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TESS PROCEDURE MANUAL

Procedure T5063
I lnstallation tank seal Revision 1
I g"n"ral procedure November 1st 2017
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1. PURPOSE

This document describes the process involved with installation of tank seals. This procedure is
made to ensure the safety of the workers on site and will guarantee the quality of the seal after
installation.

2. SCOPE

This procedure is valid for all tank seal installation projects where TESS is responsible for the
on site ac;tivities (either full installation or supervision only).

O 3. DEFrNtrtoNS

4, RELATED DOCUMENTS

Proced u res

. SA025 'Job Risk Analysis (JRA)'

Forms

. T5061 'Tank lnspection sheet for seal engineering'


. TS064 'Checklist supervision seal'
. TS065 'Checklist tank seal completion'
. SA029 'Toolbox meeting attendance registration'

5. PROCEDURE

5.1 Safety measures

Installing a seal requires working in a possibly hazardous environment lt is therefore of utmosi


importance that the safety guidelines and safety policy of the installation location is folloired tc
the letter The general safety procedures as set out in the accredited safety manual of TESS
will also have to be followed. The site supervisor will have a copy of the manual availabie for
rnstruction and review purposes

We recommend at least the following safety precautions:


. Blocking and blinding of all the pipes going to the tank
. Measuring the tank for being gas-free and below 10% LEL
. Sufficient fire extinguishers need to be on site (at least 2)
. Fire retardant overalls are recommended for all workers on the roof
. Further PPE consists at leas of: Hard hat, protective gloves, safety spectacles and safety boots
. Fastening of the bolts needs to be done by air tools. The use of electric tools needs to be prevented
. A material safety data sheet (MSDS) of the previously stored material will have to be
present on the jobsite

Printed versions of this document are uncontrolled and will not be updated
reE# Page 2 of 5

ln case of an emergency the procedures applying on site need to be followed Therefore it is of


utmost impoftance that the workers have the following trainings prior to work:

. Site orientation
. Emergency procedures
. Meeting point location
. Site supervisor will be responsible for the trainings levels of the workers

Process FIow

1. Seal materials
lifted onto the
floating roof

- Toolbox
- Seal
installation
manual
- JRA

3 Materials and
tools check

Printed versions of this document are uncontrolled and will not be updated.
Tre
5.3 Process Description
Page 3 of 5

1 The tank seal can be installed after the materials have been lifted onto the tank Lifting of
these materials will have to be done by qualified lifting company according to the current
safety procedures

2 Set up a toolbox meeting regarding the tank seal installation. ln thts toolbox the instruction
manual for the appropriate tank seal will be discussed with the crew along with the safety
measures and the task risk analysis The seal installation manual is provided by TESS
This toolbox meeting is mandatory for all crew members involved with the seal installation
This attendance is checked with the toolbox attendance checklist,

J Pneumatic tools are needed for installing a tank seal Prio to installation one has to make sure
all needed tools are present before starting with the work the seal installation, ln the
installation manual, supplied with the shipment the relevant tool list can be found During the
whole installation sequence, the supervisor is responsible for the tools

4 All seal installation materials should be loaded on the floating roof before installation The
completeness of the materials should be checked by the supervisor according to the packlng
list Any material incompleteness or damages should be reported immediately to the prolect
manager for quick action in order to minimize any possible delays during installation

A The actual installation of the seal will be done according to the appropriate seal installation
manuals discussed during the toolbox meeting The proper manual is always supplied with the
seal shipment The TESS supervisor rs responsible for the availability of the manual on site at
any time during the installation

Both after completion of the primary as afterthe installation of the secondary seal the seal wtll
be inspected according to the seal installation checklist This is important as the primary seal
cannot be inspected afterthe installation of the secondary seal Afterthe seal installation is
complete, the seal will undergo a final inspection All inspections will be done according to
'Checklist tank seal completion'

7 Following every project that involved work on site (either supervision or full installation) the
project must be evaluated Depending on the size of the project or the encountered problems
this can range from a brief conversation to a detailed meeting These evaluatton wtll help to
fine-tune the installation procedures and to continuously improve our quality and level of
safety

5.4 lnstalling seal in service

Atank seal can be installed in both newtanks ortanks which are already in service ln case of
installing a seal on a tank which is already in service, extra safety measurements has to be
taken addition on top of the standard safety procedures mentioned above

Printed versions of this document are uncontrolled and will not be updated
Trs
5.5 Safety measures for installing seal in servtce
Page 4 of 5

Depending on the voiatilitv of the stored product a safety plan needs to be set out, which
should at least lnclude the following safety precautions We recommend making a task risk
analysis w th the fire depaftment HSE and the foreman of the installation crew.

. Makesurethetankisathighlevel (within2mfromtopangle) Thiswill makesurethat


possible hazardous vapours are removed instantly
. Constantly monitorthe concentration of hazardous vapours (not above 50% MAC value)
. Equip al workers with escape masks, filters or use fresh air equipment if necessary.
o Monitorthe explosive levels atthe seal area Above 10% LEL all work should be stopped
instantly
o Keep at least 5 mobile fire extinguishers on the floating roof at all times,
. Keep a foam system operational that is attached to the fire extinguishing system and the
foam supply.
. At least the amount of foam needed for a 5cm foam layer in the complete rim area should
be available when the work starts.
. Use spark free tools

5.6 lnstalling seal in service

lf the safety precautions are approved and in agreement with the requirements as set out by
the local fire fighting department the installation of the seal can take place The following steps
need to be taken to install the seal

. Before installing the prrmary seal first completely remove the secondary seal
. Remove the various items of the secondary seal to facilitate the installation of the primary
seal
. Lay out 40meters of prrmary seal to facilitate installation
r Remove a porlion of the primary seal No more than 30 meters of seal should be removed
at a time
. After removing a porl of the primary seal apply 2-5cm of expanded fire fighting foam on the
stored product This will reduce the emission and make the installation safer
. lnstall the laid out porlion of the primary seal according to the seal installation manual
. Make sure that the seal is completely covered with fire retardant blankets after each work
shift
. Continue the process until the primary seal is completely installed
o After installation of the primary seal remove the fire fighting foam with a suction unit
o Thoroughly inspect the installation of the primary seal and install the secondary seal
according to the seal installation manual, with the normal safety precautions

5.7 Post installation insPection

It is very impoftant to pedorm a post installation inspection to check every aspect of the seal
installation

Primary sealinspection
We recommend to perform the inspection after installing the primary seal Without the
secondary seal installed it is much more convenient to inspect the primary seal, before the
view is blocked by the secondary seal

Printed versions of this document are uncontrolled and will not be updated
Tr. Page 5 of 5

From the top of the external floating roof the following items will have to be inspected:
. Welds on the vapour barrier
. Fastening of the nuts on the rim
. Sealing force against the tank shell
From underneath the internal floating roof it is necessary to inspect the following.
. Sealing of the shoe plates
. Scissor mechanisms, placement and assembly
. Tensioners, placement and assembly
After inspecting the primary seal the installation of the secondary seal can commence

Secondary seal inspection


After installation of the secondary seal it has to be inspected as well The inspection points
include.

. Weids of the lip profile


. Fastening of the nuts on the rim above the clamp bars
. Sealing of the lip profile against the tank shell
. Shunt placement
. Seal pressure against the tank shell
. Orientation of the lip profile
. Welds of the vapour barrier

After inspecting the secondary seal it is also necessary to inspect the tank shell for
obstructions lf an obstruction ts found this must be corrected prior to taking the tank into
service, lf it is not possible to remove the obstruction the movement of the external floater
must be limited so thatthe seal does not come in contactwith the obstruction, (high level alert)

TESS can supply a detailed inspection protocol upon request

6. REVISION OVERVIEW

Revision Date Author Description


1 01-11-2017 A Suhafto Oriqinal issue

Printed versions of this document are uncontrolled and will not be updated
TH Page 5 of 5

From the top of the external floating roof the following items will have to be tnspected.
. Welds on the vapour barrier
. Fastening of the nuts on the rim
. Sealing force against the tank shell

From underneath the internal floating roof it is necessary to inspect the following.
. Sealing of the shoe plates
. Scissor mechanisms, placement and assembly
o Tensioners placement and assembly
After inspecting the primary seal the installation of the secondary seal can commence

Secondary seal inspection


After installation of the secondary seal it has to be inspected as well The inspection points
rnclude:

. Welds of the lip profile


o Fastening of the nuts on the rim above the clamp bars
. Sealrng of the lip profile against the tank shell
. Shunt placement
. Seal pressure against the tank shell
. Orientation of the lip profile
. Welds of the vapour barrier

After inspecting the secondary seal it is aiso necessary to inspect the tank sheli for
obstructions lf an obstruction is found this must be corrected prior to taking the tank into
service lf it is not possible to remove the obstruction the movement of the external floater
must be limited so that the seal does not come in contact with the obstruction (high level aleft)

TESS can supply a detailed inspection protocol upon request

6. REVISION OVERVIEW

Revision Date Author Description


1 01-11-2017 A Suhafto Oriqinal issue

Printed versions of this document are uncontrolled and will not be updated
T.-
5.5 Safety measures for installing seal in servtce
Fage 4 of 5

Depend ng on the volatrlity of the stored product a safety plan needs to be sei out, which
should at least include the following safety precautions We recommend making a task risk
analysis with the fire deparlment, HSE and theforeman of the installation crew

. Make sure the tank is at high level (within 2m from top angle) This will make sure that
possible hazardous vapours are removed instantly
. Constantly monitor the concentration of hazardous vapours (not above 50% MAC value)
. Equip al workers with escape masks, filters or use fresh air equipment if necessary
. Monitortheexplosivelevelsattheseal area Abovel0%LELall workshouldbestopped
instantly
. Keep at least 5 mobile fire extinguishers on the floating roof at all times
. Keep a foam system operational that is attached to ihe fire extinguishing system and the
foam supply,
. At least the amount of foam needed for a 5cm foam layer in the complete rim area should
be available when the work starts
. Use spark free tools

5.6 lnstalling seal in service

lf the safety precautions are approved and in agreementwith the requirements as set out by
the localfire fighting department the installation of the sealcan take place The following steps
need to be taken to install the seal

. Before installing the primary seal first completely remove the secondary seal
. Remove the various items of the secondary seal to facilitate the installation of the pi r.ary
seal
. Lay out 40meters of primary seal to facilitate installation
. Remove a portion of the primary seal No more than 30 meters of seal should be removed
at a time
. After removing a port of the primary seal apply 2-5cm of expanded fire frghting foam cn the
stored product This will reduce the emission and make the installation safer
. lnstall the laid out portion of the primary seal according to the seal installatio n m a. !ai
. Make sure that the seal is completely covered with fire retardant blankets after eacn work
shift
. Continue the process until the primary seal is completely installed
. After installation of the primary seal remove the fire fighting foam with a suction un t
. Thoroughly inspect the installation of the primary seal and install the secondary seal
according to the seal installation manual, with the normal safety precautions

5.7 Post installation insPection

It is very imporlant to perform a post installation inspection to check every aspect of the sea
installation,

Primary sealinspection
We recommend to perform the inspection after installing the primary seal Without the
secondary seal installed it is much more convenient to inspect the primary seal, before the
view is blocked by the secondary seal.

Printed versions of this document are uncontrolled and will not be updated
TH
53 Process Description
Page 3 of 5

1 The tank seal can be installed after the materials have been lifted onto the tank Lifting of
these materrals will have to be done by qualified lifting company according to the current
safety procedures

2 Set up a toolbox meeting regarding the tank seal installation ln this toolbox the instruction
manual for the appropriate tank seal will be discussed with the crew along with the safety
measures and the task risk analysis The seal installation manual is provided by TESS
This toolbox meeting is mandatory for all crew members involved with the seal installation
This attendance is checked with the toolbox attendance checklist

J Pneumatic tools are needed for installing a tank seal Prio to installation one has to make sure
all needed tools are present before starting with the work the seal installation ln the
installation manual, supplied with the shipment the relevant tool list can be found During the
whole installation sequence, the supervisor is responsible for the tools

4 All seal installation materials should be loaded on the floating roof before installation The
completeness of the materials should be checked by the supervisor according to the packing
list Any materral incompleteness or damages should be repofted immediately to the project
manager for quick action in order to minimize any possible delays during installation

E
The actual installation of the seal will be done according to the appropriate seal installation
manuals discussed during the toolbox meeting The proper manual is always supplied with the
seal shipment The TESS supervisor rs responsible for the availability of the manual on site at
any time during the installation

b Both after completion of the primary as after the installation of the secondary seal the seal will
be inspected according to the seal installation checklist This is imporlant as the primary seal
cannot be inspected after the installation of the secondary seal After the seal installatton is
complete, the seal will undergo a final inspection All inspections will be done accordtng to
'Checklist tank seal completion'

7 Following every project that involved work on site (either supervision or full installation) the
project must be evaluated Depending on the size of the project or the encountered problems
this can range from a brief conversation to a detailed meeting These evaluation will help to
finetune the installation procedures and to continuously improve our quality and level of
safety

54 lnstalling seal in service

A tank seal can be installed in both new tanks or tanks which are already in service ln case of
installing a seal on a tank which is already in service, extra safety measurements has to be
taken addition on top of the standard safety procedures mentioned above

Printed versions of this document are uncontrolled and will not be updated.
rew
5.3 Process Description
Page 3 of 5

1 The tank seal can be installed after the materials have been lifted onto the tank Lifting of
these materials will have to be done by qualified lifting company according to the current
safety procedures

2 Set up a toolbox meeting regarding the tank seal installation. ln this toolbox the instruction
manual for the appropriate tank seal will be discussed with the crew along with the safety
measures and the task risk analysis The seal installation manual is provided by TESS
This toolbox meeting is mandatory for all crew members involved with the seal installation
This attendance is checked with the toolbox attendance checklist

Pneumatic tools are needed for installing a tank seal Prio to installation one has to make sure
all needed tools are present before starting with the work the seal installation ln the
installation manual, supplied with the shipment the relevant tool list can be found During the
whole installation sequence, the supervisor is responsible for the tools.

4 All seal installation materials should be loaded on the floating roof before installation The
completeness of the materials should be checked by the supervisor according to the packing
list Any material incompleteness or damages should be repofted immediately to the project
manager for quick action in order to minimize any possible delays during installation

t The actual installation of the seal will be done according to the appropriate seal installation
manuals discussed during the toolbox meeting. The proper manual is always supplied with the
seal shipment The TESS supervisor is responsible for the availability of the manual on site at
any time during the installation

b Both after completion of the primary as after the installation of the secondary seal the seal will
be inspected according to the seal installation checklist This is impoftant as the primary seal
cannot be inspected afterthe installation of the secondary seal. Afterthe seal installation is
complete, the seal will undergo a final inspection. All inspections will be done according to
'Checklist tank seal completion'

7 Following every project that involved work on site (either supervision or full installation) the
project must be evaluated Depending on the size of the project or the encountered problems
this can range from a brief conversation to a detailed meeting These evaluation will help to
fine-tune the installation procedures and to continuously improve our quality and level of
safety.

5.4 lnstalling seal in service

Atank seal can be installed in both newtanks ortanks which are already in service. ln case of
installing a seal on a tank which is already in service, extra safety measurements has to be
taken addition on top of the standard safety procedures mentioned above

Printed versions of this document are uncontrolled and will not be updated.
Tffi# Page 5 of 5

From the top of the external floating roof the following items will have to be inspected:
. Welds on the vapour barrier
. Fastening of the nuts on the rim
. Sealing force against the tank shell

From underneath the internal floating roof it is necessary to inspect the following
. Sealing of the shoe plates
. Scissor mechantsms, placement and assembly
o Tensioners, placement and assembly

After inspecting the primary seal the installation of the secondary seal can commence

Secondary seal inspection


After installation of the secondary seal it has to be inspected as well The inspection points
include

. Weids of the Iip profile


o Fastening of the nuts on the rim above the clamp bars
. Sealing of the lip profile against the tank shell
. Shunt placement
. Seal pressure against the tank shell
. Orientation of the lip profile
. Welds of the vapour barrier

After inspecting the secondary seal it rs also necessary to inspect the tank shell for
obstructions lf an obstruction is found this must be corrected prior to taking the tank into
service lf it is not possible to remove the obstruction the movement of the external floater
must be limited so that the seal does not come in contact with the obstruction (high level aled)

TESS can supply a detailed inspection protocol upon request

6. REVISION OVERVIEW

Revision Date Author Description


1 01-11-2017 A Suharto Oriqinal issue

Printed versions of this document are uncontrolled and will not be updated
PT TESS Services lndonesia
.1
LAVENUE OFFICE TOWER 3th FIOOT

I FSE
Jl. Raya Pasar Minggu Kav '1 6B
Pancoran, Jakarta Selatan
Ind onesia

Tel.: +62 8'16190 3553


E-m ail: a. salim@tess-ind onesia. com

Picture installation manual Date: May 1st 2018


Revision: 1

By: Agus Salim


TC2a Rim mounted independent
secondary compression plate seal

EARTHING SHUNT

SEAL TIP (LIP PROFILE)

VAPOUR BARRIER

SECONOARY SEAL PLATE

I
I I TESS is specialised in support, services and supplies for atmospheric storage tanks
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XH Integrity
Retiabitity
Performance

Table of contents

General seal information

1. General product information


2. Toolbox meeting
2.1. General
22 Safety

1. General product information


This installation manual represents installation instructions for our TC2i seal system This seal is
meticulously designed to fit the tank it is destined for, generating minimum emissions It represents
BAT (Best Available Technique) or BACT (Best Available Control Technique) and does meet all
international standards for tank seals as related to the design, safety and emissions Uslng this
detailed manual will allow swift and accurate installation from local crews or contractors,

Please make sure that you follow this manual when installing our seal systems. There might be
very minor discrepancies between this manual and the drawings accompanying your shipment, as
we tailor make each seal system. So we might have minor variations for each seal being installed

So the relevant documents to consult are the following, in listed order of preference:
- Order related seal drawings
- lnstallation manual

Some important steps in handling our shipments for tank seals are as follows.
- Start with ensuring all boxes are received, and have remain closed till arrival at site
- Make sure boxes are checked for content as per packing lists
- Boxes do allow outside storage outside or inside the storage tank
o - Materials do have to remain inside the boxes till start of installation
- Lip profile to be unpacked and rolled out - to remove wavy ness - a few weeks for
installation (preferably positioned immediately inside pontoons on centre deck, or app
4-5m from the tank shell for double deck external floating roof)

We are confident we have shipped a quality product, meeting your expectations. lf you feel that
anything remains unclear or our manufacturing or shipment does not meet your expectations then
please contact us immediately Our address and contact details are as follows:

PT TESS Services lndonesia


LAVENUE OFFICE TOWER 16th Floor
Jl. Raya Pasar Minggu Kav 168
Pancoran, Jakarta Selatan
lndonesia

Tel.: +62 816 190 3553


E-mail:

I TESS is specialised in support, services and supplies for atmospheric storage tanks
^< -!

3ot21

TH lntegrity
Retiabitity
Performance

Toolbox meeting
2.1. General
We would recommend the pre-construction (toolbox) meeting prior the start of the pro.1ect. This
meeting should cover ail procedures that matter for that particular project. location of staging
areas, working hours, safety rules, regulations at the construction site etc
It is the foreman's / supervisor's responsibility to review the entire range of work He is also
responsible for all necessary safety precautions that need to be taken for this specific project or
product The safety precautions are explained in more detail below. The supervisor/foreman has to
communicate with the customers' project leader. This wlll be done prior to the meettng

2.2 Safety
lnstalling a seal requires working in hazardous environment lt is therefore of utmost impoftance
that the safety guidelines and safety policy of the installation location is adequately followed The
general safety procedures as set out in the accredited safety manual of TESS will also have to be
followed. The site supervisorwill have a copy of the manual availablefor instruction and review
purposes.
We recommend at least the following safety precautions:

. Blocking and blinding of all the pipes going to the tank


. Measuring the tank for being gas-free and below 10% LEL, and for Oxygen level to be
between 18.5-20 5%o
. Sufficient fire extinguishers need to be on site (at least 2)
. Fire retardant overalls are recommended for all workers on the roof
. Further PPE consists at least of. Hard hat, protective gloves, safety goggles and safety
boots
. Fastening of the bolts can be done by using normal hand tools, which can be manual
spanners, or tools driven by air or battery. Given the metal structure of the tank there
will be specific instructions on using any electricity network inside the tank.
o A material safety data sheet (MSDS) of the product(s) previously stored in the tank will
have to be studied prior to starling work to understand any risks related to any remains
of these products still present

ln case of an emergency the procedures that apply on site need to be followed. Therefore it is
recommended that the workers have the following trainings prior to commencing installation work:
. Site orientation
. Emergency contact details and procedures
. Assembly point location

I ffSS is specialised in support, services and supplies for atmospheric storage tanks
reH 4of2l

1 - Seal materials should be lifted into the tank in a safe way,


without getting damaged.

'
g
-?--1

I ffSS is specialised in support, services and supplies for frncptreft storage tanks
reH 5 :'21

2 - Materials, inspection for quantity.

TES$,

Y-

NB: Precise seal configuration and part numbers used in your order related drawings might be
different from this manual describing a typical seal configuration. ltem descriptions should
match though, so please study those to ensure correct installation. Order related documents
such as drawings are leading to ensure correct seal installation.

I TESS is specialised in supporl, services and supplies for atmospheric storage tanks
6of21

resH
3 - ltems packed in multiple cases do allow moving the case inside the tanlg
to minimise sea! component handling.

I fgSS is specialised in support, services and supplies for atmospheric storage tanks
7 ol21

BSH
4 - Secondary seal plates to be distributed around the floating
roof perimeter as well.

,J

v
u t

I ffSS is specialised in support, services and supplies for atmospheric storage tanks
8 of 2'l

TSU
5 - Rubber sealtip to be unpacked and unrolled, in full contact with the steel roof, to
eliminate waviness as a result of packing and shipping.

I f fSS is specialised in suppoft, services and supplies for atmospheric storage tanks
resu
9of21

6- Apply caulk between the ends of the flat bars of the primary seal rim connection,
Glue foam tape on top of the flat-bars.

-*,.#*+.l#e

NB: Precise seal configuration and parl numbers used in your order related drawings might be
different from this manual describing a typical seal configuration. ltem descriptions should
match though, so please study those to ensure correct installation. Order related documents
such as drawings are leading to ensure correct seal installation.

I ffSS is specialised in support, services and supplies for atmospheric storage tanks
10 of 21
lntegrity
Retiabitity
Performance

7 - lnstall sections of the TC2i secondary vapour barrier


followed by fitting the TC2i secondary seal plates.

z.
r@

t
\,

The vapour barrier must not be tight between the rim bolts, it must be wavy between the bolts
otherwise the vapor barrier will be too tight at the top of the secondary seai plates.

NB: Precise seal configuration and part numbers used in your order related drawings might be
different from this manual describing a typical seal configuration. ltem descriptions should
match though, so please study those to ensure correct installation. Order related documents
such as drawings are leading to ensure correct seal installation.

I feSS is specialised in support, services and supplies for atmospheric storage tanks
11 of 21

8 - You can use magnets to keep the vapour barrier up during


installation of the TC2i secondary seal plates.
I

Ensure a correct overlap of the secondary seal plates.


I

n
\_/

r-l
L/

\
I
\e ls
I
\* I
1

\r
I
\

I feSS is specialised in support, services and supplies for atmospheric storage tanks
12 of 21

9 - Join the loose end pieces of the vapour barrier together using
duct-tape and the splice set provided.

NB: Precise seal configuration and part numbers used in your order related drawings might be
different from this manual describing a typical seal configuration. ltem descriptions should
match though, so please study those to ensure correct installation. Order related documents
such as drawings are leadrng to ensure correct seal installation.

I TESS is specialised in support, services and supplies for atmospheric storage tanks
13 of 21

TESS
Integrity
Retiabitity
I Performance

i tO - Assembling splice set around the secondary seal


I plate

I ffSS is specialised in support, services and supplies for atmospheric storage tanks
TSU
14 of 21

11 - Place the rim U-bar in position, fit the M10 washer and nut.
DO NOT TIGHTEN YET !

NB: Precise seal confrguration and parl numbers used in your order related drawings might be
different from this manual describing a typical seal configuration. ltem descriptions should
*^'ch though. so please study thoseto ensure correct installation. Order related documents
r as drawings are leading to ensure correct seal installation

I ff SS is specialised in support, services and supplies for atmospheric storage tanks


15 of 21

12 - Place the integral lip tip profile with the vapour barrier over the secondary seal
plate, let the vapour barrier come out slightly from under the seal tip to ensure it is in
proper position.

SEAL TIP CONNECTION

NB: Precise seal configuration and part numbers used in your order related drawings might be
different from this manual describing a typical seal configuration. ltem descriptions should
match though, so please study those to ensure correct installation. Order related documents
such as drawings are leading to ensure correct seal installation.

I feSS is specialised in support, services and supplies for atmospheric storage tanks
16 ot 21

TESS
lntegrity
Retiabitity
I Performance

13 - Drill holes in to the integral tip lip profile,


use the drilling template supplied.

I feSS is specialised in support, services and supplies for atmospheric storage tanks
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14 - Drilling template

I feSS is specialised in support, services and supplies for atmospheric storage tanks
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'15 Fit the L-bar clamp bars to the tip of the seal using the slotted pan head
-
screws M6x35. large M6 washers and nut. The nut must be installed at the side of
the L-bar

SEAL TIP CONNECTION

NB: Precise seal configuration and part numbers used in your order related drawings might be
different from this manual describing a typical seal configuration. ltem descriptions should
match though, so please study those to ensure correct installation. Order related documents
such as drawings are leading to ensure correct seal installation.

I ffSS is specialised in support, services and supplies for atmospheric storage tanks
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TH
'16 - lnstall a joint splice each end of the tip lip profitre.
The nut must be installed on the side of the L-bar tip.
It is not necessary to bolt the joint splice.
Note: lf seal expansion is of importancesplices areto be installed at joint between seal
plates, to allow maximum seal flexibility for tanks with large variations in rim gaps

I f fSS is specialised in supporl, services and supplies for atmospheric storage tanks
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a shunt per every

:
I

Optional, suppotl for rim fire


detection cable.

M1O RIM BOLTS CAN NOW BE


COMPLETELY TIGHTENED TO
ENSURE SEAL NS TIGHT
AGAINST TANK SHELL!

NB: Precise seal configuration and part numbers used in your order related drawings might be
different from this manual describing a typical seal configuration. ltem descriptions should
match though, so please study those to ensure correct installation. Order related documents
such as drawings are leading to ensure correct seal installation.

I f fSS is specialised in supporl, services and supplies for atmospheric storage tanks
21 of 21

18 - Foam poft

f TESS is specialised in support, services and supplies for atmospheric storage tanks
PT TESS Services lndonesia
LAVENUE OFFICE TOWER 13th F|oor
Jl Raya Pasar Minggu Kav '16B

TE* Pancoran, Jakarta Selatan


lndonesia

Tel :
E-mail:
+62 816 190 3553
a.salim@tess-indonesia.com

lnstallation manual Date: May 1 st 201 8


Revision: 1

By: Agus Salim


TC2t Rim mounted independent
secondary compression plate seal

EAFTHING SHUMT

SEAL TIP (LIP PROFILE)

I TESS is specialised in support, services and supplies for atmospheric storage tanks
2of11

TSH
Table of contents
General seal information

1. General product information


2. Toolbox meeting
2.1. General
2.2. Safety
3. Tools and materials
3.'1. Tools
3.2. Materials
4. lnstallation
5. TC2i lnstallation
5.1. lnstallation
5.1.1. Assembly procedure
6. Post installation inspection
6.1. Secondary seal inspection
7. Tool list

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1. General product information


This installation manual represents installation instructions for our TC2i seal system This seal s
meticulously designed to fit the tank it is destined for. ensuring this tank will be generating
mlnimum emissions lt represents BAT (Best Available Technique) or BACT (Best Available
Control Technique) and does meet all international standards for tank seals as related to the
design, safety and emissions Using this detailed manual will allow swift and accurate installation
from local crews or contractors

Please make sure that you follow this manual when installing our seal systems There might be
very minor discrepancies between this manual and the drawings accompanying your shipment. as
we tailor make each seal system. So we might have minor variations for each seal being installed
a So the relevant documents to consult are the following, in listed order of preference:
- Order related seal drawings
- This installation manual
Some important steps in handling our shipments for tank seals are as follows:
- Start with ensuring all boxes are received, and have remain closed till arrival at site
- Make sure boxes are checked for content as per packing lists
- Boxes do allow outside storage outside or inside the storage tank
- Materials do have to remain inside the boxes till starl of installation
- Lip profile to be unpacked and rolled out - to remove wavy ness - a few weeks for
installation (preferably positioned immediately inside pontoons on centre deck, or app.
4-5m from the tank shell for double deck external floating roof)

We are confident we have shipped a quality product, meeting your expectations lf you feel that
anything remains unclear or our manufacturing or shipment does not meet your expectations then
please contact us immediately. Our address and contact details are as follows:

PT TESS Services lndonesia


LAVENUE OFFICE TOWER 16th FIOOr
Jl. Raya Pasar Minggu Kav 168
Pancoran, Jakarta Selatan
lndonesia

Tel.: +62 816 '1 90 3553


E-mail:

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2. Toolbox meeting
2.1, General
Wewould recommend the pre-construction (toolbox) meeting priorthe start of the project This
meeting should cover all procedures that matter for that particular project. location of staging
areas, working hours. safety rules. regulations at the construction site etc
It is the foreman's / supervisor's responsibility to review the entire range of work He is also
responsible for all necessary safety precautions that need to be taken for this specific prolect or
product. The safety precautions are explained in more detail below The supervisor/foreman nas to
communicate with the customers' project leader This will be done prior to the meeting

o 2.2 Safety
lnstalling a seal requires workrng in a potentially hazardous environment lt is therefore oi utmost
importance that the safety guidelines and safety policy of the installation location s aoequate y
followed The general safety procedures as set out in the accredited safety manual of TESS will
also have to be followed The site supervisor will have a copy of the manual available for
instruction and review purposes

We recommend at least the following safety precautions.


. Blocking and blinding of all the pipes going to the tank
. Measuring the tank for being gas-free and below 10% LEL, and for Oxygen level to be
between 18.5-20 5%o
. Sufficient fire extingurshers need to be on site (at least 2)
. Fire retardant overalls are recommended for allworkers on the roof
. Further PPE consists at least of. Hard hat, protective gloves, safety goggles and safety
boots
. Fastening of the bolts can be done by using normal hand tools, which can be manual
spanners, or tools driven by air or battery. Given the metal structure of the tank there
will be specific instructions on using any electricity network inside the tank.
e A material safety data sheet (MSDS) of the product(s) previously stored in the tank will
have to be studied prior to starling work to understand any risks related to any remains
of these products still present.

ln case of an emergency the procedures that apply on site need to be followed. Therefore it is
recommended that the workers have the following trainings prior to commencing installation work:
. Site orientation
. Emergency contact details and procedures
. Assembly point location

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3.Tools and materials

3.1. Tools
lnstallation of our seal systems does not require any specialtools. A set of common hand tools wtll
allow full installation of the systems. Typical tools include spanners, a metal saw or grinder an
industrial knife a tape measurer and spud bars to line out holes. For an extended list of tools see
Tool list (7)

3.2. Materials
Before the start of the seal installation all seal materials must be loaded on top of the External

o Floating Roof The materials are supplied in wooden cases to facilitate loading on the roof The
amount and execution of the different supplied items is mentioned on the packing list Subject to
the size of thetank and the possible locations of the craneyou mightoptto distribute cases
containing the same seal components around the perimeter of the externalfloating roof. to reduce
efforts to distribute materials around the roof circumference. Materials should be inspected during
unpacking.

4. Installation starting point and rim details


The starling point of the seal installation is typically picked near the boxes with components Do
note that seal installation is to starl at one point only, do not pick multiple starting points. We also
recommend not to start seal installation immediately behind any gauge poles, to avoid complicated
routines for finishing the seal assembly in this area. Please ensure that rim details such as pitch of
the holes in the rim and diameter or details of these holes do match drawing details.

Figure 24, Hoizantal nm Figure 28, Vertical nnt

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5. TC2i lnstallation
Note, if the installation consists of a primary and secondary seal, the primary seal must be installed
f irst

5.1. Secondary Seal lnstallation


Begin the installation of the secondary seal as described at the begin of this chapter, by finding the
starting point

5.1.1 .TC2a installation and assembly procedure:


1. Unload the material from its packing crates, distributethe secondary seal plates and rim
fabric shoe channels around tank
2. Unroll the integral tip lip profile around the tank and lay sections straight and flat on top of
the floating roof, to ensure it will be straight at time of installation
3 Unroll sections of vapour barrier (17) around thetank, for instance app 20m at a time The
vapour barrier is not pre-punched. Place fabric onto the rim bolts by slitting the fabric
approximately 25mm long about 25mm from the edge of the fabric at each rim bolt
4. Set secondary seal plates (1 5) onto rim bolts The support plates will overlap each other
the last plate these will also hold the primary seal vapour barrier in place
5. Place the shoe channels (24) onto rim bolts, loosely install a washer and nut. Normally
assembly drawing. (see drawing below)

EXPLODED VIEW RI'Vl CONNECTION

NB: Precise seal configuration and pad numbers used in your order related drawings might be
different from thrs manual describing a typical seal configuration. item descriptions should
match though, so please study those to ensure correct installation Order related documents
such as drawings are leading to ensure correct seal installation

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6. By connecting the vapour barrier (17) together, keep an overlap of approximately 50mm
Place duct tape (37) on the 2 sites off the overlap like fig 1
Lay the vapour barrier into rim space for installation of the secondary seal plates (15)

Fig. 1l

VAFOUR BARR1ER SPLICE


DETAII- (PRlr'd SEAL)

Fold the vapour barrier (17). Connect the splice set (12) with slotted pan head screw
M6x20 (34) washers MG (36) and nut MO (35)

NB: Precise seal configuration and part numbers used in your order related drawings might be
different from this manual describing a typical seal configuration. ltem descriptions should
match though, so please study those to ensure correct installation. Order related documents
such as drawings are leading to ensure correct seal installation.

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7 Pull the vapour barrier (17) upfrom behind the secondary seal plates (15) and overthetop
of the secondary seal plates Tape can be used to holo fabr c rn place The vapour barrier
should be loose do not tightly pull the vapour barrier
8. Unroll asectionof theintegral liptipprofile(19)andplaceitoverthetipof thesecondary
seal plates and vapour barrier. The rounded side of the integral lip tip profile should be
against the shell Force the tip onto the plates until the piates are completely inset into the
tip. ln cold weather the tip may require to be pulled as it is rnstalled to remove buckles
9. The secondary seal plates (15) have existing holes. Drill the rntegral tip lip profile at each
hole with a 8mm drill bit and install the slotted pan head screw i33) and nut (35) with a
washer (36) on each side of tip.
10 Asintegraltiplipprofileisbeingdrilled,checkthealignmentof thesecondaryseal plates
Plates should be straight up with consistent overlaps.
11 lnstall the L bar (23)
12. lnstall the static grounding shunts (21) every 3m.
13. Drill and attach the shuntto the integraltip lip profile (19), bolt leaving the s^--::'.e-t ^j
over the tip Bend the end of the shunt backward. The shunt shall be rn ccn:a:: ,', :^ :^:
tank shell, and settings do allow manual correction for position if and when rec-'er

S EAL TI P COhJNI EC-TIOT-J

NB: Precise seal configuration and paft numbers used in your order related drawings might be
different from this manual describing a typical seal configuration. ltem descriptions should
match though, so please study those to ensure correct installation. Order related documents
such as drawings are leading to ensure correct seal installation.

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14. lnstall integral tiplipprofileendjointsplice(20) Wherethesealtips(19) endsmeet,install


a splice plate (20) Bend over tip ends front and back and drill two holes through seal and
bolt into place
1 5. Tighten all rim bolts Bolts should be tighten moving around the roof in the opposite

direction the secondary seal plates (15) were installed As bolts aretightened pressure can
be applied in the mid section for each support plate. This can ease bolt pressures while
tightening

6. Post installation inspection


It is very important to perform a post installation inspection to check every aspect of the seal
installation.

NB: Precise seal configuration and part numbers used in your order related drawings might be
different from this manual describing a typical seal configuration. ltem descriptions should
match though, so please study those to ensure correct installation. Order related documents
such as drawings are leading to ensure conect seal installation.

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Retiabitity
Performance

6.1. Secondary seal inspection


After installation of the secondary seal it has to be inspected as well. The inspectton points include

. Welds of the lip profile


. Fastening of the nuts on the rim above the clamp bars
. Sealing of the lip profile against the tank shell
. Shunt placement
. Seal pressure against the tank shell
. Orientation of the lip profile
. Welds of the vapour barrier

After inspecting the secondary seal it is also necessary to inspect the tank shell for obstructions lf
an obstruction is found this must be corrected prior to taking the tank into service. lf it is not
possible to remove the obstruction the movement of the external floater must be limited so that the
seal does not com in contact with the obstruction (high level aled)

TESS can supply a detailed inspection protocol upon request.

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7. Tool list
Quantity Size Description

4 10R Vise grip pliers


o 1'1R Vise grip'C'clamps (for horizontal rims)
4 l12" drive Air impact tool
2 17mm Deep socket (box wrench) for impact wrench
2 17mm Ring/open end spanner (wrench)
10mm Socket for impact wrench
o 2
2
2
1Omm Ring/open end spanner (wrench)
Razor blade utility knife with extra blades
1 Hacksaw with extra blades
1 Air compressor
2 To suit compressor Hoses to reach all over roof
1 To suit hoses 90" Right angle air drili
6 11mm Drlll bit (suitable for drilling steel)
6 Bmm Drill bit (suitable for drilling steel)
1 125mm Air or electric angle grinder (to cut last secondary seal
plates if and when required)

I TESS is specialised in support, services and supplies for atmospheric storage tanks