dismantle tank procedure (rev. a)
DESCRIPTION
Dismantle TankTRANSCRIPT
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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
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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
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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
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
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
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
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
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
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
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
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.
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
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
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
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
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
6.1. Attachment
Page : 11 of 17
Figure 1. Assesment Site
TANK FACILITY UPGRADE – BANGKO GS
DISMNATLE TANK PROCEDURE
Doc No : ME – GSBGKO – TFU – QC - 001
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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
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
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
6.2 Load Chart
Page : 13 of 17
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
Page : 14 of 17
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
Page : 15 of 17
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
Page : 16 of 17
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
Page : 17 of 17