HASAN JUMA BACKER 19 & Contracting Co.LLC loman Haas oes: (as fie: [iesscalon tessa nro Sr srzzan roc eressere1 fsrtrationartetiorn imthen snacaiana oom Js Awl pbad poy Qatar Petroleum hyporraass + Paoe tol DOCUMENT TRANSMITTAL NOTE [Project No: 2555 Contract No: GC 09107200 CONTRACT TITLE: EPIC FOR RLC POTABLE WATER STORAGE TANKS AND PUMES AT RAS LAFFAN INDUSTRIAL CITY “MESSERS (QATAR PETROLEUM (EDR) [Nour Re. jaa MR ABDULLA HUM AL SULATVFROFECT MANAGER RALLAFFAN | aay, seve era. Owrnet: |HJB/GC09107200/QP/T/0052 Subleet___|Method Statement for Potable Water Tank Febrication Pate 26/05/2010 oceument No fetal | Rev | yy. ee Code ‘Method Statement for fabrication of 2555-5-74-0001 4] oo | 2 Cpatis Warten 4 Cotes TI 1 Aproved GowAFC [] 2 Approve With Comment GoTOAFS E] 3 Novagproed ReSubaat 4 ForRevew And] 6 For Inermation And Reffense A 4 fetes 5 Issued For Approval o 1 7 seeRemarts 65 signet AFC- For Retention (9 Rect 10_ ia or Sipunre sue a ie CO taste 2 Fert A ‘Origi =a “sh Dates [CCEDRTya00sii0 ISSUED FOR APPROVAL, DATE DESCRIPTION co eee mar ENGINEERING DEPARTMENT CONTRACT REF.: GC 09107200 RLC POTABLE WATER STORAGE TANKS AND PUMPS. DOCUMENT TITLE: METHOD STATEMENT FOR ERECTION OF POTABLE WATER TANKS. ATSITE MAIN CONTRACTOR TANK VENDOR o Vijay Tanks & Company LLC, Hasan Juma Backer PO Box 107, PC 131, Hamriya, Trading & Contracting Co LLC ‘Sultanate of Oman. Po sox 2200, DOHA TAR Fax: serecaaeiest pera (2 (= S, & jn SPST DOC. NO: 2655-5-74-0002 Se Done Oat “Ssstster Trade. & Coos Page 1 of 19A EPIC FOR RAS LAFFAN Hasan Juma (\, EMERGENCY AND SAFETY COLLEGE] Backer sere Usa Lad Bog Juss’ Qatar Petroleum mma Method Statement for Erection of bnyay ranxsa rT Jacking Method Me Table of Contents 1. SCOPE Page RESPONSIBILITIES: PROCEDURI RECORDS: ATTACHMENTS: Re P.O. Box: 22590 Doha - Qatar scher Trad, & COS 2 a y y os CONTRACT No. 6c09107200 DOG. No. REV. No. 2555-5-74.0002 0 SHEET 20F 190 EPIC FOR RAS LAFFAN Hasan Juma 7 EMERGENCY AND SAFETY COLLEGE} Backer eULDING afl bad Bg frctser Qatar Petrolcum mam| Method Statement for Erection of |asay ranks Jacking Method aw + ‘SCOPE The scope ofthis document applies to site works during erection of 2 nos 24-meter diameter x 15.5, meter high fixed cone roof potable water Storage tanks at Ras Latfan Industral City 2. PURPOSE: ‘This document covers erection and testing of storage tanks as per contract specification and Intemational codes, This procedure may be altered during construction depending on actual site Condition for each operation; however the final inspection and acceptance shall be stricly as per contract specification, DEFINITIONS: sm - Site Manager PS = Production Supervisor QA/ a6 (1) = QA/QC Inspector AFC. = Approved For Construction REFERENCE: ‘The following documents and codes shall be referred to: 2) AEC drawings. )APLS50 11th Esliton, 1" Addendum, November,2008. ©) ASME Sec. Ik ©) Quality Control Plan - 2565-5-25-0112 ©) Contract Specification for Storage tanks Doc.no. 2555-1052 rev! 4) QP Engineering Standard ES 6.05.0006 revA 9) OP Standard ES-S-60 rev 4 F) Viay Tanks Project Quality Plan -2555-5-25-110 i) NDT Procedure ~ 2585-6-25.0135 |). Standard Operating Procedure-Vacuum Box test 2556-6.25.0128 1) Standard Operating Procedure-Reinforcement Pad test 2555-6-25.0129, 1) Standard Operating Procedure-Hydro test. 2555.5-25-0131 RESPONSIBILITIES: ‘The personnel responsible for satisfying the requirements of this document are SM, QA / QC (Engineer) and PS. The responsibilities will be 2s stated in the Project Quality Pian and Inspection Test Pian PROCEDURE: 6.1 SITE CLEARANCE: Before starting any construction activity itis required to obtain site clearance from client for the construction work and the area to be well identi ice, storage yard, prefabrication and actual site for erection Zab ie Mae ‘CONTRACT No. DOG. Nes & No SHEET < 6c09107200 2555-5-74,9902 0 30F 19 P20. Box : 22500 , bohar= Gata Tend & 28EPIC FOR RAS LAFFAN Hasan Juma , 0), EMERGENCY AND SAFETY COLLEGE) Backer Js Lad og =s (Qatar Petroleum ‘Method Statement for Erection of bnjay ranks Potable Water Tank at Site [company ite 4 Jacking Method 62 i In principle the erection method employed for the construction of tanks shall be by jacking method. ‘The erection sequence of work items shall be as detailed below. It should be noted, however, this ‘sequence may be changed in accordance with site progress and work schedule and other reasons, such {38 paralla installation of work items etc. Civil foundation construction, Laying and welding of annular plates, Laying and welding of bottom plates. Erection and welding of top 2 shell courses. Erection and welding of top curb angle Assembly & erection of Roof structure & roof plates, Jacking, erection and welding of intermediate shell courses. ‘Jacking, erection and welding of bottom shell course. Fitting of shell nazzies 10. Hydro testing of tank 14 Painting & lining works (By others) 6.3 CIVIL FOUNDATION: (By others) ‘The foundation levels around the periphery atthe tank radius shall be checked, The levels shall be taken every S-meters of circumference. The elevation diference, as per API 650, shall not exceed Plus for Minus 3mm in any 3 meter crcumference and Plus or Minus 13mm in the total circumference. After inspection and acceptance, reference points shall be checked on foundation with respect to tank's north position, O degree, $0 degrees, 180 degrees and 270 degrees. Markings shall be done in such a ‘manner that it doss not get erased during tank erection, 64 — WELDING PROCEDURE / WELDER QUALIFICATION: All welding including tacking shall be made as per approved welding procedure. Welders and welding operators shall be qualified in accordance with ASME Section IX and API 650, ‘A vmritten Welding Procedure Specification (WPS) and applicable Procedure Qualification Record (POR) shall be submitted to client for approval, prior to start of any welding operation. Welding procedure shall include detail of joint preparation, electrode J filer metal, welding process and base ‘materials, No welding shall be performed prior to clients’ written acceptance of the welding procedure, 65 MATERIALS: All material shall be as per specification and shall be approved / identifed before use and necessary documentation shall be made. Prior to starting any prefabricaton, materials shall be identified ‘against specification, test certifcate and heat number. All documents shall be maintained for ‘material traceability ‘CONTRACT No. 6c09107200 “ Kn, Doha = Qatar SZecter trade, & 2880 EPIC FOR RAS LAFFAN is (\, EMERGENCY AND SAFETY COLLEGE| Js fal pa ey [Qatar Petroleum Method Statement for Erection of bnay raksa Potable Water Tankat Site _[companyute | Jacking Method a | 6.6 BOTTOM PLATE ASSEMBLY: ‘Annular plates with backing strips attached thereon shall be laid, abutting one another, to form a ring with outside diameter as specified, Annular plate butt joints shall be welded as shown in weld sequence. To control distortion of the Plate, strong back may be provided. Alternatively, the joint may be raised 50 - 100 mm by a steel bar and welded with the joint pecking up, and the bar subsequently removed. Refer to Fig 04. Radiography shall be taken as per construction code and contract specifications for annular plate butt welds. The bottom sketch and full plates shall be laid with plates lapped as shown on drawings. Plates shall be held together by a few light erection tacks. ‘Sequence of welding bottom plate joints- Refer to Fig.02 2) Short seams to be welded firs. ») Afterall short seams in two successive rows of bottom plate are welded, the long ‘seam between these two shall be fitted and welded, working from the centre outwards, €) The peripheral seams between sketch and annular plate shall be lef free 2s expansion Joint. This seam shall be fitted after the shell / bottom filet joint is welded. To reduce ‘buckling caused by welding, this closing seam shall be welded during the hottest period ofthe day with at least four welders working simultaneously, equi-spaced 6) Fitment of seams, which are not fet, shall be made using channels and lugs shown in Fig.03, Channels shall cover the ful length of seam requiring to be straightened, and shall be left in place unt the weld has been cooled. Welding shall be done by using approved welding procedures. Each pass shall be cleaned thoroughly of slag prior to deposition of subsequent passes. Blowholes and other defects shall be removed by grinding or other means and replaced by acceptable quality weld prior to deposition of ‘subsequent passes. Al tack welds made on the bottom plate surface for ftment of seams shall be chipped or ground ‘smooth, ‘The shell to boitom joints shall be welded after the first course of shelljoints hasbeen welded, ‘Annular plate to sketch plate joint shall be welded last To ensure welds on tank bottom plates are free from leaks, tests shall be carried out as required by construction code or contract specications 6.7 PROCEDURE FOR SHELL PLATE ASSEMBLY BY JACKING METHO! ‘The liting equipment consists of a number of liting trestles with hydraulic climbing jacks and one ‘common high-pressure pump. Refer to Fig.04. Lifing Jacks Date: ‘CONTRACT No. Tce REV NO ‘SHEET Ss o. coast07200 @ \ sorts PO. Box: 22560 J ,Doha - Qatar‘ EPIC FOR RAS LAFFAN Hasan Juma & z (\, EMERGENCY AND SAFETY COLLEGE] Backer aoe Lisl bad ef Juters (Qatar Petroleum mem| Method Statement for Erection of biyayranksa Potable Water Tank at Site —_[Coupanvute Jacking Method | Calculation for number of jacks 12 MIT capacity is as follows:- Weight of tank shell excluding frst shell course 144. Weight of roof structure and roof plates 39MT Miscellaneous (Nozzles, Stairway, Pipe work etc) _25MT ‘Total Weight = 258 MT. Considering a safety factor 1.5 times the total weight = 258 x 1.5 = 387 MT Minimum number of jacks required would be = 00 MT / 12MT 32 Nos. ‘Therefore provide 34 Nos. of 12 MT capacity jacks. ‘Top 2 shell courses shall be assembled at s base elevation of about 1 foot (300 mm) above the bottom plate assembly using steel spacer blocks of ‘I’ Beam (300mm ‘T beam of 200mm length See Fig.08). The assembly shall be done over the specified tank radius punch marked, on which shel plates would be resting, Plates shal be erected by means of mobile / crawler cranes having adequate liting capacity, ‘Thereafter, vertical seams shall be welded on the outside face first, progressing up hil. The reverse side of the joint shall be gouged / ground to sound metal removing all siag, impurities and areas of incomplete fusion before reverse side welding is commenced in accordance with the approved WPS, Depending on the extent of peaking of the joint, reverse side welding may be done either by the back step method or progressing continuously uphill, The letter procedure shall be followed if greater correction of peaking is required Peaking measured wit a horizontal sweep board at the vertical weld joint shall not exceed 13mm as per the tolerances of API-650. ‘After all vertical seams on the shell course are welded, the horizontal seam connecting the two courses shall be fitted and set up for submerged arc welding of the seam. Fitting of the seam shall bbe made as per relevant drawings. The maximum out-of plumbness of the top shell relative to the bottom of the shell shall not exceed 11200 as specified in codes. “The top curt angle ring shall be fited and welded as per approved drawings. Ling lugs shall be fitted to the tank shell inside (as shown in Fig.06) at every position where a jack Is tobe installed, A circumferential angle iron of 120 x 120.x 12 mm size shall be installed as shown in Fig, 08 to interconnect al the lifting lugs for shell stability during jacking-up operation. The shell sub-assembly shall be raised through a distance of about 84 feet (2.650 meters). While the upper sub-assembly is resting on the jack posts, the immediate lower shell plates shall be erected over the steel spacer blocks, Al the vertical weld seams on this lower shell course shall be fitted and welded by following the same steps 2s stated above. CONTRACT Wo. DOG. No. REV.No, SHEET 6c09107200 28565-5-74.0002-G Os 6oF 19 ae “A = *¥\ G, rosmz0 etyg , DONA = Qatar Becker Tradg. & 9SEPIC FOR RAS LAFFAN Hasan Juma i _ 0) EMERGENCY AND SAFETY COLLEGE, "Bachar Ja fall pb & fare Qatar Petroleum Method Statement for Erection of \yaxy rans Potable Water Tank at Site COMPANY LLC ay “Jacking Method ad! Raise the lower shell ring assembly using 3 or 4 Nos. mechanical jacks of 10 tons capacity and fit- Up the circumferential joint of shell sub-assembly ‘Temporary circular rang made out of 100 x 10 mm flat should be fixed above the horizontal joint to be welded, (Refer to Fig.07). Welding of the seam shall be done on the outside face fist. Shell stifeners shall be fitted and welded as per approved drawings. Lower the jacks and reinstall the liting lugs and circumferential angle ring on the lower shell Raise the shell sub-assembly through a height of 8 4 feet (2.550 meters) and install the next lower shell course. While the vertical seams are being welded, the reverse side of circumferential seam left incomplete shall be attended to, as the seams would now be unhindered for movement of SAW machine. Banding at horizontal weld joint shall not exosed @mm as per the tolerances of contract specifications, Radiographic inspection ofthis seam as per construction code / contract specification requirements shall be carried out before further progress of the tank lit. Spiral stairway of the tank shall be installed progressively moving downwards from the top-wind sirder. All erection lugs and fixtures shall be progressively removed by careful grinding and the attachment ‘surface shall be dressed up and checked before the next Iift ofthe tank. Breaking lugs off the parent plate using force will not be permitted. Inthe above sequence, the complete assembly of the tank shells shal be followed by the inspection ‘activities as per construction code and contract specification, When installation of the lowest shell course viz. the “First Shell’ is done, the stee! spacer blacks referred fo above shall be removed and the first shell course be made to rest directly on the tank bottom plate After fiment and welding of the fist horizontal seam is completed, the jacks and the liting lugs / Circumferential angle ring assembly shall be dismantled and removed from the tank. ‘The shell to bottom joint shall be set up and welded inside first and outside later. The weld after its visual inspection completion shall be MPI tested as per contract specification 2676-5-14-1001 1 employing automatic welding, the following shall be followed: 2) Welding procedure specification and welding qualification record shall be approved by the Client, prior to welding commencement, 'b) Automatic welding operator shall be qualified as per the code ©) Horizontal joint welding shall be commenced only after completion of all vertical joint welding in the two adjacent courses. ©} Incase of any excess gap in the joint, it shall be filed up by manual welding, 68 SCAFFOLDING FOR TANK SHELL ASSEMBL’ CONTRACT No. ‘SHEET 6c09107200 70F 19‘ EPIC FOR RAS LAFFAN Hasan Juma = Oy EMERGENCY AND SAFETY COLLEGE] Backer ae JsAnl ba Bg tere \Qatar Petroleum mam=| Method Statement for Erection of yay tanks a Potable Water Tank at Site COMPANY LLC Jacking Method | ‘Scaffolding for working on the tank shell shall be as shown in Fig.08. These shall be provided with a cross bar wedging two adjacent scaffold platforms or Jllies’ together. This tight clamping results in 2 continuous ring being attached to the tank shell that also acts as a “Wind girder" and protects the tank from heavy winds. (On completion of tank erection, welding and NDT tests, the scaffolding shall be cismantled, and all clips weided to the tank shall be carefully gouged out and removed. Any loss of parent metal during the above activity shall be made good by welding and the surface ground off to a smooth finish, ‘After completing all welding, the tank shall be cleaned prior to final inspection, 6.9 ERECTION OF ROOF RAFTERS & ROOF PLATES: Roof plates shal be lad on the temporary roof structure with laps as shown in the AFC drawing, Raters shall be erected using a crane and welded tothe tank roof plato, ‘After completing ll works, the tank shall be cleaned prior to final inspection 6.11 RADIOGRAPHY CHECKS ON BUTT WELDS: Radiography of shell plate butt welds shall be carried out in accordance with an approved procedure, API 850 and Contract Specification 2676-5-14-1001, as soon as possible after a shell Course is welded. Radiography reports shall be submitted to client's inspector. Defects, if any, shall be rectified as soon as possible, by grinding out the weld areas indicating defects, and re-welding as per approved procedures. ‘Such repairs shall again be examined by radiographic inspection and reports submitted again to Clent’s inspector fr final approval 6.12 SHELL APPURTENANCES ‘The position of nozzles and other appurtenances shall be accurately marked out and the ‘same shall be inspected before cutting. Attach nozzies by tack welding. Check joint ft up, nozzle orientation etc., before welding is carried out. Reinforced nozzles and manholes shall have their reinforcement plates clamped to the shell by horse shoes and wedges, while the nazzle neck is welded to the tank shell from inside (Weld A) and to the reinforcing plate on the outside (Weld B) as shown in Fig.09. After completing Weld 'A’ & Weld B' the reinforcement pad shall be fied up with the shell piate and welded. To reduce the distortion on shell, siffeners willbe provided on shell plate as shown in Fig.10 during shell plateRF pad to nozzle neck welding To ensure the welds between shell plates to nozzle reinforcing pad, nozzle neck to reinforcing pad and between nazzie necks to tank shell inside are free from leaks, RF pad test shall be cartied out as per SOP-2676-VIJY-8106, 6.13 HYDROSTATIC TEST OF STORAGE TANK Refer to hyo test procedure CONTRACT No. so REveNOS SHEET 6co9107200 0 =—S\_— sorts 5 FO BE ZIT Sey, Doha = Qatar Sacer Tend. & 280 EPIC FOR RAS LAFFAN Hasan Juma (), EMERGENCY AND SAFETY COLLEGE] —_Backer Js fall pb e& Qatar Petroleum Method Statement for Erection of yay ranks. Potable Water Tank at ‘COMPANY LLC Jacking Method 7. RECORDS: Recoids as detailed in the Inspection Test Pian shall be maintained ATTACHMENTS: 01 Fig. 01 Rev. O-Distortion control of annular plate butt joints 02 Fig 02 Rev. 0-Bottom welding sequence-Typical 03 Fig. 03 Rev. O-Fitment of bottom plate seams that not fat 04 Fig. 04 Rev. O-Details of jack and assembly 05 Fig. 05 Rev. 0-Top shell course with cone roof on packing beam 08 Fig. 06 Rev. Lifting lug details 07 Fig. O7 Rev. O-Rails on shell for SAW machine, 08 Fig. 08 Rev. O-Scaffolding arrangement for tank shell 09 Fig. 09 Rev. O-Nazzle fit up and welding 10 Fig, 10 Rev. 0- Stffener arrangement on shell during nozzle welding ‘CONTRACT No, 6c09107200 DOG. No. "¢@ 2555-5-74-0008,.7 Is SHEET 90F 19 SS PO. @ 22590 y YE Doha = Qatar ol Seeker Tradg. te!STRONG BACK mx ___GENERAL a WARY TANKS & COMPANY UL. ower +Method statement of erection of cone roof tank DISTORTION CONTROL OF ANNULAR PLATE BUTT WELDS. _2885-5-74-0002 FIG: Ota v y yy 0. Box: 22590 Doha - Qatar ves__.GENERAL Qe" tare : Method statement —Erection of Cone roof tank vamwrot : BOTTOM WELDING SEQUENCE— TYPICAL 2555-5-74-0002 FIG : 02CHANNEL MC 100/150 PLACE THE CLAMP AS NECESSARY TO TAKE UP ALL BULKING. ¢ Doha - Qatar P.O. Box: 22500 Lecher traag. & CK TAPER WEDGES 200/250 LONG. oa BOTTOM/ROOF PLATE wer GENERAL MUAY TANKS & COMPANY LLC. oweme :Method Statement—Erection of Cone roof tank .FITMENT OF BOTTOM AND ROOF PLATE SEAMS THAT ARE NOT FLAT. 2555-5-74-0002 FIG: 03‘SHELL COURSE WELD JOINT 8 © IT SHELL WIDTH tallon 1600 f93 i 3 = 5 De NOTE: ITEM NOS. 3,4,6,7 & 9 FORM LIFTING JACK ASSEMBLY. 10 | STIFFENER ANGLE 120x120x12THK) 09 | sack Post 08 | LIFTING LUG 07 | STAY ARM 06 | LIFTING ARM os | FEND OFF LUG 04] SLIDING CHAIR 03 | JACK’ o2| STAY LUG BOTTOM on | BASE PLATE won GENERAL Sper, TANKS & COMPANY LLC. owaree + Method statement— Erection of Cone Roof tank esa DETAILS OF JACK AND ASSEMBLY 2555-5-74-0002 FIG : 044TH SHELL COURSE! PACKING BEAM~IPE-300 300 —| P.O. Box : 22580 Doha - Qatar e + ¥ wa ___:GENERAL @ WAY TANKS & coe Method Statement— Erection of Cone roof tank TOP 2 SHELL COURSES WITH ROOF ON PACKING BEAM. 2555-5~74—0002 Fic: 05120x120x12 THK. ANGLE RING T 60 +}— rh | | | e T 20MM THICK PLATE (SOOMM X 60MM) fa “ye STITCH WELD ON BOTH ENDS. | { I | \ t | | | | l | \ — JACK ARM Ll mex GENERAL & saat pammre smn i Method statement= Erection of cone roof tanks samen LIFTING LUG DETAILS 2555-5-74-0002 FIG: 06[| — 100 x 10 THK. FLAT SAW M/C, vawit 10 Be vetzen. —p) | | TANK SCAFFOLDING, wen GENERAL a WAY TANS & COMPANY LLG. coer : RAILS ON SHELL FOR SAW MACHINE, Method statement of erection of Cone roof tank ‘2885-5-74-0002 FIG : 07TET Iv SIS0d WOUREA UOS VE 68) SUNSNG OL SGUVOG TEGIS SHI ONY WG SSO: "38 TIVHS 0018 N3QOOR v GSN SHY SOU “TIBHS YNVL YOJ LNSNZONVENY ONITIOIIYOS * suaome —qUaLU9}0}S PoUneN WaaNao_ z000-+1-8-s982 80 : ou “LEVEE: NOILOBY3 “NM, TIWL3d 4343a NYT ONICTIDIvOS “INIOP C73K C 2 ALON 43438‘e + y o ee sth . a9 3 ven - 3 dat ssi ge weLp-a FE 2 Ne S| wo, GENERAL Vase a ware .Method statement—Erection of cone roof tank 555-574-0002 Fig :09 vexenon NOZZLE FIT UP & WELDINGSHELL NOZZLE STIFFENER ARRANGEMENT ‘SHELL MANHOLE TOP VIEW » y y ‘y 2 cost P.O. Box: 22590 yz Doha - Qatar “Sister tn ‘No.1 “Racial tifoner Length shalbo mintrum 2m Long & Thicknas shal ere than sll Pat Thccness No.2 Feet Racial ana Vora! Susonr sole at ound Tso rom te Nock "No - Second Radial and VericalSilonr sald tthe Cmvnentcf Sto Conon depending npn to Size Noe. wr GENERAL Qs RUS COMPA LL ‘mre Method Statement of Erection of cone roof tank sein: STIFFNER ARRANGEMENT ON SHELL NOZZLE FITUP TO REDUCE SHELL DISTORTION DURING WELDING 2555-5-74-0002 | FIG :10