Chevron Specification TAM-MN-2
DOORSHEET REMOVAL AND REINSTALLATION
Commented Copy - Not for Vendor/Contractor Distribution
SPECIFICATION TAM-MN-2
DOORSHEET REMOVAL AND REINSTALLATION
NOTE: This document is the "Commented" version of Specification TAM-MU-2. The
comments, based on Company experience, provide background for the requirements
stated in the Specification. These comments are for Company use only, not for
distribution to Vendors/Contractors.
Copies of the MU Specification (without comment) are available in both hard copy
(paper) and electronic (MS Word for Windows) format. To order, contact CRTC
Technical Standards at either (510) 242-7232 or -7241. Copies of the MN Specification
are available only electronically. To order, contact CRTC Technical Standards at (510)
242-7241.
June 1989 Page 1 of 9
Chevron Specification TAM-MN-2
DOORSHEET REMOVAL AND REINSTALLATION
Commented Copy - Not for Vendor/Contractor Distribution
CONTENTS
1.0 SCOPE .................................................................................................................................3
2.0 MEASUREMENTS AND CALCULATIONS .......................................................................3
3.0 CUTTING DOORSHEETS ..................................................................................................3
3.1 General Requirements .............................................................................................................3
3.2 Location of Doorsheets ...........................................................................................................4
3.3 Doorsheet Corners and Edges ..................................................................................................4
3.4 Proper Doorsheet Support .......................................................................................................4
3.5 Doorsheets for Riveted Tanks..................................................................................................5
4.0 HANDLING .........................................................................................................................5
5.0 REINSTALLATION OF DOORSHEETS ............................................................................5
5.1 Preparation of Shell and Doorsheet ..........................................................................................5
5.2 Doorsheet Welding .................................................................................................................6
6.0 DOORSHEET TESTING.....................................................................................................7
6.1 Butt Weld Testing...................................................................................................................7
6.2 Fillet Weld Testing .................................................................................................................7
6.3 Company Inspector .................................................................................................................7
6.4 Weld Repair ...........................................................................................................................7
6.5 Hydrotest ...............................................................................................................................8
Page 2 of 9 June 1989
Chevron Specification TAM-MN-2
DOORSHEET REMOVAL AND REINSTALLATION
Commented Copy - Not for Vendor/Contractor Distribution
1.0 SCOPE
This specification covers the work necessary to remove and replace a tank shell doorsheet.
2.0 MEASUREMENTS AND CALCULATIONS
The Company will provide (1) shell strength calculations as determined from shell plate thickness
measurements and (2) the location and dimensions of the doorsheet.
3.0 CUTTING DOORSHEETS
3.1 General Requirements
3.1.1 Hot cutting must be approved by the Company Representative. Normally, cutting
shall be from the tank interior.
3.1.2 The area around the cutting operation shall be roped off for adequate personnel
protection.
3.1.3 When working from the shell exterior, no cutting shall be performed above a point
four inches (4 inches) below the lower edge of the seal assembly.
3.1.4 No freehand cutting is allowed.
Comment 3.1 There are three common methods of cutting doorsheets:
a. Hot cutting. This requires the interior of the tank to be cleaned and gas freed for
hot work. No freehand cutting should be allowed (unless the tank is being
abandoned or dismantled).
b. Cold Air Chisel cutting. This method does not require tank cleaning and gas freeing.
An air hammer with cutting chisel point is used to cold cut the opening. This results
in a rough surface that should be ground. Additional weld may be required to fill
the gap removed by the chisel. This method is faster than hydrocutting but requires
considerable preparation of the edges prior to welding.
c. Hydrocutting. This method does not require tank cleaning and gas freeing. Ultra-
high water pressure along with fine abrasive injection into the water is used to cut
the opening. Normal pressure will be 35,000 psi plus. The equipment uses a very
small quantity of water, and as a result is easier to handle than the conventional
hydroblast units operating at 10,000 psi and used for cleaning. The cut made is very
narrow and is as smooth as glass. This is a slow method but leaves an ideal edge
for welding. One edge of the cut can be beveled during cutting.
June 1989 Page 3 of 9
Chevron Specification TAM-MN-2
DOORSHEET REMOVAL AND REINSTALLATION
Commented Copy - Not for Vendor/Contractor Distribution
3.2 Location of Doorsheets
3.2.1 For Bottom Replacements: The edge of the bottom horizontal shell cut shall be the
same distance above the existing bottom as are the top edges of the slots for the
bottom replacement.
3.2.2 If Tank Bottom is Not To Be Replaced: The edge of the bottom horizontal shell cut
shall be a minimum of four inches (4 inches) above the existing bottom.
3.2.3 Doorsheet edge cuts shall not be closer than six inches (6 inches) from any parallel
weld seam (other than the bottom), or ten inches (10 inches) from a riveted seam.
3.2.4 If possible, no doorsheet shall be cut in a tank shell within twenty feet (20 feet) of a
previous doorsheet.
3.3 Doorsheet Corners and Edges
3.3.1 For Bottom Replacements. The bottom corners of the opening shall be cut square.
The upper two corners of the opening shall be cut with a radius equal to 5 to 10 times
the plate thickness with a minimum four-inch (4 inches) radius.
Comment 3.3.1 This will avoid additional trimming or makeup weld or metal when
the doorsheet is reinstalled.
3.3.2 If Tank Bottom is Not to be Replaced. All four corners shall be cut to the radius
discussed in 3.3.1.
3.3.3 All doorsheet edges shall be cut square and level. No freehand cutting is allowed.
3.4 Proper Doorsheet Support
3.4.1 Before the doorsheet is cut completely free of the shell at the top, an adequately sized
clip shall be attached and the doorsheet supported by the crane or the mechanical
hoist to be used to move it to its storage site.
Comment 3.4.1 Failure to support the doorsheet may result in major damage to
the bottom and shell.
3.4.2 Prior to removing the doorsheet, Contractor shall install steel angle or channel vertical
and curved horizontal bracing on the shell to prevent it from going out of round. On
riveted shells, no welding on the brace shall be performed closer than ten inches (10
inches) from a riveted seam. The brace shall be notched to miss rivet heads.
Comment 3.4.2 This is very important on open top and internal floating roof
tanks.
Page 4 of 9 June 1989
Chevron Specification TAM-MN-2
DOORSHEET REMOVAL AND REINSTALLATION
Commented Copy - Not for Vendor/Contractor Distribution
3.5 Doorsheets for Riveted Tanks
Doorsheets for riveted tanks shall be cut in the same manner as for welded tanks with the
exception that the location for the doorsheet shall be selected so that no cuts are made across
any vertical riveted seams, and waterstops are installed at all cut edges of riveted seams.
4.0 HANDLING
After removal, the doorsheet shall be stored in a safe location, near the tank, as approved by the
Company Representative. The doorsheet shall be supported to retain curvature.
5.0 REINSTALLATION OF DOORSHEETS
5.1 Preparation of Shell and Doorsheet
5.1.1 The surface of the doorsheet and shell shall be cleaned of contaminants, paint,
coatings and oxide at least 1 inch from each side of the welding groove.
5.1.2 The welding groove may be prepared with conventional oxyacetylene cutting torches
or with air-arc equipment. The welding groove shall be prepared as shown on
Figure 1.
5.1.3 When air-arc equipment is used, the following method shall be followed: make the
groove on one side, make the weld on that side, and then back gouge the reverse side
deep enough to clean up the root pass of the first weld. Before welding, clean up the
air-arc grooves.
5.1.4 The plate surfaces on each side of the welding grooves made by either oxyacetylene
torches or air-arc equipment shall be ground to ensure the surfaces are free of oxides.
5.1.5 Set doorsheet in place and bow out approximately 1/2 times the plate thickness past
its original radius. Brace with cleats and clips.
Comment 5.1.5 When the vertical edges of the doorsheet are welded the doorsheet
plate will be in tension. The additional curvature avoids flattening of the sheet.
5.1.6 Before reinstalling the doorsheet, waterstops shall be installed on both the shell and
doorsheet sides of every cut across a riveted seam.
Comment 5.1.6 The purpose of the waterstop is to tie both pieces of the plate
together by a weld using minimum heat input, thus stopping the spreading apart of
the plates caused by the large amount of heat from the full-penetration butt weld. At
June 1989 Page 5 of 9
Chevron Specification TAM-MN-2
DOORSHEET REMOVAL AND REINSTALLATION
Commented Copy - Not for Vendor/Contractor Distribution
least 3 rivets closest to the weld will need to be seal welded also, plus probable
caulking and sealing of the seam beyond that point.
5.2 Doorsheet Welding
The Contractor shall furnish the Company with a welding procedure for approval. The
following procedure is recommended:
5.2.1 Weld Rod Requirements
5.2.1.1 Doorsheet to shell butt-joint. Use 3/16-inch maximum diameter E-6010 or
E-7018 weld rod for the root pass, followed by 3/16-inch maximum diameter
E-7018 weld rod for subsequent passes. The weld joint shall be prepared by
back gouging and back welding.
5.2.1.2 Doorsheet to annular ring corner joint. Use 3/16-inch maximum diameter
E-7018 weld rod for all passes.
5.2.2 Weld sequence and direction: refer to the sequence numbers and direction arrow on
attached Figure 1. Downhill welding will not be allowed.
Comment 5.2.2 The restriction on downhill welding is to reduce the chance of slag
inclusion and lack of fusion.
5.2.3 Welding instructions for sides 1 through 3 of the doorsheet: use stringer beads having
widths of about twice the diameter of the electrode. Avoid excessively high welding
currents. Hold weld reinforcement to a maximum of 1/16 inch. After each weld is
completed either inside or outside air-arc, grind the opposite side of the weld to sound
metal and dye-check. Repair any defects, then finish the weld with stringer beads
described above.
5.2.3.1 Set gap on side 1 at 1/8 inch to 5/32 inch and weld completely, inside and
outside.
5.2.3.2 Tack weld side 2 and remove bowing clips. Weld completely, inside and
outside.
5.2.3.3 Remove cleats and completely weld side 3.
5.2.4 On replacement bottoms, fillet weld the doorsheet-to-annular-ring corner joint in
accordance with API 650. Clean the doorsheet on both sides a minimum of 3 inches
beyond the weld area. Weld with a continuous fillet weld deposited with three total
passes (two visible) on both the internal and external sides of the shell plate.
Page 6 of 9 June 1989
Chevron Specification TAM-MN-2
DOORSHEET REMOVAL AND REINSTALLATION
Commented Copy - Not for Vendor/Contractor Distribution
5.2.5 Doorsheets cut with no bottom replacement shall be welded all around in the same
manner as the sides and top.
5.2.6 NOTE: At this point, prior to making the external weld, diesel test the internal weld
as specified in Section 6.2.
5.3 Once the doorsheet has been reinstalled and tested, the bracing shall be removed and any
sharp or jagged protrusions shall be ground down flush to the shell. Clips shall be cut off, not
knocked off. Gouges in the sheet shall be repaired by welding and then ground smooth.
6.0 DOORSHEET TESTING
6.1 Butt Weld Testing
6.1.1 Doorsheet butt welds shall be 100% radiographed by the Contractor. Butt weld
acceptance will be based on the standards in ASME Section VIII.
6.1.2 With Company approval the butt welds may be inspected by ultrasonic means in lieu
of radiography.
6.2 Fillet Weld Testing
6.2.1 All fillet welds shall be diesel tested. The diesel test shall be witnessed and subject
to approval by the Company Inspector. The following diesel test is recommended:
6.2.2 Diesel test shall be made on the internal fillet weld. After all three fillet weld passes
have been made, soak the external doorsheet-to-annular-ring corner joint with No. 2
Diesel from a pressurized spray can.
6.2.3 Allow the diesel to soak a minimum of 8 hours unless a variance is obtained from the
Company Inspector.
6.3 Company Inspector
Call out the Company Inspector to witness the test.
6.4 Weld Repair
Contractor shall grind out and weld-repair any weld defects marked by the Company
Inspector. Retest any repaired areas. Weld repair and retesting shall be done at the
Contractor's expense.
June 1989 Page 7 of 9
Chevron Specification TAM-MN-2
DOORSHEET REMOVAL AND REINSTALLATION
Commented Copy - Not for Vendor/Contractor Distribution
6.5 Hydrotest
The new doorsheet shall then be hydrotested to the safe oil height of the tank for at least 24
hours. The Contractor shall do all piping work necessary to perform the test.
Page 8 of 9 June 1989
Chevron Specification TAM-MN-2
DOORSHEET REMOVAL AND REINSTALLATION
Commented Copy - Not for Vendor/Contractor Distribution
Figure 1. Doorsheet Cutting and Replacement Details
June 1989 Page 9 of 9
