PAKISTAN REFINERY LIMITED

DRAFT EVALUATION REPORT RECONSTRUCTION OF TANK T-53 AT KEAMARI TERMINAL

PROJECT : RECONSTRUCTION OF TANK T-53 AT KEAMARI TERMINAL CLIENT : PAKISTAN REFINERY LIMITED LIMITED JOB NO. : 0800 CONSULTANTS : PETROCHEM ENGINEERING SERVICES

Disclaimer This report has been prepared on behalf of and for the exclusive use of Pakistan Refinery Ltd. (PRL), and is subject to and issued in accordance with the agreement between Petrochem Engineering Services and PRL. Petrochem Engineering Services accept no liability or responsibility whatsoever for it in respect of any use of or reliance upon this report by any third party. Copying this report without the permission of Petrochem Engineering Services is not permitted.

CONTROLLED COPY HOLDERS NO. NAME COMPANY NO. NAME COMPANY

1 2 3 4
REV

Nadeem Akhter Imran

PRL PRL

5 6 7 8

DESCRIPTION

ORIG

REVIEW

PES APPROVAL

DATE

CLIENT APPROVAL

DATE

Issued for internal review Issued for Client Comments.

Faizan

Umair

Shoaib

Apr. 11, 12

Faizan

N/A

N/A

Apr. 12, 12

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CONTENTS

SECTION 1.0 2.0 3.0 4.0

DESCRIPTION INTRODUCTION RECOMMENDATIONS CODES AND STANDARDS TOLERANCES

PAGE NO. 04 04 06 06

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1.0

INTRODUCTION Pakistan Refinery Limited (PRL) is converting existing storage tank T-53 from Fixed Roof to External Floating Roof for the storage of crude oil at its Keamari Terminal. As per existing condition, fixed roof and top 4 courses have been removed. Bottom plate is disengaged from annular plate. It was observed at site that tank plumbness at fourth course is deviated from allowable limits as mentioned in API 653. Furthermore settlement was found at portion of Earthen foundation of tank. PRL hired SGS for the inspection of tank T-53 as per API 653. Report has been submitted by SGS which is the basis for further evaluatoion of tank conditions. The Plumbness, Shell bulging and Roundness reports provided by SGS are thoroughly viewed and calculated by PES. On the basis of calculation results and standards, followings are our observation and recommendations.

2.0 2.1

RECOMMENDATIONS Tank settlement at one side is minor issue. The major observation is as under: i) ii) Plate squarness was not maintained at the time of construction of Tank Welding sequence was not followed by the Contractor and therefore overheat regions were developed on tank shell which created bulging effect.

2.2

Plumbness values found in Course 1 & 2 (from Bottom to Top) are in allowable limits of API 653 (See Annexure-1)

2.3

Plumbness in Course Number 3 & 4 (from Bottom to Top) is more than allowable range as per API 653 i.e. 1/100 of tank height which is not acceptable. Courses 3 & 4, therefore cannot be used and shall be removed. (See Annexure-1)

2.4

For foundation settlement, it is recommended that remaining two courses shall be lifted through jacks and repair the area (See Annexure-2)

2.5

Plumbness found in courses 1 & 2 is in allowable limits but there are some portions in course no. 2 where repair work is required for the proper erection of upper

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courses. It is recommended to cut and re-roll the plates of course no. 2 at 45o, 180o, 165o, 285o, 300o & 330o to minimize the bulging / deformations. 2.6 After repair of course no. 2, it is necessary to check again the Roudness and Plumbness of top course 2. There may be a possibility to adjust some plate dimensions of course no. 3 as per inspection data of course no. 2 after its erection. 2.7 Before cutting courses 3 and 4, following steps shall be done for the repair of course no. 2. i) ii) iii) Channel of 6 x 3 x 12mm thick shall be weld to the top of course 2 before cutting of course 3 & 4 Curvature plates of size 9 shall be welded to the shell No direct hammering to the plates shall be carried out to remove the deformations. Hammering, if carried out, shall be on an intermediate block part placed to avoid direct impact on plates. iv) v) Wages shall be used in the gaps to remove deformation of shell plates. After being rolled, the plates shall be checked with steel templates having a radius equal to rolled inside radius. For a 2 m. long template, the clearance between template and plate surface shall not be greater than 3.2 mm vi) Rolling radius of plates for tanks of 8 m. diameter and larger, plates upto 25 mm. thick are recommended to be rolled at 1.25 x tank radius. For plates thicker than 25 mm. rolling radius shall be equal to tank radius. vii) viii) Over rolling of plates is not allowed. No heating is allowed to straighten the plates deformed by shrinkage. Eventual straightening shall be done by cutting the respective welding seams and rewelding them on the basis of an approved procedure. ix) Plates of second course shall then be mounted according to the orientation. After being adjusted, aligned and tack welded, vertical seams shall be welded. x) For finished horizontal butt welds the upper plate shall not go beyond the lower plate surface in any point by more than 20% of upper plate thickness, but not greater than 1/8" (3.17 mm). xi) xii) Horizontal welding shall then be performed between the first two courses. Welding shall be performed with shielded metal arc, shielded arc, or submerged arc procedure using suitable equipment.

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xiii) xiv)

Each metal layer of a welding seam shall be cleaned free of slag and other foreign matters before applying the next layer. The edges of all welds shall merge into plate surface without forming a sharp angle.

3.0

CODES AND STANDARDS All engineering, repairing, technical documentation shall comply with the

requirements of this report and the following codes/standards referred herein:

API Standard 650 API Standard 653 ASME Section IX ASTM specification for carbon steel plates.

4.0

DIMENSIONAL TOLERANCES As per API 653(Tank Inspection, Repair, Alteration & Reconstruction)

4.1

Plumbness The Maximum out of plumbness of the top of the shell relative to the bottom of the shell shall not exceed 1/100 of the total tank height.

4.2

Roundness Radial measurement at 300 mm above lap weld between shell and bottom shall not exceed the following tolerance: Tank Diameter 0 to 12.2m exclusive Radius Tolerance + 12.7mm + 19.0mm + 25.0mm + 32.0mm

12.2 to 45.7m exclusive 45.7 to 76.2m exclusive 76.2m and over

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4.3

Peaking With a horizontal sweep board 36-in. long, peaking shall not exceed . The sweep board shall be made to the true outside radius of the tank.

4.4

Banding With a vertical sweep board 36 long, banding shall not exceed .

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PAKISTANREFINERYLIMITED
Tank53KeamariTerminal CalculationsforTankRoundness/Plumbness OptionICoursenos.1to4

ANNEXURE1 Doc.No: 0800TR53001 Date: 11/4/2012 Prepby: Faizan

Location

Course-1

Course-4

Plumbness Calculated

SGSAnnexure 1

Roundnessat1ft Roundnessat1st abovethebottom Allowable courseTop/ cornerweld API653 Bottom(SGS) (Approx.)

Remarks

A 0o 45o 90o 135o 180o 225o 270o 18.304014 18.276373 18.267085 18.266647 18.187036 18.3475 18.197815

B 18.299377 18.297309 18.288496 18.275004 18.211426 18.32917 18.222318

A 18.277084 18.304203 18.309717 18.261834 18.264316 18.288437 18.270240

B 18.265974 18.305685 18.316336 18.255099 18.276166 18.269143 18.278567 0.038 -0.029 -0.049 0.012 -0.089 0.078 -0.081 0.051 0.021 0.047 0.015 0.101 0.091 0.077 0.072 0.072 0.072 0.072 0.072 0.072 0.072 0.001 0.017 0.028 0.003 0.035 0.023 0.025 4 9 6 6.5 13 0 0

AllowablePlumbness:0.072asperAPI653 AllowableRoundness:11/4''(32mm)asperAPI650/653

PAKISTANREFINERYLIMITED
Tank53KeamariTerminal
CalculationsforTankRoundness/Plumbness OptionIICourseNos.I&2

Doc.No: Date: Prepby:

ANNEXURE1 0800TR53002 11/4/2012 Faizan

Location

Course-1

Course-2

Plumbness SGSAnnexure AllowableAPI Calculated 1 653

Roundnessat1st Roundnessat1ft courseTop/ abovethebottom Bottom(SGS) cornerweld(Approx.)

Remarks

A 0
o

B 18.299377 18.297309 18.288496 18.275004 18.211426 18.32917 18.222318

A 18.31043 18.301015 18.298866 18.277808 18.217577 18.326758 18.227533

B 18.294682 18.31395 18.297964 18.274639 18.23186 18.319235 18.239172 -0.009 0.038 0.031 0.008 0.045 -0.028 0.041 -0.014 0.036 0.028 0.005 0.058 -0.031 0.044 0.072 0.072 0.072 0.072 0.072 0.072 0.072 0.001 0.017 0.028 0.003 0.035 0.023 0.025 4 9 6 6.5 13 0 0

18.304014 18.276373 18.267085 18.266647 18.187036 18.3475 18.197815

45 90

135

180o 225o 270o

AllowablePlumbness:0.072asperAPI653 AllowableRoundness:11/4''(32mm)asperAPI650/653

ANNEXURE: B
For repairing the damage area of tank foundation it is needed to lift the tank up to 1.5ft height. The procedure recommended for lifting the tank (1st and 2nd course) is through hydraulic jacks. Various steps of lifting the tank through hydraulic jacks are given below: 1. Disconnect all tank attachment and piping connection also removes the annular plates from tanks shell. Ensure that top course i.e. course no:2 shall be properly secured with circumferential tack welding of channel 6x3. 2. Mark the location and install the jacking brackets on circumference of shell. 3. Install the plates in tank berm to properly distribute the jack reaction on tank foundation through these plates. 4. Install the 20 nos jacks on the plates against the corresponding brackets (capacity of each jack required is 6 tons). Lift the tank with help of jacks up to 1.5ft height. 5. Install the tripod stand. 6. From proper topographic survey, locate the damage area of foundation. Scarify the bitumen layer with sand from that portion up to 300mm. 7. Refill it with coarse sand with maximum size not exceeding 10mm and fall within following grading limits.

BS Standard Sieve

% Passing (By Weight)

(3/8 ") (3/16 ") No. 7 No. 14 No. 25 No. 52 No. 100 No. 200

100 90 - 100 60 30 15 10 5 0 - 95 - 70 - 35 - 25 - 15 - 10

8. Qualified personnels and approved laboratory facilities shall be provided to modified AASHTO 95% dry density and determination of moisture content of fill material to control the compaction. 9. Again place the bitumen layer maintaining proper slope as mentioned in project drawing.

CALCULATIONS DATA
DiaofTank HeightofTank = = 120 ft 48 ft

CALCULATION
First Course
Thikness Perimeter Height Weight = = = = 19 114.683 1.8 30.78895 mm m m Tons

Second Course
Thikness Perimeter Height Weight = = = = 16 114.683 1.8 25.92753 mm m m Tons

Angle Iron
= Weight/Length Weight/Length= Length = Weight = C6"X3" 18 kg/m 115 m 2.07 Tons = = 58.78648 TONS 60 TONS

Total Weight
OR
LIFTING JACKS

Capacityof1jack NumberOfJacks
PLATES UNDER JACKS

= =

6 20

Tons Nos

AssumeAreaOfPlate= WeightFromJack = Load/Area = BearingCapacityofsoil ThiknessOfPlate =

1mX1m 6 6 1 20

tons tons/m ton/ft mm

OR >

0.557 Tsf 0.557 OK

 BRACING (8"X4"X1) 3Tons ISECTION (8"X4"X1) SHELL WELD 3FT JACK

PLATE

Moment Sx

= =

9tonft

OR

19.836 Kft = 11in

9X2.204X12 0.6X36 8"X4"X1" Sx

USE

12.6in

OK