Page No : 1 of 22

LARSEN & TOUBRO LIMITED

Date :31-july -16

KOC Contract No Company Doc No : Rev

Project Title
14050489 NEW GATHERING CENTRE GC 30, IN NORTH KUWAIT
N/A
KOC Project No.: Contr. Doc No : Rev
EF1902 Document Title : 50489-530-300-CMS-2103 0
KOC Doc. No.: Rev
Contr. Job No.: WORK METHOD STATEMENT FOR ERECTION OF STORAGE N/A
TANK IN GC -30 FACILITIES
5026
Facility No. Equipment Description : N/A Equipment Tag No: N/A
GC-30

WORK METHOD STATEMENT FOR ERECTION OF STORAGE

TANK IN GC -30 FACILITIES

LARSEN & TOUBRO LIMITED

Heavy Engineering Industries and Shipbuilding Co.K.S.C.(Public)

P.O Box 10155,
Shuaiba 65452,
Kuwait

Signature
FATHY
B.GOPALAKRISHNAN M.SARAVANAN 31-JULY-
0 Issued for Approval HEISCO BRIAN LOUGHREY
L&T L&T 2016
TANK
PM 21-MAR-
B Issued for Approval L&T L&T BRIAN LOUGHREY
HEISCO 2016
PM 10-Dec-
A Issued for Approval L&T L&T BRIAN LOUGHREY
HEISCO 2015
CM AMEC
REV. ISSUE DESCRIPTION PREPARED REVIEWED DATE
CHECKED APPROVED

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KOC Contract No WORK METHOD STATEMENT FOR ERECTION OF STORAGE Contractor Document Number Rev
14050489 TANKS IN GC -30 FACILITIES 50489-530-300-CMS-2103 0

INDEX

1.0 PURPOSE......................................................................................................................................... 3
2.0 SCOPE............................................................................................................................................... 3
3.0 REFERENCES................................................................................................................................. 3
4.0 DEFINITIONS.................................................................................................................................. 4
5.0 PERSONNEL / MANPOWER......................................................................................................... 4
6.0 MATERIAL / EQUIPMENT /TOOLS........................................................................................... 4
7.0 METHOD OF STATEMENT.......................................................................................................... 5

1.0 PURPOSE
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KOC Contract No WORK METHOD STATEMENT FOR ERECTION OF STORAGE Contractor Document Number Rev
14050489 TANKS IN GC -30 FACILITIES 50489-530-300-CMS-2103 0

The purpose of this method statement is to provide a methodology of different activities like
Erection of Bottom Plates, Annular Plates, Shell Plates, Roof Plates, Roof Structural, Nozzles
and Internal Pipes to be carried out during the Erection of Field Erected storage Tanks in New
GC-30.

2.0 SCOPE
This Method Statement applies for Erection of Bottom Plates, Annular Plates, Shell Plates,
Roof Plates, Roof Structural, Nozzles and Internal Pipes to be carried out during the erection
at Field Erected Storage Tanks, New GC-30 for storage tanks considering all HSE / QC
requirements.

3.0 REFERENCES
API 650 : Welded Steel Tanks for Oil Storage

KOC-MV-007 : Field Erected Storage Tanks

ASME Sec. IX : Welding & Brazing Qualifications

ASME Sec. V Article 2 : Radiographic Examinationv

ASME Sec. VIII Div. I : Rules for Construction of Pressure Vessels

KOC-P-001 Rev.3 : Painting & Coating of metal surfaces - New Construction

50489-530-450-PRO-1007 : Receiving and Inspection of Good at Site.

50489-530-450-PRO-2105 : Procedure for Fabrication,Erection & testing of field erected

Storage Tanks

EF1902-530-DE2-SPC-0003: General Welding Requirements.

015-WH-1001 : Welding Procedure Approval and Welding Quality

Requirements

015-WH-1002 : Field Welding Requirements

KOC.HE.004 : Occupational Health and Hygiene – First Aid

KOC.HE.007 : Occupational Health and Medical Surveillance

Procedure

KOC.GE.033 : KOC HSEMS Guidelines for Contractor

KOC.SA.035 : Safe Control and Use of Gas Cylinders

50489-530-450-INS-2100 : Inspection & Test Plan (ITP) for Installation & Testing of Tanks

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KOC Contract No WORK METHOD STATEMENT FOR ERECTION OF STORAGE Contractor Document Number Rev
14050489 TANKS IN GC -30 FACILITIES 50489-530-300-CMS-2103 0

50489-530-450-PRO-2100 : Project Material Control Procedure

50489-530-450-PRO-2101 : Procedure For Welding Control

50489-530-450-PRO-2110 : Procedure For Radiographic Testing

50489-530-460-PLN-2100 : Project HSE Plan

50489-530-450-PLN-2100 : Project Quality Plan

Tank Drawings ‘Issued For Construction’

Relevant Tank Data Sheets

4.0 DEFINITIONS
Project - New Gathering Centre GC-30 In North Kuwait

Company - Kuwait Oil Company, KSC (KOC)

Contractor - Larsen & Toubro Limited

Sub-Contractor - Heavy Engineering Industries & Shipbuilding Co. (HEISCO)

5.0 PERSONNEL / MANPOWER

 Work Site Supervisor
 Foreman
 Equipment Operators
 Riggers/Helpers
 Rigging Team (Rigger Foreman/Rigging Supervisor)
 Welder
 Fitter /Fabricator
 Gas Cutter
 Grinder
 HSE Personnel
 QC Personnel

6.0 MATERIAL / EQUIPMENT /TOOLS

 Crane (Suitable Capacity)
 Fitting Tools
 Hydarulic Jack
 Rigging Tools
 Hand Tools
 Pick –up
 Boom Truck / Trailer

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 Bus
 Manlift

7.0 METHOD OF STATEMENT

ERECTION:

Foundation handing over:

All the tank foundations shall be checked and cleared by the civil sub-contractor QC engineer
and by Main contractor / Company QC personals.

The foundation will be taken over by the Tank Contractor after thorough inspection by their
QC Engineer / Execution engineer, for elevation, compaction, slope, orientations etc. the
contractor should provide necessary QC clearance documents for variations and
documentation purpose.

Annular Plate Erection:

The annular plate shall be laid on the tank foundation to match the tank outer dia of annular
plate as per the tank radius given in the approved drawings and to suit the foundation physical
conditions.Any trancit/ Handling damage to soil side coatings to be repaired before laying of
the plates

 Annular plates with backing strip attached to end shall be laid abutting one another to
form a ring with the outside diameter as specified and orientation as per approved
drawings.
 Tank Inner Radius shall be marked on the Annular plate after completion of the fit up
to suit the foundation physical conditions
 Annular plate butt joint shall be welded as soon as possible after layig to avoid any
debris/corrosion to the joint as per approved drawings and WPS. Initially alternate
annular joints need to be welded and subsequently balance joints should be welded
leaving one make-up joint. The makeup joint should be welded after completion of all
annular joint welding.
 To control distortion, weights shall be placed on either side of the joint during welding
or the joints may be raised about 50 mm to 100mm by a channel steel rod / steel
packing materials and welded with the joint peaking up and the packing mateirals
subsequently removed after the welding cooled down.
 Annular plate butt joints shall be spot radio graphed at one location on all the weld
joints as per KOC Spec MV-007. The preferable location of the Radiography shall be
at Shell Resting area.
 All the annular plate joints shall be vacuum tested 100% as per procedure 50489-530-
450-PRO-2114. If there is repair on weld,after repairworks again vacuum box testing
will be carried out where the repair has done.

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ANNULAR PLATE WELDING SEQUENCE

BOTTOM PLATE ERECTION:

 Draw off sumps shall be installed before laying of Bottom Plates and sketch plates.
 Bottom sketch plates shall be laid over the foundation with the plates lapped as shown
on the approved drawings. The plates shall be joggled for correct fit-up at three plate
lap joints.
 For Bottoms sloping towards the periphery, the bottom sketch plate shall be laid
working from the periphery towards the centre. Whereas for Bottoms sloping towards
the centre of the tank, the bottom sketches plate shall be laid working from the centre
towards the periphery.
SEQUENCE OF WELDING BOTTOM PLATES:

 Welding shall be performed by SMAW or SAW process as per approved WPS.

 Short seams shall be fitted first and tacked into position ensuring sufficient lap as per
approved drawings.
 All short seams are to be then welded. (Joints marked 1 in sketch )
 On completion of welding of short seams, the long seam between two successive rows
shall be fitted-up and welded, working from the centre towards the periphery. To
reduce the heat input and consequent bulging while using SMAW process it is
recommended that step back sequence of the welding shall be carried out from center
towards circumference to (Stepping back 24” to 30”) avoid buckling with proper
stiffener supports.
 Long seams are to be welded alternatively leaving one seam free to cater for any
shrinkage due to welding.
 If need be necessary channels could be fitted across the long seams to arrest
bulging/buckling of bottom.
 Care is to be taken to ensure that while carrying out bottom plate welding the welding
current is maintained within the specified current range only. Welding carried out

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using high current would increase the heat input and consequently the bulging of
bottoms.
 The Typical sequence of welding of bottom plates is outlined in the sketch below.

BOTTOM PLATE WELDING SEQUENCE

 Draw-off sump shall be fitted and welded to bottom as per orientation indicated in the
approved drawings. Dye Penetrant testing of the sump has to be carried out prior to
installation.
 The peripheral seam between sketch and the annular plate (Joint 6 in sketch) shall be
left open and should be welded only upon completion of shell to bottom weld. This
seam is to be locked in place using C clamps and wedges only.

SHELL ERECTION

ERECTION:

After completion of annular plate welding and necessary NDE the shell ID shall be marked on
the annular plate at entire circumference. All annular joints vacuum testing shall be carried out
the same shall be checked and witnessed by Company/ Contractor. The shell plate seating
area in the annular plate welded portion shall be flush grinded for shell seating.

 The entire circumference shall be fixed with elevator with temporary stopper plate, with
the help of necessary lifting beam and vertical plate lifting clamps the Second Top
shell course shall be erected as per the orientations given in the approved shell plate
development drawings.
 Provide necessary stiffener bracing support at the centre of the plate to the bottom
plate using channel/angle as shown.
 Check the radius on each end of the plate to the centre of the tank.
 Check the chord dimension of the plate.
 Erect the Top shell plate adjacent to the first in a similar fashion as detailed.
 Fit the second plate with the first using jigs and fixtures as shown.

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 Pull/push the plates using the fixture to achieve the necessary root gap.

 Ensure the top and bottom of the plates are in the same line and there is no offset.
Check the chord length and if excessively out correct the same.
 Tack the second plate with the first at the bottom only.
 Erect the balance plates of the strake as outlined.
 In case the makeup plate has been cut to correct size, on placement of last plate the
same should fit perfectly. If you have a run over/ overlap do not cut the plate and
readjust the other plates to accommodate the make-up. If you have a shortfall then
pulls the other plates to complete the strake. However if the makeup plate has been
kept in excess of the circumference, on placement of the last plate, measure the total
length of the plates erected and mark the required circumference of the strake on the
makeup plate and cut the excess. The makeup plate is to be fitted to the first plate as
outlined earlier to complete one strake.
 All vertical joints tacked at bottom earlier are now to be tacked completely. It should
be ensured that the overlap and root gap are within tolerance. Any misalignment is to
be rectified using appropriate jigs and wedges.
 Gauge Plates are to be fitted on the inside of the shell to maintain the curvature and
minimize distortion during welding.
 After erection of Each Shell Course the Fitup inspection shall be Carried out.

Vertical Seam Welding

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 The vertical seams are to be first welded from the outside.

 Start welding at the top of the joint about tweleve inches from the top of the seam and
weld towards the top of the seam.
 Now move down on the seam at least 48” below the point where the first weld was
commenced and weld upwards towards the first weld removing spacers if left in the
seam.
 Now move down further 48” below the second weld and weld towards the previous
weld.
 Continue welding by the above back step procedure (Refer sketch below) until the
seam is completed.

 Clean the weld of slag and spatter. Subsequent weld passes are to be welded till weld
is completed from the outside. The back step length for subsequent runs could be
increased to 36 to 48” inches.
 For very thin plates the vertical joints could be bowed out slightly before welding from
outside to minimize distortion.
 On completion of the vertical seam welding from outside, plates of the 2 nd shell shall
be erected on top of the 1rd Strake. Necessary spacers & erection channels are to be
used to maintain root gap and for aligning the plates.
 Before the welding of top shell course, the reverse side of the first shell course shall be
welded shall be ground to sound metal to remove slag pores and any lack of fusion.
 Visual examination is to be carried out to ensure that no slags/pores/cracks are left on
the weld.

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 Weld from the inside by back step method from top similar to the welding carried out
from outside. However after completion of outside welding in the event of the vertical
joint having peaked in excessively, weld continuously on the inside from the bottom of
the shell to the top. If additional weld passes are required as per joint design and if the
weld seam is still bowed in weld the subsequent pass continuously. Complete the
welding from inside in the manner indicated above.

 The vertical joints of the top shell shall be welded as per procedure.
 On completion of the vertical welding the horizontal seam shall be aligned and fitted-up
using spacer plates, jigs and fixtures to ensure proper roof gap and alignment.
 Horizontal welds shall be welded from outside first. The welding is to be carried out by
dividing the number of welders on the job uniformly around the circumference.
 On completion of welding from outside, the reverse side of the weld shall be ground to
sound metal to remove slag, pores and any lack of fusion.
 However before completion of the inside welding the next top shell course can be
erected at top of the top shell course
 Visual examination is to be carried out to ensure that no slag's/pores/cracks are left on
the weld.
 The banding and verticality of shell shall be checked prior to and after welding of the
seam to confirm that they are within the permissible limits of API 650.
 Radiography test of weld seams shall be carried out as per the requirement of API
650.
 After completion of top shell course erection the tank plump shall be checked and
corrected. And then the next shell shall be erected the mentioned procedure for
vertical and horizontal joints shall be followed.

ERECTION OF CURB ANGLE / WIND GIRDER /WALK WAY PLATFORM:

TOP ANGLE:

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After completion of top shell course erection, and ensuring the plumpness the top curb angle
shall be fitted from one end to other circumferentially and welded sequentially by dividing the
circumference.

WIND GIRDER CUM WALKWAY PLATFORM:

After aligning the top two shell courses for verticality and ovality erect the pre fabricated wind
girder or wind girder with walkway platforms in segment.

 First fit the longitudinal joints of the wind girder and complete the welding on both side
 Upon formation of the entire ring please fit the wind girder against shell plate and
check-up the banding on the shell plates
 After ensuring that the shell is in not having any out of plumpness start stitch welding
from one side and complete the welding in opposite side circumferentially upon
completion of stitch welding slowly complete the fillet welding of maximum 3mm fillet
per run to minimize the heat input
 Necessary handrails to be fixed around the circumference of the platform tank as per
the drawings.
ROOF STRUCTURE ERECTION:

 A layout for rafters, purlins and any other structural assemblies shall be made and
checked for proper dimension as per drawings prior to fabrication of all purlins,
rafters and such assemblies.
 On center of the tank bottom plate the temporary structure can be erected only the
support resting area in bottom plate long seam welding need to be completed before
erecting the center drum temporary support including center drum. All remaining
bottom plate welding can be done parallel to the roof structure erection
 The purlin & other structures are to be placed outside the tank after roof plate erection
and welding on temporary structures inside the tank.
 Initially the center drum is to be erected in the center of tank on derrick pipe/channel
support at the appropriate height as per approved drawing and guyed using wire rope.

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 The main rafter is then hoisted into position as per orientation given in approved
drawings using cranes and derricks.
 The roof structure shall be clamped and tacked at both ends, that is on the center
drum and the shell.
 Thereafter diagonally opposite roof structure shall be erected as per procedure.

The balance trusses are to be erected in a similar manner in a sequence indicated in sketch
below. s

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On completion of erection of trusses, the cross girders are to be erected using pulleys and
chain blocks.

Secondary & Tertiary Rafters, Wind bracing, etc shall be erected after erection of cross
girders to complete the roof structure.

After completion of the entire roof structure work and welding the welded area and paint
damaged area shall blast cleaned and painted as per the approved painting/touch up
procedure

Roof Plates & Appurtenances

 On completion of erection and welding of roof structure the roof plates shall be
erected.
 The roof plates shall be laid and welded in a sequence similar to that indicated for
bottom plates.
 The circumferential weld connecting the roof plate to the curb angle/ Roof compression
ring shall be welded only upon completion of welding of short and long seams of roof.
 The size of circumferential weld shall be strictly as per drawing, especially for frangible
roofs.
 Roof manways and nozzles shall be fitted-up and welded to correct orientation as per
approved drawings.
 Roof circumferential handrail shall be erected and welded as per approved drawings.
 Spiral stairway shall be installed progressively downwards from top landing.
 After completion of all roof plate top side welding and underside seal welding (if
required as per the tank data sheet or as per the approved drawing), the unpainted
and damaged area shall be sweep blasted and painted as per the paint touch up
procedure

NOZZLES & MISC. WORKS:

All the Shell nozzles coming in the top two shell courses shall be fitted in position as per the
elevations provided in the approved drawings.

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Top landing platform, fire ring support pad plates with gussets and insulation rings shall be
fitted and welded in the top two shell courses as per the approved drawings.

JACK ASSEMBLY:

INSTALLATION OF JACK ASSEMBLY

1. Check the Jack locations clearing the vertical joints of further shell course to be
erected
2. Place the trestle base plate center 350mm away from the shell course
3. Stitch weld the base plate of jack with annular plate at three sides leaving the inner side
(which is near to shell plate)
4. place the trestle structure horizontally on the base plate and bolt with the hinges provided
in the base plate
5. Fix two nos of trestle supporting stay pipes at trestle top side with bolt and hinges also bolt
the bottom side hinge in stay pipe
6. Install the hydraulic tank lifting jack on the square bar provided in trestle and lock the bottom
side jaw
7. Install loading point, lifting chair & lifting arm on the jack
8. Lift the trestle and keep the trestle in vertical position check the verticality and keep the
stay pipe 1500 mm away from each other and stitch weld the bottom hinge of the stay pipe with
bottom plate
9. Repeat the above procedure for all the jacks
10. Align all the jacks at the lowest elevation possible
11. Install the Chopofix at bottom and top side of lifting arm with help of “C” clamp and wedges,
the “C” clamps need to be welded on one vertical side only also provide stopper at the top of
chopofix
12. Repeat the procedure for all the installed jacks
13. Provide Ball valve in all jacks with elbow and tee connector
14. Connect all the jacks seriously with ½” hydraulic hose of 2320 PSI capacity
15. Connect the entire hydraulic circuit with hydraulic manifold at three locations using hydraulic
hoses of same capacity
16. The manifold inlet and return line will be connected with Hydraulic power pack through
isolation ball valves
17. The power pack motor will be hooked up with 220V AC power supply through DOL
Starter
18. Now the tank lifting hydraulic jacking system is ready for lifting
PROCEDURE FOR LIFTING OF TANK ASSEMBLY:

1. Before starting lifting of the tank the surrounding area to be safety barricaded

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2. The entire erection crew must be aware of the system and necessary tool box talk to be
given to the concerned people
3. The entire tank assembly should be free from any welding with bottom / annular /
scaffolding and any piping connections
4. Ensure the welding of jack base plates, lifting “C” clamps, stopper plate etc.
5. Area supervisor and Construction manager to ensure the above points before lifting
6. The trained personnel should operate the hydraulic power pack
7. All Isolation valves near to the jacks to be closed and slight pressure to be given to the
connecting hydraulic hose and manifold, leak to be checked and tightened if any
8. Stop the power pack release the pressure to power pack
9. Open all the isolation valve fitted with the jack
10. Pressurize the hydraulic system gradually the jacks will start lifting the shell course, during
initial lift slight sound will come from the shell course since it is lifting from the elevator
11. The jack will lift the entire tank assembly for 100mm
12. After completion of lifting stop the power pack motor and open the return line valve gradually
to release the pressure
13. Close the release valve and start the power pack and start pressurizing the system again
14. Repeat the procedure till achieve the required height (for example the shell course to be
erected is of 2500mm wide the tank assembly to be lifted to 2550mm from top of the elevator)
periodically checking to be carried out for evenness in lifting
15. After completion of the lifting close all top and bottom side jaws of tank lifting jack and
release the pressure from system and close all isolation valve and provide the safety tag in power
pack
16. The power pack supply line to be isolated from panel
17. Erection of Bottom shell course shall be carried out as per the earlier method

PROCEDURE FOR LOWERING OF LIFTED TANK ASSEMBLY:

1. Upon completion of erection, fit up and welding of vertical joints in bottom shell
course the top tank assembly to be lowered on the bottom shell course keeping 2-
3mm root gap in between shell courses as per the procedure given below
2. All isolation valves to be kept in open position
3. Keep all the lower jaws in open condition
4. Pressurize the hydraulic system
5. Allow the jack to open up to 70mm at bottom side
6. Shutdown the power pack and close the oil return valve from manifold
7. Close the isolation valves in jack
8. Lock all the lower side jaws with trestle
9. Again pressurize the system and open the isolation valve gradually one by one and
allow the jack to lift the tank by another 10 to 20mm
10. close the isolation valve and release the top side jaws
11. Repeat the procedure for all the jacks
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12. After completion of the points 9 & 10 Close the manifold oil return line isolation valve
and shutdown the power pack and power supply
13. Gradually Open the individual isolation valves one by one
14. After completion of the above procedure the entire system to be depressurized
gradually by crack opening the manifold return line isolation valve till the jacks
lowered down to its position
15. Before commencing lowering all other persons not involved in these operations to be
separated from the work location
16. Also ensure that the lifted tank assembly is free from any stoppers etc
17. Ensure that no body put their fingers in side the circumferential joint
18. Check the entire circumference of the tank is sitting properly on the bottom shell
course
19. Upon completion of the above procedure the horizontal joint fit up to be carried from
inside

PROCEDURE FOR RE LOCATION OF JACK ASSEMBLY FOR LIFTING OF

NEXT SHELL:

1. Upon completion of the circumferential joint fit up the jack assembly to be lowered as follows
2. The Jack assembly to be tied with ropes at two side handles
3. One person to hold the rope tightly
4. Open top side and bottom side jaws
5. Loosen the rope slowly, the jack will come to the bottom most position lock the bottom jaws
and align the jacks for next lifting
6. Remove the Chopofix and ground off /gas cut the “C” clamp fixed at top shell course
7. The temporary attachment removal areas to be inspected by MPI checking
Note:
The same procedure to be repeated till completion of the During erection of the bottom
most shell course (i.e. Ist Shell course). During lifting the elevators to be removed from the
position and the shell seating area to be cleaned thoroughly for rust, dust, oil, grease and
any other foreign matters
REMOVAL OF JACK ASSEMBLY:

After completion of entire shell course erection, the jack assembly shall be dismantled and
removed from tank inside

Erection of Balance Shell Course

 Jacks with a safe working capacity of 12 MT or 15MT. shall be installed along the
periphery of the tank and equally spaced as shown. Normally the distance between
two jacks shall be 4 mtrs. However the number of jacks may be increased if the tank
is excessively tall and the total weight of the shell is more than the lifting capacity of
the jacks.

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KOC Contract No WORK METHOD STATEMENT FOR ERECTION OF STORAGE Contractor Document Number Rev
14050489 TANKS IN GC -30 FACILITIES 50489-530-300-CMS-2103 0

 Lifting lugs shall be welded to the shell of the lower of the two courses and the lifting
arm of the jack locked into position.

 The three shell assemblies along with the roof and roof structure shall be raised by the
jacks in multiple strokes of 100 mm through a distance equal to the height of the next
course to be erected plus 50 mm.
 While jacking the tanks care is to be taken to ensure uniform lifting of tanks. In the
event of uneven lifting, the jacks of the area where excess lifting has occurred shall be
shut of and the balance jacks that are lagging shall be operated to bring all the jacks to
the same level. This operation might have to be done after every meter of jacking.
 On completion of the jacking operation the lower shell course shall be erected on the
spacers.

 The tanks are then to be lowered by the additional distance initially jacked and made
to rest on the lower shell.
 The horizontal seam shall be fitted-up and welded as per the details given above from
outside and then the tank can be lifted and next shell course erection can be done.
Then the back chipping of the horizontal joint can be done at higher elevation and
welding shall be done with SAW welding machine. This will enable the horizontal joint
by SAW welding machine
 The spiral stairway is continued progressively downwards.

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KOC Contract No WORK METHOD STATEMENT FOR ERECTION OF STORAGE Contractor Document Number Rev
14050489 TANKS IN GC -30 FACILITIES 50489-530-300-CMS-2103 0

 The lifting lugs, cleats etc, shall be removed and welded to the shell that was last
erected.
 The lifting arm of the jacks is now locked once again onto the newly welded lifting
lugs.
 The tank is once again jacked and the next course erected as per the above
procedure.
 The balance shell course shall be erected as per procedure indicated above till all
the shells are erected.
 While jacking for the bottom most shell the tank is to be jacked upto a height equal
 to the lowest shell course less the height of the spaces on which the tank was resting.
 During the jacking process, the wind girder as per drawings shall be assembled and
welded to the appropriate shell course prior to the jacking up the particular
shellcourse.
 Shell to Bottom Welding & Shell Appurtenances.
 On completion of erection & welding of all the shells the shell to bottom shall be fitted
up and welded.
 The shell to bottom shall be initially welded from outside.
 Shell to Annular plate Shall be Inspected by MPI on Completion of 1st pass on Each
side and after Final Welding of Completed Joint.
 After Completion of hydrotesting MPI shall be carried out by the final welding of Shell
to annular plate.
 On completion of diesel chalk testing the shell to bottom shall be welded from inside to
complete the shell to bottom weld.
 On completion of shell to bottom welding the annular to sketch weld shall be
completed.
 The shell appurtenances shall be marked and installed as per approved drawings to
correct dimensions and orientation.

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KOC Contract No WORK METHOD STATEMENT FOR ERECTION OF STORAGE Contractor Document Number Rev
14050489 TANKS IN GC -30 FACILITIES 50489-530-300-CMS-2103 0

Upon lowering of the first shell course on the annular plate, complete the alignment of the first
shell course inside with tank ID marking, and complete the fit up with annular plate without any
gap underneath of the first shell unless specified in the drawing.

ANNULAR TO BOTTOM PLATE FITUP AND WELDING:

After completion of shell to annular welding start fit up of annular to bottom plate starting from
one location and moving towards circumference after completion of fit up necessary stiffer to
be provided on the joint to avoid buckling of the weld joint

Slowly start welding in segments at opposite sides and control the heat input to the bare
minimum to avoid distortion.

ERECTION OF CLEAN OUT DOOR (COD)

Upon completion of Erection and assembly of floating suction and other tank internals the
clean out door shall be erected as per the approved drawings and fitted with the shell and
welding should be done in position.

ANCHOR CHAIR /SHELL NOZZLES / STAIRWAY / INTERNAL PIPES /LADDER

/PLATFORM:

All shell nozzles shall be marked in position after obtaining the necessary clearance from
Company for orientation and elevation necessary opening for the suitable sizes shall be
carried out and Reinforcement pad fit up and welding should be done than the nozzle shall be
fitted in the position and welded as per the projections. Necessary stiffener shall be provided
on the nozzle during welding to avoid distortion.

Internal Pipes, stairways and Ladder &Platform and its supports shall be fitted and welded in
position as per the approved drawings and procedures. Necessary care should be taken while
welding the pad plates since it will give the localized heat input there will be chances of
distortion.

Necessary care should be taken while fixing up the pad plates it should not foul with the weld
joints if it is coming in the joint necessary RT should be carried out as per the code
requirements.

Anchor chair shall be fitted in to the location and welded as per the specifications and
necessary sequence shall be followed

 Figure- 1 shows how the tank shells shall be erected during construction
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KOC Contract No WORK METHOD STATEMENT FOR ERECTION OF STORAGE Contractor Document Number Rev
14050489 TANKS IN GC -30 FACILITIES 50489-530-300-CMS-2103 0

MECHANICAL COMPLETION:

With all the relevant inspection documents and approved drawings with NDE reports the tank
to be offered for Main contractor / Company inspection. Upon their inspection clearance or
completion of punch list if any the tank shall be thoroughly cleaned for foreign materials and
all the connecting nozzles in the shell be boxed up with temporary blind flanges. The water
filling arrangement shall be made through roof nozzle.

BOXING UP:

The tank shell nozzles and roof nozzles except vent shall be boxed up with temporary blinds;
this activity should be witnessed by Company/ contractor safety personal.

HYDRO TESTING:

The hydro testing of the tank shall be done with fresh water, necessary pumping in and
pumping out arrangements should be made since there is not entry from shell.

If the water shall be kept in the tank more than 14 days necessary corrosion inhibitor to be
added to the water as per the recommendations by the supplier, necessary periodical samples
to be taken as per the suggestion of the supplier.

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KOC Contract No WORK METHOD STATEMENT FOR ERECTION OF STORAGE Contractor Document Number Rev
14050489 TANKS IN GC -30 FACILITIES 50489-530-300-CMS-2103 0

The filling in line should have the NRV which should not allow the water back from tank. After
ensuring all the arrangements, the tank initial level should be taken at every 3mtr interval in
circumference.

The pumping should be done as per Specification/ API 650 per hour maximum and filling
should be done maximum 5mtr of the tank in a day and it should be kept hold for 24 hours to
check the settlement of foundations. Upon completion of 25% filling reading should be taken
at circumference and after completion of 24 hours one reading should be taken, if the
settlement is very minimum or nominal considering the soil bearing capacity, than the further
filling can be allowed.

Again water should be filled as mentioned above till it reaches 50% than the same level
should be maintained for 24 hours for settlement twice reading should be taken before and
after start of holding time. After ensuring the settlement further filling can be done in stages for
75% and the same procedures can be repeated till it reaches 100%.

Upon 100% filling (the level of should be more than the topmost circumferential welding) the
water should be kept under hold for 48 hours. If required roof pressure testing can be done to
ensure the leaking of roof joints as per the procedure of 50489-530-450-PRO-2102 Clause 5.2

Settlement reading shall be recorded. Then the water can be drained in stages like 25%,
50%, 75% and 100%. During draining necessary care should be taken and maximum roof
nozzles to be kept open to ensure the necessary air enters the tank inside to avoid vacuum
collapse of tank.

After emptying,the tank internal shall be cleaned thoroughly with fresh water to remove the
salt if any or for contaminations.

The water freed tank can be released for blasting and painting from inside.

8.0 SAFETY
 Instructions/Orientation & Tool box talks shall be conducted to work force on safety
measures, heat stress, confined space entry, lifting and erection on daily basis by the
concerned Supervisor and recorded.
 Necessary Lifting Plan shall be Prepared and Obtaine Approval form L&T/PMC prior
to start of any lifiting activity.
 Work area shall be kept clean, waste segregated and disposed to authorized locations,
barricaded and warning sign boards shall be placed.
 Company approved erection equipment’s, tools & tackles with valid Clearance
Certificates (as applicable) with Third Party Certification and Calibrated welding
equipment’s with certificates shall be used.

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KOC Contract No WORK METHOD STATEMENT FOR ERECTION OF STORAGE Contractor Document Number Rev
14050489 TANKS IN GC -30 FACILITIES 50489-530-300-CMS-2103 0

 Riggers, Scaffolders, Rigging Supervisors, Crane/ Lifting Equipment Operators shall

be third party certified.
 Scaffold materials, Full Body Harness shall be third party certified and shall be
identified by visible part no’s
 Only skilled/experienced work force with proper and adequate PPE shall be engaged
to perform any activity connected with Tanks.
 Proper register and weekly checklists to be maintained for lifting tools&tackles .
 All Personnel Involved in the Fabrication activities shall be provided
awareness/Training on the hazards/risk involved in the respective work and the
required precautionary measures,including correct and appropriate use of PPE’S and
emergency response.
 All welders, Blasters & Painters to be qualified as per the KOC Standards.
 The contractor shall employ all necessary KOC Approved health & safety procedure to
protect the personnel and surrounding environment during fabrication & other field
work.
 The contractor shall keep the latest copy of MSDS for the material to be used (i.e
welding rods& Paint Materials) .Precautionary measures listed under MSDS shall be
pracited at site.

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