INSTALLATION PROCEDURE

FOR TANK

0 03 June 2005 Issued For Approval

Prepared Approved Reviewed
Rev. No Date Of Issue Status
by by by
 - CONTENT -

1. GENERAL
2. APPLICABLE SPECIFICATION, CODE AND STANDARD
3. INTRODUCTION
4. CHECKING AND ACCEPTANCE OF FOUNDATION
5. BOTTOM PLATE (Bottom Plate, annular plate and Backing Strip)
6. SHELL AND TOP ANGLE
7. ROOF STRUCTURE (CENTER RING AND RAFTER)
8. ROOF PLATES
9. ACCESSORIES ( Nozzle, manhole, Inside / outside ladder and Earth lug etc)
10. TOP ANGLE AND WIND GIRDER
11. INSPECTION AND TEST
12. HYDROSTATIC TEST
13. SURFACE CLEANING & PAINTING
14. INSPECTION

FIGURE :
1. CENTER POINT OF FOUNDATION
2. SEQUENCE OF ARRANGEMENT FOR BOTTOM PLATE
3. SEQUENCE OF WELDING FOR BOTTOM (1)
4. SEQUENCE OF WELDING FOR BOTTOM (2)
4’. SEQUENCE OF WELDING
5. ARRANGEMENT OF HORSE SHOE
6. ARRANGEMENT OF KEY NUT
7. ASSEMBLY OF 1ST SHELL COURSE
8. ASSEMBLY OF 1ST and 2nd SHELL COURSE
9. JIG FOR SHELL TO BOTTOM PLATE JOINT
10. ASSEMBLY & INSTALLATION OF SHELL PLATES
11. ASSEMBLY & INSTALLATION OF SHELL PLATES SCAFFOLDING
12. SEQUENCE OF ARRANGEMENT OF ROOF
13. SEQUENCE OF WELDING FOR ROOF ( 1 )
14. SEQUENCE OF WELDING FOR ROOF ( 2 )
1. GENERAL
This procedure cover the general requirement for installation procedure for tank and shall be applied to
reference document at site.

2. APPLICABLE CODE & STANDARD

- API Std 650 : Welded Steel Tanks for Oil Storage , Tenth Edition, November 1998
- ASTM or JIS in regard to materials
- ASME Code (2004 edition)
A. ASTM Section II : Materials
B. ASTM Section V : Non destructive Examination
C. ASTM Section IX : Welding & Brazing Qualifications

3. INTRODUCTION
Drawing and document all of field fabrication shall be performed strictly in accordance with “ FOR
FABRICATION” drawing shall be conformed the specified documents before erection works.
Material/Parts
All material / parts shall be submitted to site as prefabricated.
Jig and Welding rod for field fabrication
The necessaries jig and welding rod shall be supplied by PT. Daekyung Indah Heavy Industry. The
quantity of jig and welding rod supplied has been calculation based on extensive fieldwork techniques,
experience and past achievements.

4. CHECKING AND ACCEPTANCE OF FOUNDATION (Refer to Fig-1)

Before erection works of tank , the center of foundation, the radius of the pad, slope and level of tank
foundation marking of the center point and the orientation marks shall be checked.

5. BOTTOM PLATE (Bottom Plate, annular plate and Backing Strip)

Preparation
Center point of foundation shall be determined by stretching piano wire leveling strings between
constancy point of four datum piles 0 o, 90 o, 180 o, 270o (Refer to fig-1)
Arrangement
The bottom plate shall be arranged in accordance with drawing.
The center plate, which will be basic for lying other plates, shall be laid the center point.
One backing strip shall be welded underneath of each annular plate.
The annular plate shall be arranged with root opening as specified clockwise starting from the
basic point.
After placing of center plate, all other plate shall be arranged with appropriate lap outward from the center of the
tank (refer to Fig-2).
The bottom shall be tack-welding sing jigs (strong back, bottom piece, etc) for anti distortion.
Checking on diameter of the bottom shall be execute at point 0 o-180o; 45 o -225o; 90o -270o; 135o -315 o.
Welding
Sequence of welding (Refer Fig-3,4 & 4’)
The limit of the 200 mm outside of bottom weld seam shall be ground smoothly and liquid penetrant examination
(PT) and vacuum testing using soapsuds shall be applied.
All the welding works shall be executed, in principal from center to outside.
Care shall be paid during welding of the bottom to assure minimum distortion and uniform lapping.
After completion of welding works, vacuum testing using soapsuds shall be applied to the all welding joint.

Marking on the bottom

Before assembling of shell plates, the marking shall be execute with scrupulous care in accordance with
orientation drawing, because those will from basis for assembly of shell plates, shell accessories, nozzle and
etc.
Circular marking for the shell plates shall be divided equally with length.
After the 1st shell course is assembled, those marking shall be replaced on that.

6. SHELL AND TOP ANGLE

Preparation
After inspection of the bottom welded seams occurring.
The shell plates shall be distributed around the bottom already set up.
Prior to the assembly, horse shoes for straight and curved strong back shall be welded temporality on the shell
plates (Refer to Fig-5), and also key nut shall be welded temporality on the annular / bottom plates along shall
circumference of both sides (Refer to Fig-6).
Assembly (Refer to “Sequence of assembly and welding for shell”)
The shell plates shall be assembled on accordance with orientation and shall plate drawing.
The 1st course
a) The shell plates shall be assembled with root opening as specified clockwise starting from
“Starting point on 1st Course shell plate vertical joint” indicated in orientation drawing (Refer
to Fig-7)
b) After completion 1st course assembly, checking shall be executed to ensure that level at top
edge, plumpness, joint alignment and root opening are correct.
The 2nd course
a) Scaffolding boards with hook and bracket shall be arranged on both side 1 st course.
 b) The second course shall be assembled in accordance match mark which had made on 1 st
course (refers to Fig-8)
c) The vertical joint between 1st and 2nd shall be match accurately in position with jig.
d) The horizontal joint between 1st and 2nd course shall be match to each course retained in
position with jig.
e) Traveling, scaffolding if used shall be installed on outside of the shell
The 3rd course and upper course
a) The 3rd course and upper course shall be assembled in the same manner as the 2 nd course.
b) Temporary assembling of each course shall be completed in the day, leaving the assembly
on the way to the next day shall not be done, and maximum allowable number of shell
course to be assembled temporary shall be 2 course.
c) Principal shell course, which is higher than 5th course shall be assembled and welded one by
one.
Welding (Refer to “Sequence of assembly and welding for shell”)
Welding for vertical joint for 1st course
a) The vertical joint shall be tack-welded from inside and curve strong back, spacer with finger
pin shall be removed out.
b) The continuous welding shall be executed from the outside first.
c) Prior to application of first bead to inside welding, the welded joint shall be cleaned
thoroughly in the manner that will leave expose surface satisfactory for fusion of the weld
metal to be added.
After than, the inside of vertical joint shall be welded.
Welding of vertical joint for 2nd course shall be executed in the same manner the 1 st course.
Welding vertical joint between 1st and 2nd course
a) The horizontal joint shall be tack welded from inside and straight strong back, spacer with
finger pin shall be removed out.
b) The continuous welding shall be executed from outside first. After than, the inside of
horizontal joint shall be welded.
c) The fillet weld joint between shell and bottom shall be welded after 4 th course shell is
assembled.

Welding joint of 3rd and upper course

The vertical joint of 3rd course shall be welded before welding of horizontal joint between 2 nd and
3rd course. Regarding to the all shell plates, the welding of horizontal joint shall not be welded
before the welding of vertical joint.
7. ROOF STRUCTURE (CENTER RING AND RAFTER)
Preparation
The temporary stage shall be install on bottom center in order to fix center ring (center column). The stage which
can adjust height at the top angle, shall be made.
Correct position of bracket to be attached to shell shall be clearly marked in accordance with drawing.
Assembly
The center ring shall be fixed on the temporary stage correctly.
All the brackets to be attached to shell shall be installed by welding.
The rafter shall be connected to center ring / column and shell brackets.
Welding
When all structure are assembled and adjusted, the joint shall be welded after bolting up.

8. ROOF PLATES
Preparation
Four direction points 0o, 90 o, 180 o, 270 o shall be replaced on the top angle from existing point on the
foundation. Center point of roof shall be determined by stretching two wire of string between contrastive
points.
Arrangement
The Roof plates shall be arranged in accordance with drawing.
Center plate shall be arranged at last (Refer to Fig-12).
Sequence of arrangement for roof plates shall be contrasts of right with left.
Welding
sequence of welding (refers to Fig-13& 14)
All the welding work shall be executed, in principle, from center to outside.
Care shall be paid during welding of the roof to ensure minimum distortion and uniform lapping.
After completion of welding work, pneumatic test using soapsuds shall be applied to all weld joint.

9. ACCESSORIES ( Nozzle, manhole, Inside / outside ladder and Earth lug etc)
The hole of nozzle and manhole shall be marked and made in accordance with drawing and reinforcing plates/
pad plates shall be welded.
The clip bracket for piping support, ladder, and stage shall be marked in accordance with drawing. All
accessories shall be assembled and welded in principle, full water test in accordance with drawing.
 10. TOP ANGLE AND WIND GIRDER
After assembling of shell plate, tack welding to be applied to top angle and at such time tack welding be done to fit
"R" type stiffening plate to the joint of top angle, by paying due attention to form a correct circle.
When welding the vertical joint of upper most top plate, the vertical joint of top angle shall also be welded.

11. INSPECTION AND TEST

Inspection and test item to be witnessed by client during field erection shall be in accordance with inspection
and test procedure. The record of inspection and testing shall be submitted to client for review and approval
in accordance with inspection and test procedure

12. HYDROSTATIC TEST

12.1 Prior to hydrostatic test, the inside and outside of the tank shall be cleaned and free from all slag, loose
scale, dirt and weld spatter. No equipment surface except the underside of the floor sheets, shall be
painted until the final inspection is completed.
12.2 Hydrostatic test shall be carried out using clean water, in the presence of an authorized inspector and
subject to his approval. After successful testing, all water shall be drained and the equipment
thoroughly dried.
12.3 Tanks shall be properly vented during filling hydrotesting so as to prevent the formation of air pockets
before any test pressure is applied.
12.4 Test water shall be filled to the top of the top angle or bottom of any overflow nozzle opening.
12.5 Tell-tale holes in nozzle pads shall be tested with air at max 15 psiG prior to hydrotest.
12.6 The temperature of testing medium shall be between 5°C and 40° during hydrotest
12.7 Check points before hydrostatic test :
a). All welding works shall be finished
b). All radiographic shall be completed
c). Temporary piping for water test shall be completed
d). Cleaning inside of the tank and removal of temporary jigs and tools are completed
e). All shell opening shall be closed by appropriate cover plates

12.8 Inspection of during hydrotest

a). Settlement of tank foundation . When it is anticipated that an extraordinary settlement will occur and
case bad effect to the tank, subcontractor shall be report it to inspector as soon as possible
b). Leakage of weld seam
c). Function of level gauge and others

13. SURFACE CLEANING & PAINTING

14. INSPECTION

FLOW CHART OF TANK ERECTION

Step 1 Receiving and checking of foundation

Step 2 Arrangement and welding of bottom plates

Step 3 Assembling and welding of shell plate (1st course ~ Top course )
Make the hole for shell manhole/nozzle installation of top
Angle
Step 4 Assembling and installation of rafter

Step 5 Assembling and welding of roof plates

Make the hole for roof manhole/nozzle

Step 6 Installation of manhole and nozzle

Marking and welding for other accessories.

Step 7 Installation of stage, hand rail

Step 8 Assembling and installation of monkey ladder

Step 9 Installation of level gauge, etc

Inside/Outside cleaning

Step 10 Final inspection and testing

Step 11 Subsidence check

Step 12 Painting and coating

Step 13 Tank calibrations

CENTER POINT OF FOUNDATION

 Fig – 1

SEQUENCE OF ARRANGEMENT FOR BOTTOM PLATE

 7 7
6 5 6

4 4

40
0

2 3 1 3 2

1
1
4 4
2 2 1 2
3
6 5 6
7 7
1
1
1

2 1
BOTTOM PLATE SHALL BE PLACED
IN ORDER FROM 1 TO 10
1 1
Fig-2
1

3 2 1
2

1
SEQUENCE OF WELDING FOR BOTTOM (1)
 40
0

6
6
6

4
6
5
6

1. BOTTOM PLATE6SHALL BE WELDED IN ORDER FROM

4 1 TO 10
2. SKIP SEQUENCE WELDING SHALL BE ADOPTED
5 6

Fig – 3

6
6
SEQUENCE OF WELDING FOR BOTTOM (2)
 1. BOTTOM PLATE SHALL BE WELDED IN ORDER FROM 4 TO 6

2. BUT 6 SEAMES SHALL BE WELDED AFTER WELDING COMPLETION SHELL TO BOTTOM

ANNULAR.

Fig – 4

SEQUENCE OF WELDING FOR :

- SHELL TO SHELL
- SHEL TO BOTTOM ANNULAR
- BOTTOM ANNULAR TO BOTTOM ANNULAR
- BOTTOM ANNULAR TO BOTTOM

5 3rd vertical

6 2nd horizontal

3 2nd vertical

4 1st horizontal 6

2 1st vertical 9
5

40
01

1
40
0
9 8 9

SEQUENCE OF WELDING ARE 1 TO 9

Fig – 4’

ARRANGEMENT OF HORSE SHOE

 1ST COURSE

2ND AND UPPER COURSE

Fig-5

ARRANGEMENT OF KEY NUT

 Bottom plate

Key nuts

Fig-6

SEQUENCE OF ASSEMBLY AND WELDING FOR SHELL

ASSEMBLY WELDING

1ST COURSE
2ND COURSE
1ST AND 2ND VERTICAL

1ST AND 2ND HORIZONTAL

3rd COURSE
4th COURSE
3rd AND 4th VERTICAL

2nd x 3rd HORIZONTAL

5th COURSE
5th VERTICAL

4th x 5th HORIZONTAL

UPPER COURSE

UPPER VERTICAL

5th X UPPER HORIZONTAL

TOP COURSE

TOP VERTICAL

UPPER x TOP HORIZONTAL

TOP ANGLE

TOP COURSE x TOP ANGLE

ASSEMBLY OF 1ST SHELL COURSE

 Horse Shoe

Spacer w/finger pin

Carrot pin

Strong back
Horse shoe
Carrot pin

Key nut
Tapper pin

Fig – 7

ASSEMBLY OF 1ST and 2nd SHELL COURSE

 Match mark

Fig – 8

JIG FOR SHELL TO BOTTOM PLATE JOINT

 SEQUENCE OF ARRANGEMENT OF ROOF

ROOF PLATES SHALL BE PLACED IN ORDER FROM 1 TO 4

Fig – 10

Fig - 9

Fig – 9

ASSEMBLY & INSTALLATION OF SHELL PLATES

 Fig – 10

Fig – 10

ASSEMBLY & INSTALLATION OF SHELL PLATES SCAFFOLDING

 Fig – 11

ROOF PLATES SHALL BE WELDING IN ORDER FROM 1 TO 4

Fig – 11

SEQUENCE OF WELDING FOR ROOF (2)

Fig – 11

Fig – 11
 SEQUENCE OF ARRANGEMENT OF ROOF

ROOF PLATES SHALL BE PLACED IN ORDER FROM 1 TO 4

Fig – 12
 SEQUENCE OF WELDING FOR ROOF ( 1 )

4 2 1 3

2 1

2 1

2 1

2 1

2 1

2 1

4 2 1 3

ROOF PLATES SHALL BE PLACED IN ORDER FROM 1 TO 4

Fig – 13
 SEQUENCE OF WELDING FOR ROOF ( 2 )

5
8

7
5 8
ROOF PLATES SHALL BE PLACED IN ORDER FROM 5 TO 9

Fig – 14

ROOF PLATES SHALL BE PLACED IN ORDER FROM 1 TO 4

Fig – 14