Projects
Kroonstad TK1113
The project scope included removing and reinstating defective internal and external welds, installing new water drain supports, internal patch plates, and new davit arms on both 24-inch manways. A major upgrade involved fabricating and installing a 60-nozzle water-cooling ring made from 4-inch rolled pipe, constructed in our Germiston workshop and transported to site for installation.
A 70-meter cooling transfer line was installed to connect the ring to the terminal’s firewater manifold. The system passed all pressure and non-destructive tests, verifying full compliance with ASME B31.3 standards and ensuring structural integrity. The tank and appurtenances were grit blasted to remove deteriorated coatings, followed by the application of a multi-coat protective system in line with Engen’s specifications.
Dry film thickness was continuously monitored throughout the coating process to ensure quality and adherence to required standards.
Engen IVD Tank 89
Tank 89 was decommissioned to facilitate API 653-compliant repairs, including the installation of multiple shell insert plates, curb angle replacement, and the addition of new nozzles. The most significant upgrade involved replacing the existing cone roof with a newly engineered frangible roof and associated appurtenances. In full compliance with API 650 standards, the frangible roof was pre-assembled on the ground, where roof nozzles were fabricated, installed, and inspected. The complete roof assembly was then safely lifted and positioned onto newly installed roof rafters and a stiffening ring, followed by final welding using a multi-pass shielded metal arc welding process.
Additionally, the tank upgrades included enhancements to the firefighting systems to align with the latest NFPA 22 standards.
This involved the fabrication and installation of a top pourer system (TPS) and a cooling ring to ensure optimal fire protection.
Hoedspruit & Vryburg
The re-engineered tank designs required extensive modifications in accordance with API 650 standards. Larger pressure relief vents necessitated the fabrication of new manway covers fitted with appropriately sized nozzles. Compliant thermal relief systems were also installed on these covers, integrating seamlessly with the existing infrastructure. In addition, all tank skin valves were replaced.
To accommodate work near live tanks, the standard grit blasting process was replaced with a safer wet blasting method. One of the client’s key requirements was that both sites remain fully operational throughout the project. This placed high demands on our time, quality, and safety management systems, prompting the introduction of several new processes and procedures.
All eight horizontal tanks were comprehensively refurbished, including the saddles and connecting piping.
Throughout the project, strict adherence to the corrosion protection supplier’s specifications was maintained, ensuring quality and durability upon completion.
Kroonstad TK167 & TK168
Following the successful execution of TK1113, Petersen Industries was awarded the construction of two additional above-ground storage tanks, Tanks 167 and 168. Although smaller in diameter, the scope of work included the installation of new and upgraded firefighting systems, such as cooling rings, transfer lines, and enhanced top foam pourer systems. All new and modified piping was designed and installed in full compliance with ASME B31.3 and SANS 347.
The out-of-service inspection of Tank 167 identified non-compliant internal weld seam profiles, which were repaired in accordance with API 653. The internal coating was reinstated to client specifications, and sections of the floor-to-shell weld were removed and reinstalled to ensure compliance and structural integrity.
Repairs to Tank 168 addressed a hairline crack in a vertical weld seam, with controlled repair sequencing implemented to maintain tank integrity. Additional work included roof weld seam repairs and the installation of a new high-level foam nozzle. All repairs met API 653 peaking and banding tolerances.