TAM-SC-2-B
Doorsheet Removal and Reinstallation
Commented Copy - Not for Vendor/Contractor Distribution
NOTE: Electronic copies of the Company's Specifications and the accom-
panying data sheets and data sheet guides are available by e-mail and
from ERTC's Technical Standards website. To access the files over Chev-
ronTexaco's Intranet, use the following website address:
[Link]
To receive electronic files by e-mail, phone (510) 242-7241 or send e-mail
to TECHSTDS ("ERTC Tech Standards" in the Global Address List), or
fax your request to (510) 242-2157.
February 2003 © ChevronTexaco 1 of 9
Doorsheet Removal and Reinstallation TAM-SC-2-B
CONTENTS
1.0 SCOPE .........................................................................................................................3
2.0 MEASUREMENTS AND CALCULATIONS ................................................................3
3.0 DOORSHEETS ............................................................................................................3
3.1 ......Type of Doorsheet ............................................................................................3
3.2 ......General Requirements .....................................................................................3
3.3 ......Location of Doorsheets ....................................................................................4
3.4 ......Doorsheet Corners and Edges .........................................................................4
3.5 ......Proper Doorsheet Support ...............................................................................4
3.6 ......Doorsheets for Riveted Tanks ..........................................................................4
4.0 HANDLING ..................................................................................................................4
5.0 REINSTALLATION OF DOORSHEETS ......................................................................5
5.1 ......Preparation of Shell and Doorsheet .................................................................5
5.2 ......Doorsheet Welding ...........................................................................................5
6.0 DOORSHEET TESTING ..............................................................................................6
6.1 ......Butt Weld Testing .............................................................................................6
6.2 ......Fillet Weld Testing ............................................................................................6
6.3 ......Weld Repair ......................................................................................................7
6.4 ......Hydrotest ..........................................................................................................7
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Doorsheet Removal and Reinstallation TAM-SC-2-B
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 DOORSHEETS
3.1 Type of Doorsheet
1. A doorsheet is cut in the tank to provide access for repairs and or cleaning of the tank.
2. If the floor of the tank is not going to be replaced, consideration should be given to cutting the
doorsheet a minimum of 6 inches above the floor. By cutting the doorsheet a minimum of 6
inches above the floor, the doorsheet work will not require a full hydrostatic test of the tank.
3. The disadvantage of cutting the doorsheet above the floor is restricted access to the tank. This
can be a significant problem for floating roof tanks.
4. If the floor is to be replaced, the doorsheet should be cut to the elevation of the new floor.
3.2 General Requirements
1. Contractor should provide a plan for removing and reinstalling the doorsheet. The plan should
include the method of doorsheet removal and weld preparation for reinstallation.
2. The Company Representative must approve hot cutting. Normally, cutting shall be from the
tank interior.
3. The area around the cutting operation shall be roped off for adequate personnel protection.
4. When working from the shell exterior, no cutting shall be performed above a point four (4)
inches below the lower edge of the seal assembly.
5. No freehand cutting is allowed.
Comment: There are three common methods of cutting doorsheets:
a. Hot Cutting. This requires the interior of the tank to be cleaned and gas free 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 welding may be required to fill the gap removed by the chisel. This method is faster
than hydrocutting but requires significant preparation of the edges prior to reinstalling.
c. Hydrocutting. This method does not require tank cleaning and gas freeing. High pressure water along
with a fine abrasive in the water is used to cut the opening. Pressure will be at least 35,000 psi. The equip-
ment uses a very small quantity of water and, therefore, is easier to handle than the conventional hydro-
blast units operating at 10,000 psi 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.
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Doorsheet Removal and Reinstallation TAM-SC-2-B
3.3 Location of Doorsheets
1. Doorsheet edge cuts shall not be closer than the weld spacing requirements listed in API 653.
The weld spacing requirements of API 653 apply to all of the different types of welds and riv-
eted joints found in a tank shell.
2. When the doorsheet intersects a horizontal weld at least six (6) inches of the horizontal weld
adjacent to the doorsheet shall be removed and rewelded.
3. If possible, no doorsheet shall be cut in a tank shell within twenty (20) feet of a previous door-
sheet.
3.4 Doorsheet Corners and Edges
1. The corners of the doorsheet should be, square when they terminate at a horizontal weld joint,
and rounded when they terminate in the plate material.
2. The radius of the rounded corners should be equal to 10 times the plate thickness, but in no
case less than 6 inches.
Comment: This will avoid additional trimming, makeup welding or metal inserts when the
doorsheet is reinstalled.
3. All doorsheet edges shall be cut square and level.
3.5 Proper Doorsheet Support
1. Before the doorsheet is cut an adequately sized clip shall be attached and the doorsheet sup-
ported by a crane or a mechanical hoist.
Comment: Failure to support the doorsheet may result in major damage to the bottom and the
shell of the tank.
2. Prior to removing the doorsheet, the Contractor shall install supports around the proposed
opening to prevent shell distortions.
a. The top frame should be either a plate cut to the radius of the shell or a rolled channel that
extends at least two (2) feet beyond the proposed opening.
b. The vertical frame sections should be either angle or channel that is joined to the top frame
and runs to the bottom of the tank.
c. On riveted shells, the frame shall not be installed closer than ten (10) inches from a riveted
seam.
d. The frame shall be notched to avoid hitting rivet heads.
Comment: This is very important on internal and external floating roof tanks.
3.6 Doorsheets for Riveted Tanks
1. Doorsheets for riveted tanks shall be cut in the same manner as for welded tanks except that
the location for the doorsheet shall be selected so that no cuts are made across any vertical riv-
eted seams.
2. Additionally, waterstops are to be installed at all cut edges of the riveted seams.
4.0 HANDLING
1. After removal, the doorsheet shall be stored in a safe location, near the tank, as approved by
the Company Representative.
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Doorsheet Removal and Reinstallation TAM-SC-2-B
2. The doorsheet shall be supported to retain its curvature.
5.0 REINSTALLATION OF DOORSHEETS
5.1 Preparation of Shell and Doorsheet
1. The surface of the doorsheet and shell shall be cleaned of contaminants, paint, coatings and
oxide at least one (1) inch from each side of the welding groove.
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.
3. The plate surfaces on each side of the welding grooves made by either oxyacetylene torches or
air-arc equipment shall be ground to ensure surfaces are free of oxides.
4. Set doorsheet in place and bow out approximately 1/2 times the plate thickness past its original
radius.
5. Brace with cleats and clips.
Comment: When the vertical edges of the doorsheet are welded the doorsheet plate will be in
tension. The additional curvature avoids flattening of the sheet.
6. Before reinstalling the doorsheet, waterstops shall be installed on both the shell and doorsheet
sides of every cut across a riveted seam.
Comment: 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 least 3 rivets
closest to the weld will need to be seal welded. In addition, caulking and sealing of
the riveted joint should continue beyond the last seal welded rivet, for an additional
twelve (12) inches.
5.2 Doorsheet Welding
The Contractor shall furnish the Company with a welding procedure for approval. The following
should be included in the Contractor's procedure.
1. Weld Rod Requirements
a. Doorsheet to shell butt-joint.
(1) Use 3/16-inch maximum diameter E-6010 or E-7018 weld rod for the root pass, fol-
lowed by 3/16-inch maximum diameter E-7018 weld rod for subsequent passes.
(2) The weld joint shall be a double vee or k joint.
(3) The root pass shall be cleaned by grinding or gouging prior to starting the welding on
the opposite side of the joint.
b. Doorsheet to annular ring corner joint. Use 3/16-inch maximum diameter E7018 weld
rod for all passes.
2. Weld sequence and direction: refer to the sequence numbers and direction arrow on attached
Figure 1. Downhill welding is not allowed on the fill passes of the weld.
Comment: The restriction on downhill welding is to reduce the chance of slag inclusion and
lack of fusion.
3. Welding instructions for sides 1 through 3 of the doorsheet: use stringer beads having widths
of about twice the diameter of the electrode.
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Doorsheet Removal and Reinstallation TAM-SC-2-B
a. Avoid excessively high welding currents.
b. Hold weld reinforcement to a maximum of 1/16 inch.
c. After each weld is completed either inside or outside air-arc, grind the opposite side of the
weld to sound metal and dye-check.
d. Repair any defects, then finish the weld using stringer beads.
(4) Set gap on side one at 1/8 inch to 5/32 inch and weld completely, inside and outside.
(5) Tack weld side two and remove bowing clips. Weld completely, inside and outside.
(6) Remove cleats and completely weld side three.
4. On replacement bottoms, the doorsheet-to-annular-ring corner joint should be in accordance
with API 650.
a. The doorsheet should be cleaned on both sides a minimum of three (3) inches beyond the
weld area.
b. Weld with a continuous fillet weld deposited with a minimum of three passes (two visible)
on both the internal and external sides of the shell plate.
5. NOTE: At this point, prior to making the external weld, diesel test the internal weld as speci-
fied in Section 6.2.
6. 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.
7. Clips shall be cut off, not knocked off.
8. Gouges in the sheet shall be repaired by welding and then ground smooth.
6.0 DOORSHEET TESTING
6.1 Butt Weld Testing
1. Doorsheet butt welds shall be radiographed by the Contractor as outlined in API 650.
a. In addition, one radiograph for each of the horizontal and vertical welds shall be taken as
identified by the Company inspector.
b. All of the tee joints shall be radiographed including six (6) inches of the existing welds
that tie into the doorsheet welds.
c. Butt weld acceptance will be based on the standards in ASME Section VIII.
2. With Company approval, the butt welds may be inspected by ultrasonic means in lieu of
radiography.
6.2 Fillet Weld Testing
1. All fillet welds shall be diesel tested.
2. The diesel test shall be witnessed and subject to approval by the Company Inspector.
3. The following diesel test is recommended:
a. Diesel test shall be made on the internal fillet weld.
b. 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.
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Doorsheet Removal and Reinstallation TAM-SC-2-B
c. Allow the diesel to soak a minimum of eight (8) hours unless a variance is obtained from
the Company Inspector.
d. Call out the Company Inspector to witness the test.
6.3 Weld Repair
1. Contractor shall grind out and weld-repair any weld defects marked by the Company Inspec-
tor.
2. Retest any repaired areas.
3. Weld repair and retesting shall be done at the Contractor's expense.
6.4 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.
February 2003 © ChevronTexaco 7 of 9
Figure 1: Doorsheet Cutting and Replacement when Floor is Replaced
February 2003
Doorsheet Removal and Reinstallation
Joint Details
Oxyacetylene Cutting
1/ ”
16
T=1/2”
Max.
45°
Dogs or Cleats on Top Edge Tacked on One Edge
T>7/8” Only – Stagger Inside and Out – Allow Space for
Additional Bow in Doorsheet Plate During Fit-Up
- 1/2 Plate Thickness
45°
1/
16”
4 1/ ”-3/ ” Gap Dogs and Cleats on Side
.6T 16 16
Edges Are Installed on
Outside Only and Tacked
on Both Ends
©ChevronTexaco
12” Min. 4” Radius
(Typical) 2nd Course
1st Course
Maximum 6” of
Existing Weld to be
Removed and
Rewelded (Typical)
1 Doorsheet 2
1/ ”-3/ ” Gap 0”-1/16” Gap During Fit-up
8 16
3 1/ ”-1/ ” Gap After 1 ‘s Welded
16 8
Annular Ring or Floor Plate
Doorsheet Rests on Shell Ring
of New Bottom
1 = Weld Sequence Note: Weld vertical seams first as shown, tension in doorsheet plate
TAM-SC-2-B
= Weld Direction will remove additional bow as plate stretches and flattens.
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Figure 2: Doorsheet Cutting and Replacement when Floor is not Replaced
February 2003
Doorsheet Removal and Reinstallation
Joint Details
Oxyacetylene Cutting
1/ ”
16
T=1/2”
Max.
45°
Dogs or Cleats on Top Edge Tacked on One Edge
T>7/8” Only – Stagger Inside and Out – Allow Space for
Additional Bow in Doorsheet Plate During Fit-Up
- 1/2 Plate Thickness
45°
1/ ”
16
1/ 3
.6T 4 16”- /16” Gap Dogs and Cleats on Side
Edges Are Installed on
Outside Only and Tacked
on Both Ends
4” Radius
©ChevronTexaco
12” Min.
(Typical) 2nd Course
1st Course
Maximum 6” of
Existing Weld to be
Removed and
Rewelded (Typical)
1 Doorsheet 2
1/ ”-3/ ” Gap 0”-1/16” Gap During Fit-up
8 16
16”- /8” Gap After 1 ‘s Welded
3 1/ 1
Annular Ring or Floor Plate
4” if Bottom is
Not Replaced Doorsheet Rests on Shell Ring
of New Bottom
1 = Weld Sequence Note: Weld vertical seams first as shown, tension in doorsheet plate
= Weld Direction will remove additional bow as plate stretches and flattens.
TAM-SC-2-B
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