TANK TRAINING SERVICES

Tank Training Services is found to serve Oil and Gas, Petrochemical, Energy and Heavy Industries in terms of technical training and consultation. Our existing clientele are the Refineries, Terminals and Tank Farms, Energy Plants and Heavy Industries.

Primarily focused on Oil Storage Tanks, we serve technical training courses; a unique blend of years of industry-specific expertise and international codes & standards. In addition, we also run tailor-made in-house courses targeting sustainable operations with the help of integrity excellence.

With the help of our consultancy and expert training courses, corporations and individuals improve their performance on asset integrity while lowering their operational costs.

We believe that expert support via consultation and training is vital for business success and sustainability.

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OUR KEY KNOWLEDGE AND EXPERIENCE

For all below noted items, we can deliver project consultation and technical training courses suiting your specific needs.



1. STORAGE TANKS


Design – Design review and constructability analysis according to API 650, Tank data sheet review

Material Selection – Material selection to API650 and ASME Sec 2, including impact toughness/welding/NDE requirements, fixed and floating roof material and vendor selection including technical specification requirements.

Pre-FabricationReviewing the capacity of the fabricator, requirements for prefab including rolls for plate bending and PWHT of prefab components, conducting the welding qualifications tests WPS, PQR and WPQ per ASME Sec IX, reviewing the NDE per API 650 and ASME Sec V.

Foundation inspection of the leak detection membrane and cathodic protection grid, soil laying checks, TOC level to API 650 tolerances (7.5.5), anchorage check (if required), draw-off sumps

DocumentationErection method statement, installation and welding sequence check for least possible distortion (shell, bottom and roof), Welding Documentation reviews (ASME Sec IX), NDE documentation reviews (ASME Sec V), Coating System selection per NACE and SSPC requirements

Erection – annular plate laying w.r.t. shell vertical weld orientation, annular sumps installation (if required), backing plate requirements for annular butt welds, bottom plate laying, shell erection, installation checks of prefabricated and PWHT’d components, monitoring the progress in overall percentages, KPI preparation manhour vs. percentage, L3 and L4 schedule review.

QA/QC – ITP preparation and follow-up, all QA/QC activities supervision at site, attending and releasing the HOLD points, dimensional and welding inspection, coating inspection, roof inspection, completion and review of the quality folder, resolutions for non-conformance, Site technical query (STQ), concession request (CR) response according to the Tank Data sheet, standards and contract, Hydrostatic test requirements and conduction of the hydrostatic tests.

Mechanical Completion – initial site checks, final inspection of the tank, quality folder check and mechanical completion punch at site, preparation of punch list, classification of the punch items (A-B-C-D) per the contract,

Pre-Commissioning – mechanical completion punch items check, preparation of the pre-box-up list, pre-box-up checks at site and classification of the open items.

Commissioning – preparation of the final box-up list, final box-up checks at site and classification of the open items. Final acceptance of the tank before hand-over. Preparation of the items to be handled by Owner.

Operational Tips – Identification of the operational tips concerning the mechanical integrity of the tank, filling and emptying rates, operator checklists per EEMUA 159.

De-Commissioning – Site checks and identification of the blinds/DBBs spots. Method selection and activities for emptying the tank. Method for gas-freeing and cleaning the tank including the Tank Safe Entry requirements as per API Std 2015 and RP 2016.

Maintenance, Inspection and Repair – inspection technical spec. preparation and conducting the inspection per API 653 and/or EEMUA 159, defining the mechanical repair scope, identifying the root cause of the damage mechanisms, settlement analysis, coating inspections per API RP 652.

Asset Integrity Management – AIM methodology selection depending on the tank owner operating conditions and maintenance habits, reviewing previous tank history and data



2. PIPING


Material Selection and Concept Design – reviewing the material according to operational temperature, pressure, and corrosivity of the process fluid. Lethal service requirements according to ASME B31 series. Weld efficiency selection according to NDE and service requirements. Commenting on voluntary Material selection and PWHT per service requirements in light of NACE-MRs. Coating system selection according to service requirements, hot insulation and environmental conditions.

Pipe Supports – selection and review of the piping supports, welding requirements, additional PWHT after support installations.

Valve SelectionValve material (body and trim) selection, technical spec. preparation for correct procurement.

Documentation – P&ID reviews, connection and continuity, isometrics review, revision follow-up, random piping clash checks.

Welding – welding qualification (WPS, PQR and WPQ) according to ASME Sec IX, identifying the welding thickness and material coverage

Prefabrication and Site Installation – tips for improving prefabrication and site progress, support checks, prefabrication and site installation routine checks

QA/QC – welding and NDT logs, resolutions for non-conformance, Site technical query (STQ), concession request (CR) response according to the service requirements, ASME B31 standards and contract. Conduction of the hydrostatic test and flushing of the pipelines. Re-instatement checklist of the pipelines. Positive material identification.

Pre-Commissioning – review of the quality folder, mechanical completion punch conduction, review of the re-instatement checklists, flange integrity checklist preparation for critical pipelines, listing and classification of the open punch items.

Commissioning – final checking of the open items, checklist review for flange integrity, re-instatement checklist reviews, final acceptance of the pipelines before hand-over. Listing of the items to be handled by Owner.

Maintenance, Inspection and Repair – Damage mechanism studies as per API RP 571, remedying the situation by correct material selection, CUI inspections and inspection scope preparation for the existing lines. Reviewing of the temporary or permanent repair conditions per API 570 and ASME PCC series.



3. BOILERS AND HEATERS


Welding, NDT and QA/QC - welding qualification (WPS, PQR and WPQ) according to ASME Sec IX, identifying the welding thickness and material coverage, welding and NDT logs, resolutions for non-conformance, Site technical query (STQ), concession request (CR) response according to the service requirements, PED or ASME B31 standards and contract, conduction of the hydrostatic test and flushing of the boiler and heater tubing and manifolds. Positive material identification and tracibility

FoundationFoundation inspections according to the mechanical and civil drawings.

Prefabrication and Site Installation – tips for improving prefabrication and site installation progress, prefabrication and site installation surveillance

Refractory, Fireproofing and Hot Insultationrefractory installation and inspection per the ITP and site checks according to API Std 936 and technical specifications.

Fireproofing and hot insulation material selection and site application inspection according to the technical specification.

Pre-Commissioning – mechanical completion punch, punch items check, preparation of the pre-box-up list, pre-box-up checks at site and classification of the open items according to the contract,

Commissioning – preparation of the final box-up list, final box-up checks at site and classification of the open items. Final acceptance of the boiler or heater before hand-over. Preparation of the items to be handled by Owner.

Maintenance, Inspection and Repair – Inspection of the boiler or heater according to related construction standards, damage mechanism studies as per API RP 571, remedying the situation by correct material selection, CUI inspections and inspection scope preparation. Inspection of the tube hot spots. Inspection of the refractory (if required). Reviewing the condition and selection of the temporary or permanent repairs.



4. STATIC EQUIPMENT (REACTORS, COLUMNS, DRUMS, HEAT EXCHANGERS)


Design, Fabrication and Testing – Material selection, MDMT and material review related to NACE MR and operation conditions

Welding, PWHT, NDT and QA/QCwelding qualification (WPS, PQR and WPQ) according to ASME Sec IX, identifying the welding thickness and material coverage, welding and NDT logs, resolutions for non-conformance, Site technical query (STQ), concession request (CR) response according to the service requirements, PED or ASME B31 standards and contract, conduction of the hydrostatic test and flushing of the static equipment

Foundation and InstallationFoundation inspection and anchor points check. Initial verticality and dimensional surveys with a reference vertical piano wire. Installation inspection of the internals like trays, cyclones and other piping, lugs and supports. Equipment installation leveling and surveillance. Balance check of the symmetric feed pipework and sloped installation of train packages.

Fireproofing - Fireproofing and hot insulation material selection and site application inspection according to the technical specification.

Pre-Commissioning – mechanical completion punch, punch items check, preparation of the pre-box-up list, pre-box-up checks at site including the internals, and classification of the open items according to the contract

Commissioning – preparation of the final box-up list, final box-up checks at site and classification of the open items. Final acceptance of the static equipment before hand-over. Preparation of the items to be handled by Owner.

Maintenance, Inspection and Repair – Damage mechanism trend analysis and studies as per API RP 571, remedying the situation by correct material selection, CUI inspections and inspection scope preparation. Reviewing of the temporary or permanent repair conditions according to API Std 510. Static equipment specific inspection and integrity checks such as;

  • Defining shell and tube exchanger inspection criterion and inspection of the H/E tube sheet and bundle.

  • Inspection of the existing condition of the equipment internals like trays, cyclones and internal piping

  • Operation conditions review (temperature runaways and pressure build-ups) accountable for the cycles of the static equipment

  • Maximum allowable working pressure and minimum allowable thickness review according to API 510

  • Roundness and tilt review in light of initial roundness and plumbness survey readings

  • RBI studies and activity review in light of the existing AIM methodologies.

  • Pressure Safety Device in-situ calibration and log keeping