PAGE 1
of
PT.TIMAS
PROJECT
:
TANK FACILITY UPGRADE, BANGKO GS
DOCUMENT TITLE
:
DISMANTLE TANK PROCEDURE
DOCUMENT NO.
:
ME - GSBGKO - TFU - QC - 001
PREPARED BY : REV A
DATE 18-Feb-13
PURPOSE Issued For Information
CHECKED BY :
APPROVED
TIMAS SUPLINDO PT. NAME
NAME
DK
DS
CPI NAME
DATE
17
TANK FACILITY UPGRADE, BANGKO GS
TIMAS
DISMANTLE TANK PROCEDURE
Doc. No :
Discipline :
Rev. :
Status :
Date :
ME - GSBGKO - TFU - QC - 001
QC
A
A
18-Feb-13
Page : 2
of
17
TOTAL OR PARTIAL REPRODUCTION AND/OR UTLIZATION OF THIS DOCUMENT ARE FORBIDDEN WITHOUT PRIOR WRITTEN AUTHORIZATION OF THE OWNER
PAGE
REVISIONS B C D E F
A 1 x 2 x 3 x 4 x 5 x 6 x TITLE : Skid 7 x 8 x 9 x 10 x 11 x 12 x 13 x 14 x 15 x 16 x 17 x 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
G
CON. 107
TABULATION OF REVISED PAGES ATTACHMENTS REMARKS ATT PAGE A B C D
E
F
G
REMARKS
TANK FACILITY UPGRADE, BANGKO GS TIMAS
DISMANTLE TANK PROCEDURE
Doc. No :
Discipline :
Rev. :
Status :
Date :
ME - GSBGKO - TFU - QC - 001
QC
A
A
18-Feb-13
Page : 3
of
17
TOTAL OR PARTIAL REPRODUCTION AND/OR UTLIZATION OF THIS DOCUMENT ARE FORBIDDEN WITHOUT PRIOR WRITTEN AUTHORIZATION OF THE OWNER
TABLE OF CONTENT
Cover Tabulation of revision page Table of content 1. General 1.1 Scope 1.2 Aplicable References 1.3 Equipment & Material 1.4 Man Power 1.5 Safety
1 2 3 4
2.1 Dismantle Tank Procedure 2.1.1 Sequence for Execution Work
6
2.2 Cleaning The Tank
6
3.1 Dismantle Roof
7
4.1 Dismantle of Shell Plate
9
5.1 Dismantle of Bottom Plate
10
6.1 Attachment
11
6.2 Load Chart
13
5
TANK FACILITY UPGRADE – BANGKO GS DISMNATLE TANK PROCEDURE Doc No : ME – GSBGKO – TFU – QC - 001
Discipline : QC
Rev : A
Status : A
Date : 18-02-2013
Page : 4 of 17
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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 ReConstruction 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
TANK FACILITY UPGRADE – BANGKO GS DISMNATLE TANK PROCEDURE Doc No : ME – GSBGKO – TFU – QC - 001
Discipline : QC
Rev : A
Status : A
Date : 18-02-2013
Page : 5 of 17
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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
TANK FACILITY UPGRADE – BANGKO GS DISMNATLE TANK PROCEDURE Doc No : ME – GSBGKO – TFU – QC - 001
Discipline : QC
Rev : A
Status : A
Date : 18-02-2013
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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 .
TANK FACILITY UPGRADE – BANGKO GS DISMNATLE TANK PROCEDURE Doc No : ME – GSBGKO – TFU – QC - 001
Discipline : QC
Rev : A
Status : A
Date : 18-02-2013
Page : 7 of 17
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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 :
TANK FACILITY UPGRADE – BANGKO GS DISMNATLE TANK PROCEDURE Doc No : ME – GSBGKO – TFU – QC - 001
Discipline : QC
Rev : A
Status : A
Date : 18-02-2013
Page : 8 of 17
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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.).
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.
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 .
TANK FACILITY UPGRADE – BANGKO GS DISMNATLE TANK PROCEDURE Doc No : ME – GSBGKO – TFU – QC - 001
Discipline : QC
Rev : A
Status : A
Date : 18-02-2013
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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
TANK FACILITY UPGRADE – BANGKO GS DISMNATLE TANK PROCEDURE Doc No : ME – GSBGKO – TFU – QC - 001
Discipline : QC
Rev : A
Status : A
Date : 18-02-2013
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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 .
TANK FACILITY UPGRADE – BANGKO GS DISMNATLE TANK PROCEDURE Doc No : ME – GSBGKO – TFU – QC - 001
Discipline : QC
Rev : A
Status : A
Date : 18-02-2013
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6.1. Attachment
Figure 1. Assesment Site
TANK FACILITY UPGRADE – BANGKO GS DISMNATLE TANK PROCEDURE Doc No : ME – GSBGKO – TFU – QC - 001
Discipline : QC
Rev : A
Status : A
Date : 18-02-2013
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6.1.2. Assessment Do assessment for make sure the metodh, equipments,and tools can be aplied on Site.
Figure 2. Lay Out
TANK FACILITY UPGRADE – BANGKO GS DISMNATLE TANK PROCEDURE Doc No : ME – GSBGKO – TFU – QC - 001
Discipline : QC
Rev : A
Status : A
Date : 18-02-2013
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6.2 Load Chart
TANK FACILITY UPGRADE – BANGKO GS DISMNATLE TANK PROCEDURE Doc No : ME – GSBGKO – TFU – QC - 001
Discipline : QC
Rev : A
Status : A
Date : 18-02-2013
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TANK FACILITY UPGRADE – BANGKO GS DISMNATLE TANK PROCEDURE Doc No : ME – GSBGKO – TFU – QC - 001
Discipline : QC
Rev : A
Status : A
Date : 18-02-2013
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TANK FACILITY UPGRADE – BANGKO GS DISMNATLE TANK PROCEDURE Doc No : ME – GSBGKO – TFU – QC - 001
Discipline : QC
Rev : A
Status : A
Date : 18-02-2013
Page : 16 of 17
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TANK FACILITY UPGRADE – BANGKO GS DISMNATLE TANK PROCEDURE Doc No : ME – GSBGKO – TFU – QC - 001
Discipline : QC
Rev : A
Status : A
Date : 18-02-2013
Page : 17 of 17
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