METHOD STATEMENT

FOR
ERECTION AND TESTING
OF ELEVEN (11) UNITS OF SUS STORAGE TANKS
T-7923
T-7951
T-7942
T-7902
T-7903
T-7911
T-7912
T-7913
T-7914
T-1611
T-1613

2 ISSUED FOR 2ND REVIEW WITH UPDATE OCT VE VE 23. JAN. '18

1 ISSUED FOR APPROVAL OCT VE VE 18. JAN. '18

0 ISSUED FOR REVIEW OT VE VE 16. JAN '18

M DESCRIPTION BY CHK APVD DATE

AR REVISIONS

CLIENT : SANKYU / PHILKAO

PROJECT : PKI HCA PROJECT
JOB NO. :
DOC NO. : MS-ROOS-0010-0015
 Date: 23 Jan, 2018 Method of Statement for
Erection And Testing of Eleven (11) Units
Rev : 2 SUS Storage Tanks Page 2 of 13

TABLE OF CONTENTS

1. OBJECTIVE

2. PURPOSE

3. REFERENCES

4. DEFINITIONS

5. RESPONSIBILITIES

6. HSE INSTRUCTIONS

7. SITE PREPARATION
8. REQUESTING / RECEIVING OF MATERIALS AT THE SITE

9. UNLOADING OF MATERIALS
10. PROTECTION AND STORAGE

11. EQUIPMENT

12. ERECTION PROCEDURE

13. TESTING

14. SITE CLEAN UP

15. QUALITY MANAGEMENT

 Date: 23 Jan, 2018 Method of Statement for
Erection And Testing of Eleven (11) Units
Rev : 2 SUS Storage Tanks Page 3 of 13

1. OBJECTIVE

This Method Statement (MS) gives the general guidelines for the erection and testing of
eleven (11) units of SUS Storage Tanks including equipment and manpower required
under the ROOS scope of work that need to be accomplished with good quality and
workmanship by applicable code and standards to achieve satisfactory completion of the
whole activities as per Sankyu / PKI project quality requirement.

2. PURPOSE

The purpose of this method statement is to ensure the quality and reliability of various
erected tanks during the execution and completion of the works under the scope of
applicable codes and standards or client specifications.

Furthermore, this method statement highlights the responsibilities of various supervisory

personnel involved in the execution of the works and a means of protecting personnel
from the potential hazards associated with erection and testing works.

3. REFERENCES

The following documents are considered reference documents:

- API 650 Welded Storage Tanks for Oil Storage
- ASME Section V Non-Destructive Testing / Examination (NDE)
- AWS American Welding Society
- All other relevant codes and standards
- Project Specifications

If any conflict between COMPANY spec and CONTRACTOR spec, COMPANY spec shall
be applied.

4. DEFINITIONS

COMPANY PKI
SANKYU MAIN CONTRACTOR
ROOS SUBCONTRACTOR
HSE HEALTH, SAFETY & ENVIRONMENT
MS METHOD STATEMENT
RT RADIOGRAPHIC TEST
 Date: 23 Jan, 2018 Method of Statement for
Erection And Testing of Eleven (11) Units
Rev : 2 SUS Storage Tanks Page 4 of 13

5. RESPONSIBILITIES

Project Manager

- Is in charge of proper implementation of the project.

- Reports daily work schedule and status to SANKYU project in charge.
- Full responsible for providing the services, data, and reports necessary to complete
the work within the required safety conditions.
- Plan and conduct all the related activities to accomplish the project timely with quality
and safety.
- Ensure adequate plans and actions to solve the complaints from the client.
- Plan and schedule material, equipment, and personnel to perform the work.
- Coordinate all installation, delivery, and safety activities at the site.
- Ensures all necessary checks, inspections and tests are carried out and passed
before proceeding to the next stage of installation.
- In and outgoing materials at it.
- Review drawings specification.

Safety Officer

- Report to the Project Manager.

- Organize site safety system.
- Conduct safety orientation for all staff and workers who work on site.
- Evaluate unsafe conditions and acts to be reported if any.
- Implement safe practices o at a site, especially during erection.
- Has the authority to stop work in any unsafe act or conditions that would cause injury
to personnel or damage to property due to unsafe conditions and procedures.

Project Engineer

- Reporting to Project Manager

- Monitoring the erection team to make sure the erection work was processed in line
with the project schedule.
- Prepare site daily report for his scope of work.
- Conduct daily toolbox meetings

Assembly Supervisor

- Reporting to project engineer

- Monitoring the erection team to make sure the erection work was processed in line
with the project schedule.
- Ensures that all necessary materials and equipment were available upon execution
of the works.
- Shall be knowledgeable and experienced in the execution of the works by with
project specification and approved procedure for the assembly of stainless steel
tanks and conducts testing upon completion of the works.
- Ensures that all members fully understand the nature of work.
- Prepare site daily activity report for his scope of work.
- Conduct daily toolbox meetings
 Date: 23 Jan, 2018 Method of Statement for
Erection And Testing of Eleven (11) Units
Rev : 2 SUS Storage Tanks Page 5 of 13

Erection Team

- Directly responsible for the execution of the works.

- Able to understand and follow the instruction by procedure and project specifications.

6. HSE INSTRUCTIONS

- Safety Helmet
- Safety Shoes
- Safety Glass
- Safety Harness
- Proper Uniform
- Full body safety harness with one (1) or (2) hooks.
- Visible Signage
- Only qualified personnel are allowed to per the test of the test, approved by
SANKYU.
- Area shall be barricaded and signed “ HYDRO TEST ON GOING KEEP OFF”
- The presence of safety personnel is required during the execution of the works.

7. SITE PREPARATION

- Make sure there is space and firmed pathway for the delivery and hauling of
materials, crane, and other mobile equipment for erection.
- Decide the plan for unloading and material storage, choose a firm and dry location.
- Materials shall be placed in designated areas for each and identified for their
locations.
- Make sure the materials supply is appropriate and does not conflict with the
installation schedule and other sub-contractor schedules.
- Confirm the available supply of power and utilities at the site. Make sure there s a
safe method to lead the supply to the working area.

8. REQUESTING / RECEIVING OF MATERIALS AT THE SITE

- All required material for installation shall be requested to SANKYU for timely delivery
at the job site.
- A copy of the package list shall be confirmed and received upon delivery of the
materials.
- All materials received at the site shall be inspected by the supervisor for any damage
and inform the main contractor of any defects immediately.
 Date: 23 Jan, 2018 Method of Statement for
Erection And Testing of Eleven (11) Units
Rev : 2 SUS Storage Tanks Page 6 of 13

9. UNLOADING OF MATERIALS

- Materials were delivered to the site, they are unloaded by crane anyplace the d in
designate before or erection.
- Proper rigging shall be observed before lifting starts.
- Qualified person shall be allowed to lead the unloading works to ensure safety
among other members assisting the lifting

10. PROTECTION AND STORAGE

- To avoid contamination of materials against Carbon Steel all temporary materials

and tools shall be preferably stainless steel or its equivalent.
- Avoid direct contact of Carbon Steel with Stainless Steel Especially during storage.

11. EQUIPMENTENTS

- All cranes, rigging, and equipment shall be in good condition and properly
maintained at all times during the period of the work.
- All shall be sufficiently capable to complete every stage of erection works.
- Slings and other lifting devices that will be in contact with structural steel shall be of a
type that will not damage steel surfaces.

12. ERECTION PROCEDURE

12.1 BOTTOM PLATE

- Tank foundation shall be officially turned over to ROOS thru documented joint
inspection report or RFI duly signed and accepted by SANKYU.
- Confirm foundation elevation, alignment, and level thru (8) points method from 0 to
360 degrees.
Date: 23 Jan, 2018 Method of Statement for
Erection And Testing of Eleven (11) Units
Rev : 2 SUS Storage Tanks Page 7 of 13

- establish the tank orientation, to be marked on top or side of the foundation for future
nozzle reference.
- Final cleaning of the top foundatiobeforeto laying of the bottom plate shall be done
completely.
- Lay bottom plate as per approved construction drawing overlapping of the plate shall
be confirmed.
- Bottom plate circumferential dimension/diameter shall be established and RFI shall
be submitted to the main contractor duly signed and approved before to start of fit-up
works ( Refer to RFI ref no.DD81-EQ005-2 / EQ001-2 / EQ006-2 ).

- RFIshall be submitted to confirm the bottle layout.

- Upon confirmation of bottom plate lay-out (OD) by SANKYU fit-up works start.
- Tack weld shall be applied on the bottom plate as per illustration.
- Tack weld space at least 20 to 30mm and distance approximately.
Date: 23 Jan, 2018 Method of Statement for
Erection And Testing of Eleven (11) Units
Rev : 2 SUS Storage Tanks Page 8 of 13

- After tacking completed, established BCD, submit RFI.

- After confirmation of BCD layout, boring for chemical anchor bolt starts ( both for
plate and foundation ).
- The welding of the shell to the bottom shall be practically completed before the
welding of bottom joints that may have been left open to compensate for shrinkage
of any welds. (ref API650 7.2.2.2).
- Before full welding on the bottom plate starts a strong back shall be placed on top of
the plate continuously to avoid warping.
- Bottom plate joint portion where shell plate will rest shall be bent full welded and
flash grind approximately 100mm in length. BeThe bendingroceduris e the as
pillustratedtra below and should be done right after full welding is finished easily
bend the plate during hammering.

weld point

- A 500mm distafromrom the edge of the bottom plate considered an insider for haring
to the then tildelevelelness of overlay platestplatesate achieved, a temporary plate
will be inserted before hammering as per illustrated below.
- Locate the portion of the weld joint where the shell will rest, this overlapping portion
requires to be level by hammering, bending procedure should be done after the root
p s of the joint portion approximately 100mm in length to easily bend the plate. ( as
per the illustration below.)
Date: 23 Jan, 2018 Method of Statement for
Erection And Testing of Eleven (11) Units
Rev : 2 SUS Storage Tanks Page 9 of 13

- More after the desired level is achieved full welding of joint portions starts and flash
grind after.

- Once levelness is achieved between two overlappiplatesate an RFI shall be issued

for inspection for any variations that occur during the process if within the acceptable
tolerance.

- Upon approval of RFI full welding works continuous refer to WPS 0010-ROOS-007,
- Welding joint shall be monitored and recorded, a welding history sheet shall be
prepared and for every welding job, int a welders ID shall be indicated.
- Full welding sequence is very important to minimize or possibly avoid warping the
plate. (recommended welding sequence as per the er illustration below.)
- Also, before full welding starts an additional weight will be added to flatten the
bottom plate behalf-sizeize drum fill with concrete materials to be placed in specific
points during welding and too to removed until the plate cools down inperiodime,
additional jigs and stiffener to ensure that deformity wilessensen within an
acceptable range.

- After all full welding works on bottom plate finish, an RFI to be issued for
circumferential checking again before proceeding to vacuum test, anchor bolt boring
shall follow usia ng plasma cutter or boring machine can be used on the ice layout
has been established, a temporary plate of Carbon Steel material shall be used as
illustrated.
- In cases where deformity occurs in the bottom plate
Date: 23 Jan, 2018 Method of Statement for
Erection And Testing of Eleven (11) Units
Rev : 2 SUS Storage Tanks Page 10 of 13

- Before proceeding to the boring process an RFI shall be issued for confirmation by
the main contractor for anchor bolt layout and distance.
- Upon confirmation by SANKYU on the final dimension and distance vacuum test can
start.
- Vacuum testing is performed using a testing box approximately 150mm (6in) wide by
750mm (30in) long with a clear window on the top ( ref. API 650 8.6 VACUUM
TESTING).
- The open bottom shall be sealed against the tank surface by a suitable gasket,
connections valves, lighting, and gauges as required shall be provided. A soap film
solution or commercial leak detection solution, applicable to the conditions, shall be
used. ( as per the illustration below).
- Perform a visual examination of the bottom and welds before performing the
vacuum-box test.
- Verify the condition of the vacuum box and its gasket seals.
- Upon confirmation of the above condition vacuum test starts.
- Applying the soap solution to be wetted to a joint to be tested.
- A partial vacuum of 21kpa to 35kpa gauge shall be used for the test or 157mmHg to
262mmHg gauge Equiv. (a min 300mmHg vacuum pressure as per client
requirement was used.)
- Verifying that no quick bubble or splitting is occurring on the weld joint about 5
seconds holding time signifies that there is no leak and then can proceed to other
joint, turn off the vacuum pump and release pressure by opening the inlet valve.
- The vacuum test box shall have at least 50mm (2in) overlap of previously viewed
surface on each application. (ref API 650 para 8.6 VACUUM TESTING ).
Date: 23 Jan, 2018 Method of Statement for
Erection And Testing of Eleven (11) Units
Rev : 2 SUS Storage Tanks Page 11 of 13

- Upon 100% completion of vacuum test on the bottom plate and necessary reports
have been approved and witnessed. Shell erection shall start.

12.2 SHELL PLATE

- Chemical anchor bolt shall be installed and tightened before the erection of shell
plate (by Civil).
- Elevation of the bottom plate after tightening of Chemical Anchor shall be checked a
plus minus 3 tolerance shall be strictly followed. In case of tolerance exceeded the
max allowable a shim plate shall be inserted until the desired elevation is achieved.
- Shell plate tagging shall be confirmed at all times before erection to avoid mixing of
plate members for different tank sizes.
- After the finished erection of the shell plate starts, shell plate tagging shall be
confirmed and identified clearly to avoid using other tank plates for installation.
- Layout of shell plate outside diameter shall be established, shall be marked on
bottom plate permanently to avoid erasure during works.
- Temporary plate shall be placed around the layout it serves as a jig for the shell plate
to avoid movement of the shell during alignment.

BOTTOM
PLATE

SHELL OD
LAYOUT

- Erection of 1st coarse starts using crane or boom truck,

-
- Bottom to shell plate shall be tack weld only full weld is not allowed.
- After 1st coarse shell installation and alignment are completed (only tack weld on
shell vertical joint) on the shell plate shall be done necessary tools must be available.
- Fit up on 1st shell coarse starts only tacking.
- Erection of second coarse starts, alignment, and plumpness shall be established.
 Date: 23 Jan, 2018 Method of Statement for
Erection And Testing of Eleven (11) Units
Rev : 2 SUS Storage Tanks Page 12 of 13

- Fullwelding of 1st coarse and 2nd coarse vertical joints starts. Refer WPS 0010-
ROOS-007
- Fullwelding of 1st horizontal joints starts. Refer WPS-ROOS-0010-007
- Sequence of erection and full welding shall be followed until the last coarse erected.
- Installation of top angle starts
- After full welding of top angle flashing plate to be installed and full weld.
- Fit-up of roof plates shall be done on the ground.
- Upon complete fit up on roof plates full welding starts.
- Rafter and center ring to be installed at roof plates.
- Stitch weld on the rafter.
- Upon completion roof is to be lifted one time using a crane.
- Tank nozzles layout starts
- Railings to be installed and fully welded.
- Before boring on tank nozzles starts RFI shall be issued and approved.
- Before full welding on tank nozzles starts an RFI shall be issued first to the main
contractor for confirmation and approval.
- Upon completion of installation works tanks shall be cleaned either of recommended
chemical solution or power tool device to achieve a desired finish and appearance.

13. TESTING

- Upon completion of the erection and necessary approved documents have been
approved and cleared by the main contractor, RFI shall be issued before conducting
testing of the tank shell, make sure that all foreign materials, debris, and trash were
removed already inside the tanks.
- Ensure that all nozzles were blinded before filling with water.
- Beforeto start of the water filling of the tanks, a 10% Radiographic Test shall be
finished and documented.
- A potable water is preferred for hydro-testing, tanks shall be inspected frequently
during the filling operations.
- Allow water to overflow on the highest nozzles located on the top of the tank.
- The tanks shall be filled with water up to the max liquid level specified on the tanks
datasheet or 50mm (2in) above the weld connecting the roof plate thru a hose
connected to the main water supply line.
Any welded joints above the test-water level shall be tested either vacuum test or by
applying an internal air pressure not exceeding the weight of the roofs or 1.5 times
the design pressure.
- For tanks having a bottom coarse thickness less than 22mm (7/8in) max. filling rate
is 300mm (12in/hr). from the top coarse supply ( ref. API 650 par.7.3.6.5).
- Four (4) stages of settlement readings are required.
- 1. With tank filled to ¼ test height
- 2. With tank filled to ½ test height
- 3. With tank filled to ¾ test height
- 4. Up to the max liquid level of the tank.
- When the water level reached this certain test height, The water shall be maintained
at this height for a minimum of two (2) hours while settlement readings are
completed. Settlement readings shall be taken every 15 minutes until the end of this
hold period.
- When the tank has been filled to the maximum test height. The water level shall be
maintained at this height for a minimum of 24 hrs.
 Date: 23 Jan, 2018 Method of Statement for
Erection And Testing of Eleven (11) Units
Rev : 2 SUS Storage Tanks Page 13 of 13

- Settlement readings shall be taken every 15 minutes for the first 2 hours and then
every 1 hour thereafter until the end of this holding period.

- During the test if any leakage is observed in the shell, stop the filling and emptied the
tank up to 300mm below the leakage point, and shall be repaired.
- If any leakage from the bottom is observed the tank shall be emptied find out the
leakage point and shall be repaired.
- Make sure the tank is properly vented during draining to remove all vapor
accumulated during filling to avoid vacuum and damage to the tank.

14. REPAIRING OF DEFECTS

- Defects in welding or material shall be repaired with a consultation with the

SANKYU. Defects in welds shall be repaired by grinding out the defects from one
side or both sides of the joints, as required and re-weld again. The tank shall be re-
tested after repair of all defects.

15. SITE CLEAN UP

- Upon completion of the erection and before final acceptance, ROOS shall remove all
temporary material. He shall remove all surplus materials, temporary supports, and
rubbish.
- Disposed surplus material shall be in a manner and at a location satisfactory to the
SANKYU.

16. QUALITY MANAGEMENT

- After all of the tanks have been erected and tested, the SANKYU and the ROOS
shall conduct a final inspection to locate any damage or deficiencies.
- All visible deficiencies shall be repaired to the satisfaction of SANKYU before final
acceptance.