Essar Method Statement.pdf

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

Company Job No.

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 1 of 20

Rev.

KNPC Al-Zour Refinery Project EPC # 4

METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

O Rev.

Issue for approval Description Descriptio n

Tej

Willem

Vijay

19/03/16

Prepared

Checked

Appro pprove ved d

Date

This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

Company Job No.

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 2 of 20

Rev.

HOLDS Pos.

Sheet

Paragraph

Description

This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

Company Job No.

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 3 of 20

Rev.

TABLE OF CONTENTS 1

INTRODUCTION

4

1.1

Purpose of the Document

4

1.2

Scope of Application

4

1.3

Project Description

4

1.4

Project Objectives

5

2

PROJECT DESCRIPTION, DEFINITIONS AND ABBREVIATIONS 2.1

3

Document specific definition and abbreviation

REFERENCES

6 6 6

3.1

Company’s Specifications and Standards

6

3.2

External References

6

4

SEQUENCE OF ACTIVITIES

7

5

RECEIPT OF MATERIAL AT SITE

8

6

FABRICATION ACTIVITIES

8

7

ERECTION ACTIVITIES

13

8

INSPECTION, TESTING AND DOCUMENTATION DOCUMENTATION

17

9

TOOLS AND EQUIPMENT

17

10

RESPONSIBILITIES

18

11

HEALTH, SAFETY, SECURITY AND ENVIRONMENT (HSSE) MANAGEMENT MANAGEMENT

19

12  ATTACHMENT  ATTACHMENT - I

This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

20

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

1

Company Job No.

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 4 of 20

Rev.

INTRODUCTION

1.1 Purpose of the Document This document defines how CONTRACTOR approaches Tank Construction activities, describing methodology, methodology, roles, responsibilities, responsibilities, activities, tools and outputs. The purpose of this document is to have an appropriate methodology to carry out the construction activities of External Floating Roof Tanks in an appropriate progression. 1.2 Scope of Application This method statement illustrates comprehensive activities and guidelines for carrying out the Fabrication, Erection, Inspection, NDT, Hydro Static Test, Blasting & Painting and Insulation activities of External Floating Roof Tanks The activities described in this document will be applied to the Project KNPC Al-Zour Refinery Project EPC # 0059. 1.3 Project Description The Project consists of the EPC - Engineering, Engineering, Procurement, Construction, Pre-Commissioning Pre-Commissioning and  Assistance during Commissioni Commissioning/Start-Up/Performance ng/Start-Up/Performance testing testing of “KNPC Al-Zour Al-Zour Refinery Project EPC # 0059”, 0059”, in Kuwait. The scope of EPC#0059 includes includes Tankages (no. 66 tanks) and related facilities. The plant includes Storage Unit (Unit 67), Plant Fuel Oil and Slop Tankage (Unit 69), Water System (Unit 62), EICSS, ICSS, Access Road and bridges (Unit 77), OHL, Building and inter refinery Pipeline including Construction infrastructures. Laydown area peripheral road also included. The Water System (Unit 62) include No. 2 Firewater F irewater tanks (cone type) capacity 25,000 m3 working volume each and Fire water pumps and biocide injection system. The tankage facilities (Unit 67) planned for the New Refinery include No. 16 cone roof tanks, 38 floating roof tanks as per the following split: 

Crude Tankage (No. 5 tanks);

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Intermediate Product Storage (No. 13tanks);

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Finished Product Storage (No. 35 tanks);

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MDFI Storage tank (no. 1 tank).

The function of crude tankage is to r eceive pipeline crude from KOC and store it before transferring to the Crude Distillation Units. There are two (2) inter-refinery inter- refinery transfer pipelines 18” and 14” (Unit This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

Company Job No.

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 5 of 20

Rev.

84) carrying LSD and LSFO to AL-ZOUR Power Station. The storage area receives, stores, and transfers feed, intermediate and product streams from source units to the process units, ship loading facilities or pipe line. The plant Fuel Oil and slop Tankage planned for the New Refinery (Unit 69) include the following systems: Flushing Oil System (continuous and intermittent): intermitt ent): ULSD is used for continuous flushing and raw diesel is used for intermittent flushing.( (No. 2 cone roof tanks);

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Plant Fuel Oil system to be used by boilers, CDU CDU furnaces furnaces and ARDS ARDS Fractionator Fractionator furnaces. furnaces. (No. 2 cone roof tanks);

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Slop System: (No. 4 tanks floating roof) Slop from OSBL and Process Units. Units. Dry slop is sent to the CDU for processing processing o Wet Slop from Waste Water Treatment and Process Process Units. Dewatered Dewatered slop is sent to the o Dry Slop Tank. Oily water from the tank is sent to Sour Water Stripper Units

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ARDS Flushing Diesel System (No 2 tanks cone roof).

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 Auxiliary equipment for f or Unit 69 includes one chemical injection system, the Demulsifier Demulsifier Injection System. Demulsifier is provided to break any emulsions emulsions within the wet slop. New access roads and bridges (Unit 77) are also planned to connect laydown area located west of HW40 with Al Zour site. Three new roads are to be constructed along with bridges No 3 and Intersection 8 No. The pr oject oject is known as “KNPC “ KNPC Al-Zour Refinery Project EPC # 0059”. 0059 ”.

1.4

Project Objectives Project success is often measured in terms of achieving certain project performance objectives. objectives. It is essential that specific project performance objectives objectives are identified and the means by which they can be achieved are considered; if this is achieved a sound basis for effective project risk management management is created. The following Project objectives have been established: established:  

Operational Completion of EPC CONTRACTOR CONTRACTO R work package 0059 within the budgets and schedules o agreed to in the Contract agreement. agreement.

 

Quality

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This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

o

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Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 6 of 20

Rev.

Completion of EPC CONTRACTOR work package 0059 to the quality requirements agreed to in the Contract agreement. agreement.

Safety and Environment Environment o o

2

Company Job No.

Completion of the ZOR with with a zero lost time injury rate; and Completion of the ZOR with < 10 reportable environmental incidents.

PROJECT DESCRIPTION, DEFINITIONS AND ABBREVIATIONS ABBREVIATIONS Project description, definition and abbreviation are reported in Project Specification Doc. No. 00-ZA-E-09003-001.

2.1

Document specific definition and abbreviation

3 REFERENCES The following documents are to be considered as references for this document: 3.1

Company’s Specifications and Standards [1] Approved drawings.

3.2

External References [2] API 650 latest edition. edition.

This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

Company Job No.

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 7 of 20

Rev.

4 SEQUENCE OF ACTIVITIES 

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Material receiving, storage and inspection inspectio n of incoming material to be carried out for all the project material (plates, structure, etc) prior to use. Fabrication of Annular Plates Plates (at Fabrication Yard in TCF) followed followed by underside Blasting Blasting and primer application (at Blast/Paint shop in TCF) Fabrication Fabricat ion of Bottom Plate (at Fabrication Fabricatio n Yard in TCF) followed by underside Blasting and primer application. (at Blast/Paint shop in TCF) Fabrication of Primary Primary Wind Girder Girder and Accessories Accessories followed by fit up and welding welding in sections (at Fabrication Yard in TCF). Fabrication of tank bottom bottom sump followed with with fit-up, welding, NDT, blasting and and painting (at Fabrication Yard in TCF). Fabrication of shell shell plates of required required shell course course with respect to the type type of construction method method (at Fabrication Yard in TCF).

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Rolling for shell plates (at Fabrication Yard in TCF).

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Blasting & Primer application application of of shell plates and Inspection Inspection (at Blast/Paint Blast/Paint shop in TCF).

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Erection, Fit-up, Fit-up, Welding Welding & NDT of of Annular plates.

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Erection, Fit-up, Welding & NDT of Bottom Plates Plates progressively. progressively. Marking of tank diameter diameter on Shell Shell plates shall commence once Annular plates welding & NDT is completed. Erection of shell plates of of respective shell courses on annular annular plates followed followed by fit up, welding and NDT of vertical seam, corner & horizontal seam. Fabrication of 1st shell shell course including including nozzles, nozzles, Manholes Manholes and other attachments attachments for tanks being being constructed. (at Fabrication Yard in TCF) Fit up and welding welding of Nozzles/Manholes Nozzles/Manholes/Other /Other attachments on 1st 1st Shell course followed by PWHT for tank (wherever specified as per applicable Codes & Standards and drawings). Erection of working platform platform as required. required. Primary wind wind girder can be utilized for working platform platform for outside tank shell. Erection of shell plates for respective shell courses shall be continued till completion of all shell courses. Fabrication of structures structures for Spiral Stairway, Stairway, Foam & Cooling System, System, curb angle, compression compression ring and associated piping progressively.

This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

Company Job No.

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 8 of 20

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Fit up, welding & NDT of Curb Curb angle

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Fit-up, Welding Welding & NDT NDT of Annular Annular plate to bottom Sketch plate. plate.

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Rev.

Erection, fit up and welding welding of Roof (Deck) Plates. Plates. Deck plates shall commence after after welding of of bottom plates is reasonably reasonably completed.

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Erection, fit-up, welding welding and and NDT of tank internals.

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Erection, Fit-up, Welding Welding & NDT of Foam & Cooling Cooling System and and its associated associated Piping.

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Fit-up, Welding Welding & NDT NDT of structures structures for Foam Foam & Cooling Cooling System. System.

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Fit-up, Welding & NDT NDT of tank accessories. accessories.

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Clearance for hydro testing.

5 METHODOLOGY 5.1 RECEIPT OF MATERIAL MATERIAL AT AT SITE 

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6

All Materials shall be as per applicable codes and standards. All material received at site has to be verified before starting the job. The type of inspection required as per approved QA/QC documents shall be carried out. All materials shall be checked, sorted and arranged by type, grade and dimension in storage area.

FABRICATION ACTIVITIES

6.1 Material identification, verification and marking marking 

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All materials materials received received at site site shall carry physical physical inspection inspection / document document review review identification identification by CONTRACTOR QA/QC before starting of the job by producing relevant MTC and preparing incoming material inspection. Marking, tolerance requirements and techniques shall be in accordance with the relevant engineering drawings drawings / applicable applicable standards and codes.

6.2 Fabrication of Annular Annular Plates and Bottom Plates . After acceptance of the material, plates shall be spread over wooden sleeper/channel. sleeper/ch annel. Cranes shall be used for executing material identification and trailer shall be used for transporting and shifting of plate materials. 

This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

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Company Job No.

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 9 of 20

Rev.

Marking shall shall be done after after identification identification of the plate material in in accordance accordance with with the approved approved drawings. Field/cutting allowance shall be maintained wherever required. Tank no, Mark No, Heat No. shall be transferred to each component. While marking of annular plates, suitable templates/layout shall be used. Such templates shall be prevented from damage and shall be checked for correctness of the profile before utilizing for marking. After marking marking and identification is completed, completed, cutting/edge cutting/edge preparation preparation shall shall be made by pug cutting machine using oxygen and acetylene gases with all safety precautions. After completion completion of cutting/edge preparation, preparation, the cut edges shall shall be grinded off smooth prior to fitment at shop/field. Tack welding shall be done where applicable by the qualified tack welders and as per the approved WPS/PQR. Fabricated Plates Plates shall be stacked properly properly tank tank wise with with tank no. display display board for easy easy identification.

6.3 Fabrication of Shell Plates 

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After acceptance of the material, plates shall be spread over wooden sleeper/channel. sleeper/ch annel. Cranes shall be used for executing material identification and trailer shall be used for transporting and shifting of plate materials. The shell shell plates plates shall shall be be first stamp transferred, squared, marked & identified. identified. Cutting and beveling shall be done by pug cutting machine using oxygen and acetylene gases and care shall be taken to ensure that the required degree of beveling is being done as per the approved engineering drawing.

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The plates shall be shifted to rolling rolling area with help help of of crane, tractor-trailer.

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Plates shall be rolled rolled to the the required radius as specified in the approved engineering engineering drawing. drawing.

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The rolled rolled radius/curvature radius/curvature shall shall be checked for correctness correctness of rolling by using using templates. templates.

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Grind the cut edges edges smooth to remove remove burrs and slags.

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Saddles with necessary curvatures shall be kept under bottom most plates of a stack and adequate wooden packing between plates are provided to ensure that proper curvature of the rolled plate is maintained.

This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

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

Company Job No.

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 10 of 10 of 20

Rev.

Fabricated shell plates shall shall be shifted to blasting/painting blasting/painting yard yard for blasting blasting and primer primer application before dispatching to site for erection. Shell plates plates (marking) (marking) to be checked checked for individual individual shell courses prior prior to erection. Fabricated Plates Plates shall shall be stacked properly properly with tag no. Tag no. shall shall consist consist of Part/ Part/ Mark no., Tank no. etc. All fabricated Plates shall be stacked with a display board with tank no. on it for easy identification.

6.4 Fabrication of Roof (deck) (deck) plates and attachment, attachment, compartment plate, plate, foam dam plate, rim plate. 

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After acceptance of the material, plates shall be spread over wooden sleeper/channel. sleeper/ch annel. Cranes shall be used for executing material identification and trailer shall be used for transporting and shifting of plate materials. Marking shall shall be done after after identification identification of the plate material in in accordance accordance with with the approved approved drawings. Field/cutting allowance shall be maintained wherever required. Tank no, Mark No, Heat No. shall be transferred to each component. After marking marking and identification is completed, completed, cutting/edge preparation shall be be made by hand hand cutting/pug cutting machine using oxygen and acetylene gases with all safety precautions. After completion completion of cutting/edge preparation, preparation, the cut edges shall shall be grinded off smooth smooth prior prior to fitment at shop/field. Tack welding shall be done where applicable by the qualified tack welders and as per the approved WPS/PQR. All materials whether loose or prefabricated prefabricat ed shall be stored in a manner that will prevent any deterioration from debris, grease or any other f oreign matter. Fabricated Plates Plates shall shall be stacked properly properly with tag no. Tag no. shall shall consist consist of Part/ Part/ Mark no., Tank no. etc. All fabricated Plates shall be stacked with a display board with tank no. on it for easy identification.

6.5 Fabrication of Wind Girders and other Attachments. Attachments. 

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After acceptance acceptance of the materials materials (plates/Angles), (plates/Angles), shall be spread over over wooden wooden sleeper/channel sleeper/channel blocks. Cranes shall be used for executing material identification and trailer shall be used for transporting and shifting of plate materials. Marking shall be done after identification identification of the the materials in accordance accordance with the approved drawings. Field/cutting allowance shall be maintained wherever required. Tank no, Mark No, Heat No. shall be transferred to each component.

This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

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Company Job No.

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 11 of 11 of 20

Rev.

While marking, marking, suitable suitable templates/layou templates/layoutt shall be used. Such templates templates shall shall be prevented from damage and shall be checked for correctness of the profile before utilizing for marking. After marking, cutting & beveling shall be done by hand cutting/pug cutting using oxygen and acetylene gases cutting method and care shall be taken to ensure that the required degree of beveling is being maintained as per the approved engineering drawing. After completion completion of cutting/edge preparation, preparation, the cut edges edges shall shall be grinded off smooth prior to fitment at shop/field. Tack welding shall be done where applicable by the qualified tack welders and as per the approved WPS/PQR. Fabricated material material shall shall be stacked properly properly with with Tag no. no. and shall shall consist consist of Part/ Part/ Mark no., no., Tank no. etc. All fabricated Plates shall be stacked with a display board with tank no. on it for easy identification.

6.6 Fabrication of Structural Structural Items (pipe supports, ladders, ladders, stairways & platform, handrails, compartment box structure and stiffeners) 

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After acceptance of the materials (plates/Angles), shall be spread over wooden sleeper/channel. sleeper/ch annel. Cranes shall be used for executing material identification and trailer shall be used for transporting and shifting of plate materials. Tack welding shall be done where applicable by the qualified tack welders and as per the approved WPS/PQR before shop painting. Fabricated materials materials shall shall be stacked properly properly with Tag no. and and shall consist of of Part/ Mark Mark no., Tank no. etc. All fabricated Plates shall be stacked with a display board with tank no. on it for easy identification. identification .

6.7 Fabrication of Shell and and Roof Appurtenances Appurtenances (Sump Nozzles, Nozzles, Vents, RF Pads, Manholes and other Openings, Leg Supports) 

After inspection/acceptan inspection/acceptance ce of the material, material, components components shall shall be spread over wooden wooden sleeper.

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Marking of the components shall be done as per approved drawings.

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Cutting operation operation shall shall be carried out out after getting clearance clearance from Inspection Inspection Engineer. Engineer. All cutting operation including beveling shall be carried out using oxygen and acetylene gases cutting for ensuring good surface finish. Grinding shall be done done to remove remove burrs and and slags slags of the cutting edges.

This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

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Company Job No.

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 12 of 12 of 20

Face of the flanges shall be covered with suitable cover to protect the same from any damage during handling / transportation / fabrication. All the shell & roof fittings fittings and internals comprising comprising pipes (forged (forged or fabricated) and and flanges flanges shall shall be fabricated as per the approved drawing and the flange to pipe joints shall be completed (wherever applicable). Nozzles, which have flanges shall be prefabricated prefabricat ed and all NDT on flanges to Nozzle pipe shall be completed before erection. Marking of all all Nozzles Nozzles locations shall be done done as as per per approved approved drawings. All nozzles shall be fixed progressively along with the completion of roof, nozzles shall be set as as per orientation and elevation given in individual detail drawings for each nozzle. Mark and cut the openings in the roof plates plates as detailed in individual individual nozzle drawings. While setting setting the Nozzles, Nozzles, care care shall be taken to straddle straddle the holes off off center unless otherwise specified in drawings.

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All shell/roof shell/roof nozzles nozzles shall shall be marked on the plates plates as per the drawings.

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Openings shall be made only after getting getting the inspection inspection clearance.

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Rev.

Suitable jigs jigs and fixtures shall be used during marking marking / cutting cutting / alignment alignment / fabrication of of the above items. Tack welds shall be ground smooth smooth and also also confirm the tack welds welds are sound and there are no defects like cracks and porosity etc. After completion of welding for shell openings, PWHT shall be carried out as per the approved procedure for the shell openings if required as per the drawings and code/standard.

6.8 Inspection and testing at fabrication fabrication yard 

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All inspection inspection and testing shall be carried out in accordance accordance with the approved ITP, relevant codes and requirements of the drawings drawings and specifications. All welding welding work work shall be carried carried out out as per the approved Welding Procedure Procedure Specifications. Specifications. Welders shall shall be assigned an identification identification code code prior to undertaking undertaking any tests. This test nos. nos. shall be allocated to each test piece and stamped on the specimen. All test documentation shall be with reference to this test no. and identification cards shall be issued for each welder with the test No. for identity purpose.

This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

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7

Company Job No.

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 13 of 13 of 20

Rev.

All inspection inspection activities shall be recorded recorded in respective approved formats. Wherever changes changes required required shall shall be made during during the course of of execution of the job. job. The same same shall be submitted to COMPANY/PMC for review and approval purpose and on approval the same shall be recorded for AS BUILT records.

ERECTION ACTIVITIES

Tank Bottom plate erection 

All the Fabricated, Fabricate d, Blasted, Painted plates / structural structura l items and rolled shell plates shall be transported to the laydown area, adjacent to the respective tanks progressively.

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Check the level of top of the foundation of the tank and and slope. slope.

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Erect the Centre bottom plate plate and transfer the center point of of the tank on it.

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Lay Annular plates along the periphery of the tank taking reference from Centre point marked on bottom plate placed at the center of the t ank. Fit up, welding and NDT of of alternate joints of Annular plates followed by remaining joints progressively. progressively. Erection Erectio n of bottom plates shall be carried out starting from Centre to outwards. After Completion of Bottom Plates erection, Fit up & Welding of bottom plates (Lap joints) will be carried out. Temporary stiffeners will be fixed on the bottom plates at the time of welding to prevent any buckling occurred during welding. Erection of tank tank bottom sump in sequence with the tank tank bottom bottom plate erection. In parallel Shell erection erection shall shall be carried carried out while erection erection and welding of bottom plates are are in progress either by jacking method or by conventional method of construction.

Shell Erection of tank by Jacking method 

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All the Fabricated, Fabricate d, Blasted, Painted plates / structural structura l items and rolled shell plates shall be transported to the laydown area, adjacent to the respective tanks progressively. progressively. Erection Chairs Chairs / Stools shall be fixing on marked diameter diameter on Annular plate. Working platform by means of scaffolding wherever required shall be provided for carrying out the erection, fit-up, welding and inspection activities. activities. Shell course course plates (2nd from the top most/penultimate) shall be erected on the fixed fixed erection erection chairs/ stools.

This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

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Company Job No.

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 14 of 14 of 20

Fit up and welding of vertical vertical joints of Shell Shell course (2 nd from the top most/penultimate) shall be carried out. After completion completion of welding welding of of all the vertical joints of Shell Shell course (2 nd  from the top most/penultimate), next Shell course (1 st from the top most/top shell course plate) plates shall be erected. Alignment, fit up & welding welding of vertical joints joints shall be completed, completed, followed followed by fit up and welding of horizontal joints. After complete complete welding welding of all all the vertical vertical joints joints and horizontal joint, NDT shall be carried out as per ITP. Curb angle shall be erected on the top most shell course plates by using suitable capacity crane, followed by alignment , fit up, and welding. welding. Erection, Erectio n, fit-up, welding welding and NDT of primary wind girder along with handrail, structures progressively Erection, fit-up, welding welding and NDT of spiral spiral stairways progressively. progressively. Subsequently Subsequent ly temporary jacking arrangements activities shall be carried out by welding jacking cleats, base plates followed by erection of trussles, jacking arms etc. Power pack will will be placed at the side of the tank and will be connected with the jacks through high pressure hoses. Further subsequent subsequent shell shell courses courses from from top to bottom (descending order) to be erection followed with fit-up, welding and NDT activities till 2 nd shell. Prior to erection of 1st shell course remove the erection chairs / stools and necessary grinding at the removal area of stools. Grind flush of annular annular weld weld reinforcement reinforcement at shell shell resting resting area prior prior to erection erection of of shell course. course. Erection of 1st  shell course followed with Fit-up, welding and NDT activities of vertical and horizontal joints.

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Open the short plate (make-up plate) in 1st shell course.

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Fit-up, welding and NDT of Shell to Annular plate.

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Rev.

Jacks can be removed upon completion of welding and temporary support (Beam/channels) (Beam/cha nnels) to be provided at the opening of short plate.

This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

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Company Job No.

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 15 of 15 of 20

Rev.

Temporary support up to maintenance maintenanc e level shall be erected to support the construction construct ion of Roof (Deck). Deck Plates activity can commence in parallel while the bottom plate is completely laid and is reasonably welded. Roof (Deck) (Deck) plates plates shall be laid laid on on temporary temporary supports supports as per drawing. drawing. Short seams fit up and welding followed long seams fit up and welding shall be carried out. Outer Outer rim & inner rims shall be erected and welded followed followed by pontoon bulk heads,. Marking and cutting cutting for leg supports, Guide Guide pole, Gatch Hatch and all other roof roof (Deck) attachments shall be carried out followed f ollowed by installation. installation.

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Removal of temporary temporary staging from the tank and cleaning.

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Erection, Fit-up, welding & NDT of roof drain.

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Cathodic protection related works (Welding (Welding of of support / clits) shall be be carried carried out.

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Installation of brackets brackets / structures structures / cable trays for Electrical Electrical & Instrumentation Instrumentation items. items.

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Piping & other other Arrangement Arrangement for Tank Tank Hydrotest Hydrotest (Water (Water filling filling & dewatering). dewatering).

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Hydrotest of Tank Tank shall shall be be carried carried out out as per approved procedure.

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After successful successful Hydrotesting, Hydrotesting, dewatering dewatering & tank Cleaning shall be carried carried out.

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Tank Calibration shall be carried out as per approve procedure. procedure .

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Installation of scaffolding for Painting.

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Installation of Roof Seal

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Installation of Electrical & Instrumentation item

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Final Boxing-up of Tank

Erection of tanks by Conventional Method 

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Erection, Fit-up, vertical vertical seam welding welding and NDT of 1st shell course Plates. Installation of of working platform as required. required. Primary Primary wind girder may be used for working working platform for outside tank shell. Erection, Fit-up, vertical seam Welding & NDT of 2nd shell course Plates.

This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

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Company Job No.

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 16 of 16 of 20

Fit-up, Welding & NDT of 1st horizontal seam of tank shell Repeat the process of Erection, Fit-up, vertical seam Welding & NDT of all shell courses similarly as above.

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Erection, Fit-up, welding and NDT of welding of wind wind girder.

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Erection, Fit-up, welding and NDT of curb angle.

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Erection, fit-up, welding, NDT of spiral stairway progressively. progressively.

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Open the short plate (make-up plate) in 1st shell course.

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Fit-up, welding and NDT of Shell to Annular plate.

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Rev.

Temporary support up to maintenance maintenanc e level shall be erected to support the construction construct ion of Roof (Deck). Deck Plates activity can commence in parallel while the bottom plate is completely laid and is reasonably welded. Roof (Deck) (Deck) plates plates shall be laid laid on on temporary temporary supports supports as per drawing. drawing. Short seams fit up and welding followed long seams fit up and welding shall be carried out. Outer rim & inner rims shall be erected and welded followed by pontoon bulk heads. Marking and cutting cutting for leg supports, Guide Guide pole, Gatch Hatch and all other roof (Deck) (Deck) attachments shall be carried out followed f ollowed by installation. installation.

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Removal of temporary temporary staging from the tank and cleaning.

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Erection, Fit-up, welding & NDT of roof drain.

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Installation of brackets brackets / structures structures / cable trays for Electrical Electrical & Instrumentation items.

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Piping & other other Arrangement Arrangement for Tank Tank Hydrotest Hydrotest (Water (Water filling filling & dewatering). dewatering).

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Hydrotest of Tank Tank shall shall be be carried carried out out as per approved procedure.

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After successful successful Hydrotesting, Hydrotesting, dewatering dewatering & tank Cleaning shall be carried carried out.

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Tank Calibration shall be carried out as per approve procedure. procedure .

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Installation of scaffolding for Painting.

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Installation of Roof Seal

This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

8

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Installation of Electrical & Instrumentation item

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Final Boxing-up of Tank

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 17 of 17 of 20

Rev.

INSPECTION, TESTING AND DOCUMENTATION DOCUMENTATION 

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9

Company Job No.

All stage wise inspection, testing shall be carried out in stages and in accordance with with the approved ITP and API. Documentations Document ations shall be maintained by CONTRACTOR CONTRACTO R QA/QC department. Any defect noticed during during any any stage of inspection inspection shall shall be rectified before proceeding for further next activity. CONTRACTOR shall define define the system system for recording all quality quality control activities on a database database and listing the status and records required at each stage of construction, the database is to the reference the appropriate ITP, Procedure and Certification.

TOOLS AND EQUIPMENT Following Equipment, Equipment, Tools & Tackles shall be used

9.1 Fabrication 

Rolling Machine (Plate Bending Machine)

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Rectifier (Welding)

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Pug Cutting Machine

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Grinding Machine

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Drilling Machine

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Jigs & Fixtures

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Gas cutting Set

 

Cranes

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Trailor

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PWHT Equipment

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9.2 Blasting & Painting

This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

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Compressors

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Blasting Machines Machines (Sand Pot, After Cooler, Etc)

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Spray Painting Guns

Company Job No.

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 18 of 18 of 20

Rev.

9.3 Erection Activities 

Automatic Welding Machine. Machine.

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LT7 Machine for Lap/Fillet Welding.

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Automatic Horizontal Joint Welding Machine (SAW Machine)

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Welding Rectifiers

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Grinding Machines

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Lifting equipment like Chain Pulley Block, Lifting Lugs, Belts, Steel wire ropes etc.

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Cranes

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Man Lift, fork lift

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Different Types of Testing Equipment

10 RESPONSIBILITIES Following are the responsibilities responsibilities and reporting r eporting structure of personnel involved in the scope of this Method Statement 

Project Manager

Site Manager

Shall be responsible for providing all types of resources and for the implementation implementation of this methodology

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Shall report to the Project Manager

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Ensure compliance compliance to project specification. specification.

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Provide and fulfill all required safety measures.

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Provide adequate resources for execution of erection work.

Construction Manager-Tanks Manager-Tanks

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Overall in-charge of Tankage Work

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Shall report to Site Manager

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Planning and execution of Fabrication & Erection work in line with project schedule.

This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

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 Area Manager (Fabrication/ (Fabrication/ Erection)

Company Job No.

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 19 of 19 of 20

Rev.

Shall be responsible for day day to day planning of job and implementation of mentioned activities as per this methodology and preparation of job activity records.

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Shall report to QA/QC Manager.

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Shall be responsible to implement, monitor and ensure the quality of work is in accordance with these methodology/codes/specificatio methodology/codes/specification n requirements. requirements.

QC Engineer

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Report noncompliance to the concerned personnel before starting next activity.

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Shall be responsible to prepare and maintain quality related inspection records.

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Shall report to HSE Manager.

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Shall be responsible to identify, implement, monitor & ensure the specific requirements of health and safety of all persons engage at site.

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Shall provide trained, experienced and competent personal and supervision. supervision.

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Shall inform all relevant persons with detail method statement and risk assessment, which may affect their health & safety.

HSE Officer 

Shall review HSE performances performan ces statistics statist ics and initiative action for improvement, setting HSE target and planning to enhance HSE performances. performances.

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Responsible to monitor monitor & ensure ensure the Safety of work work in in accordance with this procedure.

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Report non-compliance non-compliance to the concerned Engineer/supervisor Engineer/supervisor and ensure rectifications r ectifications at the same time.

11 HEALTH, SAFETY, SECURITY AND AND ENVIRONMENT ENVIRONMENT (HSSE) MANAGEMENT Risk Assessment of all activities associated with this procedure shall be done before starting any This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC

KNPC Al-Zour Refinery Project EPC # 0059 DOCUMENT TITLE METHOD STATEMENT FOR CONSTRUCTION OF EXTERNAL FLOATING ROOF TANKS

Company Job No.

Company Doc. No.

ZOR/EPC-0059

P4059ZOR-xx--xx-xxx P4059ZOR-xx--xx-xxx

Contractor Job No.

Contractor Doc. No.

032192 / I-1006

00-ZA-E-xxxxx-xxx 00-ZA-E-xxxxx-xxx O

sh. 20 of 20 of 20

Rev.

activity. 

Barricading shall be provided provided at erection site.

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Equipment and Personnel shall be deployed as per requirement.

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All instruments instrum ents / equipment shall be maintained in good working condition as per maintenance maintenanc e schedule. Radiography shall be done at lean time. Nobody shall be allowed to work work nearby during radiography. All workmen, supervisors and engineers shall use proper personnel protection equipment. equipmen t. All employees should follow the HSSE Rules. Full body harness and lifeline will will be used while working at height. Sufficient numbers of Fire Extinguishers will be placed for any fire incident. All power tools will be inspected by competent person before use. Lifting will be done as per the lifting plan. All necessary precautions shall be be taken during lifting operation. Before the start start of work Tool Box Talk shall shall be be conducted conducted by by the site supervisor supervisor and monitored by HSE supervisor.

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All types of emergencies emergencies shall be tackled as per approved emergency response plan.

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The housekeeping housekeeping shall be done before close of work.

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Cable management shall be done with proper care. Stubs and J-Hooks shall be used for carrying power & welding cables. All welding cable shall be routed to avoid cable damage and tripping hazards To prevent prevent dehydration for long long time working working exposure, drinking water facility, rest shelter, shelter, toilets shall be provided.

12 ATTACHMENT - I 

Welding Sequence for Annular & bottom plates. Same sequence shall be followed in Deck (Roof) welding as well.

This document and the information contained herein are the sole property of KNPC and shall be treated as confidential. No reproduction in full or in part of this document shall be made for any use other than for the purpose of the Contract without the written consent of KNPC