METHOD OF STATEMENT FOR FIELD

ERECTED TANKS

Crown Specialized For Steel Contracting Co. Ltd Document Id: CS-005 Rev. No. 02

Date: 16-DEC-2018 Page No.2

CONTENTS

1. Scope

2. Purpose

3. Reference

4. Responsibility

5. Method Of Construction

6. Identification Of Materials

7. Erection

 Bottom Plate Laying

 Shell Course Erection

8. Erection Of Cone Roof Plates And Structures

9. Appurtenances Installation

10. NDT TESTING

11. Hydro Test
12. Quality Assurance & Quality Control
13. Safety
14. Records
 METHOD OF STATEMENT FOR FIELD
ERECTED TANKS

Crown Specialized For Steel Contracting Co. Ltd Document Id: CS-005 Rev. No. 02

Date: 16-DEC-2018 Page No.3

1 SCOPE:-
 This procedure covers detailed activities for fabrication, erection and testing of the storage tanks, and also
equipment & manpower required for the same. All the tasks / activities need to be carried out with atmost care
with good workmanship and in accordance with the specifications to achieve satisfactory completion of the whole
activities.

2 PURPOSE:-
 The purpose of this document is to follow proper methodology to carry out the activities in a proper sequence for
Erection and Testing of the Fuel Tanks (59-B-22-1&2)

3 REFERENCE:-
 API 650
 ASME Sec IX, ASME Sec V.
 Approved Drawing / Specification.

4 RESPONSIBILITY:-
 The responsibility of implementation of this procedure rests with CROWN STEEL & with the supervision of ATTIQ UR
REHMAN CONTRACTING EST.

SITE MANAGER: -
 The Site manager is responsible over all for the implementation of the method statement
 To ensure that the team of engineers and foremen and operatives are aware of this method statement.
 To ensure that all resources (labor, material and equipment) are available to carry out the work as planned
 He shall be responsible for implementing the company safety plan overall.

QC Engineer: -
 The QA/QC Engineer is responsible for ensuring that the operations have been performed as per the specification.
 Also for ensuring that the inspections are done as per Quality Control Procedure and that the Inspections
 For managing all the necessary inspections, inclusive of witnessing, recording and reporting the results.
 To ensure that all the inspections are executed efficiently and expeditiously in order to comply with the schedule

HSE Officer: -
 He shall be responsible for the overall safety of personnel, materials and equipment, and follows.
 To ensure all the operations at the site are conducted and maintained safely throughout.
 To coordinate and preside over regular site safety meetings, to attain and maintain effective communications.
 Site HSE Officer will be fluent conversant in the relative safety regulations of the company and the statutory
requirements of the Kingdom of Saudi Arabia.
 METHOD OF STATEMENT FOR FIELD
ERECTED TANKS

Crown Specialized For Steel Contracting Co. Ltd Document Id: CS-005 Rev. No. 02

Date: 16-DEC-2018 Page No.4

SUPERVISOR: -
 Supervisor is responsible directly to the operations.
 Arrange and provide everything that is required for the operation.
 Communicate methods of operation to the team and follow all methods accordingly method of statement.
If there is any deviation between the operation and method statement, immediately report to HSE officer and site in
charge

5 METHOD OF CONSTRUCTION:-
 See below detail

6 IDENTIFICATION OF MATERIALS:-
 Each Piece of Plates, fitting or any other component of tankage system shall be clearly identified by marking heat
no. on the part using hard punching.
 Each weld joint shall be marked with joint Number with Welder Number.

7. FIELD ERECTION:-

BOTTOM PLATE LAYING:

 Check the level of foundation as per specification API 650 clause 7.5.5.
o o o
 After getting clearance for bottom plate laying, mark the 0 , 90 , 180 , 270° co-ordinates on the foundation from
the reference bench mark of the plant.
 Lay the annular plates ring on the foundation top as per drawing.
 With co-ordination of Centre plate lay the bottom plates sequentially as per drawing.
 Overlap shall be maintained while the fit-up of short seam and long seam as per drawing.
 Temporary tack weld to be carry out on the long-seam to avoid uneven movement, while the fit-up and
welding of short seam.(See Fig2)
 Short seam welding will be carried out alternatively to avoid distortion, after completion of shot seam welding
long seam welding will be carried out alternatively to avoid distortion.
 Qualified welders shall be engaged and welding shall be carry out as per WPS.
 After Completion of welding thoroughly clean the weld ‘joint by wire brushing and grinding.
 All the bottom plate's joints vacuum box test shall be carried out as per approved procedure and code
specification as shown fig 3.
 If any defect found the defect weld shall be removed by grinding and re-weld and conduct the vacuum box test.
Repeat the sequence until the defect is cleared.
 METHOD OF STATEMENT FOR FIELD
ERECTED TANKS

Crown Specialized For Steel Contracting Co. Ltd Document Id: CS-005 Rev. No. 02

Date: 16-DEC-2018 Page No.5

The joint of Annular palte & bottom plate

Fig 1

Bottom Plate Tack Welding Distance

Fig 2

Vacuum Test
Fig 3
 METHOD OF STATEMENT FOR FIELD
ERECTED TANKS

Crown Specialized For Steel Contracting Co. Ltd Document Id: CS-005 Rev. No. 02

Date: 16-DEC-2018 Page No.6

SHELL COURSE ERECTION:

 After fit-up of bottom plates, mark the tank inner radius on the bottom plates.
 Care shall be taken that the shell plate erected to the diameter marked on the bottom plate.
 Jigs and fixtures shall be use to align the shell plates.
 The 1st shell courses shall be erected by conventional method using crane. See the fig 5.
 Shell plate horizontal and vertical plate clearances are maintained by key plates, shims and wedges.
 Key plates are secured to the shell, driven wedges maintain the gap for welding.
 Shims maintain the clearance on the horizontal weld see fig 6
 Balance shell courses shall be erected by the same method as on figure.4, 5 & 7.

ASSEMBELY OF 1st SHELL COURSE

 METHOD OF STATEMENT FOR FIELD
ERECTED TANKS

Crown Specialized For Steel Contracting Co. Ltd Document Id: CS-005 Rev. No. 02

Date: 16-DEC-2018 Page No.7

ASSEMBLY OF 2nd SHELL COURSE

Fig 5

Hanging bracket type scaffolding

Fig6
 METHOD OF STATEMENT FOR FIELD
ERECTED TANKS

Crown Specialized For Steel Contracting Co. Ltd Document Id: CS-005 Rev. No. 02

Date: 16-DEC-2018 Page No.8

Fig7

 Complete the fit up of vertical & horizontal joints.

 First welds vertical joints, after vertical welds we will do horizontal fit-up and perform horizontal welding by using the
welding trolley as shown in fig 7.
 Peaking to be checked after the fit-up of the vertical joints. Peaking shall be within the tolerance as per API - 650.
(Tolerance 1/2")
 Peaking shall be checked at the top, middle and bottom of the vertical joints using a sweep board of 36” length.
 Plumbness shall be checked for the verticality of the shell course at every 60° and shall be within the tolerance
(tolerance 1/200 of the total shell height).
 For perfect verticality, channels shall be provided at regular interval inside of the shell course (3 to 5 meters), the
channels shall facilitate the alignment of shall courses.
 Tack welds of the fitted vertical joints shall be ground smooth.
 Offer for inspection and get clearance from inspection authority for the vertical and horizontal joints fit-up,
Complete the first side welding by using qualified welders
 Care shall be taken while welding to avoid the peaking and the roundness distortion.
 After completion of first side welding, back-chipping shall be carried out for sound metal from the other side of the
weld and by grinding as necessary.
 Back-chipped grooves shall be offered for inspection before the start of the welding, Complete the 2 nd side welding
using qualified welders.
 Joint Nos. & welder No. shall be marked on both sides of the weld .joint.
 METHOD OF STATEMENT FOR FIELD
ERECTED TANKS

Crown Specialized For Steel Contracting Co. Ltd Document Id: CS-005 Rev. No. 02

Date: 16-DEC-2018 Page No.9

 Clean weld joints from both sides by wire brushing and grinding.
 After completion of welding from both sides remove all the temporary jigs and fixtures and flush grind the tacks.
(Do the weld fill up wherever required)
 Check the peaking, plumb ness, circumference and the radius, offer for inspection to the satisfaction of the client
QC.
 The shell to bottom joint area from both sides shall be cleaned thoroughly to carry out the chalk-diesel test.
 Apply chalk solution from inside. Apply diesel by a hand spray pump from outside, Hold it as per instruction of the
QC and check the root weld inside for any defect.
 If any defect found the defect shall be repaired by grinding the defect area for the sound metal plus 150mm from
both end of the defect.
 Conduct the chalk - diesel test on the repair spot. Carry out the whole process until the repair cleared to the
satisfaction of QC.
 All unwanted materials and scrap shall be removed from inside of the tank.
 RT shall be carried out as per API-650.

8. ERECTION OF CONE ROOF PLATES AND STRUCTURES:

 After completion of the last shell course erection, fit up, and welding, curb ring fit up & welding shall be done.
 Erect and Lay the Roof plates on the ground as per the drawing.
 While fit up of the short seams and long seams Lap to be maintained as per drawing.
 Offer the inspection to QC after complete fit-up of roof plates
 Conduct the welding after get the clearance from QC
 Install the roof on tank as per drawing by using crane.
 Install the roof structure as per drawing.

9. APPURTENANCES INSTALLATION:
 Flanges to pipe joint shall be prefabricated and required NDT shall be completed before erection.
 Mark the nozzle location as per drawings. Cut the openings by gas cutting after proper Inspection-by-inspection
authority.
 Erect the nozzles as per the orientation & the elevation shown in the drawing.
 Install reinforcement pads wherever required before nozzle erection.
 Orientation, elevation & projection shall be maintained as per drawing and offer for the inspection clearance.
 Welding shall be as per WPS and to be welded by the qualified welder.
 All the reinforcement pad weld shall be pneumatically tested as per API 650.
 Reinforcement Pad pneumatic test shall be carried out to the satisfaction of the QC.
 Install the ladder and platform handrail and conduct the welding as per drawing.

10.NDT Testing:
 Oil & Chalk Test ( Bottom to 1st Shell joint)
 METHOD OF STATEMENT FOR FIELD
ERECTED TANKS

Crown Specialized For Steel Contracting Co. Ltd Document Id: CS-005 Rev. No. 02

Date: 16-DEC-2018 Page No.10

 PT (Liquid Penetration Test)

 Vacuum Box Test ( Bottom only)
 RT (Radiography Test) As per API 650

11. HYDRO TEST:

 Clean the tank and box up the nozzles and start the hydro test as per API 650.
 Offer for inspection to the specified inspection authority after hydro test drain the water and clean the tank from
inside.
 Start the final painting and check the DFT as per provided painting system by AUR / BIA, painting procedure will
be provided separately.

12. COATING & PAINTING:

 Coating & Painting Procedure will be submitted separately.

13. QUALITY ASSURANCE & QUALITY CONTROL:-

 This shall be followed, Maintain the compliance / adherence to the drawings, procedures and code
specifications. Records shall be kept in the relevant check sheet and formats duly signed by all the concerned
departments.

14. SAFETY:-
 Safety Precautions should be followed during erection as per site requirement.
 Welding cables and power cables to be laid properly as per site rules.
 Proper housekeeping and clean condition shall be maintained at site as per the requirement.

15. RECORDS:-
 Foundation Hand Over Report.
 RFI (Request for Inspection).
 Welding Inspection Report.
 Vacuum Box Test Report.
 Oil-Check Test report.
 PT Test Report (Penetration Test Report).
 RT Test Report (Radiography Test Report).
 Hydrostatic Rest Report.
 Painting Report.
 METHOD OF STATEMENT FOR FIELD
ERECTED TANKS

Crown Specialized For Steel Contracting Co. Ltd Document Id: CS-005 Rev. No. 02

Date: 16-DEC-2018 Page No.11

 Completion Certificate.