REPAIR PROCEDURE FOR TANK BOTTOM
(TK ….)
I OBJECT
Tank bottoms can corrode due to the fluid side or the soil side so bottom repairs
are a common occurrence particularly on old multi-product tanks without cathodic
protection.
Leaks from the tank bottom are not acceptable because the leaking liquid will
proceed directly into the foundation and eventually migrate further away from the
tank. If these leaks are left unattended for an extended period of time, the leaking
liquid could eventually undermine the foundation and lead to a more serious
bottom failure that results in more severe leakage. In any case, even small
hydrocarbon or chemical leaks result in environmental pollution concerns that
cannot be ignored. Unfortunately, a tank bottom may have been leaking into the
foundation for a very long time before any visible signs of leakage are detected.
* welded-on patch is a common solution for repairing a portion of uniformly
supported tank bottoms within some limitations.
All these limitations are for tank bottoms outside the critical zone of the tank
bottom. the critical zone: The portion of the tank bottom or annular plate within 3
in. of the inside edge of the shell, measured radially inward.
II SCOPE
MOG Company asks ETOS to perform a repair procedure to describe all repair
activities in order to ensure that the equipment remains to its original state safely
and without any impact to its design and operating parameters.
This procedure will details and identify the following points:
- Repair zones/process
- Repair steps
- Required documentation
- Required NDT
- Technical support
- Compliance of repair activities with applicable codes
III APPLICABLE CODE
- API 650: Welded tanks for oil storage.
- API 653: Tank inspection,repair,alteration and reconstruction.
- ASME section IX: American society of mechanical engineers.
- ASME V: Non Destructive Examination - Requirements and Methods.
IV DESCRIPTION / DETAILS:
-BOTTOM PLATES :
- Thickness: 8mm
- Material : A 106 G B
- Weld type : fillet weld
- Welding process : SMAW
- Welding electrode : E7018.
V METHODOLOGY OF REPAIR :
1. Procedures, Qualifications, and Records:
1.1 Welding process:
The welding process used to repair the tank bottom is SMAW according to approv
ed PQR & WPS. And by qualified welders.
1.2 Welder & welding Procedure qualification record:
Welding procedure to be used and Welders that will perform welding onto corrode
d areas shall be qualified in accordance with ASME Code, Section IX
All repairs will be performed by qualified Welders who have a good performance r
ecord.
1.3 Filler Metal Strength for projection bottom plates repair:
The filler metal used to repair the nozzles and shell is E7018 with diameter of 2.5
and 3.2 , which has a minimum specified tensile strength greater than the
minimum specified tensile strength of the shell base metal (A106 G B).
1.4 Welding Parameters:
Welding should proceed and shall be in conformity within the range listed in an
approved welding procedure specification WPS.
V SEQUENCE OF REPAIR :
1- cutting the patch plate by grinder with specific measurement and depending
the existing damage .
2- Cut the corners of the plate and make them round with a minimum of radius 2 in
.
3- Brushing all the surface where to be placed the patch plate.
4- Visual inspection of the brushed surface followed(surface to be welded shall be
free of rust ,scale,paint,coat in and other contaminants, and shall have a smooth
contour).
5- Proceed for welding.
6- After completion the weld , to carry out visual inspection followed by 100% DPI
or MPI and 100% vacuum box.
VI DOCUMENTATION :
Prior to start repair activities, the client shall provide the following documentation:
- Approved Welding procedure Specification.
- Procedure Qualification Record.
- Base material certificates for both insert plate and nozzles.
- Welder Qualification Certificate.
- NDE operator’s certificate according to the applicable construction code.
- Filler metal certificates.
VII GENERAL REPAIR REQUIREMENTS :
1- If the welded-on patch plate overlaps a bottom seam or existing patch, The
minimum dimension for the patch will be 12 in. and the welded on patch plate
may be circular, oblong or polygonal with rounded corners
2- If the welded-on patch plate doesn't overlap a bottom seam or doesn't place
fully or partially over an existing patch and extends beyond the corroded bottom
area, if any by at least 2 in. ,This patch plate must be no smaller than 6 in. across in
any direction.
3- When the edge of a welded-on patch plate is approximately parallel to a bottom
seam, the edge shall be held at least 2 in. from the weld seam.
4- patch plates that doesn't cross an existing bottom lap joint shall be no closer
than 2in. from any other bottom lap weld.
5-Patch plates that cover 3-plate laps shall extend a minimum of 12 in. in all
directions along all bottom lap welds beyond the 3-plate lap.
6-Patches over three-plate lap joints shall cross the seams at either 45 degrees or
90 degrees.
7- Patch plates that cross an existing bottom lap weld shall be no closer than 4 in.
to an adjacent 3-plate lap.
8- Patch plate that crosses existing bottom lap seams must cross creating an angle
of no less than 45 degrees.
VIII SAFETY PRECAUTIONS :
- Ensure correct PPE in good condition to use.
- Welders’ gloves, goggles/visors and spatter proof clothing to be worn.
- Electrical cables to be taken off drum and loosely coiled to avoid
overheating.
- Electrical cables for use on portable equipment are to be of sufficient length
such that extension leads are not required.
- Residual current earth leakage devices to be in place.
- Only insulated tools to be used.
- Cables to be in good condition and well protected.
- Check that sharp edges have been removed where practicable.
- Flammable and combustible material is to be removed from work surface
and surrounding area.
- Welding machines and equipment, where possible use continuous length of
cable (no connectors) in live work area.
- Welding machines and equipment to be located in non-hazardous areas and
to be earthed down.
- Safety barriers to be in place
Issued by: Checked by: Approved by:
Name: Name: Name:
visa visa visa
Date: Date: Date:
