0279STX N WM PW01 CM MET 0003 A02 - Comments

RUMAILA PROJECT
Document
0279STX-N-WM-PW01-ME-MET-0003 Rev A02
Number:
Document NR PWRI PHASE 1 – METHOD STATEMENT FOR INLET TANK

Title: ERECTION
ENGINEERING, PROCUREMENT AND CONSTRUCTION FOR THE

Project Title: PROVISION OF PRODUCED WATER RE-INJECTION PHASE 1
FACILITY
Tag No’s
(if applicable)
Contractor: Sae-A STX Entech Co., Ltd.
Contractor
H19201-PW01-ME-MET-0003 Rev 00
Document No:
A02 Issued for Review 02/07/2022 Bobby Kim STEVEN LEE B.S.CHUNG
A01 Issued for Review 01/06/2022 Bobby Kim STEVEN LEE B.S.CHUNG
Rev. Revision Description Date Originated Reviewed Approved
NR PWRI PHASE 1 – METHOD STATEMENT FOR INLET
TANK ERECTION
(0279STX-N-WM-PW01-ME-MET-0003)
Revision: A02
Date: 02/07/2022
REVISION DESCRIPTION SHEET
Rev.
Para. Reason for Revision
No.
A01 All Issued for Review
A02 All Issued for Review
Hold
Para. Description of Hold
No.
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TANK ERECTION
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CONTENTS
1.0 INTRODUCTION.................................................................................................................................... 5
2.0 DEFINITIONS AND ABBREVIATIONS ....................................................................................... 5
3.0 REFERENCE DOCUMENTATIONS ............................................................................................. 6
4.0 LIFTING AND RISK ASSESSMENT PLANS ............................................................................ 6
5.0 Tank Material Laydown Plan. ........................................................................................................ 7
6.0 SEQUENCE OF TANK ERECTION ACTIVITIES .................................................................... 8
7.0 METHOD STATEMENT...................................................................................................................... 9
7.1 Bottom & Annular Plate Erection ..................................................................................................... 9
7.1.1 Annular Plate Erection. ........................................................................................................................ 9
7.1.2 Bottom Plate Erection. ...................................................................................................................... 11
7.2 Installation of Normal & Emergency Access Point. ............................................................... 13
8.0 SHELL PLATE ERECTION (6th & 7th shell course) ........................................................... 15
8.1 Install Spacer for Supporting Shell Plates. ............................................................................... 15
8.2 6th&7th Shell Plate Installation & Welding. .............................................................................. 16
8.2.1 6th Shell Plate Installation & Welding......................................................................................... 16
8.2.2 7th Shell Plate Installation & Welding......................................................................................... 17
9.0 TANK ROOF INSTALLATION...................................................................................................... 17
9.1 Compression Ring Installation ....................................................................................................... 17
9.2 Assembling and installation of roof truss ................................................................................... 18
9.3 Assembling and installation of roof plate. ................................................................................. 20
9.3.1 Access and Safety .............................................................................................................................. 21
9.3.2 Roof plate installation........................................................................................................................ 22
9.3.3 Roof accessories installation. ........................................................................................................ 22
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10.0 REMAIN SHELL PLATE INSTALLATION (W/ HYDRAULIC JACKING MACHINE)

22
10.1 Setting up Hydraulic jacking ........................................................................................................... 22
10.1.1 Step for installation of the 5th shell course as below ............................................................. 25
11.0 Hydro Test ............................................................................................................................................ 26
12.0 SURFACE PREPARATION AND COATING ......................................................................... 26
13.0 ATTACHMENTS ................................................................................................................................. 26
Page 4 of 26
TANK ERECTION
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1.0 INTRODUCTION
The purpose of this document is to establish contractor’s methodologies for erection of INLET
Tank 403 - T001 / T002. It shall be a guideline for the various steps involved in lifting the Inlet
Tank shells by Jack Lifting Method.
2.0 DEFINITIONS AND ABBREVIATIONS
Definitions
Definition Description
ENGINEERING, PROCUREMENT AND CONSTRUCTION FOR THE

PROJECT
PROVISION OF PRODUSED WATER RE-INJECTION PHASE 1 FACILITY
COMPANY Rumaila Operating Organisation (ROO)
CONTRACTOR Sea-A STX Entech Co., Ltd.
Abbreviations
Abbreviations Description
API American Petroleum Institute
ROO Rumaila Operating Organisation
CONTRACTOR Sea-A STX Entech Co., Ltd.
PPE Personal Protective Equipment
ITP Inspection Test Plan
HSE Health Safety and Environment
PA Performing Authority
AA Area Authority
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3.0 REFERENCE DOCUMENTATIONS
CONTRACTOR shall comply with the referenced project specifications as listed below as well as
with any other relevant PROJECT Standards.
No Doc. Number Doc. Title
1 API 650 Welded Tank for Oil Storage
0000BF-C-G0-G000-ME-SPC-0007-
2 B01
Specification for Atmospheric Storage Tanks
3 0279STX-0-ME-005-B01-0001 General Assembly DWG for Inlet Tank
4 0279STX-0-ME-005-F001~121 Detail Drawing for Inlet Tank
5 0279STX-N-WM-PW01-CM-PLN-0001 Construction Execution Plan
6 0279STX-N-WM-PW01-HS-PRO-0025 Lifting Operations Procedure
7 0279STX-N-WM-PW01-QA-ITP-0001 Construction Inspection &Test Plan
4.0 LIFTING AND RISK ASSESSMENT PLANS
All Lifting activities and risk assessments associated with the tank erection works shall be carried
out in accordance with the relevant approved lifting plans and risk assessment plants that are
submitted separately.
To ensure safe and effective lifting operations the following key elements are required:
 Hazard Identification and Task Risk Assessment (HITRA) to be completed by the
Performing Authority (PA who fully understands lifting operations and the specific lift(s)
involved in the task concerned.
 Permit to work.
 Written engineered lift planning.
 Correct positioning, marking, inspecting and examination of lifting equipment.
 Provision of suitable work equipment, information, instruction, and training for operators of
lifting equipment.
 Adequate controls and control systems and stability for lifting equipment.
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TANK ERECTION
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5.0 Tank Material Laydown Plan.
All plates are fabricated and rolled from Korea supplier, also transported with supports shown as
below condition.
Materials required for tank installation work will be transported from Laydown Area to PWRI work
site as per working progress and these materials should arrive and store at site before start work.
Material will be stored at suitable locations at site, and it shall not be placed directly on the ground.
It shall be rest on timbers.
Support for Flate Bottom and Roof Plate

Support for Rolled Shell Plate
Detail lifting method will follow approved lifting plan (Doc. 0279STX-N-WM-PW01-HS-PLN-
02-A01 approval)
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6.0 SEQUENCE OF TANK ERECTION ACTIVITIES
Detail the methodology for roof-level

nozzles, accessories and platforms
etc installation.
When are internal accessories

installed? We need to detail the
sequencing and methodology for
installation of the internal accessories
within this document.
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7.0 METHOD STATEMENT
7.1 Bottom & Annular Plate Erection
7.1.1 Annular Plate Erection. Incoming annular plate material shall be inspected and released by QC
department.
Check the level of foundation as per approved drawing. Mark the centre of tank-on-tank
foundation and after getting clearance for annular plate laying, mark the 0°, 90°, 180°, 270° co-
ordinates on the foundation from the reference point shown in Figure 1.
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[Figure 1. Lines to be marked prior to laying bottom plates]

Annular plates shall be laid as per an approved drawing (DWG No. 0279STX-0-ME-005-F01-
0008~0010) and orientation of annular plate joints to be checked.
Out radius of the annular plate shall be in positive side (5 to 10mm) in order to achieve the final
required radius after weld shrinkage. Fit up of annular plate`s joints shall be carried out using
proper fit-up gear and tools. Care shall be taken while fit-up such at gap between the annular
plates shall be carried out as per approved drawings.
Details how lifting of the

annular and bottom plates will
be performed?
<example of fit-up gear and tools>
Annular plate`s joints welding shall be carried out by welding alternative joint at four quadrants.
Provide proper support by using channel and beams to avoid buckling.
Qualified welders shall be engaged for the welding work according to WPS. Complete the welding,
Clean the final weld surface by wire brushing. Remove the jigs and fixtures which were used for
fit-up of the annular joint and grind the tack. All Radiography shall be taken as per API-650 Sec
8.
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7.1.2 Bottom Plate Erection.
Lay the canter plate on the foundation as shown in Figure 2.

Incoming bottom plate material
shall be inspected and released by
QC department.
[Figure 2. Sequence of laying out Annular and Bottom plates]
All plates in canter row shall be laid first in overlapped condition as mentioned in the drawing; all
other plates in subsequent rows shall then be laid moving towards the tank peripheral area as
per approved drawing.
< example of fit-up gear and tools>
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While fitting up all tank bottom plates; care shall be taken to have all fillet joints in close contact.
Laps shall be maintained as per drawing and inspection shall be carried out before starting the
welding process.
Temporary tack weld to be carry out on the Long-seam to avoid uneven movements, while the
fit-up and welding of short-seam. Short seam welding will be carried out alternatively to avoid
distortion.
<Example of plate distortion preventive jigs>
After the completion of short-seam welding, remove the temporary tacked on the Long-seam by
grinding to facilitate the long-seam fit-up. Minimum laps shall be maintained while the fit-up of
long seam as per approved drawing. Joggling shall be carried out by indirect hammering
wherever it is necessary. (Tree plate joining junction.)
Close monitoring and inspection shall be carried out against distortion of bottom plates during
welding.
Before starting the welding, channels shall be tacked along the long-seam to avoid the distortion.
Qualified welder shall be engaged, and welding shall be carried out as per approved WPS.
After the completion of the welding, the final weld surface shall be cleaned properly. Sketch to
annular plate joint shall be welded only after shell to bottom joint welding.
Vacuum box test shall be carried out on entire bottom weld joints as per approved procedure
(Doc. 0279STX-N-WM-PW01-QA-PRO-0012) and code specification. 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 cleared. All Inspection to done as per API 650 and approved ITP.
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7.2 Installation of Normal & Emergency Access Point.
Construct Normal & Emergency access for entry and exit confined space during tank erection as
per company requirement. Two access points (Normal / Emergency) per each tank is required.
Opening on the
annular and bottom
plate shall be
located coincident
with the opening
created for the ring-
wall foundation.
Design of Access Point with Protection Plate & Accessibility
 Height (Ground to Tank Shell Plate) : 1.8m

 First Step of Stair to Tank Shell Plate : 1.6m
 Width of Stairs : 1m
 Cascading slop with sandbag will be applied around access points.
Patient Transport by Stretcher
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 Shall keep Stretcher and First Aid Kit near the emergency access point.
 When a person injury occurs, the injured person is transferred in a group of three.
 Emergency Drill (Personnel Injury) shall be scheduled and carried out periodically.
at the ring-wall foundation and making necessary repairs

After closing the opening, annular and bottom plate shall be reinstated thoroughly with the same
type of butt joint with annular plate and bottom plate.
After Reinstatement, As per ITP below mentioned Inspections for welding will be carried out
1.Weld visual inspection

2.RT for Annular butt welds
3.PT/MPT for all fillet welds
4.Vacuum box test for bottom plate welding seams
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8.0 SHELL PLATE ERECTION (6th & 7th shell course) Incoming shell plates shall be inspected and
released by QC department.
8.1 Install Spacer for Supporting Shell Plates.
Considering that shell plates have been erected on spacer therefore, to accommodate access
and egress during the case of an emergency. (SSTX installed main Normal & Emergency Access
Point # 6.2)
Spacer beams (400 to 500 mm hight) are placed on the annular plate at a spacing of 1500mm
(Spacing distance would be flexible according to the site condition) around the periphery of the
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tank shell. Spacer beams have guide cleats welded onto them. Quantity of spacer required is 84
pieces.
For every horizontal shell to shell weld of each

8.2 6th&7th Shell Plate Installation & Welding.
automatic welding machine, the first 1 meter of the
8.2.1 6th Shell Plate Installation & Welding. weld shall be RT filmed for clearance against poor
quality.
Erect scaffolding at inside and outside and around 6th course shell plates. This scaffolding will
be used as working platform for erection and welding of shell plates.
Mark the starting point of the 6th shell course vertical seam as per the approved drawing. (DWG
No. 0279STX-0-ME-005-F01-0004~0007). The rolled shell plates shall be shifted to the tank
foundation area and kept along the periphery.
Erect 6th shell course on the spacers placed on the annular plate and taking care to match inner
Dia. (Proper fit-up gear and tools shall be used to align the shell plates.)
< example of fit-up gear and tools for vertical joint)

All Vertical shell joints fit-up shall be made barring the final joint. Make-up plate joint which shall
be fitted up only after completion of other vertical joints to take care of shrinkages during welding
& ensuring correct circumference.
After completing fit-up of vertical joint, inspection shall be carried out as per an approved ITP.
Upon clearance, all joints shall be welded from first side by using qualified welders. Care shall
be taken during welding to avoid distortion.
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(★) After completion of one side welding, back chip shall be carried out up to sound metal from
other side by grinding. Back chipped grooves shall be inspected thoroughly for any defect before
starting the welding.
(★) Subsequently inside welding shall be completed using qualified welders. Peaking shall again
be carried out to ensure that the curvature of tank is well within the specified limits as per the
code. Joint number and welder number shall be marked on the weld joints.
At the same time, all nozzle, skimming, handrail etc.. should be considered and installed on the
shell plate (According to Logistic schedule, erect what arrived item). Purpose of this for
minimizing of high place work.
After completion of welding from both sides, all temporary jigs & fixtures shall be removed, and
flush grinding shall be carried out to maintain evenness & smoothness of tank shell. Peaking,
plumb ness, circumference and radius shall be checked.
8.2.2 7th Shell Plate Installation & Welding.
Erect 7th shell course plates on top of the 6th shell course plates by staggering the vertical seam
as shown in the drawing. 3mm thick spacer shall be kept between 6th & 7th top shell course
plates to maintain horizontal seam gap. Proper erection channel shall be provided at regular
intervals from inside.
< example of fit-up gear and tools for horizontal joint>

After all the shell plates for 7th shell course are erected in place, align the vertical seam joint and
tack weld the seam. Proper Jigs and fixtures shall be used to align the shell plates.
Horizontal seam between 6th shell courses shall be aligned and tack welded. All spacers
provided during erection shall be aligned and tack weld shall be ground smooth. It shall be
ensured that tack welds are free of defects like cracks, porosity etc..
Welding of shell plates shall be done as started on (★) above explanation.
9.0 TANK ROOF INSTALLATION

9.1 Compression Ring Installation
The compression ring will sit on the top edge of the 7th shell course. It will be fabricated in
workshop and it will be divided 16EA (DWG No. 0279STX-0-ME-005-F01-0013)
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All transported material shall be checked against

damage and proper material storage will be
controlled.
Welding of the compression ring to the top of shell plate shall be carried out as per the approved
construction drawing.
9.2 Assembling and installation of roof truss
Assembling method may be used with one by one system at the same time.
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Erection of central column in centre of tank bottom as per DWG (0279STX-0-ME-005-F01-0019)
Connect with
Compression Ring
Connect with
Central Column
Erection of Roof truss resting chair as per below DWG (0279STX-0-ME-005-F01-0015) detail “A”
and marking should be done as per DWG (0279STX-0-ME-005-F01-0014) where roof truss will
rest. (20 Nos)
Erection of main truss assembly at the 0°, 90°, 180°, 270° sequence is opposite direction like
0°&180°, 90°&270°(4Nos)
Erection of balance 16 Nos main truss assembly. 5Nos Purlin will erect in each bay from 0° to
Clockwise (total 20Nos Bay & 100Nos Purlin) and Horizontal bracing in Bay – 1, 2, 3, 4 & 6Nos
bracing in each bay.
Erection of rafter channel assembly – 3Nos each bay

Total → 60Nos rafter channel assembly // Rafter channel → 120Nos
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After arrangement shall be fastened firmly by bolts and each other’s, and then will be assembled
in each position at every member, welding shall not be done for further level correction. The
demolished opening shell plate shall be kept safe condition after that all assembling is completed,
dimensions must be checked by drawing.
9.3 Assembling and installation of roof plate.
The fully assembled roof truss steel structure shall be inspected and accepted before starting the
installation of roof plates. Roof plates shell be assembled on the structure in the manner to avoid
excessive unsymmetrical loads working from the centre.
<Figure 3. Laying out the roof plates with the sequence>

Roof plates shall be hung up and carried on the roof structure by crane. Arrangement of the roof
plates shall start from the tank centre toward the circumference. <Figure 3.> Lifting lugs (if
necessary) will be welded as per the approved lifting plan and PT report for lifting lug welding
joint testing shall be available at site.
As per ITP Roof plate inspection will be carried out with leak test of roof seam weld by Vacuum
Box test.
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9.3.1 Access and Safety
Scaffold erected during 6th shell plate installation around tank and stairs will be used for access
to tank roof during roof plate installation. Scissor lift will be used for fixing and welding activities
underneath the roof plates.
<Typical Settlement for Roof Plate with Column>
Typical Settlement for Roof Plate with Column shall be provided as described as below.
① Erect scaffold with two stairs at opposite direction to install roof plate
② Roof plate No. 1 (Figure. 3) shall be welded with two columns at the edge of roof plate
as shown upper sketch and other plates shall be welded with 1column in the centre of
roof plate. Lifeline on roof plate No.1 shall be set with enough length to reach the edge
of roof on ground before lifting. All roof plates shall be tack welded with roof steel
structure spacer.
③ Workers reach the top centre plate No.1 by secure the safety harness on the lifeline
and adjust the exact location of the other 4 plates (2, 3a,b, 4a,b). During location
adjusting, stopper and clamps will be welded onto roof plate to ensure the roof plate fit-
up.
④ During other roof plate installation, scaffold pipe column and life lines shall be set on
the roof plate to ensure workers can walk and perform tack welding by securing the
hardness to lifeline. At least one lifeline in each direction (0°, 90°, 180°, 270°) tied to
the top compression ring to ensure worker can reach the scaffold around tank in
emergency.
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9.3.2 Roof plate installation.
Mark the directions of tank orientation (0°, 90°, 180°, 270°)

Lay out the plates in accordance with the sequence as shown in figure 3.
Roof plate shall be tack welded with the spacer on roof steel structure to fix the roof plate. Area
to be welded on shall be grinded immediately to get the cleaning surface for welding executing
once the welding area marked on the roof plate underneath.
Fix all roof plates together by tack welding and the use of metal clamps to ensure the stability of
tank roof.
9.3.3 Roof accessories installation.
Roof accessories including platform, walkway, handrail, nozzles shall be installed after roof plate
welding works are completed. Nozzles are available at the same time during the installation of
roof plate. Other accessories shall be installed after roof plate installation complete for safety
reason.
10.0 REMAIN SHELL PLATE INSTALLATION (W/ HYDRAULIC JACKING MACHINE)

10.1 Setting up Hydraulic jacking
Jack-up system description to be provided with identification of various components,
together with description of arrangement, how lifting/descent operations are controlled?
Jacking Procedure If there are any references to jack-up system supplier provided procedures or method
statements, please include here.
Repeat the below procedures for installation of next lower shell course.
Check setting up of all jacks → Start the motor to begin lifting up → Check required lifting
height achieved in all directions → Install shell plates underneath the shell course already
installed → spot welding and fastening all shell plates → Lower the jacks → start welding
the shell plates.
Equipment for hydraulic jacking system shall be prepared inside the tank during the installation
of tank roof. Hydraulic jacking system shall be installed at the distance between the jacks shall
be installed 2.5m. (Supplier recommend the jacks shall not exceed 3.5m)
Circumference 125,600
Quantity of spacer (each 2.5m) 50
Total weight 658,919
Lifting weight
591,509
(except bottom and annular plate)
Hydro Jack Capacity (for each jack) 18,000
Installed Jack (for each tank) 43
Total Capacity 774,000
Ratio (Lifting Weight/Tatal Capacity) 76%
.
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Lifting lug shall be fitted to the tank shell inside at every position where a jack is to be installed
and consider installation of scaffolding location also. After the lifting operation the lifting lugs shall
be removed without damaging the base metal.
1 Foundation of 11 Lifting Lug

the Tank
2 Bottom Plate 12 Jack Rod of the

Lifting Trestle
3 Power Pack 13 Next Uppermost

Shell Ring
4 Oil Line of 14 Uppermost Shell

High-Pressure Ring
Hose
5 Lower Lug 15 Vertical Column of

Lifting
Trestle/Trestle Box
6 Stay Pipe 16 Sliding Chair
7 Base Plate for 17 Spacer Cum Guide

Trestle Box Beam
8 Hydraulic 18 Roof Beam

Climbing Jack
9 Fend-Off Lug 19 Roof Sheet
10 Lifting Arm 20 Manifold Block
< General Layout of Jacking Equipment>
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< Jacking System Main Components >
1 Trestle Base Plate 6 Elbow and Stop Cock Valve 11 Stay Pipe
2 Trestle Box 7 Sliding Chair 12 Upper Lug
3 Loading Point 8 Fend-Off Lug 13 Lower Lug
4 Jack 9 Lifting arm
5 Oil Hose 10 Lifting Lug
Power pack (20HP) shall be connected at the total system shall be checked for its readiness for
lifting of the shell.
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10.1.1 Step for installation of the 5th shell course as below
① Jacking up the 6th shell course and roof.
② Fit up the 5th course shell plates one by one with spot welding and fasten them with vertical
plate clamp. Fit up and align the shell plates in one direction till closing the shell course. A
crane will be used for lifting these shell plates.
③ Start the shell plates welding works as per sequence below

External Vertical joint welding (Manual) → Internal Vertical joint welding (Manual) →
External Horizontal joint welding (AGW. Automatic Girth Welding and Manual if required)
→ Internal Horizontal joint welding. (Manual)
④ Install the wind stiffener on the external face of 5 th shell course
⑤ Release pressure of jacking system and remove to 5th shell plate course
⑥ Jack up the 5th shell course after completion of welding, NDT and inspection.
⑦ Repeat the above steps for installation of 4th, 3rd, 2nd and 1st shell course.
⑧ Completion of shell – to bottom welding and installation correspond components on shell

plates
Be sure that the nozzles©location, orientation etc. are correct before and after
jack up for each shell course.
At the same time, all nozzle, skimming, handrail etc.. should be considered and installed on the
shell plate.
Item Installed Shell Course DWG

Upper Skimming 6th shell course 0279STX-0-ME-005-F01-0062,63
Lowwer Skimming 2nd shell course 0279STX-0-ME-005-F01-0062,63
Nozzle no.
6th shell course 0279STX-0-ME-005-F01-004~7
1,3,4,5,6,10,20,21,22
Nozzle no. 8 5th shell course 0279STX-0-ME-005-F01-004~7

Nozzle no. 11,23,24,25 2nd shell course 0279STX-0-ME-005-F01-004~7
Manhole no.1,2,3,4
1st shell course 0279STX-0-ME-005-F01-004~7
Nozzle no.7,9,14, K2
Internal piping installation shall be executed after shell plate installation completed except the
last piece shell plate hold for entry access. Material for internal piping shall be placed inside tank
before installing the last piece of 1st course shell plate. Connecting point shall be considered by
flange type to minimized welding point. Internal piping hyrotest shall be stated.
At only the 1st shell course, one piece of shell plate will not be installed until the hydraulic jack
and other construction equipment are being removed from the tank.
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The shell plate may be attached on the prior course to ensure the circumference and external
vertical joint welding may be carried out firstly with one box up plate hold. Then jack the prior
course and start the horizontal joint fit-up.
The revere side of double-welded butt joints shall be thoroughly cleaned in a manner that will
leave the exposed surface satisfactory for fusion of the weld metal to be added, prior to the
application of the first bead to the second side. After completion bottom sketch to annular plate
joint fit up, welding shall be carried out. Vacuum Box Test will be done and if any repair occurs
the same shall be repaired and retested as per approved procedure.
Plumbness of tank shell shall be inspected after completion of all shell welds. The out of
plumbness measured for shell top to bottom shall not exceed H/200 with a maximum of
50mm.(“ H” means the total height of the tank) ( as per API 650 paragraph 7.5.2)
Roundness of tank shell shall be inspected as per API 650 paragraph 7.5.3
Radii measured at 0.3m (300mm) above the bottom corner weld shall not exceed the
following tolerances
Radius Tolerance ± 13 mm for tank diameter range < 12 m
Radius Tolerance ± 19 mm for tank diameter range 12 to < 45 m
Radius Tolerance ± 25 mm for tank diameter range 45 to < 75 m
Plate misalignments shall not be corrected by grinding off plate thickness to reduce offset.
Hydro test duration, water quality etc. and acceptance criteria shall be stated acc.to
API650.
11.0 Hydro Test Measurements shall be taken by surveyor before and after hydrotest for tank
foundation settlement tolerance acc. to API650
Tank hydrotest will be carried out after inspection by STX on the completed tank installation. This
test shall be carried out as per separated method statement for tank hydro test.
12.0 SURFACE PREPARATION AND COATING
After successfully completion of the tank hydro test, surface preparation and coating of tank roof,
tank shell and other accessories will start. These works ill be carried out as per the approved
method statement for tank surface preparation and coating.
13.0 ATTACHMENTS
- RISK ASSESSMENT FOR TANK ERECTION

- TANK MATERIAL PACKING LIST
Page 26 of 26
STX RISK ASSESSMENT
Job Description: Risk Assessment for Tank Erection (Shell installation, Hot works, W@H, CSE) at PWRI Site
PPE Controls Physical Controls Permit to Work (PTW)
Safety Helmet √ Respirator Ventilation √ Lifting Work Permit
Safety Shoes √ Goggles √ Warning Signs √ Gas test √
Safety Glasses √ Face Shield √ Barricades √ Radiation Permit
Hearing Protection √ Safety Harness √ Gas monitor √ Toolbox talk √
Gloves √ Ear Plug √ Wind speed monitor √
FR Coverall √
Training needs to be obtained before work
Site induction All workers CSE All workers
PA STX/Subcontractor
W@H All workers
5. 8.
7. PERSON
RESPONSI
9. ALARP?
OR ROLE
INITIAL RISK RESIDUAL
1.
BLE
RISK
SUB-TASK No
2. SUB-TASK
3. HAZARD
ACTIVITY /
DESCRIPTION
DESCRIPTION 4. CONSEQUENCE 6. LIST ALL CONTROL MEASURES REQUIRED
Consequence/
Consequence/
Risk Rating
Risk Rating
probability
probability
Severity
Severity
1 Preparation of • Tool Box Talk to be organized with detailed explanation 5 Y
D 3 7 PA/ D 2
work area • Trip/Slip/fall • Injury. for the job.
HSE/All
• Property • Only authorized personnel are allowed to work. staff
• High Noise damage. • Proper barricading with safety signages
• Fire. • It should be ensured all workers have proper and
• Manual adequate PPE as well as specific PPE for welding and
Handling grinding such as Welding glove, welding mask, face
shield, ear plug etc.
• Make sure working area free from obstacle, proper
material arrangement, pay attention and assess the work
area for potential hazards on the ground.
• Suitable, slip-resistant footwear to be worn.
• Avoid rushing, shortcuts while working and moving on
task
• Good housekeeping around the work area.
• If you have a spill, clean it up immediately.
Date: 22/05/2022
Document Title: Risk Assessment for Tank Erection (Shell installation, Welding,
Grinding, W@H, CSE) at PWRI Site Page: 2 /7
5. 8.
7. PERSON
RESPONSI
9. ALARP?
OR ROLE
1.
BLE
RISK
SUB-TASK No
2. SUB-TASK
3. HAZARD
ACTIVITY /
DESCRIPTION
Consequence/
Consequence/
Risk Rating
Risk Rating
probability
probability
Severity
Severity
• Weight of load to be checked before manual lifting – trial
lift.
• Try lifting one corner, if it’s too heavy use second person
or other means (Mechanical) to lift item.
• Proper manual lifting techniques. Use of more than one
person to lift
• Consider dual manual lifting (general rule of thumb if
above 25 kg).
• Regular breaks should be taken.
• Load to be carried close to body at waist height.
• Check the route first before lifting.
• Correct manual lifting techniques to be used at all times
e.g., lifting using legs with load held close to your body,
take a firm grip, maintain straight back, turn body not
twisting upper body and avoid overreaching.
• Make sure you can see over the load.
• Try to push the load rather than pull.
• Use leg muscles as much as possible.
2 Welding and • Flying • Injury • Never stand in line of sparks when cutting or grinding. 6 Y
B 3 9 PA\All C 2
grinding particles • Electic shock • Always ensure correct disc for cutting/grinding. Ensure staff
• uncovered • Electocution correct rated speed in accordance between disc and
rotating parts. • Burns grinder.
• Sparks /fire • Fatality • Ensure that the specific disc is not used for a task not
• Electric arc • Property intended or designed for.
• Fatigue damage • Never force grinder whilst cutting or grinding.
• Fumes • Health issues • Check the equipment before use
• Ergonomics with Inhalation • Face shield shall be worn during work and correctly used
• A fire extinguisher should always be readily available.
Date: 22/05/2022
5. 8.
7. PERSON
RESPONSI
9. ALARP?
OR ROLE
1.
BLE
RISK
SUB-TASK No
2. SUB-TASK
3. HAZARD
ACTIVITY /
DESCRIPTION
Consequence/
Consequence/
Risk Rating
Risk Rating
probability
probability
Severity
Severity
• Hot surfaces • fire • Remove flammables materials or object before work
• Pinch point start.
• Heat stress • Use the fire blanket, and fire blanket must available on
site
• Fire extinguisher shall standby work area and fire watch
man shall standby work site
• Close supervision to ensure the welder to wear the eye
protection equipment while welding.
• The welder shall wear welding face cover
• Wear Rubber sole boots and gloves to avoid electric
shock.
• Grounding (earthing) cable should be connected directly
to the piece being welded.
• Ensure regular rest breaks are taken by employees.
• Welders should change positions and postures for
welding at times.
• Preventing to touch the welding surface.
• Take a 10m break every 30m work and drink sufficient
amount of water.
• PA shall be present at all times.
• Properly shaded and ventilated rest areas shall be on site.
• PPE is needed to avoid getting injured.
• Visual inspection of cables, plugs and electrical
equipment prior to work commencement
• Inspection of welding machines with valid tag on them
Date: 22/05/2022
5. 8.
7. PERSON
RESPONSI
9. ALARP?
OR ROLE
1.
BLE
RISK
SUB-TASK No
2. SUB-TASK
3. HAZARD
ACTIVITY /
DESCRIPTION
Consequence/
Consequence/
Risk Rating
Risk Rating
probability
probability
Severity
Severity
3 Working at height • Acess/ Egress • Injry and fatality D 3 7 • All man-lift/scissor-lift shall be inspected by PA/OA/ D 2 5 Y
• Falling objects • Slipping and STX with Vailed ATO prior to mobilize to work Staff
• Falling of people tripping site.
• All man-lift/scissor-lift to be moved on work
site shall be monitored by banksman.
• Personnel working at height to attend Working
at height (WAH) training course
• Tools shall be handled and/or secured to prevent
falling. When not in use the tools should be
placed in a secure container
• Workers must wear safety body harness and tie
off 100% while working 1.8 meters and above.
• Inspect the safety harness before commencing
the activity.
• Reduce numbers of personnel under work at
height, barriers restricting entry shall be put in
place below the worksite.
• Do not allow potential dropped objects to
accumulate
• Inspect the access/ egress to be in safe and good
condition
• PA shall be present at all times.
• Post Safety signage to inform personnel of
WAH requirements
Date: 22/05/2022
5. 8.
7. PERSON
RESPONSI
9. ALARP?
OR ROLE
1.
BLE
RISK
SUB-TASK No
2. SUB-TASK
3. HAZARD
ACTIVITY /
DESCRIPTION
Consequence/
Consequence/
Risk Rating
Risk Rating
probability
probability
Severity
Severity
4 Confined Space Entry • Access/ Egress • Slipping and B 3 10 • Proper access and egress shall be prepared for PA/OA/ B 2 7 Y
• Poor Lighting tripping the confined space. Staff
• Poor venilation • Fisrt aid cases • Proper lighting, if needed, shall be installed
• Toxic and fatalities.
prior to work commencement.
environment • Suffocation
• A competent and qualified rescue team shall be
• Oxygen • Intoxication
deficiency
valid on site at all time.
• Slippery surface • A competent and authorized first aider shall be
present o site with all the needed equipment for
first aiding.
• A standby man shall be present with an entry log
sheet to record peoples’ access and to inform the
PA in cases of injury and fires.
• PA shall be present at all times
• Proper ventilation for the confined space area.
Fans for air inlet and outlet shall be installed.
• Gas test, if needed, shall be conducted by a
competent certified (LV1) Authorized Gas
Tester.
• Proper PPE shall be worn.
• Radio communication shall be set up between
watch man and P.A
5 Positioning the shell • Unstable position • Injury and B 3 9 • Proper support shall be installed for the plate to PA/OA/ B 2 7 N
plates for the shell plate. fatality. prevent it from toppling over nearby people and Staff
• Poor support • Hand injury equipment.
during the • Property • The plates shall be properly positioned in the
installation of the damage.
plate.
guide fixtures.
• Handling Heavy • PA shall be present at site at all time.
weight plates • Proper PPE (e.g., Gloves, helmets and safety
• Poor supervision shoes) shall be worn at all times.
Date: 22/05/2022
5. 8.
7. PERSON
RESPONSI
9. ALARP?
OR ROLE
1.
BLE
RISK
SUB-TASK No
2. SUB-TASK
3. HAZARD
ACTIVITY /
DESCRIPTION
Consequence/
Consequence/
Risk Rating
Risk Rating
probability
probability
Severity
Severity
from PA • Proper bracing supports to secure the plates in
vertical and safe position
6 The use of hydraulic • Uncerified • Injury and B 3 9 • TBT shall be conducted on a daily basis. PA/OA/ B 2 7
jack systems equipment in use fatality. • All hydraulic equipment shall be 3rd party. Staff
• High prssure • Equipment Certified by ROO approved companies.
hydraulic failure.
• Only competent and trained personnel shall
• Suspension and • Skin irritation
lifting of tank due to direct
conduct the job.
contact with • Hydraulic jacks shall be properly positioned in a
hydraulick way that prevents falling.
liquids. • Daily visual inspection shall be conducted.
• Collapsing of • Equipment shall be free from leaks.
the tank • Propper PPE shall be worn.
Structure
• Material damage
Date: 22/05/2022
Risk Assessment Work Team Sign-on/ Review Register

Prepared
by:
Ali Mahmood Company STX Position HSE Supervisor Signature Date 22/05/2022
Reviewed
by:
Rasoul Mokhtari Company STX Position HSE Manager Signature Date 23/05/2022
Approved
Company Position Signature Date
by:
PACKING DETAILS OF GOODS
PKG TAG/ PACKAGE DIMENSIONS Gross Weight
PKG Descriptions PKG No. Kind of Packing Length Width Height Required Crane Lay Down Location
Serial No. (KG)
(CM) (CM) (CM)
3-1-1 WOODEN BOX 1 OF 5 110 110 100 1,294.40 Crane 50 ton Camp Yard
Bolt,Nut,Washer 3-1-3 WOODEN BOX 3 OF 5 110 110 100 1,668.30 Crane 50 ton Camp Yard
Bolt,Nut,Washer 3-2-1 WOODEN BOX 1 OF 1 80 80 60 600.00 Crane 50 ton Camp Yard
Gasket 3-3-1 WOODEN BOX 1 OF 1 160 130 55 45.00 Crane 50 ton Camp Yard
Hatch Cover 3-4-1 WOODEN BOX 1 OF 1 107 227 50 530.00 Crane 50 ton Camp Yard
T1 Annular plate 3-5-1 WOODEN BUNDLE 1 OF 48 785 200 60 18,271.60 Crane 100 ton PWT Yard
T1 Bottom plate 3-5-2 WOODEN BUNDLE 2 OF 48 920 275 55 22,200.00 Crane 100 ton PWT Yard
T1 Shell plate s1 3-5-6 WOODEN BUNDLE 6 OF 48 900 290 65 21,416.61 Crane 100 ton Camp Yard
T1 Shell plate s1,2 3-5-9 WOODEN BUNDLE 9 OF 48 900 290 65 22,578.65 Crane 100 ton Camp Yard
T1 Comp. Ring, s7 3-5-19 WOODEN BUNDLE 19 OF 48 900 120 90 15,689.90 Crane 100 ton Camp Yard
T1 Roof plate r1 3-5-21 WOODEN BUNDLE 21 OF 48 co 275 55 23,425.00 Crane 100 ton Camp Yard
T1 Roof plate r1 3-5-22 WOODEN BUNDLE 22 OF 48 920 275 55 22,200.00 Crane 100 ton Camp Yard
T1 Roof plate r2-20 3-5-23 WOODEN BUNDLE 23 OF 48 920 275 55 22,064.40 Crane 100 ton Camp Yard
T1 RF Comp, Ring plate 3-5-24 WOODEN BUNDLE 24 OF 48 790 100 60 19,103.60 Crane 100 ton Camp Yard
T2 Annular plate 3-5-25 WOODEN BUNDLE 25 OF 48 785 200 60 18,271.60 Crane 100 ton PWT Yard
T2 Roof plate r2-20 3-5-47 WOODEN BUNDLE 47 OF 48 920 275 55 22,064.40 Crane 100 ton Camp Yard
T2 RF Comp, Ring plate 3-5-48 WOODEN BUNDLE 48 OF 48 790 100 60 19,103.60 Crane 100 ton Camp Yard
T1 Stiffener ring plate 4-1-1 WOODEN PALLET 1 OF 4 720 100 57 896.10 Crane 50 ton Camp Yard
T2 Stiffener ring plate 4-1-2 WOODEN PALLET 2 OF 4 720 100 57 2,514.20 Crane 50 ton Camp Yard
T1 Nozzle, support 4-1-3 WOODEN BOX 3 OF 4 270 200 135 10,610.50 Crane 50 ton ,R=8M Camp Yard
T2 Nozzle, support 4-1-4 WOODEN BOX 4 OF 4 270 200 135 510.30 Crane 50 ton Camp Yard
5-1-1 WOODEN BOX 1 OF 48 130 130 110 130.20 Crane 50 ton Camp Yard
5-1-4 WOODEN BUNDLE 4 OF 48 975 120 77 360.40 Crane 50 ton Camp Yard
PACKING DETAILS OF GOODS
PKG TAG/ PACKAGE DIMENSIONS Gross Weight
PKG Descriptions PKG No. Kind of Packing Length Width Height Required Crane Lay Down Location
Serial No. (KG)
(CM) (CM) (CM)
Support, Truss, Nozzle

0279STX N WM PW01 CM MET 0003 A02 - Comments

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RUMAILA PROJECT

Document NR PWRI PHASE 1 – METHOD STATEMENT FOR INLET TANK

ENGINEERING, PROCUREMENT AND CONSTRUCTION FOR THE

Contractor: Sae-A STX Entech Co., Ltd.

REVISION DESCRIPTION SHEET

2.0 DEFINITIONS AND ABBREVIATIONS ....................................................................................... 5

3.0 REFERENCE DOCUMENTATIONS ............................................................................................. 6

4.0 LIFTING AND RISK ASSESSMENT PLANS ............................................................................ 6

5.0 Tank Material Laydown Plan. ........................................................................................................ 7

6.0 SEQUENCE OF TANK ERECTION ACTIVITIES .................................................................... 8

7.0 METHOD STATEMENT...................................................................................................................... 9

7.1 Bottom & Annular Plate Erection ..................................................................................................... 9

7.1.1 Annular Plate Erection. ........................................................................................................................ 9

7.1.2 Bottom Plate Erection. ...................................................................................................................... 11

7.2 Installation of Normal & Emergency Access Point. ............................................................... 13

8.1 Install Spacer for Supporting Shell Plates. ............................................................................... 15

8.2 6th&7th Shell Plate Installation & Welding. .............................................................................. 16

8.2.1 6th Shell Plate Installation & Welding......................................................................................... 16

8.2.2 7th Shell Plate Installation & Welding......................................................................................... 17

9.0 TANK ROOF INSTALLATION...................................................................................................... 17

9.1 Compression Ring Installation ....................................................................................................... 17

9.2 Assembling and installation of roof truss ................................................................................... 18

9.3 Assembling and installation of roof plate. ................................................................................. 20

9.3.1 Access and Safety .............................................................................................................................. 21

9.3.2 Roof plate installation........................................................................................................................ 22

9.3.3 Roof accessories installation. ........................................................................................................ 22

10.0 REMAIN SHELL PLATE INSTALLATION (W/ HYDRAULIC JACKING MACHINE)

10.1 Setting up Hydraulic jacking ........................................................................................................... 22

11.0 Hydro Test ............................................................................................................................................ 26

12.0 SURFACE PREPARATION AND COATING ......................................................................... 26

13.0 ATTACHMENTS ................................................................................................................................. 26

2.0 DEFINITIONS AND ABBREVIATIONS

ENGINEERING, PROCUREMENT AND CONSTRUCTION FOR THE

COMPANY Rumaila Operating Organisation (ROO)

CONTRACTOR Sea-A STX Entech Co., Ltd.

API American Petroleum Institute

ROO Rumaila Operating Organisation

CONTRACTOR Sea-A STX Entech Co., Ltd.

PPE Personal Protective Equipment

ITP Inspection Test Plan

HSE Health Safety and Environment

3.0 REFERENCE DOCUMENTATIONS

No Doc. Number Doc. Title

1 API 650 Welded Tank for Oil Storage

3 0279STX-0-ME-005-B01-0001 General Assembly DWG for Inlet Tank

4 0279STX-0-ME-005-F001~121 Detail Drawing for Inlet Tank

5 0279STX-N-WM-PW01-CM-PLN-0001 Construction Execution Plan

6 0279STX-N-WM-PW01-HS-PRO-0025 Lifting Operations Procedure

7 0279STX-N-WM-PW01-QA-ITP-0001 Construction Inspection &Test Plan

4.0 LIFTING AND RISK ASSESSMENT PLANS

5.0 Tank Material Laydown Plan.

Support for Flate Bottom and Roof Plate

6.0 SEQUENCE OF TANK ERECTION ACTIVITIES

Detail the methodology for roof-level

When are internal accessories

7.0 METHOD STATEMENT

7.1 Bottom & Annular Plate Erection

[Figure 1. Lines to be marked prior to laying bottom plates]

Details how lifting of the

<example of fit-up gear and tools>

7.1.2 Bottom Plate Erection.

Lay the canter plate on the foundation as shown in Figure 2.

[Figure 2. Sequence of laying out Annular and Bottom plates]