Doc.

No 600-500Z-1827
METHOD STATEMENT FOR BOTTOM Revision No 0

PLATE REPLACEMENT Revision Date May. 31. 2011

Page 1 of 9

METHOD FOR REPLACEMENT

THE BOTTOM PLATE WITH NEW ONE.
Project Title: Saudi Kayan Amine Project
Project Number: SC-2157
Requisition Description: FIELD FABRICATED TANK
Requisition Number: MFB120
Item Description: -
Item Number: ALL ITEM

　 　 □ APPROVED 　 　 □ WITH COMMENTS 　 　

　 □ REVIEWED □ RESUBMIT 　
　 　
THIS APPROVAL OR REVIEW DOES NOT RELIEVE THE
VENDOR/SUBCONTRACTOR OF HIS RESPONSIBILITIES
TO MEET ALL OF THE SPECIFIED REQUIREMENTS OF
THE PURCHASE ORDER
　 　
　 ORIGINATOR CHECKED APPD(PR)
SIGN 　 　 　
DATE 　 　 　
CTCI Overseas Corp. Ltd

0 31-05-10 ISSUED FOR APPROVAL AM.S AMM Y.S.LEE

REV. DATE DESCRIPTION MADE BY CHECKED BY APPROVED BY

WINTECO CORPORATION
SEOUL, KOREA

CTCI Overseas Corp. Ltd

TAIPAI, TAIWAN

SAUDI KAYAN PETROCHEMICAL COMPANY

AL-JUBAIL, SAUDI ARABIA
 Doc. No 600-500Z-1827
METHOD STATEMENT FOR BOTTOM Revision No 0

PLATE REPLACEMENT Revision Date May. 31. 2011

Page 2 of 9

TABLE OF CONTENTS

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

2. REFERENCE CODES AND

STANDARDS………………………………………………………….…3

3. Work PROCEDURE
SEQUENCE…………………………………………………………………………...3

4. WORK SEQUENCE DETAIL…………………………….……..

…………………………………………………6

5. Figure for Welding Sequence…………………………….……..

…………………………………………………7

6. Figure for Jacking detail…………………………………….……..

…………………………………………………8
 Doc. No 600-500Z-1827
METHOD STATEMENT FOR BOTTOM Revision No 0

PLATE REPLACEMENT Revision Date May. 31. 2011

Page 3 of 9

1. SCOPE
1.1This Method is intended to Replace the bottom plate of the tank, for those
tanks in which pitting have been observed after the hydrostatic test conducted
in the site.

1.2 This Method is for the following tanks :

Size (m) Operating Temp. Operating Pressure

Tag No. Service
DxH (C) (mbarg)
TK-68007 DIETHANOLAMINE 13900X13900 50 10
TANK

2. REFERENCE CODES & STANDARDS

2.1API 650 – Welded Tanks for Oil Storage

2.2API 653 – Tank Inspection, Repair, Alteration and Reconstruction

2.3API 575 – API Recommended Practice.

2.4Q03-T01 – Engineering Standard

2.5Tank Mechanical Specification Drawings

3. Work Sequence (Replacement of Bottom Plate).

1. Mark the centre point and degree of orientation on shell plate as per approved
drawing.

2. At first course install the Stopper outside the shell plate for the jacking system
which provides the easy access way to remove and install the Bottom plate.

3. Installing the jacking Supports on the external shell all around the tank at equal
interval which maintains equal distribution of Tank load.
 Doc. No 600-500Z-1827
METHOD STATEMENT FOR BOTTOM Revision No 0

PLATE REPLACEMENT Revision Date May. 31. 2011

Page 4 of 9

4. At the same location of Jacking support inside of tank fixing curvature channel to
maintain the roundness of Tank.

5. After shifting of dimension start the cutting of old bottom one by one.

6. First cutting the Close seam and then cutting Shell to bottom by means of Plasma
Cutter.

7. Make sure that Shell to annular plates is completely free from weld joint before
replacement.

8. Jack up the Shell plate at the same time with the help of same number of operator.

9. Localized Jacking (Maximum height between 50 to 60mm)

10. During jack up make sure that annular plate properly put down from shell plate

11. After Jack up cut the bottom part of the anchor Chair as per sketch for the welding
of shell to Annular Plate.

12. Replace the Annular plate piece by piece until to complete the arrangement and
shall be arrange according to the radius that exceed the dimension of the
construction drawings to compensate for the welding shrinkage.

13. After cutting the first course annular plate side Edge to be smooth grinds and
should be clear from any crack.

14. QC Personal is responsible to inspect after cutting and grinding.

15. Install the Temporary platform on the suitable opening location for shifting the
bottom plate inside the tank.

16. Before shifting the Material, Cutting one Anchor Bolt for the access of material
movement. (Due to Plate Width)

17. Lay down the bottom plate from outside toward the centre in principal as per
approved drawing

18. Plate to plate overlap in long seam and short seam shall be maintained as per
Drawing.

19. After shifting plate to inside start the fit up Shell to annular Plate.

20. During fitup shell to annular plate maintain the radius and avoid from any sagging.
 Doc. No 600-500Z-1827
METHOD STATEMENT FOR BOTTOM Revision No 0

PLATE REPLACEMENT Revision Date May. 31. 2011

Page 5 of 9

21. After fitup annular to annular weld the joint and perform the RT as per API 650.

22. After accepting of RT result Start the Fitup of Shell to Annular Plate.

23. Before Jacking down, make sure that proper guider plate tacking inside and
outside on the annular plate which control the radius of Annular Plate.

24. Level, Roundness and Verticality of the shell plate to be checked prior to Welding.

25. Proper Care shell be taken to avoid distortion during welding.

26. Joint shall be welded in proper sequence: first shall be welded the short seams,
after the long seams shall be welded from center going outwards to the periphery

27. After completing all the welding, the dimensions to be checked.

28. Inspection sequence will be followed according to joint completed and will be
recorded as per ITP

29. Perform shell to bottom Liquid Penetrant test as per API 650 S.4.10.1.

30. Conduct the vacuum Box as per approved Method statement 600-500Z-4432.

31. Chemical cleaning to be carried out prior to Hydro TESTING.

32. Hydro-test to be performed.

33. On acceptance of hydro-test the procedure is complete.

34. For detail follow the sequence of work.

 Doc. No 600-500Z-1827
METHOD STATEMENT FOR BOTTOM Revision No 0

PLATE REPLACEMENT Revision Date May. 31. 2011

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4. Work Sequence

Cutting the Old Bottom

Arrange Curvature channel

and Install jacking System

Cutting Shell to Annular

Plate

JACK UP the Tank

Remove and Transfer the

New Bottom Plate

Laying New bottom as per

Drawing

Fitup and Welding of

Annular Plate

RT OF Annular Plate

Jack down and Fitup

shell to Annular Plate
Follow below welding Sequence

Vacuum Box

Acid Cleaning

Hydro Testing
 Doc. No 600-500Z-1827
METHOD STATEMENT FOR BOTTOM Revision No 0

PLATE REPLACEMENT Revision Date May. 31. 2011

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4.1 General welding sequence is as follows :

1. ANNULAR BUTT JOINT

2. ANNULAR TO SHELL

6. ANNULAR TO BOTTOM

4. BOTTOM LONG SEAM

3. BOTTOM SHORT SEAM

FIG. 1
 Doc. No 600-500Z-1827
METHOD STATEMENT FOR BOTTOM Revision No 0

PLATE REPLACEMENT Revision Date May. 31. 2011

Page 8 of 9

4.2 Jacking System Detail.

FIG. 2
 Doc. No 600-500Z-1827
METHOD STATEMENT FOR BOTTOM Revision No 0

PLATE REPLACEMENT Revision Date May. 31. 2011

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4.3 Anchor chair Rib Plate Modification

FIG-03