QCP-505

OGD III PROJECT

REV. No.: 0

COMPANY Doc. No.: VEN-5208-000-2520-111 Page 1 of 10

BECHTEL Doc. No.: 25113-000-V21-MTDO-KB002

METHOD STATEMENT
FOR
CONSTRUCTION OF STORAGE TANKS

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TABLE OF CONTENTS

1.0 PURPOSE________________________________________________________________2
2.0 SCOPE__________________________________________________________________2
3.0 REFERENCE DOCUMENTS_________________________________________________2
4.0 TERMS AND DEFINITIONS__________________________________________________2
5.0 RESPONSIBILITIES________________________________________________________2
6.0 METHODOLOGY__________________________________________________________2
7.0 HEALTH, SAFETY RISK ASSESSMENT________________________________________9
8.0 QUALITY ASSURANCE & QUALITY CONTROL_________________________________10
9.0 APPENDICES / FORMATS___________________________________________________2

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1.0 PURPOSE

The purpose of this document is to follow proper methodology to carry out the activities in sequence for fabrication
and erection of atmospheric storage cone roof tanks for Onshore Gas Development project Phase-III

2.0 SCOPE

This document covers general method statement for fabrication, erection and testing of cone / dome roof tanks.
Tank erection by both hydraulic jacking method and conventional method are covered in this document.

PLL shall erect some of the tanks by using jacking method and the balance tanks will be erected by conventional
method, using suitable capacity crane. By analyzing the sizes of the tanks and also the construction schedule, the
erection methodology will be finalized for each tank. All the tasks / activities need to be carried out properly with
good workmanship and in accordance with specifications / method statement to achieve satisfactory completion of
the work.

3.0 REFERENCE DOCUMENTS

1. Departmental Method statement

2. All Relevant Tank Drawings
3. Tank Data Sheets
4. Project Quality Plan
5. H.S.E. Plan

4.0 TERMS AND DEFINITIONS

All terms definitions used in this document shall be in accordance with the documents and specifications available
in the contract documents and applicable codes.
.

5.0 RESPONSIBILITIES

Following are the responsibilities of personnel involved in the scope of this method statement.

Construction Manager

 Shall report to Project Manager.

 Shall be responsible for overall implementation, monitoring and control of activities pertaining to the
fabrication and erection of tanks with safe working practices.

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Site Planning Engineer

 Shall Report to Project Manager and also to Project Control Manager.

 Shall be responsible for day to day micro planning in co-ordination with Site Engineers.

Site Engineers

 Shall report to Construction Manager.

 Shall be responsible for execution and implementation of all site activities related to this method
statement.

QC Engineer

 Shall report to Site QC in-charge.

 Shall be responsible for overall control and inspection of QC activities at site during fabrication and
erection of tanks.

Safety Engineers

 Shall report to Site HSE In-charge

 Shall be responsible for overall safety in the execution of day to day site activities related to this method
statement.

6.0 METHODOLOGY

6.1 FABRICATION

All activities of fabrication work involving material identification, marking, cutting, rolling and welding shall be done
in accordance with this method statement, API 650, latest edition and above mentioned reference documents. The
workmanship shall be good in every respect meeting all safety & NDT requirements stipulated and in close
coordination with inspection.

6.1.1 Material Identification and Marking of Components

 Prior to fabrication, spread all plates, structural sections & pipes required for the tank in such a way to
facilitate proper checking of dimensions, Heat No., AV marking (as required).

 Mark the components as per cutting diagrams & instructions furnished in relevant drawings.

 Transfer Heat no. & AV marking of each plate, structural section & pipe to all components and offer the
same for inspection and clearance before cutting.

6.1.2 Fabrication of Annular and Bottom Plates

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 Mark the components as per cutting diagrams & instructions furnished in relevant drawings.

 Carry out cutting operation as required, after getting clearance from inspection authority.

 All cutting operation shall be carried out by Oxy–fuel gas cutting method.

 Grind the cut edges smooth to remove burrs and slag.

 Stack the plates at designated place in the fabrication yard taking care to avoid mixing of tank
components

6.1.3 Fabrication of Roof Plates

 Mark the components as per cutting diagrams & instructions furnished in relevant drawings.

 Carry out cutting operation as required, after getting clearance from inspection authority.

 All cutting operation shall be carried out by Oxy–fuel gas cutting method.

 Grind the cut edges smooth to remove burrs and slag.

 Stack the plates at designated place in the fabrication yard.

6.1.4 Fabrication of Roof Structural (For Cone / Dome Roof Tanks)

 Ensure that all structural items are straightened to remove distortion, if any, before fabrication.

 Mark the components as per cutting diagrams & instructions furnished in relevant drawings.

 Carry out cutting operation, after getting clearance from inspection authority.

 All cutting operation shall be carried out by Oxy-fuel gas cutting method.

 Truss and rafters shall be fabricated and kept ready for erection, by welding the structural members as
given in the roof structural drawings. Holes are drilled as required for bolting to central drum and tank side
gussets.

 Central drum is fabricated by welding the members as per the drawing.

6.1.5 Fabrication of Appurtenances.

 Mark the components as per cutting diagrams & instructions furnished in relevant drawings.

 Carry out cutting operation as required, after getting clearance from inspection authority.

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 All cutting operation including beveling for CS items shall be carried out by Oxy–fuel gas cutting method.

 Grind the cut edges smooth to remove burrs and slag.

 Face of flanges shall be covered with suitable cover to protect the same from any damage during
handling / fabrication / transportation.

 All the roof fittings and internals comprising of pipes (forged or fabricated) and flanges shall be fabricated
as per the approved drawings and the flange to pipe joint shall be completed (wherever applicable).

 All items shall be offered for stage-wise inspection as required.

 All NDT requirements as specified in relevant drawings / specifications shall be completed before shifting
to tank site.

6.1.6 Fabrication of Shell Plates

 Spread all the Shell plates in an open area.

 Mark and square the plates and offer for inspection before the start of cutting operation. Marking of plate
shall include the edges as well as the bevel.

 All cutting operation including beveling shall be carried out by Oxy–fuel gas cutting method

 The plates will be shifted to rolling gantry area with the help of crane / tractor-trailer.

 The plates shall be fed to the bending roll with the help of crane using proper lifting tools and tackles.

 The plates shall be rolled as per the requirement of rolling radius mentioned in relevant drawing and shall
be checked by using a template.

 Care shall be taken to ensure that the plates are rolled to a smooth curve and are not over rolled.

 All rolled plates shall be checked using the template at three (3) different locations with a maximum
deviation of 3mm allowed to the template dimensions.

 After rolling, all plates shall be shifted to fabrication stockyard and stacked in a proper sequence as per
the marking of each plate.

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

 Grind the cut edges smooth to remove burrs and slag.

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 Roll the plates in the rolling machine. For having accurate curvature during rolling, approx. 1.5 meters
long templates shall be prepared from 5 / 6 mm-thick plates. The curvature of this template shall be
inspected and cleared by inspection authority

 Carry out profile & dimensional check before the plates are sent for erection.

6.1.7 Fabrication of Spiral Stairway, Hand railings, Curb Angle, Stiffeners and other structural members

 Ensure that all structural items are straightened to remove distortion, if any, before fabrication.

 Mark the components as per cutting diagrams & instructions furnished in relevant drawings.

 Carry out cutting operation, after getting clearance from inspection.

 All cutting operation shall be carried out by Oxy-fuel gas cutting method.

 All items shall be cut to size and drilled as per relevant drawings.

 Grind the cut edges smooth to remove burrs and slag.

6.1.8 Fabrication of Wind Girder (wherever applicable)

 Mark the components as per cutting diagrams & instructions furnished in relevant drawings.

 Mark, cut & finish the templates, as per the template drawings for all size of wind girders. Templates shall
be checked, certified and stamped by the inspection authority

 Carry out cutting operation as required, after getting clearance from inspection.

 All cutting operation including beveling shall be carried out by Oxy–fuel gas cutting method.

 Grind the cut edges smooth to remove burrs and slag.

 For having accurate curvature during cutting of platform, approx. 1.5 meters long templates shall be
prepared from 5 / 6 mm-thick plates. The curvature of this template shall be inspected and cleared by
inspection.

 Ensure that all structural items meant for wind girder brackets are straightened to remove distortion, if
any, before fabrication.

 The gusset plates, wind girder flange plates and the angle brackets shall be cut to size and fabricated as
per relevant drawings

 Approved WPS and qualified welder shall be deployed to carry out welding of brackets and flange plate.

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6.2 ERECTION

6.2.1 Erection by Hydraulic Jacking Method

FIXED ROOF TANKS

 Prior to starting of jacking procedures the bottom / annular plates including sketch plates shall be placed
in position and annular plates welding will be completed.
 All NDT requirements of annular plate weld joints as specified in relevant drawings / specifications shall
be completed before erection of shall plate to tank
 The 2nd topmost shell course shall be put in position with temporary supports on annular plates of as
specified radius in relevant drawings.
 All vertical joints of the shell courses shall be welded with suitable fixtures maintaining the required profile,
curvatures, etc.
 The Curb angle/Compression ring shall be fixed in position, Stiffeners, if any, shall then be fixed in the top
shell course.
 The circumferential weld between the top and second shell course shall be completed in all respects.
 Gussets for welding roof structural are then welded on the inside of the top shell.
 Roof structure (Central drum, roof truss, rafters and purlins) will be then erected using a central king post.
 Roof Plates are then laid on the structural and welding between the plates shall be carried out.
 Roof plates to roof structural shall be a free joint and not welded.
 All the appurtenances coming on the tank roof shall be erected and welded at this level.
 Hand rails and top landing platform of the stairway also shall be erected at this level.
 The sub assembly of two shell courses, roof plates and structural, along with roof appurtenances, curb
angle and stiffeners is now ready for lifting.
 The jacks used for lifting shall have capacity of 12 ton each and the number of jacks required shall be
calculated based on the total weight of the tank to be lifted by jacks and also the wind moment.
 The shells shall be erected on guide trestles that are fixed and welded on annular plates at equal intervals
with provision of suitable backstays.
 A synchronised operation of all jacks is ensured during raising and releasing at a predetermined level.
 After erection of this sub assembly to a height equal to the width of third next (third from top), the third
shell course is put into position and the similar operations of fit up of vertical joints welding, etc. are
carried out and the sequence of jacking operation is continued.
 Nozzles coming on the shell shall be erected and welded during the erection of the respective shell
course.

 Stairway shall be erected progressively to avoid any erection work at elevated heights.

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 After completion of all shell courses erection including appurtenances and stairway, the final welding
between the bottoms most shell course and annular plate is carried out. Thereafter the sketch plates are
welded with annular plates

6.2.2 Erection by Conventional Method

FIXED ROOF TANKS

 After checking and acceptance of tank foundation, laying & welding of annular plates shall be completed.
 All NDT requirements of annular plate weld joints as specified in relevant drawings / specifications shall
be completed before erection of shall plate to tank.
 For conventional method of tanks, the bottom most shell course will be erected first with suitable jigs &
fixtures.
 After completion of vertical joints welding, second shell course shall be erected with supports of erection
channels.
 After completion of all vertical joints of second shell, horizontal weld joint between first and second shell
course will be welded.
 Balance shell courses will be erected in this manner up to top shell course.
 Stiffeners and curb angle will be then welded to the respective shell courses.
 After completion of shell, roof shall be erected as explained under section 6.2.1 – Fixed Roof Tanks.
 Roof appurtenances and stairway shall be installed subsequently.
 After completion of erection of all shell courses and roof, final welding between the bottom most shell
course and the annular plate shall be carried out.
 Thereafter the sketch plates are welded with annular plate maintaining a welding sequence of bottom
plate.

7.0 HEALTH, SAFETY AND RISK ASSESSMENT

 The HSE In-charge shall be responsible for presenting all employees with a pre-work briefing using the
risk assessment / method statement before work starts.

 Where work activities may conflict with or impact upon other work activities, necessary steps shall be
taken to discuss the matter with relevant parties and establish a consensus. Ensure that both parties and
their teams are fully aware of potential hazards together with appropriate precautions.

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 All plant and equipment shall be inspected before work commences and at periodic intervals thereafter.
This shall be done by the construction Engineer. All plant and equipment shall be safe before and during
use.

 Only competent personal are permitted to operate plant and equipment and such persons shall be tested
by a competent person.

 The Construction Engineer shall immediately correct any hazards observed or reported to him. In the case
of major hazards work shall be stopped and appropriate and satisfactory temporary / permanent action to
remove the hazard shall be taken.

 Method statements / risk assessment shall always examine the people, equipment, materials and the
environmental aspects of the proposed work.

 Ensure that an emergency / rescue plan to cater for any mishap (injury, fire etc.) is available, known to all
people and capable of immediate activities.

 Where incidents / accidents occur the Resident Construction Manager shall immediately report the matter
to the safety department. Verbal reports shall be confirmed in writing. Proper first aid and medical care
shall be given immediately to injured persons. Good housekeeping shall be maintained at all times.
Adequate hygiene and welfare facilities such as toilets, hand washing measures, drinking water etc. shall
be provided and maintained.
 A specific task related risk assessment shall be completed for this work activity and appended to the
method statement. Risk assessment shall be completed on the approved format.

8.0 QUALITY ASSURANCE & QUALITY CONTROL

This shall be followed and maintained with the compliance / adherence to the method statement, Inspection
Test Plan and by keeping records in the relevant check-sheet and formats.

9.0 APPENDICES / FORMATS

As per approved QCP / ITP.

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