1.

Scope

This procedure covers inspection and repair of Tk-7 bottom plate and annular plate to
shell (including critical zone). The repair carry out during Tk-7 out of service are
covered:-
1.1 The replacement of annular plate to shell including critical zone (3 int & ext
distance from tank shell) is to address an extensive damage of existing area
detected during on-stream inspection.

1.2 The bottom plate weld patch repair is to address the minimum thickness as found
during tank floor scanning.

2. Definition

Annular plate - an approximate 2 feet of bottom plate area from outer rim are consider
annular plate.

3. Consideration

All new material used for repair, alteration shall meet applicable of tank standard API
Standard 653/650.

4. Safety Consideration

4.1 Prior to proceed with tank repair, Tk-7 shall be clean and gas free compliance.

4.2 If product suspected under floor plate, prior to any hot work special procedure
shall be developed by the repair contractor and review with respective PDR
personnel.

4.3 If existing material where repair require was confirm contaminated with other
hazardous material e.g lead, special procedure shall be developed by repair
contractor and review with respective PDR personnel.

5. Reference

5.1 ExxonMobil Global Practice

5.2 API Std 653

5.3 API Std 650

6. Repair Procedure

6.1 Welding

6.1.1 Welding procedure shall be in accordance with API Std 653.

6.1.2 When necessary to weld new annular to existing shell plate:-

6.1.2a Clean to SSPC SP-7 brush off cleaning from rust, mill scale and/or
old coating.

6.1.2b Assemble the annular plate and shell plate. All assembly to be
witnessed by contractor QC and reviewed with ESSO personnel.

6.1.2c Using low Hydrogen electrode (E-7018/E7016) to deposit a fillet

weld. As per design 1st pass weld deposit should be on vertical leg against
shell plate and for 2nd pass weld deposit should be on horizontal leg
against annular plate. Refer to below sketch-1 for details:

Shell plate

1st 1st
3rd 3rd

2nd 2nd
Bottom plate

Sketch-1

6.1.2d Perform visual inspection on root to be sure all welds area free
from notches and undercut, grind remove any finding is recommended.
Perform magnetic particle inspection prior to proceed with 2nd and 3rd pass.

6.1.2e Visually inspect final weld, also inspect using Dye penetrant
testing.

6.1.3 All other bottom plate to bottom plate fillet weld shall made using 2
passes with low hydrogen electrode.(E-7018/E-7016)

6.1.3a Visually inspect final weld, random DPT shall be performed and
100% vacuum box testing.

6.2 Replacement of annular to shell plate including critical zone.

6.2.1 Unless otherwise specify during construction, all plate shall be uniformly
cut in parallel to tank bottom. Details dimension and number of annular
plate to shell replacement will be refer to drawing no Tk-7-001/09.

6.2.2 Site verification and marking on removal annular plate and shell to
annular plate weld seam should be carry out before any hot work activity
start.

6.2.3 Mobilize of equipment and tools to site for inspection by PDR personnel

6.2.4 All fabrications on new annular plate should be carry out in fabrication
yard. Traceability should be recorded as per API Std 653.

6.2.5 Temporary square nut (100mm X 100mm X 25mm) shall be use as a part
of component to wedge the shell plate up. Refer to sketch-2 AND
Drawing Tk-7 004/09 for details.

6.2.6 Weld vertically the square nut at 25mm elevation from tank bottom
outside of Tk-7 shell with approximate spacing between 2.3m surrounding
the tank perimeter where wedges are required. Refer to sketch-2(a) & (b)
for details. Refer Attachment 1.0, Drawing Tk-7001/09, Tk-7002/09, Tk-7
004/09, Tk-7 003/09 SHT 1, Tk-7 003/09 SHT 2,

Shell Plate
C-Channel
as stiffener
ring Square Nut
100mm X 100mm X
25mm

Square Nut
166.7 mm 100mm X 100mm X
elevation 20mm

Wedges

25 mm 50mm
Max elevation
15mm
gap

Annular Plate 250mm

Skecth-2(a) Side View Skecth-2(b) Front
View

6.2.7 Visually inspect final weld, also inspect using dye penetrates testing.
6.2.8 Tack weld temporary stiffener rings (C-channel 100mm x 50mm x 6mm)
to shell according to ID. The stiffener shall be attached 166.7 mm from
tank bottom around the tank shell. Refer to sketch-2(a) for details.

6.2.9 Temporary back up jack (support) install internally (4 locations) to assist

during wedging the square nut. Refer to sketch-3 for details.

Square Plate
210mm X 210mm X
20mm

266.7 mm Square Nut

elevation 100mm X 100mm X
20mm

25 mm
elevation

Annular Plate
Skecth-3 Side View

6.2.10 Gouge shell to annular plate weld seam with approximate of 80m length
on internal and external of the Tk-7 except the length of weldment around
marine line noozle.

6.2.11 Clean the gouging area from scale or other foreign material and ensure all
remaining welding are completely removed between shell and annular.

6.2.12 Lay the wedges in between the square nut and bottom plate with slight
force by hammer.

6.2.13 Standby 20 workers to raise up the half round tank to the height of 15mm
by wedging.

6.2.14 Raise up the other half round of the tank to 15mm as item 6.2.13

6.2.15 Gouge and cut the annular plate as mark in drawing Tk-7-001/09.

6.2.16 To prevent shell distortion at Marine Suction Line, attached related bottom
plate will be gouged.
 6.2.17 After complete gouging, pull out the 1st 2 pieces of the existing annular
plate in sequence (Refer Drawing 05/09 SHT 1) Grind off all gouging
plate to smooth and clean edges of shell or annular plates.

6.2.18 To prevent from galvanic corrosion, ensure old bottom plate and other
foreign materials are completely removed prior to install new annular
plate.

6.2.19 Install the 1st new annular plate from tank outside by the method as per
Drawing 05/09 SHT 1 after inspection of tank pad. Any voids on the
foundation below the old bottom plate should be filled with material such
as oil sand and premix. (temporary platform may require to prevent further
damage on tank pad)

6.2.20 Install the 2nd new annular plate from tank outside after 3rd piece of
existing annular plate is removed .Tack welding 1st to 2nd new annular
plate after installation as per Drawing 05/09 SHT 2. Fit up the new plate
with existing bottom plate as per drawing Tk-7-001/09 and ensure it meet
API Std 650 for critical zone and outer rim.

6.2.21 Repeat the removal and installation of annular plates in sequence as item
6.2.19 and 6.2.20.

6.2.22 Remove few wedges at nearest to fit up plate and let Tk-7 shell plate
laying down on it.

6.2.23 Once shell plate was completely settle down on new annular plate tack
weld should be carry out. The tack weld shall be remove prior to actual
welding of the annular to shell plate weld seam.

6.2.24 An alternate welding at approximate 1m length as per 6.1 shall be carry

out in sequence to minimize distortion on shell and annular plate.

6.2.25 All square nuts shall be remove by grinding. Also inspect the area using
penetrant testing (DPT). Any defect on the shell course shall be repair.

6.2.26 All grinded area are to be touch up paint.

6.3 Patching of bottom plate.

6.3.1 Site verification and marking on bottom plate should be carry out before
any hot work activity started.

6.3.2 Mobilize of equipment and tools to site for inspection by PDR personnel
6.3.3 Patch plate shall be size to allow welding to the bottom with remaining
thickness at least 0.20 (5.08mm)

6.3.4 Individual weld patch plate should be limited to an area of 10 ft square or

less. The min. requirement of patch plate should be refer to API Std 653.

6.3.5 All weld patch plate may be circular, oblong, or polygonal with rounded
corners.

6.3.6 All weld patch shall be examine with DPT and vacuum tested.