-012 Latest WPS with PQR (Field)

VP-42-T-404-E-013 Latest Inspection & Test Procedure with Plan at (Shop)VP-42-T-404-E-014 Latest Inspection & Test Procedure with Plan at (Field)VP-42-T-404-E-015 Latest Non-Destructive Examination Procedure (Shop)VP-42-T-404-E-016 Latest Non-Destructive Examination Procedure (Field)VP-42-T-404-E-017 Latest PWHT Procedure (Field)VP-42-T-404-E-018 Latest Hydrostatic Test Procedure (Field)

VP-42-T-404-E-019 Latest Packing & Marking Procedure

VP-42-T-404-E-020 Latest Fabrication Procedure


3/18

3. OVERALL SEQUENCE

The planned sequence of construction and completion involves the erection of spheres inaccordance with the construction schedule and approved drawings.

Deliveries of materials are scheduled to satisfy the erection sequence, mobilization of facilities &equipment and mobilization of manpower.


4/18


5/18

D

G.L

C

A B

E

4. FOUNDATION

The foundation shall be checked using an accurate instrument set on center of grade.

4.1 The following dimension typically marked A, B, C, D, E, F1 ~ Fn, and H as shown in Fig-1shall be checked and adjusted as necessary prior to commencement of field erection.

4.2 Tank center point shall be established on the tank foundation. The orientation of tankfoundation shall be subjected to the approved construction drawing.

Fig-1 Anchor Bolt & Orientation of Tank Foundation

4.3 Inspection

Before acceptance of foundation, inspection shall be made for the following items withpresence of Vendor/Subcontractor, Contractor's inspector. All dimensions shall bechecked against approved drawings and ensure that the standard tolerances are met. Allrecords shall be reported and reviewed by Contractor.

(1) Intervals between anchor bolts(2) Measurement of the distances between individual column foundation centers

(between adjacent column, column diagonal distances)(3) Measurement of foundation level(4) Measurement of bolt projection length(5) Check the mark of tank center line

4.4 Leveling of foundation surfaces

(1) On the foundation for supports, pipelines, and stairs, padding shall be made after

measuring the level of foundation surface with the presence of QC inspector foracceptance. The foundation surfaces shall be roughened, before padding installation.(2) Padding for support foundation shall be formed in such a way as shown in Fig-2 so as to

meet the tolerances.(3) Grouting using non-shrinkage mortar between the foundation surface and base plate

180

F2F3

F4

H

90

0

270

Anchor bolt Concrete base

F1

F5


6/18

LINER PLATE

PAD

TANKCENTER

LINE

ANCHOR BOLT

SCALELEVEL

shall be completed after PWHT and before the pressure test of tank.(4) The difference in pad levels shall be within 2.0 mm.

Fig. 2 Padding on Foundation Surface

4.5 Allowable tolerance of each dimension shall be in accordance with the specific Inspection

and Test Procedure with Plan at Field.

SCALE


7/18

5. ASSEMBLING OF TANK

5.1 Typical erection sequence

Lower column

! Equator plate with upper column and equator without column

" Bracing (Note 2)

# Lower ring plate

$ Bottom crown plate and pole plate

%

Upper ring plate& Top crown plate and pole plate (Note 1)

' Stairway & platforms

( Internal pipes & ladder

) Water spray system

* Accessories (nameplate, earth lugs, etc.)

+ OthersNote:

(1) For ventilation of inside welding fume and heat, one of crown plate mayopen until completion of production welding of all shell joints, and then theplate will be installed and welded to the final weld joint.

(2) When PWHT is required for assembled tank, the column-bracing pipeshall be welded after PWHT.

5.2 Assembling of column

(

!

&

)

#

"

%

$

'

*

*


8/18

(1) Lower columns shall be assembled first.

The plumb of each column shall be checked as shown in Fig-4 and adjusted afterassembling of equator plates in the presence of QC inspector for acceptance

Fig-4 Plumb Check of Tank Column

(2) Allowable tolerances of plumb and levelness of each column shall be in accordance withthe Inspection & Test Procedure with Plan at Field.

1) After erection of each lower column, the top of lower column shall be levelwithin ! 3 mm in any one.

2) After erection of lower column and stress relieving the tank, the verticality ofeach lower column shall not exceed 1/500 of the total length.

3) Sequence and installation notice, when applicable PWHT;

Before and during the Post Weld Heat Treatment (PWHT), following shallbe kept carefully.

- To provide sliding between base plates and sliding plate during PWHT,grease shall be applied on the sliding plate before erection of lower column.

- Before PWHT, the bracing shall be released on thread parts or bracingpipes.

- To adjusting within tolerance between low columns, temporary hydraulic jack or jigs shall be installed before PWHT performed.

- During PWHT, a distance between lower columns shall be adjusted withtolerance according to the Inspection and Test Procedure at Field.

- Tack welding shall be done sliding plate to base plate.

- After checked by QC Inspector for a distance between lower columns after

PlumbCheck Points

A

B

2 0 0

4 0 0

5 0 0

G.L

Reference MarkFor Levelness CheckString with

Plumb-Bob


9/18

2

3

4

5

6

7

8 9

10

1

12

13

14

15

16

0

90

180

270

PWHT, welding shall be done and removed temporary hydraulic jacksand/or jigs.

5.3 Assembling of equator plate

(1) Typical assembling sequence

Fig-5 Typical Assembling Sequence of Equator Plates

(2) Erection of equator plates

Fig-6 Typical Guy-Wire for Equator Erection

Equator Plate

Wire Rope

Turn Buckle

Angle Stake or Concrete Block


10/18

1) As shown in Fig-7, assemble each equator plate successively, and make surface alignedtack welding shall be performed by qualified welder.

Fig-7 Erection Schematic of Equator PlatesNote

(1) To adjust verticality of lower column and root gap between equator plates, thebracing pipe should be installed after erection and fit-up of equator plates. (See Note 2of 5.1)

(2) When rigging the shell plate to assembling each other, pulling rope should be usedto prevent rotation, and it shall be tied in with both sides of erection key-nuts on theinside and outside surface of shell as shown in the above Fig-7.

(3) When available, equators may assemble and/or weld two plates between column shelland non-column shell on the ground before erection.

2) The difference between maximum and minimum diameter "D" given as Fig-8 shall notexceed 0.3% specified diameter in the approved construction drawing

G.L

D D"

Wire Rope

G.L


11/18

TAPER PIN

BALL PIN

KEY PLATE

KEY NUT

UPPER RING PLATE

LOWER RING PLATE

EQUATOR PLATE

500mm

500mm

Fig-8 Diameter Check

(3) Procedure for alignment

Fig-9 Temporary Assembly of Jigs Alignment

1) As shown in Fig-9, surface alignment of shell plates shall be

adjusted using temporary jigs such as key-plates, key-nuts, wedge, etc.

2) Perform alignment from the plate center marks with each other, andperform tack weld on the central portions only, in this way, assembletemporary, assemble temporarily all of the plates.

3) After temporarily assembled plates, make surface alignment and tackwelding upward and downward starting from the plate center. (Thetolerances for the measurement of level in the surface alignment shallcomply with Inspection & Test Procedure with Plan at Field.

4) For tack welding of equator plates, as shown in Fig-10, about 500 mm inlength at top and bottom portions adjacent to the upper and lower ringplates should be made surface alignment and tack welding after

temporary assembly of each crown plate.5) Arc strike on the surface of the base metals shall not be permitted. The

proper non-destructive examination shall be applied on the area aboveafter rectification.


12/18

Fig-10 Tack Welding on Equator Plates

(4) In fitting the plate, put the scaffold blanks, key-plates, etc., on the ground as shown inFig-11, when possible, and lift them together with plates.

Fig-11 Typical Scaffolding

5.4 The lower ring or bottom crowns as shown in Fig-12 are supported by temporary jigs (key-plate, key-nut, etc as per Fig-9) with tack welding during erection and the inclination inadjusted with them.

Fig-12 Erection Schematic of Lower Ring or Bottom Crown Plates

Hand Rail

Scaffold Plate

Bracket

Level BlockFor Ad ustment

Pipe Support

Lower Ring


13/18

5.5 Assembling of bottom crown plates(1) As in the case of equator plates, attach each jig and make temporary assembly.

(2) Each bottom crown plate is installed and tack welded respectively in order /! and

then (3) as shown in Fig-13. The curvature of joint is checked with a curvature gauge asper Inspection and Test Procedure with Plan at Field.

(3) Before the erection of the bottom crown, the roundness of the lower ring should bechecked by QC inspector and adjusted if it is necessary, refer to Inspection and TestProcedure with Plan at Field.

Fiq-13 Assembling of Bottom Crown Plates

5.6 Assembling of upper ring plate

The upper ring or top crown as shown in Fig-14 are supported by temporary jigs (key-plate,key-nut, etc as per Fig-9) with tack welding during erection and the inclination in adjustedwith them.

Fiq-14 Assembling of Upper Ring or Top Crown Plates

JACK

" !

CURVATURE GAUGE

Upper Ring


14/18

5.7 Assembling of top crown plates

(1) The top crown is erected after the roundness adjustment of the upper ring opening.

(2) The erection procedure is similar to the bottom crown.(3) Mount the members after assembling the internal scaffold.

Fig-15 Inspection Scaffolding

5.8 Erection jigs for shell plate(1) Key plate and key nut

Shell plates are installed with key plates, key nuts and drift in. Key is set 4 pieces for avertical joint and 2 pieces for a horizontal joint.

a) Detail of key plate b) Detail of key nut

Fig-16 Detail of Key-plate and Key-nut

INSIDE

INSIDE SCAFFOLD

BRACKETS

OUTSIDE

INSPECTION SCAFFOLD


15/18

(2) A plate joint is adjusted plainly with suitable device (plain-dog) if it is uneven.

The plain-dog shall be the same P-Number material as the base metal of the tank(with regardless Group Numbers).Qualified welder shall perform the attachment of plain-dog to base metal,which is to adjusted alignment.Not allowed to remove the plain-dog with hammering and the reminder on theplates shall be applied non-destructive examination.

Fiq-17 Detail of Plain-dog

(3) Strong back

Strong backs with the same P-Number material with regardless Group Number as thebase metal shall be used to reinforce the shell plate and to prevent the weldingdistortion; two pieces of them are set for a plate on the horizontal joint.

For each shell-to-shell joint, key-plates will substitute for strong-backs if those shall notbe taken off until completion of one side of the production welding.

Fiq-18 Strong Back

(4) Typical Direction of Bracket Shoe

400

120

40R

C=150mm

Strong back

Welding

Top crown

Upper ring

Center ring

Lower ring

Bottom crown

To be seton outside

To be seton inside

Strong back

Wedge Plain dog

Welding

Plain dog

Wedge


16/18

The bracket shoe for scaffolding should be set on ground prior to starting erection

for each plate.Bracket shoe are set as given in below;

Fiq-19 Typical Direction of Shoe

6. WELDING

Full welding shall be done with the approved welding procedure specification (WPS) andqualified welder. Welding sequence shall be minimizes distortion and shrinkage. Welding repairsshall be made using the same WPS that used for original production welding with approvedWPS.


17/18

6.1 Typical welding sequence

Fiq-20 Typical Welding Sequence

Weld equator course radial joints

!

Weld column splices any time after equator course radial joints and before test." Weld lower ring course radial joints#

Weld upper ring course radial joints (It may weld with joint no. (3) at same time.$ Weld lower and upper course radial joints%

Weld girth joint joining equator to lower and upper courses& Weld girth joint joining ring courses to lower and upper course'

Weld bottom head plates together( Weld girth joint joining bottom head plates to adjoining course)

Weld top head plates together* Weld girth joint joining top head plates to adjoining course+

Weld column-to-bracing pipe (See Note 2 of 5.1)

NOTE:1) Perform welding on equator course vertical joint as soon as they are fitted. The

columns splices may be welded after a minimum of one side of all equatorcourse plates are welded.

2) Welding of girth joint may be performed simultaneously with running of welding radial joints which the welding of girth joints does not cross the unwelded or partiallywelded radial joint.

3) Perform fit-up for the vertical or girth joint with key-plates and tack welding.Finger bars should be used at all times on the fit-up side of welding courseseither distortion of the plate of the joint could be close. If the key-plate isinsufficient, the amount of finger bar shall be increased in alternate to the

amount of key-plates. Finger bar minimum thickness shall not be less than 1/4 inch(6 mm), weld the groove at 1500 mm interval distances and a minimum of 6 inches(150 mm) in length and the weld deposited shall be at least 6 mm thickness.

6.2 Dimensional Tolerance


18/18

After the completion of the shell plate welding, the maximum permissible deviation

between maximum and minimum diameter shall not exceed 0.5 % of specified diameter indrawing.

7. INSPECTION

All inspection shall be done in accordance with the specified Inspection and TestProcedure with Plan at Field for the spherical tank.

All NDE inspection shall be carried out in accordance with the Inspection and TestProcedure with Plan at Field, the approved NDE Procedures and approvedconstruction drawings.

8. POST WELD HEAT TREATMENT

When applicable at field, PWHT shall be done in accordance with the approvedPWHT Procedure.

9. ASSEMBLING OF ACCESSORIES

When specified in the contract, the items shall be done according to the following articles.

9.1 Accessories such as top stages instrument nozzle (stand pipe) and water spraysystemshall be installed successively after the non-destructive examination of the body.

9.2 Valves and instruments9.3 The thermometers should be set before the hydrostatic test.9.4 The pressure gauge should be set after completion of hydrostatic test.9.5 Valves should be set with special care of the adequate tightening center ring gasket.

10. HYDROSTACTIC TEST

Refer to the approved Hydrostatic Test Procedure at Field.

11. CLEANING AND PAINTING

Refer to the approved Painting Procedure Specification.

12. FIRE PROOFING ON COLUMN

Fire proofing on the column, it shall be constructed according to the drawingafter completion of hydrostatic test and all inspection of tank.

13. WATER SPRAY PIPING TEST

Water spray piping test shall be performed according to the drawing or the specifiedspecification.

brazil csp-ball tank erection manual

Documents