The Process

The tank maintenance Scope Development Process that GPG Consulting has perfected has been able to identify various savings opportunities by engaging experienced tank maintenance resources during the planning, development, and execution of tank repairs. Effective management of Storage Tank Turnarounds is a complex and demanding function. Budget overruns, schedule delays and adverse Safety and Environmental exposure are all potential consequences of inadequate scope development. Our goal is to help save you time and money by quickly evaluating your tank repair needs and highlighting the most effective way to perform the repair. We can pinpoint savings opportunities in scope reduction, material costs, and schedule improvements.

Improvement opportunities from utilizing our process:

  • Reduced tank maintenance costs – up to 25%
  • Reduction of tank turnaround duration – up to 50%
  • Improved asset reliability through better compliance with repair codes and specifications
  • Improved project controls:
    • Clearly defined goals and objectives
    • Early identification of risks
    • Baseline costs and schedules
    • Quality and Safety awareness
    • Detailed field execution plans

01 Preliminary Scope of Work

Key Actions

  • Develop tank general information sheet
  • Identify key stakeholders
  • Set up standard filing system for key documents
  • Obtain 12/18-month preliminary anticipated scope list
  • Conduct tank condition history assessment
  • Set premise and goals for turnaround
  • Gather scope items from all internal stakeholders
  • Identify improvement opportunities
  • Conduct field survey – Tank Picture Log
  • Scope review meeting

Freeze Scope #1 (Scope items selected but not defined)

Key Deliverables

  • Anticipated scope list
  • Line item budget estimate (+/-30 to 50%)
  • Confirmed tank general information sheet
  • Additional inspection requirements:
    • In-Service
    • Out-of-Service
  • Hazard Mapping and Safety Considerations

02 Discovery

Key Actions

  • Conduct pre-inspection review meeting with Inspection Contractor
  • Develop written inspection scope of work
  • Review/confirm inspection execution plan
  • Review inspection findings from contractor and confirm asset integrity scope of work
  • Develop final scope of work details for final distribution

Freeze Scope #2 (Scope items clearly defined)

Key Deliverables

  • Final Scope of Work
  • Management of Change (MoC) Approvals for required scope items
  • Funding approvals (Capex/Opex: +/- 10%)
  • Approved drawings for design/fabrication/construction
  • Approved field construction procedures:
    • Field best practices
    • Approved weld procedures
    • Approve inspection test plans (ITPs)

03 Project Readiness Review

Key Actions

  • Develop and approve field execution plan
    • Safe Work Plan
    • Quality Control/Quality Assurance Plans
    • Approved Repair Procedures
    • Document Control Process
  • Confirmation of contract compliance
  • Confirmation of field construction schedule
  • Confirmation of tank turnaround premise

Key Deliverables

  • Field Execution Package:
    • Clearly defined goals/objectives
    • Clearly defined scope of work
    • Baseline budget
    • Baseline schedule
    • Approved field execution plans

04 Field Execution

Key Actions

  • Audit job site to ensure compliance with:
    • Safety
    • Quality
    • Costs
    • Scope
    • Schedule
  • Approve all field delays
  • Approve all scope changes – EWAs
  • Communicate daily/weekly progress

Key Deliverables

  • Key Performance Indicators:
    • Number of First Aids
    • Number of OSHA Recordables
    • Number of Lost Times
    • Number of Environmental Reports
    • % of jobs done right the first time
    • % of jobs on schedule
    • % of jobs completed within +/-5% of budget

05 Look Back

Key Actions

  • Obtain “As-Built” drawings from contractor
  • Obtain copies of material POs/invoices/MTRs
  • Obtain copies of all approved contractor invoices
  • Obtain copies of all field change orders
  • Obtain copies of all approved T&M sheets
  • Receive all field QA/QC documentation

Key Deliverables

  • Confirmation of project premise:
    • Actual versus baseline costs
    • Actual versus baseline schedule
    • Quality – Rework
    • Safety objectives – “goal zero”
  • Properly recorded/filed turnaround control documents
  • Corrective actions/improvement opportunities for future turnarounds

Repair Definition Process

The scope of the repair cannot be defined in the absence of some basic understanding of how to execute the repair.

External Floating Roof Tank
Product Scope

Mechanical

  • foundation
  • bottom
  • shell
    • roof
      • nozzles
      • appurtenances
      • other
Activity List

Roof

  • install new roof
  • install roof mw

Install Striker Plates

  • install roof sump
  • install new seals
Task Description

Striker Plates

  • 4.71 ln ft of weld
  • 1/4″ thick plate
  • A 36 material
  • single pass welding
  • vacuum box test
  • install per drawing
    No. SD-001

GPG Consulting’s five-step process will help make your tank repairs as efficient and effective as possible.

Typical Timeline of Events

typical-timeline-of-events