Br. C.A.

T International Company Limited MS/CIVIL/02

Contract Number : 7200023808 Revision 02
Name of Project : Construction of New Industrial Waste Lift Page 1 of 6
Station IW-10A

METHOD STATEMENT

FOR

REPAIR OF LEAK OUTLINE TANK-01D - 7200019321

00 Issued for Approval 8 March 2015 Gemlin V.Guarino Tanios Daher

Khttar

Prepared Checked
Rev. Comments Date Approved by
by by
 Br. C.A.T International Company Limited MS/CIVIL/02
Contract Number : 7200023808 Revision 02
Name of Project : Construction of New Industrial Waste Lift Page 2 of 6
Station IW-10A

INDEX

1. PURPOSE

2. SCOPE

3. REFERENCES

4. PROCEDURE

5. TOOLS AND EQUIPMENT

6. SAFETY INSTRUCTIONS
 Br. C.A.T International Company Limited MS/CIVIL/02
Contract Number : 7200023808 Revision 02
Name of Project : Construction of New Industrial Waste Lift Page 3 of 6
Station IW-10A

1.0 PURPOSE
The purpose of this method statement is to clearly define a documented and recorded methodology for
repair of Leak Outline Tank – 01D – 7200019321activities to ensure that all work is executed in
accordance with MARAFIQ requirements, drawings and specifications.

2.0 SCOPE OF WORK

This method statement covers the preparation, installation and inspection of repair for Leak Outline
Tank – 01D – 7200019321 activities through all stages from location of repair to final acceptance, and
this method statement is applicable to location where the work is performed by C.A.T with MARAFIQ
representative in operation under it’s own supervision.

3.0 REFERENCES

3.1 PROJECT DRAWINGS

 Applicable Project IFC drawings.

3.2 PROJECT SPECIFICATIONS

 MARAFIQ Testing Specification
 Other related Specifications.

4.0 GENERAL AND RESPONSIBILITY

4.1 The responsibility for all inspection and testing activities rests primarily with QC Supervisor and
inspectors; however for general quality of welding, materials and storage of electrodes will rest
with the discipline Foreman and person responsible for carrying out the work i.e welder.

4.2 The QA/QC Supervisor will, under normal circumstances, assign quality control task outlined
herein to appropriate members of his staff.

4.3 The Construction Manager or Engineer and the discipline Foreman will ensure that utilized
drawings are correct and that welders are qualified.

4.4 The Project QA/QC Supervisor will verify compliance to this method statement by audit on a
continual basis, and will perform reviews on all Quality related contractual documentation.

4.5 The QC Inspector will be responsible for carrying out inspections and ensuring appropriate
documentation is maintained and distributed.

4.6 The Construction Manager and Foreman (C.A.T) will be responsible for all construction
activities for repair and liaison between parties inclusive MARAFIQ, N.D.E Unit and any other
third parties.

5.0 PROCEDURE

5.1 MATERIAL
 Br. C.A.T International Company Limited MS/CIVIL/02
Contract Number : 7200023808 Revision 02
Name of Project : Construction of New Industrial Waste Lift Page 4 of 6
Station IW-10A

 Materials shall be in accordance with the specifications and MARAFIQ requirement and from
approved source, All materials utilized will be verified as correct by the QC Inspector.
 Patch Plate size 150mm X 150mm by 6mm Thick, ½” hole drilled into the plate and ½” pipe
coupling welded over the hole.
 Patched prepared using next larger pipe, cut so that it extend at least 2” on all sides of the
rupture.


5.2 FLANGE JOINT ASSEMBLY

4.3.1 For Tie-in flange connection, use calibrated torque wrench with certificate for
verification.
4.3.2 Spool material for tie-in has been hydro tested prior for installation.
4.3.3 Secure the required work permit and prepared the required personnel protective
equipment for crews assigned.
4.3.4 After verification that material spools has been hydro test, activity for tie-in shall start.
4.3.5 Used approved flange bolting and gasket verification procedure.
4.3.6 Flange, Gasket and Bolt shall be inspected for any damage, dirt or any thing that may
interfere with the integrity of the joint.
4.3.7 All bolt and nuts will be inspected to ensure correct materials are being used and items
are free from any damage, each stud shall be numbered in accordance with its position.
4.3.8 Gasket shall be checked for size, rating type and condition.
4.3.9 Stud bolt shall be tightened in stages to obtain final torque values in accordance to
MARAFIQ specification.
4.3.10 Bolting shall be identified & controlled by markings & personnel shall be trained to
recognize the various bolting grade required.
4.3.11 Inspector and crews assure proper torque sequence and values.
4.4 BOLT TIGHTENING
4.4.1 Bolt, nuts and washer shall be visually checked for proper size, grades and dimension
comply to specifications, cleanliness and absence of burrs, also checked suitability
of the stud bolts and nuts material for the service temperature and the compatibility with
the flanges material.
4.4.2 Lubricant shall be applied to stud threads prior to assembly and ensure that the nuts
run freely down the thread of the studs. In accordance with appendix (Friction Factor
for different lubricant)
4.4.3 All studs and nuts shall be installed hand tight, ensure that studs pass freely through
flange holes. By doing this, the nut installed near the end of the stud may be easily
removed later as threads will not be coated or contaminated with rust.
4.4.4 Each stud shall then be numbered in accordance with it’s position on the flange in
accordance with appendix V (Stud Bolt Tightening Sequence).
4.4.5 Stud bolt shall tightened in stages to obtained final torque values in accordance with
 Br. C.A.T International Company Limited MS/CIVIL/02
Contract Number : 7200023808 Revision 02
Name of Project : Construction of New Industrial Waste Lift Page 5 of 6
Station IW-10A

appendix III Torque Value Tightening shall have a minimum of four passes
(30% - 66% - 100% - 100%).
4.5 BOLT TORQUING
4.5.1 Torque value varies according to flange rating, bolt size, type of gasket and friction
factor of the thread lubricant.
4.5.2 Torque value are specified in appendix IV (Torque values for isolating gasket on ASME
B16.50 and ASME 16.47 series A & B class 150 through class 2500 flanges.
4.5.3 Friction factor for different lubricant applied to all gaskets, except for insulating gasket
based on a friction factor of 0.16 using graphite & oil.

5 QUALITY CONTROL REQUIREMENT

All records related to the above procedure shall be maintained by Quality Control department and all
stages of work and testing shall be documented as per the approved Inspection and Test Plan. This
procedure shall be filed and maintenance in the project QA/QC office until completion of the project at
which time they shall be transferred for archiving in accordance with project requirements.

 Material Verified
 Valve tested
 Tie-in package number
 Test equipment available
 Test package

6 TOOLS & EQUIPMENT

 Calibrated Torque Wrench

 Minor Tools

7 SAFETY INSTRUCTIONS

CAT will follow all the requirements of Safety.

 All personnel involved will wear necessary PPE as required such as Safety Helmet, Glasses,
Shoes, gloves etc.
 The workers will be made aware of safety requirements related to this activity through daily tool box
and safety talks.
 All required work permits will be acquired and the necessary copy will be kept at respective work
site in the personal possession of area supervisor/foreman.
 Safety notice board/s will be installed at main/prominent location/s.
 All equipment will be inspected by MARAFIQ representatives prior to use & inspection checklist
signed by MARAFIQ will be maintained for reference.
 Area for testing will be barricaded and only authorized/concerned persons will be allowed to work
inside the barrication.
 All persons working at height more than 1.5 meter should wear safety harness with double lanyard
and shock absorbing device.
 Br. C.A.T International Company Limited MS/CIVIL/02
Contract Number : 7200023808 Revision 02
Name of Project : Construction of New Industrial Waste Lift Page 6 of 6
Station IW-10A

 Access and good housekeeping should be maintained in all work and office areas.
 All activities at height should be provided with suitable working platform in accordance with the
approved safety plan.
 All access ladders and scaffoldings shall be secured and tagged before use.
 Waste Management Procedure shall be strictly followed to keep the job site neat and clean.