REFINERY TANK FARM

PACKAGE 6

Document No. Doc. Type Discipline System JOB No.

SA-JER-TFAAA-PSCL-508011 PRC CNS 3000235438

BACKFILLING OF DRY CEMENT AND

SAND MIXTURE

Revision
Remarks Issued Date Return Date
No.
00 Issue for Review 27-APR-2010 10-MAY-2010
01 Issue for Acceptant 14-MAY-2010 31-MAY-2010
02 Issued For Construction 31-MAY-2010

RAJ JOSEPH GILBERT HO

Prepared By Checked By Approved By Issued By

IMPORTANT:

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by means of electronic,
mechanical, photocopying, recording, or otherwise, without the written permission of Rotary Engineering Limited.
 REFINERY TANK FARM
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Revision History

Revision Revision date Page Scope of Revision

00 27-APR-2010 ALL Issued for Review

01 14-MAY-2010 ALL Issue for Acceptant
01 14-MAY-2010 3 AS CLOUDED
01 14-MAY-2010 4 AS CLOUDED
01 14-MAY-2010 6 AS CLOUDED
01 14-MAY-2010 7 AS CLOUDED
01 14-MAY-2010 8 AS CLOUDED
01 14-MAY-2010 10 AS CLOUDED
02 31-MAY-2010 ALL Issued For Construction

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TABLE OF CONTENTS

1. SCOPE……………………………………………………………………………….…4

2. REFERENCE DOCUMENTS…………………………………………………………4

3. DEFINITIONS .......................................................................................................5

4. RESPONSIBILITES……………………………………………………………...……6

5. METHODOLOGY………………………………………………………………………7

6. QUALITY CONTROL AND QUALITY ASSURANCE………………………………7

7. MACHINERY AND RESOURCES……..…………………………………………….8

8. SAFETY EQUIPMENTS… .…………………………………………………………..8

9. HEALTH, SAFETY AND RISK ASSESSMENT…………………………………….8

10. ATTACHMENT………………………………………………………………………….9

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1. SCOPE
This Scope is to derive the methodology of backfilling of dry cement and sand
mixture works to be performed for the Bund wall construction of tank farms for
SAUDI ARAMCO TOTAL REFINING & PETROCHEMICAL COMPANY (SATORP)
in package 6 at Al-Jubail, Kingdom of Saudi Arabia, in order to qualify and comply
with all the company standards.

2. REFERENCE DOCUMENTS 01

2.1. Approved IFC Drawings

2.1.1. Earth work drawings – Layout and Sections (North side)
2.1.2. Earth work drawings – Layout and Sections (South side)
2.1.3. Tank Foundation drawings – North & South sides
2.1.4. Road drawings – Layout & Sections (North side)
2.1.5. Road drawings – Layout & Sections (South side)
2.2. Project Quality plan
2.3. Project ITP

2.4. Safety and Medical plan

2.5. Schedule “D” & Sec. 11-2 & 11-14 of JER Construction Safety Manual
2.6. Project Specifications & Standards
2.6.1. JERES-A-114 Excavation & Backfill
2.6.2. JERES-A-111 Borrow pit requirements
2.6.3. JERES-L-450 Construction of land and near shore pipelines
2.6.4. JERES-L-460 Pipeline crossing under road and rail roads
2.6.5. JERES-Q-001 Criteria for design and construction of concrete
structures
2.6.6. JERES-Q-006 Asphalt concrete paving
2.6.7. JERES-Q-007 Foundation and supporting structures for heavy
machinery
2.6.8. JERES-S-070 Installation of utility piping systems
2.7 Industry codes and standards-American Society of testing and materials
2.7.1 ASTM C 136 Sieve analysis of fine and coarse aggregates
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2.7.2 ASTM D 422 Particle size analysis of soils

2.7.3 ASTM D 1140 Standard test methods for amount of material in soils
finer than the no 200(75-um) sieve
2.7.4 ASTM D 1556 Standard test method for density and unit of soil in place
by the sand cone method
2.7.5 ASTM D 1557 Laboratory compaction characteristics of soil using
modified effort 56000 ft-lbf/ft3 (2700 KN-N/m3)
2.7.6 ASTM D 2167 Standard test method for density and unit weight of soil
in place by rubber balloon method
2.7.7 ASTM D 2487 Classification of soils for engineering purposes
2.7.8 ASTM D 2922 Standard test methods for density of soils and soil
aggregates in place by nuclear methods (Shallow method)
2.7.9 ASTM D 2937 Standard method for density and soil in place by the
drive cylinder method
2.7.10 ASTM D 4253 Maximum index density and unit weight of soils using a
vibratory table
2.7.11 ASTM D 4254 Minimum index density and unit weight of soils and
calculation of relative density
2.7.12 ASTM D 4318 Liquid limit, plastic limit and plasticity index of soils
2.8 Process industry practices
2.8.1 PIP CVS 02100 Site preparation, Excavation and backfill specification

3 DEFINITIONS

All the definitions mentioned in the JER Documents have priority over other
standards and any deviation of these standards shall be brought to attention of the
COMPANY. It means to the company representative for resolution.

All terms used in the development of this procedure are defined below:

 COMPANY - SATORP
 CONTRACTOR - Petrol Steel Company Ltd / Rotary Engineering Ltd
 PSCL - Petrol Steel Company Ltd.
 Shall - Indicates a mandatory requirement

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 Should - Indicates a recommended practice

4 RESPONSIBILITIES

4.1 Project manager shall ensure that all operations related to backfilling of dry
cement and sand mixture works have been risk assessed and necessary
control measures have been implemented to carry out the task in a safely
manner.

4.2 Contractor shall engage their own surveyor for all the related surveying works.
Contractor shall follow IFC drawings Coordinates and data, issued from the
company. Contractor shall check and verify the BM before execution of the
works. Any changes and deviation found shall be immediately notified to the
company for resolution.

4.3 Construction engineer shall review and confirm that all backfilling of dry
cement and sand mixture works are being implemented as per the activities
stated in this method statement and in compliance with the (SATORP) codes,
standards and project specifications.

4.4 Contactor’s supervisor shall supervise all backfilling of dry cement and sand
mixture activities as required by the project drawings and specifications. He
shall prepare all the necessary permits in advance and get it approved from
the company designated representative for the execution

4.5 QC supervisor shall prepare and arrange the test packs, ensure that
inspection, testing and nde are completed as per relevant documents (ms, itp,
quality manual and etc.)And that the relevant test pack contains the correct
documentation

4.6 HSE officer shall control, supervise and record toolbox meetings. Inspect,
approve or reject engaged resources. Ensure that all HSE requirements are
met and implemented while executing the works. Notify the person in charge
on site if any deviation and / or corrective remedy action to be applied before
and while executing the works. Ensure that recommendation of work place
precaution followed up strictly. Stop any/ or all works in case specified
recommendation / observations were not followed up by construction
management team.

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5 METHODOLOGY

5.1 Required material (cement and sand) shall be approved by the SATORP prior
application. Materials shall be mixed according to the standard specification
requirements.

5.2 The ratio of the dry cement and sand mix shall be maintained as 1:6 (1
volume of cement and 6 volumes of sand).

5.3 Used approved machines for mixing the material to ensure the proportionate
and uniformity of mixture of the ingredients. Ensure that the machines are free
from foreign particles, cleaned and cleared from heavy rust and mechanically
operated.

5.4 Proper supervision during the mixture shall be required to prevent from over
mixing and shall meet the exact duration for placing of the materials, overdue
hard materials are not allowed for placement

5.5 The top of the tank foundation shall be cleaned properly and shall free
rubbish, wooden and oil stain before placement of the dry mix over the
foundation.
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5.6 The cement and sand dry mix shall be placed on top of the tank foundation up
to the required level as per IFC drawing. Elevation has to check constantly by
the company surveyor to achieve the final and accurate reduce level.

5.7 The shape and levels as per IFC drawings shall be maintain and the
maximum variation in any direction in the final surface shall be maximum one
per mille (0.1%)
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5.8 The layer should be compacted with vibratory compaction equipment.

5.9 FDT is not required if the layer thickness is less than 150 mm but samples
shall be taken for testing where the minimum compressive strength shall be
no less than 550 kpa at 28 days..

6 QUALITY ASSURANCE AND QUALITY CONTROL

The quality of the works shall be on line with the SATORP standards.
Required tests shall be performed on each stage of backfilling of dry cement
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and sand mixture works and the report based on the ITP ref: SA-JER-TFAAA-
317418 shall be prepared and submitted to the company representative for
prior approval.

01
Contractor’s QA/QC Inspector shall closely monitor and assure all backfilling
of dry cement and sand mixture shall comply with project specifications and
as per (SATORP) QA/QC requirements and shall conduct frequent
inspections and maintain all records as required by project QA/QC project.

7 MACHINERY AND RESOURCES

Excavators
Grader Machine
Dump Trucks
Dumpers
Plate compactors
Roller compactors
Dumpy Levels
Water truck
Concrete trucks
Sand to cement mixer

8 SAFETY EQUIPMENTS 01

Fire extinguishers
Hand-held sirens

Warning signage’s

9 HEALTH, SAFETY AND RISK ASSESSMENT

The health and safety shall perform a splendid role in all construction activities
to ensure that all the works are carried out in a safe manner and creating a
healthy environment. All works performed by individuals shall comply with the
company SATORP health and safety standards.

Contractor’s site supervisor shall conduct regular toolbox meetings and

explain the requirements of PPE and other special needs to create a safe
working environment. He is responsible for achieving the target and the
project milestones.

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Appropriate work permit shall be applied in accordance to the requirements of

Schedule “D” and Section II-14 of the JER Construction Safety Manual.

Contractor’s Safety Inspector shall closely monitor and assure that all works
are carried out in highly safe manner, gearing the workers with full strength of
safety protective equipment, preparation of safety barricading and dust control
screening wherever applicable in safe manner, safe workability of equipment
to be used and fulfilling any other additional safety needs as required during
work executions. He shall also check and ensure that only qualified personnel
are carrying out the equipment & machinery related works.

Contractor shall appoint their own safety manager and he shall conduct safety
walk around the site in weekly basis and prepare and submit a report to the
company. Any accidents or incidents that occurred shall be informed
immediately to the company and recorded accordingly.
9.1 A safety officer shall be at site during the execution of works.
9.2 Daily toolbox meetings shall be conducted as mandatory.
9.3 Following safety requirements shall be fulfilled
9.3.1 Safety barricade shall be provided wherever necessary.
9.3.2 Necessary safety signboards shall be provided as required.
9.3.3 All workers shall be provided with job specific Personal
Protective Equipment.
9.3.4 Safety flickering lights shall be provided for vehicles working on
longtime hours.
9.3.5 The approving authority prior to start of the work shall inspect all
equipment.
9.3.6 Working equipment shall be equipped with amber lights, horns,
safety guards etc. as required per safety provisions.

9.4 Any incident at site shall be immediately reported to company and

recorded.

9.5 Weekly safety statistics reports and safety performance reports etc.
shall be prepared and recorded.

9.6 Daily safety task assignment to be prepared.

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9.7 Man shelters shall be provided to protect the workers from adverse
climatic condition, i.e. sand storm, high temperature.

9.8 Potable water source shall be provided for adequate numbers for
workers.

10 ATTACHMENT INSPECTION FORM

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