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Tank Farm Field Construction Work Progress Measurement System- Sample Template for Practical Use

Tank farm mechanical construction progress calculation sheet (system) would be an excellent resource for those who have never done field fabricated above ground tank construction work. The basis of an external floating roof type, tank farm construction progress calculation sheet/system is mainly depending on

(1) Scope : Mechanical work for an external floating roof type, single deck with internal pontoon type for oil and fuel storage above ground tank. Civil foundation, cathodic protection work, fire system, cabling works and instrumentation works are not included in this calculation sheet. Engineering details design is done by Owner or EPC Contractor.


(2) WBS (Work Breakdown Structure): As described on Progress Calculation/Tracking System for Oil and Fuel Storage Tank Fabrication.

(3) Work Steps and Weight Factor: Field Construction for Each Construction Steps

Method of progress calculation is the same as Progress Calculation/Tracking System for Fabrication. The only difference is construction work steps and weight factors. The details are as the following.

Tank Bottom and Floating Roof Plate Field Erection Work Steps and Weight Factors

Field erection works steps for tank bottom (annular plate, sketch plate and rectangular plate) and floating roof (centre deck plates, pontoon plate and stiffeners) installation are

1) Position/lay plate, alignment and fit-up and tack welding (short-seam)

2) Full Welding (long-seam) and NDT (e.g. LPT at center deck, pontoon deck, RT test, etc.)

3) Field Blasting/Primer at field weld joints/Final Coating (if carbon steel tank)

4) Final inspection as per API 650 or Owner’s specific requirements

Tank material at erection area is added as part of construction progress calculation assuming that prefabricated materials are delivered by Contractor. Once again, decision on whether it will be included or not depends on company specific requirement and client’s approval. Work steps weight factor needs to be adjusted so as to facilitate exclusion of that work step. Use the sample work steps and weight factor table below for starting point. 

Work Steps
Weight Factor
Material at Erection Area
5%
Lay Plate/ Alignment & Fit up welding
35%
Full Weld/NDT
45%
Field Blasting/Final Coating
10%
Final Inspection
5%


Tank Shell Side Field Construction Work Steps and Weight Factor

Shell plate field erection work steps includes as minimum,

1) Position, alignment and fit-up and tack welding

2) Full Welding at both sides(Front & Back joints) and Inspection (DP Test/NDT)

3) Field Blasting/Primer at field weld joints/Final Coating (if carbon steel tank)

4) Final inspection as per API 650 or Owner’s specific requirements 

Then, they are listed in Work steps and % weight table for physical progress calculation. See a sample table below.

Work Steps
Weight Factor
Material at Erection Area
5%
Position Plate/Alignment & Fit up Welding
35%
Full Welding both sides(Front & Back) /NDT
45%
Field Blasting/Final Coating
10%
Final Inspection
5%


Tank Accessories and Fittings Field Construction Work Steps and Weight Factors for Physical Progress Calculation 

Two different work steps weight factor tables are made in this system as the construction method for tank external accessories is different from internal apparatus. This will help you to track the progress closely without distorting overall construction progress.

(a) Construction work steps for tank external accessories installation at site includes

(1) Member Assembly:


-Lift each section of prefabricated spiral stairway and welding onto tank body (Shell side),

- Lift the prefabricated platform and handrail materials on to tank roof, welding onto tank body and final bolt up

- Lift the prefabricated rolling ladder/rail tracks and handrails on to tank roof, welding on centre deck and final bolt-up with gauger platform

(2) Final inspection as per API 650 or Owner’s specific requirements


Then, the sample work steps and weight factor table can be used for tank external accessories conduction physical progress measurement.

Work Steps
Weight Factor
Material at Erection Area
5%
Member Assembly
85%
Final Inspection
10%

(b) Construction work steps for tank internal accessories and nozzle installation at site includes 

1) (Marking & Cutting for Nozzle holes, Alignment & Fit-up Welding for all) includes


Marking & cutting on nozzle locations, install reinforcement pad and fit-up weld with pre- fabricated nozzle,
# Alignment & fit-up/tack welding of pontoon legs, center deck support legs and gauge poles

2) Full Welding/NDT

3) Field Blasting/Primer at field weld joints/Final Coating (if carbon steel tank)

4) Final inspection Then, the work steps and % weight table for physical construction progress can be defined as below


Work Steps
Weight Factor
Material at Erection Area
5%
(Marking & Cutting for Nozzle holes, Alignment & Fit up Welding for all)
35%
Full Welding/NDT
45%
Field Blasting/Final Coating
10%
Final Inspection
5%


Once you get construction work steps and weight factors above,.......

Apply Construction Work Steps and Weight Factors in Quantity and Physical Progress Calculation Sheet

As described in fabrication progress sheet, list the tank components, man hours, weights, etc. so as to track and monitor the status of each member to high level WBS which is in line with GA drawing.

Firstly, find the quantity progress calculation sheet on “Field Installation Status-Qty” tag. Spread sheet is filled with complete data so as to show progress calculation sheet work. Construction work step progress for each member can be tracked by entering each work step progress status. See the below snapshots of field erection progress updating section for tank bottom and roof plate erection work,




Secondly, you will find the construction progress summary by quantity at the same tag “Field Installation Status-Qty”. The progress summary for an individual GA drawing is calculated so as to track the summary progress of all members for each work steps. See the snapshot below.



Finally, find the "Physical Prog Tracking Sheet" tag. The quantity wise progress data is used to enter into the physical progress calculation sheet so as to measure an individual physical progress to overall progress. An individual physical progress calculation method is used in the following table.

E.g. Individual physical progress (Tank platform/Handrail) = Material at Erection Area (5%) x quantity wise progress + Member Assembly (85%) x quantity wise progress + Final Inspection (10%) x quantity wise progress



For your project reference, simply download the sample progress measurement sheet/system for tank farm mechanical construction work.

You can modify and prepare your own tank farm construction progress measurement sheet/system using the same methodology to suite your project requirements. You might just need to work either one or all of the following items,

#1 Change scope of work (tank components and materials)

#2  Add or remove field construction works steps

#3 Change work steps weight factor percentage

#4 Work Breakdown Structure for the level of detail of progress reporting

Enjoy! 

31 comments:

  1. This is really comprehensive detail and I am really impressed with the data showing Construction work steps for tank internal accessories and nozzle installation at site.

    ReplyDelete
  2. Thank you for your effort Min Oo.

    Do you have something similar for checking E&I progress in an industrial installation?

    Many thanks,

    Galego

    ReplyDelete
    Replies
    1. Dear Galego,

      You are welcome. E&I Progress sheet is in our list to be published in future. Stay tuned for new post updates.

      Delete
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