Doc No: AGMF-QCCPP-

- MST- 001
ARABIAN GULF METAL FACTORY
Rev.: 01

METHOD STATEMENT FOR LEAK REAIR OF

BOTTOM PLATE FOR DIESEL TANK NO: 3

Project Title: QUARRAYAH COMBINED CYCLE POWER PLANT

Client: SAUDI ELECTRICITY COMPANY

Contractor: ARABIAN GULF METAL FACTORY

Rev. Date Prepared By Checked By Approved By

00 03/05/18 Radhakrishnan Radhakrishnan

01 02/07/18 Radhakrishnan Radhakrishnan

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 Doc No: AGMF-QCCPP-
- MST- 001
ARABIAN GULF METAL FACTORY
Rev.: 01

INDEX

1. PURPOSE

2. SCOPE

3. REFERENCE DOCUMENTS

4. DRAWINGS

5. SAFETY

6. EQUIPMENTS & MATERISLS

7. MANPOWER

7.1 KEY PERSONEL

7.2 TRADES MAN

8. DETAILS OF WORK

8.1 PRE-FABRICATION

8.2 SITE WORKS

9. INSPECTION

10. HYDRO TEST

11. SURFACE PREPARATION & PAINTING

12. POST REPAIR ACTIVITY

13. HANDING OVER

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 Doc No: AGMF-QCCPP-
- MST- 001
ARABIAN GULF METAL FACTORY
Rev.: 01

METHOD STATEMENT

1.0 Purpose:

The purpose of this method statement is to brief the safe and efficient method of
performing the leak repairing of bottom plates for Diesel tank No: 3 at Quarrayah
Combined Cycle Power Plant, Saudi Electricity Company, Qurrayah.

2.0 Scope:

The scope of work includes sand blast cleaning, inspection, cutting and removal of
damaged bottom plates, installation of new plates, patch works, weld build-up and
welding of bottom plates, NDT, hydro testing, Surface preparation, Painting and box
up of diesel tank No:3 as per project specification and the instruction of QCCPP
Engineer-in-charge.

3.0 Reference Documents:

3.1 API 653 – Addendum 3

3.2 API 650 12TH Edition
3.3 ASME Section IX
3.4 ASME Section V
3.5 ARAMCO Standards SAES-D-108
3.6 ARAMCO Standards SAES-W-107
3.7 ITP
3.8 WPS
3.9 Painting Procedure: AGMF-QCCPP-PP-00, Rev-00
3.10 Vacuum Box Test Procedure: AGMF-QCCPP-VBT-00, Rev- 00.

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 Doc No: AGMF-QCCPP-
- MST- 001
ARABIAN GULF METAL FACTORY
Rev.: 01

4.0 Drawings:

List of approved drawings Issued for Construction:

 AGMF-QCCPP-TNK-DIE-03

5.0 Safety:

5.1 All Safety Regulations and Guidelines of Saudi Electricity Company - QCCPP
will be adhered at Site by AGMF Site Supervisory Staff, Safety Representative
and employee.

5.2 All works will be carried out using the permit to work system.

5.3 AGMF Safety Representative and Supervisor staffs to ensure that all the Project
safety plans are compiled throughout the works.

5.4 All employees shall have undergone Safety Induction course as per SEC-EOA
safety policy and procedures prior to commencement of the work.

5.5 All employees at site shall be equipped with complete PPE.

6.0 Equipment & Materials

6.1 Mobile Crane

6.2 Welding Generator / Rectifier
6.3 Power Generator
6.4 Compressor
6.5 Grinding Machine
6.6 Vacuum Box Tester
6.7 Blasting Equipment
6.7 Air less Spray Equipment

7.0 Manpower

7.1 Key Personnel –

7.1.1 Construction Manager

7.1.2 QC Engineer
7.1.3 Site Supervisor
7.1.4 Safety Officer

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 Doc No: AGMF-QCCPP-
- MST- 001
ARABIAN GULF METAL FACTORY
Rev.: 01

7.2 Tradesman – will be to the requirement of the job

7.2.1 Crane Operator

7.2.2 Fabricator
7.2.3 Welder
7.2.4 Riggers
7.2.5 Helpers
7.2.6 Blaster
7.2.7 Painter

8.0 Details of Work

8.1 Pre-Fabrication

8.1.1 Bottom Plate No # 26 will be prefabricated in two parts as per drawing (sketch
attached), blasted and painted under side as per approved paint procedure and
delivered to site from AGMF Work shop.
8.1.2 Patch plates will be prefabricated as per approved drawings and delivered to site
from AGMF work shop.

8.2 Site Works:

8.2.1 Pre-start of Repair works:

Ensure the Tank is emptied, cleaned and gas freed prior to entry in to tank.
Carryout the cleaning of bottom plate at defective areas as instructed by the
Engineer-in-charge.
Perform the joint inspection of bottom plate surface along with QCCPP
inspection team.
Identify and mark the area to be repaired as per the instructions of QCCPP
inspection teams and the scope of work.

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 Doc No: AGMF-QCCPP-
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ARABIAN GULF METAL FACTORY
Rev.: 01

8.2.2 Repair works:

8.2.2.1 Bottom Plate replacement:
Cut and remove the plate No: 26 by means of Gas cutting and Grinding using
cutting torch and grinders.
Repair the tank foundation on cut areas as per Project specification.
Inspect the repaired foundation prior to installation of new plates.
Install new plates through the Cleanout door using Crane and skidding process.
Carryout the fit-up of new plates and do the inspection
Carryout the welding of new plates as per approved procedure.

8.2.2.2 Patch Works:

Mark the location of patches on Plates No: 3,5,19,20,28 and 31 as per the drawing.
Carryout the fit-up of new patch plates and complete the fit-up inspection.
Carryout the welding of Patch plates as per approved welding procedure.

8.2.2.3 Weld Build-up:

Mark the location of heavily pitted areas as specified in the work scope.
Clean the surface by means of grinding.
Carryout the voids filling by means of weld metal as per approved welding
procedure.
Clean the excess weld metal by means of grinding and ground flush with the
Original plates.
8.2.2.4 Annular to Shell Welds:
Mark the defective weld areas as specified in the scope works.
Remove the weld defects by means of grinding.
Carryout the DP test on repair areas and ensure the defects are completely removed
prior to welding.
Carryout the weld repair works as per approved weld procedure.

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 Doc No: AGMF-QCCPP-
- MST- 001
ARABIAN GULF METAL FACTORY
Rev.: 01

9.0 INSPECTION
9.1 Complete the weld visual inspection of bottom plates repaired areas.
9.2 Carryout the Vacuum Box Test for new bottom plate welds as per approved
procedure.
9.3 Carryout DP test for patch works, weld build -up areas and Annular to Shell
joins welds
9.4 Carryout final visual inspection and release the tank for hydro test.

10.0 Hydro test.

10.1 Carryout the blinding of Shell Man ways, Cleanout Door, Nozzles & internal
piping’s.
10.2 Install temporary filling point from the battery limit.
10.3 Fill the tank up to ¼ the height of tank as instructed by the Engineer – in –
charge.
10.4 Carry out the visual inspection of tank bottoms from outside for any leakages.
10.5 Record the tank settlements and document the same.
10.6 Carry out the dewatering from the tank and release for painting.
10.7 Open the clean out door & Manways and allow the tank for dryness
completely.
.
11.0 Surface Preparation and Painting

11.1 Carry out the surface cleaning of entire bottom plates and Shell surface up to 1 mtr
height from tank inside by blasting and complete the primer coat.
11.2 Complete the primer coat inspection and record the coating thickness.
11.3 Carry out 2nd coat and final coat paintings as per approved Painting Procedure.
11.4 Carryout visual inspection, measure the coating thickness and record the same.

12.0 Post Repair Activity:

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 Doc No: AGMF-QCCPP-
- MST- 001
ARABIAN GULF METAL FACTORY
Rev.: 01

12.1 Box up the man holes & Cleanout Door with New Gaskets.
12.2 Remove the blinds from the tank inlet lines and hook up to the tank with the
new gaskets.
12.3 Remove all the materials around the tank and do the house keeping.

13.0 Handing Over:

13.1 Carryout joint walk down inspection along with SEC-QCCPP inspection teams.
13.2 Attend the punch points if any observation made during Walk down inspection.
13.3 Submit the all Inspection reports / final documents and hander over the system.

Notes
This method statement is made based on the present conditions / available data. This
method statement describes the general sequence of work to be carried out towards
tank repairing work. During actual execution, there may be changes according to
existing site conditions. If such changes are required, this procedure shall be revised or
addendum shall be issued.

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